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

2. 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.

3. 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

4. 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

5. 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

6. 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
From Jane Street –
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
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)
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

7. 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.

8. 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

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

10. 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

11. 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

12. 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

13. 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

14. 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.

15. 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

16. 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

17. 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.

18. 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:
Vic Roads allows for up to 30% recycled content in asphalt
Code of Practice , 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.

19. 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

20. 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)
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

21. 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

22. 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 Km – 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

23. 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.

24. 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.

25. 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

26. 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

27. 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 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

28. 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 tonnes over 3 months
Also Nillumbik, Sydney, Salisbury, Kingston, Manningham
Dandenong Boroondara Stonnington Hume Banyule

29. 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 Performance Specifications
430,000km Car Travel / 457 Trees

30. 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

31. 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

32. 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
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%

33. 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

34. Thank You – Questions?
State of the Art Asphalt Plants