MINIMIZED MINIMIZED WASTAGES IN WASTAGES IN

CONSTRUCTION CONSTRUCTION PROJECTPROJECT

PRESENTED BY PRESENTED BY

IR. SUYANTO HJ. IR. SUYANTO HJ. OSMANOSMAN

BRICKS

CEMENT

WOOD

REBAR

SAND

INDISCRIMINATE DUMPING

INDISCRIMINATE DUMPING

INDISCRIMINATE DUMPING

WHAT ISWHAT IS ‘WASTAGE‘WASTAGE’’

Something that is wasted; waste or

waste materials.

What is construction waste?

Construction WasteWaste generated by

design activitiesWaste generated by

construction activities

Drylining: cutting of plasterboard sheets and metal studs to fit wall heights and openings

Flooring: cuttings of floor tiles to fit room layouts Ceilings: cuttings of ceiling tiles and fixings to fit room layouts Insulation: cutting of insulation boards to fit openings Tiling: cutting of floor and wall tiles to suit design and room shapes Paving: cutting of paving slabs to fit layout Brickwork and blockwork: cuttings of bricks and blocks to suit

building dimensions and building services

Construction WasteWaste generated by design activities

Inaccurate or surplus ordering of materials that don’t get used Damage through transportation and handling errors Damage through inadequate storage Damage generated by poor co-ordination with other trades Rework due to low quality of work Inefficient use of materials Temporary works materials (e.g. formwork, hoarding etc)

Construction WasteWaste generated by construction activities

Construction Waste Facts(UK Statistics)

Recent research indicates that about 5-10% of building materials end up as waste on building sites.

2.5 to 4 tons — about 1.5 to 2.5 kg per square foot — of waste is created during the construction of a typical home.

Most construction waste currently goes into landfills, increasing the burden on landfill loading and operation.(In Malaysia, most construction waste goes into illegal dumping site)

Construction Waste Facts(UK statistics)

Consists mainly of :

lumber and manufactured wood products

35 %

drywall 15 %

masonry materials 12 %

cardboard 10 %

roofing materials, metals, plaster, plastics, foam, insulation, textiles, glass and packaging

28 %

The process of buying materials A ‘waste allowance’ is generally included within the order to

account for design waste and construction process waste.

Often generic and not project specific and as such run a risk of being inaccurate.

Leads to either the order of a surplus of materials or a materials shortfall.

Little evidence exists on the practice of reconciliation between materials ordered and materials used, therefore limiting the information available on contractors’ knowledge of their own efficiency levels.

Typical Malaysian Contractor’s Material Wastage Allowance

Material Wastage Allowance

Concrete 7%

Rebar up to 16mm 8%

Rebar more than 16mm 15%

BMC 15%

Formwork 12%

Cement screed 30%

Red bricks wall 12%

Metal roofing 5%

Tiling 8%

The true cost of waste

Purchase Cost of the delivered

materials wasted

Cost of waste storage,

transport, treatment and

disposal

Loss of not selling waste for salvage or not recycling+ +

Cost of waste usually included in the project tender price. Contractors often underestimate the real cost of waste. Clients often end up paying for new materials that simply get

thrown away.

WHY BOTHER?

An effective effort in minimizing wastage in construction can:

1. Make significant savings to the client, contractors and the environment

2. Divert a high percentage of all construction waste materials from the landfill and recycled into new products.

Conventional Construction Structure

Client

Main Contractor

Sub Contractor

Sub Contractor

Financial Benefits to clients and contractors

Clients end up paying for material wastage.

By reducing wastage, a reduced cost for the project can be achieved.

Cost saving may be shared by main contractors, sub contractors and clients

Financial Benefits to sub contractors

Minimized wastage

= total saving

or

increased profit.

Drop in tender prices

=

Commercially

Competitive

advantage.

Environmental benefits

Reduced waste =

less landfill space used

reduced environmental impacts

Recycled packaging and waste

=

reduced demand for virgin materials

stimulate demand for recycled materials amongst product manufacturers

Recycled

Materials

10 tonnes

Virgin

Materials

90 tonnes

Recycled

Content

10%

Many products contain recycled material.

Recommended minimum target 10% recycled content

Materials

Purchased

100 tonnes

Let’s assume that 20% of the materials purchased for this project will be wasted.

Materials

Used In

Project

80 tonnes

Materials

wasted

20 tonnes

Let’s now look at what happens to the waste that has been generated.

