WAS006-002: Demolition Exemplar Case Study

Recycling Demolition arisings at

Cardiff City Centre


Despite time and programme constraints imposed by the competitive tender
process, 98% of the demolition arisings were recycled.











Project code: WAS006-002 I SBN: 1-84405-361-X
Research date: April 2007 Date: J uly 2007





Front cover photograph: Aerial view of ongoing demolition works by Cuddy Group at Cardiff City Centre using
traditional demolition methodology to progressively deconstruct and recycle the various buildings.
While steps have been taken to ensure the accuracy of this case study, WRAP and Golder Associates 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. Care should be taken in using any of the data provided as
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Recycling Demolition arisings at Cardiff City Centre 1

Executive summary
Land Securities Plc appointed Cuddy Demolition and Dismantling Ltd to demolish numerous shops, an ice rink,
library, offices, car parks and other buildings at St Davids 2, Cardiff City Centre, to make way for the construction
of a new retail area with associated car park. This construction programme involved design, demolition,
construction and refurbishment in the city centre. Cuddy was awarded the 8 month contract worth 2.7 million
for the demolition works and construction of the sheet piling system only.

To date a recycling rate of 98% has been achieved. This is includes approximately 100,000 tonnes of demolition
waste (90,000 tonnes of which consisted of hardcore materials) This can be attributed to the use of the Cuddy
Cardiff Quality Protocol that was submitted to the EA SE Wales office and based on the WRAP quality protocol.
This document allowed for the classification of the inert demolition materials as a product rather that a waste.

The demolition works were carried out adjacent to a live shopping centre, residential area and traffic therefore
special measures were required. All buildings were demolished, using modern procedures including the following:
manual or mechanical soft strip, followed by structural demolition of the buildings by high-reach 50 to 80 tonne
excavators with concrete pulveriser attachments. Demolition works will be completed by digging a trench to
remove any obstructions and backfill the perimeter of the site in advance of the sheet piling system. The
construction of the sheet piling system will form the external wall of the basements for the new-build.



























Recycling Demolition arisings at Cardiff City Centre 2

Contents
1.0 I ntroduction............................................................................................................................. 3
2.0 KEY FACTS................................................................................................................................ 3
3.0 Project Details.......................................................................................................................... 3
4.0 The Quality Protocol for the Production of Aggregates from Inert Waste............................... 4
5.0 Project Planning....................................................................................................................... 4
5.1 Contractor Involvement .........................................................................................................4
5.2 Achievable Recycling Targets .................................................................................................5
5.3 Site Waste Management Plans................................................................................................5
6.0 Demolition works..................................................................................................................... 5
7.0 Reuse and Recycling Activities................................................................................................. 6
7.1 Soft stripping ........................................................................................................................6
7.2 Demolition and Recycling of Inert Materials.............................................................................6
7.3 Metals Recycling....................................................................................................................7
7.4 Materials Disposal..................................................................................................................8
8.0 Recycling Rates........................................................................................................................ 9
9.0 Quality of Recycled Materials................................................................................................. 10
10.0 Drivers and Barriers to Recycling........................................................................................... 10
11.0 Environmental and Social Considerations.............................................................................. 11
11.1 Transportation..................................................................................................................... 11
11.2 Socio- Economic Considerations ........................................................................................... 11
11.3 Environmental, Safety and Quality Considerations ................................................................. 12
12.0 Project successes and future improvements ......................................................................... 12
13.0 Further I nformation............................................................................................................... 12



Recycling Demolition arisings at Cardiff City Centre 3

1.0 I ntroduction

Land Securities Plc appointed Bovis Lend Lease Ltd (hereafter referred to as BLL), as the building contractor, and
Cuddy Demolition and Dismantling Ltd (hereafter referred to as Cuddy), as the demolition contractor, to demolish
numerous shops, offices and other buildings in the centre of Cardiff.

This case study looks at the factors attributing to and hindering the recycling rates of materials generated from
the demolition of mixed use and aged buildings at St Davids 2, Cardiff City Centre. The site was scheduled for
demolition during a strict 8 month time contract to make way for the construction of a new retail area with
associated car park in the city centre.

