PUNE CONSTRUCTION ENGINEERING RESEARCH FOUNDATION

1. Project on Construction Waste Management Reuse & Recycle To Achieve “Zero Debris” PUNE CONSTRUCTION ENGINEERING RESEARCH FOUNDATION

2. PCERF PCERF is an NGO established with the initiative of prominent construction professionals from Pune.

3. PCERFObjectives • Research & Development in construction materials methods. • To organize seminars & workshop. • To update knowledge of professionals. • To provide a common platform for interaction. • Education through Exhibition “Constro”. • To publish books, newsletters , reports on various topics for the building industry. • To establish a well-equipped laboratory and training center.

4. Introduction Construction Waste Management (CWM) • Present working methods of construction projects. • Mass work, speed, quality, use of machinery. • Every work on sq.ft. basis. • Measurement sheets, quantity surveying & supervision become secondary part. • Piece workers achieve speed irrespective of Economy saving of material, clearing & cleaning before & after completion of day’s work.

5. Introduction Construction Waste Management (CWM) • Major part of debris is created during foundation. R.C.C. frame work, brickwork and plaster - 50% of project work. • Indirect waste of natural resources -Sand,Bricks, Quarry metal, along with cement. • No control on site , helplessness of promoters & builders. • There are exceptions , but % is very less. • Generally huge debris is created. • Huge amount spend on transportation, removal by machine • Spoiling Environment & Ecology of nature & National Wealth .

6. Introduction Construction Waste Management (CWM) Practically not possible to transport & recycle in factory . Ban on dumping Debris on fertile land, river Bed or road sides by local authorities. Grave situations are created day by day. Find out solutions to reuse & recycle all debris with in the site itself to achieve minimum or “Zero Debris” situations avoiding heavy transport cost. Joint efforts by PCERF and C’Cure for creating “Construction Rubble” in the form of regular or irregular shapes, Road dividers, curbing stones, bricks, blocks & other useful items. Awareness to evaluate National Waste of Resources by creating non-productive debris neglecting it, transporting wasting fuel.

7. Project: Objectives (CWM) • Evaluation of construction waste & possible recovery. • Data collection: • Case study of 4/5 projects – start to finish –with the help of contractor, promoter, builder – jointly with the help of PCERF & C’ Cure team – 1 year. • At random data collection – by PCERF & C’Cure team , on various sites, with prior permission of the owners ,evaluation of quantity at particular stage of construction ,type of materials and costing, w.r.t. to built up area. Also recording supervisory staff appointed for the work, w.r.t built up area. This will help in preparing R& D documentation & introduction to project.

8. Project: Objectives (CWM) • To find out standards of consumption on sq.ft basis with the help of case studies. • To create Awareness about reuse & recycle amongst promoters & builders. • To find out the cause & care taken by the builder to control the waste. • To formulate solutions to avoid construction waste

9. Project: Objectives (CMW) • Introducing the concept of “Site Keeping” contracts on sqft basis for systematic planning, cleaning, storage & protection of materials. • Looking at the general apathy of labour and supervisors, need of mechanism of self operating screening system on site . • Generally debris is collected in huge quantity in open ducts of the project, unfortunately it gets automatically cured, due to excess curing it requires breaking & cutting with JCB machines, at the time of handing over & cleaning. • To promote curing by gravity basis against electrical pump directly.

10. Project: Objectives (CWM) • Invention of heavy mechanically operated vibrating screening platform of suitable size be installed in duct area. With continuous vibrations automatic screening will create usable crushed sand which can be used immediately, with in ‘ few’ days time ,for non concrete items like pcc, brickwork, filler material below flooring ,etc. • Boulders or large size brick bat , concrete bulbs, plastered mortar, etc. be separated by various shoots by tilting the screen mechanically .This will create pure construction waste( debris) for recycling. • In addition to molding fly ash bricks and tiles in factory we can prepare , on site “Concrete Rubble” out of construction waste.

11. Project: Objectives (CWM) • Using system of table vibrator or orbiter sander and suitable moulds ( either uniform or variable size) We can create “Concrete Rubble” at site. Construction waste will get directly consumed with cement, fly ash and screen crush sand. This rubble can be used for rubble walls in foundation, compound walls, for soling below flooring, road dividers, curbing, blocks, pavement tiles and or for decorative items in Garden and Landscaping.

12. DEMOLITION WASTE Factors Creating Construction Waste • Concrete: Mixer, RMC pump, Lift, Sukada, Platform . • Brick Work: Pieces, unused mortar, patli, lintels & chajja . • Cement Plaster: Bulk mortar, ideal period, non cleanliness. • Water: Curing by electric pump – huge wastage.

13. THREE – POINT ACTION FOR PMC • The primary responsibility for removal of debris would be that of generator. • The generator of waste should inform the civic authority in writing in advance before undertaking such activity. • In case of new construction ,the advance is to be deposited with the application for sanction of the building plan. Results: • New DP to have Debris Dumping Policy. • PMC is following state Govt. and trying to create scientifically designed dumping ground for collecting debris for recycling. • In Mumbai it will be use for special Economic Zones.

