Prepublication issue for EPA libraries
and State Solid Waste Management Agencies
EVALUATION OF SOLID WASTE BALING AND BALEFILLS
VOLUMES I and II
This final report (SW-121c.l) describes work performed
for the Federal solid waste management programs under contract No. 68-03-0332
and is reproduced as received from the contractor
Volume I reports on a one-year evaluation of a solid waste high-density
baling plant and the associated transportation and sanitary landfill operation.
Volume II contains the technical appendices.
SW-lllc.2
Copies of both volumes will be available from the
National Technical Information Service
U.S. Department of Commerce
Springfield, Virginia 22151
U.S. ENVIRONMENTAL PROTECTION AGENCY
1975
-------
This report as submitted by the grantee or contractor has not been
technically reviewed by the U.S. Environmental Protection Agency (EPA).
Publication does not signify that the contents necessarily reflect the
views and policies of EPA, nor does mention of commercial products
constitute endorsement or recommendation for use by the U.S. Government.
An environmental protection publication (SW-lllc.l) in the solid waste
management series.
-------
ACKNOWLEDGMENT
We gratefully acknowledge the U. S. Environmental Protection Agency personnel who
provided assistance during the research reported herein: Mr. Robert A. Colonna,
Acting Director, Systems Management Division and initial Project Officer; Messrs.
Harvey Rogers and Steven Hitte served as Project Officers during the latter part of the
contract. This report was researched and written by Ralph Stone and Company, Inc.
Ralph Stone served as Project Director, and Richard Kahle was Project Engineer.
Ralph Stone and Company, Inc. staff participating on this project were James Rowlands,
Carlton Haywood, Paul Mak, H. A. Smallwood, Timothy Zimmerlin, J. Rodney Marsh,
John East, Edward Daley, James Osborn, Roxanne Martin, and Brooke Stiling.
Valuable secretarial assistance was provided by Martha Lieberman, Greta Wallin, and
Ruth Michaels.
We also thank the many individuals and agencies whose generous assistance and
cooperation made this study possible. Field studies were completed with the full
cooperation of the American Hoist and Derrick Company staff represented by Mr.
William Faulkner, Vice-President, Harris Economy Group; Mr. Joe Zook, Vice-
President of the St. Paul plant; and Mr. Rolf Ljungkull, Assistant to the Corporate
Vice-President - Engineering, who also acted as coordinator for the study. Professor
Hans-Olaf Pfannkuch, of the University of Minnesota Geology Department, provided
guidance to local employees of Ralph Stone and Company, Inc. in St. Paul. Excellent
cooperation throughout the contract investigations was provided by the concerned
authorities representing the Environmental Protection Agency's Office of Solid Waste
Management Programs.
iii
-------
ABSTRACT
This final report presents the results of a one-year evaluation of a solid waste high-
density baling plant, transportation and associated land disposal operation of the
American Hoist and Derrick Company in St. Paul, Minnesota. The work program
consisted of four stages: (1) a five-day intensive monitoring program of the baling plant
and bale transportation operations; (2) cost analysis during two years of plant operation;
(3) a nine-month period of monitoring the St. Paul bale landfill operation; and (4) a
14-month period of monitoring a bale test cell constructed at the balefill.
The five-day monitoring program consisted of the following: time and motion studies of
the bale plant using video tape and activity time charts; density measurement; sorting
by component and laboratory analyses for moisture and organic content of the incoming
solid waste; sampling and laboratory analyses for moisture and organic content of baled
solid waste; sample volume measurement and laboratory analyses of liquid squeezed from
solid waste during baling; compaction ram hydraulic pressure, bale production time,
and time-phased measurement of dimensions on every tenth bale produced; bale weights;
monitoring of the volume of incoming solid waste and the number of incoming vehicles;
and measuring the travel time, distance travelled, number of bales per load and activities
of the trucks and drivers transporting the bales to the landfill. Photographs were taken
to illustrate the baling operation activities.
Analyses were completed of the reliability, interference and utilization of equipment
and labor in the bale plant and transport operations separately, and for the bale plant/
transport/landfill system as a whole. Standard MTM analyses were completed for tasks
to define labor efficiency and human factors parameters. The density and springback
in every tenth bale were determined as a function of time. Limited time studies were
made of transport truck rigging operations. Operation and amortization costs are present-
ed for a two-year period covering 12 months of historical data from July 1972 to June 1973,
and data during the contract through closing of the baling plant in June 1974.
Landfill operations were monitored weekly over a nine-month period for bale spacing,
surface water, broken bales, cover soil quantities and depth, litter, dust, vectors
including fly emergence, time and motion studies of landfill equipment operation, photo-
graphs and samples of water from a well located in a completed landfill area.
A test cell was constructed at the bale landfill and filled with bales produced during one
week of baling plant operation. Gas, temperature, and settlement probes, leachate
collection membrane, sump, and lysimeters, were installed in the test cell which was
covered woth six inches of soil to duplicate the regular bale landfill. Weekly
monitoring over a 12-month period consisted of temperature (daily during the first two
weeks), gas, leachate from a leachate collection system and probe lysimeters, and
surveying for settlement.
iv
-------
Analytical comparisons were made between the bale landfill and normal landfill
environmental conditions. The feasibility of solid waste high-density baling plant,
transportation and landfill operation was evaluated and compared to milling, combined
milling and low-pressure solid waste baling systems and conventional solid waste systems.
The data in this report are presented in metric units with some fiiglish units in parenthesis.
A conversion table is included.
-------
TABLE OF CONTENTS
Section Page
ACKNOWLEDGEMENT ii:L
ABSTRACT iv
TABLE OF CONTENTS
LIST OF FIGURES
LIST OF TABLES xi
LIST OF PHOTOGRAPHS xiii
SUMMARY OF FINDINGS xiv
RECOMMENDATIONS xix
1. INTRODUCTION 1
A. OBJECTIVES AND SCOPE 1
B, APPROACH 2
2. GENERAL AREA AND OPERATIONS 4
A. CITY OF ST. PAUL 4
B. BALING PLANT GENERAL LOCATION AND ACCESS 4
C. BALING PLANT SITE 4
3. SOLID WASTE DESCRIPTION 21
4. BALE DESCRIPTION 29
A. MONITORING METHOD 29
B. RESULTS OF BALE MONITORING 29
5. TRANSPORT NET DESCRIPTION 42
A. LOADING ZONE PLAN 42
B. TRANSPORT VEHICLES 42
C. TRANSPORT OPERATIONS 42
D. ROUTE PLAN 47
6. BALE LANDFILL EVALUATION 48
A. LANDFILL DESCRIPTION 48
B. LANDFILL MONITORING 48
C. RESULTS AND DISCUSSION 49
vii
-------
Section Page
7. TIME AND METHOD STUDY 56
A. PURPOSE AND SCOPE 56
B. PLANT PERFORMANCE 56
C. ABILITY, RELIABILITY, AND ACCESSIBILITY 67
8. MAINTENANCE STUDY 74
A. PLANNED MAINTENANCE 74
B. PLANNED INVENTORY 79
C. SERVICE AND PARTS POLICY 82
9. COST STUDY 83
A. COSTS AT THE ST. PAUL BALING PLANT 83
B. PROCESSING AND COST COMPARISON OF ALTERNATIVE
SOLID WASTE PROCESSING SYSTEMS 101
C. COMPARISON OF PROCESSED SOLID WASTE IMPACTS ON
THE LANDFILL AND THE ENVIRONMENT 120
10. SIMULATION OF A BALE SANITARY LANDFILL IN A TEST CELL 127
A. PURPOSE 127
B. METHOD OF STUDY 127
C. RESULTS AND DISCUSSION 142
11. GLOSSARY 188
12. METRIC TO ENGLISH CONVERSION TABLE 191
FIGURES
Figure No.
1-1 "BALING PLANT MONITORING TASK SCHEDULE 3
2-1 BALING PLANT LOCATION 5
2-2 BALING PLANT VICINITY MAP WITH TRANSPORT FLOW 6
2-3 BALING PLANT SITE LAYOUT 7
2-4 BALING PLANT FLOOR PLAN 9
2-5 BALING PLANT MATERIALS FLOW SCHEMATIC 10
2-6 BALING PLANT MATERIALS FLOW PROCESS 11
2-7 BALING PLANT HYDRAULIC PUSHERS 14
-------
FIGURES (Cont.)
Figure No. Page
3-1 SOURCES OF BALING PLANT SOLID WASTE 22
4-1 FIRST SHIFT BALE PRODUCTION 30
4-2 SECOND SHIFT BALE PRODUCTION 31
4-3 BALE SPRING BACK - 9/20/73 33
4-4 BALE SPRINGBACK - 9/21/73 34
4-5 BALE SPRINGBACK - 9/24/73 35
4-6 BALE SPRINGBACK - 9/25/73 36
4-7 BALE SPRINGBACK - 9/26/73 37
5-1 GANTT CHART OF TRANSPORT TRUCKS 46
6-1 ST. PAUL BALEFILL PLACEMENT PROCEDURE 50
7-1 STATE UTILIZATION BY MACHINE 58
7-2 SOLID WASTE VOLUME FLOW RATE INFLOW AND OUTFLOW 61
7-3 CUMULATIVE AVERAGE SOLID WASTE VOLUME FOR 62
EXISTING (137 SEC CYCLE) ST. PAUL BALER
7-4 CUMULATIVE AVERAGE SOLID WASTE VOLUME ON 63
BALING PLANT FLOOR FOR 90 SEC CYCLE BALER
WITH ST. PAUL WASTE INFLOW
7-5 ABILITY DENSITY CURVE 68
7-6 RELIABILITY DENSITY CURVE 71
7-7 BALE PRODUCTION DENSITY CURVE 72
8-1 LUBRICATION POINTS OF VARIABLE SPEED 75
CONVEYOR DRIVE
9-1 HIGH DENSITY BALER SYSTEM I OPERATION SCHEMATIC 104
9-2 HIGH DENSITY BALER SYSTEM II OPERATION SCHEMATIC 108
9-3 MILL SYSTEM OPERATION SCHEMATIC 112
9-4 MILLING, BALING SYSTEM OPERATION SCHEMATIC 116
10-1 TEST CELL DESIGN 128
10-2 TEST CELL WALL CONFIGURATION 130
10-3 TEST CELL PROBE LOCATIONS 133
10-4 TEST CELL GAS PROBE 136
10-5 GAS SAMPLING APPARATUS 141
10-6 SUMP LEACHATE FLOWS 145
ix
-------
FIGURES (Cont.)
Figure No. Page
10-7 PRECIPITATION AND SUMP LEACH ATE TRENDS 146
10-8 SUMP LEACHATE PH 150
10-9 SUMP LEACHATE BOD. 151
5
10-10 SUMP LEACHATE ORGANIC NITROGEN 152
10-11 SUMP LEACHATE Cl 153
10-12 SUMP LEACHATE TDS 154
10-13 LYSIMETER LEACHATE BOD5 160
10-14 LYSIMETER LEACHATE TDS 161
10-15 LYSIMETER LEACHATE ORGANIC NITROGEN 162
10-16 LYSIMETER LEACHATE Cl 163
10-17 LYSIMETER LEACHATE PH 164
10-18 TEST CELL TEMPERATURE: STATION 1 165
10-19 TEST CELL TEMPERATURE: STATION 2 166
10-20 TEST CELL TEMPERATURE: STATIONS 167
10-21 TEST CELL TEMPERATURE: STATION 4 168
10-22 AVERAGE BALE AND AMBIENT AIR TEMPERATURES 169
10-23 TEMPERATURE TRENDS: AT LAND DISPOSAL SITES 170
10-24 GAS ANALYSIS: STATION 1 AT 0.9 M (3 FT) DEPTH 172
10-25 GAS ANALYSIS: STATION 1 AT 2.4 M (8 FT) DEPTH 173
10-26 GAS ANALYSIS: STATION 2 AT 0.9 M (3 FT) DEPTH 174
10-27 GAS ANALYSIS: STATION 2 AT 2.4 M (8 FT) DEPTH 175
10-28 GAS ANALYSIS: STATION 3 AT 0.9 M (3 FT) DEPTH 176
10-29 GAS ANALYSIS: STATION SAT 2.4 M (8 FT) DEPTH 177
10-30 GAS ANALYSIS: STATION 4 AT 0.9 M (3 FT) DEPTH 178
10-31 GAS ANALYSIS: STATION 4 AT 2.4 M (8 FT) DEPTH 179
10-32 GAS COMPOSITION COMPARISON 180
10-33 DIFFERENTIAL SETTLEMENT SCHEMATIC 181
10-34 TOTAL AVERAGE DIFFERENTIAL EXPANSION 182
10-35 EXPANSION/SETTLEMENT TRENDS: ST. PAUL AND NORMAL 183
LANDFILL CELLS
-------
TABLES
Table No. Page
3-1 INCOMING WASTE TYPES 23
3-2 INCOMING SOLID WASTE DENSITY 25
3-3 BALER FEED WASTE COMPOSITION 26
3_4 ANALYSIS OF MOISTURE AND ORGANIC CON- 27
TENTS FOR UN BALED AND BALED SOLID WASTE
3-5 CHEMICAL AND BACTERIOLOGICAL ANALYSES 28
OF BALER LIQUID SQUEEZINGS
4-1 TENTH BALE PRODUCTION TIMES 32
4-2 TENTH BALE DIMENSIONS, VOLUME, EXPANSION, 39
WEIGHT, AND DENSITY
4-3 OVERALL BALING PLANT PRODUCTION DURING 41
5-DAY PLANT MONITORING
5-1 VEHICLE LOAD REQUIREMENTS 43
6-1 RESULTS OF FLY EMERGENCE STUDIES 54
7-1 MACHINE INTERFERENCE BY MACHINE 59
7-2 REDUCED BALED SOLID WASTE NETWORK 66
7-3 BALING RATES UNDER MEASURED CONDITIONS 69
8-1 DAILY MAINTENANCE IN BALING PLANT 76
8-2 WEEKLY MAINTENANCE IN BALING PLANT 77
8-3 LONG-TERM MAINTENANCE IN BALING>LANT 78
8-4 TRANSPORT NET MAINTENANCE 80
8-5 BALEFILL EQUIPMENT MAINTENANCE 81
9-1 HISTORICAL PRODUCTION DATA FOR THE PERIOD 84
10/1/72 TO 9/22/73
9-2 HISTORICAL COSTS FOR THE BALING PLANT 85
9-3 HISTORICAL COSTS FOR THE TRANSPORT NET 87
9-4 HISTORICAL COSTS FOR THE BALEFILL 89
9-5 HISTORICAL PRODUCTION DATA 92
9-6 HISTORICAL COSTS FOR THE BALING PLANT 93
9-7 HISTORICAL COSTS FOR THE TRANSPORT NET 95
xi
-------
TABLES (CONT.)
Table No, Page
9-8 HISTORICAL COSTS FOR THE BALEFILL 97
9-9 SUMMARY 99
9-10 HISTORICAL COSTS FOR RECYCLING CORRUGATED TOO
CARDBOARD
9-11 HIGH-DENSITY BALING SYSTEM 1 - CONSTRUCTION 106
COSTS
9-12 HIGH-DENSITY BALING SYSTEM 1 - OPERATING 107
AND MAINTENANCE COSTS
9-13 HIGH-DENSITY BALING SYSTEM II - 110
CONSTRUCTION COSTS
9-14 HIGH-DENSITY BALING II - OPERATING AND 111
MAINTENANCE COSTS
9-15 MILL SYSTEM - CONSTRUCTION COSTS 113
9-16 MILL SYSTEM - OPERATING AND MAINTENANCE 114
COSTS
9-17 COMBINED MILLING/BALING SYSTEM - CON- 117
STRUCT!ON COSTS
9-18 COMBINED MILLING/BALING SYSTEM - OPERA- 118
TING AND MAINTENANCE COSTS
9-19 SYSTEM SUMMARIES 119
9-20 AMORTIZATION SUMMARY 121
9-21 COST SUMMARY—TRANSFER, PROCESSING, 122
TRANSPORTING AND LANDFILLING
9-22 WASTE DENSITIES 123
10-1 BALE TEST CELL MONITORING SCHEDULE 138
10-2 ANALYTICAL METHODS 139
10-3 TEST CELL PRECIPITATION 143
10-4 ST. PAUL BALE TEST CELL SUMP LEACHATE 148
ANALYSIS
10-5 LEACHATE COMPONENT COMPARISONS OF 156
DIFFERENT LANDFILLS
10-6 ST. PAUL BALE TEST CELL LYSIMETER LEACHATE 158
ANALYSIS
-------
TABLES (CONT.)
Table No.
