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AGREGADOS RECICLADOS

MITOS Y REALIDADES

UNION EUROPENNE DES PRODUCTEURS DE GRANULATS


EUROPISCHER GESTEINSVERBAND
EUROPEAN AGGREGATES ASSOCIATION

The European Aggregates Association

Recycling of C&D Materials


= European Perspectives
Jim OBrien, President UEPG
Bogot DC, Colombia, July 27, 2011

Presentation Overview
1.Introduction to UEPG
2. EU Aggregates Production & Recycling Data

3. EU Driving Forces on Recycling


4. Examples of Recycling in Ireland, Finland,
Switzerland (CRH) and Netherlands (FIR/BRBS)
5. Economic, Technical and Other Aspects
6. Some Conclusions & Open Discussion

Introduction to UEPG
UEPG created in 1987
Brussels Office since 2003
Now 31 Member Countries

Represents Industry with:


Sales of ~20 billion
Over 3 billion tonnes of
aggregates per year
24,000 quarries & pits
16,000 companies
300,000 employed
(including contractors)

UEPG Vision, Mission


Our Vision: A Sustainable

Industry for a Sustainable


Europe
Our Mission: To be the
Industry Champion and a
Trusted Partner
Our Objective: To be
Economically Competitive,
Socially & Environmentally
Responsible
Our Values: To be Open,
Transparent and Honest

UEPG Secretariat
Secretary General:
Antony Fell
Public Affairs
Manager:
Dirk Fincke
Public Affairs Officer:
Sandrine Devos
Public Affairs Officer:
Miette Dechelle
Very dynamic, active
& effective Team!

UEPG Lobbying Activity

Frequent informal & formal meetings with officials


They listen to us - industry viewpoint is respected
We prepare briefing notes to inform our Members
EU Commission High-Level Conferences
Parliamentary Dinner Debates (involving MEPs)
Partnership with Environmental NGOs
Site visits with EU key decision makers

Presentation Overview
1. Introduction to UEPG
2.EU Aggregates Production & Recycling Data

3. EU Driving Forces on Recycling


4. Examples of Recycling in Ireland, Finland,
Switzerland (CRH) and Netherlands (FIR/BRBS)
5. Economic and Other Aspects
6. Some Conclusions & Open Discussion

EU Geology
Geology varies
widely across EU
Determines quality
& aggregate types
Some countries well
endowed with hard
rock sources (eg
Norway, Finland)
Others with scarcity
even of sand &
gravel (eg Poland,
Hungary)

Aggregates Production 2009

Total EU 2009 production was 3.25 billion tonnes


Overall 51% crushed stone, 39% S&G, 2% marine,
6% recycled and 2% manufactured aggregates

S
O
Z
N
Z

yp
N ru
or s
w
Fi ay
nl
A and
us
S tri
w a
ed
Ir en
e
D la
en nd
m
a
N Be rk
et l g
h iu
er m
l
G an
er d s
m
G any
re
e
C c
C ro e
z a
S ech ti a
w
i t Re
ze p
rl
a
Fr nd
an
ce
H Ita
un ly
S ga
lo ry
va
P kia
ol
an
S d
P pai
or n
tu
Tu g a
l
B rke
ul y
g
ar
ia
U
S K
e
R rb
om ia
an
ia

Aggregates Tonnes/Capita
Tonnes/capita 2009

16.0

14.0

12.0

10.0

8.0

6.0

4.0

2.0

0.0

EU average was (only) 5.4t/c in 2009, Colombia ~3t/c


European output fell -11% in 2009, ~-10% in 2010

Trend in Tonnages 2010 v 2009


Tonnage Predictions 2010 v 2009
20%
10%

-10%
-20%

B UK
el
gi
u
Fi m
nl
an
P d
ol
an
Tu d
rk
Fr ey
a
G nc
er e
m
an
N Cy y
et
he pru
rl s
an
d
S s
er
b
A ia
C us
ze tr
ch ia
D Re
en p
m
ar
k
I
S tal
lo y
va
H kia
un
ga
r
S y
pa
G in
re
P e ce
or
tu
B ga
ul l
ga
r
Ir ia
el
R an
om d
an
C ia
ro
at
ia

N
or
w
S ay
S we
w
it z de
er n
la
nd

0%

-30%
-40%
-50%

There are a few green shoots, but overall further


economic and tonnage declines in 2010
Has the EU now reached the bottom of the cycle?

