Germany CD Waste

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STUDY

CONSTRUCTION and DEMOLITION WASTE MANAGEMENT IN GERMANY

Lead Partner TuTech Innovation GmbH

Harburger Schlossstr. 6-12 21079 Hamburg, Germany

Contact persons: Prof. Dr. Walter Leal, Dr. Claudia Schultz, Julia Gottwald

Telephone number: +49 40 76629-6345 Fax number: +49 40 76629-6349

E-mail: [email protected] Website: www.tutech.de

& www.cowam-project.org

Study by ZEBAU GmbH

Simona Weisleder, David Nasseri Grosse Elbstr. 146

22767 Hamburg, Germany Contact person: Simona Weisleder

Telephone number: +49 40 380384-28 Fax number: +49 40 380384-29

E-mail: [email protected] Website: www.zebau.de

This project is financed by the EU-ASIA PRO ECO II B Post-Tsunami PROGRAMME, an initiative to rehabilitate and reconstruct areas affected by the Indian Ocean Tsunami on 26 December 2004.

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CONSTRUCTION and DEMOLITION WASTE MANAGEMENT IN GERMANY CONTENTS

1 OVERVIEW OF CONSTRUCTION WASTE MANAGEMENT IN GERMANY............................... 3 1.1 INSTITUTIONAL FRAMEWORK .............................................................................................................. 4 1.2 REGULATORY FRAMEWORK ................................................................................................................ 5 1.3 RESPONSIBILITIES OF KEY ACTORS AND RELATED ECONOMIC ISSUES ............................................ 7 1.4 QUANTIFICATION OF C&D WASTE IN GERMANY .............................................................................. 11 1.5 RECYCLING, RE-USE AND DISPOSAL OF C&D WASTE IN GERMANY ............................................... 13 1.6 C&D WASTE MANAGEMENT FACT SHEET ....................................................................................... 16

2 OVERVIEW OF CONSTRUCTION WASTE MATERIALS IN GERMANY................................... 20 2.1 MATERIAL FACT SHEET CONCRETE ............................................................................................. 23 2.2 MATERIAL FACT SHEET BRICK ....................................................................................................... 29 2.3 MATERIAL FACT SHEET WOOD....................................................................................................... 32 2.4 MATERIAL FACT SHEET METAL (STEEL)........................................................................................ 37 2.5 MATERIAL FACT SHEET METAL (ALUMINIUM)................................................................................ 40 2.6 MATERIAL FACT SHEET PLASTICS ................................................................................................ 44 2.7 MATERIAL FACT SHEET TILES ........................................................................................................ 48 2.8 MATERIAL FACT SHEET EXCAVATION MATERIAL .................................................................... 49 2.9 MATERIAL FACT SHEET ASBESTOS.............................................................................................. 51 2.10 MATERIAL FACT SHEET MIXED CONSTRUCTION WASTE ....................................................... 54

3 OVERVIEW OF CONSTRUCTION WASTE COMPANIES IN GERMANY................................... 56 3.1 COMPANY FACT SHEET OTTO DÖRNER....................................................................................... 60 3.2 COMPANY FACT SHEET CV-ABBRUCH ............................................................................................ 64 3.3 COMPANY FACT SHEET GOLLAN ................................................................................................... 67 3.4 COMPANY FACT SHEET EHLERT & SÖHNE ...................................................................................... 72 3.5 COMPANY FACT SHEET HME ........................................................................................................... 76

4 CONCLUSIONS........................................................................................................................................ 78 5 SOURCES .................................................................................................................................................. 80 6 ANNEX....................................................................................................................................................... 82

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1 Overview of construction waste management in Germany

Construction and demolition (C&D) waste management in Germany is a mature and well integrated sub industry within the broader German construction market.

In 2002, German construction and demolition activity generated 214 Megatonnes of

waste composed two thirds of excavation material, nearly another third of building and road demolition waste and a smaller fraction of mixed construction site waste. Despite these high numbers, only 15% of this material was disposed of in landfills, while the remaining 85% was recovered and reused in further applications or recycled.

Germany’s high material, energy and labour and waste disposal costs favour the

economics of recovering, reusing and recycling as much C&D waste as possible. Additionally, strong waste management systems have been long required by laws and regulations at all levels of government in order to minimise the impact of C&D waste in the waste stream. More recent versions of these regulations focus on the complete material cycle, working towards a closed loop substance cycle in construction and demolition, known as “Kreislaufwirtschaft”. This combination of regulatory pushes from government and economic pulls from the market have helped Germany establish an effective C&D waste management infrastructure. Furthermore, waste management and abatement practices have been integrated into mainstream architectural and engineering education and practice. Architects and engineers designing and constructing buildings are obliged to consider the entire life cycle of materials, from production, to removal and reuse or recycling, of components they install in buildings.

There is however room for improvement, specifically in increasing the proportion of

material uptake directly by the construction industry, improving demolition and material processing techniques and developing higher value applications of for higher value recovered C&D materials, such as concrete and brick, and diverting them from lower value applications such as soil stabiliser.

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1.1 Institutional Framework

The Federal German Republic is composed of 16 states (Laender) with relatively

broad powers and responsibilities over their regions. Three Laender (Bayern, Sachsen and Thueringen) are considered Freistaaten (Free States) and posess somewhat more autonomy than their counterparts. Another three Laender (Berlin, Hamburg, Bremen) are city-states and combine the identities and responsibilities of a state and a muinicipality. Generally, the Federal level of government establishes laws that the Laendner must implement and administer.

In Germany, the primary responsibility for ensuring the proper treatment of C&D waste

is in the hands of local authorities. Meanwhile, the Laender, are responsible for the implementation and enforcement of regulations meant to achieve C&D waste goals set by higher levels of government, particularly the Federal government of Germany and the EU.

At the EU level, regulation of Construction and Demolition Waste falls under the broader category of waste and is integrated into the broader targets set by legislation in this area of concern. Member states were obligated to adopt the original waste Directive of 1975 and all further amendments to the law. The Sixth Environment Action Programme 2010 is the most recent of EU initiatives to improve implementation of EU legislation in member states and is overseen by the European Commission with the European Environment Agency as a supporting institution. The European Commission itself is responsible for ensuring the compliance of member states with EU legislation.

At the national level, Germany’s Ministry of the Environment, Nature Conservation and

Nuclear Safety, supported by the Federal Environmental Agency, is responsible for the development of legislation on C&D waste. The national level of responsibility includes the provision of technical instructions regarding the disposal of wastes, the setting of targets and goals and transposition of EU Directives. All federal level legislation overrides regional and local legislation when conflicts arise.

At the state level, “Laender” are responsible for the implementation of federal

legislation and establishing more specific extensions waste management legislation. They are responsible for the enforcement of regulations on C&D waste and overseeing the proper operation of waste treatment and disposal facilities.

At the local level, municipalities are responsible for the administration and issuing of

demolition and construction permits that now occasionally include detailed deconstruction plans and detailed recycling specifications of the building’s materials. While local authorities are responsible for arranging the collection, recycling and disposal infrastructure of household waste, commercial waste such as C&D waste is solely the responsibility of the waste’s owners. The local authority ensures this responsibility is met according to federal and state legislation and is responsible for initiating prosecution against offenders. Any commercial use of the processing, recycling and disposal infrastructure operated by the municipality is paid for directly by the user.

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1.2 Regulatory Framework

The disposal of waste is regulated by a multiplicity of laws and regulations as well as

technical regulations on both the European and national levels.

Germany’s first law on waste disposal was enacted in 1972, establishing a change from rubbish tips (most of them unregulated and uncontrolled) to centralised, controlled and regulated landfills.

In 1986 the law for the prevention and disposal of waste was enacted. It outlined for first time the principles for the transition from disposal to waste management. According to this law, the first goal must be the prevention of waste and if prevention is not possible, the composition of waste must be improved in order to permit reuse or recycling.

Generated in 1993, the Technical Instruction for Municipal Waste (DAVA, 1993), based on the former Law on Prevention and Disposal of Waste of 1986, specifies the treatment and disposal of waste and deals with waste streams such as domestic waste and building and demolition waste. The goals of this order are to recycle unavoidable waste, to reduce the toxicity of waste and to ensure that an environment friendly treatment or disposal of waste is maintained. It describes that construction and demolition waste should be collected and prepared for recovery separately at the place of arising. The responsible municipalities should encourage the utilisation of mobile or semi-mobile recovery installations. It also contains requirements concerning the disposal of waste. Fractions which do not meet the requirements set out in the Technical Instruction for Municipal Waste will not be allowed to be landfilled and will have to be treated further.

In October 1996, the Recycling and Waste Management Act was enacted (Gesetz, 1994). This law set principles for the development of waste management towards a closed loop economy. It established a new hierarchy for waste treatment where the avoidance of waste is better than the recycling of waste, but recycling is more preferable to the disposal of waste. The disposal of waste is only permitted when recycling is much more expensive or impossible and the waste is unavoidable. This Act established also the responsibility of the producers for the waste arising from their products.

In order to comply with the objectives of the Act, waste destined for recovery is to be kept and treated separately. Recovery of waste has priority over disposal to the extent that recovery is technically possible and economically reasonable (Art. 5 Krw-/AbfG). Art. 7, 23 and 24 KrW-/AbfG authorises the federal government to enact administrative orders and statutory ordinances, with the aim of enforcing prevention, recovery and to reduce contamination on wastes. The Recycling and Waste Management Act contains supplementary subsidiary regulations, which consist of various ordinances and are shown in table 1.

Table 1: Supplementary regulations of the Recycling and Waste Management Act of

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1996 Source: Schultmann (2001) Ordinances that restructure supervision under waste management law and align it with EU law • Ordinance on the Classification of Waste Requiring Special Supervision (Verordnung,

1996a) • Ordinance on the Classification of Waste for Recovery that Requires Supervision

(Verordnung, 1996b) • Ordinance on the Furnishing or Proof (Verordnung, 1996c) • Ordinance on Licensing of Transport (Verordnung, 1996d) Ordinances that create a basis for further deregulation of supervision • Ordinance on Waste Management Concepts and Waste Life Cycle Analysis (Verordnung,

1996e) • Ordinance on Specialised Waste Management Companies (Verordnung, 1996f) • Directive on the Activities and Approval of Waste Management Partnerships

In 1992 a statutory ordinance was drafted in the context of construction and demolition waste (ZBV, 1992), containing the requirements of waste prevention, recovery and disposal without affecting the quality of the environment. It also contains quantitative targets for waste recovery and recycling with a recycling rate of 60% to be met by 1995.

In 1996 a new draft was launched containing requirements for demolition or deconstruction (ZBV, 1996). The draft requested, among other things, a deconstruction plan enabling a separation of recyclable materials. The draft established that the disposal of recyclable construction and demolition waste should be reduced by 50%, based on 1995 levels, by 2005.

Though these two drafts have not thus far come into force they spawned a Voluntary Agreement (FSBW, 1996) signed in 1996 by several industrial organisations. The Agreement mainly focused on construction and demolition waste management and set out the goal of achieving the targets laid out in the draft ordinances. Table 2 shows the measures included in this agreement.

Table 2: measure related with C&D waste from the Voluntary agreement of 1996 Source: Schultmann (2001) Measures • Information and advisory services to be made available to construction and

demolition companies • R&D about avoidance of construction and demolition waste, separation and

sorting of wastes and recovery measures, quality assurance for recycled materials and promotion of applications for recycled materials.

