Development in Recycling of Construction and Demolition Materials

by
Ir. CHAN Chi-yan, Henry and Ir. FONG Fu-ki, Winston
Civil Engineering Department
The Hong Kong Special Administrative Region Government

Summary

The local construction industries generate about 14 million tonnes of construction and
demolition (C&D) materials every year. In the past, the inert part of the C&D materials has
been reused as public fill in reclamation projects, which results in land supply for
development. However, with the recent raised awareness of sustainable development,
recycling is accepted as a valuable process that turns useless materials into useful products.

The inert C&D materials comprise of rocks, sand, mud, slurry, broken concrete, and rubble.
It could be recycled into aggregate for use as civil engineering construction materials. The
construction industry is seeking ways to ensure that recycling of C&D material is viable and
sustainable.

The paper discussed the initiation of the idea of recycling of C&D material, the preparation
for introducing the use of recycling C&D products, the promotion of its use and the
establishment of the first pilot recycling plant. Finally, the paper describes the strategy for
recycling of C&D materials.

Key words: Construction and Demolition Materials, Recycling, Beneficial Use

1. Introduction

Hong Kong has a population of about 6.8 millions and about 2,100,000 household. The
averaged population density is approximately 6,300 persons per sq.m., covering an area of
just under 1,000 sq.km. Due to the mountainous nature, Hong Kong has to gain lands by
either reclamation or excavation of the hillside. Additional floor spaces are generated by
redevelopment of the urban area with more old building being demolished and replaced by
high-rise buildings. As a results of these activities, the local construction industries generate
about 14 million tonnes of construction and demolition (C&D) materials every year.
Development in Recycling of C&D Materials in Hong Kong.DOC
Although there may be some decreases in the construction activities due to the financial
downturn in the recent year, there is a rising trend in the generation of C&D materials in a
long run. To ensure the sustainable development of Hong Kong, there is a need to manage
the C&D materials systematically and maximize the utilization of these materials in the
development of the estate and infrastructure in Hong Kong.

2. What is Construction and Demolition Materials?

C&D materials consist of inert and non-inert materials arising from demolition works,
excavation, road works, renovation works and formation works. In Hong Kong, more than
80% of the C&D materials are inert materials, comprising brick/tiles, asphalt, broken concrete,
rock, soil and excavated earth, etc. It can be reused as public fill for use in formation works
and reclamation works, and can also be recycled into construction materials for use in
construction works. The remaining materials are non-inert materials, called C&D wastes,
comprising bamboo, plastic, timber and packaging wastes etc. They are often mixed and
contaminated. They are not suitable for reuse in reclamation works or recycled and have to
be disposed of at landfill.

C&D Materials

(Approx.14 M tonnes per Year)

Inert (84%) Non-inert (16%)

Soft (59%) Hard (25%)

Recyclable (20%) Non-recyclable (5%)

3. Needs for Recycling of C&D Materials

C&D materials are voluminous and take up a lot of the limited landfill spaces. In order
to divert inert C&D materials away from the landfills and or else deplete the diminishing
landfill spaces and to reduce the reliance on reclamation as the sole outlet for accommodation
of inert C&D materials, the Government of the Hong Kong Special Administrative Region
(HKSAR) has identified recycling as part of the strategy on management of C&D materials,
in addition to reduce and reuse.

Development in Recycling of C&D Materials in Hong Kong.DOC

 The local consumption of aggregates and rock products is about 13 millions tonnes in
2001. Despite of the recent financial downturn, it is expected the demand for aggregates
will increase in a long run. At present, about 60% of Hong Kongs demand for rock
products can be met by local supply, while the remaining 40% relied on import from
Mainland. However, the local quarries will be gradually closed and will cease production in
2013. Depending on the speed of excavation, the rock reserve of our nearby quarries in
Zhuhai and Shenzhen areas could be exhausted in 2009. There would be a shortage in the
supply of aggregates. The recycled aggregates can supplement the virgin aggregates to meet
the demand in aggregate products in addition to reserving public fill capacity and the
depleting landfill spaces.

4. What can be recycled?

Theoretically speaking, all inert C&D materials can be recycled. However, the market
force will dictate which kinds of hard inert C&D materials can be recycled practically into
products with commercial value. As metal has a very high scrap value, it is normally
savaged during the demolition process for recycling. The hard inert portions, such as
concrete, rocks and rubbles, can be sorted out and recycled into aggregates and granular
materials for use in construction. Although brick and tiles have been recycled together with
other inert C&D materials into road sub-base materials in overseas countries, such as
Denmark and Germany, they are classified as non-recyclable materials in Hong Kong.

