residentlal remodeling waste reduction · ing projects. three remodeling projects were selected:...

RESIDENTLAL REMODELING WASTE REDUCTION

DEMONSTRATION PROJECT

Contract No. 902741

O'Brien & Associates Palermini & Associates

June, 1993

METRO Residential Remodeling Waste Reduction Demonstration Projert

TABLE OF CONTENTS

TOPIC

Project Summary

Key Findings

Kitchen Remodel

Waste Audit

Kitcheflamily Room Remodel

Waste Audit

Bathroom Remodel

Waste Audit

Recycled Content Building Materials

Recycling Trailer Design

Recycling Trailerachematic Design

Waste Audit Forms-Appendix A

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METRO Residential Remodelina Waste Reductwn Demonstration Rokt

PROJECT SUMMARY

The purpose of this project was to develop, document and teach cost effective waste reduction techniques for residential remodeling projects.

Three remodeling projects were selected:

Project Type Budget Sq. Ft.

Kitchen $24,000 250

Family roodkitchen $80,500 550

Bathrooms $9,800 90

The wastes generated during each project’s demolition and construction phases were audited to determine the weight and type according to standard classifications used by METRO. Materials that could be diverted were identified and their disposition was recorded. Diversion was defined as source separation, salvage and reuse, and recycling. No effort was made to affect the design or construction of the projects to reduce waste generation.

The contractors’ budgeted costs for waste disposal were compared to the estimated costs of diversion. The contractor’s actual added time and expenses for source separation were recorded. The waste auditor (Don Palermini) carried out the diversion. He recorded his added time and expenses for salvage, reuse and recycling of all materials. His labor was charged at the same rate as the contractor to determine the estimated cost of diversion.

Each remodeling contractor and client vol- unteered to participate in the project. The contractor who did the kitchen and bathroom projects had already established source separation and recycling as part of standard jobpractice with hiscrew,all ofwhomworked for him regularly. The other contractor was

interested in learning about job-site recycling. He had typically sent all wastes to be disposed of at a landfill, with occasional salvage.

The projects were able to divert 76%, 88% and 62% of their solid wastes from landfill disposal to salvage, reuse and recycling. Bamers to diversion were identified by ob- servation and by interviews with the contractors and crews.

Remodel designers were interviewed regarding their acceptance of recycled content building materials.

A prototype for a job-site trailer to temporarily store recyclable wastes was developed by one of the remodeling contractors who participated in the study.

PROJECT TEAM

Contractor Coordination Debbi Palermini, Palermini & Associates Waste Audits Don Palermini, Palermini & Associates Salvage Jerry Greene, The Wherehouse Project Analysis and Reports Michael OBrien, O’Brien & Associates

PARTICIPATING CONTRACTORS

Kitchen, Bathrooms Bill Hawley, Hawley Construction Wendi Hawley, Designer

KitchenlFamily Room Bob Fleming, Neil Kelly Company, Project Supervisor Michelle Rolland, Designer

We wish to express thanks to these contractors for their interest and participation.Their generous sharing of ideas, experience, cre- ativity and time has been critical to the success of this project.

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KEY FINDINGS

Waste Characterization Materials removed from the buildings typically included dimensional lumber, woad composites, drywall, metals, cabinets, plumbing fixtures, appliances, lighting fixtures, windows, and doors, ceramic tile, vinyl, carpet and pad, cement and masonry. One job also produced a large volume of topsoil. Most ofthese wastes were generated early in the process (within the first week to ten days.

Mixed waste that was not practical to separate resulted from a) glued-together compo- nentsand b)rot- and water-damaged compo- nents.

Some potentially toxic materials were removed, including pressure-treated lumber. No materials were removed that appeared to contain asbestos. A small area of wall was removed in the kitchen project that may have had lead-based paint.

Wastes produced during construction and installation were similar to those removed and also included insulation, plastics, cardboard, paper (mainly from packaging), con- tainers for paint, caulk, adhesives, and food.

Salvageable Materials Salvageable items included cabinets, appliances, plumbing and lighting fixtures, windows, doors, and carpet. The key to salvag- ing cabinets was screwed-together construction that could be readily disassembled. Older cabinets that are nailed and glued together may be less practical to salvage.

Removal and separation ofsalvageable items required little or no extra labor in comparison with standard removal practices. Sal- vageable items were identified early with each contractor, who instructed the crews. On the kitchen project, removal for salvage

and source separation added six hours of labor. On the kitchedfamilyroom and bathroom projects, no additional labor was required.

High-quality salvageable materials can easily be diverted to resale andlor reuse. All of the items removed from the kitchedfamily room project were less than ten years old and in excellent condition. They were sold by the salvage contractor with a few days.

Lower value items can also be resold. Cur- rently, t he ability of t h e nonprofit Wherehouse Project to meet contractors' needs for prompt pickup is the most signifi-. cant bamer.

Contractor Attitudes An important variable in successful source separation, recycling and salvage is a positive attitude among the contractor and crew. When they are motivated and understand the goals, they will figure out creative ways to overcome obstacles and work efficiently.

Client Attitudes On-site storage ofsalvageable and recyclable items can be a significant barrier. Clients may desire a clean site, with frequent removal of what they perceive as wastes.

Hauling and Disposal Logistics The single most important bamer to diverting wastes is the added labor and hauling expense to take materials to several different disposal sites.