10-7 BORE HOLE TEMPERATURE PROFILE 184
10-8 BORE HOLE ORGANIC CONTENT 186
10-9 BORE HOLE MOISTURE CONTENT 187
PHOTOGRAPHS
Photograph No.
2 - 1 BALING PLANT OPERATIONS (I) 17
2-2 BALING PLANT OPERATIONS (II) 18
2-3 BALING PLANT OPERATIONS (III) 19
2-4 BALING PLANT OPERATIONS (IV) 20
5 - 1 BALE TRANSPORT AND PLACEMENT 44
10 - 1 TEST CELL CONSTRUCTION 129
10-2 TEST CELL INSTALLATIONS 132
10-3 COMPLETED TEST CELL 135
10-4 TEST CELL MONITORING 137
XTM
-------
SUMMARY OF FINDINGS
In accordance with the Scope of Work outlined in EPA Contract No. 68-03-0332, the
following results and findings are summarized for the five-day baling plant survey and
long-term monitoring program.
A. Baling Plant and Operations.
1. The labor force at the baling plant consisted of eight employees: one gate attend-
ant, one loader operator, one forklift operator, one maintenance man, two cardboard
sorters, one control tower baler operator, and one plant foreman.
2. Stationary equipment at the baling plant consisted of one horizontal and one
inclined conveyor, a load-cell scale, a high-density 137-second-cycle baler, a central
control tower with control panels, two hydraulic bale push rams and a bale truck loading
platfor.n.
3. Mobile equipment used at the plant consisted of an articulated.front-end loader,
a small general purpose "bobcat" loader, and a forklift.
4. The front-end loader mixes and pushes waste onto the horizontal conveyor; the
conveyors carry solid waste to the baler, which consists of three hydraulic rams and a
baling chamber. Two hydraulic pushers move completed bales onto a flat-bed truck.
Fourteen to sixteen bales were loaded on a single truck. The small "bobcat" loader
was used to pile corrugated material and for cleanup; the forklift was used to remove
bales not going to the landfill such as corrugated cardboard and metal.
5. Minor quantities of dry, residual bale particles and liquids squeezed from the wastes
were observed to collect directly below the baler and on the vertical tramper ram tower
walkway and ram framework. Liquid wastes were observed to occasionally squirt onto
the control tower concrete supports.
B. Nature of Incoming Solid Waste.
1. Peak period for incoming solid waste was 9:00 A.M. to 2:00 P.M. Forty-four
percent of the incoming collection vehicles were 11.4 to 15.2 cubic meters in volume,
and twenty-five percent were 3.8 to 10.6 cubic meters. Thirty-eight percent of the
incoming vehicles belonged to the St. Paul Department of Public Works; lesser percent-
ages belonged to each of several private collectors.
2. Nine-kilogram daily composite samples of incoming waste were analyzed. Baler <-
feed sample solid waste densities ranged from 39 to 103 kg/m , with a mean of 79.5 kg/m"
and a standard deviation of 17.5 kg/m (wet weight).
XIV
-------
3. Average wet weight composition of baler feed waste samples in percent was: paper-
31, metal - 13, wood - 11, glass and ceramics - 9, garden - 8. Less than 7 percent
composition each was observed for textiles, rubber and leather, food, rocks and dirt,
and smalls and fines. Average dry weight moisture content of the solid waste samples
and bale core samples, respectively, was 45.4 and 31.5 percent. Average dry weight
organic content for the solid waste and bale samples, respectively, was 76.2 and 75.2
percent. The range of organic content of the solid waste samples was 60 to 89 percent,
and bale samples 64 to 84 percent. The range of moisture content was 15 to 71, and
26 to 82 percent for incoming and baled solid waste, respectively.
4. Ten samples of both strained and unstrained liquid squeezed during baling showed —-
the following ranges of constituents: pH - 3.2 to 4.9, total coliform - 1,200 to
24,000 MPN/100 ml, fecal coliform - 0 MPN/100 ml, BOD5 - 0 to 3,940 mg/l,
chloride - 965 to 2,620 mg/l, SO4 - 3,800 to 4,400 mg/l, sulfide - 5 to 17 mg/l,
TDS - 40,820 to 64,310 mg/l, NO3 - 11.1 to 70.6 mg/l, NH3 - 0 to 1,445 mg/l, and
organic nitrogen - 730 to 2,817 mg/l.
C. Nature of Bales Produced.
1. Three methods of bale monitoring were employed: each bale was weighed by the
control tower operator, each tenth bale was measured for volume and expansion, and
three 5-cm core samples from two randomly chosen bales were taken daily.
2. Average bale production time for the tenth bale was 1.73 minutes, with a small
standard deviation of 0.16, indicating a consistent production time.
3. Bales were observed to expand somewhat initially during the period ten minutes to
one day after production, and then to contract somewhat between one day and one week
after production. This latter settling phenomenon is attributable to evapotranspiration of
bale moisture. At one hour after production, average bale expansion (in terms of volume)
was 7.4 percent; at one day (and for one days' tenth bales three days elapsed over a week-
end before measuring) after production, 28.4 percent; and at one week after production,
24.6 percent.
4. Ten minutes after production, average tenth bale height was 1.12m, average
width was 1.04 m, and average length was 1 .35 m. Percent expansion at one hour,
one day, and one week after production, respectively, was height - 2.5. 5.7, and 3.7;
width - 1.4, 8.3, and 9.6; and length - 3.3, 13.0, and 10.8.
5. Average bale weight for all bales was 1,282 kg, with a standard deviation of 50 kg.
Average daily densities ranged from 725 to 933 kg/cu m ten minutes after production;
density was thus fairly non-uniform. Two of 66 tenth bales (3 percent) were observed
to fall apart at the baling plant; these had large quantities of grass. At the landfill,
14 of 582 bales (2.4 percent) observed were damaged or broken.
6. The average number of bales produced per hour was 18.1 up to March 1974, and
22 thereafter. The average number per day was 256 and 341, respectively. The increase
after March was due to change in personnel and an overhaul of the baling mechanism. The
first and second labor shifts each worked an average of 8 hours per day.
XV
-------
D. Transport Net and Balefill Operations.
1. The transport network consisted of four enclosed cab tractors and five flat-bed
trailers. Sixteen bales can be carried on each vehicle, but the usual load was 14
bales to comply with Minnesota State Highway vehicle load limits.
2. Transport vehicle rigging placement time averaged 6.69 man-minutes, with a
standard deviation of 2.06. Transport vehicle tailgate installation time averaged
1.17 man-minutes, with a standard deviation of 0.51. One, two, or three men
completed these tasks. This translates to 2.4 and 3.2 man-hours per day before and
after March 1974, respectively, for the total rigging and tailgate installation procedure.
3. Bales were stacked three high and side-by-side at the landfill. The frequency of
soil cover was observed to be at approximately weekly intervals, except that during
winter periods when the ground was frozen no cover soil was applied.
4. The balefill scored 66 out of a possible 100 on an EPA landfill evaluation form.
The lack of daily cover soil reduced rating by 20 points. Spaces between bales were
generally greater along the long face than the short; site irregularities caused spaces
in the fill. Surface water, broken bale, litter, dust, and non-fly vector problems
were not significant. Fly emergence studies indicated baling alone without cover
soil will not significantly reduce fly emergence.
E. Time Performance of Baling Plant and Transport Net.
1. Time studies of the baling process were made for 30 minutes twice daily. Daily
video tape recordings of the gateman, loader operator, and control tower baler
operator were made.
2. Measured percent machine idle times, including waiting time, were: loader - 30,
conveyors - 49, scale - 38, baler - 20, pusher - 72, and transport trucks - 29.
3. Average process times for significant operations at the baling planf and balefill
for the 137-second-cycle baler were observed to be (in min/bale): dumping solid
waste - 2.40, loading conveyor - 1.50, conveying solid waste - 3.00, measuring
charge - 0.05, baling (includes loading charge box) - 3.05, and loading trailer - 3.15.
Other process times are recorded in minutes per truckload (an average of fifteen bales):
waiting before travel - 21.0, transporting bales - 30.0, and waiting to be unloaded -
25.0. Average time from when collection trucks dumped solid waste to when loaded
transport trucks left the plant was 48.85 minutes, excluding solid waste storage time
between dumping and the beginning of the baling operation.
4. Percent idle times for the baling plant personnel were gateman - 55, loader oper-
ator - 25, transport drivers - 31, and sorters - 84.
5. Problems observed with baling plant machines were interference with the baler by
the loader and conveyor, stopping of the conveyor while loading the scale, and an
inoperative unloading platform requiring a special forklift to raise it while trailer beds
were changed.
xvi
-------
6 . Coordination of work positions may be improved, as indicated by high idle time
percentages, overloading of the gateman at times, and unclear assignment of records
and maintenance responsibilities.
7. A way for employees to temporarily fill in for the gateman, loader operator, and
control tower operator could improve bale production rate as much as 5 percent.
Such redesigns of work responsibilities will increase productivity and minimize labor
costs.
8. Improved operations in loading the conveyor may help to reduce delays and
collision risks and keep a more constant amount of unbaled solid waste on the baling
plant floor.
9. Under 90-second bale cycle conditions, as opposed to the current 137-second cycle,
the conveyor loader and scale configuration will have to be modified or replaced.
An overhead crane, a conveyor covering the total length of the plant, a gravity convey-
or, and a mechanical mixer and loader are possible modifications.
10. Mechanical means of sorting solid waste may make recycling of materials such as
paper, aluminum, steel, tin, and glass economically feasible. Separation of corrugated
is presently accomplished by hand at a profit.
11. Ability, reliability, and accessibility for the baling system were determined over
two time periods. Ability average 18.1 and 21 .6 bales/hour, reliability figures were
6.38 and 6.78 (average 6.53) hours/8-hour day, and accessibility was 21.5 hours/day.
Overall plant performance averaged 128 bales/8 hour shift before March 1974, with
expected daily output of 256 bales.
12. To improve plant performance and lower costs, the following measures are suggested
for large-scale baling operations: larger storage pits to store and mix the solid waste,
better control of drainage at the baling plant, better ventilation at the plant, shielding
of the baling equipment to prevent squirting of wet wastes, implementation of dust
control at the baling plant, and a more systematic traffic pattern for collection vehicle
arrivals.
F. Costs.
1. Total baling plant costs were $5.41 per bale, $4.17 per kkg, and $3.78 per ton dur-
ing the first period and $6.95 per bale, $5.33 per kkg, and $4.83 per ton during the
second monitoring period.
2. First-year transport net costs were $1.73 per bale, $1.33 per kkg, and $1 .21 per ton;
second period costs were $2.15 per bale, $1.65 per kkg, and $1.50 per ton.
3. Balefill costs ran $1.47 per bale, $1.13 per kkg, and $1.03 per ton during the
first period and $1.34 per bale, $1.03 per kkg, and $0.93 per ton during the second period.
xvii
-------
4. Total system, costs were $8.61 and $10.44 per bale, $6.63 and $8.01 per kkg, and
$6.02 and $7.26 per ton during the first year and second monitoring periods, respectively.
5. System maintenance costs remained at about 15 percent of the total through both
periods .
6. Predicted total costs for a revised system using the 90-second-cycle baler and an
overhead crane, at $4.23 per kkg ($3.82 per ton), were less than comparable milling
costs of $4. 73 per kkg($4.30 per ton), or combined milling/baling costs of $4.90 per
kkg ($4. 47 per ton).
G. Test Cell Monitoring.
1 . Sump leachate had an average pH of 6.7 and an initial BOD,- of 25 mg/l .
peaked about 312 days after test cell filling at 545 mg/l . Organic nitrogen
levels fluctuated between about 10 and 20 mg/l . Chlorides and total dissolved solids
showed level trends of about 379 and 1,982 mg/l, respectively. The bale test cell
leachate was low in BODr, chlorides, and TDS, compared with values from other land-
fills. The total leachate quantity from the test cell measured 18,800 liters, and total
precipitation onto the cell was 490,000 liters, over a 11-month period.
2. Leachate samples taken from lysimeters showed that BOD,-, total dissolved solids,
and chlorides increased with an increase in depth, while pH remained relatively constant
at all levels.
3. With the exception of an early sharp increase in bale temperatures (due to decom-
position), trends in the baled solid waste followed fluctuations in ambient air tempera-
tures.
4. Carbon dioxide gas concentrations reached a maximum of 30.5 percent by volume
and methane 17. 6 percent during the 14 months of monitoring. Oxygen ranged from
zero to 18.2 percent by volume.
5. Carbon dioxide and methane levels increased with time at all depths, while oxygen
dropped. These effects were more pronounced at the eight-foot depth. In all cases,
hydrogen sulfide levels remained lower than 0.1 percent by volume.
6. Elevation changes were determined at five monitoring stations. The test cell bales
expanded 13 percent during the first 10 days and remained stable over the following
12 months. The bottom bales expanded the least.
7. Auger sampling was performed once after about one year of field studies, on both
the test cell and landfill . The temperature at the same depths decreased with the age
of the fill material. Temperature in all boreholes increased with depth. The average
organic content decreased, apparently with fill age from 54.5 to 38,4 percent between
wastes placed two years apart. Moisture content ranged from 24.8 to 96.5 percent by
weight, averaged 46.5 percent, and was independent of the age of the fill.
xvm
-------
RECOMMENDATIONS
The following recommended improvements are based on a five-day on-site study of the
St. Paul high-pressure baling plant.
A. Dumping Area
Random arrivals of full refuse trucks at the baling plant sometimes exceeded the gate-
man's ability to direct them for loading and do simultaneously the necessary paperwork
for fee charging. This paperwork was done inside the plant building, but automatic
measuring and billing equipment installed away from the unloading area would have ex-
pedited the unloading process and plant operations. Improved unloading and storage fa-
cilities (such as a larger storage hopper) would have improved materials handling.
Traffic in the dumping area created a safety hazard. Arriving trucks had to back in
across the unloading floor, where other trucks and the loader were maneuvering. The
resulting congestion and confusion impeded unloading and made for generally poor
operating conditions. This could have been avoided by two changes in building layout.
First, waste could be dumped into a pit where waste mixing, loading, and conveying
could be readily handled in a separated area. This measure would have increased plant
storage capacity, eliminated the potential for accidents between trucks and the loader,
and also alleviated the need for an inside gateman. Second, a well-defined traffic-
flow pattern, where all trucks travel in the same direction, would have reduced the
accident potential among the trucks themselves.
B. Conveyor and Baler
It would have been advantageous to have eliminated the raised section of the conveyor.
Then the loader could have filled any empty sections of the conveyor and, in case of a
conveyor shutdown, loaded the scale platen directly. A variable speed control on the
conveyor would also have been useful in efficiently regulating the speed at which full
or empty sections of the conveyors were moved. Having a completely level conveyor
would require that the baler be installed in an excavated area or that the refuse truck
access be elevated above ground level. A combination would be best so that the bale
transport trucks could gain access to the baler pushers to load bales from a shallow, be-
low-grade access ramp. By allowing the scale platen to be loaded directly by the loader,
the availability and reliability of the baling plant would increase since the conveyor
experienced more downtime than the baler.
A pan to collect slurry and liquid squeezed from the baler should be designed and in-
stalled below the baling chamber, gathering ram and compacting ram. The pan would
collect liquid that drips from these areas and also would intercept liquid that tended
to squirt a considerable distance from the baling chamber. The liquid could be directed
by gravity into a large mobile drum or an equivalent container that could be unloaded
onto the solid waste storage pile for baling.
xix
-------
C. Alternative Baling Plant Equipment
Under 90-second bale cycle conditions, as opposed to the current 137-second cycle,
the waste feed will have to be faster and more reliable. An overhead crane should be
considered as an alternative to the skiploaders and possibly even the conveyor. If
designed and installed properly, this alternative could significantly reduce construction
and operating costs and might possibly improve the waste handling efficiency. The
control room might be mounted above the conveyor, giving one operator responsibility
for all solid waste handling inside the plant. This would require an improved automatic
baler control system so that the operator could load the scale platen with a new solid
waste charge while the baler was baling the previous charge.
A conveyor extending the entire length of the plant would allow more rapid loading
from many positions. A gravity conveyor chute would reduce downtime associated with
mechanical conveyors, but would have to be monitored for jamming. A diverging chute
could minimize }am-ups.
A mechanical mixer and loader may be a possible configuration. The waste would be
deposited in a pit with a mixer. The waste would be loaded directly from the mixer
onto the baler scale, or by conveyor or chute.
D. Bale Transport
The tractor-trailers used to haul the bales to the landfill were equipped with custom-
made, nylon mesh curtains. These curtains covered the bales during transport to keep
litter from being blown off. It took about three minutes either to close or open the
curtains. This time could have been reduced by improved curtain design or enclosed-
body trailers with hinged sides to allow unloading of bales.
