There isn’t a single piece of equipment that can effectively sort construction and demolition (C&D) recycling streams all on its own. However, by combining the right equipment in the proper sequence, operators can reduce their reliance on manual sorting, better manage contamination and lower their overhead at the same time.

For Will Hancock, stationary equipment sales manager for Komptech Americas and Plexus Recycling Technologies, a combinational approach to equipment investment featuring low-speed shredding on the front end of a system, followed by ballistic separation and then robotic sorting offers the optimal return on investment for C&D recyclers.

While Komptech Americas’ single-shaft Terminator low-speed shredder reduces the bulk density of incoming material and creates a uniform composition, its Ballistor combines ballistic separation and screening to sort the resulting 3D material, 2D material and fines into A and B lines.

This one-two punch offers a uniformly sized and sorted product that is then able to be effectively managed by Plexus’ ZenRobotics Heavy Picker robots.

Hancock says that the AI-powered ZenRobotics sorting system, which can be customized to focus on whatever materials an operator wants to prioritize, can offer recyclers the ability to automate operations and lessen reliance on manual pickers. However, the key for maximizing output is taking a “tortoise over the hare” approach, Hancock says.

He notes that the Heavy Picker robots are rated to handle 40 tons per hour of front-end throughput. While some recyclers like to throw as much material on the belt as possible, sticking with a more measured throughput on the front end allows for better results. The beauty of sticking with this slower-but-steady throughput is that recyclers can process as much or more material over the course of a day than would be possible by overloading the belt.

Hancock says that some operators utilize manual sorters to focus on incoming 3D material during the day and then use the robots for a fully automated night shift to sort the rest of the material. Others choose to use manual sorters and robots in tandem to ensure material recovery is augmented.

Additionally, Hancock says that utilizing robots for negative sorting operations where the automated pickers take out the less desirable material from the material of value can be an effective strategy.

To put the efficiency of the ZenRobotics Heavy Picker robots into perspective, Hancock cites Atlanta-based C&D recycler Metrosite.

Where similar-sized operators might require 20 workers to operate a C&D recycling facility, Metrosite employs only six to eight to run its entire operation.

By working with a skeleton crew, Metrosite can achieve similar tonnages as more heavily staffed sites do but with much lower overhead.

According to Metrosite owner Scott Ledford, the ZenRobotics Heavy Picker has allowed his facility to remain profitable even during staffing shortages.

“I feel like the robots have helped us cut down around 18 or 20 positions in the facility. We still have some quality control people on staff, but their workload is extremely light because the robots do such a good job,” said Ledford. “We opened our doors around the same time the COVID pandemic started, and if it wasn’t for the robots, I probably couldn’t have kept the doors open because we couldn’t find workers. By using the Ballistor ballistic separator, which does a tremendous amount of work on the front end, by the time the material gets to the robots, there is not a lot of contamination in it. Then we just use the robots to pick some of the larger 3D material, and they do a marvelous job at it.”

By being willing to invest in C&D sorting solutions from Komptech Americas and Plexus Recycling Technologies, Ledford has been able to work smarter, not harder, to achieve his recovery goals while simultaneously saving on operational costs.

For more information, visit bit.ly/2XUuziy

A look at regional or national pricing figures for some of the most commonly produced C&D materials.

Scrap Iron: Reported United States aggregated spot market prices per gross ton shown for each commodity are based on all Management Science Associates’ (MSA) Raw Material Data Aggregation Service (RMDAS) participants’ actual order data submitted to and processed by MSA as of the 20th of each respective “buy month,” rounded to the whole integer. A map of RMDAS regions is available at http://rmdas.msa.com, as is a further explanation of RMDAS methodology and an accompanying disclaimer.

No. 1 HMS defined as prepared obsolete scrap, 5 feet long and under. Additional pricing information on each grade can be found at www.RecyclingToday.com.

© 2019-2020 Management Science Associates Inc. All rights reserved RMDAS is a trademark of Management Science Associates Inc.