Whereas landfill disposal is a convenient one-stop trip, reuse and recycling require trips to separate sites for salvageable, dirt, concrete and masonry, wood, drywall, cardboard, and metals. Each site has unique operating requirements, such as materials accepted, hours and fees. The contractor has to go to more effort to cope with these requirements.

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costs Budgeted cost for hauling and disposal, compared to estimated costs for diversion to salvage, reuse and recycling:

Budgeted Est Cost Project (Disposal) (Diverted)

Kitchen $390 $305 KitcheniFamily Room $1300 $1100 Bathrooms $95 $100

On the kitchedfamily room project, where there was a savings, this was partly because of the high proportion and weight of salvageable materials.

Designers To enable them to select recycled content materials, designers need unbiased information regarding their characteristics and performance. Possible venues for information include professional gatherings, remodeling shows and workshop settings.

The designers didn't consider the issue of reducing waste generation in the design process. Reducing wastes is a variable that would affect the size, the dimensions and the selection of materials or structural systems for a project. It would add to the complexity of decision making, because there are no clear design guidelines or materials selection guidelines available to help the remodel designer.

KITCHEN REMODEL Contractor: Hawley Construction

Job Supervisor: Bill Hawley

Project Description The remodel is in a 1940's vintage house located in a suburb of Portland. The job is a gut remodel of a kitcheddining area and adjacent entry. The floor area is approximately 275 sq.ft.. No new floor area was added. The kitchen has flat ceilings, no sky-

lights and about 30 sq. R. ofwindow area. An existing built-in cupboard and most of the built-in cabinet frames remained. Cabinets, including an island and floor-to-ceiling with built-in oven; floor and wall coverings, trim, one window, sink, existinglight furtures and appliances were removed. Some soffits and lath and plaster finish were removed.

New items included: wood flooring, drywall, cabinet doors and drawers, sink, garden window, island, appliances, recessed ceiling lights, built-in etorage shelves and total repaint.

The total project cost was approximately $24,200.

The contractor had previously done two other jobs on the same house. The owner has a high degree of trust and confidence in the contractor, and was therefore very coopera- tive with the research.

Task 1 - Project Coordination Debbi Palermini and Mike O'Brien met with Bill and Wendi Hawley at the remodeling site. We reviewed the construction drawings. Wendi explained the remodel, including items to be removed and replacement items. Bill reviewed the schedule for removal and installation of new items. He also reviewed his standard disposal methods and costs for removal, separation, transport and fees. He had budgeted $390.00 for these items. He agreed to track all extra labor costs for removal and separation. Weagreed to perform the waste audit and dispose of or pay for disposal of removed items so that we could accurately track those costs.

Bill is already well organized for separating wastes so the materials can be recycled. He has labeled bins (metal trash cans) on site. He has trained his crew and regular subtrades to source separate. The crew can recognize salvageable items on their own.

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Approximately fifteen people worked on the job and all were aware of the recycling goals. His company has been recycling wood, metals, and cardboard. Recently, with the opening of the Knez drywall recycling operation,they added drywall. He has salvaged aome items and transported them to The Wherehouse Project. Therefore, the $390.00 he had budgeted included transport to different disposal sites and respective fees. We asked what he would have budgeted had he simply taken all removed materials to the landfill in two loads. He estimated that cost at about $250.00. The audited weight of approximately 1300 Ibs. supports this esti- mate. If Bill had actually budgeted $250.00 for disposal, then reuse and recycling at an estimated $305.00 would have increased the cost.

Bill is probably not typical of the industry. He has thought out many details of what is needed to encourage salvage and recycling, based on his experience. The Task 2 section includes his comments regarding barriers and solutions to salvage and recycling.

Task 2 - Waste Management Planning The items to be removed that could be identified on the plans and by discussion with the designer and remodeling contractor included:

Built-in cabinets Cabinet doors and drawers Built-in oven and cabinet (floor-to-ceiling unit) Builbin dishwasher Island with built-in cooktop Wood veneer wall paneling Framing lumber (2x4 stock) Soffit lath and plaster Aluminum 2G sliding window Wood door and window trim Wood cabinet trim (quarter-round) Fluorescent ceiling light fixtures (2.4x40W)

Bi-fold wood door Vinyl flooring Vinyl base Ceiling exhaust fan

Thislistwas providedto Jerry Greene for his review and identification of materials with potential salvage and resalevalue.Theowner decided to sell the island, built-in oven unit and antique chandelier herself.

We visited The Wherehouse, where Jerry Greene gave us a tour of the premises and showed us typical salvaged remodeling materials in stock. During this visit and sub-. sequent phone calls we discussed the following:

What items typically go to sale or to high-end salvage companies?

Antique light and plumbing fixtures, hardware. Good qualitymaterialslikeinteriordoors, any crafted wood items. New vintage appliances.

What items don’t have a market?

Single-pane windows or storm windows, toilets. Damaged items. Scraps of wiring, plumbing, ductwork. Obsolete appliances.

Haw do remodelers know that they can do- nnte materials to The Wherehouse?

Jerry has done some informational ac- tivities, but has no systematic market- ingprogramtoletremodelersknowabout The Wherehouse and the tax benefits of donation. We suspect most remodelers aren’t familiar with the operation or what materials they can accept. Jerry doesn’t have the budget or time to do a marketing plan; there’s not enough money in donated materials to support it. Antique style chandelier

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How does The Wherehousearrange topick up donated materials?