In locations where land disposal sites are over 50 to 100 miles from the baling plant
(as determined by local economics), the use of railroad or barge transportation would
be less costly.
E. Maintenance and Repair
Lists of recommended spare parts inventories for the baler and other plant equipment
were available from equipment manufacturers. An inventory stock of the recommended
parts could have reduced some of the time to complete parts replacement maintenance.
Also, the parts inventory list should be reviewed annually to determine which parts are
replaced most frequently and the inventory adjusted accordingly. This will keep the
inventory adjusted to the age of equipment and thus allow for maintaining the minimum
inventory.
xx
-------
F. Labor
Mechanical equipment and automation could have reduced operating costs, although the
scope for this in the baling operation was comparatively small since mechanical power
did most of the work in the system. Labor was used largely for control, maintenance,
and the salvage (metal and corrugated cardboard) operation. The recommendation on
use of a crane to load the baler scale platen eliminates one employee.
Revision of work assignments to designate employees that would temporarily fill in for
the gateman, loader operator, and control tower operator could improve the overall
plant bale production rate as much as 5 percent. Such revised work responsibilities will
reduce plant downtime due to labor break time and thus increase productivity.
G. Plant and Grounds Design
Adequate drainage and grading outside the plant would eliminate muddy roadways.
Gravel or asphalt road surfacing with stormwater drainage are needed to eliminate bale
truck and other vehicle wet weather access problems. Also, dry weather dust problems
would be eliminated.
Improved forced air or induction ventilation at the roof of the baling plant would assist
in removing odors and dust created by the solid waste. Particularly, if an inclined
conveyor is used to feed waste into the baler, the elevated conveyor section where
waste is dropped onto the scale platen creates the most dust and could be removed
through roof vents. Cross ventilation through open doors at each end of the baling
plant is also helpful.
Techniques to control dust, in addition to the aforementioned roof vents, are needed.
Face masks with filters were provided to employees at the St. Paul plant. Possibly,
dust control could be accomplished by small quantities of water sprayed onto the wastes.
The amount of water required would have to be minimized to keep the moisture content
below the 30 percent wet weight maximum for making structurally sound bales. Other
problems of increased odor may develop if the waste is moistened. The aforementioned
roof ventilation may reduce the impact of odors.
H. Resource Reclamation
Mechanical methods of segregating solid waste components such as corrugated cardboard,
ferrous, aluminum and glass may make recycling economically feasible. Separation of
corrugated was accomplished by hand at a profit. Without preprocessing, magnetic
separation may be feasible for ferrous. Shredding and air classification would allow
separation of the above-mentioned materials. The shredded waste may not produce
good bales without binding.
XXI
-------
I. Landfill
Daily placement of cover soil on the horizontal surface of the top bales in the bale
landfill would make the operation more in compliance with a sanitary landfill.
(Although daily cover was not feasible in St. Paul during the winter due to thick ground
frost, it could have been placed daily at other times.)
Placing daily or other cover on the vertical working face is not feasible. Thus, a new
definition and guidelines for a "sanitary" bale landfill should be developed as a guide
to environmentally safe operation for bale landfills.
J . Recommendations for Further Study
The completed test cell and full-scale balefill should be monitored for a five-year period
to establish longer term gas, temperature, leachate, settlement, and biodegradation data.
The potential for groundwater pollution (from the leachate) and for other environmental
impacts could be more accurately determined as a result of such additional data
acquisition and analysis. Additional monitoring for balefill foundation characteristics
should be performed to determine the potential suitability of balefilled land for support-
ing structures of various sizes.
Additional investigations at other sites and with different waste compositions are needed
to extend available technical knowledge. The purpose of these additional investigations
would be to determine the environmental impact of the St. Paul fill (for comparison with
other balefills and with traditional landfills), to ascertain the potential of the completed
site for various uses (including waiting time and special measures required), to begin to
generalize for balefills as a category of land disposal alternatives, and to obtain
sufficient information to develop guidelines for an environmentally acceptable bale
landfill operation.
xx ii
-------
SECTION 1
INTRODUCTION
A. Objectives and Scope.
As authorized by Environmental Protection Agency Contract 68003-0332 (June, 1973,
and extension August, 1974), a 19-month investigation of the operational, economic,
and environmental aspects of baling solid waste, transporting bales,and disposal into
a sanitary landfill was undertaken. This report presents the results of two phases of work
under which the project was performed. Phase 1 consisted of an intensive five-day
field study of the baling plant and transport network under normal operating conditions,
as well as a review of historical cost and operating information. Technical planning
for the field-test work program involved three months of professional preparation. The
purpose of this first phase of the study was to define baling plant operation to determine
the parameters affecting the production rate and quality of the bales. The objectives
designed to fulfill this phase were to describe the following:
1. The physical plant, including facilities layout, and stationary and mobile equip-
ment.
2. The plant operation, including equipment reliability, maintenance requirements,
and use of labor.
3. The nature of the incoming solid waste, including the rate of inflow and the
physical characteristics of the solid waste.
4. The baling operation, including rate, method and an analysis of the bales and the
liquid squeezed from the solid waste during baling.
5. The activities associated with the baling plant, i.e., the transport network and
the landfill.
6. The environmental impact of the baling system.
7. The costs associated with construction, maintenance, and operation.
Phase 2 of the study included organizing the results of specific monitoring activities,
both at the landfill and at the test cell, where conditions were evaluated under more
controlled circumstances. In the test cell, gas generation, temperature, settlement,
leachate qualities, moisture content, and organic content were measured. Auger
drilling was conducted in the test cell and landfill areas on one day to assess biodegra-
dation conditions.
-------
B. Approach.
The baling plant was located in St. Paul, Minnesota,and operated by American Systems,
Incorporated, a division of American Hoist and Derrick Company. The Phase I monitor-
ing of the plant described in this report took place September 20 through 26, 1973. In
order to evaluate the baling operation on each of these days, the daily monitoring work
task schedule, shown in Figure 1-1, was developed. Task numbers one, ren,and eleven
were performed by a Ralph Stone and Company, Inc.,staff member with the cooperation
of the baling plant forklift operator, an employee of American Systems, Incorporated.
The forklift operator removed each tenth bale from the plant discharge platform, trans-
ported it to the temporary storage area designed for the bale measuring, and finally
placed the segregated tenth bales on a separate truck for transportation to the balefill.
Another American Systems, Incorporate4employee then drove this truck to the landfill
at the end of the first shift each day. The bale fill operator unloaded the truck and
placed the special bales in the test cell area. A crew of three Ralph Stone and Company,
Incorporate^staff performed tasks two, three and eight (see Figure 1-1). They were
assisted by the loader operator, an employee of American Systems,lncorporated,staff
engineers in cooperation with American Hoist and Derrick Company balefill staff.
Data forms usedduring the five-day monitoring period are included in Appendix A. The
data resulting from the five-day monitoring program provided the information neces-
sary to accomplish objectives two, three, and four: descriptions of the plant operation,
the incoming waste and the baling process. The information necessary for objectives one
and five,descriptions of the baling plant, the transport network and the balefill, respec-
tively, were either provided by American Hoist and Derrick Company personnel or ob-
tained through the efforts of Ralph Stone and Company, Incorporated, engineers prior to
the five-day monitoring period. Environmental impact and cost analyses, objectives
six and seven, respectively, were based on data obtained during the five-day monitor-
ing program and guided by comparison with other solid waste disposal operations.
Phase 2, test cell and landfill monitoring,was set up between August 2, 1973 and October
5, 1973, with baseline monitoring beginning on September 27, 1973. The test cell
measurements were taken through the end of November, 1974. Section 10 of fhls report
thoroughly details the results of test cell monitoring. The bale landfill monitoring ended
June 26, 1974, the last monitoring day during which the landfill was being covered with
soil prior to ending all solid waste baling operations on June 29, 1974. The baling plant
.was sold and operations ceased in June, 1974.
-------
LU
IT)
E
i*
a
«T
CM
CM
•o
0)
<1>
I
o
O)
c
L-
£
'E
I
1
x
&
X
mension
<§
a>
8
TJ
Ba
So
.
I
I
I
X X
& 0
x. x
CM CM
I
a
XV3H9
1
.§
P
i/>
<
0)
-
l M
Oj
"!lcQ
i
D) ~£. —
.
T3
0) C
o3
100
r- CM
CO
O^ J^ ^1 r- -^
-------
SECTION 2
GENERAL AREA AND OPERATIONS DESCRIPTION
A. City of St. Paul.
The baling plant served the City of St. Paul, a part of the Minneapol?s/St. Paul Stan-
dard Metropolitan Statistical Area. This area is located in the southeast part of
Minnesota and includes the Counties of Anoka, Dakota, Hennepin, Ramsey, and
Washington. The Minneapolis-St. Paul SMSA covers 5,457 square kilometers (2,107
square miles) and has a population of 1,813,647 (1970 census).
B. Baling Plant General Location and Access.
The American Systems, Incorporated, baling plant lay two city blocks south of the
Mississippi River (Figure 2-1). It was directly across the river from downtown St. Paul.
South Robert Street was the nearest arterial roadway, running north-south and crossing
the Mississippi River at the Robert Street Bridge. The baling plant lay approximately
180 meters (200 yards) west of South Robert Street. Plato Boulevard, a smaller east-
west roadway, provided access to the plant from South Robert Street or from Wabasha
Street, the north-south roadway to the west. Starkey Street, a dead-end street that
extends south from Plato Boulevard, provided access to the plant (see Figure 2-2).
The baling plant was located in a commercial-industrial zoned area. The traffic to
and from the baling plant was composed of solid waste collection trucks and baling
plant-related vehicles, as well as commercial-industrial vehicles. 'rhe nearest
residential area lay approximately 90 meters (100 yards) south of the site, across Wood
Street. However, Wood Street is at the top of a rise, approximately 10 meters higher
than the adjacent land, making the plant invisible from the residences.
Noise, dust and odor resulting from the baling operations were largely contained
within the plant structure. As shown in Photograph 2-2 (b), from the outside the plant
appeared to be a typical prefabricated light industrial plant. The only outdoor storage
was a neatly stacked pile of wooden pallets located west of the building. The transport
vehicles were parked near the southeast corner of the lot. The asphalt-paved yards
greatly minimized the dust raised by the vehicles. All roadways were asphalt-paved,
including the southern side of the structure where the bale loading dock was located.
Figure 2-3 shows the site layout. Except for a few flies transported with the collected
unbaled refuse, no vectors were observed at the baling plant site.
C. Baling Plant Site.
1. Physical. The baling plant building was an Inland-Ryerson prefabricated 400-D
metal building, 73 meters (240 feet) long and 37 meters (120 feet) wide. The eastern
24 meters (80 feet) of the plant have 10-meter (32-foot) high sides. The gabled roof rises
at a 4/12 slope to reach a central crown 16 meters (52 feet) above the base of the
building. The remaining sidewalls of the building are 7 meters (24 feet) high and the
crown of the roof is 13 meters (44 feet) high. This split-level design provided additional
-------
(1" = 0.7 miles)
* {CARROLL, i zL*JL^U-?-
^^^^^N^SsiS-f-l^l^lsri^a
^*s*»*Hi. /?.
-------
Commercial -
Industrial
Collection
Vehicles
Scale:
1 cm = 36 m
(1" = 300')
FIGURE 2-2
BALING PLANT VICINITY
MAP WITH TRANSPORT FLOW
-------
o
CM CO
S5
33
— Q_
""z
11
<
CQ
<0 II —
o
o
CO
E "
o =
-------
height In the east section where the baler is located (see Figure 2-4).
The plant appurtenances, such as in-wall partitions, loading dock, conveyor pit, etc.,
were constructed of concrete and/or 15-centimeter (6-inch) lightweight concrete blocks
with a 10-centimeter (4-inch) thick Spancrete roof. The building was serviced by
telephone, water, gas, sewer and electric utilities. The inner wall partitions were
3 meters (10 feet) high. The service area in the southeast corner also had concrete
block walls and a 15 centimeter (6-inch) thick Spancrete roof. This area contained the
toilet, parts storeroom, a lunch room, office, and mechanical (power) room which
housed the baler electrical, oil pump and other equipment. The gate attendant's room
was a portable wood structure about 1.0 m by 1.0 m by 2.4 m high. It contained a small
table and a cash register. The control tower housed the control panel, the scale readout
dial, and the operatot responsible for running the baler and conveyor. Details of these
structures can be found in Appendix D.
2. Operation. The labor force at the baling plant during the one-week monitoring
consisted of a gate attendant, a front-end loader operator, a utility (fork I iff) man, a
maintenance man, two segregators, the control tower baler machine operator and the
plant foreman. The control tower operator was designated a working leadman. The bale
plant superintendent was also responsible for operating the landfill and the transport trans-
fer trucks. Although he spent most of his time at his office in the baling plant, he
technically was not part of the direct baling plant production staff.
The mobile equipment used at the baling plant consisted of a front-end loader, a forklift,
a small "bobcat" type loader, and a hand-pushed electric floor sweeper which was on
loan. Descriptions of baling plant machines can be found in Appendix C.
The baling plant functions constituted a process; the input to the process consisted of local
municipal type solid waste and the output was the high density bales. The plant was
designed on a linear basis; the input entered the plant at the west end, was transported
through the plant, and the output exited at the east and ready for transport (Figures 2-5
and 2-6). A simple, direct way to describe the plant is to follow one cycle in the process.
Vehicles bearing incoming solid waste proceeded southward on Starkey Street and entered
the site via the driveway at the end of Starkey Street. They then proceeded along the
driveway to the eastern entrance yard. Here they were directed by the gate attendant
from his position near one of the four eastern doors. The gate attendant's first function
was to direct the driver of the vehicle to enter the plant through a designated door. The
driver of the vehicle then used the yard to turn around and proceeded to back in through
the designated door. Following the directions of the gate attendant, the driver continued
backing the collection truck until he reached the desired dumping area. He then stopped
and dumped his waste load onto the dumping floor. The gate attendant observed the load
dumping to identify solid waste composition and note other special billing items and
material requiring careful handling. (A copy of the fee schedule is shown in Photograph
2-1a.) During the unloading process the gate attendant filled out a vehicular fee ticket.
(See Appendix B for data form.)
-------
t 5Z
c^<<
LU O- Q_
CD
O
Z
1
J
-------
CN Q_
y
<
*
&
^
O
10
-------
8.
Vi
u3
g
O-
o
u.
to
o <
UJ t—
O
Z
co
.2T5
« "5
O-O)
C Q)
D_ "
"O ai
8>
T)
JJ
O
O>
11
-------
Prior to vehicle departure he approached the collection vehicle driver arid collected the
fee. If the owner of the vehicle had a charge account with American Systems, Incor-
porated, the driver needed only sign the ticket; the vehicle was then free to leave.
If no account existed the gateman collected the necessary fee. In this case the gate
attendant returned to the gate attendant's room. In the room he used the cash register to
ring up the fee on the ticket, deposit the money in the cash register and make change,
if necessary. He then returned to the vehicle to give the driver the receipt and any
change. The collection vehicle was then free to leave.
As soon as possible following empty vehicle departure, the loader operator drove the
loader to the unloading area used by the vehicle and pushed the unloaded solid waste
toward the east end of the building into a pile with other previously received solid waste.
This kept the unloading areas open so that incoming waste collection vehicles could
unload at all times. When the loader was not moving waste in the unloading areas, it
loaded solid waste onto the horizontal pit conveyor. Incoming solid waste was unloaded
on both sides of the conveyor by periodically directing trucks to each side. The solid
waste was loaded alternately onto the conveyor from both sides so that the unloading area
remains clear. The loader was used to mix the solid waste, keep the unloading floor clean,
to sort out large metal objects white goods such as water heaters, stoves, etc., and also to
segregate large corrugated items. The loader operator used the loader to mix the solid
waste by turning the pile of waste in a rolling motion with the bucket. This was accom-
plished by inserting the bucket near the bottom of the pile and raising it until the material
taken from the pile bottom was pushed onto the top of the pile. The loader operator used
the loader to keep the work area neat by placing the bottom of the bucket on the ground
and scraping it along the floor using a broom-like motion. He used the loader to sort out
white goods by employing the bucket to back-drag the metal objects away from the pile.
The loader bucket was then swept like a broom once again to push the item over to the
north wall metal storage area. These rejected items were stored in a pile near the
north wall. They were removed from the bale plant on a van truck when a full load
accumulated, and either taken to a nearby scrap yard or alternately baled into Number 2
steel scrap and then sold.
