SAMARISsamaris.zag.si/docsys/documents/SAM_GE_DE15v01_01.pdf · Foundry sand Material obtained as a by-product during processing of steel (used foundry mould). Clear reclaimed foundry

Competitive and Sustainable Growth (GROWTH) Programme

SAMARIS Sustainable and Advanc r Road InfraStructure

REPORT

ed MAterials fo

in road construction and rehabilitation in the Central and East European countries

Review of the state of art in road and other industry by-product use

Document number: SAM-06-DE15 FINAL Date: 2004-09-30

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TABLE OF CONTENTS 0 ABSTRACT........................................................................................................................6

1 INTRODUCTION .............................................................................................................7

1.1 Scope .............................................................................................................................7 1.2 Reporting countries .....................................................................................................7 1.3 Terminology .................................................................................................................8

1.3.1 General...................................................................................................................................8 1.3.2 Specification and definition of road by-products ...................................................................8 1.3.3 By-products from the metallurgical industry..........................................................................9 1.3.4 By-products from other industries..........................................................................................9 1.3.5 Road materials .....................................................................................................................10

1.4 Report structure and methodology ..........................................................................11 1.4.1 Assessment of use of various by-product materials ..............................................................11 1.4.2 Assessment of the waste management and recycling policy .................................................11

1.5 The main influence on the use of by-products ........................................................11

2 RECYCLLNG OF ROAD BY-PRODUCTS.................................................................13

2.1 Survey from CEE countries ......................................................................................13 2.2 By-products and their use .........................................................................................13

2.2.1 Reclaimed Asphalt Pavement (RAP) ....................................................................................13 2.2.2 Reclaimed Concrete Pavement (RCP)..................................................................................15 2.2.3 Reclaimed base and subbase material..................................................................................15 2.2.4 Mixed RAP, RCP and reclaimed base and subbase material...............................................16 2.2.5 Technical guidelines and specifications ...............................................................................16

2.3 Environmental requirements for recycling .............................................................16 2.4 Situation in particular countries ..............................................................................17

2.4.1 Belarus .................................................................................................................................17 2.4.2 Bulgaria................................................................................................................................17 2.4.3 Czech Republic .....................................................................................................................17 2.4.4 Hungary................................................................................................................................21 2.4.5 Poland .................................................................................................................................21 2.4.6 Romania ...............................................................................................................................21 2.4.7 Russia ...................................................................................................................................21 2.4.8 Slovakia ................................................................................................................................21 2.4.9 Slovenia ................................................................................................................................22 2.4.10 Ukraine.................................................................................................................................22

2.5 Conclusions.................................................................................................................22

3 RECYCLING OF NON-ROAD BY-PRODUCTS........................................................23

3.1 Survey from CEE countries ......................................................................................23 3.2 Non road by-products................................................................................................23 3.3 Non road by-products and their uses .......................................................................23

3.3.1 By-products from the metallurgical industry........................................................................28 3.3.2 By-products from other industries........................................................................................29

3.4 Situation in particular countries ..............................................................................31 3.4.1 Belarus .................................................................................................................................31 3.4.2 Bulgaria................................................................................................................................31 3.4.3 Czech Republic .....................................................................................................................31 3.4.4 Hungary................................................................................................................................33 3.4.5 Poland ..................................................................................................................................33 3.4.6 Romania ...............................................................................................................................34 3.4.7 Russia ...................................................................................................................................34 3.4.8 Slovakia ................................................................................................................................34 3.4.9 Slovenia ................................................................................................................................34

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3.4.10 Ukraine.................................................................................................................................35 3.5 Conclusions.................................................................................................................35

4 STRATEGIES PROMOTING RECYCLING..............................................................36

4.1 Introduction................................................................................................................36 4.2 Policy in particular countries....................................................................................36 4.3 Responsibilities...........................................................................................................37 4.4 Market parties............................................................................................................38 4.5 Market forces .............................................................................................................39 4.6 Instruments.................................................................................................................39 4.7 Requirements and criteria for acceptance of by-products.....................................40 4.8 Market introduction ..................................................................................................42 4.9 Barriers - obstruction ................................................................................................42 4.10 Incentives - Stimulation...........................................................................................44 4.11 Knowledge transfer..................................................................................................45 4.12 Conclusions...............................................................................................................45

5 CONCLUSIONS AND RECOMMENDATIONS.........................................................46

ANNEX A..................................................................................................................................49

0 WP6 QUESTIONNAIRE..........................................................................................51 Survey A: Road By-products ..........................................................................................51 Survey B: Other By-products (Non-Road Materials)...................................................53 Survey C: Policy/Strategy of Recycling .........................................................................55

1 BELARUS.........................................................................................................................57

Survey A: Road By-products ..........................................................................................57 Survey B: Other By-products (Non-Highway Materials) ............................................57 Survey C: Policy/Strategy of Recycling .........................................................................57

2 NO.BULGARIA...............................................................................................................58

2 BULGARIA......................................................................................................................58

Survey A: Road By-products ..........................................................................................58 Survey B: Other By-products (Non-Highway Materials) ............................................60

3 CZECH REPUBLIC........................................................................................................62

Survey A: Road By-products ..........................................................................................62 Survey C: Policy/Strategy of Recycling .........................................................................74

4 HUNGARY.......................................................................................................................77


5 POLAND...........................................................................................................................85


6 ROMANIA .....................................................................................................................101

Survey A: Road By-products ........................................................................................101 Survey B: Other By-products (Non-Highway Materials) ..........................................103

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Survey C: Policy/Strategy of Recycling .......................................................................105

7 RUSSIA...........................................................................................................................106

Survey A: Road By-products ........................................................................................106 Survey B: Other By-products (Non-Highway Materials) ..........................................108 Survey C: Policy/Strategy of Recycling .......................................................................110 Survey C: Policy/Strategy of Recycling .......................................................................111

8 SLOVAKIA ....................................................................................................................113

Survey A: Road By-products ........................................................................................113 Survey B: Other By-products (Non-Highway Materials) ..........................................116

9 SLOVENIA.....................................................................................................................120

Survey A: Road By-products ........................................................................................120 Survey B: Other By-products (Non-Highway Materials) ..........................................122 Survey C: Policy/Strategy of Recycling .......................................................................126

10 UKRAINE.......................................................................................................................127

Survey A: Road By-products ........................................................................................127 Survey B: Other By-products (Non-Highway Materials) ..........................................131 Survey C: Policy/Strategy of Recycling .......................................................................138

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0 ABSTRACT The report presents a review of the current state of road and other industry by-products use

in road construction and rehabilitation in the Central and East European (CEE) countries. It assesses the extent of current use of various by-product materials and the recycling policies in these countries. The report is organized into five chapters and one annex.

Chapter 1 presents the scope, terminology and methodology of the report. Chapter 2 presents the use of road materials and recycling technologies in road construction

and rehabilitation. Chapter 3 presents the use of industrial by-products in road construction. Chapter 4 describes the policy, obstructions and promotion of the use of by-products and

recycling technologies. Chapter 5 presents the conclusions and recommendations. Annex A contains all responses to the questionnaire submitted by CEE countries. The Annex

A also includes the list of laws, goverment regulations, standards dealing with test methods and product specifications, and CEE countries recommendations.

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1 INTRODUCTION

1.1 Scope

The scope of this report is to survey road and other industry by-products used in road construction and rehabilitation in the Central and East European countries (CEE countries). The report was prepared in the frame of the SAMARIS project by Working Group 6 (WP 6). On the basis of this report a set of technical recommendations dealing with road and other industry by-products use in road construction and rehabilitation will be prepared (as activity of WP 6) Technical Recommendations will serve as a technical guide helping the administration bodies and road contractors in CEE countries.

The report was prepared on the basis of a WP 6 questionnaire. The questionnaire was the same as the OECD one, on the base of which the OECD report “Recycling strategies for roadwork” was prepared in the year l997. Therefore, some parts of the report are formally similar.

The report presents data collected from questionnaire answers of national reporters.

1.2 Reporting countries

The report was elaborated on the base of a WP 6 questionnaire and the responses were received from the following CEE countries:

1. Belarus (BY), 2. Bulgaria (BG), 3. Czech Republic (CZ), 4. Hungary (H), 5. Poland (PL), 6. Romania (RO), 7. Russia (RUS), 8. Slovakia (SK), 9. Slovenia (SLO), 10. Ukraine (UA).

No response was received from Estonia, Latvia and Lithuania though the questionnaire was sent to 3 experts of each of these countries.

The report was prepared by the following SAMARIS contractors: Brno University of Technology (TU Brno, CZ) and Road and Bridges Research Institute Warsaw (IBDiM, PL).

TU Brno prepared and evaluated the questionnaire responses from: BG, CZ, H, SLO and SK. IBDiM prepared and evaluated the questionnaire responses from: BY, PL, RUS, RO and

UA. The report was completed and the results were evaluated by TU Brno. The responsible

authors are Jan Kudrna and Michal Varaus.

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1.3 Terminology

For the purposes of the report the members of WP 6 agreed to use the following definitions of materials mentioned in the report.

1.3.1 General

By-product Material obtained during production of another material, which is considered to be the main

product.

Waste Material remaining at the end of the consumption cycle; it is a useless, unwanted or

discarded material.

Secondary material It is a common term for a by-product or waste that can be used as a raw material for any

product.

Recycling Recovery of a material from the waste stream and processing it, if necessary, so it may be

used again as raw material for products that may or may not be similar to the original product from which it is derived.

Reuse Recovery of a material from the waste stream that is to be used in the same kind of

application as before, without any change of its identity.

1.3.2 Specification and definition of road by-products

Reclaimed Asphalt Pavement (RAP) Reclaimed asphalt pavement material is a material obtained during disposal or reconstruction

of old asphalt pavements. It is a product consisting of approximately 95 % by mass of natural aggregate or by-products aggregate and remaining 5 % by mass of bitumen.

Reclaimed Concrete Pavement (RCP) This material arises from the demolition of concrete pavement (highways, runways,

provisional road constructions). This recovered material consists of well-graded aggregate that is bonded by hardened cement paste.

Reclaimed base and subbase material Base or subbase layers are composed of bound or unbound materials. Base unbound

materials include mainly mined or crushed rock; bound layers consist of crushed rock or/and natural aggregate with binder (cement, binder suspension). Materials obtained from reclaimed subbase are reused for the construction of a road structure. Reclaimed base and subbase materials are obtained during disposal roadways or railways to be reconstructed.

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Mixed RAP, RCP and reclaimed base and sub-base Mixture of reclaimed asphalt pavement material or concrete from concrete pavements with

reclaimed base and/or subbase.

1.3.3 By-products from the metallurgical industry

Blast furnace slag, air cooled Blast furnace slag is a by-product obtained during production of pig iron. Air-cooled blast

furnace slag cools slowly in open air; it can be used especially in road construction.

Blast furnace slag, ground granulated Using water to hasten the cooling process granulated blast furnace slag is produced. This

material can be used as a replacement for natural aggregates of unbound and stabilised base layers and ground material is also used for the Portland blast-furnace cement.

Steel slag Material obtained as a by-product during production of steel. It is a hard material with

characteristics similar to gravel. Crushed steel slag is advisable for use in civil engineering.

Non-ferrous slag Non-ferrous slags are produced during the recovery and processing of metals such as copper,

nickel, lead, zinc and phosphorus from natural ores. These materials can be used in hot mix asphalt and rail ballast.

Foundry sand Material obtained as a by-product during processing of steel (used foundry mould). Clear

reclaimed foundry sand is reused in processing of steel and the devalued reclaimed foundry sand can be used for road construction or as a replacement for natural aggregates in concrete.

1.3.4 By-products from other industries

Coal fly ash These ashes are by-products from burning coal used as a fuel in power stations or heating

plants. The fly ash is collected in electrostatic filters or wet collectors of the air pollution control system through which smoke passes during combustion. Coal fly ash is usually used as a supplementary cementitious material in Portland cement concrete and filler in hot mix asphalts, as well as in stabilised base and embankments. Using lime or cement it can also be stabilised itself to produce artificial aggregate.

Coal bottom ash Bottom ash is coarser agglomerate that is collected in chambers at the bottom of the furnace.

This material can be used as a lightweight substitute for sand in base and subbase courses or in embankments, fills or reclamation of land.

Mine waste rock Mine waste rock is a waste product obtained during a mine activity. This by-product is

usually composed of large-size particles. If this material is similar to a conventional aggregate, the same type of equipment can be used. Suitable mining waste rock can be used as aggregate

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in all pavement layers (after crushing and screening). Unsuitable mining waste rock is used in embankment.

Municipal solid waste incinerator bottom ash Incinerator bottom ash is a residue from the incineration of solid municipal waste composed

of combustible materials (paper, food waste, packaging materials, etc.). This by-product is advisable for use in civil engineering - road construction (granular subbase courses, embankments and fills) and for land reclamation.

Scrap tyres Incorporation of ground rubber from scrap tyres into hot mixture asphalts can be carried out

using two processes - wet or dry. In the wet process, a very fine ground rubber is blended with asphalt binder and a binder modified in this way is added to the aggregate. In the dry process a ground rubber is used as a partial substitute for fine aggregate in the hot mix asphalt. An alternative use of scrap tyres has been found in noise barriers, erosion protection, embankments or they can be used as a fuel.

Waste glass The principal reuse of glass is its recycling in glass factories. Small amount of this material

is experimentally used in road engineering as an aggregate in Portland cement concrete wearing courses and hydraulic bound road base.

Building demolition materials This by-product can include reinforcing steel, tiles, bricks and other building materials.

Waste concrete, tiles and bricks from buildings are in large quantities obtained during the demolition process. These materials are processed by selection, crushing, removal of reinforcing steel, sieving and washing, and are usually used in unbound bases or subbases of roads.

1.3.5 Road materials Pavement is the part of the road structure above the subgrade (improved subgrade). The

structure consists of one or more courses to assist the flow of traffic over terrain. Asphalt concrete, also known as bituminous concrete, is a mixture of bitumen and well-

graded aggregate used in paving applications. Asphalt concrete is used in wearing, binder and base courses. In this report the term Hot Mix Asphalt (HMA) is also used.

Cement concrete, also known as Portland cement concrete, is a mixture of coarse and fine aggregate and hardened cement paste (that is the product of the chemical reaction between Portland cement and water).

Base course is the main structural element of a pavement. The base may be laid in one or more courses described as “upper” base course, “lower” base course, etc. The base can be unbound (granular base) or a bound (stabilized) one. The binder in bound bases can be Portland cement and/or other binders (lime, pozzolana or ground granulated blast furnace slag, bitumen, bitumen emulsion or bitumen foam).

Subbase is the first layer of pavement construction, the lowest base course, that is usually unbound. It is not necessary that this layer is in all types of road constructions. This layer is mostly added to protect the subgrade from the penetration of frost.

Subgrade is soil (in embankment and cut) prepared to support a pavement; it is a layer influenced by traffic loading and climate.

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1.4 Report structure and methodology

The tasks undertaken by the WP 6 to fulfil the study objectives are listed and described below.

1.4.1 Assessment of use of various by-product materials This assessment was accomplished on the base of distribution of the survey questionnaire in

the CEE countries. Materials generated in road construction were considered separately from those generated in

other industries. Regarding road materials the information requested in the survey included the amount of

annual production of different road materials and percentage of their different road applications. This information as well as some comments dealing with applied technologies, test methods, guidelines and description of any new techniques are given in Chapter 2 of the Report. The summary and the answers to the questionnaires from each country are given in Annex A.

For non-road materials, the information requested included extent of use (rated on a numerical scale in various road applications). For these materials and application combinations currently in use, additional information was requested on amounts, material tests and acceptance criteria, construction equipment and procedures, quality control tests, standard specifications and factors used in evaluation of environmental and economic suitability. A summary of this survey is included in Chapter 3, Annex A, Survey Results, presenting the summaries and complete responses received from the mentioned countries.

1.4.2 Assessment of the waste management and recycling policy This task was also accomplished by the survey. Information requested dealt with official

policy, organisation(s), responsibilities of the policy, economic issues affecting the policy, regulations, obstructions to implementation and technology transfer. The summaries of these surveys are in Chapter 4 and the answers to the questionnaires from each country are given in Annex A.

1.5 The main influence on the use of by-products

The main benefits of road and other industry by-products use in the road construction are known in the CEE countries. The EU legislation is obligatory for those CEE countries that are its members. The technologies of recycling are also known but comparing to West European countries their usage and application is not widespread in such an extent..

There are several reasons for the rare use of by-products and recycling technologies in these countries:

• The economical decrease in transformation period caused the decrease in the road construction industry production.

• After privatisation foreign investments were usually put into industry producing the natural construction materials (quarry, Portland cement and lime industry) and quality and quantity of products increased at relatively low price.

• The waste treatment technology was supported from the ecological point of view; the whole cycle of secondary materials use was not proportionally developed.

• Wider use of recycling technologies of road pavement materials depends on national road rehabilitation programs. Due to government economical problems rehabilitation of roads has been minimized.

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• Technology transfer helps to recycling technologies use but it is necessary to develop national requirements complying with local material and climate conditions. Long-term experience will signal the necessary improvements on testing and technologies.

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2 RECYCLLNG OF ROAD BY-PRODUCTS

2.1 Survey from CEE countries

This Chapter describes the characteristics of road by-products currently being recycled in countries mentioned in 1.2. The Chapter also provides information from the survey concerning uses of each by-product. A survey of technical guidelines and specifications used in mentioned countries is collected in Annex A.

The most commonly used by-products in the road construction discussed in this Chapter are: a) Reclaimed Asphalt Pavement (RAP); b) Reclaimed Concrete Pavement (RCP); c) Reclaimed base and subbase material; d) Mixed RAP, RCP and reclaimed base and subbase material. The definitions of mentioned by-products are given in Chapter 1.3.

2.2 By-products and their use

Table 2.1 provides the survey results for the most commonly used road by-products. For each available by-product (e.g. reclaimed asphalt pavement, reclaimed concrete pavement, etc.) the amount in thousands of tonnes produced in the previous years (2002 or 2003) is registered. The particular uses of these available materials expressed in percentage are listed, too.

2.2.1 Reclaimed Asphalt Pavement (RAP)

Characteristics of available by-products The bitumen used in asphalt concrete is mainly produced from Russian crude oil. A usual

gradation of virgin bitumen was 70/100, in northern part of Russia the gradation was softer (160/220), in central and southern countries bitumen 50/70 was used. The usage of polymer modified bitumens has started relatively recently and these bitumens are rarely contained in the RAP.

Bitumen in bituminous hot mixtures usually does not contain coal tar. Coal tar contains significant Polynuclear Aromatic Hydrocarbons (PAH) concentrations. Nevertheless, coal tar was used for many years in pavement construction in the layer known as penetration macadam and also in surface treatments that were applied for its maintenance. Some countries indicated that a significant portion of their existing pavements contains coal tar, which may impede recycling.

Use of the by-products As can be seen in Table 2.1, the responding countries produce very different amount of road

by-products. Generally, reclaimed asphalt is used for the production of HMA (in plant and in situ). Some

countries recycle the available amount of this by-product in new HMA. In this case RAP can be added either cold or hot. Several countries use both hot-mix and cold-mix technologies.

The process of reclaimed asphalt used in recycled HMA (plant mix) respects all important characteristics, such as moisture content, bitumen content and aggregate gradation. Simultaneously, the penetration of the recovered bitumen is evaluated and virgin bitumen is

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added to influence the stiffness of aged bitumen in the recycled material. The processed material should be free of contaminants, such as excess granular material, surface treatments and joint sealant material. As the material coming from several pavements exhibiting different properties is stockpiled before processing, the homogeneity of reclaimed asphalt pavement properties should be ensured. The maximum particle size is 22 mm or 32 mm. The amount of reclaimed asphalt pavement that can be practically processed in a conventional batch-type plant is 25 percent, and 50 percent (80 % at max.) in drum-mix plant. The total amount of processed RAP and its percentage division into different applications in particular countries were investigated. Some of the CEE countries have to submit the annual data about the amount of produced asphalt mixtures and the amount of RAP for EAPA statistics (European Asphalt Pavement Association). These amounts do not comply with the data found in the questionnaire surveys.

Concerning in situ hot recycling the existing pavement is evaluated to ascertain the pavement thickness, density, aggregate gradation, bitumen content penetration, softening point of the recovered bitumen and the air voids of the mix. Surface treatments, rubberised joint or crack sealants and spray patching material are removed prior to recycling. Wearing courses recycled in situ using the remix method can incorporate up to 80 percent of the original wearing course, provided that the recycled material complies with the specification for wearing courses.

Thickness of the layer, bitumen content, gradation and recovered bitumen penetration is determined for cold in-situ recycling as well.

Table 2.1 – Commonly recycled road by-products

Available Products

Applications BY BG CZ H PL RO RUS SK SLO UA

Available RAP per year (kt)

3 690 50 140 300 22 30 10 355

Plant recycling (%) - 20 20 20 50 - - 80 3 In situ recycling (%) 100 50 15 80 30 50 40 - 11 Stock (%) - 20 65 - 15 - 30 15 86

Reclaimed Asphalt Pavement (RAP)

Landfill (%) - 10 - - 5 50 30 5 - Available RCP per year (kt)

- 10 5 200 100 - - - -

Plant recycling (%) - 45 50 100 - - - - - In situ recycling (%) - - 50 - 85 - - - - Stock (%) - 15 - - 15 - - - -

Reclaimed Concrete Pavement

(RCP)

Landfill (%) - 40 - - - - - - - Available material per year (kt)

- 50 7 420 150 - - - 10

Plant recycling (%) - - - - - - - - - In situ recycling (%) - 100 100 100 100 - - - 100 Stock (%) - - - - - - - - -

Reclaimed Base and Subbase

Landfill (%) - - - - - - - - -

To a great extent reclaimed asphalt pavement is also used for stabilised bases, unbound

bases, subbases, and fills. When reclaimed asphalt is used in unbound base applications, it is blended with aggregate to

meet the physical requirements specified for conventional granular base materials (consistent gradation is particularly important). If only reclaimed asphalt is used in unbound base of usual

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thickness, the permanent deformations caused by static loading may occur. That is why a thin layer of reclaimed asphalt (approx. 50 mm) is preferred.

2.2.2 Reclaimed Concrete Pavement (RCP)

Characteristics of available by-products The reclaimed concrete pavement refers to Portland cement concrete recovered in the course

of demolition of roads, runways and concrete curbs and gutters. The reclaimed concrete pavement may be contaminated with chloride ions due to the

application of de-icing salts to roadway surfaces, sulphates generated from contact with sulphate-rich soils, and presence of alkali-reactive aggregates is also known.

Concrete pavement can be recycled in situ by breaking the existing concrete slabs and then overlaying it with a new asphalt surface. Alternatively, the existing concrete can be broken up, removed and crushed into aggregate sizes at a central plant. Both reusing of Portland cement pavement are mentioned in figures of Table 2.1.

Use of the by-products, Reclaimed concrete pavement is used for newly constructed cement concrete binder courses

of rigid pavements. In several CEE countries it is mostly used in unbound base and cement-stabilised base courses.

Several factors, including gradation, bearing capacity, durability and drainage characteristics are considered when reclaimed concrete pavement is used as an unbound base material. Crushed reclaimed concrete pavement exhibits good resistance to weathering and erosion, and as long as an excessive amount of crushed reclaimed concrete pavement fines is not used, the resulting base is usually free-draining, non-plastic and non frost-susceptible. The inclusion of bitumen-coated particles (from an overlay, asphalt patching or asphalt base interlayer) is not harmful as their content is 10 % at max.

