Title: Shingles Recycling: Quality Assurance / Quality Control
1Shingles RecyclingQuality Assurance / Quality
Control
- A Presentation at theSacramento RMRC Workshop on
- Tuesday, April 11, 2006
- Presenter Dan KrivitDan Krivit and Associates
2Recycled MaterialsResource Center
www.rmrc.unh.edu
3Presentation Outline
- 1) Material Introduction
- 2) Engineering Properties
- 3) Applications and Performance
- 4) States Using Shingles in HMA
- 5) Specifications
- 6) Testing and Design Procedures
- 7) Further Information
- 8) Summary
4Presentation Outline
- Modified from presentation already in your
big books! - Make sure to get all additional inserts
- AASHTO spec
- Bibliography
- SWMCB packet
5Material Introduction
6Definitions
- Manufacturers Asphalt Shingle Scrap
- Tear-Off Asphalt Shingle Scrap
- Recycled Asphalt Shingles (RAS)(Crushed
screened)
7History
- 15 years
- Multiple research studies in lab and field
- Manufacturer shingle scrap in hot-mix asphalt
best known, most accepted practice - Still relatively new application
8Engineering Properties
9Composition of Residential Asphalt Shingles
10Composition of Asphalt Roofing Shingles
- Asphalt binder content 20 to 40
- Aggregate material 40 to 60
- Fibrous reinforcement 20
11Recent Composition Weight Ranges of Typical
Asphalt Shingles
- 32 to 42 Coating filler (limestone or fly ash)
- 28 to 42 Granules (painted rocks coal slag)
- 16 to 25 Asphalt
- 3 to 6 Back dust (limestone or silica sand)
- 2 to 15 Mat (fiberglass, paper, cotton rags)
- 0.2 to 2 Adhesives (modified asphalt based)
12Applications and Performance
13Multiple Applications
Most Proven
Aggregate (gravel)
Dust control
Cold patch
Ground cover
Fuel
New shingles
14Factors Affecting HMA Performance
- Aggregate gradation of RAS
- Properties of final blended binder content within
the HMA as affected by - RAS asphalt binder
- Virgin binder
15Factors AffectingHMA Performance(continued)
- Location RAS is incorporated into HMA
- Temperature
- Moisture content of RAS and other aggregates
- Retention time in HMA drum
16Source Newcomb, April 2003.
17Source Newcomb, April 2003.
18Source Newcomb, April 2003.
19Source Newcomb, April 2003.
20Source Newcomb, April 2003.
21Source Newcomb, April 2003.
22Source Newcomb, April 2003.
23Engineering Performance Advantages
- Reduce need for virgin binder
- Add fibrous reinforcement
- Modify PG grade binder
- High temp performance
- Reduce landfill needs
3-11
24Potential Benefits ( Manufacturers RAS)
- Cracking resistance
- Rutting resistance
- Conservation of landfill space
Source Paul Lum, Lafarge Construction Materials
Ltd., April 13, 2003.
25Challenges
- Need for improved grinding and handling
- Blending and storage
- Continued research into engineering effects of
RAP and RAS on AC binder content - Quality control and quality assurance
26Barriers to Shingle Recycling
- Economic reasons
- Policy and regulatory compliance
- Environmental concerns
- Technical reasons
- Public sentiment
- -----------
- (Note These barriers may be real or perceived!)
27Engineering Performance Disadvantages
- Hotter mix requirements
- Stiffer mix
- Possible contamination
(Justus, September 2004)
3-12
28Source Lum, April 2003.
29Source Lum, April 2003.
30Source Lum, April 2003.
31Source Lum, April 2003.
32Source Lum, April 2003.
33Source Lum, April 2003.
34Source Lum, April 2003.