The horizontal 2-bar slat conveyor moved the solid waste along the pit and dumped it onto
the bottom of the inclined conveyor. The inclined 2-bar slat conveyor then carried the
waste upwards and discharged solid waste onto the scale platform. Just prior to the upper
end of the conveyor there were platforms on both sides of the conveyor which were
utilized by the two men that were corrugated segregators. These two men were equipped
with hook poles to reach past the middle of the conveyor. They removed all corrugated
that was in good condition and placed it on chutes behind them which were sloped down
and away from the conveyor. The chutes directed the corrugated into piles on the plant
floor which were periodically pushed into storage areas along the side walls. Corrugated
moving was completed by the forklift operator, using the small "bobcat" loader. The area
near the side door on the north wall was used for corrugated storage; incoming vehicles whose
load consisted primarily of corrugated entered through the side door and dumped near the
corrugated storage area. The corrugated was also baled in a separate run and sold to the
secondary material dealer providing the highest bid.
12
-------
The baler operator controlled the conveyor, scale, and baler equipment operation.
When the weight of the waste material on the scales reached the desired amount (990 kg
for normal solid waste), the baler operator stopped the conveyor. The subsequent events
could then occur automatically or be controlled manually by the baler operator; in either
case, the sequence of events was the same. The next step was the activation of the
platen, a metal plate that pushed the waste across the scale and into the baler charging
box. It could not be activated until the baler charging box lid opened. The charging
box lid had to remain closed while the baler was producing a bale. A short delay
routinely occurred between the stoppi ng of the conveyor when the desired waste weight
was reached and the activation of the platen to load the charging box. Once the lid
closed, the baling process began.
The baler was basically composed of three hydraulic rams and a baling chamber which
had three fixed walls, and a sliding door which acted as a fourth wall. The gatherer
ram activated first and pushed the waste from the hopper into the baling chamber. The
gatherer ram remained extended during the operation of the other two rams. The vertical
ram, called a tramper, activated next. It pushed the charge down into the chamber and
provided a ceiling (fifth wall) for the baling chamber. The final operation was the
activation of the third ram, the compactor. The compactor became the final chamber
wall, creating a box-like area into which the waste was compressed to about a 91.4 cm
(36 in) by 91.4 cm by variable length (average = 122 cm or 48.0 in) bale. The wall on
the eastern end of the baling chamber was the baler discharge door. After the bale was
produced, the baler door opened. The compactor ram, which was still extended, was
further extended to eject the bale out of the baling chamber onto a platform.
Two hydraulic pushers moved the bales into loading position (Figure 2-7). Pusher
One, located adjacent to the baler door, pushed the ejected bale southward across a
platform and extended just short of the path of Pusher Two, which was perpendicular to
Pusher One. Thus, one discharged bale rested in front of Pusher Two after Pusher One
retracted. However, Pusher Two had enough room in front for two bales. It, therefore,
was activated only on every second cycle. Pusher One moved a second bale adjacent
to the first and then pushed both bales into position in front of Pusher Two. When Pusher
One retracted. Pusher Two was activated to push the two side-by-side bales onto a
flat-bed truck. Two cycles later, Pusher Two was again activated. This time, the two
bales pushed would, in turn, push the previous two bales along the truck bed. Each
time two bales were pushed onto the vehicle, they pushed all of the bales ahead of them
further along the truck bed. Loading continued until 14 or 16 bales occupied the truck,
at which point Minnesota State Highway Department legal load limits were reached.
Operation of Pusher Two (see Figure 2-7 ) was the last operation part of the baling plant
process. It was also the last operation which was controlled by the baler control panel.
As was mentioned, the baler operator might, if desired, manually control all of the steps
from the stopping of the conveyor through the operation of Pusher Two. He was also the
working leadman. The height of the control tower allowed him to view the entire
13
-------
GO
-O
.2
tJ
S
0)
TJ
+J
"x
LU
c
o
Q>
"5
03
T3
CO
v
U
3
t—
Loading Platform
0)
o>
s<5
— __«—_-« ^i I
8
O
k.
0)
I.
Jl
Z a>
"I
o o
_0) «-
O
0)
VI
Q_
to
D
a.
U
UJ >_
^^
M
a.
O
Z
03
01
T3
O
I/)
o
14
-------
operation, and through the use of a public address system with a microphone in the
control tower, he could communicate with other workers on the plant floor. He was
responsible for assuring that the entire process ran smoothly.
The utility man has been mentioned only in connection with the operation of the small
loader to move segregated corrugated, but his major responsibility was operating the
forklift. He used the forklift whenever it was necessary to remove a bale from the bale
discharge platform. This became necessary to remove occasional broken bales from the
platform and deposit them onto the incoming solid waste pile for re-baling. Any portions
which broke off of bales were swept up, placed in a wheelbarrow, and returned to the
incoming waste stream for rebaling. If enough of the bale remained intact, it was
loaded directly onto the transport vehicle using the forklift. Another major use of the
forklift was to lift up the edge of the loading platform so that the bed of the transport
vehicle could fit under the edge of the loading platform. This corrected the loading
platform deflection caused by the weight of the bales. The lifting required was usually
2.5 to 5 cm (1-2 in.). When the forklift operator was not busy with the forklift or the
small loader, he was responsible for other duties. He used the automated sweeper
(when it was loaned to the plant) to keep the floors swept and helped the vehicle
transport drivers perform the rigging operation. This operation was technically a part
of the transport network, so it will be discussed in a later section.
A maintenance man was responsible for keeping the baling plant equipment in operating
condition. He repaired minor equipment breakdowns which did not require extensive
parts replacement. He could also fill in for the loader operator, the gateman, or the
forklift operator in case of illness or injury. If not busy, he also assisted in transport-
vehicles rigging and floor sweeping. There were two occupational trainees who work
part-time at the baler plant. They were strictly used as cleanup men. The maintenance
man spent some time supervising the work of these two employees.
The duties of the foreman were administrative; he was also responsible for repairing major
breakdowns that occurred which did not involve obtaining parts or services not available
at the baler plant.
In addition to all of the above activities, one hour of each day was devoted to plant clean-
up. All employees, excluding the foreman and the gate attendant, cleaned up the con-
veyor pit and the area below the baler. The waste they cleaned out of these areas was
added to the incoming waste pile and subsequently baled. During the week of monitoring,
cleanup was completed by both work shifts on different days. The first shift operated from
6:00 a.m. until 2:30 p.m. with one half-hour for lunch from 12:00p.m. to 12:30 p.m. A
second shift started work at 2:30 p.m. and worked eight hours.
The above work description applied to the normal plant operation through September 17,
1973. The bale plant fees were scheduled to be increased on September 17, and many
private solid waste collectors hauled their waste to an alternative private landfill
location to avoid paying the higher fee. Institution of the fee increase had been initially
delayed by the President's Cost of Living Council economic regulations. The diversion of
15
-------
the private solid waste collectors to the alternative private landfill disposal site reduced
the number of hours worked at the plant during the second shift. The second shift hours
varied from 4 to 8 per day during the week of monitoring, depending on fhe amount of
solid waste received.
3. Qualitative Observations. The interior of the baling plant was described as musty.
During dry periods trie air was dusty, and during warm weather natural ventilation was
provided at both ends of the plant through the open doors. During rainfall periods when
solid waste was wet, there was little to no dust, but the solid waste characteristic odor
increased. Some workers wore face masks provided by the Company, which covered
the mouth and nose to cut down on the inhalation of dust particles. The plant was not
well lighted, and much darker than normal daylight illumination. The plant interior
was noisy due to the large empty building volume acting as a sound chamber. On the
west end of the plant, noise sources were the loader and the unloading waste collection
trucks. The east end of the plant was less noisy at floor level due to the conveyor-scale-
charging box lid operations, which were the major noise sources; these were elevated
high above floor level.
Plant operation aspects are shown in Photographs 2-1 through 2-4. Solid waste residues
were ejected from the baler at several points, but the majority of the squeezings were
extruded when the bale door opened. Small particles of solid waste, primarily gfasTand
wood, were also squeezedout from the baling chamber past the gatherer and compaction
rams. The vertical tramper ram tower walkway and ram framework had similar minor
deposits of dry, crushed solid waste particles. A pile of this residue was observed
blocking one side of the uppermost railing surrounding the tramper ram tower. Atjcer-,
tain times during the hjjjhjDressure compression, some liquid wastes squir_te(Loyf^of^the
baler^nd were sprayed up to 4.6 meters (T5 feet) oato the control tower concrete supports
One section of the service room waTTopposTte Pusher Two was also occasionally sprayed
with liquid, leaving a permanent stain. The liquid spray quantities were minor, but
proper shielding and drainage would have eliminated this phenomenon.
The activities occurring at the plant normally followed a moderately active pace. When
several waste collection vehicles arrived simultaneously, the unloading area became
jammed due to lack of a coordinated traffic flow plan. Cleanup was an ongoing
effort involving the movement of wheelbarrows, shovels, brooms, and men. Corrugated
usually cascaded down from the laborers positioned at the top of the conveyor. Personnel
on the plant floor had to be alert to avoid walking under the falling corrugated. The
corrugated fall area was roped off to keep people from walking in the area where the
corrugated was falling to the floor. Often when a waste collection vehicle unloaded
mostly corrugated, the hand separation of the salvageable material from unreusable
waste took place directly on the baling plant floor. Minor plant maintenance operations
took place at any time, involving transport vehicles, the baler, the forklift, or other
equipment.
16
-------
SI 30 PER COMPACTED CUBIC VAKO
SI 00 PER LOOSE CUBIC YARD
si 25 MINIMUM PER CAR OR STATION \VAGOH
S3 ?5 MINIMUM PER TRAILERS AND PICKu^S
S300 APPLIANCE (LOOSE)
S 70 CAR TIRES
S1 00 TRUCK TIRES
MM IS 6 80 A M 10 8 00 f ffl SSI I 00 ft M HI ,i Oil f V SUN
a. Prices for facility use
b. Bale plant bale truck loading area
c. Segregation of cardboard
d. Refuse to be baled
e. Baler - view of compaction ram
f. Baler control room
PHOTOGRAPH 2-1
BALING PLANT OPERATIONS (I)
17
-------
a. Conveyor and control tower
b. Incoming waste vehicle entrance
c. Cardboard sorters
d. Front end loader placing waste on conveyor
PHOTOGRAPH 2-2
BALING PLANT OPERATIONS (II)
18
-------
a. Hydraulic oil and liquid squeezed
out under pressure
b. Horizontal conveyor belt and pit
^»w,r ,,,
#*•*' -
c. Waste fallen off of inclined conveyor
d. Baler charging box
PHOTOGRAPH 2-3
BALING PLANT OPERATIONS (III)
19
-------
a. Small volume of squeezings from
bale
m —
- - • * •* -m
c. Baler and loaded bale truck
e. Preparing truck for departure
b. Truck backing into baler platform
*-» '•e^^^^PilTWW^^I^I,^ s ^
#•
d. Protective curtain on bale truck
~—™™™.»™«lll&H'«' =B^*W^S««[«SA^gS8gi|Sll!j^
f. Sweeper for bale plant floor
PHOTOGRAPH 2-4
BALING PLANT OPERATIONS (IV)
20
-------
SECTION 3
SOLID WASTE DESCRIPTION
The baling operation depends to some extent on the nature of the solid waste. During
the five-day study the incoming vehicles and waste characteristics were monitored.
The American Systems baling plant gate attendant recorded the incoming vehicle owners,
volume, and type of waste on the Gate Attendant Form provided by Ralph Stone and
Company, Inc. (see Appendix A).
Representative samples of solid waste were removed twice daily, placed into a 510 liter
(2 cu yd) bin and sorted into the following categories: paper, wood, metal, textile,
plastic, rubber and leather, food, glass and ceramics, garden, rock and dirt, smalls
(2.5 to 0.32 cm s?eve),and fines (less than 0.32 cm sieve). Three additional 510-liter
bins plus the two sorted bin fulls of waste were weighed each day to determine baler
feed waste density. At the end of each day, a 9 kg (20 Ib) sample was composited in
proportion to the constituents in the two daily sortings for laboratory analysis.
The liquid squeezed from solid waste during baling was collected in several pans, and
a bucket placed at points under the baler where leakage occurred. The volume of
squeezings was measured and two samples were taken each day for laboratory analysis to
determine pH, coliforms (total and fecal), BOD/j, Cl, SO4, sulfides, TDS,and nitrogen
series (NOg, NhU, and organic).
The St. Paul baler plant receives incoming solid waste from 6:00 a.m. to 8:00 p.m.
The peak period is from 9:00 a.m. to 2:00 p.m., except during the lunch hour. This
information is presented graphically in Figure E-12 for each day during the five-day
study period, and in Figure E-13 for the entire weekly period.
The origin and size of the solid waste vehicles varied greatly. As can be seen in
Figure E-14,almost half of the vehicle sizes were between 11.4 and 15.2 cu meters. The
basis for this observation may be found in Figure 3-1, which indicates that over one-third
of the incoming vehicles were St. Paul Public Works vehicles, which fall into this size
category. Of the large vehicles, most were 57 cu meter (75 cu yd) vehicles
owned by American Systems which hauled waste from the American Systems Midway
Transfer Station in St. Paul. The percentage of vehicles under 3 cu meter (4 cu yd) in size
corresponds well with the percentage of private vehicles arriving at the baler plant. This
percentage may have been lower than usual in the time period studied because on
Saturday, September 22, there was a city cleanup campaign in St. Paul. The public was
allowed to dispose of refuse at several sites in the city without paying a fee. The St. Paul
Public Works System vehicles brought these materials to the baling plant. On a volume
basis, American Systems vehicles contribute 39 percent of the incoming waste, St. Paul
Public Works vehicles 24 percent, private collectors 35 percent, and the public at large
contributed 2 percent. The volume and type of solid waste received during and prior
to the five-day study can be seen in Table 3-1. About one-half of the solid waste
received was residential. The large amount of waste received on Monday, September
24, 1973,can be accounted for by weather conditions. Sunday evening and Monday morning
21
-------
Others
Wai (master
Brennan Rub.
Mickey's Rub.
Cashfll Rub.
c American
.2
t£
.N Waste Cont.
Private
_
c August
O
Pub. Wks.
Hamm's
Sp lie ha I Rub.
Red Arrow
Re mac ke I
18.5%
1.1%
0.8%
1.1%
1.8%
8.9%
- 1.1%
12.9%
3.9%
- 0.8%
4.7%
.5.0%
0
38.3%
I I I
10 20 30
Total Vehicle Arrivals (percent)
40
Legend: Arrivals on 9/20, 21
22, 24, 25 and 26,1973,
combined. FIGURE 3 - 1
SOURCES OF BALING PLANT SOLID WASTE
22
-------
TABLE 3 - 1
INCOMING WASTE TYPES
Date
9/73
13
14
17
20
21
24
25
26
Total Solid Waste
Volume
Received
(m3)
1,004.9
939.76
679.6
1,203.3
1,133.4
1,315.7
1,117.7
834.8
Type
.Residential
443.16
439.40
317.84
528.9
435.51
637.3
610.1
371.49
of Waste Load
Industrie]
314.34
289.36
170.87
362.69
361.36
422.1
245.4
241.3
(m )
Commercial
247.45
211.0
190.93
311.8
336.32
256.38
262.2
222.98
23
-------
experienced heavy rainfall. Many private haulers who had been driving to the com-
petitive private sanitary landfill located outside of town to avoid paying the disposal
fees brought their refuse to the baler plant during rainy weather to avoid the landfill,
which reportedly became very muddy on wet days. The time lost due to trucks becoming
stuck in the mud at the landfill compensated for the higher price charged at the baler
plant at that time.
The density of the incoming waste can be seen in Table 3-2. The average density of
79.53 kg/m (4.96 Ib/ft3) and the standard deviation, of 17.46(1.09) indicates that the
solid waste is not uniform. The process used to measure the density involved filling
with solid waste a 510-liter (2 cu yd) bin which was provided by American Hoist and
Derrick Company. The contents of the bin were then weighed by the sorting crew.
The loader was used for filling the bin, taking a bucketload of refuse from the same area
from which solid waste was obtained to load the conveyor, and dumping this bucketload
instead into the storage bin. The level of mixing of the samples was, therefore, approxi-
mately the same as the level of mixing of the solid waste provided to the conveyor and
the baler.
For sorting, the aforementioned bin was again filled by the loader. The contents were
then sorted into standard categories by the sorting crew. The percentages shown in
Table 3-3 are based on the wet-weight results of this sorting process. Once again, the
standard deviation is large, indicating a large variation in incoming waste constituents.
Table 3-4 shows an equally diverse moisture content for both the incoming solid waste
and the bales. The organic content percentage is one of the few parameters that re-
mained fairly stable.