Copper - LME Pricing: Source: London Metal Exchange, www.lme.com

Aluminum - LME Pricing: Source: London Metal Exchange, www.lme.com

Stone and Aggregate Pricing: *Index is based on 1982 average price as 100 Source: U.S. Bureau of Labor Statistics

Wood Scrap: Source: Forisk Wood Fiber Review; detailed pricing and market analysis for regions in the U.S. and Canada available by subscription at www.forisk.com.

Canada-based Sanexen creates valuable end markets for C&D fines through the development of a first-of-its-kind recovery plant.

An unavoidable byproduct generated during the recycling of construction and demolition (C&D) debris, C&D fines—or recovered screen materials—have created a persistent dilemma for recyclers looking to find end markets for the materials they produce.

While some applications have been identified in recent years, such as for use as alternative daily cover (ADC) at landfills, consistent markets for C&D fines have not yet been identified due to heavy contaminants found within the material.

Consisting primarily of soil, wood, concrete, gypsum and other miscellaneous material particles, fines have received increased scrutiny due to their propensity to omit hydrogen sulfide (H2S)—a colorless gas that generates toxic emissions, odors and presents a risk for fires even in low concentrations.

In addition to H2S, concerns over toxic compounds polycyclic aromatic hydrocarbons (PAHs) and polychlorinated biphenyls (PCBs) have left recyclers stumped on how to utilize fines in a safe and environmentally friendly way.

For Canada-based Sanexen Environmental Services Inc. (Sanexen), a member of the company Logistec, this challenge posed an opportunity to apply its experience in contaminated soil and residual material management to generate a valuable product from C&D fines.

The close to 40-year-old company has historically focused on environmental remediation projects, such as water rehabilitation, site remediation, regulated materials management, risk assessment and environmental compliance audits. Overall, Sanexen has treated more than 3 billion gallons of heavily contaminated water and roughly 15 million tons of contaminated soil.

“Five years ago, we identified internally that there were upcoming issues of disposing C&D fines. So, our group started working on the research of this particular waste stream, identified the characteristics of the C&D fines, and made sure that we had proper analysis and that we understood the difference between regions that will generate the fines,” says Mathieu Germain, director of strategic development at Sanexen.

Given the growing percentage of C&D waste created each year—EPA’s latest estimates show 600 million tons were generated in the U.S. in 2018—finding an economically feasible way to utilize C&D fines was Sanexen’s first target.

“There’re millions of tons [of C&D fines] that are being generated in North America every year, so we evolved a solution over the last five years to ensure that we would answer that particular need to have a large-scale solution that can be applied at an economic cost that would make sense for the operator,” says Germain.

This development transpired into the construction of the first C&D fines recovery plant of its kind in North America. Located in Montreal, the plant offers large-scale processing of up to 150,000 metric tons per year, allowing for C&D fines debris to now be recycled rather than ending up in landfill.

At the facility, the reclamation process turns accepted debris into byproducts such as aggregate materials, wood residues and compost.

“Our process is a combination of mechanical sorting and biological treatment,” says Germain. “We took the knowledge that Sanexen has develop over almost 40 years now in order to ensure that we would be able to dedicate a solution that will treat the contaminants that are contained in C&D fines.”

According to Sanexen, the process begins with the coarser component of the C&D material residues being mechanically screened to obtain bituminous mix and aggregate materials for road applications. The lighter component of the stream is then directed towards added-value processing for biofuels and renewal chemicals.

As for the ultra-fine components of the C&D material residues, this is biologically treated into compost for mining sites, landfill cover materials and landscaping applications. This material can also be further transformed into additives for manufactured construction or products like foams, composites and plastics.

“The interesting part of our patent-pending solutions that we implemented is that we’re adding the flexibility of the components that enter the biological treatment [phase of our process] in order to adapt it to the local market,” says Germain. “So, for instance, if you’re looking for compost that will be used in the Northeast, we have a solution in place—namely, the one that we have in Montreal—that’s able to fulfill needs throughout the year. So, whether it’s January or July, we’re able to answer the needs of the market.”