35Asphalt Shingles in HMAMissouri DOT Experience
- Joe Schroer, PE
- Construction and Materials Division
- March 30, 2005
36In The Beginning
- Approached by Pace Construction and Peerless
Landfill - MoDOT Not Using RAP in Mixtures
- Deleterious Material
- Stiffness of Asphalt in Shingles
37First LookThe Ex Factor
- Exhaustive Literature Search
- Exclusion of Tear Offs in States Allowing
Manufacturing Waste - Extra Clean Material Contained Little
Deleterious Matter - Exceptionally Stiff Asphalt Extracted from
Shingles
38Shingle Components
- Asphalt ? 20-40
- Stiffen Roadway Asphalt
- Aggregate ? ?30
- Good Stuff
- Fiberglass or Paper Mat ? ?30
- No Harm if Well Dispersed
39MoDOT Goals
- Engineering Properties First
- Harmful Effects of Deleterious Material
- Asphalt Binder Properties
- Traffic Safety Nails, etc.
- If Everything Else Works Out, Landfilling is
Reduced
40Why Should We Pursue Shingles?
- High Asphalt Content
- Granules Are Hard and Durable
- Recycling
COT
41Concerns
- How Will Deleterious Material Affect the Mixture
- Can the Low Temperature Grading be Maintained at
Various Blending Ratios
42Asphalt After Blending with Shingle Asphalt
- Resist Rutting
- Resist Fatigue Cracking
- Resist Cold-Weather Cracking
43Asphalt Grades
- High Temperature for Rut Resistance
- Low Temperature for Fatigue and Cold Weather
Performance - Performance Graded PG
- PG 64-22 (PG Sixty-four Minus Twenty-two)
- High Temp 64C (147F)
- Low Temp 22C (-8F)
44Asphalt Modifications Require PG 64-22
- Stiffer at High Temperature OK
- Stiffer at Low Temperature
- Use Lower Percentage of Shingles
- Use Softer Roadway Asphalt
45Deleterious Evaluation
- Specification for Aggregate
- 0.5 Other Foreign Material
- Sticks, mud balls, deer fur, etc.
- Shingle OFM
- Approximately 3 Total
46Deleterious Material
- Nails
- Wood
- Plastic
- Cellophane
- Paper
- Fiber Board
47Trial by Fire
48No Difference
- Visually
- Standard Mixture Tests
- Placement
49Big Difference
- Rut Resistance
- Cold Temperature Tests
- OFM in Mixture
50Can Tear-Off Shingles be Used?
- Allowance in OFM Due to Small Percentage of
Shingles and Trial Mixture - Start with Softer Roadway Asphalt
51Where Are We?The Ex Factor 2
- Extrinsic Material Allowance Raised
- 3.0 Total
- 1.5 Wood
- Expect PG 64-22 met w/ PG 58-28
- Extra grades optional w/ testing
- Examining various proportions and asphalts
- Exuberant Contractors
52U of M Lab DataMissouri Samples
- Prof. Mihai Marasteanu,U of M Dept. of Civil
Engineering - Preliminary results as of 4-6-2006
- Report with Mn/DOT lab data to be released soon
53MO Mix Stiffness _at_ 100sec. (PG 64-22)
54MO Mix Stiffness _at_ 100sec. (PG 58-28)
55MO Mix Stiffness _at_ 500sec. (PG 58-28)
56MO Tensile Strength (PG 64-22)
57MO Tensile Strength (PG 58-28)
58Mn/DOT lab data
- Jim McGraw, Director of Mn/DOTs Chemical Lab,
Maplewood, MN - Preliminary lab data as of Thursday, April 6,
2006 - Report with U of M lab data, including Mo/DOT
samples, to be released soon
59New Minnesota Lab Study
- Funded by OEA
- Co-sponsored by Mn/DOT
- Comparing manufacturer RAS to Tear-Off RAS
- Mn/DOT to conduct PG extractions
- U of M Civil Engineering to conductindirect
tensile strength tests
60MN Gradation of RAS Tear Off
61MN Gradation of RAS Manufacturers
62MN Gradation of RAP
63MN Asphalt Content of RAS
64MN PG Grade of RAS
65MN PG Grade of RAS
66MN Deleterious in RAS
67U of M Lab DataMinnesota Samples
- Prof. Mihai Marasteanu,U of M Dept. of Civil
Engineering - Preliminary results as of Thursday, April 6,
2006 - Report with Mn/DOT lab data to be released soon
68MN Mix Stiffness GPa _at_ 100 sec.
