Use of Recycled Materials in Pavement construction Trish McGee, Senior Manager, EY - Climate Change and Sustainability Services 14 May 2015

Use of Recycled Materials in Pavement A number of organisations have been involved for nearly 20 years: Sustainability Victoria MAV VicRoads Resource and Recovery Industry Local government Industry Net Balance/EcoBuy/EY As a result the industry and products have evolved. SITA/Alex fraser/Citywide/Close the loop So not really a trend as an institution but still slow uptake Using recycled materials in appropriate applications can contribute significantly towards making prime non renewable resources last longer. Roads is a great initiative as it is a high user of materials. This is particularly important for applications where virgin hard rock can not be substituted. High quality rock and sand, accessible sources are becoming very limited. Crushed rock under footpaths and slabs should be discouraged.

Environmental Benefits Increase the life of landfills, recovering recycled materials. Increases life of non renewable quarry materials Old buildings and bottles build new roads. Recycled concrete provides a carbon benefit of up to 65% over equivalent virgin quarried material. Recycled crushed concrete are less dense than traditional quarry products, providing a 10-20% weight saving, delivering more material per dollar. Benefits of using recycled materials Reduced impact on the environment Reduced waste to landfill Reduced energy to produce pavement materials Reduced land use conflict Improved security of supply Reduce risk to Council Recycled materials can be cheaper

Local Government Roads 85.6% of Australia’s 887,748 km road network are managed by local government! Victoria - Of 200,340 km Councils manage 176,000 km ! Use Vic Roads Standards

What is important to Local Government? Buy Recycled Business Case Availability and reliability of supply Quality Cost impacts and transport Specification Demonstration of use MAV Survey in 2013 – Use of Recycled Pavement materials Driven by reports of shortages of quarry materials Asked Councils to commit: low response, multi-functional: engineering, works, procurement, contracts (and contractor choice) senior management not involved, timing issues 2013: survey of 30 Councils, 97% use recycled if no cost difference and supply OK New procurement guidelines evolving Business case would be advantageous

Business Case Report: ‘Recycled materials in pavement construction’ Understand availability and benefits on supply of virgin vs recycled material Assisting local government to make an informed and confident choice to use recycled materials in pavement construction Being able to present the case to senior management http://www.sustainability.vic.gov.au/services-and-advice/local-government/recycled-materials-in-pavement From Jane Street – 100.000 tonnes of glass in Victoria. Used 4 million tonnes of glass    Reports of 70% increase in price of quarry materials in Sydney: sourced from 200km It would be great if you can highlight the following in the presentation at the MAV conference: Business case document http://www.sustainability.vic.gov.au/services-and-advice/local-government/recycled-materials-in-pavement VicRoads accredits all sites that produce roadbase from recycled materials and the products themselves. It’s a bit buried on the VicRoads website currently but this is the list of accredited suppliers can be found (or you can ref the doc “management of quarry reference specimens RC500.3) https://www.vicroads.vic.gov.au/~/media/files/technicaldocuments/codes%20of%20practice/code%20of%20practice%20rc%2050003%20%20management%20of%20quarry%20reference%20specimens.ashx Upcoming changes to VicRoads specs – Graeme Newman to advise you on  details VicRoads changes to their own sustainable procurement process – tenders over $10 million have an additional 5 % weighting for sustainability attributes that include use of recycled materials. I’ve attached more info on this but you might like to speak to Simon Renton at VicRoads too. His details are below

Position of Quarry Industry Not a shortage of supply as lack of availability New quarry approvals difficult and costly, up to $1million for $10 million, 200,000 tonne quarry Councils conflict – need aggregate but reluctant to approve new quarries, and risk adverse. Future use of land needs to considered beyond quarry in planning process Environmental/fauna overlays make process onerous Community concerned about encroachment of quarries Encroachment risk of buffer zones Conflict between council team that approves new quarries and team that requires road materials. Extractive development interest areas last mapped in 2003 Significant residential growth has happened since then – requiring more materials but also sterilising interest areas through encroachment. Lack of experience in contractors and council officers in using recycled materials High quality rock and sand, accessible sources are becoming very limited. Crushed rock under footpaths and slabs should be discouraged.

