January 14 – 16, 2007 ● San Antonio, Texas Shingles Recycling: CMRA’s Best Practices Guide A presentation at the CMRA Annual Meeting On Sunday, January 14, 2007

Definitions Manufacturers’ Asphalt Shingle Scrap Tear-Off Asphalt Shingle Scrap Recycled Asphalt Shingles (RAS) (Crushed & screened)

Comprehensive Quality Control Plan  Quality control of supply (Must comply with NESHAP*)  Worker safety and health protection  Final product quality, storage and handling  Shingle recycling system design  Final product sampling and lab testing

“Best Practices Guide” Markets first (especially HMA) RAS product specifications Processing guidelines Worker health and safety Sourcing * Overall system design

Key Barriers Lack of clear industry standards and specifications Inconsistent state regulations Lack of adequate information / technology transfer Lack of national leadership by private industry and government

Acknowledgments Sean Anestis, Roof Top Recycling Ken Snow, Recycle America Enterprises John Adelman, Commercial Paving & Recycling Systems Ron Sines, PJ Keating

Acknowledgements (continued in the midwest) Dusty Ordorff, Bituminous Roadways Jim Omann, Omann Brothers Roger Brown, Pace Construction Joe Schroer, MoDOT Mn/DOT NAPA

CMRA’s Web Site

Multiple Applications Hot mix asphalt (HMA) Aggregate / gravel Dust control Cold patch Ground cover Fuel (e.g., cement kilns) New shingles

Factors Affecting HMA Performance Aggregate gradation of RAS Properties of final blended binder content within the HMA as affected by: –RAS asphalt binder –Virgin binder

Factors Affecting HMA Performance (continued) Location RAS is incorporated into HMA drum Temperature Moisture content of RAS and other aggregates Retention time in HMA drum

Potential Benefits Rutting resistance (especially at warmer temperatures) Conservation of landfill space Economic savings to HMA producer due to reduced need for virgin asphalt binder (add oil)

Potential Disadvantages Contamination (tear-offs) Added costs of processing and use in HMA Increased low-temperature / fatigue cracking

Performance Grading (PG)

Asphalt Grades PG (“PG sixty-four minus twenty-two”) High temperature for rut resistance 64°C (147°F) Low temperature for fatigue and cold weather performance (e.g., cracking) -22°C (-8°F)

Mitigating Low Temperature Impacts of RAS Use less RAS instead of 5% (e.g., use 2% to 3%) Adjust the virgin binder PG to one grade softer (e.g., PG 52-34) Assure minimum amount of virgin binder (regardless of PG )

Engineering Design Philosophy Manufacturing a high quality product Not just recycling a waste material Long-term sustainability

Deleterious Material Nails Other metal Wood Cellophane Other plastic Paper Fiber board

List of Roofing Waste Items Included for Recycling “YES” (Include these items): Asphalt shingles

List of Roofing Waste Items Excluded for Recycling “NO” (Do NOT include): Wood Metal flashings, gutters, etc Nails (best effort) Plastic wrap, buckets Paper waste No other garbage or trash

Lista de material para techos basura artículo para reciclar: Si (Incluya)No / Ningun (No incluya) Repias Madera Papel del fietro Metal: flashings, canales Clavos Plastico Basura de papel La otra basura

Two Sourcing Alternatives Source separation (at the job site) Central processing (at the shingle recycling facility)

Pre-Sorting Inspections prior to any grinding Manual removal of any large items Elevated sorting platform

Require Certification Require written “chain-of-custody” certifications Develop pre-approved customer list of certified suppliers Maintain permanent file of all supply certifications

Grinding Equipment Vendors Examine designs dedicated to shingles Get customer references and then ask the questions about actual operating performance Plan for adequate maintenance

Ayres, April 2004

Dust Control Comprehensive plan Spray with optimum amounts of water at critical grinding stages Shrouds Negative air (i.e., suction) systems to remove ambient dust and light debris Standard employee health and safety protection equipment and procedures