14. THREE – POINT ACTION FOR PMC Remedies: • Incentive to supervisors and separate contract for site keeping on sq.ft. basis. • To develop separate accounts and record for construction waste on site evaluation wrt to standards . • Judicial planning for material purchases, storing at site ,separating with time management.

15. THREE – POINT ACTION FOR PMC Remedies: • Awarding site keeping contract on sft basis, for day to day. • Cleaning, screening , protecting, separation and proper storage. • Avoid curing by direct application of pump. • Make a habit of gravitational curing method. • Reuse maximum possible material on site itself. • As far as possible allow one agency to work and complete its job in given time. • Give 25% more time for completion of job. • Keep perfect record of purchase of cement, sand ,stone metal ,bricks, sagol etc.

16. THREE – POINT ACTION FOR PMC • The primary responsibility for removal of debris would be that of generator. Local body will purchase providing containers and service for removal with nominal charges. • The generator of waste should inform the civic authority in writing in advance before undertaking such activity. Will deposit container rent .Fine & penalty for defaulters. • In case of new construction ,the advance is to be deposited with the application for sanction of the building plan.

17. PCERF is trying to create a Bond between Promoters , Builders , Academicians ,Students Professionals and Consultants through this research project.

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24. DATA COLLECTION WITH THE HELP OF STUDENTS • Joint Meeting with Engineering College. • Maximum number of students who can participate from one college. • The level of technical staff required from the college. • The calendar period for starting of the data collection and finishing the entire work as expected . • Sponsoring the traveling & other expenses of students by Promoters & Builders.

25. Guidelines For The Survey • Method of Execution of project, staff and its working • Day to day contact of the site in charge and collecting information with his help or independently. • No of site visits by group of 5 – during 60 days. • Method of storage of materials at site. • No of labour working on site. • Adopting method of calculating quantity of debris and wastage of materials used.

26. Guidelines For The Survey • Method of curing- pump and gravity • Wastage of water-minimum required and actually adopted. • Recording observations stage of constructions , built up area under work, quantity of materials laying on site for use, details' of ongoing works . • Generation of debris during work by which work? How much?

27. Guidelines For The Survey Testing of recycled products. Possible use of Ferro cement technique for reuse and recycle process and products. Regular mesh screening with 15mm,10mm and 6 mm and using simple moulds like bucket and Ghamelas.

28. Standards Derived For Evaluation of Debris • For arriving of standards on construction work reuse and recycle to achieve “Zero Debris” case study of one project self supervised without watchman & without supervisor . For Example sample standard are presented here. All other standards will be derived in process.

29. Case study at 25, Madhavbaug, Pune.  Site Keeping ,Screening & Handling of Debris. • Details of Expenditure (Exp. For) : • Transport Of debris away from site after screening of demolition of old existing structure for connecting new construction. • 05.12.09 4 x 550 = 2,200 • 23.01.10 1 x 550 = 550 • 30.01.10 2 x 550 = 1,100 • 14.01.10 2 x 550 = 1,100 • 25.01.10 2 x 550 = 1,100 ---------- --------- 11 Trucks 6,050 ------------------------------------- A • ======= =====

30. Case study • (Labour) :By contract- Lump sum for screening of above debris. • 16.10.09 Rs. 2,000 • 12.11.09 Rs. 2,000 • 28.11.09 Rs. 500 • 23.01.10 Rs. 500 -------- Rs. 5,000 -------------------- B =====

31. Case study • (Labour) :Daily wages for screening cahwl o& double screening of debris. • 27.02.10 3 Female x 150 = 450 • 23.04.10 5 ½ Female x 150 = 825 • 01.05.10 2 Female x 150 = 300 • 10.05.10 5 & 8 Female x 150 = 2,200 • 17.05.10 10 = 1,300 ---------- Rs. 5,075 -----C ====== B+ C = Rs. 10,075/-

32. Case study • Demolition of old work : • Total expenses for transport of 11 trucks Rs. 6,050/- to thrown away debris -------A • Total expenses for screening and cleaning the open site – Rs. 10,075/- ---------(B+C)

33. Case study • Material cost received from above : • Brick pieces – 2200 s.ft. thick / 4” = 710 cft i.e.3.5 trucks @ 5000/- = 17,500 ( all used for water proofing.) • Fine sand 3/8 sieve : After Plastering • 300 cft chaal : Is screened after 1st screening received (112.50 cft) sand @ 40/- use for brickwork, under flooring. 4,480.00 • 3/4 2nd screening :100.00 cft sand @ 40/- used below flooring 4,000.00 • Balance Pure Chal or shingles : 100.00 cft @ 20/- used below flooring for crushing to drainage line and pee . 2,000.00

34. Case study • Fine sand received from: • Rabbit or Malawa 200 cft • (+) 2nd Stage 72 cft • (+) additional last stage 28 cft • --------------- • Screening total 300 cft @ Rs. 20/- 6000.00 --------------- Total Rs. 33,980.00---------------------------D =========

35. Case study • Now after completion of flooring balance on site of waste materials  • Brickbat small 50 cft • Rabbit with concrete & brick bat 150 cft • Broken pieces of kota stone 100 cft  • Useful for pee below paving etc. Which is negligible approaching for Zero Debris.

