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Resources, Conservation and Recycling 54 (2010) 250–255

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Resources, Conservation and Recycling


journal homepage: www.elsevier.com/locate/resconrec

A life cycle based environmental impacts assessment of construction materials


used in road construction
Raja Chowdhury a,∗ , Defne Apul a , Tim Fry b
a
Dept. of Civil Engineering, University of Toledo, 2801, West Bancroft St., Toledo, OH 43606, United States
b
Dept. of Mechanical Industrial and Manufacturing Engineering, University of Toledo, 2801, West Bancroft St., Toledo, OH 43606, United States

a r t i c l e i n f o a b s t r a c t

Article history: Industrial byproducts such as coal fly ash, coal bottom ash, and recycled concrete pavement (RCP) are
Received 18 July 2008 being used in considerable amounts as a full or partial replacement of natural aggregates. Studies com-
Received in revised form 10 August 2009 paring road construction byproduct materials with natural aggregates are limited. In the present study,
Accepted 14 August 2009
a comparison of these byproducts with natural aggregates was carried out with respect to cost, envi-
ronmental pollutants generated, and energy consumption. Pollutant emission data were aggregated to
Keywords:
express results in terms of global warming potential (GWP), acidification potential and various toxicity
Recycled materials
potentials. For assessment of toxicity potentials, all the toxicities were represented with respect to 1,4
Life cycle assessment
Toxicity potentials
dichlorobenzene. Mixed results were found from the Life Cycle Assessment (LCA) and no single material
Road construction performed superiorly in all categories. Fly ash and bottom ash were found attractive in cost, GWP, and
Aggregates acidification potential categories. RCP had higher GWP and acidification potential compared to natural
Fly ash aggregates. In toxicity categories, in some cases fly ash and bottom ash had higher; and RCP, in all cases,
RCP had much lower toxicity compared to natural aggregates.
Bottom ash © 2009 Elsevier B.V. All rights reserved.
Model
BenReMod

1. Introduction The Recycled Materials Resource Center has developed and made
available online (RMRC, 2008) a framework for screening the indus-
Extensive use of natural aggregates in construction projects trial byproducts for beneficial uses. The framework consists of lab
has been gradually depleting this resource near areas where scale leaching tests followed by field scale long term monitoring of
aggregates are in high demand. The need for resource conser- groundwater, surface water and soil quality surrounding the area
vation and lengthened transportation distances has increased where the byproduct is used. An industrial byproduct can be used
the demand to introduce substitute materials for natural aggre- for a beneficial purpose if the byproduct passes these screening
gates. At the same time, industry, construction and other tests.
similar activities produce large quantities of industrial byproducts Lab scale leaching tests have been a topic of research for many
such as coal combustion byproducts, foundry sand, construc- years. Different types of leaching tests have been developed to
tion and demolition waste, and steel slags that cause a assess the extent of long term pollution from subsurface use of
heavy burden on landfills. These byproducts can and have byproducts for conditions where environmentally relevant param-
been beneficially reused mainly as road construction materials eters such as pH, redox potential, and liquid to solid ratios may
(Ahmed, 1993). change (Kosson et al., 2002; prEN 14405, 2001; prEN 14429, 2001).
Industrial byproducts can contain trace concentrations of var- The leaching test protocols did not always simulate the proper envi-
ious pollutants that may potentially leach and contaminate the ronmental conditions and thus underestimated or overestimated
underlying soil and groundwater. Currently there are no universal the mobility of a pollutant from an industrial byproduct (Ghosh
specifications for addressing the environmental impact of byprod- et al., 2006). While much emphasis has been placed on leaching
uct reuse in road construction. Faced with this challenge, each state test protocols and risks of contaminant leaching, little attention has
has a different approach for decision making on byproduct reuse. been paid to other kinds of impact, such as energy consumption and
emissions that do not directly originate from the road materials. To
evaluate the use of energy consumption and environmental impact
∗ Corresponding author. from a broader perspective, a life cycle analysis (LCA) approach can
E-mail address: raja.chowdhury@utoledo.edu (R. Chowdhury). be used.