The Commercial Wastes Ordinance entered into force on 1 January 2003. It

regulates the separation of certain types of waste from commercial enterprises that is suitable for recycling and the construction waste sector. Where mixtures are nevertheless submitted to recycling, they must only contain these specific, recyclable categories of waste and no other waste which could impair recycling. The ordinance also obliges commercial enterprises to keep a residual waste container for wastes destined for disposal; it is assumed that as a general rule, commercial enterprises will also generate non-recyclable waste which must not be mixed together with the recyclable waste and must instead be disposed of separately. (BMU, 2003)

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In March 2003, the Waste Wood Ordinance entered into force. The legal framework of the Ordinance divides waste wood into four categories, according to pollutant type. Certain material or energetic recycling processes are only admissible for individual or multiple waste wood categories. Affected parties are responsible for keeping records and arranging periodic external controls to verify their compliance with these provisions. Because waste wood can always be recycled, either materially or energetically, except contaminated waste wood, which must be thermally treated (incinerated), the dumping of waste wood on landfill sites is prohibited. (BMU, 2003) Listing of Regulations Significant to Waste Management in Germany

AbfAblV – regulation on the environmentally compatible deposit of human settlement wastes AbfKoBiV - regulation on refuse economy concepts and waste balances AbfVerbrG - law on the monitoring and control of the transnational movement of wastes BestueVAbfV - regulation on the usage of waste needing monitoring AltholzV - regulation on requirements regarding removal and usage of mature timber AltoelV - waste oil regulation AVV - regulation on the European waste listing DepV - regulation over dumps and long-term camp EfbV - regulation on specialized disposal enterprises GewAbfV - regulation on the disposal of commercial wastes and of certain building and demolition wastes KrW /AbfG – Act promoting closed substance cycle waste management and ensuring environmentally compatible waste disposal NachwV - regulation on furnishing of proof for recycling and disposal PCBAbfallV - PCB/PCT Waste Ordinance SolidarfAbfV - regulation on the Solidarfonds Institute Waste Recirculation TgV - transportation permission regulation VerpackV 1998 - regulation on avoidance and usage of packing wastes VersatzV - regulation on the storage of waste

1.3 Responsibilities of Key Actors and related Economic Issues

As established by the Recycling and Waste Management Act of 1996, the waste

producer is ultimately responsible for the disposal of any waste they generate. In Germany however all actors in the building material cycle share responsibility in facilitating the feasibility of reducing, recovering and recycling of C&D waste.

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As per § 22 KrW /AbfG construction material manufacturers are responsible for

ensuring that their products are designed in such a way as to reduce wastage (eg: different lengths of floorboards to reduce cutoffs), facilitate recovery after usage, work towards making them recyclable and make them environmentally compatible with post recovery applications.

Building owners, developers and their agents (engineers and architects) are

responsible for integrating a waste management strategy into their construction plan. This includes the use of recyclable building materials. Despite this being a regulatory requirement recyclable buildings provide developers and owners with cost advantages as demolition materials that can not be recycled must be disposed, making them a financial liability rather than a valuable asset.

Demolition contractors have a special multi role responsibility in the C&D waste

management process. They provide invaluable service to building owners by taking over responsibility of recovering, treating, processing and marketing a building’s materials. To accomplish this demolition and recycling contractors must demolish buildings in such a way that material recovery and recycling is made possible. They are bound to do this both by legal considerations as set out in the regulatory requirements for C&D waste management and financial interest. A demolition company is responsible for the marketing of recovered demolition materials and can earn a significant portion of its revenues through the sale of recovered and recycled building materials. Part of the market competitiveness of a demolition company is their ability to offer demolition services at low or no cost (occasionally they will pay the building owner). The company that can extract the highest value possible from demolition wastes will be the most competitive and profitable on the market. This arrangement bodes particularly well for ensuring the recovery of waste as either the building owner or demolitions contractor face large costs if recovered C&D waste is contaminated. Not only does the responsible party lose the sale value of the material but they must also pay for disposal of the contaminated material in a landfill or incinerator.

Voluntary Industry Initiative

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Working Group on Closed Loop Recycling Management in Construction www.arge-kwtb.de The “Working Group on Closed Loop Recycling Management in Construction “ (ARGE KWTB) is an initiative of all trade associations involved in the building process. Its primary objective is to promote and develop a Closed Loop Recycling System in the construction industry. The ARGE KWTB was founded in 1995. In 1996, the organisation made a committed to the government to reduce by 50% the volume of recyclable construction waste disposed in landfills by 2005. This obligation has been met annually since 1996. Performance of the C&D waste and recycling industry are reported every two years to the Federal Ministry of the Environment. For a resource-saving, sustainable closed loop recycling system it is necessary -to avoid construction waste, e.g. by preserving existing building fabric and construction that has been built for a long useful life. -to keep construction waste in the economic cycle, e.g. by maintaining nearly homogeneous division of substances, by recycling methods that allow good future reutilisation of the material and by the adequate use of recycled construction waste. - to reduce the disposal of construction waste to the inevitable minimum and to avoid the disposal of recyclable construction waste.

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Table 3 shows some measures taken in order to influence the management of construction and demolition waste in Germany (Symonds, 1999)

Table 3: Summary of Measures used to Influence the Management of C&DW in Germany Source: Symonds (1999) Measure Comments Restrictions or bans on disposal

Mixed or recoverable C&DW may not be landfilled.

Mono landfill (for possible future recovery)

Some, for inert waste and/or soils.

Other environmental or planning controls

Disposal sites tightly controlled, re-use sites less so. Destination of C&DW has to be documented from 1.1.1999. System differs for inert/hazardous wastes.

Taxes (landfill and others) No federal tax or levy. 5 Länder tried to impose levies on waste incineration and disposal generally but this power was overturned in the courts. There are different prices for landfilling according to the hazardousness of the waste.

Subsidies

No direct subsidies.

Positive waste planning measures

There is an obligation to draw up waste management plans. The 1996 Closed Cycle & Waste Act requires recycling where possible and economic.

R&D support Various programmes for contaminated soils, use of recycled materials and selective demolition.

Pilot and demonstration schemes

Some projects including selective demolition projects.

Voluntary Agreements National and local VAs to encourage separation, re-use and recycling.

Education and training Part of VA.

Advisory services Part of VA.

Waste exchanges National and regional Internet-based exchange schemes for inert materials.

Other measures Return systems for PVC products.

Most effective measure(s) Combination of measures.

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1.4 Quantification of C&D Waste in Germany

During 2002 and 2003, Germany generated 381.3 and 366.4 million tons (Mt) of

waste respectively. From these amounts, construction and demolition waste (C&DW) represented 63.2% in 2002 and 61.0% in 2003.

Slag from mining (non hazardous

waste)45,46111.9%

Production and industrial

wastes42,21811.1%

Construction and

demolition wastes (incl.

road demolition

waste)240,81263.2%

M unicipal waste52,77213.8%

Municipal waste49,62213.5%Slag from

mining (non hazardous

waste)46,68912.7%

Production and

industrial wastes46,71212.7%

Construction and

demolition wastes (incl.

road demolition

waste)223,38961 0%

Figure 1: Generation of waste in Germany, in 1000t (2002) Source: Destatis (2005)

Figure 2: Generation of waste in Germany, in 1000t (2003) Source: Destatis (2005)

The total generation of C&DW in 2002 was 240.8 Mt (see figure 1). From this amount, 230.9 Mt (95.9%) were non-hazardous waste and 142.0 Mt (59.0%) corresponded to excavated material

. In 2003, the total generation of C&DW in Germany was 223.4 Mt (see figure 2).

From this amount, 213.7 Mt (95.7%) were non-hazardous waste and 130.3 Mt (61.0%) corresponded to excavated material. Deeper analyses of the constitution of C&DW for 2003 are still not available.

According to the report generated by the Arbeitsgemeinschaft Kreislaufwirtschaftsträger Bau (KWTBau, 2005), the total amount of C&DW generated in 2002 was 213.9 Mt. From this amount, the main part corresponded to excavation material (65.9%), followed by building demolition waste (24.3%), road demolition waste (7.8%) and construction site waste (2.0%)

According to the Federal Statistical Office, from the total amount of C&D waste generated in 2002, the percentage of recycling was 85.6%. In 2003 this value reached 86.2% (see figure 4).

Road demolition

waste16,67,8%

Building demolition

waste52,1

24,4%

Construction site waste

4,32,0%

Excavated material

140,965,9%

Figure 3: Composition of C&D waste in Germany, in Mt (2002) Source: KWTBau (2005)

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34.736 30.763

206.076 192.626

0

50.000

100.000

150.000

200.000

250.000

300.000

2002 2003

x 10

00t

Recycling

Disposal

Figure 4: Handling of C&D waste in Germany, 2002-2003. Source: Destatis (2005b; 2005c)

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1.5 Recycling, re-use and disposal of C&D Waste in Germany

Of the total amount of C&D waste generated in 2002, the percentage of recycling

was 85.6%. In 2003 this value reached 86.2% (see figure 4). Table 4 and figures 5 and 6 present the specific treatments applied to C&D waste in 2002 and 2003. Table 4 and figures 5 and 6 present the specific treatments applied to C&D waste in 2002 and 2003.

Table 4: Amount and treatment of C&D waste in Germany, 2002-2003 Source: Destatis (2005b; 2005c)

2002 2003 Treatment Tons (x

1000) % Tons (x

1000) %

Total (including road demolition waste)

240,812

100

223,389

100

Disposal 34,736 14.4 30,763 13.8 Landfilled 30,741 26,878 Incinerated 410 497 Treated 3,585 3,388

Recycled 206,076 85.6 192,626 86.2 Thermal 162 142 Material 205,914 192,484

M aterial recycling205.91485,5%

Incinerated410

0,2%

Treated3.5851,5%

Thermal recycling

1620,1%

Landfilled30.74112,8%

M aterial recycling192.48486,2%

Incinerated4970,2%

Thermal recycling

1420,1%

Treated3.3881,5%

Landfilled26.87812,0%

Figure 5: Treatment of C&D waste in Germany, in 1000t (2002) Source: Destatis (2005)

Figure 6: Treatment of C&D waste in Germany, in 1000t (2003) Source: Destatis (2005)

The Arbeitsgemeinschaft Kreislaufwirtschaftsträger Bau (KWTBau, 2005) estimates the amount of C&W generated in 2002 in 213.9 Mt (see table 6).

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Table 5: Composition of C&W in Germany (2002) Source: KWTBau (2005) Origin Amount

(million tones) %

Road demolition waste 16.6 7.8 Building demolition waste 52.1 24.3 Construction site waste 4.3 2.0 Excavated material 140.9 65.9 Total 213.9 100

According to the KWTBau (2005), the 73.0 Mt of generated C&D waste excluding

excavated material, generated 51.1 Mt of recycled material, representing a 70% rate of recovery.

From these 51.1 Mt of recycled construction materials, 18.0 Mt (35.2%) were treated in 639 stationary plants. The other 33.1 Mt (64.8 %) were treated in mobile/semi-mobile plants, the number of which cannot be established due to the possible double-use of the plants in different locations. Data from Destatis (2004b) indicates that the total number of operators of plants is 2,011.

In the case of building demolition waste, KWTBau (2005) determined that from the 52.1 Mt corresponding to this item, 35.7 Mt were recycled representing a 68.5% recycling-rate. 7.0 Mt (13.4%) were used in mining installations and 3.8 Mt (7.3%) were directly used by public authorities. 1.6 Mt (3.1%) were used for landfill construction and 4.0 Mt were landfilled. (Figure 7)

From the 16.6 Mt of road demolition waste generated in 2002, 14.2 Mt (85.5%) were recycled (KWTBau, 2005). 1.7 Mt (10.2%) were used by public authorities, 0.3 Mt (1,9%) were used in mining installations, 0.1 Mt (0.6%) were used in landfill installations and 0.3 Mt were landfilled. (Figure 8)

Figure 7: Treatment given to building demolition Waste (2002) Source: KWTBau (2005)

Figure 8: Treatment given to road demolition waste (2002) Source: KWTBau (2005)

According to KWTBau (2005), from the 4.3 Mt of construction site waste, 2.3 Mt

(53.5%) were landfilled, 1.2 Mt (27.9%) were recycled and 0.8 Mt (18.6%) were used in superficial applications. (Figure 9)

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Excavation material represents the bigger amount of C&D waste generated in Germany in 2002 with 140.9 Mt. From these amount (see figure 10), 74.4 Mt (52.8%) was used in mining installations, 35.8 Mt (25.4%) were used by public authorities, 6.1 Mt (4.3%) were recycled, 3,6 Mt (2.6%) were used in landfills and 21.0 Mt were landfilled. (KWTBau, 2005)

Figure 9: Treatment given to construction site waste (2002) Source: KWBau (2005)

Figure 10: Treatment given to excavation material (2002) Source: KWTBau (2005)

Application of Recycled C&D Waste

Germany’s annual raw construction material demand is far higher than the annual amount of recycled building material, implying that all recycled C&D material can potentially be absorbed by the construction industry alone. This is not however the case and it appears that a major reason is that engineers and architects have not been able to specify recycled material without assurances that it will perform equivalent to new materials.

Much progress, however, has been made in this regard, particularly in terms of

setting and verifying engineering standards for recycled building material, particularly for use in higher value applications. While applications such as road construction are valid and cost effective for many C&D materials they imply a downcycling aspect, for example, from structural components such as brick and concrete, to road base crush.

The German Institute for Quality Assurance and Marking operates a certification

program for C&D material allowing recyclers to market their materials with the confidence that they are suitable for a particular application. Likewise a builder or material specifier (architect or engineer) may compare new materials with certified recycled materials, and take better advantage of the cost savings and ecological benefits inherent in recycled material.