The Wherehouse has a volunteer with a truck who can pick up materials. The charge is $45.00. The contractor pays this fee. Or, the contractor candeliver the materials himself. This process has drawbacks: the contractor has to guessti- mate whether hauling is cheaper than taking the materials to a landfill. He may not like paying a fee to donate materials. He has to deliver when the Wherehouse is open to receive.

It can be difficult for the volunteer hauler to coordinate pickup date and time with the crew; he can't afford a cellular phone and hastobereachedviaThe Wherehouse phone.

A caIler to the telephone number for The Wherehouse listed in the directory may get an answering machine with instruc- tions on donations. This might discour- age donations.

We discussed the tax benefits of donating materials to a non-profit organization with the contractor. Bill stated that typically the contractor would dispose of removed items and would pay fees or receive sales or tax benefits, but in this case he would pass the tax deduction for donated items to the client as a "thank you" for her cooperation.

On site storage was set up in the back yard. A tarp was provided to protect materials from rain. Appliances and cabinets were stored under a picnic shelter. Typically, Bill would not store removed items on site longer than a week, to avoid making a bad impression on the client. Because most removal is done during the first few days of the job, he typically hauls a load at the end of the first and third weeks. In some yards, even tempo- rary bin storage is a problem because there is no part of the yard or garage available.

Bill identified several bamers to separation and salvage or recycling:

Education All members ofthe contractor's crew and the subtrades must be familiar with the meth- odsfollowed on thejob site.Thisrequires the contractor to spend some time with each person initially, and t o follow up with re- minders and clarifications. When jobs get busy, the contractor may give education a low priority.

Bill and Wendi recommended creation of a laminated poster that could be hung at the job, with diagrams and short, simple in- structionson handlingeach type ofmaterial.

He recommended against incorporating recycling language into subtrade contracts, because such a requirement would probably inflate bids. He felt voluntary compliance was feasible and easier to implement.

Multiple Disposal Sites Salvage and recycling currentlyrequires the contractor to arrange for hauling to several different disposal sites and the payment of their respective fees. This increases the overall disposal cost. The logistics are com- plicated, because the contractor has to keep track ofdisposal options, get materials to the right places, and record his expenses. Each different disposal site has different expectations and procedures, creating at least a perception of added complexity.

Bill thinks this factor alone is a major barrier to many contractors. He strongly recommended one-stop disposal.

Disposal Site Organization Some disposal sites are organized better than others to receive materials. Bill estimated that it can take anywhere from 5 to45 minutes to drop materials, depending on how the site is organized. He commented

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favorably on METRO West, where the hauler can bypass the weigh station to drop recyclables first, and the stations are close together. Ideally, a site would have staffwho could help speed the unloading of materials. Bill thinks this could be feasible if most materials amved with correct sorting.

Job-Site Storage As previously discussed, on-site storage of materials is not usually feasible because of space constraints and the contractor’s desire to maintain a tidy job. It is important to maintain a good impression with the client and minimize their sense of disruption.

Bill’s recommendation is a standardized trailer design. The trailer size would allow it to be parked at the site and towed by a standard pickup or van. The trailer would be compartmentalized into labeled bins for separated materials. The bins would always be in the same position, making it easier for crews to remember where to drop materials. A tarp cover would be adequate to keep out water and provide a suitable appearance.

A standardized trailer design would allow the one-stop disposal site to be organized to quickly unload materials. For example, the bins could be hinged to tilt out into acollection bin or pit. This would also allow hauling and disposal tobedonebyonlyonecrew member, minimizing transport costs.

The standardized design trailers could be purchased or rented to accommodate the volume fluctuations remodelers experience.

Client Acceptance On this $24,200 remodel job, separation, salvage and recycling added an estimated $150.00 to the costs over straight removal and landfill disposal. Bill feels he can sell that added cost to a client and leave them feeling good about their contribution to a cleaner, more sustainable environment.

However, he noted that some contractors may fear even bringing up such an added cost and may not know exactly how much to budget. For contractors, the ideal situation would be to reduce the costa of proper disposal so there is no direct penalty in added costs to the contractor or client. There i s also B need to develop client awareness and tol- erance for the salvage and recycling process.

Task 3 - Develop a Salvage and Recycling System We did not have to develop a salvage and recycling system for this job because of the system already in place. On this job the process went as follows:

At the beginning of the job, the contractor identified items to be removed carefully for salvage. He informed his crew, who just memorized the list of items. (On biggerjobs, the items could be tagged with a colored stickerorsimilarJThe contractor determined where to temporarily store removed items until they could be reused or hauled. The contractor decided on an appropriate disposition of each salvage item: for reuse, resale, or donation. Theclient handled resaleitems. Reuse items were labeled and stored in the house. Items for donation were stored in the yard under shelter.

The contractor set labeled bins for materials to be recycled out in a location acceptable to the client, where they could stay for at least the first three weeks. The bins were labeled for wood, metal, drywall, and trash. Card- board was stacked with the bins.

The contractor explained to the crew and to subs the procedure and expectations. Be- cause he worked on the job, he was on site to remind workers of the procedures.

At the end of the first week, the contractor normally arranged for hauling of the first load, including salvaged and recyclable items.

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In this case, we tookover that function so the waste audit could be performed accurately.

The contractor typically hauls items to some combination of the following disposal sites:

a drywall recycler anon-organiclandfill (e.g., glass, plaster, tile) a wood recycler a METRO landfill (e.g., metals and wastes, hazardous materials) a cardboard recycler a non-profit salvage company his own storage Yard until a full load is

and for future Or re- processing.