Reclaimed concrete pavement is also recycled as aggregate in Portland cement concrete pavements. The coarse portion of reclaimed concrete pavement substitutes up to 100 % of conventional coarse aggregate in cement concrete. However, to avoid workability problems, the replacement of conventional fine aggregate with reclaimed concrete pavement fines should be limited to 20 percent or less by mass. The level of impurities in reclaimed concrete pavement should not exceed the allowable limits for virgin aggregate. Similarly, the potential reactivity of reclaimed concrete pavement containing alkali-reactive aggregate must be kept within the allowable limits for conventional materials. To ensure uniformity of the aggregate properties reclaimed concrete materials from different sources or types of concrete should be properly blended or separately processed in large stockpiles.

Reclaimed concrete was usually used as a coarse aggregate in asphalt concrete and only bitumen content was a bit higher (the content is designed in accordance with an improved Marshall test).

2.2.3 Reclaimed base and subbase material Reclaimed base and subbase (also referred to as Reclaimed Aggregate Material or RAM) is

reported as a by-product that is used in most countries. This by-product is primarily used for cement-stabilised bases, unbound bases and as the material used in subgrade or embankment. Some reclaimed base or subbase materials are also used in noise-reduction barriers. In general, the recycled material being used must fulfil the same requirements as a new base or subbase material or must fulfil the requirements for its use in embankments.

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Reclaimed base and subbase materials are also used in cold recycling (in situ) with Portland cement and bituminous emulsion binder or bituminous foam. The use of hydraulic binders (mixture of cement, lime, fly ash and other binders, eventually special additives) has been launched. This type of recycling is used in pavements for both heavy and light traffic. Cold recycling using only bituminous emulsion was not mentioned in the responses of the mentioned countries.

2.2.4 Mixed RAP, RCP and reclaimed base and subbase material The mixture of these by-products has its source in the excavation of the full or partial

pavement structure. This material can be recycled either in plant or in place. The in plant recycling process consists of crushing, screening and further treatment of the material. The mixed material can be used in stabilised base and unbound base applications. Using in-situ cold recycling process these materials (without RPC) are crushed, mixed and hydraulic binders and/or bituminous emulsion are added as described in 2.2.3. These by-products are usually incorporated in bases and subbases.

2.2.5 Technical guidelines and specifications The specifications for virgin materials used in the individual countries are quite similar

throughout the world. However, in technical guidelines for recycling of road by-products there are different additional specifications as they have been based on the historical development of applied materials and mixes and the type, characteristics and availability of raw materials.

There is a certain number of possibilities that are used in contract specifications for highway construction using road by-products: 1. Use of the same guidelines and specifications for virgin materials without modification (it

is appropriate for by-products that do not differ substantially from conventional virgin materials, e.g. recycled aggregate, recycled concrete).

2. Use of modified versions of current guidelines and specifications for virgin materials (applications in technical guidelines and specifications for recycled materials are essentially the same as those for conventional virgin materials but there are additional constraints, such as purity and limitations on the maximum allowable amount of the by-product that requires modifications or additional provisions to the normal guidelines and specifications).

3. Use of the technological guidelines applied in other countries. If the modifications of the requirements or tests are not carried out, the problem with lifetime of pavement may occur (e.g. cold recycling has to respect tests simulating cold climate in CEE countries).

4. Development of new guidelines and specifications for by-products (it is applied to non-traditional applications or combinations of materials).

The list of standards, recommendations and manuals used in particular CEE countries is given in Annex A.

2.3 Environmental requirements for recycling

The thorough control of environmental influence is focused on stabilisation of tar in recycled material from road base of wearing courses of light traffic road. Leaching test controlling the stabilisation of tar is used.

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2.4 Situation in particular countries

This part of the report represents an abstract of questionnaire responses of the CEE countries. The abstract contains some additional information to Table 2.1 and gives the fundamental standards, recommendations and manuals used in these countries. The responses to the questionnaire are summarized in Annex A.

2.4.1 Belarus This part of questionnaire was not responded.

2.4.2 Bulgaria From the road by-products only asphalt materials are recycled. The annual amount of RAP is

approx. 2 800 t, 100 % of which is recycled in situ using hot process. To accept this material, the demands of BDS (Bulgarian National Standard) 4132 for hot mix asphalt or “Asphalt Institute Mix Design Method Manual, MS 2” have to be fulfilled. A special set of Wirtgen machines for milling, mixing of old asphalt and fresh asphalt and laying are being used. There are no differences between tests for new and reclaimed asphalt. For this application Technical Specification “Asphalt - hot mix recycling” by Road Executive Agency was issued.

2.4.3 Czech Republic

2.4.3.1 Reclaimed Asphalt Pavement (RAP)

Origin, composition and annual amount The reclaimed asphalt pavement (RAP) is obtained from asphalt layers of flexible pavement

structures. The asphalt is either milled or crushed. The amount of the RAP in the year 2003 was approximately 690 000 tonnes while the amount of pavement material containing tar was about 35 000 tonnes.

Current and planned applications Both hot and cold asphalt recycling processes are used in the Czech Republic. These

processes can be further subdivided into central-plant recycling and in-situ recycling. Central-plant recycling involves the removal of old pavement material from the construction

site to a plant located in the vicinity of the construction site. Recycling plants are mobile or stationary.

In-situ recycling uses old pavement materials from the construction site that are processed on site and incorporated back into the new pavement construction.

Central-plant hot recycling technologies

Batch mixing plant technology: Hot mix technology consists of adding of cold (mostly 0/11 or 0/22) RAP fractions into the

mixer of the batch mixing plant to virgin material in the amount of approximately 10 % (wearing course) to 25 % (base course).

Hot-mix technology employs the direct preheating of the RAP. The direct preheating is usually accomplished using an extra drum dryer. The RAP is dried and heated in the second drum then transferred via a buffer silo to the mixer to virgin material. The amount of hot RAP is approximately 30 % – 60 %.

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Continuous mixing plant (drum mix) technology: This technology consists of mixing 0/11 or 0/22 fractions of RAP (the weight content of

which can be in the range of 10 % - 80 %) in the drum mixer together with aggregate and hot bitumen 70/100, 100/150.

Steamed recycling technology: RAP is put into hoppers, steamed through and via conveyor belt brought into mixer where it

is mixed with bituminous emulsion and cement.

Central–plant cold recycling technologies

Batch mixing plant technology:

Mixing of RAP with bituminous emulsion and cement or foamed bitumen is used.

In situ hot recycling technologies Hot mix technologies are similar in concept and involve special equipment usually referred

to as an "asphalt recycling travel-plant". Technologies such as Repave, Remix or Remix+ are used. The special nature of the travel plant and the size of economically viable contracts have limited their use primarily to maintenance purposes.

All hot-mix methods involve the partial removal or scarification of the existing pavement to a controlled depth. Then quality virgin materials are either incorporated into the reclaimed material for final layer placement or a new hot-mix layer is placed immediately over the recycled mix (generally, where no new material has been added).

In-situ hot-mix techniques have the advantage of reducing or eliminating the transport of RAP to a central site and providing for the rapid completion and re-opening of a new road surface with improved riding qualities.

In situ cold recycling technologies Using the in situ cold recycling technologies the scarified road is mixed together with

cement and bituminous emulsion or foam bitumen. The recycled material is then spread and compacted and generally a new wearing surface course is laid or at least surface dressing or slurry seal is applied.

In some cases the RAP is newly laid without addition of binders to replace the commonly used base and subbase courses – see Technical Recommendations TP 111 in Table 2.2.

Environmental issue Both hot and cold processes permit the rapid rehabilitation of an existing pavement with

significant reduction or even elimination of RAP material transport from the site for processing based in another place.

In some cases tar can be present in RAP. In this case the amount of Polynuclear Aromatic Hydrocarbons (PAH) has to be found out and special approaches have to be applied – see Technical Recommendations TP 150 in Table 2.2.

Technical standards The list of standards and Technical Recommendations is in Table 2.2.

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Table 2.2 - Survey of CZ Standards and Technical Recommendations for RAP

Regulation Title in CZ and E Summary ČSN 73 6121 CZ Stavba vozovek – Hutněné asfaltové vrstvy

E Road Building – Hot mix Asphalt

In the standard there are incorporated the maximum allowed percentages of reclaimed asphalt into particular courses. The demands on resulting penetration grade and its calculation in cases when RAP is admixed are cited.

CZ Přímé zpracování recyklovatelného asfaltového materiálu do vozovek.

TP 111

E Direct processing of reclaimed asphalt materials in road construction.

TP (Technical Recommendations) specify different types of reclaimed materials, technical demands on these materials and courses and conditions under which they can replace the courses made from virgin materials + system of quality control.

CZ Použití R-materiálu smícháním s kamenivem a asfaltovou pěnou pro pozemní komunikace.

TP 126

E Application of reclaimed asphalt mixed with aggregate and foam bitumen for road construction.

TP (Technical Recommendations) specify demands on input materials, compacted mixtures of these materials, conditions for the manufacturing and laying + system of quality control.

CZ Údržba a opravy vozovek s použitím R-materiálu obalovaného za studena asfaltovou emulzí a cementem

TP 134

E Maintenance and repair of roads with application of reclaimed asphalt coated with asphalt emulsion and Portland cement using cold process

TP (Technical Recommendations) specify demands on input materials, conditions for the use of reclaimed asphalt that is to be mixed at mixing plants with additives and its application in the road construction + system of quality control.

CZ Souvislá údržba a opravy vozovek pozemních komunikací obsahujících dehtová pojiva

TP 150

E Continuous maintenance and rehabilitation of pavements containing tar

TP (Technical Recommendations) describe the way of detection of Polynuclear aromatic hydrocarbons (PAH) and the maintenance and rehabilitation methods for RAP with tar.

CZ Recyklace konstrukčních vrstev netuhých vozovek za studena na místě s použitím asfaltových pojiv a cementu

TP 162

E Cold in place recycling of flexible pavement courses with application of bituminous binders and Portland cement

TP (Technical Recommendations) specify conditions for using this technology, two different laboratory mix design procedures + system of quality control.

CZ Evidence vozovek silnic s dehtovými pojivy Methodological Instruction E Documentation of roads with tar binders

The instruction describes the way of documentation and the determination of Polynuclear aromatic hydrocarbons.

CZ Recyklace netuhých vozovek pozemních komunikací na místě za studena s použitím hydraulického pojiva.

TP XX

E Cold in place recycling of flexible pavements using hydraulic binders.

TP (Technical Recommendations) specify conditions for using this technology, mix design procedure + system of quality control.

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2.4.3.2 Reclaimed Concrete Pavement (RCP)

Origin, composition and annual amount In the Czech Republic RCP is obtained prevailingly from wearing courses of concrete

motorways. The annual amount of the RCP is approximately 25 000 tonnes, sometimes it is up to 40 000 tonnes; it depends on the length of the motorway under reconstruction. Both technologies are used, i.e. asphalt overlaying and new concrete pavement.

Current and planned applications The old concrete slabs are shattered using a breaker (a guillotine) or they are divided into

halves by drilling several small holes that are filled with expansion mixture. They are hauled to a crushing plant and processed into fractions. The fractions of RCP can be used for the binder course of two-course concrete of the newly constructed motorways.

The use of RCP also represents a possible further application for unbound or hydraulically bound base courses. The RCP aggregate exhibits very good mechanical properties – abrasion and polishing resistance and soundness.

Environmental issue RCP may contain chloride ions caused by the use of de-icing salts, sulphates due to the

contact with sulphate soils or alkali-reactive aggregate. Chloride ions can cause corrosion of steel, sulphate expansive disintegration of cement paste and alkali-reactive aggregate cracking.

Technical standards for Portland cement pavement ČSN 73 6123 Cementobetonové kryty (Portland Cement Pavements Wearing Courses).TP 91 Rekonstrukce vozovek s cementobetonovým krytem (Reconstruction of Portland

Cement Pavements)

2.4.3.3 Mixed RAP and reclaimed base and subbase material

Origin, composition and annual amount If the reconstruction or rehabilitation of pavement is carried out, the HMA is usually milled

and the rest of pavement is stabilized either by cold mixing technology or the material is removed and used as a fill, especially in subgrade. The amount mentioned in Table 2.1 concerns only cold recycling technologies. Due to a great contract, 75 000 tonnes of cold recycled materials were used in the years 2001 and 2002.

Two different materials are used in cold recycling: 1. Unbound material such as gravel and bitumen or tar penetration macadam. The material

contains a great deal of the 32/63 aggregate; the content of sand is low. Mostly 0/4 aggregate fraction with high amount of fines has to be added to improve the resulting sieve curve.

2. Portland cement base stabilization. The failure of the stabilization was caused by water and salt penetrating into the course through reflective cracks in asphalt courses. Another failure was caused when mine waste rock with small volume changes was used as an aggregate.

Both materials need different mix design.

Current and planned applications In the cold recycling technologies reclaimed base or subbase materials are mixed together

with Portland cement and bituminous emulsion or bitumen foam. The recycled material is then spread and compacted and generally a new wearing course is laid or at least surface dressing or slurry seal is applied.

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The technology of using mixture containing hydraulic binders, Portland cement, fly ash, lime and special additives has started to be used.

If the unbound material was mixed with cement only, the transversal and longitudinal cracks occurred and during 8-year period of pavement service the course was again unbound and some problems with bearing capacity occurred. The addition of sand into recycled material seems to be necessary.

The cracks often occur when the cold recycling with Portland cement and bitumen emulsion is used.

In both cases the frost actions have to be evaluated.

2.4.4 Hungary In the field of road by-products the following materials are recycled: asphalt materials

(RAP), highway concrete materials (RCP), base and subbase materials. The annual amount of RAP is approx. 50 000 t, 20 % of which is recycled in plant and added into hot asphalt mixtures (batch mixing plants), 15 % is processed using in situ cold recycling technologies and consequently used in construction of base courses without binders and 65 % is stockpiled. The allowed quantities of RAP for hot asphalt mixtures are 20 % for wearing courses, 25 % for binder courses and 30 % for base courses. The amount of RAP containing tar is not known.

The annual amount of RCP is 5 000 t, 50 % of which is recycled in plant and 50 % on site. It is used for the construction of base courses. The material from base and subbase courses representing 7 000 t is annually recycled using the cold in place recycling technologies with addition of cement.

2.4.5 Poland In Poland the following materials are recycled: asphalt materials (RAP), highway concrete materials (RCP) and base and subbase materials. The RAP and the base and subbase materials are mostly recycled on site; the RCP is recycled in central plant. The list of standards, specifications and recommendations is in the Annex A.

2.4.6 Romania In the field of road by-products in Romania all available products (RAP, RCP, base and subbase materials and a mix of them) are recycled. In particular cases RAP is recycled in plant and in situ, other products in situ. The most popular application is in granular base courses.

2.4.7 Russia According to the data given in the questionnaire Russia has replied that only RAP is

recycled. The annual amount of RAP is approximately 22 000 t, 50 % of which is recycled in situ and 50 % is land filled. It can be supposed that the data do not cover the situation in the whole country.

2.4.8 Slovakia

In the field of road by-products only asphalt materials are recycled. The annual amount of RAP is approximately 30 500 t; 40 % of this amount is recycled in situ by the hot in place Remix technology, 30 % is stored in stocks and 30 % in landfills. The amount of RAP containing tar is not known. However, it is prohibited to recycle RAP containing tar via hot Remix technology.

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Nowadays the newly introduced technologies are as follows: • Cold in place recycling of asphalt pavement layers, • Cold in place and cold in travel plants recycling of mixtures from unbound and hydraulically

bound pavement layers.

2.4.9 Slovenia As regards road by-products only asphalt materials are recycled. The annual amount of RAP

is approximately 8 000 t, 80 % of which is recycled in plant and added into hot asphalt mixtures (batch mixing plants), 15 % is stored in stocks and 5 % in landfills. Furthermore, Mastic Asphalt is recycled, too. The annual amount of RAP-mastic was 1 500 tonnes, 100 % of which was hot recycled. The amount of RAP containing tar is not known. The required technical quality of recycled aggregate is the same as the virgin one and is given by the requirements of the standard TSC 06.800. Regarding the environmental requirements there are special regulations in case of recycling of asphalt materials containing tar.

2.4.10 Ukraine Regarding road by-products only the asphalt materials are recycled in Ukraine. The annual

amount of RAP is approximately 355 000 tonnes, 86 % of which are stored in stocks. The usage of reclaimed base and subbase materials and their mix with RAP is not common.

In Ukraine the special standards for reclaimed aggregate that should conform to common standard requirements have not been established yet.

2.5 Conclusions

From the responses to the questionnaire, discussions with the experts from CEE countries and their experience it appears: • The recycling technologies are known. In some countries they are constrained to only one

type of recycling method or the recycling methods have been just introduced. • In the responding countries there are often no appropriate specifications for particular

technologies or the specifications are being developed and adapted to the national conditions.

• The finances for the research are limited. Sometimes the introduction of new technologies is based on activities and performance of test sections carried out by foreign contractors.

• The road authorities are not well informed about the new development in recycling technologies and they often distrust their application.

• The most detailed information was found in the Czech Republic. This is mainly due to the technology transfer from the neighbouring and other European countries (Germany, Austria, France) and through the branch offices established by these firms (EUROVIA, SKANSKA, STRABAG, etc.). The use of RAP in the Czech Republic is on the level comparable with West Europe.

• Newly developed technology of cold in situ recycling uses several types of binders: Portland cement and bitumen emulsion or bitumen foam or only hydraulic binder as Portland cement often used together with lime, fly ash or other hydraulic or pozzolane reactive binder and sometimes special additives are used, too. The reliable bearing capacity and resistance to frost cracks and failure in severe CEE countries climate conditions are neither known nor have been investigated up till now. The research in this direction is necessary.

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3 RECYCLING OF NON-ROAD BY-PRODUCTS

3.1 Survey from CEE countries

The questionnaire was sent to CEE countries mentioned in 1.2.

3.2 Non road by-products

Non-road by-products are defined in 1.3. In this Chapter the following by-products are considered:

- By-products from the metallurgical industry; - Coal fly ash and coal bottom ash/boiler slag; - Foundry sand; - Mine waste rock, quarry fines and mine tailings; - Scrap tyres; - Building demolition by-products; - Waste plastic and waste glass; - Incinerator ash.

3.3 Non road by-products and their uses

Tables 3.1 to 3.14 present an inventory on the use of the most commonly recycled non-road by-products in road construction in each of the investigated countries, using a zero to four numerical rating scale, with the following meaning:

• 0: Currently not used and should not be used. • 1: Currently not used. • 2: Currently not used, a potential use is considered. • 3: Currently limitedly used. • 4: Currently generally used.

The answers to the questionnaire submitted by the mentioned countries are included in Annex A

The abbreviations used in tables are: PCC = Portland Cement Concrete pavement (wearing course). HMA = Hot Mix Asphalt pavement. CM/ST = Cold Mix or Surface Treatment. GS = Granular Surface (e.g. gravel road). SB = Stabilized Base. GB = Granular (unbound) Base. EMB = Embankment. FILL = Fill (e.g. backfill, subgrade, flowable fill). STR = Structures (e.g. bridges, culverts, storm drain inlets and pipes). APP = Appurtenances (e.g. curbs, gutters, sidewalks, median barriers). SAF = Safety-related items (e.g. guardrails, signposts, lightposts, striping, etc.). LS = Landscaping (e.g. mulch, picnic benches, etc.).

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Table 3.1 – Blast Furnace Slag, Air Cooled used in CEE countries Blast

Furnace Slag, Air Cooled

PCC HMA CM /ST

GS SB GB EMB FILL STR APP SAF LS

BY 2 4 2 0 0 2 0 0 0 0 0 0 BG 0 0 0 2 2 3 3 3 0 0 3 2 CZ 3 3 3 3 3 3 3 3 2 2 2 4 H 3 3 3 2 2 3 1 2 2 0 0 0

PL 2 2 2 4 4 4 4 4 2 3 0 3 RO 2 1 1 1 4 4 2 2 1 1 0 0 RUS 2 2 1 1 2 2 2 0 0 0 0 0 SK 0 1 1 2 1 3 2 3 0 1 0 1

SLO 0 0 0 0 0 0 0 0 0 0 0 0 UA 1 2 3 4 3 4 3 4 3 3 3 4

Table 3.2 – Blast Furnace Slag, Ground Granulated used in CEE countries Blast

Furnace Slag,

Ground Granul.

PCC HMA CM /ST


BY 2 3 2 0 2 0 4 2 3 3 0 4 BG 0 0 0 2 3 2 0 0 0 0 3 0 CZ 0 0 0 0 2 0 0 0 0 0 0 0 H 0 0 0 0 3 0 0 0 0 0 0 0

PL 1 0 0 0 1 0 3 3 2 3 0 2 RO 2 1 1 1 4 4 2 2 1 1 0 0 RUS 2 2 1 1 2 0 0 1 1 1 1 1 SK 0 0 0 1 0 0 1 0 0 0 0 0

SLO 0 0 0 0 0 0 0 0 0 0 0 0 UA 2 3 4 4 4 4 0 3 3 2 3 4

Table 3.3 – Coal Fly Ash used in CEE countries Coal Fly

Ash PCC HMA CM /ST


BY 0 0 0 0 0 0 0 0 0 0 0 0 BG 0 0 0 0 2 2 0 0 0 0 0 2 CZ 0 0 0 2 3 2 3 3 2 2 0 4 H 3 3 0 0 3 0 3 2 0 0 0 0

PL 2 2 0 0 3 0 4 3 0 0 0 4 RO 0 1 1 2 2 0 2 2 0 0 0 0 RUS 0 0 0 0 0 0 0 0 0 0 0 0 SK 0 0 0 0 1 0 0 0 0 0 0 0

SLO 2 1 4 2 2 2 4 2 1 1 1 1 UA 0 0 0 3 3 3 3 3 0 0 0 3

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Table 3.4 – Coal Bottom Ash used in CEE countries Coal

Bottom Ash

PCC HMA CM /ST


BY 0 2 2 0 2 4 3 3 1 1 0 1 BG 0 0 0 0 0 0 2 3 0 0 3 0 CZ 0 0 0 2 3 2 3 3 2 2 0 4

H 0 0 0 0 2 0 1 1 0 0 0 0 PL 0 0 0 0 3 0 4 3 0 0 0 4 RO 0 0 0 0 0 0 0 0 0 0 0 0 RUS 0 0 0 0 0 0 0 0 0 0 0 0 SK 0 0 0 0 1 0 0 0 0 0 0 0

SLO 2 1 2 2 2 2 2 2 0 1 1 1 UA 0 0 0 1 3 1 1 0 0 0 0 0

Table 3.5 – Foundry Sand used in CEE countries Foundry

Sand PCC HMA

CM /ST


BY 0 0 0 0 0 0 0 0 0 0 0 0 BG 0 0 0 0 0 0 0 0 0 0 0 0 CZ 2 2 0 1 1 1 1 2 0 2 0 3 H 0 0 0 0 0 0 0 0 0 0 0 0

PL 0 0 0 0 0 3 0 0 0 0 0 0 RO 0 0 1 0 0 0 0 0 0 0 0 0 RUS 0 0 0 0 0 0 0 0 0 0 0 0 SK 0 0 0 2 1 2 2 2 1 0 0 1

SLO 1 2 1 1 1 1 2 2 1 2 1 2 UA 0 3 3 4 3 3 0 0 0 0 0 4

Table 3.6 – Mining Waste Rock used in CEE countries Mining Waste Rock

PCC HMA CM /ST


BY 0 2 1 0 0 0 0 0 0 0 0 0 BG 0 0 0 0 0 0 4 4 0 0 0 0 CZ 0 0 0 0 1 1 3 3 0 0 0 4 H 4 0 0 3 3 4 0 3 0 0 0 0

PL 0 0 0 2 2 2 4 2 0 2 0 4 RO 0 0 0 0 0 0 0 0 0 0 0 0 RUS 0 2 1 0 0 0 0 0 0 0 0 0 SK 0 0 0 2 1 1 2 2 1 0 0 0

SLO 2 1 1 2 2 1 2 2 1 2 1 2 UA 0 3 3 3 3 3 3 0 0 0 0 4

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Table 3.7 – Municipal Soil Waste Incinerator Bottom Ash used in CEE countries Municip. Bottom