16
13.5
20 RAP
15 RAP 5 Tear-off
12
15 RAP 5 Manufactured
10.0
8.2
8
Stiffness GPa
5.5
5.0
4
2.7
0.5
0.2
0.2
0
0
-10
-20
o
Temperature
C
69MN Mix Stiffness GPa _at_ 500 sec.
70MN Tensile Strength MPa
71MN vs. MO Mix Stiffness GPa _at_ 100 sec.
72MN vs. MO Mix Stiffness GPa _at_ 500 sec.
73States Using RAS
74(Justus, September 2004)
75(No Transcript)
76(No Transcript)
77Western States
- California
- Montana
- Texas
- Oregon
78Source Ordorff, March 2005
79Source Ordorff, March 2005
80Source Ayres, April 2003.
81Other States Specificationsand Experiences
82- Georgia
- - Manufacturing and Post Consumer Shingle
- - Mixing Permitted
- -100 passing the ½ inch Sieve
- - Maximum 5.0 RAS permitted
- - Gradation - meet requirements of Mix
Design -
-
- - No foreign material ( paper, roofing nails,
wood, and metal flashing) - - Free of Asbestos when tested with Polarized
- Light Microscopy. Test every 1000 Tons
(Justus, September 2004)
83- Manufacturing Shingle Waste Only
- 100 passing the ½ inch Sieve
- Maximum of 5.0 RAS permitted
- Gradation meet the requirements of the mix design
- Performance grade of virgin asphalt binder based
on the properties of the shingle asphalt binder - No limits on deleterious materials or asbestos
(Justus, September 2004)
84- New Jersey
- Manufacturing Shingle Waste Only
- 100 passing the ¾ inch Sieve
- Maximum of 5.0 RAS permitted
- Gradation meet the requirements of the mix design
- No limitations on deleterious materials or
asbestos
(Justus, September 2004)
85- North Carolina
- Manufacturing Shingle Waste Only
- 100 Passing the ½ inch Sieve
- Maximum of 6.0 RAS permitted
- Gradation meet the requirements of the mix design
- No Limitations on the presence of deleterious
materials or asbestos
(Justus, September 2004)
86 Texas DOT
- Texas DOT- State Highway 31 Corsicana,
- Navarro County 1997
- - 2 x 1,000 foot sections post consumer RAS
- - 2 x 1,000 foot sections manufacturing RAS
- - 2 x 4,000 foot sections Control Mixture
- The Mix Design required 5 Post Consumer RAS
and 5 Manufacturing RAS - All three Mixes required 5 Stripping Agent
(Justus, September 2004)
7-2
87Texas DOT Constituents of Roofing Shingles Used
in Test Project
Tear-Off Shingles
Manufacturers Shingles
Asphalt Cement ()
25
22
50
39
Mineral Filler ()
3778
Viscosity of Asphalt _at_ 140F (Poise)
1223
Penetration _at_ 77F
24
37
(Justus, September 2004)
88Texas DOT- Conclusions
- Shingle binder content does not relate to reduced
quantity of virgin binder - Felt appeared to migrate to the surface
- Processed shingles (RAS) did not clump
- Post consumer shingle more difficult to handle
(Justus, September 2004)
89Texas DOT - Conclusions
- Smoothness, stability, moisture susceptibility,
creep indicated similar characteristics among the
three mixes. - 1999 Falling Weight Deflectometer testing showed
performance agreement among the three mixes. - Visual evaluation shows no apparent distress in
any of the mixes. -
-
(Justus, September 2004)
90- Texas (old proposed specification)
- Both Manufacturing and Tear-Off Shingle Waste
permitted - 100 passing the ½ inch Sieve
- Gradation meet the requirements of the mix design
- No Contamination - dirt or other objectionable
materials - No harmful quantities of asbestos when tested
according to EPA guidelines
91New TCEQ Memo
- March 20, 2006
- Manufacturers RAS in HMA approved
- Tear-offs not approved depending on stack testing
results and subsequent review of impacts - Must follow same procedures as RAP into HMA
92Testing and Design Procedures
93American Association of State and Highway
Transportation Officials (AASHT0)
- Recycled asphalt shingles specification and
practice was approved by the Subcommittee on
Materials (SOM) August 2005
94AASHTOSubcommittee on Materials
- THOMAS E. BAKER
- (360) 709-5401 Tumwater, Washington
bakert_at_wsdot.wa.gov
95Review of AASHTO Specification Subcommittee on