0921-3449/$ – see front matter © 2009 Elsevier B.V. All rights reserved.
doi:10.1016/j.resconrec.2009.08.007
R. Chowdhury et al. / Resources, Conservation and Recycling 54 (2010) 250–255 251

An LCA is a method of accounting for the environmental impacts from it, the leachate would be treated and there would not be any
associated with a product or a service. The method takes into major emissions to the environment. We followed the same logic
account various upstream processes and emissions generated dur- in this paper and accounted for the concentrations leached from
ing the lifetime of a product. Therefore, the primary task in an LCA the materials into the environment only when they are placed in
study is the estimation of emission factors (emissions generated the road.
from the production of unit mass of product) from various upstream The thickness, width and length of the section were taken as
processes directly and indirectly linked to the manufacturing of the 600 mm, 2.5 m and 1000 m respectively, resulting in a volume
products. The processes one would include to calculate emissions of 1500 m3 . We assumed that industrial byproducts and natural
depend on the system boundary of the project, which needs to be aggregates were transported from source to site by 32 ton trucks for
determined upfront. 50 km and 100 km, respectively. Cost of transportation was taken
There are several published examples of the use of LCA for eval- as $0.13/ton/km (Wilburn and Goonan, 1998).
uation of different materials in road construction. Rajendran and
Gambatese (2007) and Zapata and Gambatese (2005) presented a 2.2. System boundary
comparative analysis of energy consumption and solid waste gen-
eration associated with traditional reinforced concrete and asphalt System boundary is one of the most important parameters that
pavements. In Denmark, a model for LCA of road construction and affect the results of an LCA (Suh et al., 2004). System boundary of
disposal of waste generated from municipal solid waste incinerator a material in this study included the production and transporta-
was developed (Birgisdottir, 2005). In Finland, Mroueh et al. (2001) tion of the material and associated electricity and oil consumption
used an LCA model for road construction to assess the environ- (Fig. 1(a and b)). In production of the material (and refining the
mental impact from several alternative materials such as fly ash, oil) electricity is needed. In this work, only coal combusted electric
steel slag and crushed concrete. They found that the use of the generation was taken into consideration. Approximately 49% of the
industrial byproducts as a substitute for natural aggregate could electricity in the US comes from coal plants (EIA, 2008a). Energy
reduce the environmental impact for some of the impact categories. information administration data (EIA, 2008b) show that coal is the
However, except for the Danish model, none of these studies have primary power source for electricity production in some states (e.g.
included an extensive toxicity assessment approach. In the U.S., Ohio, Indiana, Kentucky). In addition, production of construction
PALATE (2008), an extensive tool for pavement life cycle analysis materials does not follow the US energy profile. For example, for
has been developed. PALATE does include a relatively more detailed cement industry 70% of the energy come from coal based power
toxicity assessment approach compared to other studies. However, (Huntzinger and Eatmon, 2009). Therefore, while the use of coal
learning and use of the model requires a significant time investment as an electricity power source is a simplification, an analysis of the
and it is also not practical to easily compare two or more materials effect of different energy sources was beyond the scope of this study
using PALATE. In addition, PALATE is based on an economic input especially considering that the energy mix changes in time, from
output analysis through use of EIO-LCA model; this approach while region to region, and from sector to sector.
powerful and well accepted may yield different results compared Most of the time, fly ash and bottom ash are readily used or
to a process based LCA approach (Junnila, 2007). The goal of this need very few processes to modify them for use in road con-
research was to develop a complementary, easy to use, web based struction. Environmental loading data from these processes is
tool for comparing materials used in road construction. We used almost nonexistent. For these reasons, environmental loadings
a process based LCA approach, and developed a web based model, of their production processes were not included in the present
BenReMod (http://benremod.eng.utoledo.edu/BenReMod/). In this study. However, their disposal cost at a landfill was consid-
paper, we report on BenReMod-LCA model results regarding the ered.
environmental impacts associated with use of natural aggregates Oil is necessary for transportation. The production of the fuel
in comparison to industrial byproducts such as coal fly ash, coal from crude oil extraction via refining to distribution was taken into
bottom ash, and recycled concrete pavement (RCP). Coal fly ash can account in this study. However, the manufacturing of production
also be used in cement manufacturing, however this study focused plants was not included in the system boundary. As far as vehicles
on direct replacement of the natural aggregate with byproduct are concerned, the production of the vehicles themselves have not
materials and evaluation of other beneficial uses of the industrial been taken into account, but we did take into account the operation
byproducts are not discussed in this paper.