The higher moisture content in the bale core samples may be due to one or a combination
of the following factors: random variations due to differences between samples; the
release of moisture from containers crushed during baling; and the diffusion of moisture
throughout the bale material under the high baling pressure.
i The main collection area for liquid squeezings was the area directly below the baler base.
The squeezings had a consistency quite like oatmeal, rather than liquid., Therefore, two
types of samples were taken. One sample was collected in flat rectangular pans (see
Photograph 2-4). Another sample was collected in a bucket which had a piece of 0.32-cm
\ (1/8-in) mesh hardware screening over the top. This method was used to strain the
squeezings. It was though that there might be a difference in the two samples when
analyzed in the laboratory, but as Table 3-5 indicates, there was in fact no noticeable
difference. For the first three days of the study the volume of squeezings was .checked
only once perjjgyjbecause very little was generated. Beginning on Tuesday, the waste
being baled was wet due to Monday's ram. (On Monday, there was a large amount of
dry waste still on the floor of the baling plant from the City cleanup campaign which
took place on Saturday. Thus, the refuse baled on Monday was dry despite the fact
that it rained on Monday.) Therefore, on Tuesday and Wednesday the squeezings were
being generated much more rapidly. As a result, the volume was checked three times
per day on Tuesday and Wednesday. It also rained on Wednesday, resulting in very wet
conditions in the baling plant. On this day, squeezings were also seeping out of the
gathering ram and the compaction ram. On Wednesday, these volumes v/ereMso recorded.
The squeezings were also much more watery on Wednesday and slightly lighter in color
than the normal greenish-gray.
24
-------
TABLE 3-2
INCOMING SOLID WASTE DENSITY
Date
9/73
20
20
20
20
21
21
21
21
21
24
24
24
24
24
25
25
25
25
25
25
26
26
26
26
26
26
Time
8:30 A.M.
9-OoA.M.
1:30P.M.
2:00 P.M.
7:30 A.M.
7:30 A.M.
9-.00 A.M.
12:00 P.M.
12.00P.M.
7:00 A.M.
7:45 A.M.
8:05 A.M.
10:45 A. M,
11:30 A.M.
7:45 A.M.
7:45A.M.
8:15A.M.
11:00 A.M.
1M5A.M.
1-.15P.M.
8:30 A.M.
11:30 A.M.
2:00 P.M.
2:30 P.M.
3:00 P.M.
3: 40P.M.
Sample Wt.
(Kg)
127.2
119.1
130.0
155.0
139.5
149.5
153.6
106.4
170.4
113.2
105.9
151.8
127.7
144.5
86.3
78.6
139.5
127.8
137.7
148.2
126.3
158.2
92.7
111.8
87.2
93.6
Sample Vol.
(cu. m.)
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
Density0 'b
(Kg/m*)
83.1
77.8
84.9
101.0
90.8
97.4
100.4
69.5
81.4
74.2
68.9
99.2
83.1
94.4
56.4
51.1
90.8
38.6
89.7
96.8
82.6
103.4
60.6-
73.0
96.5
61.2
° Average 79.53 Kg/m3 (4.96 lb/ft3); Standard DeviaHon=17.46 (1.09),
From floor storage.
25
-------
z
o
o
Q_
o
u
LU
2 I
a
UJ
LU
LU
.—
(/)
CQ
Jc
.S?
1
1
*
"5
o
'o
0)
o>
o
'c
4)
O
5
D_
£
u
8$ >
in o oo
£
= ' ° 0)
D IO CM >
£ • CO
_O
CL.
0)
"""""
1
"o
1
I
^"
L.
0)
a
o
a.
4, CO
^ \
Q ON
NO
^_
rx
CO
00
•
CO
•
ON
ON
Tf*
rx
O)
0)
.
*
CM
0
*
CM
NO
00
*
CM
CM
*
o
ON
•
^~
00
— '
CM
*
CO
CO
CM
10
—
CM
I—
rx
0
r—
ON
o
CO
10*
\
oo
•o'
00
,
^ §
•85
II
26
-------
TABLE 3-4
ANALYSIS OF MOISTURE AND ORGANIC CONTENTS
FOR UNBALED AND BALED SOLID WASTE
Date
9/73
20
21
24
25
26
Avg.
20
21
24
25
26
Avg.
Moisture Content
(% dry weight)
Incoming Solid Waste Samples
54.6
15.3
48.5
37.9
71.0
45.4
Bale Core Samples0
26.2
82.3
30.7
36.1
82.2
51.5
Organic Content
(% dry weight)
(Unbaled)
60.0
74.8
89.0
83.9
73.5
76.2
77.3
64.0
66.3
84.4
84.1
75.2
Samples taken within 15 min. of bale construction.
27
-------
Qi
LU
1
U_
O
to
LU
CO
^~
_J
*^C (/•)
O— _
< z
< N
*O fi ~j
co Q D
o O
LU ^ 00
— J ~r^
CQ O Q
| >V ^
i! 0
U 13
03
Q
Z
<(
1
•^
y
LU
X
u
W)
0)
CO ^_^
_ .•-—
0) c?
o ^5,
z
<
i
t
t
,
(
V
c
)
"(.
C
(
c
„_
£ ^
oo
ij~ O
3z
Q-
-^
(I)
a
£
o
oo
Z
O)
o
.2
c
o
1
oo
0
Z
*d^
/) N^
-J O)
-^J
S 'o^
t3
^ \^
5 ro
-^5
^
"^ ^»
" ^
_ •CT"
j^i
^<^
Q £
"o
u
LU
"o
•4— •
H*
a.
o
a
a ^*
^~
CO
"o °*
Q r"
K 3 CN — CN ^f- O
•— O CO tx IT) O CO
CO O CN — CO fX IX
II - V | S V ^ *
1 1 CN r-~ 1 — — CN —
IO
OOCO 'vfCNCO^f •?
O Or— lOOO ^O
O**1 i~" ^O S. S. K
1 1 "Nt 1 1 CO O O 1 1
1 1 NO 1 1 ^ •<*• "Nf 1 1
O CO o OO
1 1 1 1 • . . 1 1
1 1 if) 1 1 O O CN 1 1
r— r»- ^—
8O 0 O
o o o
U CO O- O '^t'
1 1 •» 1 1 N V ^ 1 |
1 1 CO 1 1 CO •**••*!• 1 1
OOO OOlOOiT)
CO^OCN NOCNONlONO
, -^ -o ix o rx CN ON
CM •— CSI CN CN •— CN 1 1
NO O O O O if) O
if) O "^ O LO O IX
,— o co OcNinoo
01 CO CO CO CN CM CN ' 1
OOO OOOOOO 0
OOO OOOOOO O
OOO OOOOOO O
CNOO ,— O — NO CO O OO
— "t CN CN — — "NtCN^Nf IX
CN i— CN
coOi — if) ' — U")NOCNIX o
OO "^~ ''Nt' fC) "^f CO "^ CO ^ ^
IDZ)oo IDooIDcoIDoo ID
O i "*sf "*Nt" if) if) NO NO
ON ON ON ON ON ON ON ON CO CO
v>
V)
>,
o
o
^~*
D
1_
f\
£
Jj)
Q.
E
o
vt
_c
0)
D
o
93
o
z
(J
• A
o
0
n
D)
£
0
-°
,
•D
0)
c
'E
•1-
w>
c
^
II
<
-o
(U
c
"5
L_
oo
II
oo
D
28
-------
SECTION 4
BALE DESCRIPTION
A. Monitoring Method
A major aspect of the performance of solid waste baling systems is quality and production
rate of the bales. These parameters were monitored in three ways. First, the control
tower operator recorded the weight of the material loaded onto the scale for each bale.
He also recorded the time of day for every 25th bale.
The second way involved a series of measurements made for every tenth bale. Each
tenth bale was removed from the baler ejection platform and placed along the wall
at the east end of the baling plant, near an auxiliary loading area. These bales were
measured for maximum and minimum distances between faces on length, width, and
height. These measurements were taken at times ten minutes, one hour, one day, and
one week after bale production. The production time and ram pressure for each tenth
bale were also recorded.
The third way consisted of taking three 5 centimeter (2-inch) core samples from each of
two randomly chosen bales each day. A 1,5-horsepower industrial drill with a core-
sampling bit was used. A standard 15.2 cm (6 in.) coring depth was attempted, but
depths ranged from 5 to 25 centimeters (2 to 10 inches). The core samples did not
remain intact but fell apart due to expansion immediately upon removal from the core
sampling drill bit.
B. Results of Bale Monitoring
The bale production for the first shift can be seen on Figure 4-1. Production for the
second shift can be seen on Figure 4-2. These figures show that bale production rate
(the slope of the curves) is not constant throughout the day. Several work stoppages
due to baler breakdowns are noted. On many days a characteristic slow-down can be
seen near the end of each shift. This is common in most production plants which are
labor-intensive.
Table 4-1 shows the production times for the tenth bales. The average production time
is 1.73 minutes. This is defined as the period from the charging box lid closing until
the ejection motion of the completed bale out the baler door is stopped. This time is
different than the baler cycle time, which extends from the activation of the platen
through the end of the ejection operation. The standard deviation of .16 minutes is
9 percent of the mean. This fairly low deviation indicates a relatively constant bale
production time.
The measurement of the tenth bales was performed at successive times to determine the
degree of springbuck of the bales. Figures 4-3 through 4-7 show the variation in the
average value (average of maximum and minimum readings) for each dimension for the
tenth bales for Day One (9/20) through Day Five (9/26), respectively. It can be
observed that the maximum dimensions were measured one day following the production
of the bales. Between this measurement and the one-week measurement, the dimensions
29
-------
o
fl>
.. o
•gp
0)
fl)
o
O r-
O
"* «">
*x *s!
O Ov
u
o
TO
4 £*
O.
&UJ
GO
Oi
O
o
in
o
10
10
CM
8
IO
IX
o
IO
IO
CM
sapg jo
30
-------
z
o
31
-------
TABLE 4-1
TENTH BALE PRODUCTION TIMES
Sept.
1973 Number of Tenth Average Production
Days Bales Timed0 Time (*nin.)
20 15 1.799
21 14 1.757
24 13 1.647
25 9 1.764
26 11 1.679
Overall 62 1.731
Standard
Deviation
0.11
0.26
0.08
0.13
0.15
0.16
Tenth bale monitoring was done only during the first six to eight hours of plant
operation, thus the number is less than one tenth of the total bale production for
each day.
32
-------
CO
_
0)
0>
CO <
I ca
-* o
LU 7
o£ £:
u_
<
CO
X
O
-o
J «
r- E
c
'i
o
CO
CN
— o
cs
•
o
33
-------
_
0)
I
5
^ a;
OQ-
_ f>
LI- m
<
CQ
fr
•o
o
O)
c
'IE
o
>o
If)
cs
•
o
uoisuaiuiQ
34
-------
ft
0)
I
o
o
s £
W l/l
CQ
X
o
0
V
e
O)
O)
c
*E
o
CO
•— •— o
(SJ9431U) UOJSUatUIQ
35
-------
_
0)
0)
UJ
C£
=>
O
OQ
O
O-
oo
X
O
•
E
E
O
CO
o
•
O
(SJ343UI) UOISU31UIQ
36
-------
CO
J I 1 1 1
_
0)
Q)
^ 03
O
LU -7
Of. *-
X
O
-
O
-C <0
_ E
c
*E
o
«•> TJ- co
• • •
^^ •"• C3 O1*
• • • •
^- r- r- O
uoisuauuiQ
37
-------
once again decreased. This seems to indicate a settling of the bales, perhaps due to
evapo-transpiration of moisture. On Figures G~l through G-5 the expansion is
shown in terms of volume percentages. With the exception of 9/26, the same settling
phenomenon is observed. A possible explanation is that the refuse being baled on
9/26 was very wet. Moisture causes paper, which comprises 30 percent or more of the
refuse (see Section 3) to lose its elasticity,. Percent linear expansion of the bales at one
hour after production was:: height - 2.5, width - 1.4, and length - 3.3; at one day after
production, height - 5.7, width - 8.3, and length - 9.6; and at one week after production,
height - 3.7, width - 9.6, and length - 10.8
The tenth bale measurements afforded a good opportunity to study bale uniformity.
Tables G-l through Table G-5show the mean value, the standard deviation, the
variance and the covariance for the maximum and minimum values of each dimension
on Day One through Day Five, respectively. The bales may be seen to be fairly non-
uniform. This cannot be attributed to the ram pressures used for the various bales,
for the pressure only ranged from 1361 -1588 kg (3000-3500 pounds) and was almost
always the specification value, 1542 kg (3400 pounds).
By combining the data reported by the control tower operator and the tenth bale data,
the densities of the bales can be obtained. The average bale weight, recorded by the
control tower operator, was 1,282 kilograms (2,826 pounds), with a standard deviation
of 50. Table. 4-2 shows the average densities for each day's production of tenth bales.
The wide range of densities (937 to 1579 rb/yd ) indicates bale densityjconuoiformify.
The core samples were analyzed for moisture content and organic content, as were the
daily 9 kg (20 Ib) composite samples of the incoming waste. The results are shown in
Table 3-4. Once again, nonuniformify was obtained, though the organic content is
much more uniform than the moisture content.
The stability of the bales was monitored by direct observation of the number of broken
bales during the five-day study period. One or two bales per day were seen to fall
apart to some extent at the baling plant. Of the sixty-six tenth bales monitored, two
(or 3 percent) fell apart at the baling plant. One occurrence was on 9/26, a very wet
day. The surface materials of wet bales tend to slough off more readily than on dry
bales. In addition, five (or 7.5 percent) of the tenth bales fell apart at the landfill
in the course of the week of measurement. Three of these were produced on 9/26.
It should be mentioned that these bales were subjected to much more handling than
normal. Breakage at the bale plant thus may be seen to increase with increasing
moisture in the incoming solid waste, and with increasing amounts of grass in the bales.
However, the percentage of breakage at the baling plant seldom exceeds one percent
under normal conditions.
Breakage at the landfill may be due to the operator mistakes. Occasionally, the
operator will drop a bale from the forklift. In a quantitative observation of broken
or damaged bales at the landfill, no distinction was macle between unstable bales and
bales damaged by operator mistakes. Of 582 bales observed, 14 bales (or 2.4 percent)
were damaged or broken. Moisture contributes to the likelihood of the bales being
38
-------
u5>-
II
2 ^
|l
CO
!r <
Z o-
LU *s^
• r**
X
c
_c
"5
X
S3
I*
1
^00 NO CO
"^" U") CN ON
rx o. oo co
IO Tj- — CN
CO ON CN O IO
o co ^o NO
CO CO "^ ~^"
^fV, 00 NO
00 ON CN ^T
CO CO S- S.
IO IO
rx ON ON NO
ON ON O O
OO CN NO ON
3334
§2 *°;±
o "*" "°
o
rx o o —
IO NO CN O
CN ON IX CO
CO CN ON ON
OO NO IX 00
IX IX IO >O
5
00
ON
ON
CN
^1" ^f CO
1 ...
1 CN NO tO
CO CO
CN CM CN CN,
NO NO CN CN
00 Tf Tj- IO
IX NO ^ CN
IO o
NO IO CO r—
ON O 10 IX
^- CO »O O
O O r— CN
r- CN i— CO
3 10 ix NO
CN 'O O 00
— t— CN —
I-1J I
ON
o 6^*0 o
fNt IX 0 O
5 CO CN tN
"* CN O °
IX IO CO O
SNQ O r—
IX NO NO
o"
Ci
CN
CN
NO
^ ON "38 2
»O co i— tx'
i— CO ON 00
IO IO IO IO
.— IO O ON
co co «o ^f
C» 00 r— •—
ON O ^ IX
•— -<• CN O
O O r- CN
IX •— CO IO
co «o rx ix
— IO O r-
— •— CN CN
• .*
'E E o |
0 -c -o *
\
NO ""^ ON NQ
NO 00 NO O
CO 00 CO CN
CN O ON O
-t IX CO 00
co -vt 10 o
IX NO IO NO
o"
o
IX
JN,
CN
CN
-Nf IO O
1 • • •
1 CO •— O
•— CO CN
CN LO' ON •O'
rx ON ON CN
o oo •— o
o -«*• 10 Njy
CO NO O 00
iO »O *-O 10
IO CO •«* ON
ON 'Sf ON CO
^"33
rx o ix NO
OO CN CN ON
IO fx 00 IO
NO O CN IX
i— CN CN —
^ *- ~o>
ON
•— IO »O NO
n rx -Nt ON
ix NO rx ix
'n
CO
IX
o
CN
•t CO NO
1 * * *
1 NO ^t —
CN "N!" CO OO
r— CN 00 Xf
rx oo rx rx
CN -O
-------
damaged or unstable. The highest percentage of instability and damage (6 percent)
occurred following a period of 20 hours of consecutive rain. Excluding wet bales
from the data, the percentage of bad bales reduces to 1.8 percent.