Removal of Nails and Other Ferrous Assure an even layer of material on conveyor belts equipped with magnets Multiple magnets (minimum of three or four) Use combination of pulley belt and overhead magnets Combine metal detection device with manual hand sorting for final quality control process

Final Product Quality Conduct adequate testing Provide quality guarantees Keep covered to reduce unwanted moisture Metered pre-blending with bituminous aggregate or RAP to reduce reagglomeration

Final Product Preparation If stockpiled, pulverization of final product may be necessary immediately prior to use in HMA plant Alternatively, use RAS “fresh” about one week after production to avoid extended stockpiling

RAS Tests Gradation Asphalt content Asphalt cement (AC) performance grade (PG) Debris Moisture

Quality Specs: Scrap Feedstock and Final Products Free of debris / trash / foreign matter Tear-off scrap must be asphalt shingles only No nails!

Economics Tipping fees Value of final product

Business Models Mobile and stationary Multiple products Integrate with existing RAP and aggregate production infrastructures

Multiple Products (Beyond RAS) Clean wood for mulch Clean wood and other organic wastes for biomass fuel Gypsum (sheetrock) for land application Metals for recycling

Regulatory Compliance Pro-active, assertive planning Anticipate requirements Use precedents to your advantage Document adequate market demand to avoid “speculative stockpiling”

Siting Optimize location of tear-off shingles processing facility Consider location of competing landfills and transfer stations Consider location of HMA plants

Additional National Developments New AASHTO specification EPA / CMRA study Asbestos data base

AASHTO Specification (continued) Deleterious material maximum limits (Section 8): (material retained on the No. 4 sieve) –Heavy fraction = 0.50% –Lightweight fraction = 0.05%

Missouri Shingle Spec Extrinsic Material Allowance Raised –3.0% Total –1.5% Wood

AASHTO Specification (continued) Asbestos levels: “…shall be certified to be asbestos free.” (Section 5.2) “(Tear-off shingles are) construction debris and various state and local regulations may be applicable to its use. The user of this specification is advised to contact state and local transportation departments and environmental agencies to determine what additional requirements may be necessary.” (Note 2)

Asbestos Risk Incidence of asbestos is extremely low Average content was only: – 0.02% in 1963 – % in 1973 NAHB, 1999

ASRAS Data Iowa (1,791 samples), no hits Maine (118 samples), no hits Mass: –(2,288 composite samples) 11 hits < 1% –(69 tarpaper samples) 2 < 5% –(109 ground RAS samples) 2 < 1% Florida (287 samples), 2 hits > 1% Ruesch, April 2003.

ASRAS Data (continued) Missouri (6 samples), no hits Hawaii (100 samples), 1 hit > 1% Minnesota (156 samples), no hits Minnesota (50 tarpaper), 1 2% - 5% We still want more data! (for EPA / CMRA project.) Ruesch, April 2003.

DKA / AES Airborne Fiber Tests As part of the RMRC Project: Environmental Testing of Airborne Particles at The Shingle Processing Plant Krivit, April 2003.

Summary Highlights Risk from asbestos is negligible to non- existent Two rounds of sampling for total: –Dust (1999) –Fibers (2002) Common sense and best management practices can help prevent employee exposure Krivit, April 2003.

Asbestos Testing Explore exemption alternative, but if not, then ….. ….develop product sampling plan ….develop supply sampling plan on whole shingles / mixed roofing scrap Recognize that more initial testing may be needed to gather adequate baseline data

Additional Environmental Risks Air emissions impacts from tear-off RAS in HMA plants PAH and other particulates Run-off from whole shingles and RAS stockpiles Run-off from RAS use as ground cover or dust control (in 100% form)

Recommendations 1. Continue MARKET DEVELOPMENT (a) 2. MANAGE the asbestos issue (b) 3. PROTECT employee health and safety (c) 4. GUARANTEE your product quality (d)

CMRA’s Web Site

January 14 – 16, 2007 ● San Antonio, Texas Dan Krivit and Associates