Wastage rate

20%

Waste Destinations

Reused on site:

Recovered off site:

Sent to landfill:

There are often opportunities to reuse some waste materials on-site.

This waste can then be included in the project instead of being disposed of in skips.

Waste Destinations

Reused on site:5%

Recovered off site:

Sent to landfill:

Let’s say that you are able to recover 50% of the offsite.

Recovered

Offsite

10 tonnes

Waste Destinations

Reused on site:5%

Recovered off site:50%

Sent to landfill:

Only 45% of the waste would be sent to landfill.

Sent to

landfill

9 tonnes

Waste Destinations

Reused on site:5%

Recovered off site:50%

Sent to landfill:45%

By setting waste reduction actions, you can reduce the amount of waste that is generated by your project. This is the first step in

reducing the amount of waste sent to landfill.

Materials

wasted

10 tonnes

Materials

Reused

Onsite

1 tonne

Materials

Reused

Onsite

0.5 tonne

Recovered

Offsite

5 tonnes

Sent to

landfill

4.5 tonnes

Once the amount of waste generated has been reduced, actions can be set to recover MORE of the wasted materials, sending LESS

to landfill.

Recovered

Offsite

7 tonnes

Sent to

landfill

2.5 tonnes

Waste Destinations

Reused on site:5%

Recovered off site:70%

Sent to landfill:25%

Wastage rate

10%

Materials

Used In

Project

90 tonnes

1.1. DESIGNDESIGN Design Changes.Design Changes. Failure to use standard Failure to use standard

production item or standard production item or standard size componentsize component

Lack of Lack of design information/delayed design information/delayed

instruction instruction Lack of dimension Lack of dimension

coordination. coordination. No consideration on Value No consideration on Value

Management. Management.

CAUSES OF CAUSES OF CONSTRUCTION WASTAGECONSTRUCTION WASTAGE

2.2. WASTAGE DURING WASTAGE DURING CONSTRUCTION CONSTRUCTION

PurchasingPurchasing Material Transportation Material Transportation

and deliveryand delivery Storage problemsStorage problems Practical wastePractical waste Handling and Fixing WasteHandling and Fixing Waste Faulty or poor Faulty or poor

workmanshipworkmanship Vandalism and Theft Vandalism and Theft

CAUSES OF CAUSES OF Cont…..CONSTRUCTION WASTAGECont…..CONSTRUCTION WASTAGE

EXAMPLES OF CAUSES

Causes of Wastage on Site Examples

Lack of a quality managementsystem aimed at wastageminimization

e.g. no waste managementplan

Untidy construction sites e.g. waste materials are notsegregated from useful materials

Poor handling e.g. breakage, damage, lossesOver-sized foundations andother elements

e.g. over design leads to excessexcavation and cut-offs

Inadequate protection tofinished work

e.g. finished concrete staircasesare not protected by boardingS

ite

Man

agem

ent

and

Pra

ctic

es

Causes of Wastage on Site Examples

Limited visibility on siteresulting in damage

e.g. inadequate lighting in coveredstorage area

Poor storage e.g. pallet is not used to protectcement bags from contaminationby ground water

Wrong construction method/Wrong construction method/ Unskilled personalUnskilled personal

e.g. poor workmanship ofFormwork

Waste generation inherited with traditional construction method

e.g. timber formwork, wet trade

Sit

e M

anag

emen

t an

d P

ract

ices

EXAMPLES OF CAUSES

Del

iver

y of

pro

du

cts

Causes of Wastage on Site Examples

Over-ordering e.g. over ordering of concretebecomes waste

Method of packaging e.g. inadequate protection to thematerials

Method of transport e.g. materials drop from forklift

Inadequate data regarding timeand method of delivery

e.g. lack of records concerningmaterials delivery

EXAMPLES OF CAUSES

THE IMPORTANCE OF THE IMPORTANCE OF MINIMIZING WASTAGE IN MINIMIZING WASTAGE IN

CONSTRUCTIONCONSTRUCTION

Wastage will have direct impact on Time, Wastage will have direct impact on Time, Cost and Quality of a construction project Cost and Quality of a construction project

TIMETIME

QUALITQUALITYY

COSTCOST

WASTAGWASTAGEE

HOW TO EFFECTIVELY HOW TO EFFECTIVELY MINIMIZE WASTAGEMINIMIZE WASTAGE

Attitude toward Minimizing wastageAttitude toward Minimizing wastage

Design to prevent waste Design to prevent waste

Use of prefabrication construction Use of prefabrication construction method instead of conventional method instead of conventional method. method.

