Life-cycle impacts of the use of industrial by-products in road and earth construction

A two-stage study "Life cycle analysis of road construction and earthworks" was part of a more extensive Finnish research project "Assessment of the applicability of secondary products in earthworks". In the first stage of this work a life-cycle impact assessment procedure for the comparison and evaluation of alternative road and earth constructions was developed. Additionally, a database containing the environmental burdens of the most significant construction materials and unit operations was constructed. In order to evaluate the applicability of the procedure, the use of coal ash, crushed concrete waste and granulated blast-furnace slag in road construction was evaluated in case studies. The use of these secondary products was also compared with the use of natural materials in corresponding applications. The aim of the second stage was to transfer the assembled data for utilisation as a practical model by creating an inventory analysis program to calculate and compare the life cycle impacts of the most common road constructions and foundation engineering methods. The data obtained in the first stage was also augmented to the extent necessary for this purpose. The results of case studies indicate that the production and transport of the materials used in road constructions produce the most significant environmental burdens. Production of the bitumen and cement, crushing of materials and transport of materials are the most energy consuming single life-cycle stages of the construction. A large part of the emissions to atmosphere originates from energy production. In the expert assessment, consumption of natural materials and leaching behaviour were also regarded as being of great significance.     

Road soil retention of Pb leached from MSWI bottom ash

Municipal solid waste incinerator (MSWI) bottom ash may be used as a road construction material; it potentially contains however a sizable quantity of heavy metals, which under the effect of rainfall infiltration through the road structure can be leached out from the material and infiltrate into the underlying soil. An eco-compatibility assessment of MSWI bottom ash reuse in road construction applications necessitates examining the solubility and retention of heavy metals in road soils. This study is dedicated to Pb transfer, sorption and desorption (NEN 7341 standard test) within various soils. These experiments yield results relative to the interaction between road soils and an MSWI bottom ash leachate representative of a "fresh" product, with a high leaching potential. For the soils investigated, the sorption of lead varies between 90% and 99%. For an extraction at pH 7, Pb release is very low (<2%) for all soils, while at pH 4 leaching varies between 4% and 47%. This work shows that Pb may be fixed by some types of road soil in mostly stable forms.     

Leaching assessment of road materials containing primary lead and zinc slags

Characterisation of the leaching behaviour of waste-containing materials is a crucial step in the environmental assessment for reuse scenarios. In our research we applied the multi-step European methodology ENV 12-920 to the leaching assessment of road materials containing metallurgical slag. A Zn slag from an imperial smelting furnace (ISF) and a Pb slag from a lead blast furnace (LBF) are investigated. The two slags contain up to 11.2 wt% of lead and 3.5 wt% of zinc and were introduced as a partial substitute for sand in two road materials, namely sand-cement and sand-bitumen. At the laboratory scale, a leaching assessment was performed first through batch equilibrium leaching tests. Second, the release rate of the contaminants was evaluated using saturated leaching tests on monolithic material. Third, laboratory tests were conducted on monolithic samples under intermittent wetting conditions. Pilot-scale tests were conducted for field testing of intermittent wetting conditions. The results show that the release of Pb and Zn from the materials in a saturated scenario was controlled by the pH of the leachates. For the intermittent wetting conditions, an additional factor, blocking of the pores by precipitation during the drying phase is proposed. Pilot-scale leaching behaviour only partially matched with the laboratory-scale test results: new mass transfer mechanisms and adapted laboratory leaching tests are discussed.     