Materials (SOM)
- Both manufacturers and tear-offs allowed
- 100 passing the ½ inch Sieve
- Maximum addition rate contractor option
- Gradation and volumetrics must meet the
requirements of the mix design
96AASHTO Specification (continued)
- Addition rates (Section 7)
- If RAS binder if greater than 0.75 percent, the
virgin asphalt binder and RAS binder combination
shall be further evaluated to ensure PG
requirements
97AASHTO Specification (continued)
- Tear-off material composition (Section 5.2)
- May only include asphalt roll roofing, cap
sheets, and shingles (including underlayment). - May not include other roofing debris such as
coal tar epoxy, rubber, or other undesirables
metal, plastic, wood, glass
98List of Roofing Waste Items Included for
RecyclingYES (Include these items)
- Asphalt shingles
- Felt attached to shingles
99List of Roofing Waste Items Excluded for
Recycling NO (Do NOT include)
- Wood
- Metal flashings, gutters, etc
- Nails (best effort)
- Plastic wrap, buckets
- Paper waste
- No other garbage or trash
100Lista de material para techos basura artículo
para reciclar
Si (Incluya) No / Ningun (No incluya)
Repias Madera
Papel del fietro Metal flashings, canales
Clavos
Plastico
Basura de papel
La otra basura
101AASHTO Specification (continued)
- Asbestos levels
- shall be certified to be asbestos free.
(Section 5.2) - (Tear-off shingles are) construction debris and
various state and local regulations may be
applicable to its use. The user of this
specification is advised to contact state and
local transportation departments and
environmental agencies to determine what
additional requirements may be necessary. (Note
2)
102AASHTO Specification (continued)
- Deleterious material maximum limits (Section
8)(material retained on the No. 4 sieve) - Heavy fraction 0.50
- Lightweight fraction 0.05
103Missouri Shingle Spec
- Extrinsic Material Allowance Raised
- 3.0 Total
- 1.5 Wood
104- NCHRP Rpt. 452 Incorporation of RAP in the
- Superpave System
- lt15 RAP, no change in PG Grade
- gt15 RAP, Assess the Effect of RAS
- on the Virgin Binder
-
- The Draft AASHTO specification recommends
- a similar approach.
- lt 5 RAS, no change in PG Grade
- gt 5 RAS, Assess the Effects of RAS on the
- Virgin Binder
-
(Justus, September 2004)
105Design Approach gt5 RAS
- Extract Shingle Binder from RAS
- Determine PG Grade of Shingle Binder
- Evaluate effect of Shingle Binder on Virgin
- Binder
- Use PP28 Volumetric Mix Design for HMA
- Determine Optimum Asphalt Content
(Justus, September 2004)
6-5
106What happens to RAS in Virgin Binder
- RAS binder dissolves into virgin binder
- RAS binder partially dissolves into virgin binder
- RAS binder does not dissolve but acts like an
aggregate particle - RAS binder particle absorbs volatile oils from
virgin binder - Additional virgin binder needed to coat RAS
binder particle
(Justus, September 2004)
107Contribution of RAS Binder to Total Binder in HMA
- Volumetric Mix Design of Control Mix
- - Determine the Optimum Virgin Binder Content
(OVB Control) - Volumetric Mix Design of Mixture with RAS
- -Determine the Optimum Virgin Binder Content
(OVB RAS Mix)
(Justus, September 2004)
6-7
108Determine the Effect of RAS on PG Grade Binder
- NCHRP No. 452 presents
- Mathematical Solution
- Graphical Solution
(Justus, September 2004)
6-8
109Graphical Solution for PG Binder
- Determine performance temperature for RAS binder
- Use monograph to evaluate effect on virgin binder
(Justus, September 2004)
6-9
110Comprehensive Quality Control Plan
- Quality control of supply
- Worker safety and health protection
- Final product quality, storage and handling
- Shingle recycling system design
- Final product sampling and lab testing
111Minnesota DOT
- France Avenue, Bloomington, Mn
- June 2002 Demonstration Project
- Project Characteristics
- 25,000 ADT
