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On-Site Reuse of Concrete From Demolition Projects for New Construction Projects– Rich Jones, John Gottleib, Richard Scheidet, and Peter D. Pohlot During 2006, Brookhaven National Laboratory (BNL) demolished 10 buildings/structures while constructing 2 new facilities (the Research Support Building and the Center for Functional Nanomaterials). This paper details how the concrete from the demolition projects was re-used as part of the new construction projects at a significant cost savings to the Laboratory. BNL has an authorization from the New York Department of Environmental Conservation to operate what’s known as the “Borrow Pit”. The Borrow Pit is an area where sand was mined for a Laboratory project, leaving a large void space in the firebreak area south of the Laboratory. The authorization allows BNL to fill the void space with Construction & Demolition (C&D) debris. Approximately 4-years ago when the Borrow Pit was close to capacity, a decision was made to bring in a concrete crusher and mine the Pit to generate Recycled Concrete Aggregate (RCA) to be used around the Laboratory’s firebreak road system to stabilize the roadways and as new road base for new parking areas and roads. Prior to this, the Laboratory purchased virgin crushed blue stone to stabilize the firebreaks. During 2006, numerous older structures (pre-1950) were demolished due to issues such as advanced stages of deterioration, energy inefficiency, and repairs not being cost effective. The following table details the buildings that were demolished and the respective amounts of material (in tons) that were recycled (concrete and metals) and the remains that were sent off-site to a C&D management facility (i.e., roofing shingles, lumber, siding, etc…) Building Concrete Metals C&D 86 300 3 260 326 5 0 18 400 parking lot 2000 0 0 422 80 0 160 445 2600 2 12 527 0 0 150 707/707A 220 20 0 707B 32 0 0 715 6 0 6 753 12 0 12 750 CT & Tank Storage 250 10 0 Totals (tons) 5505 35 618 These demolition projects generated over 5500 tons concrete, which was crushed at the Borrow Pit and recycled as RCA (see Figures 1 and 2). The majority of this RCA (approximately 4800 tons) was used as the predominant base for the parking lots of the two new construction projects – the Research Support Building and the Center for Page 2 Functional Nanomaterials (see Figures 3 and 4). The remainder was used for position: absolu

It was found to be more practical and less expensive to bring a concrete crusher to the site than to haul the 12,750 tons (12 million kilograms) of concrete elsewhere to be crushed. The crusher broke the concrete into pieces of a size that could be put back into the ground as backfill for the new construction. A conservative estimate is that more than $485,000 was saved through recycling and reusing materials on site.

Restoration specialist discovers the benefits of TCP’s compact crusher Specialising in restoration and conversion work, M.E. Endersby Builders of Willington near Bedford frequently has to remove large quantities of broken concrete and bricks from site prior to importing hardcore for new ground floor sub bases and hard standing areas. Recently Mr. Endersby, or ‘Tich’ as he is known by most people, spotted one of TCP’s compact tracked crushers during a visit to his local Wolseley UK Center and he could immediately see the many potential benefits of recycling material on his own projects. These benefits were proved conclusively the very first time the Hi-C40 was hired for a farm building conversion job where several tonnes of rubble were put through the unit for reuse on site. Commenting on the success of the trial, Mr. Endersby said: “I was delighted with the crusher’s performance and ease of use and I will definitely be hiring one on a regular basis to take advantage of both the cost and environmental savings.” The crusher offered by the Hire Center Bedford branch is in fact one of ten units recently purchased by the company. Commenting on the decision to add the machines to its nationwide plant holding, Wolseley UK brand director for Hire David Himsworth said: “Our interest was initially stimulated by an enquiry from the Isle of Man where skip charges have increased fourfold during the last two years. With the planned increases in landfill tax the problems associated with skips are set to escalate dramatically, so we took the decision to add the crushers to our fleet following the success we have already experienced with TCP’s compact tracked dumpers.” The Hi-C40 is powered by a reliable 7.4 kW Kubota diesel engine, offers an impressive crushing force of 60 tonne at the jaw outlet and has an efficient and unique method of external adjustment to provide a finished product size ranging from 20 to 70 mm.

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Finally, if your crushing jobs will be relatively small — under 150 tons per hour — and you will be moving your plant fairly often, Emigh says you should consider a compact, highly mobile “mini-crusher.” These diesel-powered plants are designed with the impact crusher, discharge conveyor, and magnetic separator all on one chassis. They can be driven to the job site and set up, ready to run, in as little as 15 minutes.