Germany has elaborated several regulations and indications determining standards

for recycling materials in order to utilize them and make them an alternative to new materials. Most of them are used in road construction. Some guidelines for the use of recycled mineral materials in Germany are shown in table 6.

Table 6: measure related with C&D waste from the Voluntary agreement of 1996

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Source: Schultmann (2001) Area of Application Regulation Application General use of mineral recycling materials

Technical Specifications of LAGA

Requirements for the recycling of mineral wastes

Road construction with recycling materials

RAL-RG 501/1

Quality assessment for recycled materials in road construction

TL Min-StB 2000 Technical delivery conditions for mineral materials in road construction

TL RC ToB-StB 1995 Supplementary technical delivery conditions for recycled mineral materials in road construction

Concrete with recycled aggregates

German Board for Steel and Concrete Code for „Concrete with Recycled Aggregate“

Guideline for concrete with recycled aggregates 1998

DIN 4226-100 Recycled aggregates for concrete and mortar

DIN 4226 Aggregates for concrete

DIN 1045 Concrete and reinforced concrete: dimensioning

1.6 C&D Waste Management Fact Sheet

Regulations Legislative Framework

Timeline:

- 1972 First Law on Waste Disposal o Controlled disposal and introduced prevention and separation

concepts - 1986 Prevention and Disposal of Waste

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o Introduced waste management principles and recycling - 1993 Technical Instructions for Municipal Waste

o Specified requirements for of treatment, recycling and disposal of waste

o Set goals to reduce toxicity, enable recycling - 1996 Recycling and Waste Management Act

o Introduced producer responsibility, closed material cycle concept, waste treatment hierarchy (avoid, reduce, reuse, recycle, dispose)

o Increased powers of enforcement - 2003 Commercial Waste Ordinance

o Makes separation of wastes from commercial enterprise a legal requirement

- 2003 Waste Wood Ordinance o Requires the recycling or energetic usage of old wood and

prohibits further landfilling o Regulates the owners of mature wood (eg: old houses, barns

etc.) - 2003 Act for Promoting Closed Substance Cycle Waste Management

and Ensuring Environmentally Compatible Waste Disposal o

Implementation All above legislation is fully implemented and enforceable

List of Regulations:

See page 6

Responsibilities Roles of key actors Municipalities - Administration of C&D permits

- Enforcement of C&D permits - Verification of compliance

Waste Companies

- Demolition/deconstruction/dismantling of buildings - Collection of waste - Segregation of recyclable and non recyclable materials - Sorting of Recyclables - Disposal - Recycling - Marketing and sales of material

Construction Companies

- Use of recyclable and recoverable materials - Avoidance of unnecessary material waste - Separation of process wastes

Manufacturers - Must facilitate recycling in product design

- Maintain the material homogeneity of products insofar as possible

Investor/ House Owner

- Financial liability for their C&D waste - Must dispose themselves or contract out the responsibility

Market

Economic Flows Who pays whom for what...

The owner of a given material is ultimately liable for the cost of disposal of that material. Demolition and recycling firms are often contracted to take over responsibility for a material and in doing so, often buy the material from the owner. They then process and market it. All disposal costs are born by the C&D contractor or its clients.

Economic Impact Dimension of waste market or construction

According to the environmental statistics of the year 2002 the volume of construction waste and demolition waste amounted to 213,9 million tons. Total German recycling industry:

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material market 2004 Turnover = 4.94 Billion euro Employees: 2000 – 13375, 2001 – 18482, 2002 - 15685, 2003 – 15103, 2004 – 17053 (Eurostat 2006) Material cost savings by use of recycled material are estimated to have contributed 3.7 billion Euros to Germany’s GDP in 2005. (German Business Institute, Cologne 2005)

Construction and Demolition Waste Composition % of materials

Composition of C&W in Germany (2002) Source: KWTBau (2005) Origin Amount

(million tones) %

Road demolition waste 16.6 7.8 Building demolition waste 52.1 24.3 Construction site waste 4.3 2.0 Excavated material 140.9 65.9 Total 213.9 100

Recycling/ Reuse Ratio performance% and main focus of recycling efforts

34.736 30.763

206.076 192.626

0

50.000

100.000

150.000

200.000

250.000

300.000

2002 2003

x 10

00t

Recycling

Disposal

Total recycling ratio (2002/2003) Source: KWTBau (2005)

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Demolition waste (2002) Road demolition waste (2002)

Construction site waste (2002) Excavation waste (2002)

Main Technologies

C&D materials are processed by a number of means and techniques. Excavators are flexible multirole tool that is also widely used along with a wide variety of task specific attachments used to methodically dismantle buildings and process material onsite. These include:

- Crushing jaws - Jackhammers - Saws - Debris buckets - Metal shears

Onsite and in plant sorting and processing of C&D waste is a vital step in the recycling process. This is accomplished both manually and by way of both mobile and stationary machines:

- Manual sorting lines - Shredders - Crushers - Aggregate sifters - Water Based Density separators - Magnetic separators - Eddy current separators - Air blower separators

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2 Overview of construction waste materials in Germany

Of Germany’s annual total C&D waste stream, materials resulting directly from

demolition and construction site waste account for only about a quarter of the annual total. These materials are however, both of higher value and more difficult to recover and process for reuse. Road demolition waste can often be reused onsite or for other roadwork but it may also be used to as site recovery backfill in mining, gavel and sand pits. Such usage is normally reserved for excavation material. The only requirement before such usage of C&D waste is ensuring the environmental inertness of the material and treating it if necessary. Recovering and recycling of building specific C&D waste involves separating materials from each other during or after demolition/deconstruction and processing each according to their specific properties and potential uses. Statistical data on the Germany wide material composition of C&D waste is unfortunately not available. Some regional studies, however, can serve as relevant examples.

A study by the French-German Institute for Environmental Research conducted in the Upper-Rhine Region and a study by the Hamburg Urban Development, Environment and Waste Authority of compiled statistics from Hamburg and Schleswig Holstein reveal the following breakdowns of C&D waste:

Bricks and Stones50.2%

Gypsum and Mortar9.2%

Plastics0.6%

Concrete25.5%

Wood13.4%

Steel0.9%

Metals0.2%

Concrete, Brick, Tile and Ceramic,

59.1%

,

Wood, 2.5%

Metal and Plastics , 2.4%

Tar free bitumen mixes, 17.7%

Mixed building and demolition waste ,

17.7%

Gypsum contaminated waste , 0.6%

Figure 11: Composition of building demolition material, Upper-Rhine Region

Figure 12: Composition of building demolition material, Hamburg and Schleswig-Holstein

In both studies, concrete, bricks and rubble resulting from either or other materials are the most common material by far. The mixed results of other materials may be due to the different measuring techniques, samples and regional differences in construction methods but highlights the requirement for standard classification of materials in order to avoid confusion among actors in the C&D waste recycling industry.

Germany has adopted the EU’s waste classification system into law and classifies all types and varieties of C&D wastes as shown below.

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EU Waste Catalogue (Regulated Waste Listing) [17 BUILDING AND DEMOLITION WASTES (INCLUDING EXCAVATION OF CONTAMINATED LOCATIONS) 17 01 concrete, brick, tiles and ceramic(s) 17 01 01 Concrete 17 01 02 Bricks 17 01 03 Tiles, bricks and ceramic(s) 17 01 06 * Mixtures of, or fractions of concrete, bricks, tiles and ceramic(s), containing dangerous material 17 01 07 Mixtures of concrete, bricks, tiles and ceramic(s) with exception of those that fall under 17 01 06 17 02 Wood, Glass and Plastic 17 02 01 Wood 17 02 02 Glass 17 02 03 Plastic 17 02 04 * Glass, plastic and wood contaminated by dangerous materials 17 03 Bitumen mixtures, Coaltar and Tar containing products 17 03 01 * Coal tar contaminated bitumen mixtures 17 03 02 Bitumen mixtures with exception of those under 17 03 01 17 03 03 * Coal tar and tar containing products 17 04 Metals (including alloys) 17 04 01 Copper, bronze, brass 17 04 02 Aluminum 17 04 03 Lead 17 04 04 Zinc 17 04 05 Iron and steel 17 04 06 Tin 17 04 07 Mixed metals 17 04 09 * Metal waste contaminated by dangerous materials 17 04 10 * Cables contaminated by oil, coal tar or other dangerous materials 17 04 11 Cables with exception of those, under 17 04 10 17 05 Soil (including excavation of contaminated locations), stones and waste 17 05 03 * Soil and stones containing dangerous materials 17 05 04 Soil and stones with exception that covered by 17 05 03 17 05 05 * Waste containing dangerous materials 17 05 06 Waste with exception of that under 17 05 05 17 05 07 * Track ballasts containing dangerous materials 17 05 08 Track ballasts with exception of that under 17 05 07 17 06 Damming material and asbestos contaminated building materials 17 06 01 *Damming material containing asbestos 17 06 03 *Other damming material, which consists 17 06 04 Damming material with exception of those under 17 06 01 and 17 06 03 17 06 05 *Asbestos contaminated building materials 17 08 Gypsum based building materials 17 08 01 * Gypsum based material contaminated by dangerous materials 17 08 02 Gypsum based building materials with exception of those under 17 08 01 17 09 Other building and demolition wastes 17 09 01 * Building and demolition wastes containing mercury 17 09 02 * Building and demolition wastes containing PCB (e.g. PCB contaminated sealants, PCB contaminated floor mats on resin base, PCB contaminated insulating glazings, PCB contaminated condensers) 17 09 03 *Other building and demolition wastes (including mixed wastes), the dangerous materials contained 17 09 04 Mixed building and demolition wastes with exception of those falling under 17 09 01, 17 09 02 and 17 09 03 (* denotes waste requiring special examination or monitoring)

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The methods for recycling each of these materials is crucial to the economic and

practical feasibility of recovering them in the first place. Wood is widely sought after by recyclers due to its wide use in energy generation. Germany boasts widespread adoption of wood based electricity and heat generation from the residential to industrial and utility scale. Other materials, like metals, have established worldwide markets for recycling while others, like recovered concrete have limited and often local markets, for example in road construction.

In order to insure the substitutability of recycled materials for new materials, a quality assurance system has been established in Germany. The Laendersarbeitgemeinschaft Abfall (LAGA) has established strict codes to which recycled material must conform in order to be reused in further applications. These codes give recyclers and contractors clear indications about what can and can not be done with a particular material, also facilitating effective estimation of a C&D waste value or cost.

Quality assurance of course involves more than simply publishing specifications.

Each load of material must be inspected and certified by a third party in order to be considered of sufficient quality for use in applications like road construction, new concrete or even backfill. This certification of material is carried out by RAL, the German Institute for Quality Assurance and Labelling. They can verify that a material conforms to the standards set by either LAGA or the more established DIN (Deutsches Institut fuer Normung) for use in a particular class of applications and apply the appropriate label. In this way, recyclers can sell their product to customers as equivalent to new material.

Equivalence to virgin materials is likely the most important factor in assuring

useability of recycled C&D materials. Achieving such material quality is highly dependant upon the unique challenges and obstacles presented by each material in the C&D waste stream. A solid understanding of these material properties is crucial to effective recycling.

The following Factsheets describe the unique contexts and properties of each

significant material in the waste stream, as well as the post recycling uses, both real and potential.

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2.1 Material Fact Sheet CONCRETE

Material CONCRETE

Normal concrete as per DIN 1045, steel reinforced concrete, concrete brick, waste concrete Concrete is produced from cement (binder), aggregate, water and additives, when required. It is cast on site in shuttering, or as blocks or concrete elements. With few exceptions, the products are reinforced. Cement-based products Foamed concrete It consists of Portland cement and fine sand in proportions of about half and half. Foamed concrete is seldom use in building construction because its relatively low thermal insulation and low load-bearing capacity. The environmental aspects of this concrete are the same as in situ concrete. Aerated concrete Aerated concrete is produced by reacting finely powdered quartz (about 50 percent by weight) with lime, gypsum and cement. A yeast constituent such as aluminium powder is added to a proportion of about 0.1 percent. Aerated concrete is the only commercial pure mineral block with good structural properties and a high thermal insulation value. (Ayres, 1999) Aerated concrete can be considered inert and problem free as waste. Both prefabricated units and the blocks can be re-used, depending upon how they were laid and the mortar used. Crushed aerated concrete can be used as insulating granules for road building, and also as aggregate in lime sandstone, different light mortars and light concretes. Concrete with light aggregate This is usually produced as blocks, slabs or floor beam units, which are relatively strong. There is a difference between products that have an organic and a mineral aggregate. Mineral insulating aggregate in concrete can be light expanded clay, pumice, fossil meal and exfoliated vermiculite, perlite or slag (Berge, 2000). Sawdust and chopped straw can be used as organic constituents in concrete. Raw materials for concrete

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with light aggregate are widely available.