Overall bale production for the five-day study period, in terms of weight of solid waste
baled, average weight per bale, number of bales per day, hours per day per shift, and
bales per hour, is listed in Table 4-3.
40
-------
TABLE 4-3
OVERALL BALING PLANT PRODUCTION DURING 5-DAY PLANT MONITORING
Date i
9/73 !
20
21
24
25
26
Average
Total Wt. j
Per Days: \
Kg (tons) !
263,591
(290)
362 , 661
(400)
350,123
(386)
383,059
(422)
275,386
(303)
326,964
(360)
Avg. Wt.
Per Bale: j
Kg (Ib)
1,305
(2,878)
1,277
(2,816)
1,273
(2,807)
1,277
(2,816)
1,263
(2,785)
1,278
(2,818)
No. Bales Hours/Day/Shift |
p-,,_ r\.n«i i } , '
rer uay jr
\ First
t
202 8
284 8
275 8
300 8
218 8
256 8
Second :
!
3.5
7.5
8
8.5
7.5
7
Bales/
Hour
17.5
18
17
18
14
17
41
-------
SECTION 5
TRANSPORT NET DESCRIPTION
A. Loading Zone Plan
Af the east end of the baler, facing the east door of the baling plant, was the loading
platform. Hydraulic pushers positioned the bales on this platform and pushed the bales
onto the transport vehicles. The vehicles therefore had to be backed up to the loading
platform. Figure 2-4 shows the location of the ramp used to accomplish this. The
area to the north of this ramp was used to park an extra vehicle. It was used for aux-
iliary loading of special bales (i.e., cardboard, scrap metal). This vehicle could be
loaded using the forklift, since the floor of the baling plant was level with the bed of
the vehicle.
B. Transport Vehicles
The transport network consisted of four enclosed cab tractors and five 12-meter (40-foot)
flat bed trailers. The extra trailer was usually parked in the auxiliary loading area.
The overall length of the cab and trailer when connected was 15 meters (48 1/2 feet.)
The tare weight of the transport vehicles was 10,342 kilograms (22,800 pounds.) The
cab tractor had two rear axles and the trailer a dual axle at the rear. As can be seen
in Table 5-1, the transport vehicles were authorized by the Minnesota Department of
Public Safety weight limits to carry a gross weight of 33,239 kilograms (73,280 pounds).
With a tare weight of 10,342 kilograms (22,800 pounds), except for a leased vehicle,
which has a tare weight of 11,022 kilograms due to a heavier truck tractor, this allow-
ed in excess of 22,680 kilograms (50,000 pounds) of load. Since the normal bales
averaged 1,281 kilograms (2,826 pounds) each, 16 bales could be carried on each
transport vehicle. However, to allow a margin of safety for vehicle weight purposes,
the usual load was 14 bales. Photograph 5-1 shows bale handling equipment.
C. Transport Operations
The transport labor force consisted of two vehicle drivers per shift. At any given time
(on the average), one transport vehicle was being loaded at the baling plant. Another
vehicle was traveling to the landfill with a full load. A third vehicle was parked at
the landfill and was unloaded by landfill personnel. The fourth trailer was parked
at the baling plant. The vehicle unloaded at the landfill was driverless. When
a vehicle loaded with bales arrived at the landfill, the driver left this vehicle and
entered the vehicle which had just been unloaded. He then drove this empty vehicle
back to the baling plant. Simultaneously, the second driver left the baling plant and
drove a full loaded vehicle to the landfill. Prior to leaving the baling plant, he
backed an empty vehicle up to the loading platform. When the first driver arrived at
the baling plant, there was usually a partially loaded vehicle at the loading platform.
He therefore parked the empty vehicle in the eastern yard of the baling plant site.
When the vehicle which was at the loading platform became fully loaded, he drove
42
-------
TABLE 5-1
VEHICLE LOAD REQUIREMENTS0
Weight irj Kg (Ibs)
Minnesota Max.
Allowable Load Bale Transport Truck Load
Single or Dual Wheel 4,077 (9,000)
Single Axle 8,154(18,000)
One Vehicle or Com- 33,196 (73,280)
bination of Vehicles
Four Axles 9.76 M
(32 Feet) Apart
28,992 (64,000)
14 Bales
16 Bales
3,532 (7,795) 3,851 (8,502)
7,063 (15,591)
7,221 (15,941 )b
7,703 (17,004)
8,036 (17,737)b
28,251(62,364) 30,811 (68,016)
28,930 (63,864)b 31,491 (69,516)b
25,759(56,364) 28,320(62,516)
26,439 (58,364)b 28,992 (64,016)b
'Source: Minnesota Department of Public Safety .
Leased vehicle with heavier truck tractor.
43
-------
a. In-plant fork lift
b. Bale fill fork lift
c. Truck prepared to unload
e. Runoff from rainfall
d. Placement of bales
f. Bale measurement
PHOTOGRAPH 5-1
BALE TRANSPORT AND PLACEMENT
-------
it away from the loading platform and parked it in the eastern yard. He then positioned
the waiting empty vehicle at the bale loading platform. He was then free to re-enter
the loaded vehicle which he had left parked in the yard and drive this vehicle to the
landfill. Upon reaching the landfill, an empty truck was waiting to be returned to the
baling plant. He entered this vehicle and the cycle began again. A Gantt chart
for this operation is shown in Figure 5-1.
The rigging and unrigging of the transport vehicle has been left out of the above dis-
cussion for the sake of clarity. The vehicles were equipped with meshed nylon curtains.
These curtains were on two wire guides which ran the length of the trailer bed, as shown
on Figure D-9. They were attached to the forward wall and to the rear posts at a
height 1.2 meters (4 feet) above the bottom of the trailer bed. When the vehicle was
empty, the curtains were at the front of the trailer bed, folded together. After the
vehicle was fully loaded, the curtains were pulled back to the rear of the trailer. This
required two men, one on each side, since the curtain sides and top were a single piece
of material. The curtains were therefore one unit and each side had to be pulled even-
ly. This rigging process was initiated at the loading platform just prior to the pushing
of the last two bales onto the trailer bed. The curtains, once pulled over the bales,
were attached at the bottom to the trailer bed by several sets of hooks spaced along the
length of the trailer. After the vehicle pulled away from the loading platform, the piece
of plywood which served as the tailgate was put in place. This was done by the vehicle
driver either before or after he backed an empty vehicle up to the loading platform.
The tailgate slid into grooves located in the two rear posts and was secured in place by
a chain that attached to hooks on the two rear posts. The placing of the tailgate could
be performed by one man, but the vehicle driver usually received help from either the
maintenance man or the forklift operator. Observed times for the two rigging operations
for one, two and three men are shown in Table E-12.
When the fully loaded vehicle arrived at the landfill, it was unrigged to provide access
to the bales. The vehicle driver, assisted by the landfill worker, pulled the curtains
forward and secured them with a cord on the forward trailer wall. The driver was then
free to drive the waiting empty vehicle from the landfill. The landill worker removed
the sideguards from one side of the trailer bed so that the bales might be removed.
After removing the bales, he prepared the vehicle for the return trip to the baling site.
This involved sweeping off solid waste that remained on the trailer bed, replacing the
sideguards, and removing the tailgate and placing it on the trailer bed near the forward
wall.
The drivers also had additional duties. The drivers assisted in the daily baling plant
clean-up, and while at the baling plant waiting for a truck to be loaded, they might
have been requested to operate the floor sweeper or the small loader. They were also
responsible for the normal maintenance of the vehicles.
45
-------
oo
^
U
ID
!!*
r~ tv
-D .
4*
.
0£. CM '
O •
_O fc
t •
O C
Q ••"• O
^ co i
8 =
4i
0>
_ r—
o
i—
-a
8 c
— i •=
\ E
^ ir>
c c .
85 •- i
^ * 0 .=
D co
in .
.!= c
o •- i
^^ ^^ '
•
§ | '£«
f~ CM '
\i
or rx
»
•
II '
"$ CO
ti CM i
5 "§3
CN
i
u
H^
•
c.E
D E ,
^™ . J^_
tS CM T
•Q
J.E
« «">
12
i •
c "t c '
L_ g^ " ^^
Q —
Q •—•
(D «O
•
c .£ .
^
.
41
CD tx
CO
f
-iC
u
1—
T3
D
_O •
5 "E
^S^ *v^
— ^
vi C .
L^ U. srt ^
CM |
1.E
tl
•o ^
E c ,
D •- '
CO '
O •
O C
c E
D E '
O CM |
£ *.! •
C u. rQ
OO srt ^^
ji O-CM 1
0
£
-
-
_
-
-
-
"*
£f} *~*.
!2
o
CO
U
s
Q_
l_
<5
0)
CM J
1—
r
• •
••" CN
i- i-
5 >
•— •—
Q Q
£ °
o e «2
cf8^
a:
O
Q_
to
if
UJ U.
-o
X
u
<
O
46
-------
D. Route Plan
The landfill was approximately twleve miles from the baling plant. There were two
routes used to reach it, shown on Figure D-10. The choice of routes was at the
driver's discretion. The Concord Street Route was slower with more traffic signals.
The Robert Street Route, though faster, had steep hills that some drivers preferred to
avoid-. Both routes traversed shopping areas. The Concord Street Route passed through
an older commercial district with narrow streets, while the Robert Street Route was
primarily through suburban shopping centers with wide streets.
47
-------
SECTION 6
BALE LANDFILL EVALUATION
A. Landfill Description.
1. Location of Landfill. The landfill is located in an area of Dakota County known
as Inver Grove Heights, approximately 19 kilometers (12 miles) south of the baling
plant (shown in Figure D-10). Rail road tracks determine the northern and western boun-
daries: the Suburban Gas Company (from which the American Hoist and Derrick Com-
pany acquired the fill site) is situated beyond the tracks to the north of the landfill.
2. Landfill Site. Figure D-ll is a topographic map of the landfill site. The railroad
tracks are shown and can be compared with the layout of Figure D-10. The ultimate
drainage is also shown. There is a small pond north of the site into which the area
drains. This pond drains a large area in addition to the landfill site. A cow-pasture
lies immediately south of the site. The area between the two railroad tracks comprises
0.12 square kilometers (29.9 acres). The area east of the Chicago and Northwestern
Railroad contributes another 0.04 square kilometers (8.9 acres). The area between the
two tracks is roughly a 365 meter (1200-foot) square with a large cutout of the north-
west corner. The area east of the tracks is roughly a 200 meter (700 foot) x 150 meter
(500 foot) rectangle with the long dimension running north-south .
B. Landfill Monitoring.
Copies of the forms used to record observations of landfill operations and environmental
conditions are included in Appendix F. This section explains how information re-
corded on the data forms was obtained.
I. Bale Spacing (Weekly). The working face was divided into ten sections of equal
size, then the middle bale in each section was selected for the spacing measurements.
One day each week field observers placed a triangular wedge perpendicularly between
the selected bale and two neighboring bales along two edges to determine the average
distance between bales.
2. Landfill Operation Record (Weekly). Observers made general notes on the condi-
tion of the landfill to determine operation effectiveness. Weekly records included a
description of the soil covering process (10 minute periods), a count of broken bales
(from observations of random samples of 100 bales on the exposed working face), and
observations of surface water pool area and depth to identify drainage problems.
3> L°ndf'" Environmental Record (Weekly). An area approximately 30 m (100 ft) square
directly adjacent to and below the working face was defined as the litter sampling
plot. Litter items were either counted individually or their total area estimated one
day each week. The observers quantified the dust problem by estimating the fraction
48
-------
of the landfill area capable of producing a dust column due to vehicular traffic. The
access road was initially divided into 30 meter lengths, then observers used a random
number table to decide which section to use to describe dust conditions each particular
week.Numbers and kinds of non-insect vectors (birds, rats, dogs, etc.) were also noted.
4. Time and Motion Studies (Weekly). Investigators used precision stopwatches and
a time-study clipboard to time equipment and labor tasks such as forklift placement of
bales, cover soil carrying and placement litter and truck clean-up, and other related
task performances.
5. Fly Emergence Studies. Special studies of fly emergence were undertaken during
periods from April 30 through May 22, 1974 and May 28 through June 22, 1974.
Ralph Stone and Company, Inc., personnel conducted the routine daily monitoring of
fly emergence traps.
Each month, two 4.6 m by 4.6 m (15 ft by 15 ft) test plots (over bales) were defined,
then covered with a moist soil layer. Initially six fly emergence traps (two were later
destroyed), each with a 1 m (3 ft) square base and 30 cm (1 ft) high were placed
1 to 1.6 m (3 to 5 ft) apart on each of the two test plots, as shown in Photograph G-la.
Photograph G-lb shows the traps, and Figure G-6 illustrates individual trap components.
Flies emerging from the baled solid waste were attracted to the light in the glass, then
trapped. The field investigator collected and counted trap contents daily, then sent
them to the company laboratory for identification. The screen in the jar and a tight
soil seal around the box prevented fly escape. The emergence tests were conducted
over a period of time long enough to allow egg hatching, larval development, and
adult metamorphosis (about 21 days).
C. Results and Discussion.
1. Landfill Operation Description. The bales were transported to the landfill on a
flat bed tractor-trailer truck as seen in Photograph D-2a. The bales were removed
from the transport vehicles by an operator using an Allis-Chalmers 840 articulated
forklift as seen in Photograph D-2b. The bales were stacked three-high in tiers and
side-by-side to form horizontal rows which are usually 80 to 120 bales long
(Photograph D-lb). Since the bales were situated with their longest dimension aligned
longitudinally along the direction of the row, the row dimensions were about 3 meters
(12-1/2 feet) high by 90 to 150 meters long by about 1 meter wide. There were 240 to
360 bales in a three-high tiered row, amounting to approximately 480,000 kilograms
(450 tons) of solid waste. The rows were constructed one at a time. The first three
bales were placed on the ground, then two bales were placed on the second level and
one placed on the top of the second level. This provided a starting point, as shown in
Figure 6-1. The succeeding bales were placed up against this first set of bales in sets
of three: bottom bale, second level bale, and lastly, the top bale. This procedure
provided continual stability to the row.
49
-------
r
0>
U
O)
c
o
c
o>
u
o
0)
O
o>
J
O
O
Q.
D
O)
X
-rf-
U
(1)
(U
u
_g
D.
«/>
0}
-Q
12
"8
u
D
U- CO
_J
<
Q_
,-Q-
-* J9J1
50
-------
The placement of the soil cover was accomplished using a Trojan 4000 loader with a
3.8 cubic meter (5 cubic yard) bucket (see Photograph D-3). The number of rows which
were placed together prior to applying soil cover was determined by the landfill geo-
graphy and the availability of cover. Ideally, the first row was placed against an em-
bankment and succeeding rows continued along and out from the embankment. When
this was done, the loader excavated cover soil from the embankment and covered the
first rows, then continued to cover away from the embankment. Using this procedure,
the loader traveled only on top of covered bales. Daily cover was not always completed.
The frequency of cover soil application was observed to be closer to once or twice
weekly.
The roads were kept hard-packed by drag-scraping a large steel support beam frame
along their surface. The loader was observed performing this operation. The loader
was also used to clean up litter, sweepings, and broken bales. This material was
pushed to the side and covered immediately with soil.
The landfill personnel consisted of two operators, one of whom served as a leadman.
The leadman saw that the orders of the superintendent were carried out. Both operators
were responsible for the maintenance of the landfill equipment. One operator worked
the first shift, 6:00 a.m. to 2:30 p.m. The leadman was responsible for the second shift,
but often arrived before 2:30, occasionally as early as 10:00, to stockpile soil cover,
maintain the roads, or perform other peripheral tasks, while the other operator concen-
trated on unloading bales from the vehicles.
There was only one structure at the landfill, a trailer located near the entrance along-
side the access road. There was no running water or electricity. Sanitation was
provided by an outhouse behind the trailer. A water tank and a fuel tank were located
nearby the trailer. A generator and a set of mercury vapor lights were kept at the
landfill and used to illuminate the working area during the evening when the second
shift was in operation.
2. Landfill Evaluation. Ralph Stone and Company, Inc. personnel evaluated the
St. Paul balefill using an EPA scoring method (Table G-9). The EPA evaluation was
designed to determine the quality of normal sanitary landfills; scoring was adapted to
suit the circumstances of the balefill. The balefill was thus rated "minimally acceptable";
the low score was due primarily to a lack of daily earth cover, which may be unnecessary
due to its high density/cohesiveness of baled materials, and vertical working face.