Availability of Pavement Materials 20 million tonne of material required for roads 1 million current used is recycled, 3 million stockpiled or landfilled Recycled material mainly metropolitan and within closer to CBD than quarries Recycling reliant on demolition Both virgin and recycled materials are reliant on construction activity Lack of experience in contractors and council officers in using recycled materials

Victorian quarry and recycling infrastructure Note concentration in the metro areas.

Regional maps – Geelong /Ballarat Central Pavement materials resource map Ballarat, Golden Plains, Hepburn, Moorabool, Pyrenees, Queenscliffe, Surf Coast There is strong availability of clay and basalt towards Geelong and stretching north east to Ballarat (as identified in extensive extractive industry interest areas). The Geelong area is reasonably well serviced by at least four C&D recycling facilities, while at least two facilities operate in Ballarat. . There is strong availability of clay and basalt towards Geelong and stretching north east to Ballarat (as identified in extensive extractive industry interest areas). The Geelong area is reasonably well serviced by at least four C&D recycling facilities, while at least two facilities operate in Ballarat. . C&D Recycling facility Quarry or mine area (existing) Current extractive industry tenement Extractive Industry Interest area

Cost impact and transport Price is comparable - $18-30 per tonne, depending on quality Recycled material can be transported up to 100km but competitive distance is 20km Virgin materials transported up to 30km Regional areas may not be as cost effective for recycled material, however alternate solutions include using mobile crusher Pricing information collected by DSDBI Speak to contractors? Ask councils to nominate section 820 and 821 as an option in pavement contract drawings, to give contract option to use recycled material. Provide fact sheets and guidance documents Get IPWEA to speak to council meeting - very successful in FNQ councils regarding glass

Glass processing infrastructure Glass Reprocessing Infrastructure Regional QLD Hamilton Island Cairns Regional Council Regional NSW Foster/Tuncurry NetWaste Region Shoalhaven Recycling Regional WA Albany, Kalgoorlie Roe Roc Rottnest Island

Quality Recycled material for pavement should meet the VicRoads specifications Significant research has shown that recycled concrete, glass and asphalt can perform as well or better than virgin (Swinburne, ARRB) May have different properties to virgin but is fit for purpose and appropriate to your needs NATA accredited testing ensures it is fit for purpose Products made from recycled materials undergo robust research and testing before being included in VicRoads specifications. Use of products made from recycled materials can provide financial and performance benefits to the asset owner. Properties of concrete (cement), glass (compaction), asphalt (recycled and well accepted) Outdated views or information on recycled materials Used in major roads projects – Grand prix, M8, Airport Risk aversion and concern for viability May have different properties to virgin but should be used fit for purpose. Inconsistent views in council – accept in principle but don’t use recycled materials. Currently will not meet market demands

VicRoads and major projects using recycled materials Eastlink Deer Park by-pass Peninsula Link Western Ring Road upgrade Melbourne Airport Grand prix M8 This is supported by major contracts such as Leighton and Downer Products made from recycled materials are being used in high profile projects.

High level ‘descriptive’ business case The business case for a Council to use recycled over virgin material: Relies on recycled materials being accepted as a substitute for virgin material. An economic decision based on the relative price of recycled and virgin material. Sensitive to the location of a pavement project and relative availability of local recycled or virgin materials. Business case will strengthen in the future: when the available supply of virgin materials from existing local quarries becomes exhausted; and viable quarry locations become increasing sterilised if the location of recycling infrastructure and local supply of waste materials becomes more dispersed, particularly in regional areas Will have long-term benefits (i.e. environmental/social) not captured in price of material Does not diminish the need to develop a sustainable quarrying sector; virgin materials are still be required. Reviewed literature from SV and MAV and additional materials sourced independently or through stakeholders Developed Terms of Reference Interviewed nine stakeholders - CCAA, CMPA, VicRoads, SV, AFGC, Resource Co, Benedicts, Alex Fraser, DSDBI Reflected on previous EcoBuy report finding on pavements

Recycled Materials - Asphalt Asphalt from old roads and car parks VicRoads accepts up to recycled asphalt in road base materials maximum of 20% Recycled asphalt (RAP) supported in hot mix asphalt up to 30% in base course asphalt. Widely accepted within industry RAP perfect for hardstand areas, better performance and dust reduction