2.0 KEY FACTS


300 million construction programme involving design, demolition, construction and refurbishment of Cardiff
City Centre;

Retail shops and units, ice rink, library, offices and car parks to be demolished in central Cardiff to make way
for a new retail development;

Demolition works were carried out adjacent to a live shopping mall, traders, businesses, residents and traffic;

The Quality Protocol for the Production of Aggregates from Inert Waste was the key to the success of the
project;

98% of demolition wastes has been reused and recycled, despite no recycling targets being set.

Approximately 100,000 tonnes of demolition waste (90,000 tonnes of which consisted of hardcore material)
had been processed at the time of writing.

3.0 Project Details

Cuddy, a multi-disciplined contractor, was contracted by BLL to demolish a number of retail shops, units, offices
and two multi-storey car parks (some being 6 stories high) at St Davids 2, Cardiff City Centre. This area is to
make way for a new retail development in the city centre.


Client: Land Securities Plc;

Main Contractor: Bovis Lend Lease Ltd

Demolition Contractor: Cuddy Demolition and Dismantling Ltd

Recycling Contractor: Cuddy Demolition and Dismantling Ltd
The 300 million construction programme involves the design, demolition, and construction of a central part of
Cardiff City Centre, covering a total area of approximately 144,000 m
2
. Cuddy was awarded the 8 month contract
worth 2.7 million for the demolition works only. The contract was procured by a lengthy, price based traditional
tendering process.

The construction works are being phased over two periods. Phase 1 involved the demolition of a mix of large
retail store, smaller retail units, ice rink, library, market stalls and trading area, offices and two multi-storey car
parks. Phase 1 is expected to be completed in mid J une 2007. Phase 2 represents the construction phase and
includes the retail development for a large J ohn Lewis store and other retail shops in Cardiff City Centre and will
be undertaken by BLL.

This case study summarises the demolition and recycling activities of the Phase 1 demolition works.








Recycling Demolition arisings at Cardiff City Centre 4




















Figure 1: Ongoing demolition works at St Davids 2, Cardiff City
Centre with high reach excavators in the background.

4.0 The Quality Protocol for the Production of Aggregates from Inert Waste

Cuddy won the tender on price and being able to meet the stipulated time frame for the completion of the
demolition works at the site. Furthermore, Cuddy was able to keep costs low for the tender price due to their
development of a site specific quality protocol (hereafter referred to as the Cuddy Cardiff Quality Protocol) for
the Cardiff City Centre demolition works. It was produced by Cuddy and was submitted to the Environment
Agency (EA) SE Wales office. This site specific document is a quality management system for reprocessing and is
based on the WRAP document entitled The Quality Protocol for the Production of Aggregates from Inert Waste
(hereafter referred to as the WRAP Quality Protocol).

Cuddys Cardiff Quality Protocol was submitted to the Environment Agency (EA) SE Wales office in order to
classify aggregates produced from the demolition arisings at the Cardiff City Centre site as a product rather than
a waste. This Cuddy Cardiff Quality Protocol played a key role in achieving high recycling rates at the site and
provided Cuddy with a key differentiation from other tendering contractors. Typically aggregates from demolition
sites are classified as a waste and require the application of a Waste Management Licence (WML), or exemption,
in order to process, reuse and recycle such materials. However, for this project, Cuddy was able to ensure that
the materials were classified as a product rather than waste, which reduced the tender price significantly.

The importance of the WRAP Quality Protocol for this project, and potentially other UK demolition projects, can
not be over emphasised since it prevented the need for WML applications, documentation and associated
regulations, which ultimately allowed high recycling rates to be achieved for this project. The wide scale use of
the WRAP Quality Protocol would facilitate high recycling rates at other similar demolition sites across the UK.

5.0 Project Planning

5.1 Contractor Involvement

Cuddy competitively tendered for the demolition works and negotiated a demolition programme with BLL prior to
commencement of the works. There was little early contractor involvement in the planning of the project since
the work was won under a conventional tendering exercise. Approximately twelve weeks was given to the
project planning stage of the demolition works. This included hand over dates, partial occupation and service
terminations, method statements, risk assessments and asbestos surveys. The type 3 asbestos survey could only
be undertaken once the properties were vacated and the mains disconnected.