Ash PCC HMA CM

/ST GS SB GB EMB FILL STR APP SAF LS

BY 0 0 0 0 0 0 0 0 0 0 0 0 BG 0 0 0 0 0 1 1 1 0 0 0 0 CZ 0 0 0 0 1 1 3 0 0 0 0 4 H 0 0 0 0 2 0 0 0 0 0 0 0

PL 2 2 0 2 2 2 2 2 0 0 0 2 RO 0 0 0 0 0 0 0 0 0 0 0 0 RUS 0 0 0 0 0 0 3 0 0 0 0 0 SK 0 0 0 0 0 0 0 0 0 0 0 0

SLO 2 1 2 2 2 2 2 2 0 1 1 1 UA 0 0 0 0 0 0 3 0 0 0 0 0

Table 3.8 – Non-Ferrous Slag used in CEE countries Non-

Ferrous Slag

PCC HMA CM /ST


BY 0 1 0 0 0 0 1 1 1 1 0 1 BG 0 0 0 0 0 0 2 2 0 0 0 0 CZ 0 0 0 0 0 0 0 0 0 0 0 0

H 0 0 0 0 2 0 1 0 0 0 0 0 PL 1 3 2 2 2 4 3 2 2 2 0 2 RO 0 0 0 0 0 0 0 0 0 0 0 0 RUS 2 2 1 1 2 2 2 1 1 1 0 1 SK 0 0 0 1 1 1 1 0 0 0 0 0

SLO 0 0 0 0 0 0 0 0 0 0 0 0 UA 0 3 4 4 4 4 4 3 3 3 3 4

Table 3.9 – Scrap Tyres used in CEE countries

Scrap Tyres PCC HMA

CM /ST


BY - - - - - - - - - - - - BG 0 2 0 0 0 0 0 0 0 0 0 0 CZ 0 3 1 0 0 0 2 0 1 1 1 1

H 0 0 0 0 0 0 0 0 0 0 0 0 PL 0 3 0 0 2 2 0 0 0 0 0 0 RO 0 1 1 0 0 0 0 0 0 0 0 0 RUS 0 0 0 0 0 0 0 0 0 0 0 0 SK 0 1 0 0 0 0 0 0 0 0 0 0

SLO 0 0 0 0 0 0 0 0 0 0 0 0 UA 0 0 0 0 0 0 0 0 0 0 0 0

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Table 3.10 – Steel Slag used in CEE countries

Steel Slag PCC HMA CM /ST


BY - - - - - - - - - - - - BG - - - - - - - - - - - - CZ 0 3 3 2 3 3 3 3 0 2 0 4 H 0 0 2 0 0 0 0 0 0 0 0 0

PL 1 3 2 3 2 4 4 3 0 2 0 4 2 1 1 1 4 4 2 2 1 1 0 RO 0

RUS 2 2 1 1 2 2 3 0 0 0 0 0 SK 0 0 0 1 1 1 1 0 0 0 0 0

SLO 2 4 4 2 1 2 1 1 1 1 1 1 UA 3 3 3 3 3 3 3 3 3 3 0 4

Table 3.11 – Waste Glass used in CEE countries

Waste Glass PCC HMA

CM /ST


BY - - - - - - - - - - - - BG - - - - - - - - - - - - CZ 0 1 1 0 0 0 0 0 0 0 0 0

0 0 H 1 0 0 0 0 0 0 0 0 0 PL 0 0 0 0 0 0 0 0 0 0 0 0 RO 0 0 0 0 0 0 0 0 0 0 0 0

RUS 0 0 0 0 0 0 0 0 0 0 0 0 SK 0 0 0 0 0 0 0 0 0 0 0 0

SLO 0 0 0 0 0 0 0 0 0 0 0 0 UA 0 0 0 0 0 0 1 1 0 0 0 1

Table 3.12 – Waste Concrete used in CEE countries

Waste Concrete PCC HMA

CM /ST


BY - - - - - - - - - - - - BG 0 0 0 0 0 0 0 2 0 0 0 0 CZ 3 2 2 3 3 3 1 1 2 2 0 1

H 2 0 0 0 0 3 0 0 0 0 0 0 PL 0 0 0 4 4 4 0 0 0 0 0 0 RO 0 0 2 2 3 3 2 0 0 0 0 0

RUS 1 1 1 1 1 1 1 1 1 1 1 1 SK 1 0 1 2 0 2 2 1 1 1 0 1

SLO 2 1 1 2 2 2 2 2 2 2 1 2 UA 1 1 1 0 2 4 2 2 2 2 0 0

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Table 3.13 – Waste Tiles/Bricks used in CEE countries Waste

Tile/Brick PCC HMA CM /ST


BY - - - - - - - - - - - - BG - - - - - - - - - - - - CZ 0 0 0 2 3 2 3 3 0 0 0 3

H 0 0 0 0 0 2 0 0 0 0 0 0 PL 0 0 0 0 0 0 3 2 0 0 0 3 RO 0 0 2 2 3 3 2 0 0 0 0 0 RUS 1 1 1 1 1 1 1 1 1 1 1 1 SK 0 0 0 0 0 1 1 0 0 0 0 1

SLO 1 0 1 2 2 1 2 2 1 2 1 2 UA 0 1 1 0 0 0 0 4 1 1 0 0

Table 3.14 – Waste Tiles/Concrete used in CEE countries

Waste Tile/ Concrete

PCC HMA CM /ST


BY - - - - - - - - - - - - BG - - - - - - - - - - - - CZ 0 0 0 2 3 3 3 3 0 0 0 3

H 0 0 0 0 0 2 0 0 0 0 0 0 PL 0 0 0 0 0 0 3 2 0 0 0 3 RO 0 0 2 2 3 3 2 0 0 0 0 0 RUS 1 1 1 1 1 1 1 1 1 1 1 1 SK 0 0 0 0 0 1 1 0 0 0 0 1

SLO 1 0 1 2 2 1 2 2 1 2 1 2 UA 0 1 1 0 0 0 2 2 0 0 0 2

3.3.1 By-products from the metallurgical industry

In road construction various types of slags from the metallurgical industry are used.The following by-products have been identified from the survey replies: blast furnace slags (air-cooled crystallised, granulated or expanded), steel slag and non-ferrous slags.

All types of slags have to fulfil the environmental requirements and specifications.

3.3.1.1 Blast furnace slags

Air-cooled blast furnace slag is currently used in embankments and subbases and bases of pavement structures. In some countries this material is also used in asphalt mixtures and surface treatments. This type of slag is recycled in large amounts and has been accepted, more or less, as a "traditional material".

Air-cooled blast furnace slag aggregates must meet the requirements set in standard specifications for materials used in different pavement layers.

Granulated blast furnace slag is used as a replacement for natural aggregate as well as

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a partial replacement for cement in concrete and stabilized base. This slag is ground and mixed with Portland cement or special hydraulic binders. In some countries large amounts of ground slag are used in cement production. The self-cementing properties of granulated blast furnace slag fines are very useful in bases and subbases applications.

Most countries using granulated blast furnace slag have standard specifications for the material itself as well as for its application in combination with other materials.

3.3.1.2 Steel slags There are several steel-making processes and the composition of slags produced varies.

Some steel slags are rich in phosphates, other contain iron oxides, lime or magnesia. When exposed to moisture, the free lime (CaO) and free magnesia (MgO) can hydrate and cause volumetric expansion of the slag. The potential for expansion can be minimised by ageing of the slag on stock for about 1 year. In CZ the tests to evaluate the expansion ability are used. Careful examination of the slag for weak or deleterious particles (usually Los Angeles test) is recommended as these materials could indicate an unstable slag.

The angularity and high shear resistance of the particles in steel slags make them suitable for several pavement layers. Due to porosity of the steel slag grain it is necessary to use higher content of water in unbound and bound mixture of steel slag aggregate and higher bitumen content in bituminous mixture (the improvement of Marshall test is described in CZ Technical Recommendations ).

In most of the CEE countries participating in the survey steel slags are used mainly as aggregate in fills, embankment, subgrade, subbase and base courses; in some countries they are used in bituminous surface course layers, i.e. in hot mix asphalt (HMA) and cold mix asphalt (slurry seal). The use is limited to the area of steel production (with the exception of surface treatment and slurry seal).

3.3.1.3 Non-ferrous slags

Potential leaching of various metals can occur when non-ferrous slags are used in wet conditions (i.e. close to the ground water level).

In PL and UA non-ferrous slags are currently used. In other CEE countries non-ferrous slags have not been used in road construction. Nevertheless, after some treatment of stockpiled material they can be used preferably in stabilized bases.

3.3.2 By-products from other industries

3.3.2.1 Coal fly ash and coal bottom ash, boiler slag The chemical elements that are present in the collected ashes depend on the type of coal

used during the combustion process. In some power stations, low-sulphur coal is used, others burn high sulphur content coal or lignite coal. Some fly ashes have pozzolanic properties, and lignite coal fly ash containing more lime (CaO) has hydraulic properties as well

Coal fly ash is used in many countries as a supplementary cementitious material or as a fine aggregate in Portland cement concrete and mortar.

Coal fly ash is also used in stabilised bases and embankments. When coal fly ash is mixed with lime or cement, the pozzolanic action can be activated and the ash acts as a binder that may be used to improve materials or soils in various road pavement layers.

Standard specifications for coal fly ash and bottom ash are simply based on those used for soils and their improvements.

In CZ fly ash mixture with Portland cement and water were used for filling the air voids in

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pavement base layer with crushed aggregate 32/63. The benefit of this layer was the strength and good bearing capacity but frost heaves of asphalt courses occurred and serious failures lead to the need of pavement reconstruction.

The use of fly ash for manufacturing the aggregate (light weight) was not emphasized in the responses of the CEE countries.

3.3.2.2 Foundry sand Foundries produce castings by pouring metal into moulds. Sands are mixed with binders and

additives and a mould is manufactured. After the casting is solidified and removed from the mould the sand can be reused in the next production cycle. The sand is bound by either mineral or organic binders. When iron is poured into the mould, the binders are partly burnt and the residual sands contain active or cooked clay in case of mineral binders and phenols from the decomposition of the organic binders. As a mineral binder bentonit is frequently used.

3.3.2.3 Mine waste rock, mine tailings and quarry fines Mine waste rock is usually composed of large-size particles. Mine tailings and quarry fines

mainly consist of fines and sand. All materials are often stockpiled in the vicinity of the mines and quarries.

These materials have unique characteristics but they are also of limited potential. If mining waste rock is geologically similar to sources of conventional aggregates, it is

crushed and/or screened and used as other natural materials. The standard specifications for this by-product are the same as for conventional materials.

Coal-mine rock is used only in fills and embankments. Embankments can burn inside due to the content of coal and regular control has to be carried out.

Since mine tailings, quarry waste (including coal-milling waste) and slate wastes often have a fine particle composition, their potential of reusing is limited. In addition, mine tailings that have been ponded may contain excessive moisture and therefore may require dewatering.

Despite the existence of large amounts of mining waste rock, their use is economical only in road projects located within reasonable hauling distance.

3.3.2.4 Scrap tyres Within the road construction sector in CZ and PL scrap scrumb tyres in HMA are used. Incorporation of ground rubber into HMA is carried out using dry or wet process. IN CZ The rubber granulate is added into the mixer prior to blending the aggregate with asphalt cement and partially substitutes fine aggregates in the mix. Technical recommendations for this use of rubber have been prepared.

In several countries scrap tyres are used as a fuel in cement kilns.

3.3.2.5 Building demolition by-products Waste concrete from buildings is seldom available in large quantities and usually contains

reinforcing steel, tiles, bricks and other building materials and contaminants. Building demolition materials are processed by selection, crushing, removal of reinforcing steel, screening and stockpiling. The material is usually used in base, subbase and embankments.

Prior to usage of various demolition wastes in road construction the leachants must be analysed for trace metals.

3.3.2.6 Waste plastics and waste glass Plastics represent quite a high percentage of the total weight and volume of municipal waste

30

but they are not recycled in road construction. The principal re-use of waste glass is its recycling in glass factories.

3.3.2.7 Incinerator ash Incinerator fly ash and bottom ash contain heavy metals (derived from items such as

batteries) and other hazardous components. Regarding road construction in CEE countries this waste material is currently used in CZ,

RUS and UA for the construction of embankments, in SLO further use is expected.

3.4 Situation in particular countries

3.4.1 Belarus The use of waste/secondary materials is not common in Belarus. The most popular materials

reused in the road construction are: blast furnace slag and coal bottom ash.

3.4.2 Bulgaria Out of other materials, blast furnace slag and mining waste rock are recycled in the road

construction. Blast furnace slag is mostly used for the construction of unbound base courses, embankments and backfilling. Mining waste rock is also used for embankments and backfilling. The demands on these materials are the same as on the virgin ones, detailed information is not available.

3.4.3 Czech Republic

3.4.3.1 Blast furnace slag Air-cooled blast furnace slag is currently used in embankments, subbases, bases and wearing

courses of pavement structures. The slag aggregates must meet the requirements set in standard specifications for base courses, concrete and HMA.

The problems of not properly deironized slag in hot mix asphalt were registered, temperature of iron grains after drum drying was higher and due to varying bulk density of slag aggregate dosing of bitumen was not reliable.

3.4.3.2 Fly ash and fly bottom ash The fly ash does not exhibit hydraulic properties. It is used as a replacement for the fine-

grained component of the unbound and hydraulic bound mixtures and Portland cement concrete for building construction.

The fly ash and coal bottom ash are usually mixed together and the by-product is not homogeneous. The coal fly ash is used in light embankment as the optimum Proctor density is (1,05 – 1,35) g/cm3. The embankment has to be covered by the course of suitable soil the thickness of which is 0,8 m at least. The fly ash can be stabilized by lime and in that case it can be used in subgrade.

In CZ fly ash mixture with Portland cement and water was used for filling the air voids in pavement base layer with crushed aggregate 32/63. Due to the sealing effect the strength and good bearing capacity were the benefit of this layer but frost heaves of asphalt courses caused by water collected in the bound fly ash (that is porous) occurred.

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3.4.3.3 Foundry sand The annual amount of foundry sand produced in the Czech Republic is approximately

480 000 t. The recycling of foundry sand is carried out only for its further reuse in foundries. 10 % of sand containing mineral binders is used as landfill and 90 % is recycled. In case of sand containing organic binders 20 % is used as landfill and 80 % is recycled.

Several attempts to recycle the foundry sand were carried out for the purposes of the building industry but problems with the remaining iron have been reported.

Maybe in future foundry sand could be used in hot mix asphalt, surface treatments, unbound and bound base courses and construction of embankments.

The danger for the environment stems from the leaching of phenols created by the burning of organic binders. According to the valid laws the phenol limits and the amount of harmful substances in the dry matter are to be controlled.

Concerning the use of foundry sand as an aggregate the same demands as for the virgin ones are applied: - see EN 13043 Aggregate for bituminous mixtures and surface treatments for roads, airfields and other trafficked areas and EN 13242 Aggregates for unbound and hydraulically bound materials for use in civil engineering work and road construction.

3.4.3.4 Mining waste rock Main waste rock is coming from coal mining. Even though the annual amount of mining

waste decreases its production is approximately 3 Mt but approximately 5 Mt are used in road construction as stockpiled waste rock (waste rock stock piled in previous years) is used.

Material is not usually used in subgrades, mainly is used in fills and embankments. Embankments can burn inside due to the content of coal and regular control has to be carried out.

Other waste mining rocks are stockpiled for ages and the use of these stockpiles as a part of natural landscape cannot be supposed.

3.4.3.5 Scrap tyres More than 50 000 t of used tyres are yearly landfilled or burnt in cement kilns. The grinding

factories are able to use about 6 000 t of tyres (mostly imported) and produced rubber granulate is used for regeneration of rubber, in sports grounds, athletic stadiums and in HMA.

HMA production uses dry method: rubber granulate is added to mixer of asphalt mixing plant. The technology needs accurate timing of rubber granulate dosing and mixing of asphalt mixture. During mixing and storing the mixture becomes very sticky. Nevertheless, it is possible to use usual technology of paving. The compaction differs a little and in some sections air voids content was higher than the required one and ravelling and potholes occurred. Most of sections have proven to be promising. The mixture can be compared with stone mastic asphalt but it produces lower traffic noise, higher resistance to fatigue cracks and permanent deformations and exhibits de-icing effect.

3.4.3.6 Building demolition waste The usage of this waste as a landfill is decreasing; in the year 2005 more than 50 % of

building demolition material will be recycled. All types of this waste (concrete, tiles/concrete and tiles/bricks) are used in road construction as fill, subbase and base. HMA wearing course with recycled concrete has also been used.

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3.4.3.7 Incinerator ash Several waste incinerators produce 90 000 t of bottom ash. The material is gotten rid of

metals and consequently stabilized. It is mostly used in landscaping.

3.4.4 Hungary As regards other materials (non-highway products) blast furnace slag, coal fly ash and

mining waste rock are reused in the road construction. The approximate annual amount of recycled blast furnace slag is 60 000 t. Blast furnace

slag is used for hot asphalt mixtures, cold mixtures or surface treatments and for granular base courses. To accept the material as a suitable one, the supplier has to perform the following tests: • Mineral composition. • Strength (e.g. LA, Deval). • Resistance to weathering. • Environmental protection. • Compactibility. • Particle size distribution.

The standard specification for the use of granular base is: ÚT 2-3.207 Base Courses without and with Hydraulic Binders for Pavements. Design Requirements.

The approximate annual amount of recycled coal fly ash is 3 000 t. The coal fly ash is used for stabilised base courses. There are chemical, physical and pozzolanic requirements on the use of this material: • Chemical requirements: content of SiO2, Al2O3, Fe2O3, CaO, SO3, ignition loss. • Physical requirements: specific surface (Blaine, cm2/g), particle size not exceeding 45 µm,

density and bulk density. • Pozzolanic requirements: MgCaO/g, pozzolana mixture strength after 28 days and swelling.

The standard specification for the use of coal fly ash in the road construction is: ÚT 2-3.603 Application of fly ash as binder in the road building.

The approximate annual amount of recycled mining waste rock is 200 000 t. The mining waste rock is used mostly for the construction of unbound base courses, in smaller extent of gravel roads, stabilized base courses and backfills. The requirements on the use of this material are: particle size distribution, amount of fine particles and Cassagrande limits. For the quality control of the built-in material at the construction site the Plate Bearing Test, as indirect method for evaluation of the degree of compaction, is used.

3.4.5 Poland The mostly used non-highway materials in road construction are: blast furnace slag (air

cooled), non-ferrous slag and ashes. There are some standards and technical approvals for the use of waste materials in the road construction. Supplier is responsible for quality of a waste material, contractor is responsible for use of adequate technology. If there is no special standard, the waste material shall conform to the requirements for common natural road materials. The list of laws, standards, specifications and recommendations is in Annex A.

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3.4.6 Romania At present in Romania the following materials are used in the road construction: blast

furnace slags (air cooled and ground granulated slags) and waste concrete/tiles/brick materials.

3.4.7 Russia Non-highway materials are not commonly used in road construction. Slags and mining waste

rocks (a burnt collier shale) are used in road construction but in a small extent. For 20 years, technologies for use of, for example, burnt collier shale, slags and ashes are

described in handbooks for technical universities. At present research on new waste materials for road application is being carried out in many

road laboratories that test them and develop new technologies of their use. There are few national standards (GOST) for use of the non-highway materials in road construction.

3.4.8 Slovakia The mostly used non-highway by-product for road construction purposes is blast furnace

slag. The annual amount of used blast furnace slag is about 350 000 t. It is used for granular base courses and fills. There are prescribed standards and tests, which the supplier has to carry out for the material to be accepted. No control tests except the common tests during construction are required. In evaluation of environmental suitability the occurrence of radionuclids and heavy metals is investigated. The use of by-products is not preferred from the point of view of economics. The list of laws, standards, specifications and recommendations is in Annex A.

3.4.9 Slovenia From non-highway products the coal fly ash and steel slag are used in the road construction. The annual amount of recycled coal fly ash is approximately 7 000 t. Coal fly ash is used for

cold mixes (5 000 t) and the construction of embankments (2 000 t). For the application of cold mixes and embankment construction the binding capacity has to

be proved by compressive strength of soil/coal fly ash mixture together with the weather resistance of stabilized soil. To use this material it is necessary to have appropriate machinery for mixing of spread coal fly ash with natural material in layer not less than 20 cm to obtain a uniform mixture of the natural material and binder. The following quality control tests are required during the construction: Degree of Compaction. Bearing Capacity. Compressive strength on test samples prepared in accordance with Proctor procedure after

7 days. Weather resistance after 7 days on test samples prepared in accordance with Proctor

procedure given by ratio between the compressive strength of dry samples and that of the samples soaked with water for 24 hours.

It was not possible to find out the annual amount of the used steel slag for hot mixture and cold mixture application.

The supplier has to fulfil the DIN standards and the Slovenian Technical Specifications for hot asphalt mixtures. The hot mix design is based on volumetric characteristics. In evaluation, the economical suitability is considered.

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3.4.10 Ukraine From the non-highway products, blast furnace slags are used in road construction in wide

range. There are standards prescribing the requirements for these materials (see Annex A). Standards for other non-highway materials have not been established yet.

3.5 Conclusions

From the responses to the questionnaire, discussions with the experts from CEE countries and their experience it appears:

• Some of non-road by-products have been used successfully in road construction. • The main problem of using non-road by-products is the environmental one. Leachable

chemical compounds or metals may present a hazard to the environment. These materials must be tested very carefully before their usage and some of them will presumably not be used at least in the lower layers of road construction where they may come in contact with surface and sub-surface water.

• Slags and mine rock waste are usually used in location of their occurrence. Their use in motorway and railway construction is sometimes limited as the old stockpiles of materials that can be used now create the natural landscape of these regions.

• Production of coal fly ash, coal bottom ash and incinerator ash is still several times greater than their use as secondary material.

• Up till now the foundry sand has been recycled only in foundries. Only Poland and Ukraine reported its use also for road construction purposes mostly in limited extent (granular base, hot mixed asphalt, cold mixes, gravel roads, stabilized base or embankments). In the Czech Republic there are now attempts to use the foundry sand as a part of the aggregate also in hot asphalt mixture. Sometimes there are some problems with its usage because the foundry sand is mostly uniformly graded and the discontinuity in the designed sieve curve occurs. The problem with phenols in some types of sands (with other than mineral binders) has also to be considered.

• Waste tyres are mostly stockpiled and burnt in cement kilns. Their usage in road embankments, sport yards, noise and vibrating protective barriers is not at the starting point. In CZ a PL rubber granulate is used in hot mix asphalt technology.

• Many tests for using of non-road by-products are empirical; it is necessary to use performance testing. Especially the frost action on base and subgrade materials containing fine-particle by-product is important.

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4 STRATEGIES PROMOTING RECYCLING

4.1 Introduction

Governments and industry spheres now try to elaborate plans for recycling and reusing waste materials generated in their countries. This Chapter describes the strategies used by CEE countries to encourage recycling.

Countries asked for responses are listed in part 1.2 of the report. In questionnaire Survey C ten groups of different questions were put together and responses

to them can describe the different situation in the CEE countries. This part of the report is a summary of the questionnaire responses. In each of the following

articles a brief text for each question is given and the responses are summarised in the tables. Subsequently, conclusions are made and recommendations given.

4.2 Policy in particular countries

"Which policy lines influence the use of secondary materials (by-products) in general and the use in road building in particular? What are the problems that are to be solved by the use of secondary materials (by-products)? Specify if possible the goals set in your country for the use of secondary materials (by-products)."