Tonnes/Capita v GDP/capita

16.0
14.0
Tonnes/capita

Aggregates
usage
continues to
grow as the
economy
grows
Growth
needs
aggregates!

Tonnes/Capita v GDP/capita 2009

12.0
10.0
8.0
6.0
4.0
2.0

Colombia

0.0
0

20

40
000 GDP/capita

60

80

Definition of Recycled Aggregates


Recycled
Aggregates are
those produced onsite or off-site
through crushing,
screening, sorting,
etc of construction
and demolition
materials

(Asphalt recycling
considered separately)

Does not include:

Excavated materials
By-products of
natural stone, slate
processes (both are
natural aggregates)
Aggregates produced
from other industrial
processes, like slag,
etc (manufactured
aggregates)

Global C&D Materials Recycled


Amount of
waste (Mt)

Europe

US

Japan

Construction
and Demolition
Waste (C&DW)

510

317

77

Municipal
Waste

241

228

53

Global data on recycling is often


based on best estimates
The recent EUs Bio-Intelligence
Report did little better
C&D materials = ~0.9-1.0t/capita
Better called materials not waste!

% EU C&D Materials Recycled


C&D Materials % Recycled (Est)
100%
80%
60%
40%
20%

B UK
N el
et gi
h um
er
la
G nd
er s
m
an
S Po y
w la
it n
ze d
rl
an
F d
ra
n
A ce
us
R tr
om ia
an
N ia
or
w
F ay
in
l
S an
lo d
va
S kia
w
ed
en

0%

These are best estimates, difficulties both in varying


definitions and probable under-reporting
Total EU C&D materials available estd at ~535mt
Overall EU just on 200mt of recycled = 37% recycled

EU Recycled Aggregates %
Recycled Aggs as % National Demand
25%
20%
15%
10%
5%

B UK
N el
et g
h iu
er m
la
G nd
er s
m
an
S Po y
w la
it n
ze d
rl
an
F d
ra
n
A ce
us
R tr
om ia
a
N ni a
or
w
F ay
in
l
S an
lo d
va
S ki
w a
ed
en

0%

Best performers are UK, Belgium & Netherlands


Even in those cases, recycled is only 20-25% market
Overall EU, only 6% of demand is recycled material
If all countries recycled 100% = ~15% total demand

Presentation Overview
1. Introduction to UEPG
2. EU Aggregates Production & Recycling Data

3.EU Driving Forces on Recycling


4. Examples of Recycling in Ireland, Finland,
Switzerland (CRH) and Netherlands (FIR/BRBS)
5. Economic, Technical and Other Aspects
6. Some Conclusions & Open Discussion

The EU Legislative Drivers


EC Raw Materials Initiative,
launched by Commission VP
Gnter Verheugen in 2008
Raw Materials and Resource
Efficiency Strategies, launched
by Commission VP Antonio
Tajani in early 2011
Waste Framework Directive,
which sets target of recycling
70% of all available C&D
materials by 2020
In some cases, even more
ambitious national legislations

The EU Legislative Obstacles


Definition of Waste as
any material not
immediately used on site
Ensuing very complex
permitting procedures
Need to establish End-ofWaste Criteria
REACH requirements,
avoided by acceptance of
Recycled Aggregates as
Articles

The Practical Drivers


Lack of landfill space,
particularly around major
urban areas (leading to the
associated landfill taxes)
Lack of availability or high
cost of natural aggregates in
some countries/regions,
particularly near urban areas
Environmental benefits,
Green Procurement, etc
Recycling is an exciting

business opportunity!