Recycling Demolition arisings at Cardiff City Centre 5

Recycling activities carried out on site, like most demolition sites in the UK, were constrained due to time and
programme pressures imposed by the main contractor and client. Even with such constraints, Cuddy were able
to achieve high recycling rates based on their experiences with processing and recycling inert demolition wastes
and through the use of the Cuddy Cardiff Quality Protocol. This enabled the reuse of aggregates off-site without
the need for a WML.

5.2 Achievable Recycling Targets

No recycling targets were set for this project. Unfortunately, not enough time was allocated for the demolition
works to enable Cuddy to maximise the reuse of materials on-site. The client had the ultimate say on the
amount of time that the contractor was allowed to spend on site, which was also specified as a strict requirement
during the tendering process. Time and programme constraints prevented the best on site recycling of resources
and only 10,000 tonnes (out of a total of 90,000 tonnes of inert material) produced on site was reused mainly by
trade contractors. However, the Cuddy Cardiff Quality Protocol was the key factor to overcoming these
constraints and to achieving high total recycling rates from the project.

The Cuddy Cardiff Quality Protocol facilitated the immediate reuse of aggregates off-site as a product. The Phase
1 demolition works have achieved a 98% recycling rate to date.

5.3 Site Waste Management Plans

A Site Waste Management Plan (SWMP) was not developed for the demolition works; however, BLL maintain
detailed weekly records of how much demolition material is produced, recycled and where it is sent by tracking
vehicle movements. All Cuddy projects include the need to integrate environmental, safety and quality
considerations into the procurement process. The contract for this project did not apply any targets to the
recycling of materials.

6.0 Demolition works

Commencement of the Phase 1 demolition was delayed by the termination of services and disconnection of mains
to the properties (i.e. gas, electricity and water). Once the mains were disconnected, the asbestos surveys were
undertaken and the demolition works were carried out in a traditional manner starting with the removal of
asbestos and any other hazardous materials.

Figure 2: The systematic demolition of the library using a high reach excavator at the Cardiff City
Centre demolition site.

Recycling Demolition arisings at Cardiff City Centre 6

The area planned for demolition consisted of a combination of building types. Most buildings were constructed of
reinforced concrete structures and steel framed buildings of various ages dating back to the 1950s and 1970s. All
of the brick and concrete structures, and steel framed buildings where demolished, using modern demolition
procedures. It began with manual or mechanical soft strip otherwise known as strip out works. This involved
the systematic removal of all internal fixtures, fittings, and temporary structures to leave an empty shell.
Structural demolition of the buildings was undertaken by high-reach 50 to 80 tonne excavators with concrete
pulveriser attachments.

The systematic deconstruction of the buildings following mains disconnection and soft stripping, allows the safe
and controlled demolition of structures and the effective management of potential environmental nuisances such
as dust and noise. It provides an orderly framework for the systematic identification and separation of material
for reuse and recycling.

At the time of the site visit demolition of the buildings was 80% completed. Once the demolition works is
completed, Cuddy will dig a trench (to a depth of 4m and width of 2m) to remove any obstructions and backfill
the perimeter of the site in advance of the sheet piling system. The construction of the sheet piling system will
form the external wall of the basements for the new-build.

7.0 Reuse and Recycling Activities

Activities on site included disconnecting the buildings from the mains, removal of asbestos, soft stripping of
materials and systematic demolition of various buildings using excavators. This was followed by removal of items
for source segregation and off site reuse, recycling or disposal.

The sequence of works was defined during the tender estimating stage to establish the most economical solution
for the demolition works within a very specific time frame and programme. The materials were identified during
a pre-demolition inspection by the Cuddys estimator based on their knowledge of the local reuse and recycling
market.

The 5 key activities were as follows:


asbestos removal and soft stripping of internal soft furnishings;

demolition of buildings and segregation of inert materials for recycling;

on site source segregation and processing of demolition wastes, largely for off-site use;

disposal by landfill of timber, glass, general wastes and asbestos materials; and

processing of 10,000 tonnes of inert material for use on site.
7.1 Soft stripping

Asbestos removal was followed by soft stripping. The soft stripping involved the removal of non-structural items
from the building interior. Typical materials soft stripped included, plasterboard, carpets, false ceilings,
furnishings, fixtures and fittings, furniture, doors and doorframes after the mains were disconnected. Soft
stripping serves two purposes; firstly, it reveals the building structure, which can then be demolished and
recycled with minimal contamination from other unwanted materials such as interior fixtures and fittings;
secondly, it allows for the effective source segregation of materials for recycling.

