1 Reverse logistics. Case study. Reverse logistics for plasterboard. A unique
operation to manage the delivery of plasterboard and backhaul the off-cuts and ...
1 Reverse logistics
Case study
Reverse logistics for plasterboard A unique operation to manage the delivery of plasterboard and backhaul the off-cuts and wastage Introduction Reverse logistics is the use of those vehicles delivering materials to a location to backhaul materials. In the context of this case study, it is the use of vehicles delivering new construction materials to a site to return the unused materials and off-cuts back to the manufacturer for reuse and recycling. There are a number of benefits to implementing an effective reverse logistics operation. These can be summarised as: effective waste management – targeting and backhauling specific waste streams often diverts this material from landfill, and ensures that it can be swiftly recycled into new product;
EJ Berry bags used to deliver and collect off-cuts of plasterboard at the Gloucestershire construction site
costs – backhauling opportunities can often save in waste management costs or be cost neutral;
Recycling gypsum from carbon impact – backhauling materials in vehicles that would previously have returned empty often results in lower waste plasterboard back emissions than those from waste collection vehicles; and into the manufacture of new health and safety / site efficiency – using plasterboard represents a reverse logistics can reduce the number of separate vehicle visits to site. closed-loop recycling solution In order to assess the potential benefits of Key facts At the site 10% of plasterboard material is wasted (typically through offcuts). This percentage compares favourably with current industry standards and good practice. Backhauling the wasted materials equates to reduced transport equivalent to approximately 1,010 km per year. There is a reduction in the site waste management costs of £1,200 per year.
reverse logistics to a range of construction sites, WRAP (Waste & Resources Action Programme) has developed a spreadsheet model that allows the user to input details about their site, and determine the costs and benefits of implementing reverse logistics. This case study assesses the benefits of reverse logistics offered as a service by Recycled Solutions UK Ltd – an organisation that combines the logistics of plasterboard supply with collection of waste plasterboard for recycling.
2 Reverse logistics
Project Details Recycled Solutions, a subsidiary of EJ Berry (a construction product supplier) was established in 2007 to provide a nationwide plasterboard backhauling service. This involves offering clients both material supply and waste management / logistics solutions in one. Focussing mainly on plasterboard and insulation products, EJ Berry delivers the new materials, and once a specified level of wasted material (spoilt materials and offcuts) has arisen, collects these in single-use bags using the same vehicles. The combined materials supply and waste logistics service suits Recycled Solutions clients’ needs, in terms of cost, reliability and in meeting their corporate targets. The service also benefits the environment in terms of reduced carbon footprint. Recycled Solutions’ facility (co-located with EJ Berry) enables them to bulk both materials for supply, and waste material for onward transport to a recycling facility. The site that is the focus of this case study is operated by building contractor Leadbitter. Operating mostly in central and southern England and Wales, Leadbitter is currently lead contractor on a site in Gloucester where they are managing the construction of a £15 million sheltered housing village. Scheduled for completion in 2010, this village will house 250 people aged 55+ with a mixture of accommodation, shopping, hospitality and recreation facilities. Recycled Solutions are managing the delivery of plasterboard to the site. Plasterboard is first delivered to the EJ Berry depot from
the manufacturer, LaFarge, based in Bristol. From their depot in Lydney, EJ Berry lorries deliver the plasterboard to the construction site, and drop off numbered waste bags for the plasterboard. The lorries used are mainly 32 tonne curtainsiders which, when there is sufficient waste arising, will pick up waste plasterboard and deliver it back to the EJ Berry depot where it is logged and weighed. EJ Berry do not collect the waste plasterboard packaging, this is dealt with by the site waste contractor. The responsibility of filling the plasterboard bags falls to plastering sub-contractor Advanced Dry-Lining (ADL). The plasterers will use the bags (standard construction one-tonne-bags) as they work, filling them with off-cuts. These are stored for a short while by Leadbitter before being picked up by the next available EJ Berry delivery vehicle. By working closely with both ADL and Leadbitter, Recycled Solutions can ensure that contamination is kept to a minimum, and pickups of new bags are made promptly and efficiently. The true reverse logistics legs of this journey are therefore from the EJ Berry depot to site and return. EJ Berry supply many projects in the south west of the country, where they operate a similar reverse logistics scheme. They accumulate plasterboard waste at their depot and when sufficient plasterboard waste has been gathered at the depot, Recycled Solutions arrange for the transfer of this material to New West Gypsum Recycling, located close to (and supplying) LaFarge.