This model of reclaiming C&D fines presents a unique opportunity for creating end markets due to its ability to successfully remove contaminants, which can include metals and asphalt shingle residues.

“After removal of these contaminants, you remain with traces of PAHs—which can be found in asphalt shingles—and gypsum. Gypsum per se is not a contaminant, but if it goes to landfill, it leads to all sorts of environmental issues because when it’s buried and interacts with water, it generates H2S,” says Martin Bureau, vice president of innovation at Sanexen.

“So, what we did instead of trying to get rid of the gypsum one way or another, we decided to use biotreatments to transform it into soil nutrients because gypsum is essentially calcium sulfate. You need sulfur for soils, as well as calcium, so we’re transforming it and not getting rid of it, but actually taking advantage of it.”

Depending on where the C&D materials are sourced from, Bureau says biotreatment might be necessary for other contaminants.

“It depends on what ends up at the C&D facility,” he says. “On a case-by-case basis, sometimes we need to look at lead and arsenic, as well.”

Although there have been several attempts to find value for C&D fines through screening methods over the years, Germain says Sanexen’s approach is unparalleled due to its ability to build upon the characteristics of each byproduct to give them a second life.

“Through this innovation, we’re able to generate revenues that are profitable for something that is the main issue with those residues—the gypsum. So, we’re taking advantage of the presence of gypsum to then create an added value product. If you don’t do that, and you just remove the aggregates and the wood, then you’re stuck with a very fine material and the process is not profitable. It’s actually a loss,” says Bureau.

The C&D fines recovery plant has been in operation since August of this year; however, Germain says Sanexen is already working on new versions of the plant.

“This is the first version of the plant that is fully operational and that has … very cool benefits, but the next version of our plant for the manufacturing of new construction products out of these outputs that we’re creating right now is a potential reality. It used to be just a thought, or a dream, but now that we have access to an input of material that we’re treating, we made a corporate choice that we can always improve what we’re doing,” he says.

“There’re really endless possibilities being offered now for the C&D world,” he concluded.

The author is the assistant editor of Construction & Demolition Recycling magazine and can be reached at hrischar@gie.net.

Construction & Demolition Recycling magazine’s Top Demolition Contractors List shows that many contractors overcame COVID-19-related hurdles to remain profitable in 2020.

Work stoppages, backlog extensions and the introduction of various health and safety guidelines complicated work on demolition job sites throughout the U.S. for much of 2020. But despite these challenges, many contractors kept busy.

According to a State of the Demolition Industry report and survey published by Construction & Demolition Recycling magazine late last year, 36 percent of contractors who responded to the survey said they had stoppages or delays between 1-2 months because of COVID-19, 21 percent said they experienced stoppages or delays of 3-4 months and 18 percent said they had no delays or stoppages. On the extreme end of the spectrum, about 18 percent of participants saw much longer delays of 5-6 months, and 6 percent said they had experienced delays or stoppages more than 8 months.

While stoppages posed a real threat to businesses, many contractors said their workload had stayed the same or increased. Nearly 25 percent of contractors who responded to the survey said they increased the number of projects completed over the previous 12 months by more than 15 percent compared to the year prior period, and 27 percent said they increased work by 5-14 percent. Fifteen percent said their workload stayed the same; 3 percent said work decreased less than 5 percent; 6 percent said work decreased between 5-14 percent; and 24 percent said work decreased by 15 percent or more.

This year’s Top Demolition Contractors List, which is based upon demolition-related revenue from 2020, shows mixed results among contractors year over year. On average, however, companies generally exhibited growth from 2019 to 2020. For example, the top 10 highest grossing demolition contractors of 2019 had an average of $173,150,000 in revenue compared to $196,825,628 for 2020.

Thanks to participation from the industry, we were able to grow the number of contractors featured on this list to 50, as opposed to 40 on the previous iteration of the list. Once again, NorthStar Group Services Inc., Brandenburg Industrial Service Co., and Penhall Company comprised the top 3 highest grossing demolition contractors.

It should be noted that in an effort to compile the most comprehensive list possible, the editors have decided to include 2019 revenues for companies we were unable to reach for this year’s version.