Material procurement and handling Material procurement and handling

Adapting a Site Waste Adapting a Site Waste Management PlanManagement Plan

Who should take action to reduce construction waste?

A shared responsibility between all parties:

The ClientThe Client The DesignerThe Designer The ContractorThe Contractor The Sub contractor and SupplierThe Sub contractor and Supplier The WorkersThe Workers

Contractors and sub contractors, cannot work in isolation.

Leadership is required from clients.

Design To Prevent Waste Examples:

Optimize designed dimensions to correspond to standard product dimensions.

Modify framing details to optimize lumber use and reduce waste and costs when ordering.

Order drywall in optimal dimensions to minimize cut-off waste. Drywall is available in different lengths, and designed dimensions should correspond to standard sizes.

Minimize the number of blueprints and reproductions necessary during the design and construction.

Evaluate if salvaging used products is possible.

TradeTradeAverage wastage LevelAverage wastage Level

(in percentage)(in percentage)Waste Waste

ReductionReduction% of % of

ReductionReduction

ConventionalConventional

(A)(A)PrefabPrefab

(B)(B)(C=A-B)(C=A-B) C/A %C/A %

ConcretingConcreting 3.783.78 1.001.00 2.782.78 73.5173.51

Rebar FixingRebar Fixing 4.334.33 1.001.00 3.333.33 76.8876.88

BricklayingBricklaying 5.505.50 0.000.00 5.505.50 100100

PlasteringPlastering 6.836.83 0.000.00 6.836.83 100100

TilingTiling 7.207.20 3.003.00 4.204.20 58.3358.33

Source : Comparing material wastage level between conventional in-situ and prefabrication construction on 30 construction projects ; Hong Kong Universities

COMPARISON WASTAGE LEVEL OF MAJOR MATERIAL USED COMPARISON WASTAGE LEVEL OF MAJOR MATERIAL USED ON SITE BETWEEN CONVENTIONAL & PREFAB ON SITE BETWEEN CONVENTIONAL & PREFAB

CONSTRUCTIONCONSTRUCTION

Avoid excessively packaged materials and supplies. Packaging should be adequate to prevent damage and waste.

Minimize waste of vinyl siding, flooring and countertop materials by ordering only the quantity needed in building specific lengths.

Evaluate estimating procedures to make sure that excess material is not delivered to the site.

Purchase To Prevent Waste

Adopt a robust system that enables the production of accurate estimates of material requirements at the start of a project that links to real waste figures on completion.

The solution

A best practice approach to waste reduction

Clients sets targets for waste

Planning

Main contractor prepares Site

Waste Management

Plan

Sub contractor estimates waste

Quantitative Estimate

Qualitative Checklist

Main contractors and

sub-contractors review waste and

take action to minimise and

manage waste

Implementation

Main contractor requests final waste

information from sub contractors

Review

Sub contractors complete waste

information questionnaires

Main contractor coordinates data and feeds back to client

Quantitative Record

Qualitative Checklist

Share lessons learned

Promote innovation

Raise awareness

Demonstrate better financial

and environmental

results

Improvement

1 2 3 4

A Site Waste Management Plan contains the following key features:

waste targets as set by client,

an estimate of the waste to be generated on site,

actions to reduce waste, and

actions to avoid waste going to landfill

Q

Client sets targets for waste

Planning

Main contractor prepares Site Waste Management Plan

Sub contractor estimates waste

Quantitative Estimate

Qualitative Checklist

Best Practices

Appoint a Site Waste Manager responsible to ensure that appropriate storage

conditions are available keep a record of all materials

brought to site Site Waste Manager to ensure materials

are supplied in an appropriate manner, and in the correct quantity

Site Waste Manager monitor costs/volumes of disposal

The Site Waste Manager to determine KPI’s on this basis

Sub contractors appoint a Trade Waste Manager

Main contractors and

sub-contractors review waste and

take action to minimise and

manage waste

Implementation

Reviewing data and providing feedback can have real benefits, such as:

Assess effectiveness of the waste minimization and management strategy.

Learn what works and doesn’t work in reducing waste

Identify exactly how efficient main contractors and sub contractors were on the project – in turn enabling them to understand how wasteful they were

Main contractors can see which trades contributed what quantity of materials to the waste stream and why – enabling them to prepare better waste estimates in the future

Capture any relevant data for future reference and use.