2. Methods

2.1. Overview

The life cycle analysis approach was taken to compare environ-


mental impacts of natural aggregate, fly ash, and RCP when they
are used in road construction. (The focus of this research was on
impacts of diverting byproducts from their placement in landfills
and on resource conservation, thus the life cycle analysis focused on
direct comparison of natural aggregates with the industrial byprod-
ucts.) Construction activities such as excavation and compaction as
well as maintenance were not considered since we assumed that
environmental emissions and cost associated would be similar for
maintenance work. The toxicities generated from materials during
life time of a road were taken into account by various time horizons
Fig. 1. A schematic representation of the system boundary in the present study. (a)
of the toxicity categories. Olsson et al. (2006) excluded the landfill
System boundary for a material production and (b) system boundary for the trans-
metal leachate concentrations in their analysis with the assump- portation. (Note: dashed arrows indicate no transportation is required to proceed
tion that if a byproduct is placed in the landfill and metals leached from one process to the other).
252 R. Chowdhury et al. / Resources, Conservation and Recycling 54 (2010) 250–255

Table 1
Summary of processes and data sources included in system boundary for each mate-
rial. [Source: Stripple (2001)].

Material/impacts Processes included

Natural aggregate Natural aggregate production, transportation,


electricity consumption (Spath et al., 1999)
Fly ash Transportation, particulate matter generation
from fly ash sintering and drying (FIRE)
Bottom ash Transportation
RCP RCP production (various resources), oil
consumption, transportation

of the vehicle and principally the consumption of fuel, which is the


dominating component of the operation part. Fig. 2. . Processes for RCP production and machines available for each process.

2.3. Data collection 2.3.4. Fly ash and bottom ash


Data from different processes needed to refine the raw fly ash
Life cycle inventory data was collected from the literature for and bottom ash to a final product that can be used for various pur-
transportation of the materials, material production, associated poses are not available and therefore, not included in the inventory
energy use, and leachate concentrations emitted from the mate- data. Factor Information RetriEval (FIRE), software developed by
rials once they are placed in the road (Tables 1 and 2). Some of the USEPA (2008a) was used to estimate emission factors for particu-
compiled data are given in the supporting information. late matters from fly ash which is included in the present inventory.