The editors of Construction & Demolition Recycling appreciate the cooperation of the demolition industry in the compilation of our newest Top Demolition Contractors List. We know you’re busy, so returning our calls, responding to our emails and filling out our online form has not gone unnoticed. Your responses help ensure the accuracy of our research. Without your cooperation, we would not be able to publish articles like this.

While we’re pleased to have received such a good response, it is likely that several companies that belong on this list do not appear—either because they have declined to participate or they have experienced enough growth over the last year that we were unaware they earned a spot.

If you work for one of the companies that was not represented on this year’s list, or know of another company that you suspect should be on this list in 2022, please let us know. Editor Adam Redling can be contacted via email at aredling@gie.net or can be reached by phone at (216) 393-0278.

Each time we present this list, we hope demolition companies will take pride in the hard work performed by their employees and will want to claim their rightful place on a list created to honor the most successful businesses in the field.

To view the Top Demolition Contractors of 2019, visit https://www.cdrecycler.com/article/top-40-demolition-contractors-united-states-2019/

Adam Redling is the editor of Construction & Demolition Recycling magazine and can be contracted at aredling@gie.net.

Since the start of the pandemic, the pool of prospective candidates for waste and recycling industry jobs has dwindled.

Last year, it is estimated that the United States lost 10 million jobs during the height of the pandemic, according to the U.S. Department of Labor. However, as the economy began to rebound from the effects of social distancing and state and local stay-at-home orders that were enacted to avoid the spread of the coronavirus, “Help wanted” signs began decorating a spectrum of businesses across the country, including recyclers and waste haulers.

While life seems to be returning to normal with the availability of the vaccines, a labor shortage is in full force in many places. Recyclers and waste haulers are now competing among themselves and other industries to hire candidates to fill open positions.

“Hiring has grown and changed during the pandemic,” says Patrick Hudson, vice president of customer experience for Phoenix-based Leadpoint Business Services, a provider of work teams and operations support services to the recycling industry. “Due to several reasons, we’ve seen a reduced interest in applying for these kinds of jobs for both passive and active applicants.”

This has disrupted the collection of waste and recyclables and scrap processing, creating cash flow issues and slowing processing times.

To understand how to solve the hiring problem, it is important to understand how it began and its impacts.

Hudson says several factors contributed to the initial slowdown in hiring and the labor shortage that persists today.

Before the pandemic began, companies such as Houston-based Waste Management (WM) had felt hiring pressures related to the aging workforce. WM’s COO John Morris says because of the increased number of retirements and a shrinking pool of younger applicants, the company was struggling.

In March of 2020, when the country began to shut down because of the pandemic, companies halted hiring and reduced staffing to save money. This led to an historic unemployment rate of 13 percent during the height of the pandemic, according to the U.S. Bureau of Labor Statistics.

The rising rate of unemployment led the federal government to launch enhanced benefits, which some industry leaders say they believe led to a decrease in interested applicants. Bill Keegan, president of Dem-Con Cos., a waste and recycling company based in Shakopee, Minnesota, says the increased unemployment benefits demotivated the labor force from seeking jobs.

“I can really only speculate on this, but I think the enhanced unemployment packages that we have federally could be contributing to the crisis based on what I’m hearing from some people,” he says.

Now that the country is opening back up, Hudson says the biggest factor contributing to the ongoing labor issues in the waste and recycling industry is outside competition for the same labor force. Hudson describes it as the “Amazon effect,” in which companies in other industries, such as technology and retail, are offering more competitive salaries as well as benefits. This means potential workers are switching industries for better opportunities.

“It’s really a hypercompetitive market to get workers right now,” Hudson says. “Our industry is losing out to companies in other industries like Amazon because there has been a failure to meet the growing demands of this post-pandemic labor force,” he adds.

As a result of the hyper competitive landscape for hiring, Keegan says turnover rates also have increased dramatically. This is because municipalities and companies in the waste and recycling industry are speeding up their hiring processes to ensure that certain positions are filled only to have new hires leave shortly afterward for different jobs.