UEPG Action on Recycling


UEPG now has the promotion
of Recycling as one of its top
priorities
It cooperates with FIR
(International Federation of
Recycling)
Both work together with others
in EPRA (European Platform
for Recycled Aggregates)
Currently seeking EC support
as an Innovation Union Project

www.uepg.eu

www.fir-recycling.com

Presentation Overview
1. Introduction to UEPG
2. EU Aggregates Production & Recycling Data

3. EU Driving Forces on Recycling


4.Examples of Recycling in Ireland, Finland,
Switzerland (CRH) and Netherlands (FIR/BRBS)
5. Economic, Technical and Other Aspects
6. Some Conclusions & Open Discussion

Irish Case Study


Company had major
quarries near Dublin
Experienced in handling
its own quarry waste
Saw Recycling as a
complementary activity
to natural aggregates - a
business opportunity!
Had existing quarry
infrastructure and plant
All recycling processing
was to be contracted out

Irish Recycling Activity

Got waste permits in 2002 a significant challenge


Used existing quarry area, mobile crushers, loaders
Focused on clean concrete waste, rigorous QC
Built up to 350kt/y by 2007, ~5m sales, profitable!
Closed down end 2008 due to Celtic Tiger collapse!

Recycling

success
depends
on state
of the
economy!

Irish Technical Aspects


Focused on producing
road base material (040mm)
Specification had to be
agreed with and tested
for local authorities
QC of incoming and
outgoing materials was
very crucial, including
on-site blending
Strong relationships with
suppliers and customers

Experiences learnt:
Need jaw/impact crusher
Hammer for items >0.6m
Strong mobile plant tyres
Strong conveyor belts

Finnish Case Study

Started in 1992, grew


steadily to 23 locations
60-70% of all demolition
materials are recycled
Very selective demolition
Tight incoming controls
Pre-cutting with scissors
and hammer to <1m
Used 3 mobile impact
crushers with screens
Made 0-45mm product
with good grading curve
Approved by authorities

Built activity over 8 years


In 2011, up to 0.5mt/y
Prices & profitability up
Had to lobby long and
hard on landfill laws

Finnish Applications
Focused on utilisation in
road construction base &
sub-base layers
Design & utlisation
guidelines published by
road authorities
Quality management
system published as

national standard
Environmental quality
tested by leaching (Cd,
Cr, Cu, Pb, SO4)

Better than natural


aggregates as rehardening adds 1-2MPa
bearing capacity, so layer
thickness can be reduced!

Other Finnish Experiences


Permitting is difficult
Some illegal dumping
Must achieve standards
higher than competitors
Advantage to combine with
other quarry/pit activities
Can be done a contract &
campaign basis
QC must cover grading,
compressive strength, frost
resistance, water content,
impurities & leaching

Other Finnish Experiences

Can recycle in all seasons (down to -30oC)!

Other Finnish Experiences

RA not used in sensitive groundwater areas

Swiss Case Study

Started 10 years ago: strong Government


pressure to increase use of recycled materials
Some operate small mobile crushing units, but
now trend is towards fixed larger recycling plants
Access to
natural
aggregates
is very
limited, also
promotes
recycling

Swiss Experiences
Big focus on selective demolition....

Swiss Experiences
Followed by careful sorting of waste streams....

Swiss Experiences
Removal of steel, metals, plastics, etc....

Swiss Experiences
Often with grading and blending on site....

Swiss Recycling Plants


Then processed at fixed recycling installations....

Swiss Recycling Plants


Including weighbridge, test laboratory, etc....

Swiss Market Demands

Most projects now demand


25-30% of RA in concrete
(also actually incentivised)
New major public projects
must have up to 60% RA in
concrete!
Major challenges on mix
design and pumpability!
Accepted to be more
expensive, also maybe not
optimum environmentally
Must also match C&D
market supply & demand!