Origin Concrete is the primary material for larger buildings in foundations, retaining walls, walls, roofs and floor construction. It is also used as pavement on roads.

REUSE Some concrete can be reused with little processing:

a) Pre Fabricated elements

b) Concrete Block (once cleaned of mortar and finishes)

Ways of collection Collection of prefabricated sections and blocks requires

careful dismantling of a building. This may be time consuming but, if the material costs saving are high enough, well worth it. Different techniques are possible but all must avoid damaging the material as this will prevent reuse.

Ways of sorting Reuse Some concrete components can be reused with little

processing: c) Pre Fabricated elements d) Concrete Block (once cleaned of mortar and

finishes)

Technologies Concrete saws, grinders, lifts Market

The market for recycled concrete is primarily in road construction as underlays and drainage material. Ideally, recycled concrete could be used as aggregate in new concrete and some progress has been made towards the normalisation of this process. Challenges do however still exist and so long as virgin material prices are competitive recycled concrete will remain primarily dependant on the road construction market.

RECYCLING The value of in-situ concrete in terms of recycling is low (Berge, 2000). It can be crushed and ground to aggregate. The majority of it has to be sorted and used as fill. Road base and construction fill Crushed concrete can be used as base fill in the construction of roads. The crushed material is used in place of lime rock. The benefits of such reuse are often

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dictated by the local availability of lime rock deposits, as hauling costs are substantial. The purity (i.e. presence of wood, dirt, other contamination) of the material may also be an issue. Crushed concrete may also be used as primary road surface material on unpaved roads in rural areas. The use of crushed concrete for driveways can also be practiced. The limitation for this use comes from the crushing of the material, which should be ideally made on site to avoid hauling costs. Aggregate in concrete Crushed concrete has been proposed for use as aggregate in the manufacture of new concrete. According to Townsend (1999), the addition of crushed concrete fines has been used, but the quality does not always meet the same results as when using clean sand and rock aggregate. Drainage material Crushed concrete that has been well screened of fine particles provides similar drainage characteristics as new rock or gravel. It can be used for drainage applications in construction. Other possibilities include septic drain fields and landfill leachate collection systems. Crushed concrete does raise the pH of water in contact with it, so care must be taken if this presents a concern with regard to water quality (i.e. impact on a surface water or groundwater supply).

Ways of collection Recovered from concrete demolition sites unprocessed or preferably, pre crushed by excavator breaker or mobile crushing machine. Reduced volume of concrete allows for fewer loads and lower transport costs.

Ways of sorting Example of central sorting plant process

Source: www.uni-weimar.de/Bauing/db/html/RCMW.htm Jackhammering and crushing in-situ, separation from

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steel components manually and by crusher and magnetic separation.

Recycling Process 1. Reduced by crusher and sorted by kernel size 2. Removal of metals by magnet 3. Used concrete as fill material, gravel substitute,

stabilising material 4. Reinforcing steel as scrap for steel production

Technologies For Example: Concrete crusher “RUBBLEMASTER” “RM60 - The FLEXIBLE ENTRANCE MODEL the crane-lift mobile RM60 produces 80 tonnes/h of granular material from

building debris, bitumen or concrete. In only ten minutes it is entirely operational. Supplementary pre- and post sorting modules can be integrated for a complete recycling system.” Roller screens The Minerals roller screens are used to separate on-size particles from the oversize and undersize fractions. Wobbler feeders/scalpers The unique action of a wobbler feeder provides feeding and scalping of materials in a single machine. Even wet, sticky materials can often be handled due to the specially designed self-cleaning, non-clogging elliptical bars. Wobbler feeders operate with low horsepower and headroom requirements, and without vibration, noise or transmitted stresses,

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making them ideal for both stationary and portable applications.

Market/Products

RC-Frostprotection material 0/32 Base/Filter layer under surface or between foundation slabs

RC Concrete - SPLITT 0-8 Selfhardening Paving

RC Concrete - SPLITT 8-16 Reinforcing of road and walkways, loose top coat

RC Concrete - SCHOTTER 16/32 Drainage layer and basement wall protection

Price per unit (if available)

Example: GOLLAN Recycled Concrete 9,90 €/t

Regulations Landfilling of waste concrete is forbidden in Germany Reuse is regulated by DIN and LAGA specifications

Cross references to companies

www.doerner.de www.cv-abbruch.de www.gollan.de

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www.ehlert-soehne.de www.buhck-hamburg.de www.baureka.de/Leistungsverzeichnis/ www.b-i-m.de/struktur

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2.2 Material Fact Sheet BRICK

Material BRICK Origin DIN 106 Standard Bricks

Clay, sand and light mineral materials are wet mixed, formed, and kiln fired

REUSE Bricks can also be re-used as bricks directly. The

greatest impediment to this reuse is the time taken to sort and clean suitable bricks.

Ways of collection Manual dismantling, cleaning and stacking Ways of sorting Manual in-situ Reuse Cleaning and separation from mortar Technologies Saws, grinders, mortar grinders Market Mainly care and restoration of monument class

buildings Price per unit (if available)

N/A

RECYCLING

Ways of collection Brick rubble is lifted by sieve shovels with excavators,

thus partial sorting is possible during collection. Ways of sorting Rubble bucket lifting, sieving, magnetic separation

Also see same section in “Concrete”

Recycling Process Crushing and sorting according to kernel size, separation from metal components

Technologies Breakers and Crushers identical to those used for concrete

Market/Products Road base and construction fill Crushed brick can be used as base fill in the construction of roads. The crushed material is used in place of lime rock. The benefits of such reuse are often dictated by the local availability of lime rock deposits, as hauling costs are substantial. The purity (i.e. presence of wood, dirt, other contamination) of the material may also be an issue. Crushed brick may also be used as primary road

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surface material on unpaved roads in rural areas. Clean, crushed brick as sports field lining and lightweight concrete addition and, with portions of flashes, mortars and ceramic, as crushed stone replacement or low density concrete aggregate.

RC-Rubble 0/32 Underlayer or Filter layer for foundations

RC-Rubble 32/56 Top layer for path and public space surfaces

RC-Rubble 0/X Mechanical Soil stabiliser



www.doerner.de www.cv-abbruch.de www.gollan.de www.ehlert-soehne.de www.buhck-hamburg.de http://www.baureka.de/Leistungsverzeichnis/

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2.3 Material Fact Sheet WOOD

Material WOOD, TIMBER Origin Timber has been the main structural and covering material in

the county all over the world. In the case of roof construction, its lightweight and structural properties have made it more attractive than any other alternative. Timber can be used to cover roofs as shakes, shingles or planks. As cladding it can be used as panelling or wattle, and as flooring it can be used as boards, parquet tiles or timber sets. The sheeting is produced as fiberboard, cork, chipboard or veneer.

REUSE Considerable quantities of reusable timber can be recovered

during the demolition of old buildings. Older buildings can have valuable timbers which were prevalent in the past but which are now quite rare. Demolition of older or unique structures can also yield materials such as wooden fixtures, moldings, and framings in addition to structural timber, which can be resold, reused or re-milled.

Ways of collection Collection of wood for direct reuse is largely done manually, with the aid of powered hand tools

Ways of sorting Reuseable wood is sorted by type, size and quality Reuse a) Direct use when free of pollutants

b) Removal of nails and foreign objects, planing, surface treatment

Technologies Saws, hand tools, planers, sanders Market

Woodworking Larger pieces of the highest quality recovered wood, such as barn boards and structural timbers can be used intact. They are largely used by the woodworking industry as raw material for furniture, flooring and specialty items.


RECYCLING

Ways of collection Wood to be recycled can be collected alone from a site or

mixed with other C&D wastes. If the material quantity is large, in-situ shredding can help reduce transportation costs.

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Ways of sorting

Recovered wood is sorted by material quality, degree of contamination, size and type. Further sorting is carried out according to intended processing.

Recycling Process 1. Wood is collected onsite with or without foreign materials.

2. Sorting is done by hand and machine

3. Wood is shredded, sometimes onsite and sometimes with foreign matter

4. Further separation, like air blower and magnetic is performed on shredded material

5. Shredded wood is marketed

Technologies Shredders Single-Shaft-Shredder

The high performance shredders from Weima’s Jumbo/Super Jumbo range of machines are specially designed for the wood processing and wood recycling industries where very large quantities of wood are shredded. The rotors, depending on the model type, are 1000 mm to 3000 mm long. This extremely high shredding capacity is guaranteed by rotors which have a diameter of 482 mm (Jumbo) and 600 mm (Super Jumbo).

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Powerline

Extremely high output rates, highly economical The Powerline shredder series are designed specially for the production of substitute fuels (RDF) and offer a wide variety of innovative equipment and ancillaries. A high output rate for all types of materials such as industrial, household and bulk waste, mixed construction site waste, production rejects, timber, paper, paper rejects etc. guarantees a maximum rate of productivity. Low power consumption and low wear costs are the basis for the Powerline's economic efficiency.

Single shaft shredder The single shaft shredders of the newPowerline series were developed from the basis of installation experience and are designed specifically for the production of substitute fuels. Along with the material to be shredded, the throughput rate and material size range determines the individual specification of the machine. More than 40 different machine options are available.

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Knife system The knife bearers are screwed or welded onto the rotor depending on requirements. The multi-turn and regrindable rotor knives, as well as the newly developed stator knife system guarantee a considerable reduction in wear costs. A durable hydraulic drive system is available for highly contaminated feedstock. The electro-mechanical drive with frequency converter guarantees maximum throughput rates for clean and pre-treated materials.

Market/Products Fuel The most common reuse option for wood recovered from C&D recycling is for fuel. Wood has a high heating value and can be used by a number of industries as boiler fuel. Wood for fuel can be chipped or pelletised for better transportation. Wood with minimal soil and other foreign objects, and low moisture content is ideal. The presence of large amounts of treated wood creates air emission control and ash disposal problems. Treated wood should be removed from the recovered wood stream prior to grinding. (Metro, 2002)

Biomass could provide for more than 10% of Germany’s present primary energy consumption needs. Though this goal in far away, operators such as EnBW power stations AG are building and successfully producing heat and electricity from waste wood and biomass. Engineered wood A number of engineered wood products can be produced from chipped wood material. These products include fiberboard, oriented strand board, and particleboard. The wood chips are formed into boards by various pressing methods and adhesives. No foreign materials should be present. Mulch Chipped wood may be used for mulch in horticultural and agricultural applications. The wood should be free of foreign material as much as possible and should contain no treated

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wood. The reuse possibilities of mulch from recovered C&D wood typically revolves around aesthetics. Foreign materials such as nails and plastic greatly limit appeal (MEO, 2004). Animal bedding and compost amendment Two other applications for recovered C&D wood that are sometimes performed because of its moisture absorptive capacity are animal bedding and bulking agent in composting. These uses require a clean wood stream in terms of foreign material. No treated wood should be present (EPA-AU, 2002; Reinhart, 2002).


Wood Pellets: €180.20/tonne (2005) (Solar Promotion GmbH)

Regulations AltholzVO According to Wood Waste Ordinance (AltholzV) Waste wood must be assigned to one of four waste wood categories and one special category: A I: Waste wood in its natural state or only mechanically worked which, during use, was at most insignificantly contaminated with substances harmful to wood (e.g. natural solid wood) A II: Bonded, painted, coated, lacquered or otherwise treated waste wood with no halogenated organic compounds in the coating and no wood preservatives (e.g. interior doors) A III: Waste wood with halogenated organic compounds in the coating, with no wood preservatives, (e.g. PVC-coated furniture) A IV: Waste wood treated with wood preservatives, such as railway sleepers, telephone masts, hop poles, vine poles as well as other waste wood which, due to its contamination, cannot be assigned to waste wood categories A I, A II or A III, with the exception of waste wood containing PCBs

Waste wood containing PCBs: Waste wood which constitutes “waste wood containing PCBs” within the meaning of the “PCB/PCT Waste Ordinance” (a total of more than 50 mg/kg PCB or similar substances) and which is to be disposed of in accordance with the provisions of this Ordinance (e.g. sound insulating board treated with agents containing PCB). This can only be done with the help of thermal waste disposal plants.


www.doerner.de http://www.hrg-mbh.de/hhr/ http://www.holz-recycling.de/

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2.4 Material Fact Sheet METAL (Steel)

Material METAL (Steel) Origin Steel is the most important structural metal, and is used in all the

structural components of a building, from foundations (usually combined with concrete) to the roof. Steel used in structural cases is often unalloyed. High quality steel is alloyed with small amounts of aluminium and titanium. The resulting material is particularly strong, and means that the amount of material used can be reduced by up to 50 percent (UKSA, 2005). Germany’s annual quantity of scrap steel is approx. 29 million tonnes, 22 million of which are supplied by the steel recycling industry. World-wide about 45% of raw steel production is based on the employment of scrap steel.