5. Development of Recycling of C&D Materials

According to overseas experience and practice, hard inert C&D materials can be
recycled into aggregate products for use as a replacement materials for virgin aggregate.
There are numerous examples in applying the recycled aggregate in various forms of
constructions, including concrete production, road works, airport runway etc. If properly
implemented, these applications will not only relieve the pressure in finding means for
accommodating the C&D materials, it will also provide an alternative source of aggregate
preparing for the closure of local quarries in the near future. Apart from these considerations,
overseas experience in the use of recycled aggregate in civil engineering projects has
demonstrated the benefits in environmental protection and sustainability.

Hong Kong is still at the infant stage of recycling of C&D materials. Currently, market
has not been established nor any recycling facility has been set up. The HKSAR
Government has to prepare for introducing the use of recycled C&D products, promote its use
in the construction industry and take the lead to establish the markets by:

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 (a) Conducting research and development to investigate the physical properties of the
recycled aggregate;

(b) Removing the obstacles which hinder the use of recycled C&D materials by
reviewing and introducing revision of construction specifications and building
regulations;

(c) Setting up temporary recycling facilities to process the suitable hard inert C&D
materials into usable recycled aggregate for use in construction;

(d) Mandating the use of recycled aggregates in government projects;

(e) Appealing the support of quasi-government organizations and private sectors to use
recycled aggregates;

(f) Reserving suitable lands for permanent recycling facilities;

(g) Exploring wider application of recycled C&D materials by trials and collaboration
with the local academia, professional institutions and construction industries.

6. Problems Encountered in Recycling

There is always inertia or conservatism in adopting new types of material in the

construction industry. Some overseas countries have taken 10 to 15 years to develop the
wide adoption of recycled C&D materials. The same difficulties are being encountered in
Hong Kong and are summarized below:

(a) Lack of confidence in the use of new construction materials and in their long-term
performance;

(b) Lack of local experience in the use of these materials;

(c) Specifications, technical and practice notes are insufficient in place;

(d) Uncertainties on the quality and steady supply of recycled aggregate;

(e) Cheap supply of virgin aggregate from our neighborhood areas, such as Zhuhai;

(f) No imposition of landfill charges and aggregate tax as in foreign countries.

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7. Establishment of Market in Recycling

The HKSAR Government has conducted study on the economic and financial viability
analysis in establishing the market for recycled C&D products and the setting up of C&D
materials recycling facility in strategic locations in Hong Kong. Findings from a recent
study have indicated that it is economical and financially viable to establish the business on
recycling of C&D materials in Hong Kong, subject to some administrative tools and the
availability of lands.

In order to initiate the establishment of the market, the HKSAR Government has
scheduled to set up a temporary C&D materials recycling facility within a public filling area
in Tuen Mun Area 38 to process inert C&D materials into aggregate products for use in public
projects. This facility will be set up for operation in mid 2002. Different sizes of recycled
aggregate will be produced to cater for various potential applications. A co-ordinated
approach is adopted in encouraging the use of the materials, with the Government revising the
engineering specifications and identifying appropriate public projects utilizing these materials.
At the same time, the concrete suppliers have been approached to sort out the logistics in
using recycled aggregates to produce ready mixed concrete. With the concerted effort by the
Government and the stakeholders of the construction industries, it is hoped that the demand
for recycled aggregate can be generated and a market can be established. With the passage
of time after gaining more experience, the business of recycling of C&D materials will be
operated under commercial principle and driven by market force. When this happens, no
further intervention by the Government will be needed.

Depending on the demand for recycled C&D materials, the HKSAR Government will
identify sites for setting up more recycling facilities.

8. Potential Applications of Recycled Inert C&D Materials

The potential applications of recycled aggregate and granular materials include:

(a) Concrete production - The Standing Committee of Concrete Technology (SCCT) in

Hong Kong recommended that recycled aggregate will only be permitted for use up
to Grade 35 until further tests have demonstrated that concrete with higher strength
can be consistently produced with satisfactory performance in long-term durability.

(b) Granular materials for filters, drainage layer, etc.;

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 (c) Road sub-base;

(d) Concrete paving blocks or similar block works;

(e) Rockfill replacement for seawall, infill to gabion walls, etc.