2.3.5. RCP
2.3.1. Transportation
In RCP production, three major steps are involved in it (i) loading
Energy consumption and emission for the transportation were
and unloading of crushed concrete pavement (ii) primary crush-
collected from Stripple (2000, 2001). The web based model, BenRe-
ing and (iii) secondary crushing. Based on our calculation, in RCP
Mod uses four kinds of transportation modes (i) 14 T truck, (ii) 32 T
production, almost 57% of the energy was consumed during pri-
truck, (iii) Ship and (iv) Train. A 32 T truck was used for the analysis
mary crushing. A number of machines are available to accomplish
presented in this paper. Stripple has taken crude oil extraction and
each step (Fig. 2). Each machine has a different loading rate, oil
subsequent refining in the system boundary; however, the break
consumption, and productivity; these data were collected from
down of the data into emissions from extraction, transportation
manufacturing companies. Emissions from these machines were
and refining were not mentioned. Hence, electricity consumption
calculated by Eq. (1). Emission factors for non-road vehicles were
data for refining could not be modified according to the US energy
taken from AP 42 (USEPA, 2008b). After emissions for each machine
consumption data.
were calculated, average values of emission for each process were
averaged again to estimate emission factors for RCP production.
2.3.2. Electricity Energy consumption from RCP production was calculated using Eq.
Electricity inventory data were taken from a US coal fired based (2).
energy plant (Spath et al., 1999). The report includes emission from  HP × LF × EF × Tons
three different kinds of boiler systems. We have taken the average E= (1)
of three boiler system as emission factors for the present study. Prod
Transportation distance (434 km in barge and 48 km in truck) for  Tons × Fuel economy × EV/Vol
Energy required = (2)
hauling coal was taken as given by the authors (Spath et al., 1999). Prod
But the emission factors for the transportation were taken from
E = emission, HP = horse power of the machine (from manufacturer),
Stripple (2001). Hence, emission factors calculated in the present
LF = loading factor of the machine, EF = emission factor (from AP 42),
study is not the same as given by Spath et al. (1999).
Tons = tons of materials processed, Prod = productivity of a machine
(from manufacturer), EV = Energy value of fuel, Vol = volume of oil
2.3.3. Natural aggregate used (from manufacturer)
Inventory data for natural aggregate was taken from Stripple
(2001) after modifying the energy emission data to assume most 2.3.6. Leaching of heavy metals
of the electricity use in industry comes from coal power plants. Once the material is constructed, constituents in road materials
Inventory data of natural aggregate has two parts (i) emission from may leach and contaminate the groundwater. Apul et al. (2007)
crushing, and (ii) emission from energy industry due to use of have developed a method for estimating the concentrations of
energy in crushing process. Data for (i) were taken from Stripple metals reaching the groundwater using a contaminant fate and
(2001) and emission factors for energy industry were taken from transport model. Yet this approach was beyond the scope of this
data we gathered from Spath et al. (1999). work and leachate data obtained directly from the literature were

Table 2
Leaching data for various heavy metals (mg/kg) used in the present study.

Material Heavy metal Reference

Pb Cd Cr Hg Cu As Co

Natural aggregate 0.07 0.04 0.1 0.033 0.16 0.08 0.2 Tossavainen and Forssberg (1999)
Fly ash 0.5 0.1 0.1 – 0.1 0.1 4 Theis and Wirth (1977)
Bottom ash 1.92 0.08 1.2 – 0.16 0.6 0 Baba and Kaya (2004)
RCP 0.02 0.002 0.02 0.0006 0.02 0.005 – Wahlstrom et al. (2000)
R. Chowdhury et al. / Resources, Conservation and Recycling 54 (2010) 250–255 253

Table 3
Units for impact categories in the present LCIA and sources of data.

Category Reference unit Source of data

Energy consumption Loading (J × 10 )9


Spath et al. (1999) and Stripple (2001)
Acidification potential kg of SO2 CMLCA and Houghton et al. (2001)
Global warming potential kg of CO2
Human toxicity potential kg of 1,4 dichlorobenzene Huijbregts et al. (2000) and CMLCA
Aquatic ecotoxicity potential
Aquatic sediment ecotoxicity potential
Terrestrial ecotoxicity potential