Other than steel and iron a number of other metals are encountered, particularly in sheeting applications, and recovered from the C&D waste stream.

REUSE Directly ready for smelting if segregated and free of hazardous

materials Reuse Occasionally used in shredded form in place of gravel fill

Technologies Crusher/scalper/separators for cleaning, magnetic separators, eddy current separators, shredders, electric arc furnaces, oxide furnaces

Market See below Price per unit (if available)

See below

RECYCLING

In 2000, 42 % of German steel was produced from scrap. The foundry industry produced approximately 5.3 million tonnes of cast steel in the same year. According to data the German Foundry Federation this was 88% more scrap utilisation than in the previous

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year. Germany’s foundry industry is highly dependant on scrap metal. Steel is an ideal recycling material as it does not lose quality in process. Greenhouse missions savings associated with steel recycling are significant amount in Germany to 27 million tonnes or 86% over virgin material only. Each tonne of steel scrap used negates the use of 1.5t of iron ore, 0.5t of coal oil and significant savings on transportation. Steel production with scrap steel requires 90% less energy than with virgin materials.

Ways of collection Metals recovered from C&D waste may be directly removed from a building already segregated from other materials. Large sections may be cut or shredded onsite before transport. When collected in conjunction with other materials such as concrete, brick, wood, plastic and others metals must be sorted out from other materials at a central processing site.

Ways of sorting Density Separation Manual separation Magnetic Separation Eddy Current Separation

Recycling Process The steel recycling process involves collecting unalloyed and alloyed scrap, sorting it manually or by magnetic separation, shredding, further sorting of reduced material and marketing it domestically or internationally to foundries. Both collected old scrap and new scrap, from manufacturing, is sorted according to internationally agreed lists, ensuring homogenous high quality materials that, once processed by shears or shredder, can go directly into the furnace for production. In this fashion secondary raw material is interchangeable with primary raw material.

Technologies In Germany two different steel production methods are used, each with different possible levels of scrap steel content. The Oxygen Steelmaking Method (in 2000 approx. 71 % of total production) works with a scrap iron employment between 20 % and 30 %. The Electric Arc Furnace steel production method (approx. 29 % of 2000 production) is capable of employing 100 percent scrap metal in production.

Market/Products Processed or unprocessed scrap steel is sold internationally and provides the raw material for roughly half of the world’s 790 million tonnes of annual steel production

Processed scrap may also be used in place of crushed stone

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Global supply of metal using scrap (Annual Tonnes)

Blue Pig Iron

Violet Electrolytic Iron

Yellow Scrap


Steel Scrap Prices (As of 10.10.2002 * in €/t) West E2/Sorte 2 New steel scrap ca. € 95,00/t - € 110,00/tE3/Sorte 3 Heavier old steel scrap ca. € 90,00/t - € 105,00/t North E2/Sorte 2 New steel scrap ca. € 95,00/t - € 110,00/tE3/Sorte 3 Heavier old steel scrap ca. € 95,00/t - € 112,00/t East Sorte E3/1 New steel scrap ca. € 64,50/t - € 67,00/t E3/Sorte 3 Heavier old steel scrap ca. € 72,00/t - € 74,50/t Southwest E1/Sorte 1 New steel scrap ca. € 60,50/t - € 61,50/t E3/Sorte 3 Heavier old steel scrap ca. € 68,50/t - € 71,50/t South E1/Sorte 1 New steel scrap ca. € 46,00/t - € 51,00/t E3/Sorte 3 Heavier old steel scrap ca. € 64,00/t - € 69,00/t Prices are for material only. All logistics, transport and labour costs must be covered by the buyer or seller.

Regulations Long before the entry into law of the Closed Substance Cycle Waste Management in 1996, the German steel recycling industry was meeting goals set out in the EU’s Agenda 21 initiative. Today, documentation, certification and industry wide quality management systems ensure a high quality of recycled steel material. This allows for even more steel to be recycled, yielding important cost, resource and energy savings.


www.doerner.de www.bdsv.de

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2.5 Material Fact Sheet METAL (Aluminium)

Material METAL (Aluminium) Origin

Aluminium is a metallic material often used in light structures and as roofing or exterior siding material. Its properties and characteristics are not affected even after it has been used in a product. Therefore aluminium can be recycled and re-used, after having undergone adequate treatment and preparation, as often as necessary without any loss in quality. The high value of the metal is maintained through multiple reapplication cycles, guaranteeing sufficient economic incentive for its collection and recycling into a similar or comparable product.

REUSE Direct reuse where appropriate when free of dangerous

materials and damage. Aluminium is rarely however directly reusable as it is often intended for one time use and easily damaged with handling.

Ways of collection N/A Ways of sorting N/A Reuse N/A Technologies N/A Market N/A Price per unit (if available)

N/A

RECYCLING The recovery and recycling of aluminium is carried out by metal

merchants, processors, aluminium refiners and remelters, the latter two groups form the end of the recycling process as producers of casting and wrought alloys. However, the aluminium recycling industry also counts among its members those companies which treat and process salt slags and filter dust, both arising during production. They contribute to the fact that Germany has already largely reached the goal of recovering and recycling aluminium without leaving any residues behind.

Ways of collection

Collection occurs onsite and during post collection of mixed wastes or mixed metal wastes. Aluminum, once reduced by crusher and shredder with mixed waste is one of many metal

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components that can be effectively separated from a mix by eddy current separation.

Ways of sorting Seperation from foreign materials Magnetic separation Eddy Current Seperation (can distinguish alloys and non ferrous metals) Density separation (dry and wet cyclonic) Inspection and removal Seperation in melting

Recycling Process

Collection and recovery Old and new scrap are collected and recovered by the metal trade or the refiners and remelters themselves. Preparation and treatment The scraps recovered are treated according to their quality and characteristics. Common treatment processes are for example sorting, cutting, baling or shredding. Turnings are dried and crushed. Free iron is removed by magnetic separators. Aluminium skimmings, a mixture of aluminium metal and aluminium oxide, are crushed or ground and air separated. Charging As a rule computer controlled selection and mixing of scrap types whose chemical composition is as close as possible to that of the required alloy. Melting Various furnace types are available for melting aluminium scrap. In Germany, scrap for the production of casting alloys is commonly melted in rotary furnaces under a layer of liquid melting salt (flux). Producers of wrought alloys prefer open hearth furnaces in varying designs. Refining The alloy production in rotary furnaces is followed by a refining process. The molten alloy is fed into a holding furnace (converter) and purified through the addition of refining agents. Quality control Every single charge of the furnace is tested in the plants’ laboratories with modern computer controlled analytical technology equipment and, provided that the result is positive, receives a certificate. Casting The molten aluminium is either cast into ingots or transported in liquid form to a foundry. The ingots weigh, depending on the shape of the mould used, between 4 and 25 kg. Liquid aluminium is filled into pre-heated thermos containers and transported to the foundries, where the liquid metal is filled into

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holding furnaces and processed immediately. Homogenising Heat treatment of extrusion billets in special furnaces in order to obtain a metal structure which is appropriate for further processing and to remove residual stress of the casting.

Technologies Shears, Shredders, Magnetic and Eddy Current Separators,

Furnaces, etc. Market/Products Scrap aluminium from product manufacture or at the end of a

product's service life becomes a secondary raw material which has markets world-wide. Primarily two kinds of firms purchase aluminium scrap. Refiner Produces casting alloys and deoxidised aluminium from old and new scrap and supplies them in the shape of ingots and liquid aluminium. Remelter Produces wrought alloys from mainly clean and sorted wrought alloy scrap and supplies them in the shape of rolling slabs, extrusion billets or master alloys. In Germany, the aluminium recycling business provides about 20,000 jobs.

Casting alloys Casting alloy, standardised or produced according to specific customer requirements, are supplied in ingot or liquid form to foundries which cast them into high quality components. Typical applications are cylinder heads, engine blocks or gear boxes in automobiles, components and parts in the mechanical and electrical engineering industries, casings for household equipment etc. Wrought alloys Wrought alloys are predominantly cast directly into extrusion billets and rolling slabs. Typical wrought alloy products are

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semifabricated items in the form of sheet, foils or profiles, which are processed into automobile body parts, commercial vehicle constructions, rail vehicles, doors and windows, packaging, etc. Deoxidised aluminium Deoxidised aluminium consists of alloys with a high share of aluminium (usually exceeding 95 %) in the form of waffle plates consisting of one or more parts, granules or pellets, which are used to remove free oxygen from the liquid steel.

Scale At present, German refiners produce about 626,600 tonnes of casting alloys annually from secondary raw materials. EU annual production is in the range of 2.3 million tonnes. Quantities of aluminum alloys made from secondary raw materials can at present only be estimated, with European production figures being in the range of 3.5 million tonnes (turnaround scrap included).


Varies according to location and material type

Regulations Cross references to companies

www.doerner.de http://www.aluminiumonline.de http://www.aluminium-recycling.com/

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2.6 Material Fact Sheet PLASTICS

Material (Bauteil/Baustoff)

PLASTICS

Origin (Stoffbeschreibung)

REUSE Reusage of plastics is rarely possible and has a very small

market Ways of collection N/A Ways of sorting N/A Reuse N/A Technologies N/A Market N/A Price per unit (if available)

N/A

RECYCLING Separated collected plastic tubes, roof sheets, floor mats and

plastic windows can be frequently well recycled. Ways of collection Plastic tubes or rohrreste can to the plastic tube federation e.V.

be transferred, which operates a country wide collecting and recycling system (www.krv.de). PVC floor mats are collected country widely by the working group PVC floor mat recycling (AgPR) and prepared in recycling plants (www.agpr.de). PVC roof sheets are collected over the working group for PVC roof sheet recycling GmbH in a country wide collecting system with the logistics enterprise Interseroh and spent to recycling plants (www.dud-ev.de). PVC plastic windows, roller-type shutters and doors are collected over a country wide collecting system of the Rewindo GmbH and supplied to the processing in recycling plants (www.rewindo.de).

Ways of sorting Recycling Process

Flooring removal Material Sorting Recycling system

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Shredding Shredded Chips (30mm) The sorted old PVC floor mats are cut up first into chips measuring at the most 30 millimeters. After a magnetic metal separation process, a hammer mill releases the chips from adhering screed and adhesive remainders. Thereupon they are separated in a sieve jigger from these reduced impurities. For following fine grinding the PVC material with liquid nitrogen is cooled on a temperature of minus 40° C. By the cooling the PVC chips briefly embrittled and finely ground into particles with a diameter of no more than 0.4 millimeters.

PVC Particles in Bags

Technologies PVC-Roofing

Recycelt recovers all sorts of plastics sheet roofings. They are separately collected depending upon the application system and physical condition and marked differently. In 2003 the collecting system ROOFCOLLECT was established based on the country wide logistics of INTERSEROH. A fax is sufficient to arrange the collection of one’s roofing materials. Clients pay for the service on a monthly billing basis. The administration expenses were made deliberately small and the required lead time to the scheduled collection time is usually four days. The system functions in

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PVC –Windows, Doors and Shutters

PVC Window Recycling Statistics 2005

PVC Recycling Statistics (Tonnes) Total Recycling potential 21500Recoverable, Available 9675Input 10848Recycled Material 7359Recycling Rate 76%

Market While the market for PVC recycling is still limited and largely driven by regulation, rising energy and material costs are making it a more attractive means of sourcing raw material for PVC manufacturing.


N/A

Regulations Vinyl 2010 – A voluntary initiative of the PVC industry towards sustainable development is a 10 year program with a mid term review of goals in 2005 and a definition of new goals in the year 2010 according to technical progress and the extension of the European Union. A component of the program is a strict monitoring process in the form of certified annual reports.