Materials Recycling – Glass Fines Glass from kerbside collections produces glass fines which cannot be manufactured into new glass bottles Glass fines are stockpiled or sent to landfill. Glass fines are crushed to produce a recycled sand material Can be used as sand replacement in asphalt manufacture and in applications such as pipe bedding and filter material VicRoads specifications (Technical Note 107) allow for use in Asphalt manufacture and as a component of blended road base/ sub base up to 10% 400,000 tonnes stockpiled, 100,000 in Victoria Approx. 400,000 tonnes of glass is stockpiled around Australia that is not being recycled WHY?? Many of the stockpiles that are occurring around Australia are there because members of the waste industry are aware of the development of potential markets looming in the future. 100,000 in Victoria Suitable alternate markets need to be developed in Australia - The product is being used and has specifications for its use in other countries such as the UK, America, Europe, and NZ. We have just been reticent in Australia to take up the use of recycled crushed glass product yet it has similar properties to natural sand, making it a viable medium for use in pavement mix design.

Materials Recycling –Concrete/Brick Rubble Recycling Construction & Demolition (C&D) waste, consisting of concrete, asphalt, bricks and rubble provides diversion of waste from landfills including the reuse of steel from concrete VicRoads supports recycled crushed concrete materials for road construction Recycled crushed concrete Section 820, design equivalent to Section 812 crushed rock Class 2, Class 3, Class 4, Pipe bedding material, hard stands, footpaths, and car parks Over 2 million tonnes of recycled crushed concrete sold P/A Recent Vicroads initiatives (further info available from Graeme Newman from Vicroads): Joint research with SV and Swinburn Uni providing technical support for use of greater %s of brick in roadbase. Joint research with SV and Swinburn Uni providing technical support to the use of recycled glass sand in cement treated roadbase blends (glass inclusion in recycled roadbase without CT has been approved for some time) Working towards a single specification for “crushed rock” pavement materials – including both virgin materials and recycled materials. This will remove some confusion that currently occurs when only the virgin rock spec is invoked in project specifications. They have implemented a “sustainable procurement” policy on all projects over $10m in value. This policy gives credits to tenderers who bid on the basis of using recycled materials (or other materials with agreed environmental benefits) that are applied in tender assessments (Simon Renton is the Vicroads contact) The use of recycled materials on recent major projects – M80 Upgrade, Eastlink, Peninsular Link, Webb Dock West. This highlights the acceptance of these products in the most demanding of environments. Frequently the high level environmental objectives of Councils do not reflect in the acceptance of recycled pavement materials on the ground – and there is no real technical impediment to their use. There needs to be a stewardship approach to C&D waste generated in their area and for glass waste generated by kerbside collections. Many Councils in metro Melbourne have issued letters that clearly state their position with the acceptance of recycled materials. This provides great assistance in clarifying Council’s position and in communicating that position to designers and contractors. The video with following link may be of interest: https://www.youtube.com/watch?v=0o71ZCIfLsw   Vic Roads allows for up to 30% recycled content in asphalt Code of Practice 500.02, Standard Sections 812, 815 and 702 which have now been issued to various industry bodies for comment. I have also attached a draft copy of Standard Section 821 which is ready to go to SWG for issue. This now permits both brick and glass (< 15%) in CT mixes initially on lower trafficked roads. Standard Section 813 is still undergoing a bit of final editing and should be available shortly and then to SWG for issue.  I will forward a copy as soon as it is finalised.

Materials Recycling – Toner, and others Toner Pave - Partnership between Downer and Close the Loop. Toner modified GTR (Ground Tyre Rubber) Acrylic emulsions (Paint) Oil Fly ash Also toner, rubber, plastics, paint Because the constructions companyesrecyclers focus on the chemical components rather than source. Low Carbon asphalt for Innovative Australian Local Government