used (Table 2) to estimate releases to the environment from the calculation of characterization factors in various toxicity categories
road construction material once it is in place. Different protocols one ionized form of each heavy metal was taken into account. For
have been used to estimate the leachable metals present in the example, for arsenic, only arsenic (V) is considered. Therefore, for
constituents. For example, leaching values obtained from natural calculation of toxicity potential, it is assumed that all the heavy
aggregate (Tossavainen and Forssberg, 1999) was used NT ENVIR metals are in one ionized form for which the characterization fac-
003 test (Swedish protocol for testing leaching of metals from solid tors are available.
matrix). USEPAs’ TCLP procedure was used to estimate the leach-
able metals content from bottom ash (Baba and Kaya, 2004). Some
data were reported in mg L−1 unit and were converted to mg/kg 2.5. Coding of calculations in BenReMod
unit for the purpose of this work. We assumed that the concen-
tration of leaching metals would be the same from different test After collecting the data, the web based model was devel-
protocols. oped for calculation and pictorial representation of the various
impact categories. Input parameters for each simulation are thick-
ness, width, and length of the road section. The other input
2.4. Life cycle impact assessment (LCIA) framework
parameters are transportation distances of various materials, and
the mode of transport. After providing the input parameters,
LCIA involves the translation of the environmental pollutants
users obtain various impact categories such as cost, energy, and
identified during data collection to environmental impacts. LCIA
various toxicity categories in tabular and in pictorial representa-
method is an area of ongoing research and different researchers
tion.
have formulated the impacts in different categories such as global
warming potential, acidification potential, and various other tox-
icity potentials (Birgisdottir, 2005; Geibig and Socolof, 2005). The 2.6. Effect of transportation
first step of LCIA is to classify the environmental loading into var-
ious categories (known as classifications). Characterization factors Transportation of materials increases energy consumption
are then used to quantify the magnitude of the contribution that and other environmental impacts. Hence, viability of a material
loading can have in producing the associated impact. depends on the proximity of the materials from the road construc-
The impact categories included in the present project were: (i) tion site. Hence, effects of transportation distance on the various
cost, (ii) energy consumption, (iii) acidification potential, (iv) global impact categories were also analyzed.
warming potential (GWP), (v) human toxicity potential (HTP), (vi)
aquatic ecotoxicity potential (FAETP), (vii) aquatic sediment eco-
toxicity potential (FSETP), and (viii) terrestrial ecotoxicity potential 3. Results and discussion
(TETP). Different characterization factors for toxicity assessment
methods are available in the literature (Huijbregts et al., 2000; 3.1. Cost of construction
Hoffstetter, 1998). Characterization factors for various toxicity
potentials were collected from the work of Huijbregts et al. (2000) In the present study, the cost of construction includes the
and from the database of CMLCA (CMLCA, 2008). Characteriza- material cost and the transportation cost. For the hypothetical
tion factors for acidification potential and global warming potential embankment construction, cost of construction varies between
were taken from Houghton et al. (2001) and from the database of −$60,000 and +$50,000 (Fig. 3). For industrial byproducts, the
CMLCA. All the characterization factors are expressed with respect tipping fee for landfills was considered and the cost of the tip-
to a reference value. For example, CO2 is used as a unit for express- ping fee was subtracted from the total cost. For this reason, for
ing global warming potential and 1,4 dichlorobenzene is used as a all the industrial byproducts, the cost of construction is nega-
unit for expressing various toxicity potentials (Table 3). The impact tive.
potentials for various categories were calculated by multiplying the
characterization factor (Ci ) with pollutants loading (Pk ) and then
summing all the multiplied values in a single impact category (Eq.
(3))


n
Impact categoryi = Cik Pk (3)
k=1

Details of the methods for derivation of characterization factors


are available in Huijbregts’ work (2000). Characterization factors
are derived for three time periods: 20 years, 100 years, 500 years
or for infinite time. For acidification potential, the characterization
factor was derived both by considering and ignoring the fate of the
pollutants (photooxidation and other abiotic processes in air). For Fig. 3. Cost of embankment construction using different materials.
254 R. Chowdhury et al. / Resources, Conservation and Recycling 54 (2010) 250–255

Table 4
Conventional air pollutants generated from material production (in kg).