Environmental impact of ferrochrome slag in road construction

Vargon Alloys in Western Sweden is one of the largest producers of ferrochrome slag in Europe. Ferrochrome slag is a by-product from the production of ferrochrome, an essential component in stainless steel. Extensive tests have been carried out on the physical properties of the ferrochrome slag from Vargon Alloys and it was found to be highly suitable as road construction material. The composition and leaching tests of the ferrochrome slag show that the chromium content is high, 1-3%, although leaching under normal conditions is very low. With the exception of potassium (K), which had a potential leaching capacity (availability test) of around 16%, the leaching of chromium, nickel, zinc and other elements was just a few per cent. However, all these tests were conducted in the laboratory. What happens out in the field, under the influence of acid rain and biological activity, and how does this compare with the laboratory results? To answer this question an investigation was carried out to study the environmental impact of ferrochrome slag in roads that were built in 1994. The investigation includes soil sampling (total content and leachable amounts of metals) and groundwater analysis (filtered and non-filtered samples). In addition, a new method involving the bio-uptake of chromium and other metals by the roots of the dandelion (Taraxacum officinale) was tested. The results show that there was a low migration of particles from the slag to the underlying soil and that the leaching into the groundwater was also low for all the elements analysed. However, there seemed to be a significant uptake of Cr by plants growing with their roots in the slag. An investigation of plant uptake was an important complement to laboratory leaching tests on alternative materials.     

Comparison of the release of constituents from granular materials under batch and column testing

Column leaching testing can be considered a better basis for assessing field impact data than any other available batch test method and thus provides a fundamental basis from which to estimate constituent release under a variety of field conditions. However, column testing is time-intensive compared to the more simplified batch testing, and may not always be a viable option when making decisions for material reuse. Batch tests are used most frequently as a simple tool for compliance or quality control reasons. Therefore, it is important to compare the release that occurs under batch and column testing, and establish conservative interpretation protocols for extrapolation from batch data when column data are not available. Five different materials (concrete, construction debris, aluminum recycling residue, coal fly ash and bottom ash) were evaluated via batch and column testing, including different column flow regimes (continuously saturated and intermittent unsaturated flow). Constituent release data from batch and column tests were compared. Results showed no significant difference between the column flow regimes when constituent release data from batch and column tests were compared. In most cases batch and column testing agreed when presented in the form of cumulative release. For arsenic in carbonated materials, however, batch testing underestimates the column constituent release for most LS ratios and also on a cumulative basis. For cases when As is a constituent of concern, column testing may be required.     

The building materials decree: an example of a Dutch regulation based on the potential impact of materials on the environment

Some 20 years ago Dutch society became very aware of the problem of the increasing production of waste materials and of the need to find solutions. Technical solutions had to be developed and introduced into society. Due to the discovery of many soil pollution problems and other environmental calamities, people asked for clear criteria on which proper and safe solutions could be based. Therefore a large number of environmental aspects had to be taken into account in the developing field of environmental policy. The Dutch building materials decree is one of the steps on the road towards a sustainable society. The decree is based on the soil protection act and the surface water protection act. The decree gives quality criteria for the application and re-use of stony materials and earth used as building materials. No difference is made between primary materials, secondary materials and waste materials. The decree is applicable in case these materials are used in constructions where they are in contact with rain, surface water and ground water (e.g. in embankments, road building, outside walls of buildings, foundations and roofs). For implementation of the decree in the construction industry it was necessary to develop standards, methods for testing and certification schemes. In order to guarantee independent testing and judgement, laboratories had to meet quality standards put forward in an accreditation scheme. Although this legislation does not cover all environmental aspects, it has proved to be an important element in judging the environmental quality of construction materials in a direct or indirect way, and a contribution to the management of waste materials. The question of clear and fair criteria was easily put forward. Answering this question, however, turned out to be a complex task in which a great number of aspects had to be considered and a great many tools had to be developed, checked and thoroughly discussed. In some cases practical choices had to be made in order to prevent an unclear situation continuing too long. After an introduction period of three years, the decree came into full operation on 1 July 1999.     