- Original Construction in 1963
- Reconstruction in 1989
- Shingle Mix Overlay in 2002
(Justus, September 2004)
112Minnesota DOT
- Overlay Construction Plan
- 550 foot Four Lane Roadway
- Northbound Lane Repaved with 5 Manufacturing
Waste Shingle - Southbound Lane Repaved without Shingle
(Justus, September 2004)
113Minnesota DOT
- Specified Binder PG 58-28
- Control Mix (30 RAP with No Shingles)
- PG 67.6-27.0
- PG 68.1-27.9
- RAS Mix (25 RAP, 5 Shingles)
- PG 66.5-27.9
- PG 67.6-28.4
114Minnesota DOT
- MnDOT Conclusions
- Constructability of RAS Equivalent to
- RAP
- Two Year performance of RAS
- Equivalent to Control
- PG Binder Performance
(Justus, September 2004)
115Mn/DOT Spec
- Maximum 5 manufacturers shingle scrap in HMA
- Considered a type of RAPExample
- 5 shingles 25 RAP 30 max RAP
- QA/QC standards apply(blending charts)
116Mn/DOT Spec on File
- Gradation of RAS
- 100 passing the ¾ sieve, and
- 95 passing the 4 sieve
- Shingles stockpiled separately
- Pre-blending is prohibited
- Crushed recycled shingles introduced with RAP
at same time
117Mn/DOT Spec on File(See SWMCB handouts of
March 4, 2004)
- Certification from
- Manufacturer
- Processor
- Sample for review
- List of pre-approved sources and processors from
MN/DOT
118Asbestos Risk
- Incidence of asbestos is extremely low
- Average content was only
- 0.02 in 1963
- 0.00016 in 1973
- Source NAHB, 1999
119ASRAS Data
- Iowa (1,791 samples), no hits
- Maine (118 samples), no hits
- Mass
- (2,288 composite samples) 11 hits lt 1
- (69 tarpaper samples) 2 lt 5
- (109 ground RAS samples) 2 lt 1
- Florida (287 samples), 2 hits gt 1
Source Paul Ruesch, April 13, 2003.
120ASRAS Data(continued)
- Missouri (6 samples), no hits
- Hawaii (100 samples), 1 hit gt 1
- Minnesota (156 samples), no hits
- Minnesota (50 tarpaper), 1 hit _at_ 2 - 5
- We still want more data!
- (for EPA / CMRA project.)
Original source Paul Ruesch, April 13, 2003.
121DKA / AESFiber Tests
- As part of the RMRC Project
- Environmental Testing of Airborne Particles
atThe Shingle Processing Plant - April 2003
122Summary Highlights
- Risk from asbestos is negligible to non-existent
- Two rounds of sampling for total
- Dust (1999)
- Fibers (2002)
- Common sense and best management practices can
help prevent employee exposure
123Sampling Results
- PEL was not exceeded
- Peak (excursion) levels under standard
- Peak exposure during cleaning
- Worst case total fibers measured at 0.06 fibers
per cubic centimeter (f/cc) of air - Well within asbestos PEL
124Key Conclusions
- Previous waste sampling indicates negligible
asbestos in used asphalt roofing shingles - Asbestos is more likely from commercial roofing
waste, mastic, caulk or felt - Any new exposure to asbestos would be at shingle
recycling (e.g., grinding) operation - Private, residential, shingle family homes are
exempt from NESHAP
125Key Conclusions(continued)
- MN OSHA sampling in 1999 indicated total dust
within PEL standards - AES sampling in 2002 indicated total fibers
within PEL standards - Operators can reduce employee risk to dust and
fiber exposure - Personal respirators are probably NOT necessary
126Information Sources
127Construction Materials Recycling Association
(CMRA)
128EPA Project
- CMRA web pagehttp//www.ShingleRecycling.orgWill
iam Turley, Executive Director(630)
585-7530turley_at_cdrecycling.org - Dan Krivit and Associates(651) 489 -
4990DKrivit_at_bitstream.net
129Equipment Vendors
www.GreenGuardian.com/pdf/shingle_vendors.pdf
130SWMCB Web Site
- http//www.greenguardian.com/business/shinglerecy
cling.asp
131Recent Resources
- April 14, 2003 Forum web page
- RMRC web page
- www.ShingleRecycling.org
- SWMCB web page
- OEA web page
- Mn/DOT RMRC handout packet
132States
- California, Minnesota, North Carolina and Texas
maintain Excellent Web Sites
(Justus, September 2004)
133Trade Groups
- Shingle Recycling- University of Florida -
