TRC

Beneficial Reuse of Waupaca Foundry By-Products

TRC determined foundry sand by-products could be used in construction of a barrier layer for a landfill, which resulted in increased volume of beneficial re-use, reduced landfill construction costs, extended life of the landfill, reduced environmental impact and improved sustainability of the foundry's operations.

Industries

Client

Waupaca Foundry, Inc.

Project Location

Waupaca, Wisconsin

Awards & Recognition

American Council of Engineering Companies 2015 Best of State Award (WI)

American Council of Engineering Companies 2015 National Recognition Award

Waupaca Foundry, Inc. (WFI), owns and operates a nonhazardous waste disposal facility near Waupaca, Wisconsin, that receives by-products from three WFI foundries located in Waupaca. WFI engaged TRC to determine if they could re-use their foundry sand by-products in construction of the barrier layer for their landfill, which could result in increased volume of beneficial re-use, reduced landfill construction costs, extended life of their landfill, reduced environmental impact and improved sustainability of their operations.

"TRC’s innovative solutions will help WFI save more than 100,000 cubic yards of mined clay and eliminate the need to send more than 80,000 cubic yards of foundry by-product to the landfill." Bryant Esch, Environmental Coordinator, Waupaca Foundry, Inc.

WFI’s six foundries located in three states produce gray and ductile iron castings using a “green sand” casting process. By-products not destined for beneficial re-use are considered waste and have been disposed in nonhazardous waste landfills. When properly hydrated and compacted, the by-product can achieve a low water permeability, which is required for a landfill liner to contain liquids. In 2011, TRC and WFI constructed side-by-side by-product and clay test pads with underlying collection systems to assess the long-term performance of beneficially re-using by-product as a landfill liner material. As a result of successful performance of the test pads, in May 2014, the Wisconsin Department of Natural Resources approved a plan modification to the landfill permit that allowed the use of the by-product material as a barrier layer in the landfill liner system. The re-use of the by-product reduces by 80,000 cubic yards the amount of material deposited into the landfill as a waste.

The success of this project offers significant benefits to WFI, including eliminating the need and cost for imported clay soil mined from an offsite location, maximizing disposal capacity, and extending the life of the Landfill. Furthermore, this project makes a significant contribution to WFI’s commitment to sustainability values.

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