Hudson says it is hard to pinpoint one specific region of the country that has been most affected.

“Every time we put a fire out in one region, a fire brushes up in a different area,” he says. “It’s not necessarily been one area that has been hit the hardest. It kind of jumps around.”

Hudson says recyclers and waste haulers in the South have not been as hurt by the situation. He says this is because a majority of the industry in the South adapted quickly to the pandemic by improving hiring practices.

Morris says WM’s operating costs have increased because when the country opened up earlier this year, processing volumes spiked, and fewer workers were available to handle it. However, he says the company overcame this issue by offsetting a portion of its workforce using new route optimization tools for trucks and artificial intelligence to help with sorting at material recovery facilities.

Still, Morris says this is the first time he has seen a crisis like this during his time at WM.

“Never in history have we seen massive demographic shifts combined with social change and ongoing generational transitions,” Morris says.

The crisis isn’t just affecting private waste haulers. In Portage County, Ohio, the Portage County Solid Waste District, which provides service to 16 communities, has reduced collection services from weekly to every-other week. It also has considered closing drop-off sites.

“It’s come down to a safety concern for our drivers,” says Bill Steiner, director of the Portage County Solid Waste District. “We have five workers, and they’d be driving 70 hours a week each. You can’t have that happen.”

As a result, some of the cities the district serves, such as Streetsboro, Ohio, have hired private collection companies to handle waste management.

Other communities, such as Chattanooga, Tennessee, temporarily shut down recycling collection services. The city’s curbside recycling program was halted for one month because it struggled to fill 32 open positions in its collections program. The program was plagued by a mix of sudden resignations, high turnover and poor pay that contributed to the decline in workers, New York-based Business Insider reports.

According to Business Insider, drivers working for the city were being paid $29,865, which is 118 percent less than what drivers in the private sector are paid. Chattanooga Mayor Tim Kelly says the city will increase pay by 45 percent to attract more drivers.

While there isn’t a definitive way to overcome the current crisis, that hasn’t stopped companies from trying. Dem-Con and WM have been working to improve the work experience for new and current employees.

Keegan says his company is trying to find a solution to labor shortages by placing a heavier focus on employees. Dem-Con has raised wages for its workers by 7 percent and also has improved its benefits package. The company is spending about three times more on recruitment efforts, as well.

“What’s really been important to us is that we put our people first,” he says. “What that means to us is offering competitive wages and extremely competitive benefit packages so that our employees know they matter to us.”

WM also has placed a heavier focus on overcoming the reduced labor pool. Morris says the company has been hosting events throughout the country to attract more workers. Additionally, WM is offering signing bonuses for essential positions, such as drivers and technicians. The company is considering increasing wages for certain full-time frontline workers, as well.

“In April, we launched ‘WM Your Tomorrow,’ an education and upskilling program for team members,” Morris says. “This program provides an opportunity for benefit-eligible team members to earn a GED or college degree at no cost to them,” he adds.

Morris says that the hardest part about the pandemic and the crisis has been making sure his workers are safe and taken care of.

Morris says it is unclear when the industry will bounce back from the hiring crisis. However, companies are finding new ways to keep up with outside competition and attract a labor force dedicated to working in the industry.

Hudson says the waste and recycling sector never will return to what it was before the pandemic.

“One of the things that I keep hearing is that there’s a belief that things will return to normal after a while,” Hudson says. “We are going to come out of this with a new normal. Nobody really knows what that is going to be. We need to be as nimble as we can and focus on adapting quickly and creating a workplace that folks want to work for.”

Some sources say the current hiring crisis permanently will change the ways the private and public waste and recycling sector hires employees and the ways the industry manages its turnover rates. Steiner suggests that the crisis also will change organizational work environments and how employees interact with employers.

Industry leaders do not have clear answers to what needs to change for the hiring difficulty to end. Until definitive answers can be found, industry leaders such as Hudson, Keegan and Morris say they will continue to find ways to understand and meet the labor shortage head-on.

The author is the digital editor for the Recycling Today Media Group and can be reached at akamczyc@gie.net.