BY No response BG Up till now there is no general policy regarding this issue and there are no official

documents for it. CZ Reduction of materials and energy consumption is the main goal of industry. The use

of by-products represents one of the possible ways. The philosophy of waste management (3. version) was published in November 2001. The use of waste materials solves protection of environment, replacement of natural materials, decrease in energy consumption and reduction of road construction and rehabilitation costs.

H A special establishment to manage the utilization of the secondary materials is under preparation. Its goal is to increase their usage in the road building.

PL The “Second Environmental Policy” was prepared by the Ministry of Environment and adopted by the Council of Ministers on 13th June 2000. It proclaims that the protection of the environment is an obligation. Hence, this new Constitutional order calls for new National Environmental Policy including sector strategies and the action plans, which are to be harmonised with the new order. There is not a distinct structurized approach to this subject. The Ministry of Environment creates the general policy but do not solve details of road building industry. Use of waste materials can help to resolve the following problems for the building industry in general: • environmental protection (decreasing quantity of stock-piled waste materials), • reduction of the cost of building materials,

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• reduction of energy consumption, • protection of mineral resources and road building in particular, • reduction of raw materials consumption, • reduction of material costs, • cost reduction of material transport.

RO There is not a distinct policy. The main problems: need of raw materials, saving of energy consumption, environmental protection, etc.

RUS The governmental program “Save of energy in Russia 1999-2003” (extend); one of its parts is the project “Save of energy in road industry, 1999”. Research to find new waste materials for road application represents main problems solved in many road laboratories that are testing them and developing new technologies of their use. The ecological safety of waste material and its influence on environment is always tested.

SK The government tries to promote recycling of materials mainly in the field of packaging materials – Act on PET bottles. The main responsibility is on the producers – compulsory measures (taxation, penalties, etc.). The government uses mainly state supervision. The methodology of economical involvement in recycling is not clear.

SLO More effort should be devoted to organised collection of waste materials and financing of research activities.

UA Government administration of the Ukraine is trying to create a policy use of waste materials in general and in road construction in detail. There are no special governmental structures involved in the application of construction waste materials. The use of secondary materials can solve the following problems: • improvement of the environment through decreasing the quantity of a storage space

needed for waste materials, • reduction of energy loss, • reduction of the amount of raw materials needed when reconstruction or heavy

repairs of roads are carried out. Government directives prescribe to collect “old” asphalt concrete and reuse it.

4.3 Responsibilities

“Is policy-making the prerogative of the (central) government or is there some way of involving other parties in policy-making and implementation? If so, what are the responsibilities of the different parties? How do you, in practice, involve those parties?"

BY No response BG There is the initiative of private contractors with the cooperation of the Ministry of

Regional Development and Public Works (MRDPW). CZ The government and Ministry of Environment form and supervise policy of waste

materials management. Activity of individual parties is coordinated by the Association for development of recycling waste materials (founded in 1995) that is a member of Federation Internationale du Recyclage (F.I.R.).

H Ministry of Environment and Ministry of Transport PL Government elaborates general laws, e.g.: The Waste Materials Act.

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Producers of the waste materials must pay for environmental pollution. If there is a technology of the waste material usage, waste material becomes a valuable product. Producers or suppliers are responsible for the waste material handling. They guarantee the quality and safety of environment. Contractors are responsible for following of the technical guidelines.

RO The road policy practiced by the National Agency for Roads is the principal one dealing with the problem.

RUS Producers or suppliers are responsible for an implementation of the waste materials. Technical parameters control of waste materials is severe (performed by laboratories of suppliers, contractors and road administration). The Russian Ministry of Transport and especially the regional road administrations control technology by special control services. They can stop the investment and punish the producers or suppliers by legal and economical penalties, reclaim of license, etc.

SK The state is entitled to supervise disposal of waste materials. Other groups or parties are not involved.

SLO The only subject in policy making is the government. UA Government administration through resolutions and directives creates the policy line

concerning the usage of building and road waste materials. Other institutions elaborate and put into practice technical recommendations for the usage of building and road waste materials. Being the authors of technical recommendations and standards, they collect and process all data about the problem. At present the contractors and organizations approving the contract can influence the use of waste materials by introducing proper recommendations in the technical specifications of the projects.

4.4 Market parties

"Who are the most important market parties involved in the application of secondary materials (by-products) and what are their roles?"

BY No response. BG The Government represented by Ministry of finance, having in their structure the

Road Agency as well as the Ministry of Environment and Waters, design companies and contractors.

CZ Research institutes: They test secondary materials and prepare new technical recommendations; they are usually supported by research projects financed by the Ministry of Transport or the Ministry of Environment. Producers of by-products: They cooperate with research institutes on development of new materials for road technology. Road Contractors: They cooperate with research institutes on development of advanced technologies and offer new building materials on the basis of secondary material. Road authorities: They approve the offered road construction; the contract is based on Ministry of Transport Technical Recommendations (prepared by research institutes).

H The use of these materials depends on the price, too.

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PL Suppliers/producers/contractors: Create new techniques in collaboration with research institutes, laboratories, etc. Road administration: Supports research and puts new technologies into practice. Research institutes (IBDiM and ITB): Elaborate technical approvals for new techniques of use of secondary material in road construction and in building industry, Design offices: Elaborate technical specifications for constructions using waste materials.

RO The national and international construction enterprises are involved in the huge road rehabilitation program undertaken in this country at present.

RUS Concept “market parties” is not clearly described. SK Product vendors: They do not want to be involved in collection of secondary

materials. The producers of secondary materials: They are interested in their reuse in production.

SLO No response. UA Economic efficiency is the most important factor of formation of building and road

waste material market in the Ukraine.

4.5 Market forces

"What is the primary policy concerning the use of secondary materials (by-products)? ls the government controlling and regulating the market for secondary materials (by-products)? Are materials prescribed or is the use of materials in conformity with general market forces?" BY No response. BG For the time being there is no such policy developed and there is no control over this

activity. CZ The government controls and regulates only the market with dangerous waste

materials. The use of secondary materials is not prescribed; it depends on the market. H See Item 3. PL The government does not control or regulate the market for secondary materials. If the

material is not on the list of dangerous waste materials (a part of waste material catalogue), it can be sold. In practice it means that possession of technical approval for the usage of waste material is necessary on the market.

RO No response. RUS The sale of waste materials is controlled and regulated only by the market. The

government does not control it. SK No response. SLO No response. UA The market of building and road waste materials does not exist.

4.6 Instruments

"What kind of instruments are used to promote the use of secondary materials? ln which way are they used and what is the target you want to achieve using that particular instrument?"

BY No response.

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BG The “transfer of knowledge” method will bring good results in the field of application of secondary material in road construction and maintenance. None of the methods listed has been employed so far. The financial instruments promoting the use of waste materials will bring very good results especially for the project contractors.

CZ The used instruments promoting the use of secondary materials and their specifications are as follows: • Regulations based on law (limits of hazardous materials); • Financial instruments (tax of by-product dumping, zero price of recycled road

materials, etc.); • Government research projects supporting the use of secondary materials, transfer of

technologies, etc; • Government and industrial support of knowledge and technology transfer.

H No response.

PL The used instruments are as follows: • Regulations based on public law (catalogue of waste materials); • Financial instruments (ecological penalty for pollution of the natural environment); • Innovation/development of knowledge; • Transfer of knowledge (publications, articles, conferences etc.); • Regulations based on private law (technical approval, technical specifications); • Creation of branch organization, which promotes the use of some waste material.

RO The instruments to promote the use of secondary materials have not been specified yet. RUS The instruments are: quality, price and transfer of knowledge. SK The act on a compulsory repurchase of selected commodities. SLO Financial instruments - high costs of dumping waste.

Research projects financed by the government. Innovation/development of knowledge, research projects financed by the government or industry. Transfer of knowledge - research projects, articles, conferences.

UA Support of the use of building waste materials is made by developing and promoting the knowledge on the new techniques.

4.7 Requirements and criteria for acceptance of by-products

"How are new materials introduced in the market? Are there specific procedures to be followed or what kind of research has to be done before the use of materials is accepted? What kinds of requirements are put to the use of secondary materials (by-products)?"

BY No response. BG Scientific research of their application in the relevant technology has to be performed,

specifications for application of the technology have to be developed. Other countries experience could be used or transferred. Nevertheless, due to specific conditions comparative testing is to be carried out and cannot be neglected.

CZ The steps of research to put a new material on the market are as follows: 1. New material is tested from environmental (leaching test, volume of dangerous

substances) and material point of view.

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2. Material is tested in technologies of its possible usage. Performance tests are preferred; test section is needed.

3. The requirements characterize the material, design of technology process (content of substitutes, preparation method, etc.), technology and control tests.

Government usually supports the research work and producers of new materials collaborating with contractors. The results of research work are summarized in technical recommendations. The use of material depends on economical benefit.

H The producer has to certify, by laboratory or by other data, the adequacy and the environmental protection of his offer. In some cases he has the possibility to build test sections. Having the data and references, the producer requests for an application and adequacy certificate. This document is to be issued by the ÁKMI (Technical and Information Services on National Roads). After some years the certificate should be renewed.

PL No special procedure for introduction a new material on the market exists. Before introduction of a new product, the producer or supplier should perform environmental tests (leaching, radiation and content of dangerous substances for the natural environment) and technical tests in accordance with required standards and/or technical approvals. Producer or supplier should also make economical analysis of the market.

RO There are specific requirements for the use of secondary materials/waste materials; for example, the phosphogypsum is forbidden because of its high level of radioactivity, tars are forbidden because of their high level of toxicity, etc.

RUS The new waste material can be put on the market after it passes the tests in a special research laboratory (road administration, university, research institute) and after guidelines are elaborated. Research includes evaluation of technical parameters, elaboration a way to give the right characteristic (quality) to use of the secondary material in a road construction. Research includes also preparation of a technological guideline (containing treatment and use). Testing of ecological impact of waste material (radioactivity, creating of new compounds during treatment). The experimental constructions are prepared. The economical evaluation is made before and after the technological guideline elaboration, so that a change of price could be considered.

SK There are two approaches: Equal to classical materials and as new products with their own technical standards and parameters.

SLO Most important are environmental requirements and the economical ones. UA It is necessary to elaborate technical recommendations, technical guidelines, etc. to

introduce building waste materials into the usage. There are specific requirements for usage of waste material: • Technical potential; • Laboratory control; • Economic efficiency; • Improvement of natural environment.

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4.8 Market introduction

"Is there a distinct policy for the implementation of the policy on the use of secondary materials (by-products) and the market introduction of those materials?”

BY No response. BG There is no such policy. CZ Distinct policy is based on general and environmental benefit of the use of secondary

materials and is supported by the Government. Road construction and maintenance technologies requiring higher costs may be supported.

H The producers offer the materials to contractors. PL There is not a distinct policy for the implementation of the policy on the use of

secondary materials and the market introduction of those materials. Producers, branch organizations or suppliers need to promote their product, pay for tests and put it on the market. Road administration or research institutes (such as IBDiM) sometimes can help to find a contractor, who will use the waste materials in road construction.

RO No response. RUS The main market parties are: producers (national industrial plants), branch

organizations and suppliers (quality, price). In Russia there is no special policy for introduction of those materials on the market. General way for implementation was described above.

SK No response. SLO No response. UA The government policy for the implementation of use of waste materials establishes

obligation of a subordinate institution by writs to use building waste materials. Design offices when elaborating road projects assume to use or not to use waste materials in the road construction.

4.9 Barriers - obstruction

"Which are the main obstructions after complying with the above given requirements that oppose a successful market introduction? What is your suggestion to overcome those hindrances?"

BY No response. BG The main barrier is the lack of regulative legislative basis for their application. There

are no financial regulators and therefore there is a lack of interest from the part of construction contractors. The experience and what had been accomplished up to present was not made popular. Up to 1992-93 there were undertaken scientific research works concentrating on secondary material application in road construction and concerning the application of old asphalt, ashes, slag, old rubber, etc., but at present they are not being developed or made popular. At restructuring the state structures the research institutes decreased their capacity and their number was reduced. Some of them were transferred to market principles. Centralized financing of research is very restricted and funds have not been granted in this area. Financial funds have to be granted for scientific and technological research in this area.

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CZ The main obstructions are: • Low homogeneity of waste materials, low control of technology and produced by-

product, greater probability of road structure failure in comparison with virgin materials.

• Lack of funds for thorough testing of new technologies (performance testing), lack of technical approvals, short time experience; there is high probability of failure.

• High investment cost of new technologies (improvement of by-product and road technology).

• From the above mentioned reasons caution of designers, investors and contractors stems.

The reasons for successful introductions: • New quality and lower price of new road construction material in comparison with

virgin material. • Good long-term experience. To overcome hindrances it is possible to suggest: • Performance testing of road construction material, evaluation and testing of

pavement test sections by independent laboratory. • Independent control system of produced secondary material and produced road

construction material. H The economy and technical advantage should be considered. PL The main obstructions are:

• Lack of funds for tests for new technologies. • Heterogeneity of waste materials. • Lack of technical approvals. • Price of new technologies. • Cautiousness of designers, investors and contractors (reluctance in case of novelty

products or technologies). • Small quantities of waste material from one supplier and no branch organization. The reasons for successful introductions (e.g. burnt colliery shale): • Accessibility. • Large quantity. • Price. • Developed technique of the use. • Good technical characteristic. The reasons for failures introductions (e.g. waste glass): • Problems with a collect system. • Material does not have adhesion to asphalt. • Material is valuable for glass industries. To overcome hindrances we should: • Precise tests of the material. • Check the demand and supply. • Elaborate more then one technology of the use.

RO No response. RUS Poor quality of waste materials.

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The main obstructions are: price increase after elaboration of a new technological guideline (it concerns road industry, too) and disregard principles of technology (ecological problems, dustiness of air, noise of road engines).

SK Success: Better prices, improvement of environment. Failure: Low publicity, inadequate legislation. Work out rules, instructions (certified by the state) for introducing secondary materials in certain branches, support (tax preferred) of investors that use materials from secondary materials.

SLO No response. UA The main problem is a lack of objective evaluation of new technologies for using

building and road waste materials. There is a problem with availability to analytical materials elaborated by EU and USA specialists. The lack of experience is the problem that could be solved by participation in foreign trainings.

4.10 Incentives - Stimulation

“Is there any support or stimulation from the government for special projects?"

BY No response. BG The scientific research of secondary material application (in the Central Laboratory of

Roads and Bridges etc.) was financed by a special committee but there is no such structure at present. Present researches, financed by funds subordinate to the Ministry of Education and the Ministry of Environment, are focused on waste depots, waste water treatment plants, etc.

CZ Support of research projects by Ministries (of Environment, Transport or Industry) and by non–governmental organizations. Examples of projects focused on technical recommendations for use of these materials are as follows: RAP, RAM, slags, fly-ash, crap tyre rubber, etc.

H Support of research institutes. PL The government does not directly support research in the field of potential uses of

secondary materials as highway construction materials. There is no special program for highway construction The road administration GDDKiA supports research program (e.g. at present IBDiM realizes project of evaluation of waste materials from the point of view of their use in road construction).

RO No response. RUS In Russia research programs have been determined for use of secondary materials in

road construction. These programs are partly financed by the Russian Ministry of Transport, partly by the producers. Research project on leaching of waste materials was carried out in Russia. The results of research are included in technical and methodological guidelines.

SK Basic and applied research. Sponsors – government, producers and customers of new products and technologies. As good examples applications of slags and ground scrap tyres may be given. Leaching behaviour is the part of the research.

SLO Government and producers fund research. Some projects are under way. UA The Ukravtodor orders a scientific-technical study of reasonable use of building and

road waste materials, e.g. cold and hot recycling.

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4.11 Knowledge transfer

"How is the transfer of knowledge regarding the possibilities of and the experiences with secondary materials (by-products) organised in your country?"

BY No response. BG For the time being the initiative is carried by private owned companies, which consider

that in future this will reflect on decreasing costs and subsequently it will lead to better revenues.

CZ Articles in technical magazines, conferences, seminars, web sites and personal transfer of experience.

H Publications, presentation, courses. PL The transfer of knowledge: articles, conferences, web sites, competition of new

technologies (also with usage of waste materials), producers/suppliers publicity. RO Unsatisfactory. RUS The transfer of knowledge of the possibilities and experience with secondary materials

in Russia is ensured by: books, articles, booklets, research conferences, web-pages. SK Special activities have been organized: workshops, seminars, staff meetings. SLO Through articles and conferences. UA Sometimes one can find some lectures on this matter during conferences and seminars.

There are some published recommendations of use of building and road waste materials.

4.12 Conclusions

Responses to the questionnaire trying to describe the policy of promoting the use of road and non-road materials in road construction and maintenance were obtained from CEE countries that are members of EU (CZ, H, PL, SLO and SK) from 1st May 2004 and countries not being EU members (BY, BG, RO, RUS and UA).

On the basis of the responses to the questionnaire the following conclusions could be pointed out: • In CEE countries there are many different reasons for recycling and reusing of by-products.

The environmental, technical end economical reasons have been reported. • Governments take the responsibility for increasing recycling and reusing of by-products.

They use legislative tools, set recycling goals for the future and influence market with by-products. They also use financial support of research activity. In some reporting countries, however, even if the Government proclaims official support to the recycling policy, there is a lack of concrete results.

• “Restrictive" or “direct” regulations were used to reduce the production of waste materials and to control their disposal. These regulations were not balanced with additional ones encouraging sorting, recycling and reusing.

• The research institutes should develop new technologies and prepare technical recommendations.

• Above-mentioned findings are at different level in the CEE countries. Better situation is in EU countries, though it is not influenced only by EU legislation. It depends on economical problems of each country, development of free market and real situation that produces the waste materials.

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5 Conclusions and Recommendations The goal of this report is to submit a survey of the use of road and other industry by-products

in road construction and rehabilitation in the Central and East European (CEE) countries. The survey was prepared on the basis of expert responses received from 10 CEE countries;

five of them are members of EU (CZ, H, PL, SLO and SK) and remaining five countries are not EU members (BY, BG, RO, RUS and UA). All data included in the responses to the questionnaire are presented in the tables that are to serve as a survey and for the comparison.

The collected data are divided into the data dealing with road by-products, non-road by-products and information about the policy and strategies promoting the road materials recycling and using by-products in mentioned countries.

From the collected data and information the following conclusions can be stated:

Road by-products • The recycling technologies of road by-products are known in the mentioned countries. The

usage is relatively widespread (for instance in CZ) or is constrained to only one type of recycling method or the recycling methods have been just introduced or are being introduced.

• There are usual possibilities that are used in contract specifications for highway construction using road by-products: - Use of the same guidelines and specifications for virgin materials without modification. - Use of modified versions of current guidelines and specifications for virgin materials. - Use of the technological guidelines applied in other countries. Some guideline

modification may be necessary; if the modifications of the requirements or tests are not carried out, the problem with lifetime of pavement may occur.

- Development of new guidelines and specifications for by-products. • The road authorities are not well informed about the new development in recycling

technologies, they often distrust their application and keep at the standard maintenance and rehabilitation solutions. This attitude is based also on the fact that there is a lack of experience or there is a negative experience with the distress development after several years.

• Better situation was detected in countries, where the transfer of information, knowledge and know-how is performed via branch-offices of foreign road construction companies (mostly Central European countries). These companies sometimes organize trial sections to promote the interest of investors.

Non-road by-products

Some of non-road by-products have been used successfully in the road construction. Blast furnace slag, steel slag, coal fly ash and mining waste rock can be mentioned as the most widely used materials.

Regarding particular materials the following conclusions can be given: • Slags and mine rock waste are usually used in location of their occurrence. Their use in

motorway construction is sometimes limited as the old stockpiles of materials that can be used create the natural landscape of these regions.

• Production of coal fly ash, coal bottom ash and incinerator ash is still several times greater than their use as a secondary material in road construction.

46

• Up to now the foundry sand has been recycled in foundries only.. Only few countries reported its use also for road construction purposes mostly in limited extent.

• Waste tyres are mostly stockpiled or burned in cement kilns. Their usage in road constructions is in two countries at the starting point.

• Only the waste glass is not expected to be used in road construction in greater extent.

Policy and strategies promoting recycling and using by-products

On the basis of the responses to the questionnaire describing the policy of promoting the use of road and non-road materials in road construction and maintenance the following conclusions could be pointed out: • In CEE countries there are many different reasons for recycling and reusing of by-products:

the environmental, technical and economical. • Governments take the responsibility for increasing recycling and reusing of by-products.

They use legislative tools, set recycling goals and influence market with by-products. They also use financial support of research activity.

• The research institutes should prepare new technologies and technical recommendations. • Above-mentioned findings are at different level in the CEE countries. Better situation is in

EU countries.

Recommendations to support the recycling technology and use of by-products

• Since the year 1975 governments of the reviewed countries have been supporting the use of some materials produced in large quantities (e.g. fly ash, slags, mine waste, etc.) to replace virgin materials. Especially the research in the mentioned countries was supported. The system of produced by-product to be used as a road construction material was not carefully controlled and a lot of technologies were abandoned due to bad results and experience. After 1990 when there was a steep economical decline in most of the CEE countries, the research activities were stopped and state research institutes were closed. Their recovery will not be achieved in the former extent as the governments neglected the investments into research due to the lack of money in all other branches. At least, in the case of EU countries it may be supposed that the situation will change as in accordance with the EU legislation an exact percentage of national budget is prescribed to be invested into the research, especially to the field of sustainable development and environmental benefits.

• Development of a catalogue of by-products containing recommendations for their road applications would be advisable for CEE countries. Another catalogue of main technologies of road materials recycling and using of by-products (especially cold mix recycling, usage of incinerator bottom ash, waste tiles/bricks/concrete and scrap tyres) is important, too. Such catalogues would be helpful for contractors, designers and road authorities, too.

• It is necessary to point out that new European Standards covering recycled and waste materials are being introduced. Therefore the application of these materials can be considered in the road construction market without special permissions if the by-products fulfil technical parameters of road building materials. Technical parameters of by-products are usually not the same in comparison with virgin materials. The survey showed that every by-product could be suitable if its characteristics are considered in the final application, e.g. road construction.

• The use of particular by-products has been evaluated differently - in some countries as “currently in general use”, in others as “currently not used and should not be used”. Therefore, this survey can encourage the information and technology exchange among the European countries.

47

• The situation in the CEE countries could also be improved by more intensive transfer of knowledge in future. This can be achieved by organizing seminars and lectures, giving a common overview of materials suitable t to be recycled for the purposes of road construction, recycled techniques and technologies. These seminars should be focused on all participants in the recycling process (road construction, industry as well as the road authorities). Seminars that specialize in one by-product should be followed by more detailed information. Study stays of technicians, organizing trial sections with financial support from the EU budgets could make the whole process easier, too.

• Even though the catalogue of materials and technologies is being prepared and the technology transfer will be launched, the condition specifications for severe climate, different types of road materials and by-products are necessary to be elaborated. Research or long-term evaluation will be necessary, too. If tests used do not reflect conditions and measured properties are not based on functional (performance) characteristics, the lifetime problems may occur. If the new technology is being developed in the EU research program, the involvement of CEE countries research organization will be very useful. The requirements developed while using recycling technology and by-products procedure can help to develop more universal technology of road recycling or the use of industrial by-products in road construction.

Conclusion

The submitted review gives an overview about the situation of the use of road and other industry by-products in road construction and rehabilitation in the CEE countries. It should not be considered as an interesting information only, but it could launch future projects in this area within the unified Europe. This impact of the process can be positive - for particular countries, for those being able to help but first of all for the healthier environment and sustainable development in Europe.