Q

Main contractor requests final waste information from sub

contractors

Review

Sub contractors complete waste

information questionnaires

Main contractor coordinates data and feeds back to client

Quantitative Record

Qualitative Checklist

Share lessons learned

Promote innovation

Raise awareness

Demonstrate better financial and

environmental results

Improvement

Appoint A Site Waste Manager

While all people involved should be encouraged to contribute their ideas and suggestions on ways to minimize waste, one person (or the Environmental, Health and Safety Manager) should act as the Site Waste Manager, responsible for overseeing the management of construction wastes.

This person will be responsible for managing waste reduction initiatives and coordinating the activities of other employees.

Key role of a site waste manager ….

Ensure that all relevant legislation and the contractor’s duty of care is complied with.

Initiate waste reduction, reuse and recycling. Ensure all site personnel know their responsibilities for site waste

management. Co-ordinate waste management on site, gather data about waste on site,

keep accurate records on waste movement on and off site. Ensure that all waste storage areas and containers are properly labelled

to show site workers where to deposit specific materials. Be aware of the construction activities currently taking place on site and

the activities planned in the short term.

Conduct a survey of wastes likely to be generated on site and keep a record of them for planning ahead.

Whenever possible, ensure the re-use or recycling of material already on site before it is carted away or new materials are imported.

Obtain a list of potential buyers or collectors of materials to be re-used or recycled.

Encourage all site personnel to use their initiative in coming up with ideas of how to reduce, reuse and recycle wastes.

Inform designers so that waste can be reused and recycled on site or on another site.

Key role of a site waste manager

Managing Subcontractors

• Use a system of allowable waste percentages. In the early pre-work agreements the site manager decides how much waste is acceptable, and agrees a percentage with the subcontractor.

If they waste more than the agreed amount, they can be charged the extra costs.

This is a great incentive to reduce wastes by efficient use ofmaterials. The lower the allowable percentage, the more care people will take with materials.

Setting the right level is crucial.

• Make subcontractors responsible for both purchasing the raw materials they need, and disposing of any waste material from their activities. This will give them a direct financial incentive to use materials efficiently with the minimum of wastage.

• Make subcontractors aware of wastage and the costs involved in dealing with wastes.

• Hold regular meetings to discuss wastage on site.

Managing Subcontractors

INCENTIVES

If contractors or sub-contractors can demonstrate a willingness to support and engage in waste reduction measures and demonstrate that these have an effect on their waste, then they be identified as preferred bidders.

Policy and legislation Currently no regulatory obligation

in Malaysia to reduce and manage waste to good practice standards.

Hope this presentation will

increase the awareness for the need of public policy to achieve greater resource efficiency and reduce wastage in the construction industry.

Landfill Tax

The Landfill Tax in UK was introduced in 1996 to encourage all organisations, including those in the construction industry, to reduce the amount of waste disposed to landfill.

Mandatory requirement for Site Waste Management Plans (SWMPs)

It is expected that the use of SWMPs will become a mandatory requirement for many construction projects throughout the UK in the near future, the current position being summarised below.

OFFENCE GUILTY PARTY/PARTIES

PENALTY

Starting a project without a SWMP

Client and principal contractor A person guilty of any offence is

liable:

(a) on summary conviction, to a fine not exceeding £20,000 or to imprisonment for three months, or to both, or

(b) on conviction on indictment, to imprisonment for two years, a fine, or both.

Where a body corporate is

guilty of an offence, proved

to be committed by a

qualified person, director,

manager, secretary or

someone acting in such

capacity he is guilty of an

offence as well as the body

corporate.

Failing to update a SWMP

when waste is removed from

the site

Principal contractor

(or client, if no principal

contractor)

Failing to make a SWMP

Available on site

Principal contractor

(or client, if no principal

contractor)

Failing to keep a SWMP for

two years from completion

Principal contractor

(or client, if no principal

contractor)

Failing to comply with

Additional duties

Client and/or principal

contractor as specified in the

Regulations

Making a false or misleading

statement in a SWMP

Client, person drafting the

plan or principal contractor

Failing to co-operate with, or

intentionally obstructing, an

Enforcing officer

Anyone responding to a

request or visit by an officer

OFFENCES AND TO WHOM (UK)

CONCLUSIONCONCLUSION

Activities that minimize wastage, such as designing to standard sizes, reusing building materials, not only cut waste and recycling collection costs but also reduces materials' expenses.

Small changes to construction practices and extra attention to detail can add up to significant savings to the client, the contractor and the environment.

Everyone of us here has a role to play in bringing changes to our construction practice. Let us begin.