9. Current Tests and Trials

In November 2000, tests were carried out on the physical and chemical properties of
some recycled aggregates produced from two sites. Results of the 10% fine value test on the
recycled aggregate, although being lower than the performance of virgin aggregates, can still
comply with the specific requirement of the aggregate for concrete production. Results are
shown on Table 1 below.

Table 1 [1]
Trial concrete mixes were produced
jointly by the Government
Laboratory and some local
academic institutions to confirm the
suitability for use in concrete
production. Full-scale plant trial
at a commercial concrete
production plant had also been
performed to verify the suitability
and identify the parameters required
for monitoring in commercial concrete production. In addition, trial section of road
pavement with sub-base made with recycled aggregate in a highways project was laid for
testing and monitoring with a view to obtaining more data for refining the specifications on
the use of recycled aggregate. It is envisaged that more tests and trials will be conducted on
recycled aggregate material after the commenced operation of the temporary C&D materials
recycling facility.

During the production of recycled aggregate, fine aggregate (i.e. 5 mm down) will be
produced but this material cannot be used in concrete production. Therefore, the less the
quantity of fine material produced, the higher the profitability of the recycling plant operation
will be. In order to explore wider application of this fine material, the Civil Engineering
Department of HKSAR Government has co-operated with a local academic institution to
produce some concrete paving blocks using recycled fines. The blocks have been laid for trial
in project sites like playgrounds in school, pedestrianways in housing estates and podium of
Development in Recycling of C&D Materials in Hong Kong.DOC
railway stations. Monitoring and testing will be conducted to obtain more data to
demonstrate the application of recycled C&D materials in engineering projects.

10. Establishment of Temporary C&D Recycling Facility

A pilot temporary recycling facility will be established in Tuen Mun. The facility is
designed for an output capacity of 1,200 tonnes per day to produce ranges of recycled
aggregates and granular materials for various potential uses. A quality assurance system will
be implemented with laboratory set up on site for sampling and testing of recycled products to
ensure that only qualified recycled products, which comply with the specifications, will be
released to the customer. Sub-standard recycled materials will be downgraded for
appropriate use.

11. Strategy for Recycling of C&D Materials

To pave the way for wider acceptance on the use of recycled inert C&D materials in
construction, the HKSAR Government has planned for the following strategic activities:

(a) Implementing waste management plan in the planning, design, construction and
maintenance stages of the project cycle;

(b) Encouraging selective demolition and on-site sorting in order to obtain good quality
of hard inert C&D materials for recycling;

(c) Reviewing and revising engineering specifications to remove obstacles for

recycling;

(d) Setting up temporary recycling facilities (short and medium-term);

(e) Encouraging the use of recycled C&D materials in public and private projects;

(f) Facilitating the construction industries to set up more recycling facilities by

allocating suitable lands at strategic locations;

(g) On-site recycling;

(h) Collaboration with the construction industries, stakeholders and academia on more
research and development into wider use of recycled aggregates.

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12. Conclusion

Natural resources are not unlimited. Wasting natural resource should be criticized.
There is a need to protect our environment and reserve natural reserves for our next
generation. Recycling of C&D materials is feasible and helps reduce the waste of natural
source and reduce the needs for quarrying. Recycled aggregate actually contains over 99%
of natural aggregates savaged from old crushed concrete. They are good materials with
physical properties compatible with virgin aggregates. More research and development can
increase our confidence in using these materials.

Acknowledgement

The paper is published with the permission of the Director of Civil Engineering of the Hong
Kong Special Administrative Region Government.

Reference

[1] Study Report on the Use of Recycled Aggregates in Ready Mixed Concrete by the
Standing Committee on Concrete Technology and Concrete Producers Association of
HK, 2001.

Biography

1. Ir. CHAN Chi-yan, Henry (BSc(Eng.), MBA, CEng, MICE, MHKIE, RPE) graduated in
the University of Hong Kong in 1979. He has over 20 years of experience in civil
engineering. He is currently Chief Engineer of Port Works Division of Civil
Engineering Department, HKSAR Government.

2. Ir. FONG Fu-ki, Winston (BSc(Eng), CEng, MICE, MHKIE) graduated in UK in 1979.
He has wide experience in ferry terminal construction, including Macau Ferry Terminal
and China Ferry Terminal, dredging and maintenance of marine facilities. He is
currently Senior Engineer of Port Works Division of Civil Engineering Department,
HKAR Government.

Development in Recycling of C&D Materials in Hong Kong.DOC