3. Monitoring Results. Data were collected by operational and environmental monitor-
ing; observations were made on bale spacing, surface water accumulation, broken
bales, cover soil application and thickness, litter, dust, vector foraging, and fly
emergence.
51
-------
a. Bale Spacing. Table G-6 displays the results of bale spacing measurements.
Entries are listed chronologically and show, for a given day, the maximum, minimum,
and average space (plus standard deviation between the 10 sample bales and their
neighbors along a long and a short bale face edge . The average space between bales
was generally much greater along the long edges than the short edges, which can be
explained by the stacking procedure. When bales were stacked, the forklift could
position them flush against bales on either side more effectively than it could fit them
flush against the bales directly behind the bale being placed. Once the loosely packed
bale "walls" reached a certain height, they tended to lean due to variations in dimen-
sions of the bales. Generally, bale size irregularities contributed to inter-bale spaces
in both directions. The majority of the bale spacing measurements were taken from above
the stacked bales until the last two months. These last measurements included observa-
tions of side spacing between bales taken from a position in front of the working face.
The data in Table 6-2 indicates the spacing trend reversed; e.g., the minimum space
was measured on the longest bale face.
b. Surface Water. Puddles were observed on 10 of 42 monitoring days, and only
once were they estimated to cover more than 15 percent of the fill sujrface. The surface
water observed on 3/3/74 accounted for almost half the total observed for all days;
including that date the average area covered with water for the 10 days when water
was present was 68 sq m (728 sq ft), and without that date the average was 39 sq m
(419 sq ft). Over the 42 days, the average submerged area was 16 sq m (173 sq ft);
over 41 days (excluding 3/3/74), 9 sq m (92 sq ft).
c. Broken Bales. The number of broken bales out of a sample of 100 bales was
determined on 11 occasions. Numbers ranged from 0 to 7, with the average 2.2; from
this it can be estimated that a minimum of 2.2 percent of all bales in the fill were
broken at any given time.
d. Cover Soil. Since both monitoring and fill covering with soil were under-
taken once a week (roughly), they rarely occurred on the same day. On the four days
(of 42 total) when covering was observed, an average of 15 cm (6.1 in), ranging between
13 and 20 cm (5 and 8 in), of soil was spread over the bales.
e. Litter. Numbers of discrete pieces of litter larger than 6 sq cm (1 sq in) were
recorded fn 3 m (10 ft) square areas of three locations below the working face, above it,
and along the fill access road. Table G-7 briefly summarizes the results. It was assumed
that extremely high values of litter were due to broken or exposed bales, and thus did not
represent normal conditions of litter escaping from bales. Therefore, the data is present-
ed in Table G-7 for all litter values (upper half of the table) and for values that were
grouped closely in magnitudes less than 100 (lower half). The data in the lower half
would indicate the litter level on typical days, and the data in the upper half for days
when broken bales occurred. The relative magnitudes of the counts for the three
locations are directly related to the amount of solid waste exposed. Thus, the values
below the working face^where trucks were unloaded and swept off,had over twice the
litter observed in the other two locations.
52
-------
f. Dust. Seven visual dust observations were made between late May and late
August to determine the height of dust columns; the dust height provides an indication
of its potential to travel off-site and cause detrimental environmental impact. Dust
was not observed during other times of the year due to rainfall, snow cover, or frozen
ground. All sample dust columns were attributed to cars or trucks, and averaged
2 m (8 ft) in height over a range of 1 to 4 m (4 to 12 ft).
g. Vectors (non-fly). On only 9 days were any non-fly vectors observed; all of
these were birds. Numbers of birds seen varied between 100 and 3. Averaged over
all observations (34), the typical number birds visiting the fill was about 4.
h. Fly Emergence Studies. The fly emergence traps were placed on cover soil
averaging 15 cm (6 in) In depth and on uncovered bales. Though the emerging insects
were all classified as "flies," technically six families represented Order Diptera and
three families represented Order Coleoptera. Representative samples of flies collected
between 4/30/74 and 5/22/74 and between 5/28/74 and 6/22/74 were sent to and
identified in the Stone company laboratory. Table G-8 shows the different families
which were collected from individual traps for both monitoring periods. Table 6-1
lists the quantitative results of the St. Paul fly studies and compares them with similar
studies undertaken in Oceanside, California, where fly emergence tests were conducted
on normal solid waste with and without soil cover and sewage sludge.
Several factors should be considered when interpreting the information presented in
Table 6-1. First, Oceanside data included only Dipterans; relative frequencies of
the two orders were not available for St. Paul. Area climates differ greatly; Ocean-
side has fairly mild weather year-around, with a sporadic winter rainy season, and
St. Paul experiences summer and winter temperature extremes and much more annual
precipitation. These climatic differences plus geographical differences can affect the
type, number, and breeding seasons of flying insects.
From the data collected, the cause of very high fly figures during the first couple of
days in St. Paul cannot be isolated. Trapping technique, age of the waste prior to
disposal, local fly abundances, operational procedures, or a combination of these
factors could explain the differences between St. Paul and Oceanside. One possibility
is that some solid waste may have been stockpiled in the baling plant for one or two
days in addition to storage at the source (households, etc.) for up to one week. The
baling plant open storage would allow additional eggs to be placed by adult flies in
the plant. Also, the extended time period between generation and landfill disposal
would allow for adult fly emergence on the first day after bale placement in the landfill.
Despite the above problems with data interpretation, the following conclusions may be
drawn from the fly emergence studies.
53
-------
to
LLJ
Q
ID
UJ
U
z
LU
o
LU
o
oo
J—
_j
Z)
t/>
LU
a
0) Q:
££
J s
o —
I- u_
0> 8.
Vs
Z.'4-
0
Q.
X
LU
U
«:
u
u
fi.
i/>
c
o
"o
8
_l
X
a> "5
•S. ^
t- O
0) U
o~i
r i C
0 a
"i »
5-£
0) D
^>T5
= "5
« o
-c •£
IT" ^
£^
(U
-D
in
O
0)
U
O
CN
£
i
CN
s
1
0 0
O O
8
8|
g 8
8*8
•B:
O 0)
. >fc
^ ^
a>
-a
i/i
8
u
o
1
\
Cvf
T
CN
^
s
K IX
0 (^
O O
CO CO
8
8>
{ 8
o -a
u c
^l
O O)
12
VI
O
0)
U
o
§
^
00^
1
CO
§
§
CO
IO
•— o
•o o
*0
tn
I-
5
o
u —
5 8
15
'i 8
•D -D
C C
D O
a) a>
O) D)
-0 TJ
D D
in
^T _C
"^- "^.
> >
(U
-o
in
0
0)
U
0
s
?!
T
CO
^
f
CN K
•O CM
O —
SCN
CM
8
u.
« —
^ 8
" t.
D >
0 O
_c u
•$~?
-D °
C 0)
0 0)
«"§
•iP-3
D 4-
2J
T^ "^^^
^ ^
0)
-D
in
O
a>
u
0
1
CN^
T
CO
$
\
oo p— co 10
«O CO -rj- IO
00 — ^-
S2 ^g
8
l_
f
o
.— o
8^ -
1- .- Q
> ^ =5 *
O-D 8 t
-o ° 0 8
C (D > u
o o> o t:
«•§ ° §
a>— ^: _c
T3 *» *• ,-t:
JJ «
•£ •£ w «
is. ~> O D
> ^ CO CO
a>
-D
*« 3
§ -§
U
o <^
s ^
Xs. cvT
K ^
rx u^
1 i
co 4
^ x-
^ 0~
CN g
vd >
CO ;-
tx •*
O ^
K«5
**mt
8
>l
S 8
O *;
^J
4- 4-
^ 5:
-a t>
(U (U
0 O
CO CO
3
O
Q_
•
•*-
CO
1
S
1
S
54
-------
• Generally, cover soil reduced fly emergence.
• The amount of cover soil necessary to reduce flies significantly varied with
seasonal changes.
• Baling alone did not appear to inhibit fly emergence.
Environmental advantages associated with balefills as compared to conventional land-
fills appear to be reduced numbers of birds; reduced surface area at the balefill;
increased density of the solid waste to be disposed (on the order of 1.5 times—see Table
9-22); and reduction in the volume of dirt needed at the fill (on the order of 90 percent)
due to reduced surface area requiring cover soil.
55
-------
SECTION 7
TIME AND METHOD STUDY
A. Purpose and Scope
This section discusses the time performance of the St. Paul baling plant, transport net,
and balefill. Since the time analysis is detailed and extensive, the more comprehensive
work on operating times and all of the work on human factors have been placed in Ap-
pendix E. Results and evaluations are presented in this section.
This analysis of time performance uses simultaneous observations of the overall system
of individual men and machines. Attaching time values to machine states that are dis-
jointed in time is a powerful method of description. This information describes the use
made of men and machines. While individual performances are not enough to describe
system performance, the effect of the defined states is to represent the system as a net-
work of operating states. This network structure is the basis for the time and method
study.
Human factors greatly influence plant performance. Factors include operator location
and visual perspective, instrument and control design and location, and required force
and precision of operator movements. These factors are identified and evaluated in
Appendix E.
Plant data for time and methods analysis was obtained as follows during a five day plant
monitoring period and over a one year study period:
1 .Stopwatch Timing. Time studies of the baling process were completed for 30 minute
periods twice daily, with revisions on three days due to plant operating variations. Two
men entered continuous time data on operations Activity Charts 1-A and 1-B (as shown
in Appendix A), simultaneously covering all operations performed during solid waste pro-
cessing .
2. Victeo JapeJRecords^ Daily video tape recordings were made of each of the three
labor positions on the production line: the gateman, loader operator and control tower
baler operator. The video tapes were analyzed by task time and motion measurement
to define human factors.
3. jBgle J-andfill Equipment Timing. Ralph Stone and Company personnel in St. Paul
timed the balefill forklift almost weekly over the year of the balefill shjdy.
B. Plant Performance
1. Machines. Within the accuracy of the observed measurements, the plant production
machines formed an integrated and compatible network of operations. Thus, when the plant
56
-------
was in steady-state operating condition, all machines showed high run percentages
and low interference.
The utilization values listed in Figure 7-1 show that the baler had the lowest flow rate:
all other machines waited on the baler. In a sequence of operations such as the baling
plant, all other machines should properly feed the major machine without slowing the
process rate. Thus, the plant could operate at a maximum rate equal to the baler rate.
The interference values in Table 7-1 show that the loader and conveyor both interfered
with the baler. To have less important machines slowing the baler (and plant) cycle
rate is a costly condition. Observation of the baler plant could explain these
interferences. First, the loader fed the conveyor easily for a long period of time,
until the loader operator stopped for personal reasons. Then the conveyor was not fed
for approximately 10 minutes, and the plant was idle until the loader operator returns.
Even if the conveyor was empty for a 6-meter stretch, it took one minute for the
conveyor to move that 6 meters. Secondly, the loader operator also affected conveyor/
baler interference by the height of the solid waste he piled on the conveyor. Thus, the
time to load one charge onto the scale would have been less than one minute or more
than two minutes depending on the conveyor's load. Thus, the conveyor can keep up
with the baler sometimes and then fall behind at other times. The loader operator
affects this balance.
The conveyor was observed to stop a number of times while loading the platen. The
occurrence of these stops varied with each load cycle. If the delay was short, it was
included in the time to load, causing the baler to wait for the conveyor at a later time.
If the delay was long, the time was included directly in the total time the baler waited
for the conveyor. Intermittent stopping was an unresolved problem with the present
conveyor.
2. Personnel. The work-station positions varied and were often poorly coordinated.
Indications of this were the high percentage of labor idle time; the lack of assistance
for the gateman during periods of peak vehicle arrivals; the lack of a replacement for
the loader operator and control tower operator; incomplete coverage of records and
maintenance responsibilities; and the many people working in the plant, particularly
on the day shift. The percent idle time was so high that employee boredom was
expected, thus further degrading labor productivity. Common percent idle times in
industry are between 10 and 25 percent. Idle time is only one parameter of inefficiency.
The factors actually lying at the root of the problem are job descriptions and defined
responsibilities.
Each man on a machine in the production line needs a backup in order for him to stop for
a time without crippling the plant. Thus, a maintenance man or other non-line man should
have been available to fill in for the gateman, loader operator, and control tower operator.
This would have improved the baling production rate by a minimum of 5 percent at St. Paul.
The responsibilities of the gateman required one man to process all trucks that entered the
plant. This was impossible when two trucks entered simultaneously. Trucks could enter
57
-------
Utilization (percent)
o
I
o
O-
Irt fx.
C r—
o
00
-0 C CN
CO
C)
\ \
a.
o
v
£
o
O
o.
E
D
U
o
-5
o
T3
O
-------
LU
U
LU
I U
3|DO$
co
JO/8AUCQ
LU
H-
z
LU
Z
X
U
UDUI3.}D£)
O
0)
-*-
O
O
D
O
x
(U
1
(J
0)
o
o
to
D
en
D
0-
8.
Ul
a
TJ
•*—
w>
10
O
^ -o
05 0
C!
;E o3
a a
« E
IE "-C
C Q)
"D
"O *"""
Q) o
^v "~
8L <
•S "
S x
_c
'i
~a
CD
CO
Q)
_c
CD
*S
_Q
O
C
Ic
o
D
14.
O
Q)
_E
Q)
O
X
u
CT)
O
>
-a
*>
E
o
L.
,
0) \
•*- sx
o *^^
• — •
•!••
t/>
LU
_Q
- JC
o
o
CO
0)
D)
C
o
D
0)
-a
d>
x
o
(U
-------
unannounced, creating a traffic fam and safety hazard. The loader was slowed and
threatened by this confusion. The degree of responsibility of the loader operator in
avoiding collisions was very great. The loader operator took total responsibility for
avoiding collisions with collection trucks. In time, a human error could prove costly.
The total number of employees on the first shift was eleven. Six men worked the second
shift. Only the gateman, loader operator, two truck drivers, and control tower operator
were production workers. The gateman was not critical to maintaining bale production,
and the difference between the four required men and the eleven actual men was very
large. Redefining work tasks and responsibilities would have improved the labor
productivity and reduced the labor requirement and associated cost.
3. Incoming Waste Handling. The plant's method of handling incoming solid waste
needed revievvT It was inconsistently performed and minimally productive. The defined
tasks and subfasks of the gateman, the floor layout and front doors, and the method of
working the floor pile contributed to this difficulty.
In order to evaluate alternative methods, consider the steps of handling incoming solid
waste as a network of operations: 1) charge a fee, 2) dump the waste, 3) mix the waste,
4) refect some items, 5) recycle some items, 6) load the conveyor, and 7) convey.
One source of the delays and the potential danger of collision was the unscheduled
arrival of the collection trucks. Figure 7-2 illustrates the pattern of arrival of solid
waste in volume terms. From one to two in the afternoon more than twice the average
hourly intake occurred. In the early morning and late afternoon, few trucks arrived.
For part of the day a gateman was idle; for part of the day two gatemen were needed to
fully handle all incoming trucks without delay. The loader vehicle had to wait when
3 or more trucks arrived,especially when the floor was already full. Thus, the condition
of a full floor and many incoming trucks slowed the loader even more. Figures 7-3 and
7-4 show the pattern of solid waste volume on the floor, using the arrival pattern of
Figure 7-2 and using different production rates for the baler.
With a faster baler, a second difficulty occurs due to the unscheduled arrival of incoming
trucks. The plant can run out of solid waste to bale at times during the day. Yet at
other times a large section of floor will be covered with solid waste recently brought in.
The fast 90-second cycle aggravates this problem; it can bale all the solid waste in eight
hours, but if more waste is brought in, it will arrive at the time of day when the floor is
most filled. Thus, solid waste arrivals should be under much tighter control; for example,
transfer stations would allow scheduled shipments to the plant. A larger floor would
provide the space to store more solid waste, although minimizing floor space is a
desirable goal to reduce cost. The gateman would be eliminated by using transfer
stations, and a larger floor would thus not be needed.
60
-------
3 3
1 1
5 s
d o
\
s>
\
HDNfTI
HDNm
oo
8
CO
8
8
o
8
1
o
o
o
o
o
§§
0
to
8 i
2 J
O
(SJS490I oiqno)
61
-------
LU
I—
1/1
0£
T3
C
S u
= 53 K
§> 2
u
o
X
o
o
0)
E
(SJ349LU
62
-------
-o
a>
O)
pspqufl
63
-------
Depending on the way incoming waste is handled, the remaining sequence of operations
on incoming waste is subject to improvement. An overhead rail crane could rapidly and
cheaply handle heavy and bulky materials; perhaps the loader and conveyor could have been
replaced by a crane. The present hand-sorting method of recycling was satisfactory at the
relatively high price prevailing for salvaged corrugated. Mechanical sorting of corru-
gated would require a shredder and air classifier which would necessitate a complete
reclamation plant with magnetic separation of ferrous materials. A baling plant built
in Cobb County, Georgia and operating since mid-1974 incorporates a complete re-
clamation system.