48

ANNEX A

Full text of WP 6 questionnaire responses of particular CEE coutries

49

Annex A consists of following CEE countries responses to WP 6 questionnaire: 1. Belarus (BY), 2. Bulgaria (BG), 3. Czech Republic (CZ), 4. Hungary (H), 5. Poland (PL), 6. Romania (RO), 7. Russia (RUS), 8. Slovakia (SK), 9. Slovenia (SLO), 10. Ukraine (UA). In Chapter 0 the text of the questionnaire is presented. In Chapter 1 to 10 responses of mentioned countries are presented. The responses of

individual countries are only numbered and abbreviations are not explained; full text of questions and explanation of abbreviation are only in Chapter 0.

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0 WP6 QUESTIONNAIRE

Survey A: Road By-products

Identification Country or Region: Your Name: Position: Organization: Address: Phone: Fax: E-mail:

1. Amount Road By-products Annually Table 1 - total amount is approximately divided into plant recycling, on-site recycling, stock

and landfill.

Table 1: Amount Road By- products Annually NAME QUANTITY

Available product ton/year %

plant recycling

% on-site recycling

% stock

% landfill

1) Reclaimed Asphalt Pavement (RAP)

2) Reclaimed Concrete Pavement (RCP)

3) Reclaimed Base and Subbase

4) Mixture of 1,2,3

2. Applications of Road By-products Table 2 - applications are listed for each road by-product, for example, asphalt mixture is

applied to recycled hot mixture, recycled cold mixture, granular base course, etc. - treatments are described for each application, for example, asphalt mixture is crushed and graded for recycling, - specify the evaluation of each application in terms of technical, economical and environmental background.

51

Table 2: Applications of Road By–products NAME TECHNICAL QUALITY EVALUATION (+. —, 0)

Available product Application

Treatment (necessary and/or possible for each application)

tech. econ. envir.




4)

Mixture of 1,2,3

3. Other Questions

3-1

State the characteristics of each available product. - chemical composition (metals, organics, type of binder, type of modifier....), - physical characteristics (grading, plasticity, hardness ).

3-2

What characteristics do you think are important for reuse-possibilities in a certain application?

3-3

What is the required technical quality for recycled aggregate in your country? Give test methods, guidelines.

3-4

What is the required environmental quality for recycled aggregate in your country? Give test methods, guidelines.

3-5

What new recycling techniques are being developed in your country (in research phase)?

52

Survey B: Other By-products (Non-Road Materials) Identification Please complete the following information. Country or Region: Your Name: Position: Organization: Address: Phone: Fax: E-mail:

Material/Application Matrix - for each material/application combination, indicate the

extent of its use according to the rating system below: 4 = currently in general use, 3 = currently in limited use, 2 = currently not used; considered a potential use, 1 = currently not used; considered a questionable use, 0 = currently not used and should not be used.

For each material/application combination rated “3” or “4” in the Material/Application Matrix, please complete the “Survey Response From for Recycled/Recovered Materials” provided. Make extra copies of this two-pages from if necessary.

Material/Application Matrix (non-highway materials) Applications

Material P C C

H M A

CM / S T

G S

S B

G B

E M B

F I L L

S T R

A P P

S A F

L S

Blast Furnace Slag, Air cooled

Blast Furnace Slag, Ground Granulated

Coal fly ash Coal Bottom ash

Foundry sand Mining Waste Rock

Municipal Soil Waste Incinerator Bottom Ash

Non-Ferrous Slag Scrap Tyres Steel slag

Waste Glass Waste Concrete

Waste Tile/Bricks Waste Tile/Concrete

53

PCC = Portland cement concrete pavement (wearing surface), HMA = Hot Mix Asphalt pavement, CM/ST = Cold mix or surface treatment, GS = granular surface (e.g. gravel road), SB = stabilized base, GB = granular (unbound) base, EMB = Embankment, FILL = Fill (e.g. backfill, subgrade, flowable fill), STR = structures (e.g. bridges, culverts, storm drain inlets and pipes), APP = Appurtenances (e.g. curbs, gutters, sidewalks, median barriers), SAF = safety-related items (e.g. guardrails, signposts, lightposts, striping, etc.), LS = landscaping (e.g. mulch, picnic benches, etc.).

Survey Response for Non-Highway Recycled/Recovered Materials

Application: ____________________

Material: _______________________

1. Approximate annual amount used in this application: __________tones.

2. What tests must the material supplier perform for material acceptance? (please list standard references (ASTM, DIN, etc., as appropriate)).

3. What (if any) modifications to normal construction equipment or procedures are required to use this material in this application?

4. Please list quality control tests, which are required during construction using this material/application (please note tests which require modified test procedures or different interpretation of results).

5. Do you have standard specifications for this material/application combination?

6. What factors do you consider in evaluating environmental suitability of this material/application combination?

7. Do you have environmental specifications or regulations pertaining to use of this material/application combination?

8. What factors do you consider in evaluating the economical suitability of this material/application?

9. Please list other pertinent information regarding this material/application combination (e.g., current research, performance, etc.)

54

Survey C: Policy/Strategy of Recycling

Identification Please complete the following information. Country or Region: Your Name: Position: Organization: Address: Phone: Fax: E-mail:

1. Policy

Which policy lines in your country influence the use of secondary materials in general and the use in road building in particular?.

Is there a distinct structurized approach to this subject and has this been laid down in relevant governmental documents. Can you give some information on how high this subject is on the political agenda?

What are the problems that are to be solved by the use of secondary materials.(e.g. the need of raw materials, environment, energy, etc.)?

Please specify if possible the goals set in your country for the use of secondary material (for the building industry in general and road building in particular).

2. Responsibilities

Is policy making the prerogative of the (central) government or is there some way of involving other parties in policy making and implementation?

If so, what are the responsibilities of the different parties. How do you in practice involve those parties?

3. Market parties

Can you explain the role of the most important market parties involved in the application of secondary materials? Who are those parties?

4. Market forces

What is the primary policy concerning the use of secondary materials? Is the government controlling and regulating the market for secondary materials? Are materials prescribed or is the material in conformity with general market forces? Please explain the policy in your country and what is the general attitude of market parties your policy.

5. Instruments What kind of instruments are used to promote the use of secondary materials? Please give

an explanation on the use of a number of possible instruments. Please state if these instruments are used, in which way they are used and what is the target you want to achieve using that particular instrument.

- regulations based on public law,

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- financial instruments, - innovation/development of knowledge, - transfer of knowledge, - regulations based on private law, - other instruments.

6. Requirements and criteria for the acceptation of secondary materials

How are new materials introduced on the market? Are there specific procedures to be

followed or what kind of research has to be done before the use of materials is accepted?

What kind of requirements are put to the use of secondary materials (e.g. environmental, technical, labor, economics)? Please give the general approach in your country.

7. Market introduction

Is there a district policy for the implementation of the policy on the use of secondary materials and the market introduction of those materials? What is the role of the different parties involved in road building concerning this subject (government, client, branch organizations, producers, contractors, suppliers)?

8. Obstructions

Which are the main obstructions after complying with the above given requirements that oppose a successful market introduction? Can you give the reasons for successful introductions and the reasons for failures that you have experienced?

What is your suggestion to overcome those hindrances?

9. Stimulation

Is there any support or stimulation from the government for special projects:

- is your country now performing, or has ever performed, research into the potential uses of secondary materials as highway construction materials? Who is funding that research, (government, producers, other organizations)?

- is there any practical or fundamental research in leaching behavior of secondary materials?

- are there any “example-projects” in your country applying secondary materials in roads construction?

10. Transfer of knowledge, possibilities and experiences with secondary materials

How is the transfer of knowledge on the possibilities of and experiences with secondary materials organized in your country?

56

1 BELARUS

Survey A: Road By-products No.

Survey B: Other By-products (Non-Highway Materials)

Country or Region: Bielorus Your Name: Wyrko N.P. Position: Professor, Doctor of Technical Sciences Organization: Technical University Address: Swierdłowska 13a, 220050 Minsk Phone: 227 10 40, 227 07 28 Fax: 8-1037517-227-62-17 E-mail: -

Material/Application Matrix (non-highway materials)

Applications

Material P

C

C

H

M

A

C

M

/

S

T

G

S

S

B

G

B

E

M

B

F

I

L

L

S

T

R

A

P

P

S

A

F

L

S

Blast Furnace Slag, Air cooled 2 4 2 0 0 2 0 0 0 0 0 0

Blast Furnace Slag, Ground Granulated 2 3 2 0 2 0 4 2 3 3 0 4

Coal fly ash 0 0 0 0 0 0 0 0 0 0 0 0

Coal Bottom ash 0 2 2 0 2 4 3 3 1 1 0 1

Foundry sand 0 0 0 0 0 0 0 0 0 0 0 0

Mining Waste Rock 0 2 1 0 0 0 0 0 0 0 0 0

Municipal Soil Waste Incinerator Bottom Ash 0 0 0 0 0 0 0 0 0 0 0 0

Non-Ferrous Slag 0 1 0 0 0 0 1 1 1 1 0 1


No responce

57

2 BULGARIA


Country or Region: Bulgaria Your Name: Nikolova Svoboda, Ph.D., Dipl. Eng. Position: Main Manager Organization: Patconsult 2000 Address: 9 A Doiran Str., Sofia, Bulgaria Phone: 003592 958 59 49 Fax:003592958 64 77 E-mail:

Your Name: Veselin Dimitrov, Scientist, Dipl. Eng. Position:Head of “Asphalt pavements” Department Organization: Road Executive Agency “Central Roads and Bridges Laboratory” Address: Sofia, Bulgaria Phone: 0035929450754 Fax:0035929450683 E-mail:veselin_dimitrov@ abv.bg

Your Name: Dimitar Nazarski, Dr., Eng. Position:Head of Department of Building Materials and Insulations Organization: University of Architecture, Civil Engineering and Geodesy Address: Sofia, Bulgaria, 1 Christo Smirnenski Blvd. Phone: 003592 8665264 Fax: E-mail:bais@ uasg.bg

1. Amount Road By-products Annually

Table 1: Amount Road By-products Annually NAME QUANTITY

Available product ton/year%

plant recycling

% on-site

recycling

% stock

% landfill

1) Reclaimed Asphalt Pavement (RAP) 2 800 - 100 - -

2) Reclaimed Concrete Pavement (RCP) - - - - -

3) Reclaimed Base and Subbase - - - - -

4) Mixture of 1,2,3 2 800 - 100 - -

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2. Applications of Road By-products

Table 2: Applications of Road By -products NAME TECHNICAL QUALITY EVALUATION (, -, 0)



tech. econ. envir.

for recycling hot mixture

Asphalt was scraped and added to hot mixtures


+ + +

There are no concrete pavements in Bulgaria



4)

Mixture of 1,2,3

3. Other Questions

3-1 It was used bitumen according Bulgarian State Standard.

3-2 The constant composition of aged asphalt.

3-3 Technical Specification “Asphalt hot mix recycling”.

3-4 There are no special requirements.

3-5 Asphalt cold mix recycling.

59


Country or Region: Your Name: the same data as in form A apply Position: Organization: Address: Phone: Fax: E-mail:


Material PCC

HMA

CM / S T

GS

S B

GB

EMB

F I L L

S T R

A P P

S A F

L S

Blast Furnace Slag, Air cooled 2 2 3 3 3 3 2

Blast Furnace Slag, Ground Granulated 2 3 2 3

Coal fly ash 2 2 2

Coal Bottom ash 2 3 3

Foundry sand

Mining Waste Rock 4 4

Municipal Soil Waste Incinerator Bottom Ash 1 1 1

Non-Ferrous Slag 2 2

Scrap Tyres 2

Steel slag

Waste Glass

Waste Concrete 2

Waste Tile/Bricks

Waste Tile/Concrete

60


A) Application:

Material: RAP 1. 2 800 tones. 2. BDS (Bulgarian State Standard) 4132 for hot asphalt mix or “Asphalt Institute Mix Design

Method Manuel. MS 2. 3. Special set of machines for milling, mixing of old asphalt and fresh asphalt and laying. The

company, which aplaying this technology last year use set of machine from “Wirtgen”. 4. There is not difference between tests for new and reclaimed Asphalt. 5. Technical Specification “Asphalt hot mix recycling” issued by Road Executive Agency. 6. There are not great experience at our country in this field. 7. There is not specification for this material. 8. Transport expenses, mechanization. 9. -

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3 Czech Republic


Country or Region: Czech Republic Your Name: Michal Varaus Position: Organization: Brno University of Technology, Department of Roads Address: Veveří 95, 662 37 Brno Phone: + 420 541147187 Fax: +420541213081 E-mail: [email protected]



Available product (2003)

ton/year%

plant recycling

% on-site

recycling

% stock

% landfill

1) Reclaimed Asphalt Pavement (RAP) 690 000 20 50 20 10

Dtto with tar 35 000 20 60 20 -

2) Reclaimed Concrete Pavement (RCP) 25 000 45 - 15 40

3) Reclaimed Base and Subbase 50 000 - 100 - -

4) Mixture of 1,2,3 +)

+) It is not documented, as all amounts are used in road construction.

62


Table 2: Applications of Road By–products NAME TECHNICAL QUALITY EVALUATION (+, -, 0)



tech. econ. envir.

Hot mixtures

In plant - adding to new mixtures

In place – Repave, Remix, Remix+

Cold mixtures

In plant – mixed with emulsion and cement


RAP without binders

Milled or crushed asphalt materials are relaid without binders as base, subbase, surface courses (low trafficked roads, rural, forest roads)

+ + +

RCP – cement stabilization or cement concrete, unbound base courses

Crushed and sieved concrete reused as aggregate for new constructed cement concrete binder courses, cement stabilizations or unbound base courses


+ + +

Cold recycling

In place cold recycling with addition of cement and/or emulsion


+ + +

Cold recycling

In place cold recycling with addition of cement and/or emulsion

4) Mixture of 1,3

+ + +

3. Other Questions

3-1 1) RAP Type of binder in RAP: non modified bitumen, tar. Physical characteristics of RAP: grading, binder – penetration, softening point.

63

Batch mixing plants: • adding of cold 0/11, 0/22 fractions of RAP into the mixer to new asphalt mixtures,

approx. 10 – 25 %, • adding of hot RAP dried in the parallel drum into the mixer to new asphalt mixtures,

approx. 30 – 60 %. Continuous mixing plant, drum mix technology: mixing of 0-11, 0-22 fractions of asphalt

recycling materials 10-80 % in the drum mixer together with aggregate and hot bitumen 70/100, 100/150.

Steamed recycling technology: Asphalt recycling materials put into hoppers are steamed and via conveyor belt brought into mixer, where they are mixed with bituminous emulsion and cement. 3.1.1.1 Cold in place recycling technologies.

2) RCP Crushed concrete – stiffness as high as aggregate, high water consumption, crushed sand not

good for production of new cement concrete – bad workability. 3) Reclaimed base and subbase Sometimes in the case of very non-homogeneous materials and lack of fines there is a

necessity to add 0-4 aggregate fraction, admixture of cement and/or emulsion according to the content of recycled asphalt material.

3-2 RAP – Hot and cold mixtures – Sieve curve, binder content, characteristics of bitumen =

penetration (softening point) RCP – Grading after milling and crushing, LA-value, water absorption, fine quotient.

3-3 The recycled aggregate (all sorts without RAP) should conform to the same requirements as

virgin aggregate. ČSN EN 13043 Aggregate for bituminous mixtures and surface treatments for roads,

airfields and other trafficked areas. ČSN EN 13242 Aggregates for unbound and hydraulically bound materials for use in civil

engineering work and road construction. The requirements on the RAP-aggregate (sieve curve, penetration of bitumen) and its limits

for the use in new hot asphalt mixtures are given by ČSN 73 6121 Hutněné asfaltové vrstvy (Hot Mix Asphalt).

3-4 The RAP-aggregate containing tar cannot be used in hot recycling processes. For the RAP

with tar there are limits for the amount of Polynuclear aromatic hydrocarbons (PAH) in case the aggregate should be reused in the cold recycling process.

TP 150 Souvislá údržba a opravy vozovek pozemních komunikací obsahujících dehtová pojiva (Maintenance and rehabilitation of roads containing tar binders.)

3-5 Nowadays the greatest attention is devoted to the cold in situ cold recycling technologies

mainly base and subbase materials. The material is mixed together with Portland cement and bituminous emulsion or bitumen foam.

The technology based on usage of mixture of hydraulic binders, Portland cement, fly ash, lime and special additives has started to be used.

64

If the unbound material was mixed only with cement the transversal and longitudinal crack would occur and during 8-year pavement service the course was again unbound (i.e. it exhibited failures – reflective cracks and bearing capacity problems occurred). The addition of sand into recycled material seems to be necessary.

The cracks often occur in the case of cold recycling with Portland cement and bitumen emulsion.

In both cases the frost action is to be evaluated.

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Survey B: Other By-products (Non-Road Materials) Country or Region: Czech Republic Your Name: Jan Kudrna, Assoc. Prof., MSc., Ph.D Position: Head of Department Organization: Brno University of Technology, Faculty of Civil Engineering, Department of

Roads Address: Veveří 331/95, CZ-602 00 Brno Phone: +420 54114 7340 Fax: +420 54121 3081 E-mail: [email protected]


C F

M P H E S A S I S G L Material G

S C M / M T P A B B L S

C A S B R P F L

T Blast Furnace Slag, Air

cooled 3 3 3 3 3 3 3 3 2 2 2 4


0 0 0 2 3 2 3 3 2 2 0 4 Coal fly ash

0 0 0 2 3 2 Coal Bottom ash 3 3 2 2 0 4

Foundry sand 2 2 0 1 1 1 1 2 0 2 0 2



Non-Ferrous Slag 0 0 0 0 0 0 0 0 0 0 0 0

Scrap Tyres 0 3 1 0 0 0 2 0 1 1 1 1

Steel slag 0 3 3 2 3 3 3 3 0 2 0 4

Waste Glass 0 1 1 0 0 0 0 0 0 0 0 0

Waste Concrete 3 2 2 3 3 3 1 1 2 2 0 1

Waste Tile/Bricks 0 0 0 2 3 2 3 3 0 0 0 3

Waste Tile/Concrete 0 0 0 2 3 3 3 3 0 0 0 3

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Survey Response for Non-Road Recycled/Recovered Materials

A) Application: HMA, CM/ST, GS, SB, GB, EMB, FILL, STR, SAF, LS

Material: Blast Furnace Slag, air cooled 1. Total production was 1 000 000 tonnes in 2001 and 400 000 tonnes in 2002. The use of materials in the region of their production was greater than the production as old stock pilings were used in motorway and road contruction. 2. Granularity, content of porous and glassy grains, contaminants, LA test, resistance to frost cycles, content of SO3. 3. No changes, greater abrasion of steel surface of construction equipment. 4. No special test. 5. ČSN EN 13043 Aggregate for bituminous mixtures and surface treatments for roads, airfields and other trafficked areas. ČSN EN 13242 Aggregates for unbound and hydraulically bound materials for use in civil engineering work and road construction. TR 138 The use of slags in road construction OTK Aggregate for railway bed ČD S4 Railway bed 6. Leaching in accordance with regulation No. 383/2001, supplement No. 6. 7. Waste act No. 185/2001 and related regulations of Ministry of Environment No. 337, 338 and 339/1997. 8. Landfilling costs support the use of material while delivery costs limit its usage in dependance on the distance from the place of its production.

9. In case of improper separation of metal particles some life-time problems of hot mix asphalt (different bitumen content and higher hardening of bitumen) occured.

B) Application: SB, EMB, FILL

Material: Coal fly ash, Coal bottom ash 1. Total annually production of coal fly ash, coal bottom ash is about 1 000 000 tonnes, only 150 000 tonnes of which are used as secondary material; in road construction it is approximately 20 000 tonnes.

67

2. Leaching test, granularity, for SB, EMB, FILL content of CaO. 3. Dewatering, production control (homogeneity of the materials). 4. Granularity, water content, compactibility (Proctor test), CBR, degree of compaction. 5. ČSN 72 2072-7 Fly-ash for civil engineering – Part 7: Fly-ash for road construction. ČSN 72 2081–12 Fly-ash for civil engineering – Part 12: Fluid Fly-ash for road construction. ČSN 73 6133 Road earthwork – design and construction. ČSN 73 6127 Road building; Grouted Courses. TR 93 Design and construction of roads structures with the use of fly ash and bottom ash. CDS4 Railway bed. 6. Dissolved metals. 7. Waste act No.185/2001 and related regulations of Ministry of Environment No. 337, 338, 339/1997. 8. Land filling costs support the use of material while delivery costs limit its usage in dependence on the distance from the place of its production. 9. Low bearing capacity of compacted fly ash especially due to the contact with water requires that the embankment has to be covered with suitable soil, the thickness of which is 0,8 m at min. If the Portland cement is used in stabilized layer chemical reaction and subsequent creation supplemental creating of ettringit causing volume changes in the layer may occur. If fly ash mixture with Portland cement and water was used for filling the air voids in crushed aggregate 32/63 used in pavement base layer, frost heaves of asphalt courses caused by water collected in the porous fly ash material occurred.

C) Application: EMB, FILL, LS

Material: Mining waste rock 1. An annual production of coal mining waste rock is approx. 3 000 000 tonnes. Yearly consumption in road construction is about 4 mil. tonnes to 5 mil. tonnes. 2. Leaching test; 3. No modification 4. Compaction field test.

68

5. CSN 73 6133 Czech Technical Standard Road earthwork – design and construction, 6. Reducing of consumption of natural materials, higher bearing capacity of fills. 7. No. 8. Transport costs, the use is limited to the region of coal mining. 9. Material cannot be used in subgrade. Coalmine rock is used only in the fills and embankments. The embankments can burn inside due to the content of coal and regular control has to be carried out.

D) Application: EMB, LS

Material: Municipal Soil Waste Incinerator Bottom Ash 1. Only a small part of the total annual production making 90 000 tones is used in road construction. 2. Leaching test; granularity 3. High content of heavy metals needs stabilization of these materials. 4. They are using the same standards as for other ashes, according to standard ČSN 73 6133 Road earthwork – Design and construction. 5. Act No. 383/20001, Waste management. No special standards, the specifications are the same as for coal bottom ash. 6. Reduction of landfilling of municipal waste, the energy production. Reduction of consumption of natural materials. 7. See coal bottom ash. 8. Easy accessibility. Reduction of landfilling. 9. Material is mostly used in landscaping.

69

E) Application: HMA

Material: Scrap Tyres 1. The total amount of used tyres is approximately 50 000 tonnes/per year and about 6 000 tonnes are imported. Approximately 3 000 tones are used in road construction in hot mix asphalt.. Furthermore, scrap tyres after rubber regeneration are used in road signs, railway crossings, etc. 2. Granularity of mechanical grinding of tyre. 3. Dry mixing of rubber granulate in hot mix asphalt plant. 4. Improved Marshall test for HMA; air voids control. 5. - TR 148 Bituminous mixture wearing course with addition of the ground tyres. 6. Following this technology no impact on environment exists. 7. In case of other technologies using scrap tyres (noise barriers, play grounds, etc.) the leaching test is required. 8. Price and durability of wearing course. 9. In several sections where the technology was not perfectly respected (higher air voids content) failures with ravelling and potholes occurred.

F) Application: HMA, SB, GB, EMB, FILL

Material: Steel Slag

1. Total production in 2001 was 550 000 tonnes and 225 000 tonnes in 2002.

2. Granularity, content of porous and glassy grains, contaminants, LA test, resistance to frost cycles, content of SO3. Determination of free lime content or volume changes of slag aggregate in hot pressure steam or volume changes of slag aggregate in HMA.

3. Hot mix asphalt is controlled to determine bitumen loss in the pores of steel slag aggregate.

4. No difference.

5.