Thedisposalprocessisrepeated attheendof the third week. At this point there are usually few salvage items and mostlyrecyclables and wastes for disposal.

Allremoveditemswereinventoried, weighed and recorded on the audit form. The completed form is attached in Appendix A.

Owner resale items:

Added hours for the contractor’s crew to source separate wastes (over the time required for removal for disposal) Hours for the auditor to pick up and

Built-in cabinets - floor-to-ceiling unit with built-in oven Island with built-in cooktop Antique style chandelier

change this job because the decisions had already been made by the owner regarding the design, and bids were already let.

We met with Wendi Hawley to identify potential applications ofrecycled materials.To evaluate materials and products, designers will need samples of recycled materials and product literature, and information regarding their character, performance and cost. Wendi’s comments and recammendations are discussed more fully later in this report.

Task 5-Waste Audit See Table 1 for a summary ofthe waste audit for the kitchen remodel. The waste audit forms completed in the field are attached to this report in Appendix A.

Task Financial To get a comparison of the cost of standard waste disposal compared to separation and diversion, t he analysis compares the contractor’s actual budgeted amount for hauling and disposal with the estimated amount for separation, salvage, reuse and recycling. The estimated amount includes the following:

Estimated weight ofowner resale items: 205 Ibs.

Reused on site:

transport materials to various salvage, recycling and disposal sites Expenses for mileage and disposal fees Expenses for pickup by the salvage company (The Wherehouse Project).

Wood - door and window trim I The auditor Drobablv did not take the same Task 4 - Use of Recycled Content Materials We discussed potential recycled building materials. Wendi and Bill are interested in learning about and possibly using such materials. However, they were reluctant to

amount oftime as t h i contractor would have to handle salvaged and recycled materials. For example, he may have made more trips than the contractor would have, because his truck is small capacity, and he did not want materialstoremainonthejobsiteanylonger than necessary. The time that the auditor

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Total Waste

Waste-disposed of

Waste-diverted

Percent diverted

1588 400

1188

74%

I SalvagedandReused I I 5% I

Sale by owner

1 Sale by Wherehouse Project I 380 I I 205

Siding

Gypsum

SubtotaZ- Wood

Ferrous metals

3

269

201

40

I Wood framing I 92 I I I Plywood I 25 I I I Composites I 10 I I 1 Paneling I 85 I I

I Non-ferrous metals I 38 I I I Cardboard I 55 I I

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Metal frame window

Lath & plaster

Plywood backing

TABLE 1 Waste Audit for Kitchen Remodel

Weights in pounds

19

30 223

I Disposal I I 4 0 I I ComDosition shingles I 34 I I

I Linoleum 1 32 I I I Carpetpad I 4 1 I I Floor sweepings I 10 I I I Miscellaneous I 48 I I

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weighing wastes and completing the audit forms is not included in the estimated costs.

Contractor's Disposal Budget Based on previous experience, the contractor budgeted $390.00 in his bid for hauling and fees for disposal of salvaged and recycled materials and wastes.

He allocated his anticipated hours and expenses in the $390.00 budget as follows:

Salvage hauling - 1 trip $50.00

$20.00

$50.00

Wood hauling - 1 trip

Drywall scrap hauling 1 trip + fee @ $55/ton

Wastes and recyclables to landfill 2 trips

Hauling $150.00

Tipping fees $100.00

Non-organic wastes hauling $20.00

TOTAL: $390.00

This contractor estimated that, if he had simple disposaed of all wastes at a landfill, hios costs would have been about $250.00.

Estimated Hours and Expenses- Salvage, Reuse and Recycling The estimated hours and expenses listed below include both the contractor's actual costa for added labor to source separate materials, and the costs for the auditor to haul wastes to recycling and disposal sites. The auditor's hours were charged a t the same rate that the contractor would bill out his crew ($18.00 per hour).

Added labor for separation and hauling:

Contractor's crew: 7 hours @ $18.00/hour $126.00

Waste auditor: 5 hours @ $18.00 per hour $90.00

Mileage: 40 @ $0.40 per mile

Fees: Wherehouse Project $45.00 Gypsum $4.50 Wood $4.00

$16.00

Disposal $19.00

TOTAL: $304.50

The auditor's travel was from the site to Sunflower Recycling, McFarland's and METRO South.

Jerry Greene estimated that the total value of salvaged items would have been $300.00. We assume the federal tax benefit to the typical contractor would be a t the 15% rate, or $45.00. This benefit is not included in the cost comparisons.

The estimated costs for separation, salvage and recycling were approximately $305.00, so diversion appears t o be a practical option in terms of cost.

KITCHENIFAMILY ROOM REMODEL Contractor: Neil Kelly Company

Job Supervisor: Bob Fleming

Project Description The room remodeled was a kitchen and family room area in a relatively new house, less than ten years old, located in an amuent suburb of Portland. The job included a gut remodel and addition; one exterior wall was completely removed. The floor area is a p proximately 550 sq.R.. A small exterior deck

METRO Residodial Remcdeling Waste Reduction &momtrotion Rojat I

was also removed and replaced by a larger deck of approximately 250 sq. R..

New items included: additional floor area, including walls, windows and doors; floor coverings, all cabinetsand countertops, sink, large island, appliances, built-in storage shelves and total repaint. All appliances, Gxtures and materials were of high quality.

Total job cost was $80,500.