Construction demolition wastes, Waelz slag and MSWI bottom ash: a comparative technical analysis as material for road construction

The objective of the study is to analyze the technical suitability of using secondary materials from three waste flows (construction and demolition waste (CDW), Waelz slag and municipal solid waste incineration (MSWI) bottom ash), under the regulations and standards governing the use of materials for road construction. A detailed technical characterization of the materials was carried out according to Spanish General Technical Specifications for Road Construction (PG3). The results show that Waelz slag can be adequate for using in granular structural layers, while CDW fits better as granular material in roadbeds. Likewise, fresh MSWI bottom ash can be used as roadbed material as long as it does not contain a high concentration of soluble salts. This paper also discusses the adequacy of using certain traditional test methods for natural soils when characterizing secondary materials for use as aggregates in road construction.     

Software analyser design using data mining technology for toxicity prediction of aqueous effluents

Database and information technology has been widely used in process industries to manage data related to environmental performance. However, apart from being collected and archived for subsequent retrieval, the data has not been effectively exploited for improving environmental performance. In this paper we report our work on application of data mining and knowledge discovery technology to the analysis of a database of aqueous effluents from an organic manufacturing plant. The focus is on developing a software analyser for Microtox prediction. However, this methodology is applicable to any ecotoxicity measurement and will therefore offer a means of minimising difficult and tedious testing. Principal component analysis is used to pre-process the data for removing noise and reducing dimensionality. Automatic clustering is employed to group the multidimensional data into classes, and from each class training and testing data sets are selected for developing a back-propagation neural network to predict Microtox. The result shows that the software analyser is able to give satisfactory predictions for both training and test data. The errors for all the training and testing data are shown to satisfy a normal distribution. The software analyser is further used to carry out sensitivity studies in order to identify compounds responsible for observed toxicity value, based on which improved process operational strategies can be developed. Several approaches are investigated, including correlation coefficient analysis, sensitivity study based on differential analysis, one variable deletion, fuzzy curve approach and combination of the above with principal component analysis.     

Norwegian Testing of Emulsion Properties at Sea--The Importance of Oil Type and Release Conditions

This paper is a review of the major findings from laboratory studies and field trials conducted in Norway in recent years on the emulsification of oils spilled at sea. Controlled bench-scale and meso-scale basin experiments using a wide spectrum of oils have revealed that both the physico-chemical properties of the oils and the release conditions are fundamental determinants of the rate of emulsion formation, for the rheological properties of the emulsion formed and for the rate of natural dispersion at sea.During the last decade, several series of full-scale field trials with experimental releases of various crude oils have been undertaken in the North Sea and the Norwegian Sea. These have involved both sea surface releases, underwater pipeline leak simulations (release of oil under low pressure and no gas) and underwater blowout simulations (pressurized oil with gas) from 100 and 850 m depth. The field trials have been performed in co-operation with NOFO (Norwegian Clean Seas Association for Operating Companies), individual oil companies, the Norwegian Pollution Control Authority (SFT) and Minerals Management Services (MMS). SINTEF has been responsible for the scientific design and monitoring during these field experiments. The main objectives of the trials have been to study the behaviour of different crude oils spilled under various conditions and to identify the operational and logistical factors associated with different countermeasure techniques.The paper gives examples of data obtained on the emulsification of spilled oil during these field experiments. The empirical data generated from the experimental field trials have been invaluable for the validation and development of numerical models at SINTEF for predicting the spreading, weathering and behaviour of oil released under various conditions. These models are extensively used in contingency planning and contingency analysis of spill scenarios and as operational tools during spill situations and combat operations.     

Leaching standards for mineral recycling materials--a harmonized regulatory concept for the upcoming German Recycling Decree