Swiss Recycled Products


Requires significant expertise
to produce various fractions
(4-8mm, 8-16mm, 16-32mm)
More profitable, but entails
higher operating costs
Minimise 0-4mm dust as it is
most easily contaminated, not
good for concrete
Rigorous sampling, testing
and reporting protocols, must
be independently verified
Margins typically ~20-30%

The Dutch Experience

Probably the longest


experience in recycling
Driven by lack of natural
resources, high degree of
urbanisation and strong
Government pressures
Landfilling of C&D materials
banned or very costly
Favourable permitting
regime
High public awareness and
acceptance & embedded in
public procurement

Dutch Experiences
Starts with selective demolition, separating out and
selling the separate streams....

Several
of these
streams
may be
quite
valuable
(cables,
plastics,
steel)!

Dutch Experiences
Must remove all hazardous and contaminating
materials (like asbestos, halons, gypsum, etc....)

Dutch Experiences
By-Products (mainly
from demolition site)
may also include:
Wood
Plastics
Metals
Glass
Plasterboard (gypsum)
These also other sources
of income!

Dutch Recycling Technology

May have large mobile installations.....

Dutch Recycling Technology

Or large fixed installations.....

Dutch Recycling Technology


Flowsheet for Van Bentum Recycling Centrale

Dutch Applications
May be used as RoadBase Material (then to
EN 13242), as

Coarse Sub-Base (roads,


airports, etc)
Unbound top layers
(paths, paving layer)

Such uses typically


necessary for Dutch
ground conditions

Dutch Applications
Also for

drains,
dykes,
riverbanks,
fillers,
banks,
lightweight foundations

50

Dutch Applications
Products also are
aggregates for
concrete, mortars
Must then comply
with harmonised
standard EN 12620
Includes testing for

Geometric Properties
Mechanical & Physical
Properties
Thermal & Weathering
Properties
Chemical Properties

Dutch Applications
In concrete, may have
up to 100% replacement
of primary materials,
including fines!
Up to 50% RA without
redesign of mixture
Up to 20% of RA without
notification
Up to C35/45 (EN206-1)
strengths to 65 N/mm2

Accepted in market as
premium products!

Presentation Overview
1.Introduction to UEPG
2. EU Aggregates Production & Recycling Data

3. EU Driving Forces on Recycling


4. Examples of Recycling in Ireland, Finland,
Switzerland (CRH) and Netherlands (FIR/BRBS)
5.Economic, Technical and Other Aspects
6. Some Conclusions & Open Discussion

Useful References - 1
Some very useful publications
are free downloads...

www.concretecentre.com
www.sustainableconcrete.org.uk

www.wbcsdcement.org/recycling

Useful References - 2
Important technical guide
now being finalised by
New Zealand Cement &
Concrete Association
Compares technical
aspects across many
countries (UK, US, OZ,
Germany, Portugal, HK)
Therefore will be a very
useful technical reference
for the recycling industry

Technical Report No. 14

Best Practice Guide


on the
Use of Recycled Materials in
Concrete

CCANZ/BRANZ/AQA

www.ccanz.org.nz

Recovered Aggregates
Recovered
aggregates (1-3% of
demand) from truck
wash-out can perform
as well as natural
aggregates
However re-use leftover sludge and
wash-water may
require testing for
alkalis, sulphates and
chlorides

NZ summary of Restrictions on RA

Draft UK End-of-Waste Criteria


Important UK document
in process of finalisation
Other similar approaches
being developed by
Belgium and Netherlands
Industry is taking the
lead in getting these
adopted at an EU level
Purpose is to reduce
legislative burden and
uncertainty of waste
designation

QUALITY PROTOCOL
End of waste criteria for the
production of aggregates from
inert waste
Contents
Section1: Introduction
Section 2: Producing aggregates
from inert waste
Section 3: Providing evidence of
compliance with the Quality
Protocol
Section 4: Application and use of
recycled aggregates
Appendix A - Definitions
Appendix B - Product standard, specification and
related testing procedures to which this Quality
Protocol applies
Appendix C - Wastes considered to be inert waste for
the purposes of this document
Appendix D - Good practice applicable to the
transport, storage and handling of recycled aggregates