Task 1 -Project Coordination DebbiPalermini andMikeO’f3rienmetwith Michelle Rolens, the project designer, at Neil Kelly Company to review the construction drawings. Michelle explained the remodel, including items to be removed and replacement items. She explained that the job would move quickly, and that daily cleanup of wastes would be expected. Fol- lowing this meeting, we contacted Jerry Greene of The Wherehouse Project regarding salvageable materials, which appeared to be extensive and of high value, and to forewarn him regarding the scheduling and short notice time for pickups.

Mike and Don Palermini met with Bob Fleming, the supervisor, at the site toreview the job. We discussed the company’s standard waste disposal methods. Bob said that typically, no source separation is done. Sometimes items are salvaged if a reuse is easily identified. Items are sometimes donated to organizations, if they can be picked upquickly. He also keeps alistofindividuals who have contacted him regarding specific materials, and if he comes across them he will contact that person regarding their pickup. Usually, no special measures are taken to separate, store or divert waste materials. This is because any added costs are charged to the project and come directly out of the supervisor’s earnings, and Bob be- lieves there would be added costs. Bob also emphasized the need to remove wastes as Boon as possible to maintain a clean job site O’Brirn & h o c i a k s P h i n i & h r o c i n k a

and keep the client satisfied.

This company usually acts as its own waste hauler for trash. A total of $1300 was budgeted for hauling and disposal fees. Typi- cally, drop boxes are placed on site and wastes disposed of at the transfer stations.

Task 2 -Waste Management Planning The items to be removed that could be identified on the plans and by discussion with the designer and job supervisor included:

Exterior deck Exterior wall, including siding, trim, framing, insulation and drywall Exterior windows and doors, including interior trim All cabinets, sink and appliances (dishwasher, microwave and oven,refrigera- tor) Island with built-in cooktop Carpet and vinyl flooring Interior wall drywall and framing materials Pantry doors Electrical wiring and boxes and light fixtures.

Bob agreed to track time for labor to separate materials, over and above the normal time to remove them. He also agreed to show the crew which items would be salvaged and might require special care to remove intact.

During the course ofthe job the exterior deck wasadded,resultingin the removal of20,OOO pounds of clean topsoil.

Jerry Greene of the Wherehouse Project came to the site and identified materials with potential resale value. His list follows. He was glad to have the materials because of their high resale value. He did have to split up the cabinets for resale; he noted that a big set of cabinets is hard to resell as a unit.

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Jerry's pickup inclu&---

Island with cooktop and exhaust fan Microwave and oven All cabinets Wood bay window Wood 3'x4' window Wood patio doors Entertainment center cabinets Bifold pantry doors Carpet and pad Light futures Porcelain double sink Under-sink disposal.

Total recorded weight of these items was 2,628 pounds. The value was estimated at $1220.00. All the items were sold within a few days. As far as we know, the contractor does not plan to take advantage of the tax benefit of the donation, so it has not been included in the financial analysis.

On site storage was set up in the driveway, for both materials and a drop box for dirt. A tarp was provided to protect materials from rain. The auditor picked up materials on an on-call basis to satisfy the remodeler's desire to maintain a clean site.

Task 3 - Develop a Salvage and Recycling System Bob Fleming agreed to source separate materials and store them separately on site. The removal was all done by two crew members, so it was easy to explain to them what the purpose of separation was. As i t turned out,the cabinets wereeasily removed because they had been screwed together, instead of glued, so they came apart easily. Bob said that separation ofwastes did not require any extra time.

Jerry asked that materials for his pickup be tagged for ease of identification, because his pickups often occur when no crew is present ortheyarebusy. Hedid havetointerruptthe

crew bAefly because of the weight of a bay window, which required four people to load. Ideally, J e n y would also like to have drawers and doors of cabinets tagged to make it easier to reassemble them after they have been moved.

Jerry has difficulty meeting this job supervisor's need for immediate removal of materials, because he has to use volunteer assistance for large loads or bulky item like the bay window. He usually can't respond as quickly as the super preferred, although he made a special effort to do so for this research project.Heisapplyingforgrantstopurchase a large capacity truck and to hire personnel so he can respond more quickly.

Source separation would normally require more on-site storage area. Because the auditor and/or the Wherehouse Project picked up materials almost daily, this issue did not come up, but for the contractor i t could be an obstacle.

The need to have quick removal ofmaterials from the job emphasizes the need for a one- stop dropoff for all recyclable and/or salvageable materials.

Task 4 - Use of Recycled Content Materials This project had already been completely designed by the time we learned of it. That means all decisions regarding materials had been made, and would be difficult to recon- sider because of possible changes in cost or appearance. The designer was also interviewed.

Task 6 - Waste Audit See Table 2 for a summary of the waste audit.

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Total Waste Waste-disposed of

10382

1170

1 W a s t d i v e r t e d I 9212 I

Salvaged and Reused Sale by Wherehouse Project

I Topsoil4iverted I 20,000 I

2628

2628

1 Percent diverted I 89% I

Wood framing

Plywood

Paneling

1373

408 1

I Recycled I I 6584 I

Prunings

Plastic sheeting

Carpet

I Concrete I 2100 I I

10

10

40

I Ceramic tile I 15 I I I Treatedwood I 1895 I I

1 89 I I Siding I 61 I I I Subtotal-Wood I I 3827 I I Gypsum I 582 I I

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Cement board-tile backing

Treated wood

ComDosites

TABLE 2 Waste Audit for KitchedFamily Room Remodel

Weights in pounds

260

115

47

Sawdust

Miscellaneous

Plastic sheeting

Gypsum

[ Concrete I 25 I I

35

117

15

32

I Ceramic tile I 105 I I

~ 1 Batt insulation

I Broken window glass [ 160 1 I I Vinyl flooring I 115 I I I Wallpaper/gypsum I 35 I I

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Estimated Hours and Expenses- Salvage, Reuse and Recycling

Hours: 11.5 @ $25.00/hour $487.50 Mileage: 316 @ $0.40/mile $144.00 Fees:

METRO South $95.00 Gypsum $15.00 GB9-W $28.00

TOTAL: $769.50

Note: Mileage is from site to McFarland's, 99-W, Gypsum Recycling and METRO South.