70

ČSN EN 13043 Aggregate for bituminous mixtures and surface treatments for roads, airfields and other trafficked areas. ČSN EN 13242 Aggregates for unbound and hydraulically bound materials for use in civil engineering work and road construction. EN 1744-1 Tests for chemical properties of aggregates – Part 1. Chemical analysis. Free lime content. TP 138 The use of slags in road construction OTK Aggregate for railway bed

6. Leaching according to regulation No. 383/2001, supplement No. 6

7. Waste act No. 185/2001 and related regulations of Ministry of Environment No. 337, 338 and 339/1997.

8.

Landfilling cost and tax support the use of material while delivery costs limit its usage in dependance on the distance from the place of its production.

9.

Volume changes cause heaving of subgrade and base and ravelling of asphalt concrete.

G) Application: HMA, GS, SB, GB

Material: Waste concrete 1. Yearly production is about 100 000 tonnes, 60 000 tonnes of which is used in road construction. 2. Granularity, content of contaminants, LA test, resistance to frost cycles, water absorption. 3. No modification. 4. GB, SB as natural aggregate. Bitumen loss in waste concrete aggregate of HMA is controlled. . 5. Draft of TR Recycled materials from building demolition in road construction 6. Leaching. 7. Waste act No.185/2001 and related regulations of the Department of Environment No. 337, 338 and 339/1997. 8. Landfilling costs and tax support the use of the material. 9. Using lower quality of concrete from demolished construction can influence the quality of waste concrete.

71

H) Application: SB, GB, EMB, FILL

Material: Waste tile/bricks

1.

Total production is 120 000 tones, most of which is used in road construction.

2. Leaching, granularity (frost susceptibility), content of contaminants (wood, plastics, etc.),

3. No modification.

4.

Compactibility (Proctor test), CBR, degree of compaction; in case of SB compressive strength after frost cycles.

5. ČSN 73 6133 Road earthwork – Design and construction (Czech technical standard), Draft of TR Recycled materials from building demolition in road construction

6. Leaching.

7. Waste act No.185/2001 and related regulations of the Department of Environment No. 337, 338 and 339/1997.

8. Landfilling costs and tax support the use of material.

9.

The quality of waste tile/bricks can be influenced by contaminants (wood, organic material, bottom ash, etc.)

I) Application: GS, SB, GB, EMB, FILL

Material: Waste tile/concrete

1.

The total production is 60 000 tonnes most of which is used in road construction.

2. Leaching, granularity (frost susceptibility), sand equivalent, content of contaminants (wood, plastics, etc.),

3. No modification.

4.

72

Granularity, water content, compactibility (Proctor test), CBR, compaction degree; in case of SB compressive strength after frost cycles.

5. ČSN 73 6133 Road earthwork – Ddesign and construction (Czech technical standard), Draft of TR Recycled materials from building demolition in road construction

6. Leaching.

7. Waste act No.185/2001 and related regulations of the Department of Environment No. 337, 338 and 339/1997.

8. Landfilling costs and tax support the use of material.

9.

The quality of waste tile/concrete can be influenced by contaminants (wood, plastics, organic material, etc.)

73


Country or Region: Czech Republic Your Name: Jan Kudrna, Assoc. Prof., MSc., Ph.D Position: Head of the Road Department Organization: Brno University of Technology, Faculty of Civil Engineering, Department of

Roads Address: Veveří 331/95, CZ-602 00 Brno Phone: +420 54114 7340 Fax: +420 54121 3081 E-mail: [email protected] 1. Reduction of materials and energy consumption are the main goals in industry. One of the possible ways is the use of by-products. The philosophy of waste management (3rd version) was published in November 2001. A new approach is under preparation. The use of waste materials solves protection of environment, replacing of natural materials, decreasing of energy consumption and reduction of road construction and rehabilitation costs. 2. The government and Ministry of Environment forms and supervise policy of waste management. Activity of individual parties is coordinated by the Association for Development of Recycling Waste Materials (founded in 1995) that is a member of Federation Internationale du Recyclage (F.I.R.). 3. Research institutes – test a secondary material and materials using secondary material/s and prepare new technical recommendations; they are usually supported by research projects financed by Ministry of Transport or Ministry of Environment, Producers of by-product – cooperate with research institutes on development of new materials for road technology, Road Contractors – cooperate with research institutes on development of new technologies and offer new building materials on the basis of secondary materials, Road authority approves the offered road construction; the contract is based on technical recommendation prepared by research institute. 4. The government controls and regulates the market with dangerous waste materials, only. The use of secondary materials is not prescribed; it depends on the market. 5. The used instruments promoting the use of secondary materials and their specifications are as follows:

• Regulations based on law (limits for dangerous materials); • Financial instruments (tax on by-product land filling, zero price of recycled road

materials, etc.);

74

• Government research projects supporting the use of secondary materials, transfer of technology etc;

• Government and industrial support of knowledge and technology transfer. 6. The steps of research introducing new material on market are as follows:

1. New material is tested from environmental (leaching test, volume of dangerous substances) and material point of view.

2. Material is tested in technologies of its possible use. Performance tests are preferred; test section is needed.

3. The requirements characterize the material, design of technology process (content of substitutes, preparation method, etc.), technology and control tests.

Government usually supports the research; producers of new material and contractors collaborate. The results of research are summarized in technical recommendation. The use of material depends on economical benefit. 7. Distinct policy is based on general and environmental benefit of the use of secondary materials and government support. Road construction and maintenance technology bringing higher cost while offering other benefit can be supported. 8. The main obstructions are: • Low homogeneity of waste materials, low control of technology and produced by-product,

greater probability of road structure failure in comparison with the road structure using virgin materials.

• Lack of funds for thorough testing of new technologies (performance testing), lack of technical approvals, short time experience; there is a high probability of failure.

• High investment expenses on new technologies (improvement of by-product and road technology).

• From above mentioned reasons caution of designers, investors and contractors stems. The reasons for successful introduction are: • New quality and lower price of new road construction material in comparison with the virgin

one. • Good long-term experience. To overcome hindrances it is possible to suggest: • Performance testing of road construction material, evaluation and testing of pavement test

sections by independent laboratory. • Independent control system of produced secondary material and produced road

construction.material.

75

9. Support of research projects by Ministries (of Environment, Transport or Industry) and by non–government organizations. Examples of projects on the base of which technical recommendations for use these materials have been elaborated are as follows: RAP, RAM, slags, fly-ash, scrap tyre rubber, etc. 10. Articles in technical magazines, conferences, seminars, web sites and personal transfer of experience.

76

4 Hungary


Country or Region: Hungary Your Name: Zoltan Valyi Position: Head of Division Organization: ÁKMI Kht. (Technical and Information Service on National Roads) Address: H-1039 Budapest, Fényes Elek utca 7-13. Phone: (36)-1-20-20-811/516 Fax: (36)-1-316-27-10 E-mail: [email protected]




plant recycling

% on-site

recycling

% stock

% landfill

1) Reclaimed Asphalt Pavement (RAP) 50 000 20 15 65 -

2) Reclaimed Concrete Pavement (RCP) 5 000 50 50 - -


4) Mixture of 1,2,3 - - - - -

77


Table 2: Applications of Road By–products NAME TECHNICAL QUALITY EVALUATION (+,–, 0)



tech econ. envir.

Hot mix Mix in plant

Cold mix Mix in site

1) Reclaimed Asphalt Pavement (RAP) Base course Without binder

–

+

+

+

+

–

+

+

+

Base course Crushed and graded


– – +

Cold mix Stabilised with cement


+ + +

4)

Mixture of 1,2,3

3. Other Questions

3-1 Physical requirements according to technical directions. The types of bituminous modifiers used are as follows: Elastomer modifier: SBS, Plastomer modifier: Polybilt, (EVA is not to be used). The allowed quantities of the reclaimed asphalt for hot asphalt mixtures are in: base courses: 30%, binder courses: 25%, wearing courses: 20%. The softening point (RB, SP) of the binder of the new asphalt mixture produced with

reclaimed asphalt can be calculated using the formula:

78

SPx = SPnew + Mag . Bag (SPagb – SPnewb) / 100 B, where SPx = softening point of the new asphalt mixture, °C, SPnew = softening point of the bitumen, planned for the new asphalt mixture, Mag = planned quantity of the reclaimed asphalt in the new mixture, Bag = binder quantity of the reclaimed asphalt in % of mass, SPagb = softening point of the bitumen extracted from the reclaimed asphalt, B = the planned binder quantity in the new asphalt mixture in % of mass.

3-2 The adequacy for the requirements of the standards and directions.

3-3 The recycled aggregate should satisfy the standard requirements (LA., Deval, grading, etc…)

3-4 Under preparation .

3-5 Breaking up of the old pavement, homogenization, new aggregate admixture, mixing with

cement, compaction, wearing course. (Mostly on low trafficked roads.).

79




Material P C C

HMA

CM / S T

GS

S B

I L L

S T R

A P P

S A F

L S

GB

EMB

F

Blast Furnace Slag, Air cooled

3 3 3 2 2 3 1 2 2 0 0 0


Coal fly ash 3 3 0 0 3 0 3 2 0 0 0 0

Coal Bottom ash 0 0 0 0 2 0 1 1 0 0 0 0

Foundry sand 0 0 0 0 0 0 0 0 0 0 0 0



Non-Ferrous Slag 0 0 0 0 2 0 1 0 0 0 0 0

Scrap Tyres 0 0 0 0 0 0 0 0 0 0 0 0

Steel slag 0 0 2 0 0 0 0 0 0 0 0 0

Waste Glass 0 0 1 0 0 0 0 0 0 0 0 0

Waste Concrete 2 0 0 0 0 3 0 0 0 0 0 0



80


A) Application: GB

Material: Blast furnace slag 1.

60 000 tones.

2. The same tests, as for the crushed rocks. (Los A., deval, grading, etc…). The standard specification of granular base is named: ÚT 2-3.207 Útpályaszerkezetek kötőanyag nélküli és hidraulikus kötőanyagú alaprétegei. Base Courses without and with Hydraulic Binders for Pavements. Design Requirements. The requirements for blast furnace slag are the same as for granular materials, e.g.:

• mineral composition, • strength (e.g. LA, Deval), • resistance to weathering, • environmental protection, • finess, • grading, • compactibility, • particle size.

3. No modifications are required.


5. Yes.

6. Under preparation.

7. Under preparation.

8. The price.

9. The material is used for 40 years.

B) Application: SB

Material: Coal fly ash 1. 3 000 tonnes.

81

2. The requirements for fly ash are regulated in ÚT 2-3.603 Pernye alkalmazása útépítési kötőanyagként. Application of fly ash as binder in the road building. There are chemical, physical and pozzolanic requirements. Chemical requirements: SiO2, Al2O3, Fe2O3, CaO, SO3, ignition loss. Physical requirements: specific surface (Blaine, cm2/g), particle m% under 45 µm, density g/cm2, bulk density. Pozzolana requirements: MgCaO/g, pozzolanic mixture strength after 28 days, MPa, swelling, %. 3. No modifications are required. 4. No modifications are required. 5. Yes. 6. Transport and storage. 7. The transport/haulage distance. 8. The price. 9. The material is used for 40 years.

C) Application:

Material: Mining waste rock

1.

200 000 tonnes.

2. Grain size distribution, fines content, Cassagrande-limits.


4. Plate bearing test.

5. No.

6. Nothing.

7. No.

82

8. The transport/haulage distance.

9. The material is used for many years.

83



1. A special establishment how to manage the utilization of the secondary materials is under preparation. Its aim is to increase their use in road building.

2. Yes. Ministry of Environment and Ministry of Transport

3. The use of these materials depends on the price, too.

4. See Item 3.

5. -

6. The producer has to certify by laboratory tests or by other data the adequacy and fulfillment of the requirements of the environmental protection in his offer. In some cases he has the possibility to build test sections. Having the data and references, the producer requests for an application and adequacy certificate. This document is to be issued by the ÁKMI (Technical and Information Services on National Roads). After some years the certificate should be renewed.

7. The procedures offer the materials for contractors.

8. It should be considered from the point of view of economical and technical advantage.

9. Research institutes No.

10. Publications, presentations, courses.

84

5 Poland


Country or Region: Poland Your Name: Dariusz Sybilski Position: Deputy Director Organization: IBDiM (Road and Bridge Research Institute) Address: ul. Jagiellonska 80, 03-301 Warsaw, Poland Phone: +48 22 811 32 31 Fax: +48 22 811 17 92 E-mail: [email protected]




plant recycling

% on-site

recycling

% stock

% landfill

1) Reclaimed Asphalt Pavement (RAP) 140 000 20 80 - -

2) Reclaimed Concrete Pavement (RCP) 460 000* 100 - - -


4) Mixture of 1,2,3 - - - - -

*) from 2002 to 2004

85


Table 2: Applications of Road By–products NAME TECHNICAL QUALITY EVALUATION (+, —, 0)



tech. econ. envir.

HMA Crushing, grading,

addition of improving materials: aggregate, binder

GB Crushing, grading,

addition of improving materials: aggregate,


SB Crushing, grading,


+ + +

Upper paving slab

Crashing, grading, addition of portland cement

Base slab Crashing, grading, addition of portland cement

2) Reclaimed Concrete Pavement (RCP) - -

+ + +



MCE (asphalt + portland cement + emulsion)

Crushing, grading, addition of improving materials: aggregate, binder, emulsion


- -

+ + +



MCE

Crushing, grading, addition of improving materials: aggregate, binder, emulsion

4) Mixture of 1,2,3

GB Crushing, grading,

addition of improving materials: aggregate

+ + +

86

3. Other Questions

3-1 1) Aggregates • Most popular types of the aggregates: granite, basalt, porphyry and limestone. • Main chemical elements: Si, Ca, Mg, Fe. • Main physical characteristics according to PN-EN 13043:2004 are:

grading, abrasion, frost resistance, polishing.

2) Sand • Main chemical elements: Si • Main types of sand: natural, manufactured. • Main physical characteristics according to PN-EN 13043:2004 are:

grading, loose bulk density.

3) Filler • Main chemical composition: CaCO3, MgO, CaO • Main physical characteristics according to PN-EN 13043:2004 are:

grading, loose bulk density.

4) Binders Bitumen

Main chemical composition: resins, hydrocarbons, asphaltens, elements: H, C, S, O2, N. Main physical characteristics according to PN-EN 12591:2002 are: penetration at 25 ºC – from 15 to 150 x 0.1 mm, R&B Softening Point – from 39 ºC to 63 ºC, Fraass Breaking Point – from –12 ºC to –5 ºC.

Cement Main chemical composition: CaO, SiO2, Fe2O3, Al2O3Main physical characteristics: setting time and soundness – PN-EN 196-3:1996, strength - PN-EN 196-1:1996, chemical analysis - PN-EN 196-2:1996, pozzolanity - PN-EN 196-5:1996.

3-2 • grading of mineral aggregate from RAP, • quantity of asphalt in RAP, • quantity and a quality of binder, which will be added (asphalt, asphalt emulsion, portland

cement), conformity with standard requirements, • quantity of a separate fraction of aggregate added, • physical and mechanical characteristics of HMA, asphalt pavement, concrete pavement and

GB: density, durability, waterproof, frost resistance, rutting resistance.

87

Table: Important environmental characteristics

application chemical

composition (organic)

chemical composition (inorganic)

loss of ignition

leachate quality

hot mix asphalt

cement concrete

granular unbound base x x x

granular unbound subbase x x x

Table: Important physical characteristics

application grading hardness permeability loss of ignition

hot mix asphalt x x

cement concrete x x

granular unbound base x x x x

granular unbound subbase x x

X: Reference to conditions/factors, which demand special attention in relation to use of reclaimed materials.

3-3 Special requirements for the technical quality for recycled aggregate have not been

established yet, this type of aggregate should conform to standard requirements for the natural mineral aggregate.

3-4 Special requirements for the technical quality for recycled aggregate have not been

established yet, this type of aggregate should conform standard requirements for the natural mineral aggregate.

3-5 Road and Bridge Research Institute develops technology for use of crumb rubber in HMA.

88


Country or Region: Poland Your Name: Dariusz Sybilski Position: Deputy Director Organization: IBDiM (Road and Bridge Research Institute) Address: ul. Jagiellońska 80, 03-301 Warsaw, Poland Phone: +48 22 811 32 31 Fax: +48 22 811 17 92 E-mail: [email protected]


Material PCC

HMA

CM / S T

GS

S B

GB

EMB

F I L L

S T R

A P P

S A F

L S



Coal fly ash 2 2 0 0 3 0 4 3 0 0 0 4

Coal Bottom ash 0 0 0 0 3 0 4 3 0 0 0 4

Foundry sand 0 0 0 0 0 3 0 0 0 0 0 0



Non-Ferrous Slag 1 3 2 2 2 4 3 2 2 2 0 2

Scrap Tyres (crumb) 0 3 0 0 2 2 0 0 0 0 0 0

Steel slag 1 3 2 3 2 4 4 3 0 2 0 4

Waste Glass 0 0 0 0 0 0 0 0 0 0 0 0

Waste Concrete 0 0 0 4 4 4 0 0 0 0 0 0



89


A) Application: PCC

Material: Coal fly ash

1.

296 000 tones

2. SiO2, AL2O3 , Fe2O3, CaO, Na2O, SO3 content – EN 196-2, Loss on ignition EN 196-2, Cl content – EN 196-21, CaO free content – EN 451-1, Pozzolana activity – EN 196-1, Fineness – EN 451-2, Volume stability – EN 196-3, Density – EN 196-6.

3. No.

4. PN-EN 450 Fly ash for concrete. Definition, requirements and quality control.

5. PN-EN 450 Fly ash for concrete. Definition, requirements and quality control.

6. Leaching test, Radiation test.

7. The Environmental Protection Act Law of 27 April 2001 (Official Journal, No. 62, Item 627; 2001). The waste materials Act Law of 27 April 2001 (Official Journal, No. 62, Item 628, 2001). The Decree of the Minister of the Environment of 27th September 2001 in case of waste material catalogue (Official Journal, No. 112, Item 1206, 2001). The Decree of the Minister of the Environment, Natural Materials Resources and Forestry of 12th February 1990 in case of air pollution protection (Official Journal, No. 15/92, Item 92, 1990). The Decree of the Minister of the Environment of 29th November 2002 in case of the conditions, which shall be fulfilled while introduction of liquid wastes to the water or the soil and in case of extremely toxic substances for the water environment (Official Journal, No. 212, Item 1799, 2002).

8. -

9. -

B) Application: SB


1.

90

60 000 tones.

2. Grading – PN-B-04481:1998 Building soils. Tests of specimens of soils. Density – PN-B-04481:1998 Building soils. Tests of specimens of soils. Activity (CaO content) – PN-S-96035 Roads. Fly ashes. SO3 content – EN 196-2 Chemical analysis of cement. Radiation – ITB procedure. SiO2, AL2O3 , Fe2O3, CaO, SO3 content – EN 196-2.

3. No.

4. Compaction, Compressive strength. According to PN-S-06103:1997 Roads. Fly ash concrete.

5. PN-S-06103:1997 Roads. Fly ash concrete.

6. Leaching test.

7. The Environmental Protection Act Law of 27th April 2001 (Official Journal, No. 62, Item 627, 2001). The waste materials Act Law of 27th April 2001 (Official Journal, No. 62, Item 628, 2001). The Decree of the Minister of the Environment of 27th September 2001 in case of waste material catalogue (Official Journal, No. 112, Item 1206, 2001). The Decree of the Minister of the Environment, Natural Materials Resources and Forestry of 12th February 1990 in case of air pollution protection (Official Journal, No. 15/92, Item 92, 1990). The Decree of the Minister of the Environment of 29th November 2002 in case of the conditions, which shall be fulfilled while introduction of liquid wastes to the water or the soil and in case of extremely toxic substances for the water environment (Official Journal, No. 212, Item 1799, 2002).

8. -

9. -

C) Application: EMB, FILL, LS


1.

300 000 tones.

2. Grading – PN-B-04481:1998 Building soils. Tests of specimens of soils. Density – PN-B-04481:1998 Building soils. Tests of specimens of soils. California Bearing Ratio – PN-S-02205:1998 Roads. Earth works. Linear swelling – PN-S-02205:1998 Roads. Earth works.

91

SO3 content – EN 196-2 Chemical analysis of cement. Radiation – ITB procedure. SiO2, AL2O3 , Fe2O3, CaO, SO3 content – EN 196-2 Angle of internal friction – PN-B-04481:1998 Building soils. Tests of specimens of soils.

3. No.

4. Compaction, bearing capacity, moisture content.


6. Leaching test.

7. The Environmental Protection Act Law of 27 April 2001 (Official Journal, No. 62, Item 627, 2001), The waste materials Act Law of 27th April 2001 (Official Journal, No. 62, Item 628, 2001). The Decree of the Minister of the Environment of 27th September 2001 in case of waste material catalogue (Official Journal, No. 112, Item 1206, 2001). The Decree of the Minister of the Environment, Natural Materials Resources and Forestry of 12th February 1990 in case of air pollution protection (Official Journal, No. 15/92, Item 92, 1990). The Decree of the Minister of the Environment of 29th November 2002 in case of the conditions, which shall be fulfilled while introduction of liquid wastes to the water or the soil and in case of extremely toxic substances for the water environment (Official Journal, No. 212, Item 1799, 2002).

8. -

9. -

D) Application: EMB, FILL

Material: Coal bottom ash

1.

252 000 tones.

2. Grading – PN-B-04481:1998 Building soils. Tests of specimens of soils. Density – PN-B-04481:1998 Building soils. Tests of specimens of soils. California Bearing Ratio – PN-S-02205:1998 Roads. Earth works. Linear swelling – PN-S-02205:1998 Roads. Earth works. SO3 content – EN 196-2 Chemical analysis of cement. Radiation – ITB procedure. SiO2, AL2O3 , Fe2O3, CaO, SO3 content – EN 196-2 Angle of internal friction – PN-B-04481:1998 Building soils. Tests of specimens of soils.

3.

92

No.


5. PN-S-02205:1998 Roads. Earth works.

6. Leaching test.

7. The Environmental Protection Act Law of 27th April 2001 (Official Journal, No. 62, Item 627, 2001). The waste materials Act Law of 27th April 2001 (Official Journal, No. 62, Item 628; 2001). The Decree of the Minister of the Environment of 27th September 2001 in case of waste material catalogue (Official Journal, No. 112, Item 1206, 2001). The Decree of the Minister of the Environment, Natural Materials Resources and Forestry of 12th February 1990 in case of air pollution protection (Official Journal, No. 15/92, Item 92, 1990). The Decree of the Minister of the Environment of 29th November 2002 in case of the conditions, which shall be fulfilled while introduction of liquid wastes to the water or the soil and in case of extremely toxic substances for the water environment (Official Journal, No. 212, Item 1799, 2002).

8. -

9. -

E) Application: SB Material: Coal bottom ash

1.

167 000 tones.

2. Grading – PN-B-04481:1998 Building soils. Tests of specimens of soils. Density – PN-B-04481:1998 Building soils. Tests of specimens of soils. SO3 content – EN 196-2 Chemical analysis of cement. Radiation – ITB procedure. SiO2, AL2O3 , Fe2O3, CaO, SO3 content – EN 196-2.

3. No.

4. Compaction, compressive strength according to PN-S-06103:1997 Roads. Fly ash concrete.


6. Leaching test.

93

7. The Environmental Protection Act Law of 27th April 2001 (Official Journal, No. 62, Item 627, 2001). The waste materials Act Law of 27th April 2001 (Official Journal, No. 62, Item 628, 2001). The Decree of the Minister of the Environment of 27th September 2001 in case of waste material catalogue (Official Journal, No. 112, Item 1206, 2001). The Decree of the Minister of the Environment, Natural Materials Resources and Forestry of 12th February 1990 in case of air pollution protection (Official Journal, No. 15/92, Item 92, 1990). The Decree of the Minister of the Environment of 29th November 2002 in case of the conditions, which shall be fulfilled while introduction of liquid wastes to the water or the soil and in case of extremely toxic substances for the water environment (Official Journal, No. 212, Item 1799, 2002).