Recycling Truths & Rationales


Truth

Rationale

Cement cannot be recycled

True, but concrete can

Demolition concrete is inert

Generally true, but may require some


leaching tests to confirm inertness

Recycled aggregate can be better than


natural aggregates in some
applications

True, as in road base applications for


example it achieves better compaction;
also can have some cementitious value

Using recycled aggregate reduces


land-use impact

True, less landfilling of waste and less


natural aggregates used

Recycling all C&D materials will not


avoid need for new natural aggregates

True, even recycling of all C&D


materials meets only about 20% of
demand

Figures are not complete for recycling


rates

True, but reporting is improving

Recycling Myths and Realities


Myth

Reality

Concrete cannot be recycled

Yes it can!

Recycled concrete aggregate may not


be used for structural concrete

Yes it can!

Although some concrete can be


recycled, it is not possible to achieve
high rates

Yes it is!

Concrete can be 100% made by


recycling old concrete

Yes, it is possible, but may not be


economically or environmentally viable

Recycling will reduce greenhouse gases Maybe, maybe not (see next slide)
and the Carbon footprint
Recycling into low-grade aggregate is
environmentally the best solution

Thats still an open debate

Recycled aggregate is more expensive

That depends on recycling location


(slide to follow)

Carbon Balance
The UK MPA has
done a detailed
study on the Carbon
footprint of RA
versus natural
aggregates
It concluded that if
the transport
distance for RA is
>15km, there will
be a negative
Carbon impact

Recarbonation through Recycling


Nordic study (2005) has
shown that between 25%
and 50% of the CO2
emitted during the
cement manufacture can
be re-absorbed by
concrete crushed during
recycling!
Confirmed by 2010 New
Zealand study
An unexpected
environmental benefit!

Relative Economics of Recycling

Illustrative Recycling Cost Structure


Waste reception fees
Product sales
Total income
Reception & storage costs
Processing costs
Total production costs
Fixed costs
Operating profit (PBIT)

Euro/tonne
10
3
13
-1
-5
-6
-1
6

100

46
8
46

Presentation Overview
1. Introduction to UEPG
2. EU Aggregates Production & Recycling Data
3. EU Driving Forces on Recycling

4. Examples of Recycling in Ireland, Finland,


Switzerland (CRH) and Netherlands (FIR/BRBS)
5. Economic and Other Aspects
6.Some Conclusions & Open Discussion

Green Building Initiatives


Use of RA gains strong
recognition in several Green
Building Inititiatives, such as:
UK BREEAM (www.breeam.org)
US LEED (www.usgbc.org)
Japanese CASBEE

(http://www.ibec.or.jp/CASBEE/english/
overviewE.htm)

NZ Greenstar (www.nzbgc.org.nz)
Austalian Green Star
(www.gbca.org.au)

Final Comments - 1
C&D recycling is a good business opportunity!
The technology is basically fairly simple
However the bigger challenges are in:

Finding the suitable market niches for the products


Finding reliable high-quality sources of C&D materials
Meeting all relevant technical standards
Finding the way through permitting hoops
Finding the way through unhelpful legislative obstacles

Plan for the long-haul in entering the business


Aim for highest quality and best market position

Regard it RA as complementary business to natural


aggregates, not a competitor

Final Comments -2
Government promotion can stimulate recycling
It can set precedence for a certain % of recycled
materials in public projects through adopting a
points scheme that will favour project bidders
Landfill tax creates a financial incentive for recyclers
Authorities, industry and standard-makers need to
develop and agree standards for recycled materials,
and these standards need to be enforced
Need a fair/easy permitting regime for recyclers
Public needs to be educated that recycling is good

Otherwise good luck to recycling in Colombia!

UNION EUROPENNE DES PRODUCTEURS DE GRANULATS


EUROPISCHER GESTEINSVERBAND
EUROPEAN AGGREGATES ASSOCIATION

The European Aggregates Association

Thanks for your Attention!


Jim OBrien, President UEPG
Bogot DC, Colombia, July 27, 2011

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