In this contribution we give a first general overview of results of recent studies in Germany which focused on contaminant leaching from various materials and reactive solute transport in the unsaturated soil zone to identify the key factors for groundwater risk assessment. Based on these results we developed new and improved existing methods for groundwater risk assessment which are used to derive a new regulatory concept for the upcoming “Decree for the Requirements of the Use of Alternative Mineral Building Materials in Technical Constructions and for the Amendment of the Federal Soil Protection and Contaminated Sites Ordinance” of the German Federal Ministry of Environment.The new concept aims at a holistic and scientifically sound assessment of the use of mineral recycling materials (e.g., mineral waste, excavated soils, slag and ashes, recycling products, etc.) in technical constructions (e.g., road dams) and permanent applications (e.g., backfilling and landscaping) which is based on a mechanistic understanding of leaching and transport processes. Fundamental for risk assessment are leaching standards for the mineral recycling materials.For each application of mineral recycling materials specific maximum concentrations of a substance in the seepage water at the bottom of an application were calculated. Technical boundary conditions and policy conventions derived from the “German precautionary groundwater and soil protection policy” were accounted to prevent adverse environmental effects on the media soil and groundwater. This includes the concentration decline of highly soluble substances (e.g., chloride and sulphate), retardation or attenuation of solutes, accumulation of contaminants in sub-soils and the hydraulic properties of recycling materials used for specific applications. To decide whether the use of a mineral recycling material is possible in a specific application, the leaching qualities were evaluated based on column percolation tests with various samples and compared with application-specific maximum concentrations.In the upcoming federal decree this simplified concept is realized using detailed tables which classify the leaching quality of mineral recycling materials and demonstrate potential application. A quality assurance system will be mandatory which defines specific testing programs (material properties and limit concentrations to be tested, number and schedule of testing) for the different mineral recycling materials using standardized methods (column percolation test).     

Genotoxicity of substances extracted from construction materials

Construction waste such as road pavement and concrete is estimated to constitute about 50% of the total industrial waste in Japan, and the recycling of such material has recently become a prominent topic among construction engineers. It has also been suggested that various types of industrial waste be utilized as components of construction materials. This paper investigates the environmental safety of certain materials in terms of the elutions and genotoxicities of these substances. The substances extracted from some materials, such as emulsifier, ash, and sediment, were found to have genotoxic characteristics. The dose-related responses of the various materials and their genotoxic strengths are shown. Received: June 16, 1998 / Accepted: September 7, 1999     

Marine dredged sediments as new materials resource for road construction

Large volumes of sediments are dredged each year in Europe in order to maintain harbour activities. With the new European Union directives, harbour managers are encouraged to find environmentally sound solutions for these materials. This paper investigates the potential uses of Dunkirk marine dredged sediment as a new material resource for road building. The mineralogical composition of sediments is evaluated using X-ray diffraction and microscopy analysis. Since sediments contain a high amount of water, a dewatering treatment has been used. Different suitable mixtures, checking specific geotechnical criteria as required in French standards, are identified. The mixtures are then optimized for an economical reuse. The mechanical tests conducted on these mixtures are compaction, bearing capacity, compression and tensile tests. The experimental results show the feasibility of the beneficial use of Dunkirk marine dredged sand and sediments as a new material for the construction of foundation and base layers for roads. Further research is now needed to prove the resistance of this new material to various environmental impacts (e.g., frost damage).     

Use of Industrial Hemp Fibers to Reinforce Wheat Gluten Plastics

The next generation of manufactured products must be sustainable and industrially eco-efficient, making materials derived from plants an alternative of particular interest. Wheat gluten (WG) is an interesting plant material to be used for production of plastic similar materials due to its film-forming properties. For usage of plastics in a wider range of applications, composite materials with improved mechanical properties are demanded. The present study investigates the possibilities of reinforcing WG plastics with hemp fibers. Samples were manufactured using compression molding (130 °C, 1600 bar, 5 min). Variation in fiber length, content (5, 10, 15 and 20 wt%) and quality (poor, standard, good) were evaluated. Mechanical properties and structure of materials were examined using tensile testing, light and scanning electron microscopy. Hemp fiber reinforcement of gluten plastics significantly influenced the mechanical properties of the material. Short hemp fibers processed in a high speed grinder were more homogenously spread in the material than long unprocessed fibers. Fiber content in the material showed a significant positive correlation with tensile strength and Young’s modulus, and a negative correlation with fracture strain and strain at maximum stress. Quality of the hemp fibers did not play any significant role for tensile strength and strain, but the Young’s modulus was significantly and positively correlated with hemp fiber quality. Despite the use of short hemp fibers, the reinforced gluten material still showed uneven mechanical properties within the material, a result from clustering of the fibers and too poor bonding between fibers and gluten material. Both these problems have to be resolved before reinforcement of gluten plastics by industrial hemp fibers is applicable on an industrial scale.     