8. -

9. -

F) Application: EMB

Material: Foundry sand

1.

No data.

2. Grading – PN-B-04481:1998 Building soils. Tests of specimens of soils. Density – PN-B-04481:1998 Building soils. Tests of specimens of soils. California Bearing Ratio – PN-S-02205:1998 Roads. Earth works. Linear swelling – PN-S-02205:1998 Roads. Earth works. SO3 content – EN 196-2 Chemical analysis of cement. Radiation – ITB procedure. SiO2, AL2O3 , Fe2O3, CaO, SO3 content – EN 196-2 Sand equivalent – PN-EN 933-8 Determination of Sand equivalent Cappilarity – PN-60/B-04493 Buildings soils. Determination of cappilarity. Angle of internal friction – PN-B-04481:1998 Building soils. Tests of specimens of soils.

3. No.


5. PN-S-02205:1998 Roads. Earth works.

6. Leaching test.

7. The Environmental Protection Act Law of 27th April 2001 (Official Journal, No. 62, Item 627, 2001). The waste materials Act Law of 27th April 2001 (Official Journal, No. 62, Item 628, 2001).

94

The Decree of the Minister of the Environment of 27th September 2001 in case of waste material catalogue (Official Journal, No. 112, Item 1206, 2001). The Decree of the Minister of the Environment, Natural Materials Resources and Forestry of 12th February 1990 in case of air pollution protection (Official Journal, No. 15/92, Item 92, 1990). The Decree of the Minister of the Environment of 29th November 2002 in case of the conditions, which shaell be fulfilled while introduction of liquid wastes to the water or the soil and in case of extremely toxic substances for the water environment (Official Journal, No. 212, Item 1799, 2002).

8. -

9. -

G) Application: HMA

Material: Scrap tyres (crumb rubber) 1. 160 tones. 2. Grading – according to hot mix specification. 3. “dry process” – No. “wet process” – modification of plant, crumb rubber must be added to bitumen. 4. Compaction, bearing capacity, moisture content. 5. No. 6. No. 7. - 8. Price of crumb rubber, cost of storage of used tyres. 9. -

H) Application: GS, SB, GB

Material: Waste Concrete 1. No data. 2. Grading– PN-EN 933-1 Sand equivalent – PN-EN 933-8. Los Angeles LA – PN-EN 1097-2. California Bearing Ratio – PN-S-06102 Roads. Unbound mixtures for bases. Frost resistance – PN-EN 1367-1. Water absorption – PN-EN 1097-6.

95

Max density – PN-B-04481:1998 Building soils. Tests of specimens of soils. Optimal moisture content – PN-B-04481:1998 Building soils. Tests of specimens of soils. PN-EN 13242:2004 Aggregates for unbound and hydraulically bound mixtures for road construction. 3. No. 4. Compaction, bearing capacity. 5. No. 6. Leaching test. 7. The Environmental Protection Act Law of 27th April 2001 (Official Journal, No. 62, Item 627, 2001). The waste materials Act Law of 27th April 2001 (Official Journal, No. 62, Item 628, 2001). The Decree of the Minister of the Environment of 27th September 2001 in case of waste material catalogue (Official Journal, No. 112, Item 1206, 2001). The Decree of the Minister of the Environment, Natural Materials Resources and Forestry of 12th February 1990 in case of air pollution protection (Official Journal, No. 15/92, Item 92, 1990). The Decree of the Minister of the Environment of 29th November 2002 in case of the conditions, which shall be fulfilled while introduction of liquid wastes to the water or the soil and in case of extremely toxic substances for the water environment (Official Journal, No. 212, Item 1799, 2002). And other approvals for material. 8. - 9. - I) Application: EMB, LS Material: Waste Tile/Bricks/Concrete 1. No data. 2. Grading – PN-EN 933-1 Sand equivalent – PN-EN 933-8 California Bearing Ratio – PN-S-06102 Roads. Unbound mixtures for bases. Moisture content – PN-B-04481:1998 Building soils. Tests of specimens of soils. Max density – PN-B-04481:1998 Building soils. Tests of specimens of soils. Optimal moisture content – PN-B-04481:1998 Building soils. Tests of specimens of soils. Capillarity – PN-60/B-04493 Buildings soils. Determination of capillarity. 3. No. 4. Compaction, bearing capacity.

96

5. No standards. Allowed specification for use of soils: PN- S-02205:1998. Roads. Earth works. 6. Leaching test. 7. The Environmental Protection Act Law of 27th April 2001 (Official Journal, No. 62, Item 627, 2001). The waste materials Act Law of 27th April 2001 (Official Journal, No. 62, Item 628, 2001). The Decree of the Minister of the Environment of 27th September 2001 in case of waste material catalogue (Official Journal, No. 112, Item 1206, 2001). The Decree of the Minister of the Environment, Natural Materials Resources and Forestry of 12th February 1990 in case of air pollution protection (Official Journal, No. 15/92, Item 92, 1990). The Decree of the Minister of the Environment of 29th November 2002 in case of the conditions, which shall be fulfilled while introduction of liquid wastes to the water or the soil and in case of extremely toxically substances for the water environment (Official Journal, No. 212, Item 1799, 2002). And other approvals for material. 8. - 9. -

97


Country or Region: Poland Your Name: Dariusz Sybilski Position: Deputy Director Organization: IBDiM (Road and Bridge Research Institute) Address: ul. Jagiellonska 80, 03-301 Warsaw, Poland Phone: +48 22 811 32 31 Fax: +48 22 811 17 92 E-mail: [email protected]

1. The “Second Environmental Policy” had been prepared by the Ministry of Environment and adopted by the Council of Ministers on 13th June 2000;, it proclaims, that the protection of the environment is the obligation, inter alia, of public authorities, who, through their policy, should provide for ecological safety for the sake of both the contemporary generation and the future generations. Hence, this new Constitutional order calls for new National Environmental Policy including sector strategies and the action plans which are to be harmonised with this new order. There is not a distinct structurized approach to this subject . The Ministry of Environment creates the general policy, but it does not deal with road building industry in detail. Use of waste materials can help resolve the following problems for the building industry in general: • environmental protection (decreasing quantity of storage waste materials), • reduction of the cost of building materials, • reduction of energy consumption, • protection of mineral resources, and road building in particular: • reduction of raw material consumption, • reduction of material cost, • cost reduction of material transport.

2. Use of natural environment is expensive. Producers of waste materials must pay for environmental pollution. If there is a technology of use of the waste material, the material will become a valuable product - not a problem. Producers or suppliers are responsible for the waste material. They guarantee the quality and safety of natural environment. They supply the technology of use. Contractors are responsible for following the technical guidelines.

3. • government – creates general laws, e.g.: The Waste Materials Act Law, The catalogue of waste materials, etc. • suppliers/producers/contractors – creation of new techniques in collaboration or research institutes, laboratories, etc. • road administration – collaboration on putting into practice new technologies, support of research, • research institutes (IBDiM and ITB) – elaborating of a technical approval for new techniques for use of secondary material in road construction and in building industry,

98

• design offices – elaborating of technical specification for constructions with waste materials.

4. The government does not control or regulate the market for secondary materials. If material is not on the list of dangerous waste materials (a part of waste material catalogue), it can be sold. In practice, possession of technical approval for the waste material is necessary on the market.

5. The instruments used to promote the use of secondary materials: • regulations based on public law (catalogue of waste materials), • financial instruments (ecological penalty for pollution of the natural environment), • innovation/development of knowledge, • transfer of knowledge (publications, articles, conferences etc. ), • regulations based on private law (technical approval, technical specifications). other instruments: • creation of branch organization, promoting the use of some waste materials.

6. There is no special procedure for introduction a new material on the market. Prior to introduction of a new product, the producer or supplier should perform environmental tests (leaching, radiation and content of dangerous substances ), all technical tests in accordance with required standards and/or technical approvals. Producer or supplier should also elaborate an economical analysis of the market.

7. There is not a distinct policy for the implementation of the policy on the use of secondary materials and the market introduction of those materials. Producers, branch organizations or suppliers need to promote their products, pay for tests and put them on the market. Road administration or research institutes (such as IBDiM) sometimes can help to find a contractor, who will use the waste materials in road construction.

8. The main obstructions are: • lack of funds for tests for new technologies, • unhomogeneity of waste materials, • lack of technical approvals, • price of new technologies, • cautiousness of designers, investors and contractors (reluctance in case of novelty products or technologies), • small quantities of waste material from one supplier, lack of branch organization. The reasons for successful introductions (e.g. burnt colliery shale): • accessibility (heap), • large quantity, • price, • an advanced (developed) technique of the use, • good technical characteristics. The reasons for failure introductions (e.g. waste glass): • problems with a system of collection, • material does not adhere to asphalt, • material is valuable for glass industries.

99

To overcome hindrances we should: • precise test of the material, • check the demand and supply, • elaborate more then one technology of the use.

9. The government does not directly support research focused on the potential use of secondary materials such as special projects for highway construction materials. There is not a special program for highway construction The road administration GDDKiA supports research program (e.g. present IBDiM realizes a project of evaluation of waste materials to be used in road construction).

10. • articles, • conferences, • web sites, • competition for new technologies (using waste materials, too), • producers/suppliers publicity.

100

6 Romania


Country or Region: Romania Your Name: Radu Andrei Position: Professor of Civil Engineering Organization: Technical University “Gh. Asachi” Iasi Address: 43 Professor D. Mangeron Str., 700050 Iasi Phone: + 40 232 278 683/ext. 1468; mobile: + 40 723 858 080 Fax: + 40 232 233 368 E-mail: [email protected]; [email protected]


Table 1: Amount Road By- products Annually NAME QUANTITY


plant recycling

% on-site

recycling

% stock

% landfill

1) Reclaimed Asphalt Pavement (RAP) 300 000 50 30 15 5

2) Reclaimed Concrete Pavement (RCP) 100 000 85 15

3) Reclaimed Base and Subbase 150 000 100

4) Mixture of 1,2,3 100 000 100

101


Table 2: Applications of Road By-products

NAME TECHNICAL QUALITY EVALUATION (+. —, 0)



tech econ.

envir.

Recycled hot mixture

Crushing, grading

Granular base-course

Crushing

1) Reclaimed Asphalt Pavement (RAP) - -

+ +

+ +

0 +

Granular base courses

Crushing, grading 2) Reclaimed Concrete Pavement (RCP)

-

+ + 0



Crushing + + 0


Crushing 4) Mixture of 1,2,3

+ + +

3. Other Questions

3-1 For RAP, the physical and chemical characteristics of the old (aged) bituminous binders are

important: Classical penetration, Ring & Ball point, Temperature Susceptibility Index, etc.

3-3 The requirements have not been established yet .

3-4 The requirements have not been established yet .

3-5 See the Proceedings of the 3rd Euroasphalt & Eurobitume Congress, Vienna, 2004/ paper

No.: 285/ Dorobantu S., Andrei R. “ New Laboratory Methodology for the Design of the Optimal Composition of the Cold Recycled Asphalt“.

102


Country or Region: Romania Your Name: Radu Andrei Position: Professor of Civil Engineering Organization: Technical University “Gh. Asachi” Iasi Address: 43 Professor D. mangeron Str., 700050 Iasi Phone: + 40 232 278 683/ext. 1468; mobile: + 40 723 858 080 Fax: + 40 232 233 368 E-mail: [email protected]; [email protected]


Material PCC

HMA

CM / S T

GS

S B

GB

EMB

F I L L

S T R

A P P

S A F

L S



Coal fly ash 0 1 1 2 2 0 2 2 0 0 0 0 Coal Bottom ash 0 0 0 0 0 0 0 0 0 0 0 0

Foundry sand 0 0 1 0 0 0 0 0 0 0 0 0 Mining Waste Rock 0 0 0 0 0 0 0 0 0 0 0 0


Non-Ferrous Slag 0 0 0 0 0 0 0 0 0 0 0 0 Scrap Tyres 0 1 1 0 0 0 0 0 0 0 0 0 Steel slag 2 1 1 1 4 4 2 2 1 1 0 0

Waste Glass 0 0 0 0 0 0 0 0 0 0 0 0 Waste Concrete 0 0 2 2 3 3 2 0 0 0 0 0

Waste Tile/Bricks 0 0 2 2 3 3 2 0 0 0 0 0 Waste Tile/Concrete 0 0 2 2 3 3 2 0 0 0 0 0

Suggestions: please analyze the following wastes: - boiler slag, - used motoroil, - waste paper, - sewage sludge, - saw dust, - ceramic waste, - incinerators residues, - highway hardware, etc.

103


A) Application: HMA

Material: RAP

1.

300 000 tones.

2. National and European Standards: National: Normativ AND 575-2002: NORMATIV PENTRU RECICLAREA LA CALD A IMBRACAMINTILOR RUTIERE BITUMINOASE, PAG. 1-22, in: AND/APDP: Bulletin tehnic ruttier, anul II, nr.18, iunie 2002,

3. See item 2.

4. See item 2.

5. -

6. -

7. -

8. -

9. -

104


Country or Region: Romania Your Name: Radu Andrei Position: Professor of Civil Engineering Organization: Technical University “Gh. Asachi” Iasi Address: 43 Professor D. Mangeron Str., 700050 Iasi Phone: + 40 232 278 683/ext. 1468; mobile: + 40 723 858 080 Fax: + 40 232 233 368 E-mail: [email protected]; [email protected]

1. There is not a distinct policy. The main problems: need of raw materials, saving of energy, environmental protection, etc.

2. The road policy, practiced by the National Agency for Roads ensures the principle way dealing with the problem.

3. The national and international construction enterprises involved in the actual huge road rehabilitation program undertaken in the country.

4. No.

5. • regulations based on public laws/ technical specifications or technical standards, • financial instruments, • innovation/development of knowledge research and development in the frame of universities, etc., • transfer of knowledge, • regulations based on private laws, • other instruments.

6. There are specific requirements for the use of secondary materials/wastes, for example the phosphogypsum is forbidden because of its high level of radioactivity, tars are forbidden because of their high level of toxicity, etc.

7. -

8. -

9. -

10. Unsatisfactory.

105

7 Russia


Country or Region: Russia Your Name: Mamontow A.A. Position: Deputy Director Organization: Federal Road Administration (South Ural) Address: Swierdlowski prospect 56, Czelabinsk, Russia Phone: (3512) 31 35 04 Fax: - E-mail: -


Table 1: Amount Road By-products Annually

NAME QUANTITY


plant recycling

% on-site

recycling

% stock

% landfill

1) Reclaimed Asphalt Pavement (RAP) 22 000 - 50 - 50

2) Reclaimed Concrete Pavementn (RCP) - - - - -


4) Mixture of 1,2,3 - - - - -

106






tech econ. envir.

- -

- -


- -

- -

2) Reclaimed Concrete Pavement (RCP) - -

GB no

- -

3) Reclaimed Base and Subbase - -

+ + +

- -

- - 4) Mixture of 1,2,3

- -

3. Other Questions

3-1 Binder BND 90/130, aggregate from 5 mm to 20 mm,

3-2 Grading.

3-3 National standard: SniP 3.06.85, GOST 12801-98,

3-4 Special instruction of environmental protection while road building, repair and routine

maintenance - WCN 8-89.

107


Country or Region: Russia Your Name: Mamontow A.A. Position: Deputy Director Organization: Federal Road Administration (South Ural) Address: Swierdlowski prospect 56, Czelabinsk, Russia Phone: (3512) 31 35 04, Fax: (3512) 65 58 86 E-mail: [email protected]; [email protected]


Applications

Material PCC

HMA

CM / S T

GS

S B

GB

EMB

F I L L

S T R

A P P

S A F

L S



Coal fly ash 0 0 0 0 0 0 0 0 0 0 0 0 Coal Bottom ash 0 0 0 0 0 0 0 0 0 0 0 0

Foundry sand 0 0 0 0 0 0 0 0 0 0 0 0 Mining Waste Rock 0 2 1 0 0 0 0 0 0 0 0 0


Non-Ferrous Slag 2 2 1 1 2 2 2 1 1 1 0 1 Scrap Tyres (crumb) 0 0 0 0 0 0 0 0 0 0 0 0

Steel slag 2 2 1 1 2 2 3 0 0 0 0 0 Waste Glass 0 0 0 0 0 0 0 0 0 0 0 0

Waste Concrete 1 1 1 1 1 1 1 1 1 1 1 1 Waste Tile/Bricks 1 1 1 1 1 1 1 1 1 1 1 1


108


A) Application:

Material: Blast Furnace Slag, Steel slag

1.

34 000 tons.

2. Crushing and frost resistance according to National standard GOST,

3. No.

4. Common.

5. National standards GOST.

6. Toxicity, radiation.

7. Yes.

8. Product and transport price.

9. Slags are tested as a filler to Portland cement concrete.

109


Country or Region: Russia Your Name: Mironow A.A Position: Deputy Director Organization: Ural branch office of Moscow Car and Road Institute Address: Jolkina 77, Czelabinsk Phone: (3512) 65 49 51, Fax: (3512) 65 58 86, E-mail: [email protected]; [email protected]

1. Economical and ecological/environmental factors influence use of secondary materials. The research institute SOJUZDORNYI is engaged in research of technical aspect of using waste materials in both the civil engineering and road building.

2. -

3.

The main market parties are: producers, branch organization and suppliers.

4. In south region of Russia the following waste materials are available: the blast furnace slag and the mining waste rock. The sale is controlled and regulated by the market only.

5. Quality, price, transfer of knowledge,

6. The laboratory and “in-situ” tests are required to create the requirements and criteria for the acceptation of secondary materials in road construction,

7. The main market parties are: producers (national industrial plants), branch organization and suppliers (quality, price).

8. Poor quality of waste materials. Who should improve quality - the suppliers.

9. There is no stimulation from the government concerning the use of waste materials. The results of research are included in technical and methodological guidelines.

10. The transfer of knowledge and experience with secondary materials in Russia is ensured by: books, articles, booklets, research conferences, web-pages.

110


Country or Region: Russia Your Name: Nemchinov M.V. Position: Professor Organization: Moscow Car and Road Institute Address: Leningradskij prospekt 64, 125319 Moscow Phone: (7095) 155 03 28, Fax: (7095) 155 03 28 (31), E-mail: [email protected]

1. Due to economical (wider range of available road materials), energy save and ecological reasons the use of waste material is very important in technical Russian policy. Russia has the governmental program “Save of energy in Russia 1999-2003” (extend), one of its parts is a project “Save of energy in road industry 1999”. As the European part of Russia is not rich in natural raw materials, the secondary materials are involved in road construction and rehabilitation, especially in towns. It happens that without any governmental directives, e.g. a burnt collier shale (from a heap) is currently in use in Russian regions: Rostov, Czelyabinsk, Kemersk, etc. For 20 years, the technologies for use of a burnt collier shale, slags and ashes are described in the handbooks for technical universities. Research to find a new waste material for road application is currently carried out in many road laboratories that test them and develop new technologies of their use. Old road materials are used in road constructions. Remixing of asphalt concrete is the most popular technology. In Moscow and many other cities it is made by in plant cold milling. It was established that these materials do not improve quality of pavement, so they can be used in limited range, only. The main problem is the price. At the beginning producer gives the waste material free, but when the waste material becomes a construction material its price usually increases. It was the case of scrap tyres in Czechow city, waste material from apatite industry in Murmansk region, etc. The ecological safety of waste material and its influence on environment are always tested.

2. Responsibility for use of waste materials is taken by: regional road administrations, Russian Ministry of Transport and parties introducing the material on road materials market. Responsibility for technical quality and technology of use exists, e. g.: in Czelyabinsk region where the producer of a burnt collier shale did not follow the technology and a large quantity of dust appeared. The citizens of Czelyabinsk submitted a complaint to the President of Russia (without any consequences, however). Responsibility – legal and economical: penalty, reclaim of license, closing the company, judicial – compensation for a loss of health. Technical parameters control over waste materials are severe. The control is carried out by laboratories of suppliers, contractors and road administrations). It is difficult to control technology during the waste material exploitation. It should be performed by sanitary-epidemiological service (SES). The technology is controlled by special control services of road administration. They are independent on contractors. The supervisor can stop the investment when the contractor does not follow the technology.

3. Concept “market parties” is not described clearly. It was described that when waste material becomes a construction material, its price usually increases because its application technology is not cost effective.

111

4. The sale of waste materials is controlled and regulated only by the market. The government does not control it.

5. Only common instruments: supply and demand, price, promotion.

6. The new waste material can be introduced on the market after it passes the tests in a special research laboratory (road administration, university, research institute) and after elaboration of guidelines. Research includes evaluation of technical parameters, elaboration a way to give the right characteristic (quality) to use of the secondary material in a road construction. Research includes also elaboration of a technological guideline (encompassing treatment and use). Testing of ecological/environmental impact of waste material (radioactivity, creation of new compounds during treatment; e.g. when a cationic emulsion is produced). The experimental constructions are under preparation. The economical evaluation is made before and after the technological guideline elaboration and then the change of price is considered.

7. In Russia there is not a special policy for introduction of these materials on the market. General way for implementation was described above.

8. The main obstructions are: price increasement after elaboration of a new technological guideline (it concerns road industry, too) and disregard principles of technology (ecological/environmental problems, dustiness of air, noise of road engines).

9. There is no government stimulation for use of waste materials in road construction. Nevertheless, in Russia have been carried out research programs for use of secondary materials in road construction. These programs were partly financed by the Russian Ministry of Transport and by the producers. Research project on leaching of waste materials was performed in Russia. Nowadays there are not any projects for use of secondary material, but they are used in satisfactory wide range. It is a result of previous long-term research program and governmental policy in the years 1970-s – 80 -s.

10. The transfer of knowledge of use of secondary material is organized in one way. Relevant information dealing with their use is included in textbooks determined for students of technical universities specializing in the field of “Road and airport”, “Bridges and Tunnels” and for colleagues specializing in programs of improving a knowledge for road employees. Researchers and road specialists elaborate and publish the monographs about these problems.

112

8 Slovakia


Country or Region: Slovak Republic Your Name: Ing. Ľubomír Polakovič, CSc. Position: Research Worker Organization: VUIS-CESTY, s.r.o. Address: Lamačská cesta 8, 817 16 Bratislava Phone: +421 54771332, 54772994 Fax: +421 54771332, 54772994 E-mail: [email protected], [email protected]



NAME QUANTITY


plant recycling

% on-site

recycling

% stock

% landfill

1) Reclaimed Asphalt Pavement (RAP) 30 500 - 36 32 32



4) Mixture of 1,2,3 - - - - -

113






tech. econ. envir.

Hot mixture Remix

- -


+ + +

- -


- - -

- -


- - -

- -

4)

Mixture of 1,2,3

- - -

114

3. Other Questions

3-1 It is prohibited to use tar during Remix technology. The resultant mechanical parameters

must satisfy the valid standards for the given technology.

3-2 It is important to determine reuse possibilities from the point of view of their negative

impact on environment during the particular technology (hot, cold) and achievement of required parameters. The most important characteristics for a reclaimed material are asphalt content in a reclaimed material, penetration of asphalt and grading of aggregate composition after milling.

3-3 There are no test methods for recycled aggregate – only for slag aggregate,

3-4 The Decree of Ministry of Healthcare No. 12/2001 Coll. "On Protection Against the

Radionuclid Radiation". The Act No. 90/1998 On Construction Products in working of later regulations. The Act No. 264/1999 On technical requirements on products and on conformity assessment

and on changes and amendment of some Acts.

3-5 We start with the practical use of commonly used technologies such as: Recycled cold mixtures from asphalt pavement layers produced in place, Recycled cold mixtures from unbound and hydraulically bound pavement layers produced in place and in mobile plants, Processing of asphalt layers in the place using Remix and Remix Plus methods. As a new recycling technology may be considered: Utilization of rubber produced by modification of old tyres in asphalt mixtures.