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• Vinyl 2010 contains the following guidance actions and obligations:

• Adherence to the ECVM Charter regarding emission limit values with the PVCHerstellung;

• Flat for a complete substitution from lead stabilizers to 2015 additionally to the substitution of cadmium stabilizers, valid since March 2001;

• The utilization of 200.000 tons of "post usage PVC wastes" in the year 2010. This goal is added to the 1999 decided utilization quantities for "post usage wastes" as well as for the any utilization of "post usage wastes" in accordance with the requirements of the conversion of the European Union guidelines for packaging wastes, old cars and electrical and electronics old devices for the period after 1999;

• Utilization of 50% of the detectable available PVC wastes of window sections, pipes, armatures and roof foils starting from 2005 as well as of floor coverings starting from 2008;

• A research and a development program for new utilization and recuperation technologies including the raw material utilization and the solvent-based technologies;

• The conversion of one with the European federation the mining industry -, chemistry and energy trade unions (European mine, Chemical and Energy Workers ' Federation - EMCEF) signed social Charter for the development of standards for the social dialogue as well as for training, health protection, security and environmental protection, including a transmission of these standards on the European Union entry countries;

• Partnership with the municipalities within the "Association OF Communes and region for recycling (ACRR)" with the goal of the promotion of best practices as well as of local pilot measures in the area of the utilization. Extension of the European Union contains. A component of the program is beyond that also a strict monitoring process regarding its conversion in the form of certified annual reports.


www.krv.de www.agpr.de www.dud-ev.de www.rewindo.de

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2.7 Material Fact Sheet TILES


TILES


Clay, Sand and Metal oxides are wet formed and kiln fired

REUSE Direct reuse when free of dangerous materials and

damage Ways of collection Requires careful, labour intensive removal Ways of sorting Cleaning and separation from grout and adhesives Reuse Reuseable as tile in further applications Technologies Powered and unpowered hand tools Market Specialty architecture, heritage restoration and

maintenance. The market for intact ceramic is rather small and oriented towards higher end specialty products.


Widely variable

RECYCLING Ways of collection Onsite Ways of sorting Seperation of non frost resistant material, Wobbler

feeders, Sifting Recycling Process Ceramics are crushed, often along with brick and

concrete. The mixtures are then sorted according to kernel size.

Technologies/Products Machines to crush ceramics are practically identical as those used to crush brick and concrete. Crushed ceramic with portions of brick, mortars and stones and concrete may be used as gravel and crushed stone replacement Applications include: noise protection barriers, soil stabilisers, cover material and backfill of excavations

Market Crushed ceramic, in conjunction with brick, concrete and rubble make for useful underlay and drainage material. Similar to brick and concrete the largest market for crushed recycled ceramic tiles (in mixed form) is in road construction.


N/A

Regulations Similar to all regulations for concrete and brick Cross references to companies

See Concrete and Brick

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2.8 Material Fact Sheet EXCAVATION MATERIAL

Material EXCAVATION MATERIAL Origin Arising from the excavation of building foundations,

excavation materials includes both urban soils mixed with old construction wastes and contaminants to virgin soils as may be found in Greenfield construction. Composition may range from organic soils, through to clays, gravels and sands, generally in heterogenous form.

REUSE The primary destination of excavation materials in

reusage as backfill for construction material mines, particularly sand and gravel pits. If the material is free from contaminants that may affect soil or groundwater quality it may be tipped directly into unused pits, aiding in the restoration of these areas to their previous state. It is unlikely that excavation material used as mine backfill will ever be used again. Despite this, the restoration role it is playing is considered to close a loop in the construction material cycle.

Ways of collection Conventional methods: Dig and Haul Ways of sorting Directly reused material is generally unsorted Reuse Backfill Technologies Excavators, Tracked Earth Movers, Trucks Market Primarily for backfill of mining operations Price per unit (if available)

N/A

RECYCLING Recycling of excavation material differs from reuse in

that it involves treatment of the material in order to make it conform to a specific use. Such processes include contaminated excavation material that must be treated in order to eliminate the contamination. Wiedereinbau bei Baumaßnahmen, ggf. vorherige Sichtung und Absieben von Steinen

Kontaminierte Böden: Wäsche oder mikrobiologische Dekontaminierung, danach Einbau

sonst: Deponie

Ways of collection Haulage from site Ways of sorting Material without dangerous materials may be sifted

and filtered in order to remove stones, rocks and

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building material waste. Contamination with hazardous materials requires, washing, biological or thermal decontamination.

Recycling Process Sorting is sufficient for most material in order to make it reuseable for a specific task. This may be done in-situ or in a central plant

Technologies Sifters, Filtering machines, Magnetic separators

Market/Products Recycled excavation material is primarily used in backfill operations, however, specific types with particular treatments can also be used in road construction and other higher value applications, generally as fill and base material.

BOMIX ® Reprepared soil, stable fill material, road construction fill, and gravel/sand pit backfill


N/A

Regulations Simple disposal is forbidden Cross references to companies

http://www.baureka.de/Leistungsverzeichnis/

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2.9 Material Fact Sheet ASBESTOS

Material ASBESTOS Origin Asbestos is the name for a group of naturally

occurring, fibrous minerals. White asbestos (Chrysotil) and blue asbestos (Krokydolith) were most frequently used. Since asbestos is extraordinarily heatproof and very chemically stable, it was used for the production of various products. It was applied in two forms. Firm fiber (non-friable) connection asbestos was used in cement products, pipes, and other building materials. It was also widely used in brake linings. Such materials are stable and present fewer risks. Weak fiber connection (friable) asbestos was often in the form of asbestos sprayed on as fire protection. It was also however used in asbestos boards, precast plates, electric insulation, noise insulation and heat and vapour protection. Asbestos contaminated wastes occur particularly in the demolition, reorganization or maintenance of old buildings. It is regulated as a dangerous material and the methods and requirements for disposal are specificied in the regulation.

Danger Products with weak fiber (friable) asbestos are particularly dangerous. Inhaled asbestos fibers are known to cause Asbestosis and/or cancers. Due to its carcinogenic effect asbestos is classified in the dangerous material regulation as a particularly dangerous carcinogenic dangerous material. As a result the prevention of asbestos fibers from becoming airborne is a very important public health measure that must be undertaken in the demolition of old buildings.

Disposal The intended measures orient themselves at the

hazard potential of the different asbestos contaminated wastes.

Ways of collection In order to make possible the processing of the usable components of building wastes as well as the normal disposal of the asbestos contaminated components the following work routine must be observed:

- Before beginning of demolition and/or renovation, an examination of asbestos

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contaminated materials and components is conducted

- If asbestos contamination is present – a specification of the demolition or deconstruction process must be provided to the responsible authorities.

- Before beginning of the demolition and/or renovation asbestos contaminated materials are to be removed and disposed according to the provided procedure.

Asbestos contaminated components such as steel girders, air ducts etc do not need to be disposed as asbestos contaminated wastes, so long as they are cleaned sufficiently according to TRGS 519. Once clean they can be reused.

Ways of sorting Asbestos in a pure form is separated from materials with asbestos contamination and these materials are further separated between those to be cleaned and those to be disposed. Sorting is important in order to ensure appropriate treatment for each particular type of asbestos form.

Disposal Process Generally, asbestos and materials contaminated with asbestos are stabilised and disposed of in specifically identified areas of landfills.

Technologies At present chemical, thermal and mechanical procedures for asbestos fiber destruction are in different stages of development and testing. Until the establishment and operation of such plants the requirements of Germany’s federal Emmission Control law apply. Sprayed asbestos and asbestos types of dust, which are to be disposed, are to be preferably solidified or stabilised by means of suitable inorganic bonding agents, like glass, at the point of accumulation. Depending upon the condition of the asbestos contaminated wastes (excluding sprayed asbestos and asbestos types of dust) different methods of the surface treatment or the packing are necessary. Wastes accompanying asbestos removal operations, primarily those with organic compounds, (e.g. carpets, textiles, curtains etc.) must be thermally treated and brought to landfill in stable, depositable form. Chemical procedures for the chemical treatment of asbestos contaminated wastes largely use hydrofluoric acid. Byproducts of this neutralisation process include calcium fluoride, metallic oxides and hydroxides as well as silica. Use of the byproducts of asbestos treatment are

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directed at cement and concrete production, as fluxing agent and as secondary raw material for hydrofluoric acid Thermal procedures include a) Vitrification of asbestos contaminated wastes involves melting them at temperatures around 1400° C. Asbestos-free glass granulates are the process output. b) Asbestos minerals are converted in special rotary kilns at temperatures by 800° C into other minerals, such as forsterite and olivin.

Market Cost per unit (if available)

N/A

Regulations Asbestos contaminated products may no longer be introduced into the material cycle in Germany but for very few exceptions.


www.doerner.de www.cv-abbruch.de www.gollan.de www.ehlert-soehne.de www.buhck-hamburg.de

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2.10 Material Fact Sheet MIXED CONSTRUCTION WASTE


MIXED CONSTRUCTION WASTE


Mixed building site wastes arise from construction, renovation, and demolition and contain mixtures of building materials, accessories, packing materials and household waste like components. These materials are often both mineral and non-mineral (concrete remainders, stones, glass, wood, scrap iron, packing, insulating materials, carpet remainders, aerated concrete, plastics etc.).

REUSE Reuse of mixed construction waste is unusual

without some sort of treatment. If the mixed waste is specifically mineral and has very little contamination it may be reused directly as construction or mine backfill.

Ways of collection Ways of sorting Reuse Technologies Market Price per unit (if available)

RECYCLING No overall statement can be made regarding

Germany’s quantities of mixed construction waste. But generally, they are composed primarily of excavation or mineral materials with smaller fractions of wood, plastics, metals, paper and packing materials.

Ways of collection Through planned and controlled waste separation already running on building sites, a large part of the wastes can be recovered as valuable material. Many can be used in material or thermal applications. Clear examples are: glass, plastics, iron and non-ferrous metals is considered.

Ways of sorting Due to its heterogeneity the processing of building site mixing wastes is technically more complex than with mineral building debris. A complete sorting of mixed building site wastes is so far only possible with manual labour. Commercial waste producers however, are obliged to separate their mixed wastes by law and thus mixed building waste quantities should be limited and/or feasibly sorted machine.

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Recycling Process Materials recovered from mixed wastes are either

added to their respective material groups and recycled, sent to an incinerator for energy recovery or landfilled.

Technologies Market Price per unit (if available)

Separation of polluting materials can allow for significant savings in disposal costs.

Regulations The Commercial Waste Regulation requires separation wastes from the building site into respective groups in order to in order to make high-quality utilization of the wastes possible. Exceptions to this requirement are only possible under certain conditions.


www.doerner.de www.cv-abbruch.de www.gollan.de www.ehlert-soehne.de www.buhck-hamburg.de

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Overview of construction waste companies in Germany

German demolition and construction waste companies are the vital link in the C&D waste management chain. They possess the technical knowledge, equipment, training and organisation vital to an effective recover C&D waste management system. Furthermore, they play an important role in the construction industry by assuming responsibility for the dismantling, processing, marketing, sale or disposal of all building related wastes. They have significant incentives to improve their techniques and the quality of the material they process because they often also earn a proportion of their revenue from selling the material they recycle. The below table lists the average deposit fees and recycling costs for various types of materials in Germany. Table 7: Comparison on Recycling and Disposal Costs

Category of Materials Disposal Fees [EUR]

Recycling Costs [EUR]

Mineral materials Concrete Scrap - 7 to 10 EUR/t Bricks - 7 to 10 EUR/t Mixed mineral Materials 80 to 200 EUR/t 9 to 13 EUR/t Metals Iron - -40 to 0 EUR/t Aluminium

- -250 to -100 EUR/t

Copper - -1000 to -250 EUR/t

Wood Untreated Wood - 35 to 65 EUR/t Lightly treated Wood - 50 to 100 EUR/t Treated Wood (pressure impregnation)

50 to 250 EUR/t

Other Building Materials Glass - 30 to 65 EUR/t Plastics - 50 to 200 EUR/t Mixed Building Materials * Mixed Materials (only recycling) 125 to 200 EUR/t Mixed Materials (recycling and disposal)

125 to 300 EUR/t

Mixed Materials (only disposal) 125 to 300 EUR/t * Mixed Material have to be sorted according to their material composition Source: Schultmann, F.; Seemann, A.; Garbe, E.; Rentz, O.