36. Case study • Single Bungalow of area 4,500 sft. Plot built up area 4000 sft. (period 12 months) : • Labour charges 10075 ÷ 4000 = 2.50 per sft. • Transportation Exp. 6050 ÷ 4000 = 1.50 per sft. • Material Recovered 33980 ÷ 4000 = 8.50 per sft. • Normally this material is not separated and reuse it is thrown away by truck away from the site involving additional transport cost that material which we have reused is therefore spend to purchase same quantity to complete the job. • By reuse we have save on transport of following material. • By keeping all the time cleanlyness on site we have saved loss of cement bags assuming average 1” layer of cement mortar on 4000 sft built up area.

37. Case study Value of the material saved  : • 40 bags cement @ 270/- = 10,800  • Additional sand required 600 cft @ 40/- = 24,000 • Additional brickbat 2.00 trucks @ 5000/- = 10,000  • Additional Metal 1 brass @ 1500/- = 1,500 • Transport of debris 6 trucks @ Rs.800/- per truck = 4,800 ------------ Rs. 51,100 ---------E • Total Saving and Recovery • D + E =Rs. 33980 + Rs. 51100 = Rs. 85080 say 85000/--------F

38. Case study At most satisfaction of cleanlyness, quality work Now assuming : Total Recovery & Saving Rs. 85000/- ---- -----F Less Expenses for recovery Rs. 10075/- -----(B+C) - ---------------- Net Gain Rs. 74,925/- Say Rs. 75,000/- --------- G • Gain is Rs. 75000 ÷ 4000 = Rs. 18.50 per sft. • For all practical purposes say Rs. 20/- per sft. • Net saving for 4000 sft. Is Rs. 80000/- • For Big project of 1,00,000 sft Gain Rs. 20,00,000/- • For project of 5,00,000 sft. Gain Rs. 1,00,00,000/- Conclusion : Out of total saving Rs. 20/- per sft. On built up area promoter or Builder can easily spent Rs. 5/- to 10/- per sft. By giving ‘Site Keeping” contract for Zero Debris and create new field in modern Royal Construction. (without any monetary loss) getting max. satisfaction & Healthy feelings at any hours of the day on site.

39. Sample Units:- Standards derived from the case study Consumption of Cement • Total • Bill No. • 02.05 -50 } 255 bags RCC • 07.05 - 50 } 1. 30.05 - 100 } • 04.06 - 15 } • 30.07 -40 } 2. 12.08 - 100 } 300 RCC/UC • 02.09 - 100 } • 09.09 - 100 } 3. 02.10 - 200 } 300 RCC/UCR • 10.10 - 100 } • 09.11 - 100 } 220 Brick work Nov/Dec • 07.12 - 120 } • 5. 16.02.10- 100 bags plaster 1st Jan.10 Feb 10 • 6. 06.03.10- 140 bags plaster March 10 • 12.04.10- 100 bags waterproofing • 7. 29.04.10- 10 bags waterproofing, plumbing • 29.05.10- 100 bags Flooring & plumbing. • --------------- • 1,525 bags • 1525 ÷ 4000 = .381 bags • i.e. 38.10 bags/100 sft. • Say 40 bags/ 100 sft5.

40. Case study M.S. & Tor Steel • Bill No. • 1. 02.05.09 to17.07.09 = 1,10,625.00 - 1,10,625.00 • 2. 13.08.09 = 3,909.00 • 31.08.09 = 90,136.00 • 05.09.09= 19,482.00 1,13,527.00 • 3. • 16.09.09 = 1,00,320.00 • 23.09.09 = 14,511.00 • 06.10.09 = 8,840.00 • 12.10.09 = 41,321.00 • ------------------------ • 1,64,992.00 1,64,992.00 • 4 • 05.11.09 = 9,591.00 • 14.11.09 = 7,366.00 • 21.11.09 = 5,208.00 • ----------------- • 22,165.00 • ========== Total 4,11,309.00  • 13000 ÷ 4000 = 3.25 kg / sft. On Built-up area with Negligible Wastage of 1% i.e. 130 kg Say 13 ton

41. Site BUNGLOW OVERHEAD TANK- GRAVITY CURING

42. CONSTRUCTION WASTE ALL IN ONE DEBRIS – NO SCREENING SEPERATED DEBRIS- PARTLY SCREENED

43. CONSTRUCTION WASTE SCREENED AND HARD DEBRIS

44. CONSTRUCTION WASTE SEPRATION – GRADING CRUSHED SAND AFTER SCREENING OF DEBRIS

45. CONSTRUCTION WASTE PROTECTION OF DEBRIES FROM EXCARATED SOIL – DRAINGE LINE WORK BOTTOM & SIDES FILLED WITH CHAWL OR DEBRIS

46. “Concrete Rubble” RECYCLING RECYCLING

47. COMMERCIAL USE POSSIBLE

48. CURBING Gutters

49. ROAD DIVIDERS

50. THANK YOU Presentation By – R. D. Nagarkar Ex. Comm. Member ,P.C.E.R.F. Chairman, Constro 2007