Soft stripping would normally be carried out at the contractors discretion, driven by financial incentives and
market forces. However, Cuddy made a contractual agreement to soft strip before structural demolition. This
played a key role in achieving high recycling rates and maintaining quality source segregation.

7.2 Demolition and Recycling of Inert Materials

After soft stripping, the structural elements were demolished and inert materials were segregated and pulverised
on site. Key material streams were concrete, steel reinforcement or rebar and brick. Due to time and
programme constraints, treatment such as crushing and sorting were primarily carried out off-site at Cuddys
screening, crushing and recycling facility in Leckwith, only basic pulverising took place at the demolition site.


Recycling Demolition arisings at Cardiff City Centre 7

At the time of writing 80,000 tonnes of demolition arisings has been source segregated on site and sent to
Leckwith. This facility is situated only 4 miles from the demolition site minimising haulage, traffic congestion and
environmental emissions. The demolition arisings were classed as a 1C product and were screened and crushed
to the required specifications for reuse. Most material was crushed to the 6F2 specification or smaller but this is
dependent on the end user and the product they require for use. Originally, before the Cuddy Cardiff Quality
Protocol was approved by the Environment Agency SE Wales office, all demolition material was sent to the
Newport recycling facility approximately 18 miles from the demolition site. However, on this project, only 10% of
the total material was sent to Newport. 10,000 tonnes of demolition material has remained on site for the
construction of the piling platform.





























The recycling rate of 98% achieved on this project is considered optimal. However, it is evident that had time
and programme allowed for it, a greater quantity of demolition material could have been crushed and reused on
site for the redevelopment works. The focus of the works was to clear the site as quickly as possible to allow the
construction of the new retail area. As a result, the fast track programme for the demolition works has been the
main barrier to the achievement of high on-site recycling rates.

The use of the Cuddy Cardiff Quality Protocol to make use of the demolition materials as a product rather than a
waste has been the main contributor to achieving a 98% recycling rate, as well as the use of nearby reuse and
recycling facilities for the inert demolition arisings, ferrous and non ferrous metals. Furthermore, the soft
stripping approach contributes to the good recycling rates of materials off-site despite the time constraints for
the planned demolition works.

7.3 Metals Recycling

Ferrous and non ferrous metals were source segregated on site for onward recycling by scrap metal merchants.
At the time of writing, 5,800 tonnes of ferrous metals and 100 tonnes of non ferrous metals have been recycled
by EMR in Cardiff and Swindon respectively.

Although all metals were recycled by scrap metal merchants, it is worth mentioning that limited time and
programme pressures to complete the demolition works restricted the cutting of reinforced rebar and structural
steel on site to the desired 5 x 2 x 2 specification, as normally required by scrap metal merchants to obtain the
Figure 3: Sorting, screening and crushing of hardcore and some reinforced rebar
at the Leckwith site, which is another civil engineering project for two sports
stadiums run by Cuddy, only 4 miles from the demolition site.

Recycling Demolition arisings at Cardiff City Centre 8

greatest revenue on this resource. Instead, uncut metal waste was sent off site in large 30 yard roll-on-roll-off
(RORO) containers and less revenue was generated for the metals.

7.4 Materials Disposal

Due to health and safety constraints and the need to maintain cost effectiveness, some soft stripped materials
such as glass and timber became mixed during the demolition process. In order to recycle the timber and glass
on site, Cuddy would have needed to increase the amount of labour required to undertake the difficult process of
manually separating such material. Increased on site labour to recycle glass and timber would be to the
detriment of health and safety and put labour in proximity with the demolition equipment. Instead, glass and
timber fixtures and furnishings were source segregated and sent to landfill in a mixed state. Glass waste
surrounded with metal frames, plastic coverings and adhesives etc was sent directly to Bryn Pica landfill in
Aberdare. Plasterboard was sent to a plasterboard producer for re-processing. Most timber, compressed paper
board ceiling tiles with nails, metal, treated chemicals, metal frames and plastic coverings were also sent to the
Bryn Pica landfill. A total of 1,536 tonnes of timber, glass, plastic and mixed waste, and 40 tonnes of asbestos
have been disposed of by landfilling at the time of writing.