As is evident in the table, while recycling is advantageous for many materials, the cost of recycling is required as disposal of recyclable C&D waste materials is simply forbidden by German law. It should also be noted that the ability of a recycler to earn revenues with the material they receive can affects the cost of recycling to the material owner. If the material is of higher quality and recovered in a manner that preserves this

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quality a recycler may be able to sell it as a higher valuable material and pass on some of these earnings to the original material owner in the form of lower recycling costs. Scale of C&D Waste Management Industry

From the 51.1 Mt of recycled material, 35.5 Mt (69.4%) were used in road

construction and 9.9 Mt (19.4%) in earth-moving. 4.9 Mt (9.6%) were used for various purposes like garden, landscape and sport-field construction. 0.8 Mt (1.6%) were used as concrete aggregate. (Figure 14)

The data of table 8 show that the main amount of the 59.8 Mt entering C&D waste treatment plants was treated in mobile/semi-mobile plants (55.3%) and the rest in stationary plants (44.7%). From this value, 57.2 Mt were recycled, representing 96% of the total C&D waste treated in Germany in 2002. The main recycled products were concrete from building and road demolition (44%); sand, gravel, crushed stones, plaster, gypsum and mixed mineral material (20%) and bricks (17%). A summary of the amount of recovered material in construction waste treatment plants is shown in table 9. Table 8: Material treated in C&W treatment plants in Germany, in 1000t (2002) Source: Destatis (2004b) Treated material Total In stationary

plants In mobile /semi-mobile plants

Rest (waste from building sites, demolition wood)

1.924,9 1,712.7 222.2

Mixed debris and excavated material 5.863,5 3,608.3 2,255.2 Excavated material 7.021,5 3,351.0 3,670.5 Road demolition waste 12.253,3

5,282.6 6,970.7

Building demolition waste

32,712.1 12,741.6 19,970.5

Treated material (total) 59,775.3 26,696.4 33,079.0

M ixed debris and excavated material5.863,59,8%

Excavated material7.021,511,7%

Road demolition waste

12.253,320,5%

Building demolition waste

32.712,154,7%

Rest (waste from building sites,

demolition wood)1.924,93,2%

Figure 13: C&D waste treated in construction waste treatment plants in Germany, in 1000t (2002) Source: Destatis (2004a)

Figure 14: Use of recycled material from C&D waste (2002) Source KWTBau (2005)

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Table 9: Recovered material treated in C&W treatment plants in Germany, in 1000t (2002) Source: Destatis (2004b) Recovered material Total In stationary

plants In mobile /semi-mobile plants

Concrete (from building and road demolition) 25,060.9 9,351.7 15,709.2 Bricks (from building demolition) 9,557.6

4,186.3 5,371.3

Ceramic and tiles (from building demolition) 311.8 240.1 71.7 sand, gravel, crushed stones, plaster, gypsum and mixed mineral material (from building/road demolition and excavation)

11,359.1

6,816.9 4,542.2

Excavated material 6,096.3

2,806.6 3,289,7

Asphalt 4,129.2

1,230.3 2,898.9

Tar containing material 688.1

276.1 412.0

Recovered material (total) 57,203.0 24,907.9 32,295 Figures 15 to 17 show some examples of mobile, semi-mobile and stationary plants used in Germany.

Economics Germany’s entire recycling market recorded a 2004 turnover of 4.94 billion Euros. Employment in the industry grew from 13375 employees in 2000 to over 17000 in 2004. (Eurostat 2006) While some of this economic activity and employment accounts for the recycling of household and commercial wastes, C&D wastes account for a large portion of the overall waste mix, implying that a significant portion of these numbers can be attributed specifically to the C&D recycling industry. While these statistics are encouraging, they reflect only one side of the economics of recycling. The Cologne Institute for Economic Research estimates that the use of secondary raw materials added 3.7 billion to German GDP in 2005 in terms of avoided material costs. Such savings are particularly significant for materials that are in short supply or regularly imported.

Figure 15: Mobile Plant Figure 16: Semi-Mobile Plant Figure 17: Stationary Plant

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3.1 Company Fact Sheet OTTO DÖRNER

Name OTTO DÖRNER Entsorgung GmbH

Contact Details Nils Siebörger

Assistent der Geschäftsleitung Lederstrasse 24 22 525 Hamburg fon +49_40_54885_125 fax +49_40_54885_204 [email protected] www.doerner.de

Organisational Form

Private company (GmbH)

Type of company Demolition, recycling Number of employees/ annual turnover

500 employees (Ganze Dörner-Gruppe Locations: Hamburg, Kiel, Lübeck, Itzehoe 135 employees (Otto Dörner Entsorgung) annual turnover: not available

General Intro Main business fields... - Transport

- Recycling - Waste Management - Intermediate storage for hazardous waste - Sorting facility (manually and mechanically) for commercial waste and building-site waste - Shredder for scrap wood - waste containers 1 - 35 m3 - collection, treatment, disposal of waste - collection and disposal of hazardous waste - consulting - waste management for commercial properties and building-sites. - garbage collection

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Materials Input: 2004: 190,000 t

Output: Seperated Materials (2004)

Processes Different processes for each material…

Construction waste: automatic and manual sorting, screening air separators, magnetic separators

Technologies/ Machinery

Used for collection, sorting, treatment….

Systems and equipment used for construction waste recycling:

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1 Segregation line with manual sorting of construction waste

1 Automated sorting line using a combination of different screens and air separators to sort debris

2 Wood shredders, one mobile and one stationary

- Excavators - Wheel-loader

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Collection 40 trucks and some trailers with 8-40 tons permissible maximum weight 25 garbage-trucks with 26 tons permissible maximum weight

Market Main Customers/Partners

- building and demolition companies - craftsmen - public-sector companies - public authorities

Fees/Financing Example Dumping Fee: 158 €/t or 45,50 €/cbm (Mixed Construction Waste)

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3.2 Company Fact Sheet CV-Abbruch Name CV Abbruch und Räumung GmbH

Contact Details Herr Schmidt

CV Abbruch und Räumung GmbH Kronsaalsweg 30 22525 Hamburg fon +49_40_896776 fax +49_40_8904732 [email protected] http://www.cv-abbruch.de/profil/default.htm

Organisational Form


Type of company Working in the areas of Deconstruction, Recycling, Environmental Technology and Earthwork - service covers the entire spectrum of modern demolition works

Number of employees/ annual turnover

25 Employees Turnover not available

General Intro Main business fields...

CV Demolition deals with a wide range of construction components, from windows and doors to the reutilisation of demolition materials. CV Demolition guarantees professional disassembly of your building and sorting of materials to be recycle. The reprocessing and marketing of demolition materials belongs to a qualified waste management company like CV Demolition.

Materials Input:

Delivery of the construction waste on the sorting plant.

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Construction waste after the first sorting

Output:

Different types of recycled materials

Processes CV Demolition produces building materials from building debris.

Mobile crushing and screening systems are used in the processing of material, allowing the recovery of valuable materials such as rough fine stones as well as road construction material from materials like brick and concrete.



Equipment for construction waste recycling:

Delivery of waste Excavator sorting tool

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Excavator jackhammer Excavator crushing tool

Mobile crushing machine Mobile crushing machine with magnetic separation

Information about the machines:

http://www.volvo.com/group/germany/de-de

Market Customers/Partners not available

Fees/Financing not available

Fax from Simona

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3.3 Company Fact Sheet GOLLAN

Name Gollan Recycling GmbH

Contact Details Herr Werner Süß

Gollan Recycling GmbH Dorfstraße 7 23730 Neustadt/Beusloe fon +49_4561_398_0 fax +49_4561_398_65 [email protected] www.gollan.de

Organisational Form


Type of company Sales and delivery of recycled building materials, Demolition and Renovation, Waste Processing, Wood Waste Processing, Excavation Material Processing, Sieving and Shredding Operation of 2 Class Z1 Landfills.

Number of employees/ annual turnover

250 Employees 30 million Euro annual turnover


Apart from the classic waste container service, Gollan offers building waste recycling with building debris sorting, crusher plants and the processing of cinder from incineration plants to building materials for road construction. Gollan also offer demolition services, the reorganization of materials and the disposal of mixed and unmixed wastes.

Materials Input: http://www.gollan.de/pdf/Annahmekatalog.pdf

Output: Examples Sales/Delivery

Concrete-Aggregate RC-Concrete

0 - 8 FSS 0 - 32, 30 % > 2 mm FSS 0 - 32, 40 % > 2 mm FSS 0 - 32, 60 % > 2 mm FSS 0 - 45, B2 > 40 % > 2 mm

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Backfill Compost Barkmulch Topsoil Gravel Gravelsand Debris Sand Natural stone Natural stone

Irregular block

FSS 0 - 45, > 60 % > 2 mm, conforms to ZTVT-STB 95 STS 0 - 45, > 60 % > 2 mm, conforms to ZTVT-STB 95 0 - 8 8 - 16 16 - 32 (from the pre-seive), dark looking Compost with organic matter spruce/fir, 0/45 sieved/unsieved washed, 8 - 16 und 16 – 32mm 0/4 0/32, 30 % > 2 mm (FSS o. L.) 8 – 45mm 0/2 0/4 washed 0 - 4 washed 0 - 8 sieved 0/2 (clean sand) 0 - 45, 60 % > 2 mm (STS) bis ø 150 cm

Sales and delivery of Recycled and Natural stone material

Our fleet of over 30 delivery and approximately 2500 containers vehicles we are able to deliver every type of material from our staging yard. Pick up of material is of course, also possible.

Processes

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Demolition/Renovation

Gollan Recycling is specially equipped with demolition excavators and machines to handle complex, fastidious core removals and the recovery of demolition wastes.

Recycling

Gollan provides waste treatment with a variety of systems, centrally in our recycling plant or on your site. Gollan can handle debris, concrete, natural stones, building -, trade and waste wood and much more.

Timber recycling

Building timber treatment is carried out by four mobile shredders preparation with four mobile and two rotary screens. Gollan is also the primary place in entire north of Germans for shredding and disposal of building timber.

Debris recycling

With twelve diverse stationary and mobile debris processing units Gollan is able to separate all varieties of waste materials

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into recyclable, quality, materials.

Sieving/Shredding

With four mobile shredders and two rotary screens Gollan is the natural choice for shipment of wood waste in northern Germany. In addition we are able to prepare green wastes from composting to sieved plant soil.



equipment for construction waste recycling: Used machines are also sold via Gollan.

Location in Neustadt/Beusloe

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Market Customers/Partners

Private and public customers

Fees/Financing From Simona

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3.4 Company Fact Sheet Ehlert & Söhne

Name H. Ehlert & Söhne (Gmbh & Co.)

Contact Details Herr/Frau H. Ehlert & Söhne (Gmbh & Co.) Grevenweg 121 20537 Hamburg fon +49_40_4013 79 - 0 fax +49_40_4013 79 - 79 [email protected] http://www.ehlert-soehne.de/main.htm

Organisational Form

Private company (Gmbh & Co.)

Type of company Number of employees/ annual turnover

General Intro Main business fields... Demolition and core removal, including asbestos removal and

disposal at all scales. Materials Input:

N/A

Output:

N/A

Processes

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Equipment for construction waste recycling:

Machines

Frontloaders up to 45 Tonnes

Excavators

45.0 to Longfront excavator Cat 330 BL

26.0 to Tracked excavator Cat 322 CL

23.0 to Tracked excavator Cat 320 CL (2 Stück)

23.0 to Tracked excavator Fiat Hitachi EX 215 ELC5

23.0 to Tracked excavator Daewoo 255

22.0 to Tracked excavator Daewoo S 225 LC-V (2 Stück)

20.0 to Mobile excavator Cat M320 C

13.0 to Mobile excavator Hyundai Robex 130W

6.0 to Mini excavator Volvo EC 55

5.5 to Mini excavator Yanmar VIO 55 VCR

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3.5 to Mini excavator Fiat Hitachi EX 35

1.5 to Mini excavator Yanmar B 15-3

0.9 to Mini excavator Kubota U 10

0.8 to Mini excavator Kubota U 08

12.0 to Wheeled loader Fiat Hitachi W110

7.5 to Wheeled loader Atlas 72 E

6.0 to Wheeled loader Zeppelin ZL 100

4.5 to Wheeled loader Volvo B 20 L

2.8 to Compact loader Cat 216

1.6 to Compact loader Bobcat M 553

1.1 to Compact loader Bobcat M 463

1.1 to Compact loader Bobcat M 453 (3 Stück)

14.0 to Mobile Crusher Prallmühle RM 80

Auxiliary Tools

5 Stck Sorting Shovel

5 Stck Concrete- / Scrap Cutter Maulweite 80 cm

3 Stck Concrete crusher Maulweite 87 cm

4 Stck Hydraulic hammer

1 Stck Gravel Shovel Hydraulisch verstellbar

3 Stck Concrete Cutter for Mini excavator Maulweite 45 cm

6 Stck Hydraulic hammer for Mini excavator

Miscellaneous Machines

LKW with Hook system

Flat bed truck

Forklift

Power System

Compressor 2.5 - 5.0 m³

Vibrator Plate

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Welder Cutting machine

Asbestos cleaning system

Worksite Truck

All excavators are strengthened, fully armoured and have quick change mechanisms for dippers, grip arms, shears, hammers and crushers. Maintenance and repairs are accomplished by our master team in the own workshop. For fast repair, two fully equipped workshop vehicles are locally available.

