2011 C&D Recycling Forum: Recycling a Larger Mix

Demolition companies and C&D recyclers struggling with what to do with vinyl siding, ceiling tile and drywall that end up in their material mix or recycling facility heard options from panelists in a session titled “Recycling A Larger Mix,” during the 2011 C&D Recycling Forum, at the Turf Valley Resort in Ellicott City, Md., in late September.

Terry Weaver, president of USA Gypsum, Reinholds, Pa., explained how his company recycles new gypsum wallboard from residential and commercial construction sites. Rolloff containers are placed at construction sites for drywall only “to keep contamination at a manageable level,” said Weaver.

His company received the first permit in Pennsylvania to recycle drywall for land applications or animal bedding products. USA Gypsum also is working with Penn State University to begin adding gypsum to ready-mix concrete. The company has done a test pour at its Reinholds facility.

Another company that is taking its products out of the demolition debris stream and reusing it to make more of its products is the ceiling tile manufacturer Armstrong, based in Lancaster, Pa. Through its recycling program, Armstrong has reportedly diverted more than 100 million square feet of old ceiling tiles from landfills. Andy Lake leads the recycling program for the company. He told attendees that recycling ceiling tile can provide up to four LEED (Leadership in Energy and Environmental Design) points on projects. “Four points is a big deal when you are at a silver or higher level,” he said.

Armstrong also can recycle ceiling tiles made by its competitors. If a job site can generate 30,000 square feet of ceiling tiles Armstrong will pick up the loads from the job site. One significant development that Armstrong recently made is it now can create bales of ceiling tiles. In the past, demolition crews were required by Armstrong to palletize tiles, which could be time consuming.

The ability to put the tiles into a rolloff, according to Lake, “is a game changer for us.”

Lake emphasizes that companies interested in recycling ceiling tiles must first register their project with Armstrong.

Sam Fisher of Shermans Valley Recycling, based in Loysville, Pa., talked about his company’s process for recycling vinyl siding.

“This year we have recycled close to 2 million pounds. Since doing the siding, we have done 4 million pounds,” said Fisher.

Fisher says that he realized there is a baling cost and operating cost for C&D recyclers and demolition companies, but that there is a strong market available for the regrinds from vinyl siding.

“When we get the bales back from your facility we have a special machine that tears the bale apart. There is also a sorting line where a positive sort is done.

“From there we take it to another building and the shredder operator watches again and pulls the negative out,” he said.

Fisher adds, companies that drop off siding do not have to worry about sorting it by color because that is done at his facility. Shermans Valley does not accept shutters, insulated siding or cedar shake siding. He said his company has the capacity to handle a lot more material than it is currently processing.

“We are a young company, but we are very excited to work with you and very excited about where vinyl siding can go,” said Fisher. “I know there is a lot of vinyl siding going into landfills every day. What can we do to reclaim that? That is a question for you to answer.”