BATHROOM REMODEL Contractor: Hawley Construction

Job Supervisor: Bill Hawley

Project Description The bathroom remodel included two bathrooms in the same house, a 1950's one-story ranch. Each bathroom was standard size, one approximately 5'x8', the second 5'xlO'.

The final project cost was $9,781, which included some other work in addition to the bathrooms.

The first bathroom had the existing shower stall, vanity and sink and toilet removed. The stall had leaked water into the cavities around it, causing extensive dry rot. The dry rot prevented much of the wood and the materials attached to it from being recycled, because the rot had destroyed the wood and the fragments were mixed with the other materials.

The second bathroom had an existingwindow removed and a skylight installed. Both bathrooms were refinished with new paint, vinyl, trim, light fixtures and mirrors,

The remodeler budgeted $55.00 for hauling and disposal. Because of the extra waste generated by the rot problems, he estimates the actual cost would have been about $95.

No extra labor was required to source separate the salvaged materials, because they were easily removed intact and the crew was already accustomed to removing salvageable items without extra supervision or in- structions.

On-site storage of salvage and recyclable items was not a problem on this job, because the client was amenable to materials being stored in the rear yard until they could be removed. However, the remodeler observed that this could be a problem on other jobs.

Salvage The entire vanity unit, including sink and faucets, was salvaged, t aken to t h e Wherehouse Project and resold. Also salvaged were the second faucet, an aluminum window plus storm, and a toilet. The Wherehouse staff did not think the metal window could be reused, even though it had B storm.

The City ofPortland Building Department is requiring new and replacement windows to have a U-value of 0.40 or lower, unless the applicant provides calculations showingthat the heat loss from less efficient windows has been compensated for by some other compo- nent. Few remodelerswish to gotothe trouble 3f making the calculations.

l'he remodeler did not get a tax deduction From the Wherehouse Project, becauseofthe low value of the items and the time it would have taken to get a receipt. He delivered the items to the Wherehouse as part of a com- Dined trip, so he estimates the trip cost $25.

15 O'Brien Q Auociatcs Polcrmini &Associates

METRO Residential Remodeling Waste Reduction Demombatwn h & t

Task 6 - Waste Audit See Table 3 for a summary of the waste audit.

Estimated Hours and Expenses Salvage, Reuse and Recycle

Hours: 7 hours G3 $18.00/hour $146.00 Mileage: 80 43 $0.4O/mile $32.00 Fees: Grimms $4.00 99-w $6.00 Gypsum Wallboard Recycling $4.50

TOTAL: $192.50

RECYCLED CONTENT BUILDING MATERIALS

Designer Acceptance We were not able to access the project designers early enough in the process to have them considerusingrecycled content building materials. We interviewed both designers to learn what their interests and needs for information would be to enable them to accept and specify these materials.

As a group, remodeling designers can play a key rolein promotingrecycled contentbuild- ing materials and products. Their role is to "preselect" materials for a project for review and approval by the client and/or contractor. Many designers work regularly with contractors, and they rely on each other's skills. Designers appear to be open to the possibility of using recycled content materials, as- suming they pass their quality evaluation.

Both designers interviewed said that they were not aware of products with recycled content or that were resource efficient, so they had not specified or used any such products. Both were open to the possibility of using such products, provided that they did not have to accept any lesser quality. Nei-

ther designer was aware of "resource effi- ciency" as being a broader term including recycled content, waste-based, salvaged, secondary resource-based or highly durable [greater than 50'year life).

The designers need to be educated about these materials, and to be satisfied that the materials meet several criteria:

Affordable cost, competitive with similar virgin materials

Performance, as good or better than virgin materials

Durability, reliability, service life

Appearance (color, texture and esthetics)

Availability through local suppliers

Where appropriate, that materials have code approvals

Ease of installation.

One designer also stated that she was also evaluating materials in terms of potential health impacts. She would not select a product that she believed might have nega- tive impacts on indoor air quality or occupant health. She cited the difficulty of finding accurate information regarding potential health effects of materials.

This designer observed that her willingness to specify recycled content materials would depend in part on her evaluation of her client, and whether or not they would be receptive. Shedefined it as having"genemsity of spirit", being open to learning and to supporting the environment. She said that some clients would have no interest in the sources or characteristics of materials or products beyond their appearance and ser- viceability.