115


Country or Region: Slovak Republic Your Name: Ing. Ľubomír Polakovič, CSc. Position: Research Worker Organization: VUIS-CESTY, s.r.o. Address: Lamačská cesta 8, 817 16 Bratislava Phone: +421 54771332, 54772994 Fax: +421 54771332, 54772994 E-mail: [email protected], [email protected]


Applications

Material PCC

HMA

CM / S T

GS

S B

GB

EMB

F I L L

S T R

A P P

S A F

L S



Coal fly ash 0 0 0 0 1 0 0 0 0 0 0 0

Coal Bottom ash 0 0 0 0 1 0 0 0 0 0 0 0

Foundry sand 0 0 0 2 1 2 2 2 1 0 0 1



Non-Ferrous Slag 0 0 0 1 1 1 1 0 0 0 0 0

Scrap Tyres 0 1 0 0 0 0 0 0 0 0 0 0

Steel slag 0 0 0 1 1 1 1 0 0 0 0 0

Waste Glass 0 0 0 0 0 0 0 0 0 0 0 0

Waste Concrete 1 0 1 2 0 2 2 1 1 1 0 1



116


A) Application: Aggregate to pavements

Material: Blast furnace slag

1.

350 000 tones.

2. STN 72 2015, STN 72 2014, STN 72 2030 – 1 (n), STN 72 2041-1 (n), STN 42 0552-6, STN 72 2015 Kamenivo na stavebné účely. Umelé hutné kamenivo z trosky pre cestné staviteľstvo. Aggregates for structural purposes. Artificial dense slag aggregates for road building. STN 72 2014 Kamenivo na stavebné účely. Umelé hutné kamenivo z trosky do betónu Dense slag aggregate for concrete. Aggregates for structural purposes. (Date of issue: 1996)STN 72 2030 – 1 Chemický rozbor vysokopecnej trosky. Všeobecné požiadavky. Chemical analysis of blast furnace slag. General requirements. (Date of issue: 1992). STN 72 2041-1 Chemický rozbor oceliarenskej trosky. Časť 1: Všeobecné požiadavky Chemical analysis of steel-making slag. General requirements. (Date of issue: 1992). STN 42 0552-6 Chemický rozbor ferozliatín. Rozbor ferosilícia. Stanovenie hliníka. Chemical analysis of ferroalloys. Analysis of ferrosilicon. Determination of aluminum. (Date of issue: 1982, its validity: from 1983-01-01)

3. Without special modifications.

4. No control tests exceeding the requirements of the standard are required.

5. Standard specifications listed in item 2 plus basic technological standards.

6. Radionuclids, lixiviums, heavy metals.

7. The Decree of Ministry of Health No. 12/2001 On Protection Radionuclid Radiation. The Act No. 90/1998 On Construction Products in working of later regulations. The Act No. 264/1999 On technical requirements on products and on conformity assessment and on changes and amendment of some Acts.

8. The use of secondary materials is not economically privileged.

9. The use of rubber from old tyres, Possibilities to apply steel slag in road building.

117

Survey C: Policy/Strategy of Recycling Country or Region: Slovakia Your Name: Ing. Ľubomír Polakovič, CSc. Position: Research Worker Organization: VUIS-CESTY, s.r.o. Address: Lamačská cesta 8, 817 16 Bratislava Phone: +421 54771332, 54772994 Fax: +421 54771332, 54772994 E-mail: [email protected], [email protected]

1. The government tries to deal with recycling mainly in the field of packings – Act on PET bottles. The main responsibility is on the producers – compulsory measures (taxation, penalties, etc.), the government uses mainly state supervision. The methodology of economical involvement in recycling is not clear.

2. Other parties can be: local administration, clients, contractors and suppliers, environmental action groups, etc. The state has the right to supervise. Other groups or parties are not involved.

3. Product vendors – they do not want to be involved in collection of secondary materials. As regards the producers of secondary materials, they are interested in reusing it in production.

4. -

5. The act on a compulsory repurchase of selected commodities.

6. There are two approaches – usage of commonly used materials and new products with their own technical standards and parameters.

7. -

8. Success: - better price, improvement of environment. Failure: - low publicity, inadequate legislation. Elaboration of rules, instructions (certified by the state) for introducing secondary materials in certain branches, support (tax preferred) of investors that use materials from secondary materials.

9. Basic and applied research. Sponsors – government, producers and customers of new products and technologies. Tests for leaching behavior are the part of the research. Application of the slag aggregate – supplier Košice, 1995-97, testing of slag pavements when loaded by 115 kN axle, KSD VUIS-CESTY, Ltd., application of modified rubber from old tyres inn the pavement in Púchov, Remix technology.

10.

118

Special activities have been organized: workshops, seminars, staff meetings and training.

119

9 Slovenia


Country or Region: Slovenia Your Name: Primoz Pavsic Position: Head of Geo-mechanical Laboratory Organization: ZAG- Slovenian National Building and Civil Engineering Institute Address: Dimičeva 12, Ljubljana Phone: +386 1 2804 245 Fax: +386 1 2804 484 E-mail: [email protected]



NAME QUANTITY


plant recycling

% on-site

recycling

% stock

% landfill

1) Reclaimed Asphalt Pavement (RAP) 2) Mastic Asphalt

8 000

1 500

80

100

- -

15 -

5 -



4) Mixture of 1,2,3 - - - - -

120




Available product

Application Treatment (necessary and/or possible for each application)

tech econ. envir.

Hot asph. mixtures Crushing and grading + + +

Granular base course Crushing 0 0 +

1) Reclaimed Asphalt Pavement (RAP) Hot mastic

asphalt Partially crushed + + 0

- -


- - -

- -


- - -

- -

4) Mixture of 1,2,3

- - -

3. Other Questions

3-1 Road bitumen (20/30 to 50/70 pen.), Polymer modified bitumen (SBS), Grading: 0/16 mm, 0/22 mm, 0/45 mm, Marshall test - stability.

3-2 Type and quality of extracted binders, grading.

3-3 Same as virgin aggregate, Technical specification TSC 06.800.

3-4 For the use in asphalt mixtures the quality should follow the recommendation given in TSC

06.800. Additionally, special care is prescribed for reusing of tar pavements (old ones).

3-5 Standard recycling techniques are used in Slovenia.

121


Country or Region: Slovenia Your Name: Primoz Pavsic, Žorsa Mitja BSc. (Chem. Eng.) Position: Head of Geo-mechanical Laboratory, Head of Laboratory for Asphalt Bitumens and Bitumen Based Products. Organization: ZAG- Slovenian National Building and Civil Engineering Institute Address: Dimičeva 12, Ljubljana Phone: +386 1 2804 245 Fax: +386 1 2804 484 E-mail: [email protected], [email protected].


Applications

Material PCC

HMA

CM / S T

GS

S B

GB

EMB

F I L L

S T R

A P P

S A F

L S



Coal fly ash 2 1 4 2 2 2 4 2 1 1 1 1

Coal Bottom ash 2 1 2 2 2 2 2 2 0 1 1 1

Foundry sand 1 2 1 1 1 1 2 2 1 2 1 2



Non-Ferrous Slag 0 0 0 0 0 0 0 0 0 0 0 0

Scrap Tyres 0 0 0 0 0 0 0 0 0 0 0 0

Steel slag 2 4 4 2 1 2 1 1 1 1 1 1

Waste Glass 0 0 0 0 0 0 0 0 0 0 0 0

Waste Concrete 2 1 1 2 2 2 2 2 2 2 1 2



122


A) Application: CM/ST

Material: Coal Fly Ash 1. 5 000 tones. 2. Binding capacity: Compressive strength of soil/coal fly ash mixture after 7 days. Weather resistance of stabilized soil. 3. Use of appropriate machinery for in site mixing coal fly ash with natural material in layer the thickness of which is not less than 20 cm to obtain a uniform mixture of the natural material and binder. 4. Degree of Compaction. Bearing Capacity. Compressive strength on test samples prepared in accordance with Proctor procedure after 7 days. Weather resistance after 7 days on test samples prepared in accordance with Proctor procedure given by ratio between compressive strength of dry samples and that of the samples soaked with water for 24 hours. 5. No. 6. Leaching limit values. 7. No. 8. No data. 9. No data.

B) Application: EMB

Material: Coal Fly Ash 1. 2 000 tones. 2. Binding capacity: Compressive strength of soil/coal fly ash mixture after 7 days. Weather resistance of stabilized soil. 3.

123

Use of appropriate machinery for mixing of coal fly ash with natural material in layer the thickenss of which is not less than 20 cm to obtain a uniform mixture of the natural material and binder. 4. Degree of Compaction. Bearing Capacity. Compressive strength on test samples prepared in accordance with Proctor procedure after 7 days. Weather resistance after 7 days on test samples prepared in accordance with Proctor procedure given by ratio between compressive strength of dry samples and that of the samples soaked with water for 24 hours. 5. No. 6. Leaching limit values. 7. No. 8. No data. 9. No data.

C) Application: HMA, CM/ST

Material: Steel Slag – Electro Furnace 1. Not available. 2. DIN standard, Slovenian technical specifications for hot asphalt mixtures (allowed usage after laboratory and field testing). 3. No additional equipment is required, only suitable crusher and sieves to produce suitable fractions. 4. Mix design should be based on volumetric properties. 5. At present we follow the DIN standard requirements. 6. As prescribed in DIN standard specifications. 7. No. 8. Agreement between the steel producer and the company that should prepare suitable fractions, technical requirements of the investor (state highway and road authorities).

124

9. Our steel factory is preparing the production of suitable steel slag for further crushing, laboratory and field-testing.

125


Country or Region: Slovenia Your Name: Primoz Pavsic, Žorsa Mitja BSc. (Chem. Eng.) Position:Head of Geo-mechanical Laboratory, Head of Laboratory for Asphalt Bitumens and Bitumen Based Products. Organization: ZAG- Slovenian National Building and Civil Engineering Institute Address: Dimičeva 12, Ljubljana Phone: +386 1 2804 245 Fax: +386 1 2804 484 E-mail: [email protected], [email protected].

1. More effort should be exerted on organized collection of materials and financing of research activities.

2. The only subject in policy making is the government.

3. No data.

4. No data.

5. - regulations based on public laws no data - financial instruments high costs of dumping waste research projects financed by Government - innovation/development of knowledge research projects financed by Government or industry - transfer of knowledge research projects, articles, and conferences - regulations based on private law no data - other instruments no data

6. Environmental requirements as well as the economical ones are most important.

7. No data.

8. No data.

9. Research is funded by government and producers. Some projects are under way.

10. Through articles and conferences.

126

10 Ukraine


Country or Region: Ukraine Your Name: Golowko S.K Position: Head of Pavement Division Your Name: Kiszczynski S.K Position: Chef of Organic Binder Division Organization: GosdorNII – Research Institute Address: Pobiedy prospect 57, 113 Kiev Phone: 201 08 72 (48) Fax: - 456 34 15 E-mail: [email protected]



NAME QUANTITY

Available product ton/year % plant recycling

% on-site

recycling

% stock

% landfill

1) Reclaimed Asphalt Pavement (RAP) 355 000 2,8 11,4 85,7 -



4) Mixture of 1,2,3 15 000 5 90 5 -

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Table 2: Applications of Road By–products



Treatment (necessary and/or possible

for each application) tech. econ. envir.


Recycled hot mixture Treatment necessary

+

+

+


Recycled cold mixture Treatment necessary 3)

Reclaimed Base and Subbase GB Treatment necessary

+ + +

4) Mixture of 1,2,3

Recycled cold mixture Treatment necessary + + +

3. Other Questions

3-1 1) Aggregate (granite, quartzite, andesite, basalt, durable limestone, others) • Chemical composition: multicomponent, majority of SiO2, CaCO3 • Physical characteristics: grain size – fraction (mm): 5/10, 10/15, 15/20, 20/40 break-up – not less then 800 abrasion – not less then ST-P frost resistance – not less then F25 content of weak rock grains – not more then 10 % content of plasticity (column) and needle grain shape – not more then 35 % content of clay particles – not more then 0,25 % 2) Sand (natural and manufactured) – fraction (mm): 0/5 • Chemical composition: multicomponent, majority of SiO2 or CaCO3 • Physical characteristics: Grain size – thickness and size factor: 1-3,5; Bulk density: 400-1650 kg/m3

Content of clayey particles – not more then 0,5 % Durability: 800 – 1400 Natural radioactivity: not more then 740 Bk kg-1

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3) Filler • Chemical composition: CaCO3, MgO, CaO • Physical characteristics: content of grain size 0.071 – not more then 70 %. 4) Binders • Bitumen Chemical composition: oils, resins, hydrocarbons, carbonates, elements: H, C, S, O2 Penetration at a temperature of 25 ºC – from 40 to 200 x 0.1 mm R&B Softening Point – from 39 ºC to 57 ºC Ductility at a temperature of 0 ºC – not less then 3 cm Flash point - not less then 220 ºC

3-2 - Grading of mineral aggregate from RAP, - Quantity of asphalt in RAP, - Quantity and quality of binder, which will be add (asphalt, asphalt emulsion, portland

cement), conformity with standard requirements, - Quantity of a separate fraction of aggregate added, - Physical and mechanical characteristics of HMA, asphalt pavement, concrete pavement

and GB: density, durability, waterproofness, frost resistance, rutting resistance.

3-3 In Ukraine special standards for reclaimed aggregate have not been established yet, this

material should conform to common standard requirements: DSTU B W.2.7-32-95. Building materials. Raw sand for construction materials, structures

and works. Technical conditions. DSTU B W.2.7-33-95. Building materials. Quartz-iron sand and a fine dispersion fraction of

waste material from Ukrainian mining industry. DSTU B W.2.7-75-98. Building materials. Breakstone and raw gravel for construction

materials, structures and works. Technical conditions. SDSTU B W.2.7-76-98. Building materials. Sand for construction works, obtained while

sieving process of crashed mining waste rock from Ukrainian mining industry. Technical conditions.

GOST 3344-83. Sand and breakstone of slag for road construction. Technical conditions. GOST 25592-91 Mixes of ash and slag from thermal-electric power stations for concrete.

Technical conditions. GOST 25818-91 Coal fly ash from a thermal-electric power stations for concrete. Technical

conditions. Quality of recycled materials is determined according to the following factors:

1) manufactured sand - grading

- break-up - abrasion - frost resistance - content of weak rock grains - content needle grain shape

- content of clayey parts according to test methods described in standard DSTU BW.2.7-71-98 Break stone and gravel from a dense rock and waste material produced by industry for road construction. Methods for physical andmechanical tests. 2) natural sand

- bulk density - grading

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- content of clayey particles - durability - frost resistance - natural radioactivity

according to test method described in standard GOST 8735 Sand for road construction. Test methods.

3-4 The recycled aggregate in Ukraine should conform with the following requirements of

environmental impact: - According to requirements of standard DBN W 1.4-1.01-97 “System of standards and principles to decreasing the level of the ionization radiation of a natural radionuclide in civil engineering. Regulating radiation factor. Acceptable level of the natural radioactivity should be less than 740 Bk kg-1. It is determined according to control method BDN W 1.4-1.01-97 “System of standards and principles to decreasing the level of the ionization radiation of a natural radionuclide in a civil engineering. Control of a natural radioactivity of building materials and structures”. - According to requirements of GOST 12.1.005-88 “General sanitary-hygienic requirements for air in a work area” the dust concentration while work with a stone material should not exceed the allowable level of concentration (GDK) 6 mg/m3. Inspection is carried out in accordance with requirements of MU No. 4436-87 “Methodical directions for test of an fibrogen action aerosol concentration”.

3-5 In Ukraine a technology of thermoregulation of asphalt concrete pavement was elaborated

and introduced in 1987. In the year 1990 a technology of hot recycling of asphalt concrete pavement in common mix

plant was elaborated and introduced. As Ukraine does not produce mix plants, the technology is not generally used.

In 1993 a technology of reclaimed stone aggregates was elaborated and introduced. In 1996 a technology of cold recycling was elaborated and introduced. In 2003 a technology of cold recycling with a different type of binder was introduced. The

Wirtgen equipment WR 2500 I WM 1000 was used.

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Country or Region: Ukraine Your Name: Golowko S.K, Position: Head of Pavement Division Your Name: Kiszczynski S.K Position: Head of Organic Binder Division Organization: GosdorNII – Research Institute Address: Pobiedy prospect 57., 113 Kiev Phone: 201 08 72 (48) Fax: 456 34 15 E-mail: [email protected]


Applications

Material PCC

HMA

CM / S T

GS

S B

GB

EMB

F I L L

S T R

A P P

S A F

L S



Coal fly ash 0 0 0 3 3 3 3 3 0 0 0 3

Coal Bottom ash 0 0 0 1 3 1 1 0 0 0 0 0

Foundry sand 0 3 3 4 3 3 0 0 0 0 0 4



Non-Ferrous Slag 0 3 4 4 4 4 4 3 3 3 3 4

Scrap Tyres 0 0 0 0 0 0 0 0 0 0 0 0

Steel slag 3 3 3 3 3 3 3 3 3 3 0 4

Waste Glass 0 0 0 0 0 0 1 1 0 0 0 1

Waste Concrete 1 1 1 0 2 4 2 2 2 2 0 0


Waste Tile /Concrete

0 1 1 0 0 0 2 2 0 0 0 2

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A) Application: GS, SB, GB

Material: Blast Furnace Slag, Air cooled 1. 50 000 tones 2. GOST 3344-8 Slag sand and aggregate for road construction. 3. Not necessary. 4. Activity. 5. Temporary technical conditions of use the blast furnace slag into road construction. 6. No, they do not have influence on the natural environment. 7. No. 8. Price of material and transport/haulage costs. 9. In Ukraine there are none.

B) Application: GS, SB, GB

Material: Blast Furnace Slag, Ground Granulated 1. 1 000 000 tonnes, 2. GOST 3476-74, 3. Not necessary. 4. Activity, quality, availability. 5. BP 218 YCCP 025-78 recommendation “ Structure of road subbase made by slag activity mix. 6. There are no criteria but the used waste materials should not have a negative impact on the natural environment. 7. No.

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8. Price of material and transport/haulage costs. 9. The usage of this material can be convenient in cold recycling because of its inclination to make crystallized compound.

C) Application: SB


1.

More than 10 000 tonnes.

2. Not yet elaborated.

3. Not necessary.

4. Determination of an amorphous silica dispersion.

5. Recommendation “Technology of a road subbase construction made by soil improved by waste industry materials.

6. They are considered to have a negative influence on the natural environment.

7. No.

8. High material losses while building.

9. In Ukraine there are none.

D) Application: GB

Material: Coal bottom ash 1. More than 10 000 tonnes. 2. Not yet elaborated. 3. Not necessary. 4. Determination of an amorphous silica dispersion.

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5. Recommendation “Technology of a road subbase construction made by a mining industry waste materials. 6. Emission of CO2. 7. No. 8. Price of material and transport/haulage costs . 9. In Ukraine there are none.

E) Application: HMA, SB, GB

Material: Coal bottom ash 1. More than 5 000 tonnes. 2. Not yet elaborated. 3. Not necessary. 4. Grading, organic impurity. 5. Not yet elaborated. 6. No influence on environment. 7. No. 8. Price of material and transport/haulage costs. 9. In Ukraine there are none.

F) Application: EMB, GB

Material: Mining Waste Rock

1.

No data.


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3. Not necessary.

4. Grading, durability.


6. No influence on environment.

7. No.

8. Price of material and transport/haulage costs.


G) Application: HMA

Material: Waste glass 1. No data. 2. Not yet elaborated. 3. Not necessary. 4. Grading, adhesion.

5. Recommendations.

6. No influence on environment.

7. No.

8. Price of material collection and transport.


H) Application: EMB

Material: Municipal soil waste Incinerators Bottom Ash 1.

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No data. 2. Not yet elaborated. 3. Not necessary. 4. Grading, leaching. 5. Recommendation “Complex reinforcement of the soil by mix of an ash, slags TES and lime. 6. Quantity of leaching compounds. 7. No. 8. Price of material and transport/haulage costs. 9. In Ukraine there are none. I) Application: GS, SB

Material: Waste concrete 1. No data. 2. Not yet elaborated. 3. Pile-driver. 4. Grading, strength resistance, frost resistance. 5. BP 218 YCCP 025-78 recommendation “Structure of road subbase made by slag-soil activity mix". 6. No influence on environment. 7. No. 8. Price of material and transport/haulage costs.. 9. In Ukraine there are none.

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J) Application: GS, SB, EMB Material: Waste tile/concrete 1. No data. 2. Not yet elaborated. 3. Pile-driver. 4. Strength resistance, frost resistance. 5. Not yet elaborated. 6. No influence on environment. 7. No. 8. Price of material and transport/haulage costs. 9. In Ukraine there are none.

137


Country or Region: Ukraine Your Name: Golowko S.K Position: Head of Pavement Division Your Name: Kiszczynski S.K Position: Head of Organic Binder Division Organization: GosdorNII – Research Institute Address: Pobiedy prospect 57, 113 Kiev Phone: 201 08 72 (48) Fax: - 456 34 15 E-mail: [email protected]

1. Government administration influence a policy use of waste materials in economy general and in road construction in detail. There are no special governmental structures involved in the application of construction waste materials. Recycling of waste materials is not obligatory. The use of secondary materials the following problems can be resolved: • improvement of the natural environment through decreasing quantity of a storage space for

waste materials, • decrease of energy loss, • decreasing demand for raw materials while reconstructing or heavy repairs of roads, Government directives prescribe to collect “old” asphalt concrete and reuse it. This role is also obligatory for a national road service “UKRAVTODOR”.

2. Government administration through resolutions and directives creates the policy line on the use of building and road waste materials. Other institutions, e.g.: GosdorNII, Ukrdortechnologia, etc. elaborate and put into practice technical recommendations serving as a guidance how to use building and road waste materials. As originators of technical recommendations, standards, they collect and elaborate all data concerning this problem. They take part in international conferences and seminars, collect material from the internet. At present the contractors and organizations approving the contract can influence use of waste material by introducing proper recommendations to the technical specification of project. In 2003 an asphalt concrete was reused during a road E40 (Kiev-Zytomierz) rehabilitation and reconstruction (Kiev – Borispol; 18 – 35 km) and the others.

3. Economic efficiency is the most important factor for formation of building and road waste material market in the Ukraine.

4. In the Ukraine market of building and road waste material does not exist. The building waste materials are not systematically produced.

5 Promotion of the use of building waste materials is made by: transfer and development of knowledge, promotion of knowledge of the new techniques, performance of the Ukravtodor.?

6. It is necessary to elaborate technical recommendations, technical guidelines, etc. to implement the usage of building waste materials. There are specific requirements for usage of waste materials:

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• technical potential, • laboratory control, • economic efficiency, • improvement of natural environment.

7. The Ukrainian government policy for the implementation of use of waste materials establishes obligation of a subordinate institution by writs to use building waste materials. Design offices when elaborating road projects assume to use or not to use waste materials in the road construction.

8. The main problem is a lack of objective rating of new technology of building and road waste materials use. There is a problem with to gain analytical materials elaborated by EU and USA specialists. The lack of experience is the problem that could be solved by participation in foreign trainings.

9. The Ukravtodor prepares a scientific-technical study of rational use of building and road waste materials, e.g.: cold and hot recycling.

10. Sometimes one can find some lectures on this matter during conferences and seminaries. There are some published recommendations of use of building and road waste materials.

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Documents

SAMARISsamaris.zag.si/docsys/documents/SAM_GE_DE15v01_01.pdf · Foundry sand Material obtained as a by-product during processing of steel (used foundry mould). Clear reclaimed foundry