www.shinglerecycling.org - Asphalt Recycling and Reclaiming
Association-www.memberservices_at_arra.org - Construction Materials Recycling Association-
www.cdrecycling.org
(Justus, September 2004)
134Summary
135Current Trends and Future Growth
- Virgin asphalt is expensive, tipping fees are
rising, improved economics - Applications other than HMA are being developed
- Use of post consumer shingle waste is promising
136National Asphalt Price Trend
Source U.S. Dept. of Labor Bureau of Labor
Statistics
137Shingles Recycling into HMA is a Proven
Technology
- History of experience
- Private operators
- State engineers
- Environmental regulators
- Substantial body of literature
- High quality HMA can be maintained
138Quality Control Savings
- QA/QC critical
- Use in HMA can be very cost effective
- Cheaper alternative to landfilling
- 0.50 to 3.30 per ton of HMA
139Quality Specs Scrap Feedstock and Final
Products
- Free of debris / trash / foreign matter
- Tear-off scrap must be asphalt shingles only
- No nails!
140Certification and Inspection of Shingle Supply
- Clear written spec for acceptable material
- Certify suppliers
- State licensed asbestos inspectors
- Visual screening of all shingle scrap
- Types of shingles
- I.d. non-shingle waste
- I.d., layers, composites, thickness, etc.
Source Paul Ruesch, April 13, 2003.
141Model Sampling Protocol (if required)
- Specified sampling frequency of incoming loads
- Sampling of recycled asphalt shingles (ground /
screened product) - Willingness to certify quality of finished
products
Source Paul Ruesch, April 13, 2003.
142Proposed Tear-Off Supplier Certification Form
- .. We . certify that
- All tear-off shingle scrap came from residential
buildings having four or fewer dwelling units
and - These residential buildings are not regulated
facilities according to state and federal rules
and - The material delivered consists of asphalt
shingles only and contains no known hazardous
material.
143Proposed Tear-Off Processor Certification Form
- .. We . certify that
- All tear-off shingle scrap came from certified
suppliers only (see Supplier Certification
forms) and - The final product contains no known hazardous
material.
144Strategy
- Identify players
- Pre-meeting
- Identify unknowns
- Request demonstration project
Source Paul Ruesch, April 13, 2003.
145Minnesota Approach
- Regulatory status under NESHAP
- Single family shingle scrap only (no commercial
or institutional buildings) - No testing required if certified as free of
asbestos
Source Dan Krivit, Overcoming the Barriers to
Asphalt Shingle Recycling, Environmental White
Paper Report, Mn/DOT, April 2003.
146Key Conclusions
- Proven and documented
- Quality control is essential
- Economics are driving the market
- Manufacturer shingle scrap recycling is here
today and commercialized - Tear-off shingle scrap is under development, but
feasible
147Recommendations
- 1. CONTINUE MARKET DEVELOPMENT
- Cities, counties and states should use alternate
bid language allowing shingles - EPA / CMRA project in progress
- Asbestos statistics
- Best practices guideline documents
- Implementation / Outreach
148Recommendations(Continued)
- 2. MANAGE the asbestos issue
- Restrict supply to private, residential homes
only (per NESHAP) - Tight supply specification
- Certify suppliers (e.g., roofing companies)
- Inspect each load (suggest becoming a licensed
inspector)
149Recommendations(Continued)
- 3. PROTECT employee health and safety
- Develop dust management program
- Develop employee hazard prevention
- Shroud grinder
- Water scrap shingles
- Provide accurate information as part of a full
employee education program
150Recommendations(Continued)
- 4. GUARANTEE YOUR PRODUCT QUALITY
- Asbestos free
- No nails (use multiple magnets)
- ½ - inch minus
- Controlled mix ratios
- Exceed State QA/QC procedures