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METRO Residential Remodelinn Waste Reduction Demonstration Rvkt

Total Waste

Waste-disposed of

Waste-diverted

TABLE 3 Waste Audit for Bathroom Remodel

Weights in pounds

2313

890

1423

Salvaged and Reused Sale by Wherehouse Project

1 Percent diverted I 62% I

85

85

Wood framing

Composites

Subtotal-Wood

Gypsum

274 37

311

185

1 Concrete I 762 1 I I Ceramic tile I 80 I I

I

O’Brien & Aseociatee Pakmini &Associates

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METRO Residential Remodeling Waste Reduction Demonstration Project

Disposal

Gypsudtildmixed waste

Wood/asphalt paper mix

Asphalt paper

TABLE 3 Waste Audit for Bathroom Remodel

Weights in pounds

890

425

35

4

’ Shower door 25

Gypsum 87

Ceramic tile 14

Vinyl flooring 26

I Concrete 85 I I Wood framing I 65 I I I Composite-rotted I 82 I I

1 Packaging ~

I 25 I I Miscellaneous I 17 I I

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METRO Residential Remodeling Waste Reduction Demonstration h j e r t

It was important for the designers to be able to see and handie%Fproducts as part of their evaluation. For example, one designer liked the concept of linoleum made from wood flour, but after seeing samples observed that it would have a hard time competing with vinyl flooring because of its limited palette of colors and designs.

The designers said that they relied on two sources for information regarding new materials and products:

ORA sponsored events where products are displayed, such as the monthlymeet- ings, annual conference and the remodeling shows, and

Materials suppliers,suchaslumberyards and specialty suppliers.

When talking to clients about products, the designers tried to recommend alimited set of options so as to provide the client a sense of choice without overwhelming them with too manydecisions. Thedesignersdo use samples to show clients, and in the case of one remodeling company, products are on display at an extensive showroom. This means that the designer may not be able t o do extensive education of clients, because they don't want to add complexity to the design process.

If a client requests an unfamiliar product, the designer will check it out before accept- ing the responsibility of specifying the product. Consumer demand may motivate designers to find out about products, but the need for information is still there.

One designer pointed out that contractors can and do change their designs and specifications. She recommended discussing product choices with the contractor, to enlist hid her understanding and support.

At the interviews we had samples of some materials to show the designers. Both de-

s ige r s felt that materials and products that weren't part of the visible finishes would be easy to specify. Examples included recycled content drywall, wood flake siding and subflooring, cellulose insulation, composite trusses to replace lumberjoists, and cabinet and underlayment boards. The designers expressed positive responses to some of the finish products we showed them, including ceramic tile made from recycled light tubes, recycled content drywall, recycled paint, carpets a n d pads made from fibers, meadowood and plastic lumber.

Our recommendations to encourage designers to learn about recycled content building materials include:

Develop a self-contained product display that can be set up at professional gatherings and at trade shows. Highlight products that can be used by remodelers. Ask manufacturers to donate samples of their products. Provide copies of the recycled content products guide.

Develop a volunteer program enlisting remodeling designers to staff the display and answer questions regarding products and materials.

Make presentations at professional gatherings to let designers know about products, product display, sources, and examples of applications.

RECYCLING TRAILER DESIGN

Background The remodeling contractors involved in the METRO Residential Remodeling Waste Re- duction Demonstration Project have de- scribed their need for a practical method of storing and handling source separated C&D materials, to make the costs of diverting these materials competitive with current

O'Brien d Assmiates 19 Pak-rmini & Associate8

METRO Residential Remmloling W M ~ Reduction Demonstration h j k t

landfill disposal costs. The remodelers also have also identified other important needs, such as maintaining a clean job site, that must be addressed.

One contractor, Bill Hawley of Hawley Construction in Tigard, recommended a trailer-based solution. Bill's trailer concept would provide for the following:

Ability to store source-separated C&D materials at job site until fully loaded.

Maintainance of a clean job site for clients.

Storage for wood, drywall, metals, cardboard and other reyclable materials in separate compartments to avoid contamination.

Ability to be loaded and unloaded with a minimum of handling and labor.

Sized to be towed by a standard pickup truck or utility vehicle.

Affordable cost for trailer to be purchased by haulers or remodeling contractors.

Durable construction and low mainte- nance.

The above parameters assume that the remodeling contractor (or a member of the crew) will be responsible for loading and unloading the trailer. Bill stated his prefer- ence that a hauling contractor be responsible for bringing the trailer to the job site and picking it up when loaded. He does not want to make a large capital investment in the purchase of a trailer.

The trailer designs also assume that the METRO transfer stations can be organized to manage the drops. Ideally, a trailer would be unloaded with only one stop, and with its driver responsible only for moving the mate-

rials off the trailer.

T y p e s and Amounts of Wastes Generated The three remodeling jobs studied in the demonstration project produced 1188,9267 and 1423 pounds ofsource separated wastes. These materials broke down as follows:

Kitchen K/F Baths

Salvage 585 2628 85 Recyclables 603 6639 1338

The salvage materials were picked up by The Wherehouse Project for resale, using their truck and volunteer labor. Many ofthe items were large, e.g., cabinets, islands,doors and windows, appliances, that would be physically difficult to store and move on site in a trailer. The trailer design does not attemptto provide forstorageofall salvagable materials.

The three jobs produced the following recyclable materials by weight:

Kitchen WF

Concrete Wood Treated wood Gypsum Metals Cardboard Ceramic tile Carpet

TOTAL:

0 2100 269 1932 0 1895

20 1 582 78 0 55 55 0 15 0 40

603 6584

Baths

762 311 0

185 0 0 80 0

1338

O'Brien & Associates Palermini &Associates

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METRO Residential Remcdeling Woaie Reduction Drmonatrorwn h j m t

While three jobs do not provide a reliable sample of all remodeling jobs, they do indi- cate the following:

The total weight of materials on each of the smaller jobs is under 2000 Ibs. One trailer with about 3500 Ib. capacity could have stored all the materials generated by these jobs and disposed of them in one trip.