Figure 4: Source segregation of metals and inert hardcore at the Cardiff City Centre
demolition site.

Recycling Demolition arisings at Cardiff City Centre 9


8.0 Recycling Rates

Despite not being set, Cuddy managed to obtain a 98% recycling rates Cuddy maintains a daily schedule of
driver tickets for all the inert material and waste transfer notes (WTNs) for all metals and landfilled materials.
The WTNs indicate the types, quantities and destinations of waste materials. The following reuse and recycling
percentages were calculated based on the total tonnages of recycled material (95,900 tonnes) from the site to
date.


93.85% Hardcore
6.05% Ferrous
metals
0.10% Non
ferrous metals
Hardcore (90,000 tonnes)
Ferrous metals (5,800 tonnes)
Non ferrous metals (100 tonnes)


Although the demolition works were only 80% completed at the time of the site visit, a 98% recycling rate has
been obtained and is expected to be the same when the works have been completed.

Typical recycling rates from demolition projects are usually in the order of 60-70%. Significantly higher rates
were achieved primarily as a result of the following:


The Cuddy Cardiff Quality Protocol and the classification of aggregates as a product rather than a waste;

Use of nearby Leckwith screening, crushing and recycling facility; and

Soft stripping of materials for salvage and reuse of items.

Figure 5: On site
sorting of ferrous
metal into large 30
yard RORO
containers for off
site recycling by
ERM in Cardiff
Figure 6: Breakdown of materials recycled to achieve the 98% recycling rate

Recycling Demolition arisings at Cardiff City Centre 10

98% Recycled
2% Landfilled












9.0 Quality of Recycled Materials

For this project, the immediate source segregation and pulverisation of inert demolition arisings to class 1C
specification followed by off-site removal of the material to the Leckwith site for further crushing and recycling
played an important role in preventing their contamination and ultimately achieving high recycling rates of inert
materials.

The quality of materials was ensured by the Cuddy Cardiff Quality Protocol, which stated that the material would
be treated as a product if the class 1C specification is achieved through pulverisation on site.

Cuddys Leckwith site processes material according to the specifications set in the Specification for Highway
Works, November 2005, Series 600. For example, the inert demolition arisings are crushed to class 1C aggregate
at the demolition site where after it is then sent to Leckwith to be crushed to the Highways Agency 6F2
aggregate specification. This 6F2 recycled aggregate is being used at the redevelopment site to build the
stadium, hotel and retail park in Leckwith.

Waste timber and glass from the site was contaminated by other materials (i.e. metal frames, plastic coatings
and nails etc). The recycling of this heterogeneous timber and glass is limited by the lack of potential markets.

10.0 Drivers and Barriers to Recycling

The underlying drivers for reuse and recycling on this Cardiff City Centre project are as follows:


The financial value of recycled material resources.

The Cuddy Cardiff Quality Protocol and the classification of aggregates as a product rather than a waste;

Use of the nearby recycling facilities for hardcore and metals; and
The technical know-how, market knowledge and the Cuddy Cardiff Quality Protocol of the demolition contractor
played a key role in unlocking the recycling potential of the project.

As with most projects that involve competitive tendering rather than a collaborative partnership approach, the
potential barriers to the recycling initiatives were programme, time and space. Programme issues and the strict
time frame to complete the demolition works within 8 months, in order not to hold up the future redevelopment
works, prevented the reuse of the recovered aggregate on site. Furthermore, the lack of UK facilities for
heterogeneous timber and glass wastes negated their reuse and recycling.

The overall 98% recycling rate to date represents an optimum recycling achievement despite the inflexibility of
the tender contract. Cuddy provided significant market knowledge, and the viability of recycling was primarily
Figure 7: The percentage of
materials recycled compared to
that landfilled to date from the
Cardiff City Centre demolition
site

Recycling Demolition arisings at Cardiff City Centre 11

driven by the Cuddy Cardiff Quality Protocol. The cost of further increasing the recycling rate would have
outweighed the value of the recycled materials, undermining the economic and practical viability of the initiative.

11.0 Environmental and Social Considerations

Cuddy has Quality Management Systems and Standards and is a member of the British Safety council. They are
BS EN ISO 9002 and BS EN ISO 18001 accredited and working towards BS EN ISO 14001 accreditation.