A pile of plasterboard at a construction site (Courtesy of Construction Photography)
3 Reverse logistics
A workman separates plasterboard waste into appropriate skips at a construction site (Courtesy of Construction Photography)
Modelling Recycled Solutions provided detailed information on the Gloucester site which included plasterboard delivery and pick up records and vehicle details such as the payload capacity. Since deliveries started in 2009, Recycled Solutions have supplied 375 tonnes of plasterboard to the site and collected 37 tonnes of wasted materials. This percentage of 10% wasted plasterboard compares favourably with current industry standard practice and has largely been achieved through the “designing out” of waste prior to the build stage of the development. In practice this means that the storey height of build has been designed so that where possible whole sheets of plasterboard are used and therefore waste from off-cuts is minimised. Quote “With our background in supplying construction materials we have been able to provide both the developer and drylining contractor with an efficient common-sense approach to plasterboard recycling. Managing plasterboard supply and waste-return offers many benefits allowing the developer to readily meet their obligations to meet sustainability targets for EcoHomes, ‘the Code’, SWMPs and deliver tangible CO2 savings. All this can be provided at costs equal to or lower than the traditional skip and fewer vehicles visiting each site removing the waste.” Paul Trickett General Manager Recycled Solutions UK Ltd
In order to be able to determine the true benefits of reverse logistics, the operation was compared to a scenario where the wasted material is not backhauled but is instead collected by the site waste contractor in 12 yard skips. The waste contractor would deliver the wasted material to New West Gypsum Recycling where the wasted material would be reprocessed. The vehicles would then return empty to the waste contractor’s depot. What are the results of using WRAP’s Reverse Logistics model? Modelling shows that by backhauling the wasted material there is a reduction in the site waste management costs of £1,200 per year. This is based on a quoted figure by a waste management contractor of £150 per skip. The carbon footprint of the Reverse Logistics and Waste Contractor scenarios were also calculated. This exercise showed that the distance travelled in the reverse logistics scenario through the backhauling of materials is approximately 1,010 km less per year than the scenario where wasted material is collected by the waste contractor. The equivalent net reduction in carbon emissions is 0.86 tonnes CO2 per year.
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Recycling waste plasterboard Recycling gypsum from waste plasterboard back into the manufacture of new plasterboard represents a closed-loop recycling solution. Alternative uses for recycled gypsum include use in the manufacture of cement, ceramic products and as a soil improver. Further information can be found on WRAP’s website.
The model can be used at a number of different times during a project lifespan:
Application to other materials Where manufacturers can recycle the off-cuts of their materials back into new product, take back schemes are becoming increasingly popular. WRAP’s Reverse Logistics model is free to download (www. wrap.org.uk/constructionlogistics) and can be used to assess backhauling opportunities for a specified operation and a wide range of construction materials. The model is designed to be used by both material suppliers and building contractors in determining the most efficient logistics solution for their site.
At project scoping
To determine the potential benefits to the project that reverse logistics could bring.
When tendering for material suppliers
To assess the best combination of material supply and waste management. The outputs from the model can be used to guide discussions between suppliers and contractors.
During the project
To assess progress against plan
Retrospectively
To determine what benefits could have been realised on a previous project.
With access to the right data, the model takes approximately 30 minutes to complete for a first pass assessment of a few material take-back opportunities. If fewer data are available, then the user can select from predefined information regarding a wide range of material types. WRAP Construction Programme: http://www.wrap.org.uk/construction Case Study – Plasterboard take-back EJ Berry: http://www.wrap.org.uk/constructionlogistics While steps have been taken to ensure its accuracy, WRAP cannot accept responsibility or be held liable to any person for any loss or damage arising out of or in connection with this information being inaccurate, incomplete or misleading. This material is copyrighted. It may be reproduced free of charge subject to the material being accurate and not used in a misleading context. The source of the material must be identified and the copyright status acknowledged. This material must not be used to endorse or used to suggest WRAP’s endorsement of a commercial product or service. For more details, please refer to our Terms & Conditions on our website – www.wrap.org.uk
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