Recycled sand in lime-based mortars

The increasing awareness of the society about safe guarding heritage buildings and at the same time protecting the environment promotes strategies of combining principles of restoration with environmentally friendly materials and techniques. Along these lines, an experimental program was carried out in order to investigate the possibility of producing repair, lime-based mortars used in historic buildings incorporating secondary materials. The alternative material tested was recycled fine aggregates originating from mixed construction and demolition waste. Extensive tests on the raw materials have been performed and mortar mixtures were produced using different binding systems with natural, standard and recycled sand in order to compare their mechanical, physical and microstructure properties. The study reveals the improved behavior of lime mortars, even at early ages, due to the reaction of lime with the Al and Si constituents of the fine recycled sand. The role of the recycled sand was more beneficial in lime mortars rather than the lime–pozzolan or lime–pozzolan–cement mortars as a decrease in their performance was recorded in the latter cases due to the mortars’ structure.     

Environmental effects of using clay bricks produced with sewage sludge: leachability and toxicity studies

Use of sewage sludge from wastewater treatment plants as a raw material for making clay bricks has been analyzed to be an option to dumping sludges into landfills. This alternative has been shown feasible and interesting due to the high rate of use of ceramic materials in the building sector. However, it meets with some environmental issues and some prejudices on the part of users. This work shows some leachability and toxicity tests (outgassing and offgassing) which demonstrate the environmental compatibility of these ceramic products to be used as building materials and even in deconstruction of the building once its useful life is ended.     

Removal of batteries from solid waste using trommel separation

This paper describes the design and testing of a trommel for separation of batteries from solid waste. A trommel is a cylindrical separation device that rotates and performs size separation. It has also been used in areas such as municipal solid waste (MSW) processing, classifying construction and demolition debris, screening mass-burn incinerator ash and compost processing. A trommel has been designed based on size separation to separate household batteries from solid waste, which can then be used as feedstock for alternative applications of solid waste combustion, particularly where the metal content of the product is also a critical parameter, such as the Co-Co process for integrated cement and power production. This trommel has been tested with batches of university office and restaurant wastes against various factors. The recovery efficiency of batteries increases with decreasing inclination angle of the trommel and decreasing rotational speed. A physical characterization of the university solid waste has been performed with a 20-kg sample of the tested waste. It was found that there is a trend of decreasing recovery of batteries with increasing paper composition, and a trend of increasing recovery of batteries with increasing organic materials composition.     

Quantification of the Erosion Resistance of Undisturbed and Remoulded Cohesive Sediments

Cohesive sediments besides their typical heterogeneity are characterised by structural discontinuity. Particularly, organic consolidated muds are a good example of sediments that consist of vast aggregates, pore water and gaseous products. The texture of a cohesive sediment bed is a result of a number of mutually affecting factors, such as deposition history, mineral and organic composition, kind of biota and oxygen uptake. The presented work attempts to quantify the effect of sediment physical properties and sediments structure on the sediment erosion potential, considering incipient motion and erosion rate. This quantification is made on the basis of comparative testing of both unremoulded and remoulded samples of a river mud. Due attention is paid to sediment handling to preserve the delicate structure of the sediment for the laboratory experiments. Mud with two degrees of consolidation has been examined in a tilting flume under different flow situations. The test results show a typical increase of erosion strength with dry matter concentration of the mud. It has also been found that the structural properties increase the erosion strength for the less consolidated mud. An opposite effect has been recorded for a more consolidated deposit. As a consequence, due to the sediment structure, the original beds differ much less in erosion resistance in relation to the dry mass concentration than their disturbed analogues. Finally, the erosion resistance of the examined mud is compared with data from the literature.