Draft 9/17/09 ACTIONS AIMED AT INCREASING THE BENEFICIAL USE OF FOUNDRY SAND A MULTI-STAKEHOLDER ACTION PLAN September, 2009 Draft 9/17/09 September, 2009 Over the past year, a core planning group has worked in consultation with a broad group of stakeholders, to consider various actions for increasing the beneficial use of foundry sand. This process has produced a Multi-Stakeholder Action Plan (MAP) which identifies key challenges to increased beneficial use, and a comprehensive set of actions aimed at increasing the beneficial use, of foundry sands. These actions will a) document the economic and environmental case for beneficial use, b) foster sustainable markets linking sand generators with end users, c) address regulatory processes, and d) establish a coordinated framework to oversee implementation and measure progress. The planning process also generated a set of Initial Priority Actions that various key parties are undertaking over the next few years. These actions will address many of the challenges identified in the MAP and lay the groundwork for implementation of additional MAP actions. Currently, the foundry industry estimates that about 28% of sands are directed to beneficial use. The industry’s national trade association—the American Foundry Society—has set a goal of 50% beneficial use by 2015. During the development of the MAP, the stakeholders listed below expressed support for this goal and committed to work together towards achieving it through implementation of the Initial Priority Actions. Organizations Playing Key Roles Implementing the Initial Priority Actions American Foundry Society American Foundry Society-Foundry Industry Recycling Starts Today (AFS-FIRST) USEPA, Office of Policy, Economics, and Innovation USEPA, Office of Resource Conservation and Recovery USEPA Region 3, 4, 5, and 9 Federal Highway Administration, Pavement Technology Division Federal Highway Administration, Resource Center United States Department of Agriculture, Agricultural Research Service United States Department of Agriculture, Cooperative State Research, Education, and Extension Service Beneficial Use Task Force of the Association of State, Territorial, Solid Waste Management Officials Michigan Department of Environmental Quality Recycled Materials Resource Center American Association of State Highway and Transportation Officials Mulch & Soil Council United States Composting Council ASTM International American Public Works Association National Association of County Engineers Draft 9/17/09 THE MULTI-STAKEHOLDER ACTION PLAN (MAP) FOR INCREASING THE BENEFICIAL USE OF FOUNDRY SAND TABLE OF CONTENTS INTRODUCTION PART 1 INITIAL PRIORITY ACTIONS STAKEHOLDERS ARE UNDERTAKING Chart of Initial Priority Actions The Implementation Steering Group PART 2 A COMPREHENSIVE LIST OF CHALLENGES AND ACTIONS FOR INCREASING BENEFICIAL USE APPENDICES 1. ORGANIZATIONS THAT CONTRIBUTED TO THE DEVELOPMENT OF THIS MAP 2. CHARACTERISTICS OF FOUNDRY SAND Draft 9/17/09 INTRODUCTION Industrial byproducts that historically have been disposed of are now being considered for beneficial use. Beneficial use can reduce our nation’s carbon footprint and consumption of virgin materials, and result in economic gains. It is an important component of the nation’s solid waste management hierarchy that first promotes source reduction or waste prevention, followed by reuse, recycling, energy recovery, and disposal. Foundry sand from iron, steel, and aluminum foundries is a prime candidate for beneficial use (see Appendix 2 for a brief discussion of the physical, functional, and risk characteristics of these sands). Its recycling can result in cost savings for both foundries and end users, while also leading to a net reduction in greenhouse gas emissions and raw material extraction and consumption. Furthermore, a draft USDA/USEPA risk assessment of foundry sands from aluminum, iron, and steel foundries indicates that most of these foundry sands are safe for beneficial uses including manufactured soils in residential settings.1 As much as 9-10 million tons of sand are discarded by foundries in the United States each year. This sand has been used to form the molds into which molten metals are poured, thereby producing everything from kitchen faucets to engine blocks. Although the sand is used multiple times in the foundry, eventually it must be replaced in order to maintain proper grain size. Once its useful life at the foundry is reached, sands that meet environmental criteria can be beneficially used as fill in road and building construction, as an ingredient in cement or asphalt, and in soil blends for landscaping and horticulture. Currently, the foundry industry estimates that about 28% of sands are directed to beneficial use. USEPA has estimated that this