Cuddy carried out asbestos surveys, prepared method statements and risk assessments for all their demolition
projects to identify risks to human health and the environment and develop effective mitigation measures to
reduce risks to an acceptable level.

A key challenge for the Cardiff City Centre project was to carry out the demolition while allowing normal activities
to continue in the adjacent retail shops, businesses and residential areas. The close proximity of traffic and
nearby shoppers and businesses were vulnerable receptors, and care had to be taken to ensure their health and
safety, control risks and manage the demolition without harm to human health and the environment.




11.1 Transportation

Traffic congestion caused by vehicles removing materials from the site was kept to a minimum by using nearby
recycling facilities. However, the negative impacts of reduced parking and road closures to make way for the
demolition and redevelopment of this area were unavoidable. This negative impact on traffic will remain until the
new car park is constructed and road closures are removed.

11.2 Socio- Economic Considerations

Adjacent shopping activities, local businesses and residents also needed to be protected from potential adverse
impacts of the demolition work. Cuddy ensured the health and safety of nearby businesses and residents by
undertaking risk assessments prior to carrying out the works.

Dust, noise and increased traffic congestion were the main negative environmental impacts as a result of the
works. Dust suppressors were used throughout the works. Furthermore noise and increased traffic is
unavoidable until the redevelopment is completed.

Positive social impacts of the actual project works included the removal of unsightly buildings to make way for
new and better facilities for the public. Furthermore, the removal of vacant building prevented antisocial
behaviour that is commonly associated with vacant, derelict properties.
Figure 8: Aerial view
of the demolition works
at Cardiff City Centre,
illustrating the
proximity to live
businesses, residents,
neighbouring buildings
and roads.


Recycling Demolition arisings at Cardiff City Centre 12


11.3 Environmental, Safety and Quality Considerations

Cuddy is committed to reaching high Quality Management Systems and Standards and is accredited to BS EN ISO
9002, which underpins their commitment to continuous improvements. In August 2000, Cuddy gained the highly
prestigious Quality Assurance Award by the Asbestos Removal Contractors Association (A.R.C.A.) under their site
audit accreditation scheme in recognition of their excellent site standards, safe working methods and
management systems.

Cuddy is committed to working towards Health, Safety and Environmental Best Practice. As such, the key aims of
all Cuddy projects include the need to integrate environmental, safety and quality considerations into the
procurement process.

Cuddy incorporated their environmental, safety and quality considerations into the traditional competitive
tendering for this project. It should be noted that the tendering process did not involve any early dialogue with
the contractor or main client. Furthermore, the tender did not require detailed recycling targets to be set.
Instead, the long tendering process stipulated a strict time frame for completion of the demolition works within
one year from commencement.


12.0 Project successes and future improvements

Cuddy is committed to continual improvement in services and environmental performance for their clients.

They endeavour to incorporate recycling as part of their standard operations; however, traditional competitive
tendering and strict time and programme pressures often hamper the recycling of resources and sustainability
objectives of a project.

Cuddy successfully overcame the barriers of inflexible competitive tendering by making use of the Cuddy Cardiff
Quality Protocol based on the WRAP Quality Protocol, which allowed for the classification of the inert demolition
materials as a product. This document played a key role in keeping the expenses of the project low, since WMLs
were not required for the recycling facility at nearby Leckwith. The use of other nearby recycling facilities and
value of recycled resources provided successful mechanisms for incorporating high recycling rates and
sustainability objectives into the project delivery process.

The actual recycling rate of 98% to date surpassed the average 60-70% recycling rate at UK demolition sites.

Due to site constraints, some heterogeneous wastes such as glass and timber could not be recycled and had to
be transported off site for landfilling.

Future projects should aim to push the classification of aggregates from demolition sites as a product rather than
a waste and place more emphasis on the reuse of such materials. This project demonstrates that classing the
recycled aggregates as a product rather than a waste can overcome perceived barriers associated with cost and
programme. Economically viable high recycling rates can be achieved far beyond the norm.

13.0 Further Information

WRAP has developed a step-by-step guide to the efficient use of materials in regeneration projects which will
integrate the ICE Demolition Protocol, SWMP and WRAP recycled content approaches.



Written by: Natalie Kohler




Published by
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