Market Customers/Partners

Fees/Financing

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3.5 Company Fact Sheet HME

Name Buhck Gruppe

HME – Hamburger Müllentsorgung Rohstoffverwertungsges. mbH Contact Details Herr Ulf-D. Hennies

HME – Hamburger Müllentsorgung Rohstoffverwertungsges. mbH (ein Unternehmen der Buhck-Gruppe ) Hamburg fon +49_40_736093_56 fax +49_40_736093_66 [email protected] http://www.buhck-hamburg.de

Organisational Form


Type of company Entsorgungsunternehmen / Sortieranlage Number of employees/ annual turnover

31 / 8 Mio. €


The HME Waste Management Center in Hamburg undertakes the sorting of construction and demolition wastes into materially pure fractions. HME also prepares foundation engineering materials intended for use in road construction.

Materials Input: Beside excavation material and road demolition waste we rimarily deal

with unsorted building debris building site wastes. Approximately 1,100 m3 of these materials are delivered to the HME on a daily basis.

Output: Contaminating materials are removed from the input yielding a rate of

up to 80% of reusable, new economic good.

Processes Crushing of building debris and sieving from earth.



Crusher, Earth sieve with maximum size of 200mm

A first approach years ago involved the simple sorting of materials by

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hand. From this beginning arose the concept of a large scale mechanical sorting installation, begun in Hamburg as HME in 1986.

AUA – HME – Liebigstraße 22113 Hamburg

Market Customers/Partners Hamburg region contractors, disposal companies and container

services

Fees/Financing Pricelist

Sales from building materials unit Euros

Mixed Mineral (MG) 0-45 As per LAGA specification

per tonne 5.40

Concrete Mineral Mix (BMG) 0-32

As per LAGA specification

per tonne 8.50

Sieved sand per tonne 6.00

Sieved Topsoil per tonne 8.50

Services Sorting per hour 45.00Sorting of Hazardous material per hour 53.0

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4 CONCLUSIONS

Germany has a successful and effective construction and demolition waste management system. The recovery, reuse and recycling of these waste materials ensures the diversion of what was historically the largest portion of the waste mix. Simultaneously, the demand for new materials is reduced, conserving domestically available virgin materials and energy while reducing the need for imports.

A particularly important challenge in any waste management system is ensuring

consistent, high quality recycled material. The roles of LAGA in publishing specifications for recycled materials and RAL in inspecting and labelling materials for quality assurance are key to the smooth running of a the German recycled C&D waste materials market. Without the vital contribution of specification and quality assurance, sellers and buyers would be forced to evaluate and negotiate every sale or purchase on a case by case basis. While the work of LAGA and RAL has simplified much of this process, implementation of these practices is still underway.

There is however room for improvement in the performance of Germany’s construction

material cycle. The potential for Germany’s C&D waste companies to provide even more savings is evident in the literature on the subject as indicated by the Schultmann and Co. in the following case study figure:

Locationuse of buildingtype of building

-5

0

5

10

15

20

25

30

35

40

45

50

Cos

ts [

?/m

³]

recycling / disposal /transportdismantling or demolition

selectivedismantling


conventionaldemolition

Dobel (D)hotel

timber framed building

Mulhouse (F)dwelling -house

masonry building



Strasbourg (F)industrial buildingmasonry building



Rottweil (D)school building

masonry building

vgl-dbmhstrw

13,5

16,7

13,3

7,9

1,5

3,5

15,1

44,4

[EU

R/m

³]


Figure 18: Comparison of costs for selective dismantling and conventional demolition

As is evident above, in Germany, the costs for recycling and disposal of demolition waste range are the same category as the costs for demolition. So it can be advantageous to dismantle as many building elements as possible if this leads to a decreasing of the recycling and disposal costs. (Schultmann, 2005) This is especially true if dismantling

79 - 27.10.2006

preserves the quality of the recovered materials, making them available for higher value uses than if they were simply demolished. This may go some length to addressing the phenomenon of downcycling in the C&D waste management cycle.

A study of 70 recycled C&D waste material sales outlets by the Ruhr University of Bochum showed that more than 60% of recycled C&D material sold was used in road construction , particularly as crushed stone base and frost protection. An additional 30% of material was used in landscaping and earthworks (eg: soil stabilization) while reusable materials like tiles, fixtures and windows constituted the smallest portion of sales.

The more specific of Hamburg and Schleswig-Holstein’s experience with C&D recycling show that while nearly 90% of the 10 million Mt of C&D materials are recovered, only about 40% of this material is reabsorbed by the construction industry. The remainder, largely mineral materials resulting from excavation is used to backfill old gravel and sand pits.

Road construction is a notable exception to this norm and is often able to achieve

nearly 100% recycling of materials, sometimes in place and with significant savings in materials and energy.

If a truly cyclical flow of construction materials is to be achieved, the preservation of

material quality in demolition as well as the improvement of recycling of used material into new equivalent material requires some improvement. In today’s environment of high raw material prices and even higher energy costs there is significant incentive to take these steps towards improvement. It seems therefore, that Germany’s progressive success in abating the disposal of C&D wastes is bound to continue.

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5 Sources

1) BMU. 2003. Waste Legislation News: Ordinances of the Federal Repubic of Germany on Sustainable Waste Management, May 2003. Federal Ministry for the Environment, Nature Conservation and Nuclear Safety. [online]. Available from: http://www.bmu.de/files/pdfs/allgemein/application/pdf/waste.pdf [Accessed 15 February 2006]

2) Behoerder fuer Stadtentwicklung und Umwelt Abfallwirtschaft. 2006. Gemeinsamer

Abfallwirtschaftsplan fuer Bau- und Abbruchabfaelle von Hamburg und Schleswig-Holstein, Hamburg, 2006.

3) Bustamante, Waldo. 2006. Construction Waste in Germany, Technische Universitaet

Hamburg Harburg, Hamburg, 2006. 4) Destatis. 2004a. Pressemitteilung vom 14. September 2004. Statistisches Bundesamt

Deutschland. [online]. Available from: http://www.destatis.de/presse/deutsch/pm2004/p3840111.htm [Accessed 15 February 2006]

5) Destatis. 2004b. Erhebung über die Aufbereitung und Verwertung von Bauschutt,

Baustellenabfällen, Bodenaushub und Straßenaufbruch - Ergebnisbericht 2002. Statistisches Bundesamt. Juni, 2004

6) Destatis. 2005a. Amount of waste generated. Statistisches Bundesamt Deutschland. [online].

Available from: http://www.destatis.de/basis/e/umw/umwtab1.htm [Accessed 15 February 2006]

7) Destatis. 2005b. Aufkommen, Beseitigung und Verwertung von Abfällen im Jahr 2002. Juni,

2005. Statistisches Bundesamt Deutschland. [online]. Available from: http://www.destatis.de/download/d/umw/entsorgung2002.pdf [Accessed 15 February 2006]

8) Destatis. 2005c. Aufkommen, Beseitigung und Verwertung von Abfällen im Jahr 2003. Juni, 2005. Statistisches Bundesamt Deutschland. [online]. Available from: http://www.destatis.de/download/d/umw/entsorgung2003.pdf [Accessed 15 February 2006]

9) FSBW. 1996. Freiwillige Selbstverpflichtungserklärung der am Bau beteiligten

Wirtschaftszweige und Verbände zur umweltgerechten Verwertung von Bauabfällen, 1996.

10) Gesetz. 1994. 28 Gesetz zur Förderung der Kreislaufwirtschaft und Sicherung der umweltverträglichen Beseitigung von Abfällen (Kreislaufwirtschafts- und Abfallgesetz - KrW-/AbfG), 27. September 1994, Bundesgesetzblatt I S. 2705-2728.

11) KWTBau. 2005. Monitoring-Bericht Bauabfälle, Erhebung 2002. Arbeitsgemeinschaft

Kreislaufwirtschaftsträger Bau. Berlin, 31. Oktober 2005. [online]. Available from: http://www [Accessed 15 February 2006]

12) Schnurer, H. 2002. German Waste Legislation and Sustainable Development: Development of

waste legislation in Germany towards a sustainable closed substance cycle. [online]. Available from: http://www.bmu.de/files/pdfs/allgemein/application/pdf/entwicklung_abfallrecht_uk.pdf [Accessed 15 February 2006]

13) Schultmann, F. 2001. Deconstruction in Germany. French-German Institute for Environmental

Research (DFIU), University of Karlsruhe, Germany. [online]. Available from: http://www.dcp.ufl.edu/ckibert/DeconstructionBook/CountryReports/2.Germany2003.doc [Acccessed 17 February 2006]

14) Symonds. 1999. Construction and Demolition Waste Management Practices, and their

Economic Impacts. Report to DGXI European Commission. Final Report, February 1999. [online]. Available from: http://europa.eu.int/comm/environment/waste/studies/cdw/cdw_report.htm [Accessed 20 January 2006]

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15) Verordnung. 1996a. Verordnung zur Bestimmung von besonders überwachungsbedürftigen

Abfällen (Bestimmungsverordnung besonders überwachungsbedürftige Abfälle - BestbüAbfV), 10. September 1996, Bundesgesetzblatt I S. 1366-1376.

16) Verordnung. 1996b. Verordnung zur Bestimmung von überwachungsbedürftigen Abfällen zur

Verwertung (Bestimmungsverordnung überwachungsbedürftige Abfälle zur Verwertung - BestüVAbfV), 10. September 1996, Bundesgesetzblatt I S. 1377-1381.

17) Verordnung. 1996c. Verordnung über Verwertungs- und Beseitigungsnachweise

(Nachweisverordnung - NachwV), 10. September 1996, Bundesgesetzblatt I S. 1382-1410.

18) Verordnung. 1996d. Verordnung zur Transportgenehmigung (Transportgenehmigungsverordnung - TgV), 10. September 1996, Bundesgesetzblatt I S. 1411-1420.

19) Verordnung. 1996e. Verordnung über Abfallwirtschaftskonzepte und Abfallbilanzen

(Abfall¬wirtschaftskonzept- und -bilanzverordnung - AbfKoBiV), 13. September 1996, Bundesgesetzblatt I S. 1447.

20) Verordnung. 1996f. Verordnung über Entsorgungsfachbetriebe

(Entsorgungsfachbetriebeverordnung - EfbV), 10. September 1996, Bundesgesetzblatt, I S. 1421-1427.

21) ZBV. 1992. Zielfestlegungen der Bundesregierung zur Vermeidung, Verringerung oder

Verwertung von Bauschutt, Baustellenabfällen, Bodenaushub und Straßenaufbruch (Entwurf), Bonn, 1992.

22) ZBV. 1996. Zielfestlegungen der Bundesregierung zur Vermeidung, Verwertung und

Beseitigung von Bauabfällen (Entwurf), Bonn, 1996.

82 - 27.10.2006

6 Annex List of Regulations

- AbfAblV – regulation on the environmentally compatible deposit of human settlement wastes

- AbfKoBiV - regulation on refuse economy concepts and waste balances

- AbfVerbrG - law on the monitoring and control of the transnational movement

of wastes

- BestueVAbfV - regulation on the usage of waste needing monitoring

- AltholzV - regulation on requirements regarding removal and usage of mature timber

- AltoelV - waste oil regulation

- AVV - regulation on the European waste listing

- DepV - regulation over dumps and long-term camp

- EfbV - regulation on specialized disposal enterprises

- GewAbfV - regulation on the disposal of commercial wastes and of certain

building and demolition wastes

- KrW /AbfG – Act promoting closed substance cycle waste management and ensuring environmentally compatible waste disposal

- NachwV - regulation on furnishing of proof for recycling and disposal

- PCBAbfallV - PCB/PCT Waste Ordinance

- SolidarfAbfV - regulation on the Solidarfonds Institute Waste Recirculation

- TgV - transportation permission regulation

- VerpackV 1998 - regulation on avoidance and usage of packing wastes

- VersatzV - regulation on the storage of waste

Documents

Germany CD Waste