beneficial use is “saving 212 billion BTUs of energy per year…enough to provide electricity to over 5,500 houses a year. In addition, [it is] preventing 20,000 tons of CO2 emissions. This is equivalent to taking 3,382 cars off the road for a year.”2 The industry’s national trade association—the American Foundry Society—has set a goal of 50% beneficial use3 by 2015, which will almost double these environmental benefits. USEPA and other stakeholders support this goal and commit to working with the industry to achieve it through implementation of the priority actions identified in this document. Significant investment by industry and government agencies in research and demonstration projects has enabled many foundries to successfully recycle foundry sands. Nonetheless, in order to reach the 50% goal by 2015, more must be done to ensure that research results, case studies, and economic and environmental benefit information is made available to a broader range of stakeholders. As important, new efforts are needed to develop and disseminate information about sand characteristics and to better identify markets for individual foundries and sources of sand for individual end users. This Multi-Stakeholder Action Plan (MAP) provides an overview of the actions most needed to increase beneficial use of safe, functional foundry sands from aluminum, iron, and steel foundries. Part 1 of the plan lists a set of Initial Priority Actions stakeholders are undertaking, and describes the Steering Group that will keep track of and guide implementation. Part 2 presents the challenges stakeholders need to address and an array of actions that should be undertaken to maximize beneficial use over the long term. A “core planning group” composed of representatives from the USEPA, the American Foundry Society – Foundry Industry Recycling Starts Today (AFS-FIRST), and the Association of State and Territorial Solid Waste Management Officials (ASTSWMO) Beneficial Use Task Force prepared the MAP through discussions with, and written input from, a broad range of stakeholders (see Appendix 1 for a list of organizations that contributed to the effort). Following the identification of the general challenges and accompanying actions, the planning group and other stakeholders prioritized activities and compiled the list of Initial Priority Actions. 1 USEPA, US Department of Agriculture, Ohio State University, “Risk Assessment of Spent Foundry Sands in Soil-Related Applications, Peer Review Draft”, May 2009 (formal peer review to be conducted in August – September 2009). 2 USEPA presentation at the Foundry Sands Soil Forum, July, 2008 (Columbus, Ohio). 3 The AFS survey did not include alternative daily cover for municipal landfills. To remain consistent, the 50% goal also does not include alternative daily cover. 1 Draft 9/17/09 PART 1 – INITIAL PRIORITY ACTIONS STAKEHOLDERS ARE UNDERTAKING Chart of Initial Priority Actions The chart below sets forth the Initial Priority Actions that stakeholders are undertaking. (A list of the chart acronyms follows the chart.) Initial Priority Actions Stakeholders Are Undertaking Lead Entity Additional Completion Entities The USEPA/USDA Risk Assessment 1. Complete final Foundry Sands Risk Assessment USEPA/ORCR USDA/ARS TBD 2. Develop “laypersons” summary of the Assessment USEPA/ORCR TBD 3. Develop training tools (e.g., webinar) targeting state regulators and end-users regarding the findings USEPA/ORCR, ASTSWMO-BUTF TBD and implications of the risk assessment USEPA R5 The 50% Goal and making the business case to foundries 1 4. Implement industry communications strategy , including completing and disseminating the Beneficial AFS, AFS-FIRST Ongoing3 2 Use Guide 5. Conduct industry survey in consultation with the Steering Group AFS, AFS-FIRST, 6/2012 Steering Group Web-based tools: www.FoundryRecycling.org and the GIS mapping tool 6. Redesign/update the www.foundryrecycling.org website, including adding search capabilities to the AFS, AFS-FIRST ASTSWMO-BUTF 1/2010 technical library, updating index/summaries of risk studies, and updating state regulatory profiles 7. Develop web-based GIS mapping tool to serve function of connecting end users and foundries USEPA/OPEI, AFS- USEPA/ORCR 1/2010 FIRST Road/construction end uses: fact sheets, guidance, specifications, outreach 8. Develop technical fact sheets addressing basic physical and environmental characteristics and RMRC 1/2010 specific end uses (hot mix asphalt, base and sub base, structural fill, and flowable fill) 9. Develop case-studies for bases & sub-bases, blended bases, and structural fill AFS-FIRST 1/2010 10. Take lead in moving IN-DOT structural fill and embankment specifications through AASHTO AASHTO 8/2010 11. Take lead in moving hot mix asphalt specification through