A trailer with a capacity of about 8-10 cubic yards, divided into 4-5 compartments, could have handled the total volume and types ofmaterials on the smaller jobs.

The large job generated weights and vol- umes that would require 2-3 tripsto store and handle using a 3500 Ib. capacity trailer.

The 2100 Ibs. of concrete is not a large volume. Concrete has a density of about 140 Ibs. per cubic foot, so this weight is equivalent to about 15 cubic feet or 1/2 cubic yard. However, the weight of the concrete may create a handling issue; for example, if the bins or compartments on a trailer had to be tilted t o drop the contents.

There is a need to accomodate bulky items, such as appliances, tubs, toilets, water heater tanks, lengths of pipe and lumber, that would not fit into compartments or bins.

The major materials by weight are concrete and masonry, wood, and gypsum.

’hailer Design In general, the towing vehicle is assumed to be a full size pickup or utility vehicle. These vehicles have a practical upper limit for towing a trialer of about 3500 Ibs. More weight pushes the trailer into being beefed up with such things as its own separate O’Brien & h s c c i a t e s Polennini & hsccioks

braking system, stronger axle, strongerhitch (for both the trailer and the towing vehicle) and so on. More weight also places more stress on the towing vehicle and pushes it towards having a tow package, including beefed up cooling, shocks, and so on. This design assumes that the truck is not required to have a towing package.

A 3500 Ib. capacity translates into a trailer volume ranging between about 7 and 10 cubic yards. The overall dimensions at the smaller end of the range would be about 6’x 10’ x 3’, going up to about 8’ x 12’ x 3’. An 8’ widthis themaximumallowable forautility trailer under state regulations, and 12’ is about the practical maximum length for handling purposes. The schematic design shows the larger size. The overall volume of the trailer might be larger, if for example a sloped floor was built in for ease of unloading.

The trailer should be compartmentalized to accomodate source separated materials and variations in volume between differentjobs. One or two small compartments would be useful for low volume materials, such as ferrous and non-ferrous metals. Smaller compartments may be required over the trailer’s wheels.

The sides of the compartments should be as low as possible for ease of loading materials into them with a minimum of lifting, for example, a low trailer bed and a limit on the height of the compartments on the outside.

The compartments should have covers to keep rain out, maintain acceptable appearance, and to prevent contamination of the wastes.

There are at least two options for unloading the bins. Bill recommends a tilt-out design where each bin is hinged at the bottom. His experience indicates that the weight of the bins would be practical for one person to tilt.

21

METRO Residential RemodPling Waste Reduction &mowtiation ?“jet

These bins would have the covers hinged ai the top rear edge. Another option, found or EOme recycling trucks, is a sloped bin with I hinged wall on the outside. These bins let tht contents slide out when the hinge wall ir lifted. The schematic design shows the tilt, out bin.

Trailer Manufacturing Costa Based on preliminary discussions witk manufacturers, this trailer can be produced economically. The bed, axle, wheels, hitch and other trailer parts could be stock items The bins and possibly the tilt-out mecha. nism are not familiar to manufacturers 01 trailers, so they were unable to predict theii cost. Exact costs wouldrequire detailed plans and manufacture of a prototype, but thc manufacturers think that the trailer can bc produced for well under $2000. This cost does not include custom manufactured plastic bins.

There are at least three trailer manufactur ers in Oregon who have experience building utility and recycling trailers. One companq has already built compartmentalized trail. ers for building contractors who had similar specifications.

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METRO Residentid Remodeling Waste Reduction Ikmonsiraiion h j m i

RECYCLING TRAILER SCHEMATIC DESIGN

Recycled plastic bins Hinged covers Accessible for loading Tllt-out bln unloading Space for bulky and long Items Movable stakes 3500 ibs. capacity

23 O’Brien & Associates P h i n i & A.uxiotes

. . M E h O Residential Remodeling Waste Reduction Demonstration Pm&t

APPENDM A

0 Brien Q Asrociates 24 P a h i n i Q Ascciatos

. . "e.

Pnna P

- Appendix A (continued)

6 - B V 3 WASTE CWCT~RIZATION FORM

r Notcr

I I 1 I I

. - 4 r \ f l ; 9 O h 6 - 7 - y ~ . '

Appendix A WASTE CHARACTERIZATION FORM

Rqucn For ProporPls - Demonruation of Chrnneriution of Conrvuction Sire Wure Page I 1

Dacmber 1992 Wp Y 92R-IP-SW

Appendix A (continued) WASTE CHARACTERlZATION FORM

CSL Code Dwrlptlon Weigbt Recycling Dllpold Notes --.- ---- flbr) Lbcatlon Locltioa

10800 K i i c h w t h f t m u u 2 a. toilel

~cquen For Proposals - Dcmonnrsrion of C m a e r i u t i o n of Consuuction Site Wane Page I 2

D m m k r 1992 RFP a 9 2 ~ 4 9 . ~ ~

M c j a k i Appendix A (continued)

WASTE CHARACTERIZA7lON FORM

Adhesives I I I l a d (Metal) Aerosol MI I I I

Rquw for propwl8 - DemomUon of Chmweriulion of Consmaion Site Waste Page 13

December 1992 RFp Y 92RJPmSW

residentlal remodeling waste reduction · ing projects. three remodeling projects were selected:...

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