Specifications and VicRoads VicRoads accredits recycled product suppliers. (Refer to RC500.3 for accredited suppliers) Increasing VicRoads activity in using recycled materials in pavements and results in new standards (15-30% glass/brick) Specification testing (15% & 30%) and workshops VicRoads currently reviewing technical note 107 and specifications One specification 812 & 820 for road base materials. Self regulation Code of Practice VicRoads 5% weighting for sustainability/recycled content and local purchasing VicRoads accredits all sites that produce roadbase from recycled materials and the products themselves. It’s a bit buried on the VicRoads website currently but this is the list of accredited suppliers can be found (or you can ref the doc “management of quarry reference specimens RC500.3) https://www.vicroads.vic.gov.au/~/media/files/technicaldocuments/codes%20of%20practice/code%20of%20practice%20rc%2050003%20%20management%20of%20quarry%20reference%20specimens.ashx Upcoming changes to VicRoads specs – Graeme Newman to advise you on  details VicRoads changes to their own sustainable procurement process – tenders over $10 million have an additional 5 % weighting for sustainability attributes that include use of recycled materials. I’ve attached more info on this but you might like to speak to Simon Renton at VicRoads too. His details are below

Recycled Roads to Zero Waste Municipal Association Victoria - (MAV) Swinburne University, ARRB, Manningham, Brimbank, Surf Coast, Bayside and Port Philip Councils, Sustainability Victoria 4 x shared pathway sites using 15% & 30% Recycled Glass Sand in 150mm-200mm sub-base Results 255 tonnes recycled material used Specifications developed for recycled glass in base aggregate GHD cost benefit report ARRB report To numerous to mention

Recycled Pavement to Zero Waste Before construction After construction Casey council also actively uses recycled materials Construction projects $100M capital program >$30M civil works Footpaths 12.5km – replacement 40.8Km – New Pavement 27.6km – New Asphalt 14.3km – resurfacing 27.5km – New Spray Seal 44.6km – reseals Maintenance 9.5t asphalt/day 40,000t rock gravel roads Steampacket Place, Geelong

Recycled Roads to Zero Waste Brown Property Group The Avenue Estate and Village Shopping Centre, at Cranbourne. 1500 lot sub-division 14 km of roads Supplied 22,000 tonnes of 20mm recycled crushed concrete class 3 & class 4. Material used in sub-base layer in roads, under shopping centre slab, and car park.

Tasmania TAS - DEMONSTRATION SITES Clarence City Council, Hazell Bros P/L, Roadways P/L Tasmania – Rosney Park, Bastick ST 53 tonnes RCG = >250k stubbies ASPHALT 13T - 15% RCG, 8% sand PIPE BEDDING 33T - 100% CONCRETE 7T - 24% RCG of total fine aggregate per m3. of mix used Rosny Tennis court car park - 3 applications – base/ pipe embedment material, kerbing and asphalt. Used 53 tonnes of crushed glass sand In partnership with Clarence City Council, Hazel Bros and Veolia. The original site was uneven clay surface with deep ruts from rain water running over its surface. Works included drainage work using 33T of RCG as pipe embedment. Surfacing of the car park area with asphalt using 15% RCG equating to13T in the wearing course mix. Concrete pathway was also constructed linking the carpark to the tennis club and nearby Bastick St bus shelter using 7 T RCG which was 24% of the total fine aggregate per cubic metre of mix used.

Waverley Council NSW Blair Street Bondi Junction NSW Performance Constructed in 1926 completed March 2011 16,000 vehicles per day 130 bus movements per day Pavement details: 100m long x 3m wide travelling lane 40 Mpa concrete saw cuts at 4.2m thickness of concrete 225mm using a control, 44% glass and 56% sand replacement with glass. (RTA QA Specification R83) Performance Both surfaces performing well Showing no visible signs of deterioration Visible inspection of concrete surface appears to be stronger. Conclusion The use of Recovered Crushed Glass in civil road construction is a viable medium Cost benefits can be achieved via the use of RCG in road construction RCG is available for civil construction purposes in some areas In regional and rural areas the production of locally produced RCG can prove to be an economical and environmentally sustainable solution

O’Brien St Bondi Junction Constructed in 1926 completed March 2011 16,000 vehicles per day 130 bus movements per day Pavement details: 100m long x 3m wide travelling lane 40 Mpa concrete saw cuts at 4.2m thickness of concrete 225mm using a control, 44% glass and 56% sand replacement with glass. (RTA QA Specification R83) Performance Both surfaces performing well Showing no visible signs of deterioration Visible inspection of concrete surface appears to be stronger. Conclusion The use of Recovered Crushed Glass in civil road construction is a viable medium Cost benefits can be achieved via the use of RCG in road construction RCG is available for civil construction purposes in some areas In regional and rural areas the production of locally produced RCG can prove to be an economical and environmentally sustainable solution