4. Concept Performance. The newest American Hoist and Derrick Company baler was
designed for a 90-second cycle, excluding the idle and dump operations. This means
that a plant can have under a 1.9 minute baling production cycle using 0.20 minutes
for both dump and idle. The other machines in the sequence would need to have increased
operating rates, and some machines may need to be redesigned or replaced.
The conveyor and scale were time-costly and troublesome. Thus, this pair of opera-
tions might best be achieved using different methods.
The pusher and transport net performed dependably. Under the more rapid bale
production rate, the transports might be a problem due to traffic delays. As cycle time
decreases, more trucks might be needed depending upon the maximum permitted by
state vehicle load limits.
The behavior of the loader was less obvious. Using present data, the loader could not
load the new baler fast enough. But under improved solid waste handling conditions
associated with a transfer station or new floor layout, perhaps one loader would be fast
enough.
Any new baling plant should have a conveyor that is level for its total length, if feasible.
The loader can then load the conveyor along its total length, thus avoiding costly delays
due to an empty conveyor. Also, excess travel time from the solid waste stockpile to a
single conveyor loading point would be eliminated. The conveyor must be jam-free;
otherwise, high labor activity and cycle delays are inevitable. A gravity chute, a fast-
er scale platen, and a mechanical mixer and loader are possible innovations.
The number of employees should be kept to a minimum. Perhaps six men are needed per
shift: a foreman-control tower operator, a loader operator, two truck drivers, a leadman-
mechanic, and a maintenance man. The control tower operator should be in charge of the
shift due to the qualities required in his position and the overview of his location. The
mechanic and maintenance men should be able to fill in other positions when necessary.
The recycling of solid waste is a relatively new concept. The benefits of recycling will
probably continue to grow in the future. A baling plant may be an economical place
to recycle many items such as cardboard, paper, aluminum, steel, tin, and glass. For
a baling plant performing recycling, advertising for and accepting or purchasing sorted
64
-------
solid waste may be as profitable as the baling operation.
In order to perform sorting, mechanical and electrical methods are needed, since labor
cost compared to productivity is prohibitive. Sorting may be accomplished in partial
stages during regular handling processes of dumping, storing, mixing, and conveying.
Differences in size, shape, weight, and denisty may be employed to initially separate
items.
5. Alternatives in Design of a 90-Second Plant. A new baler would significantly in-
crease the productivity of a plant to as much as 160 percent of past production.
This provides an impetus to develop high speed equipment for bulk handling and sorting
of solid waste. The reduced network in Table 7-2 is a basic model by which to compare
various alternative systems.
Transfer stations are a likely part of baled solid waste system. A system of transfer
stations can reduce travel and dump times for collection crews, eliminate the cost of
handling the trucks at the baling plant, and will premix the solid waste. The drawbacks
are the investment in property and special pits and the increased time that waste is in
storage. Train cars can be used: collection trucks can dump directly onto the open tops
of hopper cars. Trains can transfer the solid waste from remote areas. Bottom-loading,
high-wall cars can be unloaded on a fixed schedule.
A gravity-feed conveyor chute would eliminate labor and power requirements in waste
handling. Thus a chute may be aimed directly onto the scale. A power ram would be
necessary to push the waste down the chute at a predetermined rate to provide control
of the weight of waste in each bale. A problem might still be encountered, however,
in controlling the quantity of waste in each bale charge since the charge on the scale
may reach the desired weight while more waste is coming down the chute.
Mechanical sorters now on the market sort by density, size, weight, color, ferromag-
netism, and strength. These sorters don't collect 100 percent of the desired items, but
hand-sorting also does not approach this figure. Actually, sorting between 25 and 80
percent of such items as steel, aluminum, glass, cardboard,and paper will suffice to
recycle large amounts where markets exist.
A combination of conveyor and sorter would save time and money. The state-of-the-art
uses magnetic separation somewhere in the sorting. Tentative methods use density dis-
persion, air classification, magnetic and eddy current separation of ferrous and nonferrous
metals, photoelectric color identification, shredding, and bouancy. A larger baling
plant with high volume through-put can meet the investment costs required for sorting
machines. Perhaps one fundamental justification for baled solid waste systems is the
convenience of recycling at the baling plant.
The scale-baler-pusher for the 90-second baler are basically the same as the
St. Paul model. The small detail of providing a hydraulic lift to raise the bale discharge
65
-------
TABLE 7-2
REDUCED BALED SOLID WASTE NETWORK
Operation
0) Dump on Floor
(2) Store/Mix
(3) Load Conveyor
(4) Convey
(5) Measure Charge
(6) Bale
(7) Load Trailer
(8) Wait on Trailer
(9) Transport
(10) Waif on Trailer
(11) Stack
(12) Cover
Cycles Per
Baler Cycle
-
-
2.8
1
1
1
0.5
0.07
-
-
1
-
Average
Per Bale
2.40°
-
1.50
3.00
0.05
3.05
3.15
21.0
2.0
25.0
1.5
-
Process Times ~(m'\ n . )
Per 1,000 Kilograms
1.90
-
1.20
2.35
0.04
2.40
2.50
16.5
1.6
19.7
1.2
-
Estimated from video tapes.
66
-------
platform over the truck bed will hopefully be resolved. The control tower, pump room,
and utilities are unchanged except for adding another pump.
The 90-second plant would be able to complete the solid waste processing by loading
bales two at a time into train cars for long-distance removal. A justification for the
baled solid waste system is inexpensive transportation costs. The destination of the
solid waste bales would be a remote balefill. Perhaps many cities will use a single fill.
A fundamental justification for baling solid waste is the reduction in volume and lack
of settlement at the fill and the ease of reclaiming the waste at future dates. The bales
may be used as engineering materials, but little research has been completed on bales
as foundation materials over a long time period.
C. Ability, Reliability, and Accessibility
Knowing the ability, reliability, and accessibility of plant components provides informa-
tion on different facets of productivity and indicates anomalies and necessary improvements.
Management can use this information for planning production schedules and calculating
design parameters in general (such as required storage space).
7. Ability. Ability refers to the probability that a system is producing at a stated rate;
for a baling plant, the hourly average number of bales turned out (over an eight hour
shift) is the rate most appropriately indicating ability. Figure 7-5 presents the probability
distributions for ability during two separate study periods.
The two distributions are sufficiently different in mean value and shape to indicate changes in
baling plant equipment conditions. Unfortunately, the causes cannot be determined by
ihe ability distributions. It is known that two factors changed between observation periods:
the baler's lining was replaced; and the production data was made to include all production
on the second shift. The increased ability, therefore, could have been a function of im-
provements with the new liner, higher second shift product!vijty, or some other factor.
The later ability distribution is superior due to its higher mean production rate and its
much smaller variation about the mean production rate. The reason for two peaks is not
known, but the rise of almost forty data points, producing an otherwise smooth curve,
strongly indicates the existence of two peaks. Under the more recent conditions, manage-
ment could expect to produce between 19.5 and 23.5 bales per hour during production time,
with 64.8 percent probability of baling at between 22.0 and 22.49 bales per hour. Notice
that labor management conditions have a strong effect on the shape of the ability curve of
a specific plant.
The effects of moisture content and automatic or manual control on bale production also
requires investigation. During the five day plant study, data were gathered on average
production rates under varying conditions. Table 7-3 summarizes the results. No measure-
able difference exists between automatic and manual production rates. The longer production
67
-------
oc
Z>
U
K
CO
<
/4i|iqDC|OJcj
68
-------
TABLE 7- 3
BALING RATES UNDER MEASURED CONDITIONS
Group Baling Cycle Bales per hour Conditions
Date (min.)
1973 x
T~ ' Automatic
9-20/21 2.80 21.4 Dry Waste
2 Automatic
9-24/28 3.15 19.0 Wet Waste
3 Manual
9-25 2.80 21.4 Moist Waste
4 Manual
9-24/26 3.30 18.2 Wet Waste
Total 3.05 19.7 Summary
69
-------
times in groups 3 and 4 were mostly due to unrelated" difficulties with the conveyor and
loader. Thus, the mode of control has minimal effect when a skilled operator
is in control, and higher moisture contents will slightly lower the ability to produce,
but not enough to require special consideration.
2. Reliability. Reliability refers to the probability that a system will operate any given
percentage of the scheduled operating time. For the baler, an appropriate reliability
measure is the probability of operating a given number of hours per 8 hour shift. Figure
7-6 presents reliability curves for two different time periods and their average.
The difference in reliability between the two time periods is not large. The more recent
period has a better reliability curve but has the same basic shape as the previous period.
The average curve is probably the best for application since it uses all available data.
The shape of the curve is typical of most systems. The basic shape indicates no dominant
pattern of breakdown, as might appear if a specific part continually broke and was re-
paired repeatedly within a shift. For the earlier 1973 time period (see Figure 7-6), the
peak at 7 hours is typical of a specific reliability problem, but it disappears in the later
1974 time period. The minor peak at 5 hours indicates a loose pattern of breakdowns
and repairs taking 3 hours to complete.
3. Accessibility. Accessibility refers to the maximum time per operating cycle that the
system can be scheduled for operation; the remaining time is dedicated to scheduled,
periodic maintenance. For the baling plant, the basic cycle is the 24 hour day. Longer
cycles (weeks, months, etc.) are of minor importance and must be considered only when
the plant is scheduled three shifts, seven days a week.
On a 24-hour cycle, the baling plant can run 23 hours if lunches are staggered and each
man has a replacement during his lunch period. If the plant shuts down for lunch, then
only 21.5 hours can be scheduled per day. At least one hour per day is needed to re-
move waste from between machine parts. Most likely, any municipal baling plant will
operate one to two full shifts. Thus, the time lost to periodic maintenance and lunches
does not restrict production time.
4, Time Performance. Bale plant performance, in terms of bales per shift, is presented
in Figure 7-7. These production curves were determined directly from the sampled pro-
duction days, but they could have been found by the mathematical convolution of the
ability and reliability curves. These curves are useful when designing system parameters
such as waste storage space and landfill equipment requirements.
A significant difference exists between the production curves for the earlier and later
periods as seen by the respective means of 119 and 142 bales per shift. This difference
could be expected from the difference in ability and reliability curves, but the physical
reasons are buried in the complex interactions of the plant. The existence of distinct
70
-------
CO
-------
or
U
K uj
•J Q
K
10 r^
§g
OU
^g
o
Qi
Q_
LU
-C
CO
1_
o
00
Q)
Q.
u>
J)
O
02
(U
-Q
72
-------
peaks is not typical since a bell-shaped curve is the usual distribution configuration.
For production planning purposes, however, a normal distribution with given mean
and variance can be substituted.
Ability, reliability, and accessibility curves are the basis of any probabilistic description
of the baler plant. This can be seen by their possible use in constructing a shift produc-
tion curve. This information can be used both in evaluating the St. Paul plant and plan-
ning other plants.
73
-------
SECTION 8
MAINTENANCE STUDY
Planned maintenance is a program of scheduled maintenance as opposed to maintenance
occurring for random emergency repairs. Checklists of cleaning, lubricating, inspecting,
adjusting, and replacing parts are the working tools of such a planned program. Accurate
and accessible records of downtimes, broken parts, maintenance labor times, and causes
of trouble are the solid foundation on which to base this program.
A planned inventory is a stock of critical parts on immediate hand with crucial sub-
assemblies preassembled, ready to be installed on the machine. Critical parts are those
that break often, are scarce, have close tolerance, require special tools and skills to
install, or take a long time to assemble. A planned inventory reduces procurement and
repair time and related cost, thus achieving higher productivity at lower overall
maintenance cost.
A manufacturer's policy on service and parts is one key to the productivity of the equip-
ment he makes. This section outlines the policy and practice of American Hoist and
Derrick Company, with regard to maintenance and parts inventories.
A. Planned Maintenance.
Planned maintenance included the whole baling system, but this section concentrates on
the major items of equipment. In the plant these consisted of the baler, scale, conveyor,
and front end loader. The transport net consisted of four transport trucks, and the balefil!
had a forklift and a front end loader.
1 . Baler, Scale, Conveyor, and Loader. Each morning a pre-startup inspection of the
baler, scale, conveyor, and loader was performed.The baler was cycled without a charge
in order to warm up the oil. Lubrication points for the conveyor are illustrated in
Figure 8-1 . The equipment was run for between four and six hours, after which the area
behind the gathering ram and the base of the baler were cleaned of litter. The higher the
moisture and vegetation content of incoming waste, the more frequently this cleaning was
needed. Once each day the conveyor pit was cleaned of litter.
At the St. Paul baling plant the hour between 6 and 7 a.m. characteristically
was reserved for the daily inspection and conveyor pit cleaning during the five day plant
study. Previously a third shift performed the cleanup. The baler was cleaned as needed,
and any idle men were assigned cleaning duties. Table 8-1 lists the daily inspection tasks.
Note that the conveyor was cleaned during lunch break on the first shift, and frequently
during the second-shift lunch break.
Other plant maintenance was performed as scheduled. Tables 8-2 and 8-3 present the
maintenance performed less frequently. A maintenance schedule is half of the planned
maintenance program at the baling plant. The other half is a file of maintenance records.
74
-------
\J
Legend:
A = Pulley adjustable sliding disk, driver.
B = Pulley adjustable sliding disk, follower.
Dl = Motor drive variable shaft bearing.
E = Motor bearings.
FIGURE 8-1
LUBRICATION POINTS OF VARIABLE
SPEED CONVEYOR DRIVE
75
-------
TABLE 8-1
DAILY MAINTENANCE IN BALING PLANT
A. Baler and Scale
1. Clean behind rams of baler and pusher. Do every four to six hours of operation.
2. Check bolts for wear and tightness.
3. Check oil level in tank, making sure it is from 5 to 15 cm (2-6 in.) from top of
the gage.
4. Check oil temperature. Use oil heaters overnight in cold weather. Never run
pumps if oil is below 60°F.
5. Start motors from power room control station and check motors and pumps for
ease of turning.
6. Check pumps, lines/and baler for leaks.
7. Check and lubricate push ram guides.
8. Check push ram cylinder mounting and rod clevis pin.
9. Check baler cycle for several runs. Run 8 to 10 cycles in cold weather, with-
out a charge.
10. Clean limit switches of foreign materials. Make sure the limit switch arms move
freely.
11 . Zero out load cells. Allow at least 10 minutes for the electronic equipment to
warm up.
12. Check the tie-rods for levelness.
B. Conveyor
1 . Clean conveyor pit.
2. Check bolts for wear and tightness.
3. Check drive chain and wheels for wear and tension.
4. Check conveyor belt for snags and jams.
C. Bobcat Loader
1 . Check fuel and crankcase oil levels.
2. Check radiator water level.
3. Start and warm up engine.
4. Check hydraulic hoses and fittings for wear and tightness.
5. Check bolts for wear and tightness.
6. Lubricate as manufacturer recommends.
76
-------
TABLE 8-2
WEEKLY MAINTENANCE IN BALING PLANT
A. Baler and Scale
T". Check and clean screens in oil reservoir.
2. When oil is cool, check hydraulic pressure adjustments and set per hydraulic
circuit specifications.
3'. Lubricate motor to pump couplings.
4. Lubricate mounting blocks for shifter cylinders.
5. Lubricate baler lid cylinder trunnions.
6. Check hydraulic hoses and fittings for wear, tightness, and leaks.
7. Check wear plates for missing bolts, wear, or damage.
8. Check bolt flanges of all cylinder rods.
9. Check all bolts for wear and tightness.
B. Conveyor
1 . Check and adjust chain slack and take-ups.
2. With conveyor empty, check skirts for damage, especially the lower lips of the
conveyor.
3. Check rail and rail fasteners for wear and tightness.
4. Lubricate the pillow blocks and takeup bearings.
C. Bobcat Loader
1. Check tire pressure.
2 . Check accessories.
3. Clean windows and cab.
4. Lubricate as manufacturer suggests.
77
-------
TABLE 8-3
LONG-TERM MAINTENANCE IN BALING PLANT
A. Baler and Scale
Six-Months:
1 . Drain oil from reservoir and clear tank.
2. Filter or replace the 1800 gallons of hydraulic oil.
Year:
] . Have an electrician to lubricate all motors.
2. Check wiring, switches, and fuses in the electrical system.
B. Conveyor
Monthly:
1 . Lubricate the sliding disks of the variable speed drive at points A and B in
Figure 8-1 .
Two-Months:
1 . Check oil level in the motordrive reducer.
2. