Multiple fixes are often needed to overcome the challenges posed at a complex site such as our facility located in Saugus, Massachusetts.  This case study shows how each improvement incrementally contributes towards improved performance.  These investments have intangible “payback” in terms of employee pride in the company, neighbourhood and host community goodwill, and environmental sustainability. 

At our Saugus property, which consists of a deep rock quarry, two asphalt production facilities and a ready-mixed concrete plant, significant improvements in the plant’s infrastructure and appearance have been completed.  The company faced a water management dilemma:  unlike many facilities in the western part of the United States where water is a scarce commodity, in New England, a water surplus can be a significant challenge, particularly during deluge rainstorms.  To optimize water re-use, stormwater pollution prevention and creative management of large quantities of water, the company enacted the following improvements:

• Constructed a $1.3 million subsurface stormwater infrastructure that captures stormwater and diverts it back into the quarry.  Run-off from the area surrounding the quarry is collected by a new drainage system that passively drains the quarry.  A quarry pond creates an excellent, passive means of settling out solids prior to discharge.  Under certain high intensity rain events, stormwater bypasses the collection system and discharges to a nearby stream after treatment by Stormceptor™ units.  The stormwater management system was designed to meet all contingencies to ensure compliance with stormwater quality requirements.
• The clean water pumped from the quarry is used for multiple site needs, including dust suppression and process water for ready-mixed concrete production.
• A number of sediment source control measures are employed in the program to ensure that stormwater run-off is not carrying excess sediment loads.  A large retaining wall was erected to contain stockpile areas.  Slopes were landscaped and seeded.  A landscaped berm was constructed along the 400-foot long front entrance of the facility and planted with shrubs and trees to promote sediment control, infiltration and improve the appearance of the entrance.

Entrance to Saugus Facility, Massachusetts.

• Antiquated crushing equipment was dismantled and sold to an outside operation and the underlying area graded and paved as a source control measure.
• The Ready-mixed Concrete Division of the company has implemented new water recycling procedures.  Concrete truck drivers returning from a job wash the truck drums out into a concrete-lined washout facility from which water is drawn into the concrete production process, as quality specifications allow. 
• The Division also has significant enhanced the use of making concrete blocks dedicating an area and resources for this activity.  Ready-mixed drivers returning to Saugus with concrete remaining in their drums, empty the surplus into forms which, once set, are stacked and sold as barriers.  This practice minimizes the stockpiling, double-handling and energy-intensive crushing of broken recycled concrete and more efficiently recycles the material.
• The Asphalt Division maintenance garage has installed a truck and equipment washing facility.  A nylon curtain is used during the power washing process to contain solids and is equipped with floor drains that empty to an oil/water separator (OWS).  All process water flows through the approved OWS and into an evaporator which creates a sludge for off-site disposal.  This system results in a zero discharge of process water.

Due to the joint efforts of the Asphalt, Ready Mix and Aggregates departments dedicated efforts, many rewards are realized.  Investment in the long-term wise and efficient management of the site will pay off in multiple ways in the coming years by minimizing pollution, earning goodwill from neighbours and the town regulators and achieving the cost savings emanating from recycling initiatives.