Western Australia Shire Augusta Margaret River 100 tonnes RCG Two sections 1x 200m asphalt 1x 215m granular 5%RCG, in conformity with Australian Standard AS 2150 and relevant Aust Roads and AAPA specifications Constructed in 1926 completed March 2011 16,000 vehicles per day 130 bus movements per day Pavement details: 100m long x 3m wide travelling lane 40 Mpa concrete saw cuts at 4.2m thickness of concrete 225mm using a control, 44% glass and 56% sand replacement with glass. (RTA QA Specification R83) Performance Both surfaces performing well Showing no visible signs of deterioration Visible inspection of concrete surface appears to be stronger. Conclusion The use of Recovered Crushed Glass in civil road construction is a viable medium Cost benefits can be achieved via the use of RCG in road construction RCG is available for civil construction purposes in some areas In regional and rural areas the production of locally produced RCG can prove to be an economical and environmentally sustainable solution

Toner Pave – 35 demonstration sites Victoria Boroondara Hume Greater Dandenong Banyule Manningham Kingston Nillumbik Mornington Peninsula   South Australia City of Salisbury New South Wales City of Sydney Warringah 35 sites -6091 tonnes over 3 months Also Nillumbik, Sydney, Salisbury, Kingston, Manningham Dandenong Boroondara Stonnington Hume Banyule 153 218 71 411 68 203 388 70 75 57 161 421 76 139 81 201 283 204 65 101 196 102 152 205 80 62 207 235 631 210 200 227 62 76 68 1176 1846 870 1602 597

Downer Low CO2 Asphalt Nearly 1 million tonnes recycled mix supplied Over 3100 jobs/projects 20% Reduction In Emissions 38 NATA accredited laboratories Australia wide World class research staff with combined >100 years experience in civil engineering, chemical engineering, geotechnical & material science Specialist Asphalt Designs – Airfields, Helipads, Military Installations, Race Tracks, Container Yards Proprietary Binders Since 2007 430,000km Car Travel / 457 Trees Energetics Low CO2 Asphalt = High Performance Asphalt Low CO2 Asphalt is the way forward to ensure a sustainable industry Low CO2 Asphalt has been accepted and placed in numerous Victorian councils LCA designed to have a significant reduction in greenhouse gas emissions LCA designed to perform equal to or better than the virgin counterpart LCA is Designed to Meet VicRoads RC 500.01 Performance Specifications 430,000km Car Travel / 457 Trees

Identified as no greater risk than natural aggregate What about OHS? e.g. -reduced risk of silicosis -non toxic product -no sharp edges -MSDS Identified as no greater risk than natural aggregate

Specifications for recycled glass e.g. -reduced risk of silicosis -non toxic product -no sharp edges -MSDS MODULUS AND DEGRADATION REPORT Accelerated modulus testing Performance confirmed Positive degradation results Evidence based results

Recycled materials in pavement construction Recommendations for Councils: Commit to use of recycled material which meets specifications and cost (Council choice) Identify current availability of recycled material and potential barriers in your Council Require contractors to report on their use of RM Develop a strategy to increase use of recycled content: discuss with contractors Include VicRoads spec 820 and 821 for road design Refer to Business case for your region at www.sustainability.vic.gov.au Option to use recycled materials OR Where there is supply at cost competitive rates, Council preference is for recycled materials in blends of 15%-30%

Acknowledgements Chris Jeffreys - formerly from PSF Dean Reid - Resource Co Mark Barraclough - Alex Fraser Vicki Shelton - City of Greater Geelong Jane Street - Sustainability Victoria John Hennessy - MAV Steve Morriss - Close the Loop Graham Newman - VicRoads John Hassall - CityWide Concrete Recycling Since 1992 concrete recycling operation core business for ResourceCo Group Victorian operation started in 2010 primarily process Construction & Demolition (C&D) Now processing in excess of 800,000 tonnes of recycled concrete per annum in SA & VIC

Thank You – Questions? State of the Art Asphalt Plants