Foundry Sand Use in Wisconsin Highway Projects July 9, 2012 Bryant Esch Environmental Coordinator Waupaca Foundry, Inc. Wisconsin Cast Metals Association
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Metalcasting as a Sustainable Industry – Primary Recycling General Steel Scrap
Compressed Pucks
Tin Bales
Cast
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Waupaca Foundry Typical Light Vehicle Products
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Waupaca Foundry Typical Commercial Truck Products Diesel Engine Cast Components
Chassis Casting Components rs ve co ff Di
Ductile Iron Gray iron
dru ms
hub s
s ke Yo
• Oil Pans • Bearing Caps • Pulleys • Water Pumps • Flywheels
• Turbochargers • Front Engine Covers • Engine Brackets • Compressor Housings • Oil Pumps
Transmission & Clutch Cast Components • Main Housings • Pressure Plates • Clutch Housings • Intermediate Plates • Rear Housings • Friction Plates • Valve Housings • Spring Plates • Transmission Covers
Suspension Cast Components • Spring Hangers • Frame Hangers • Saddles • Top Pads • Bottom Caps
• Equalizer Beams • Frame Brackets • Torque Rods • Steering Gears • Saddle Caps
Sp rin gH Br ang ak ers eS pid Axl ers eS S Tra add nsm A lack l e s issxle C Adju Vib ion ar s t rat Co rier ers ion mp Da one m Shi nts pe f t r Bra s L Air Steeri ke D ever Co ng mp Hou rums Hs sing ng
Driveline Cast Components • Brake Drums • Brake Rotors •Brake Calipers • hubs • Spiders
• Diff carriers • Diff Cases • Transfer Cases • Covers • Slip Yokes
Clutch Plate Castings Turbocharger Castings
Brake Castings
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Waupaca Foundry Typical Agriculture Products
There are over 50 Waupaca castings on a John Deere Tractor
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Waupaca Foundry Typical Construction Products
Drive Housing
Water Pump
Bracket
Bracket
Carrier
Hydraulic Pump Housing
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Waupaca Foundry Typical Industrial Products
Water Meter Box
Valves
Housings
Hydraulic Housings
Power Transmission Bracket
Electric Motor Housing
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Foundry Byproducts • Slag • Foundry Sand • Foundry Sand Dusts
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Beneficial Reuse Flowable Fill
Gravel Pit Reclamation
Embankment Fill
Road Construction
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Additional Spent Foundry Sand Uses • Cement Production • Geotechnical Fill • Soil Amendments/Agriculture • Impermeable Layers (Manure Pits/Landfill Liners)
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Characteristics of Foundry Sand • Well documented in existing literature • Wisconsin NR 538 Category 2 • Often demonstrates a high degree of consistency • Readily handled and compacted with proper moisture control 2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Typical Physical Properties of Foundry Sand
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Foundry Sand Use in Transportation Projects (USH 10 Roadway Embankment) Wisconsin Department of Transportation - Northeast Region •
USH 10 Corridor, Winnebago County (2002) – Sand used as overpass fill for the eastern approach of USH 10 overpass of North Oakwood Avenue – 80,000 cubic yards – Material staged near project site prior to startup of construction – Lysimeter installed and monitored to satisfy NR 538 requirements
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Foundry Sand Use in Transportation Projects (USH 10 Roadway Relocation) Wisconsin Department of Transportation - North Central •
Region USH 10 Corridor, Portage County (2006) – Sand, slag, dust used as subbase fill to relocate USH 10 to the north over an adjacent historical sand mine – 160,000 tons
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Foundry Sand/Slag Use in Transportation Projects Waupaca County Highway Department (Wisconsin) •
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County Trunk Highway QQ, Waupaca County (2005) – Slag used as road bed base coarse – 10,500 tons County Trunk Highway X, Waupaca County (2005, 2010) – Slag used as road bed base coarse (10,500 tons) – Sand used as road subgrade fill (32,000 tons)
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Additional Beneficial Reuse of Foundry Sands/Slags (2010 to present) •
Gravel pit reclamations – 74,500 tons • Free stall barns, equipment storage pads, manure storage berms, agricultural etc. – 111,000 tons • Church congregation outdoor activity and recreational area – 75,000 tons • City park sledding hill and recreational area – 278,000 tons • Commercial yards, parking lots, and material handling pads – 133,000 tons 2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Before Foley Pit Mine Reclamation Waupaca County After
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Foundry Sand as an Impermeable Construction Material •
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Select foundry sand exceeds the environmental barrier requirements for landfill construction projects. Select foundry sands may contain up to 15 percent clay Can be used as a sustainable alternative to native clays in construction projects requiring impermeability barriers.
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Beneficial Uses of Foundry Sand by Rexnord Industries Contact: Tom Frost Director – Environmental
[email protected]
Rexnord Industries – Gear Products • Rexnord Industries – Gear Products (Falk Corporation) • Steel Foundry – Milwaukee, WI • Manufacturer of Gear Boxes and Ring Gears
• • • •
Generate ~30,000 tons of used foundry sand per year Mined landfilled sand from company-owned landfill Rexnord screens sand at the foundry or landfill Sand meets Wisconsin Category 2 beneficial use standard 2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Recent Foundry Sand Reuse Projects •
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Interstate 94 – Mitchell Interchange Project, Milwaukee • Sand used as utility trench backfill • 56,000 tons Runway Expansion – General Mitchell International Airport, Milwaukee • Sand used as structural backfill • 71,500 tons
• College Avenue & Interstate 94 Overpass, Milwaukee • Bridge abutment backfill • 16,000 tons
• Contractors have indicated that the used foundry sand meets or exceeds the quality of comparable virgin structural and fill materials 2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Technical Resources for Highway Engineers •
AFS-FIRST, Inc. - http://www.foundryrecycling.org and/or http://www.afsinc.org/first AFS-FIRST is the non-profit industry association that promotes the reuse of foundry sand and provides technical information about primary uses of foundry sands, as well as case studies and a searchable library that contains research and technical reports. An on-line foundry sand locator is also available that can be used to find quantities of foundry sand within reasonable shipping distances of job sites.
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RMRC Foundry Sand Portal - http://www.rmrc.wisc.edu/foundry-sand-portal.html RMRC's Foundry Sand Portal contains a number of important references on the use of foundry sand in highway applications. These include specifications and standards; and technical case studies, including some showcasing Wisconsin projects. RMRC also produced a series of six webinars on the use of foundry sand in highway applications. The webinars are available via the website and can be viewed either as the full one-hour webinar or downloaded in PDF format.
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
Technical Resources for Highway Engineers, continued…. •
"Foundry Sand Facts for Civil Engineers“ http://www.fhwa.dot.gov/pavement/pub_details.cfm?id=55 In 2004, FHWA published the first edition of this basic primer on the use of foundry sands in highway applications. PDF copies can be downloaded from the FHWA and AFS-FIRST website
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Foundry Sand Usage in Transportation Applications – http://www.trb-adc60.org/downloads/E.%20Olenbush%20-%20Foundry_Sand.pdf This is a link to an overview presentation given at the TRB ADC-60 summer workshop in 2007.
2012 TRB: Waste Management & Resource Efficiency Workshop, July 9, 2012