Material SO2 CO NOx PM10 CO2

Natural aggregate 29 (88) 5 (33) 49 (44) 314 (100) 8487 (54)


Fly ash 0 (0) 0 (0) 0 (0) 230341 (100) 0 (100)
Bottom ash 0 (0) 0 (0) 0 (0) 0 (0) 0 (0)
RCP 50 (96) 99 (93) 457 (91) 33 (100) 20315 (80)

3.2. Pollutants generated of contaminants. Hence, for industrial byproducts, emission takes
place in soil compartment. At 20 years and 100 years time peri-
Conventional air pollutants generated from material produc- ods, air emission has higher impact to HTP. At infinite time horizon,
tion are shown in Table 4. Data shown in parenthesis is the % however, emission in soil compartment was also important for HTP.
of total emissions (material production and transportation) com- That is why at infinite time horizon, HTP generated due to indus-
ing from material production. Emissions from material production trial byproducts is higher than the shorter time span (20 years and
were higher for RCP than the natural aggregates. Emission of CO, 100 years).
CO2 and NOx from transportation were relatively high (67, 46, and For other type of toxicities, such as FAETP, FSETP, and TETP, emis-
54% of total emissions) for natural aggregates and not significant sions in soil compartment had more impact because leaching of
for RCP. heavy metals can directly reach the water bodies, and thus affect
the aquatic organisms (FAETP). Some of the heavy metals have high
3.3. Impact categories adsorption coefficient in soil particles and so they adhere to solid
surfaces and affect the organisms that live in sediments resulting
Results obtained from LCIA for each material are shown in in higher FSETP.
Figs. 4 and 5(a and b). Impact values (energy, GWP and AP) obtained The time for simulation was also found to be important for esti-
for natural aggregates were used as the reference values. To calcu- mating impacts. In the present study, all the emissions (except
late the normalized impact values, impact values obtained for other some heavy metals from natural aggregate) take place in the soil
materials were divided by the corresponding impact value obtained medium. Therefore, depending on the adsorption coefficient of
for natural aggregates. The normalized and absolute values of the heavy metals, some metals strongly adsorb to the solid surfaces,
impact generated by natural aggregates are shown as the solid line whereas other metals easily dissolve in water. Therefore, those
and the numbers above the solid line, respectively. metals that have strong affinity on solid surfaces take a longer time
Energy consumption, GWP and acidification potential generated to reach the human body through water or by accumulating in the
from the use of fly ash and bottom ash are almost one-third of the food chain. For these reasons, when metals are released into the
value of the natural aggregates. However, the impact generated air, they affect humans immediately, and so their effects become
from RCP is higher than the natural aggregate. In the acidification apparent within a short time frame (20 years for the present study).
category, the impact was almost three times higher for RCP com- But when they are released to the soil compartment, depending on
pared to natural aggregate. Acidification is a result of emission of their adsorption coefficients, they take a longer time to reach the
nitrogen oxide and sulfur dioxide gases. In RCP production, non-
road vehicles such as crusher and loader emit a high amount of
this acid producing gases/ton of produced RCP (data from individ-
ual vehicles are not shown here) resulting in a higher acidification
potential for RCP compared to natural aggregates.
In toxicity potential (HTP, FAETP, etc.) categories, mixed results
were observed. In HTP categories, all the materials had very low
toxicity compared to natural aggregates. However, in infinite time
period, bottom ash had higher toxicity compared to natural aggre-
gate. In TETP categories, fly ash and bottom ash had higher impacts
compared to natural aggregate.
For natural aggregates, emission of heavy metals takes place in
two compartments (a) air and (b) soil. For all the industrial byprod-
ucts, as there is no processing step, emission takes place as leaching

Fig. 4. Normalized values of energy consumption, GWP and acidification potential Fig. 5. Normalized values of toxicity potentials generated from construction using
for coal fly ash (FA), coal bottom ash (BA), and RCP. (Values over the line are for different materials. (Values over the line are for natural aggregate and approximated
natural aggregate and approximated to their nearest hundred). to their nearest hundred).
R. Chowdhury et al. / Resources, Conservation and Recycling 54 (2010) 250–255 255

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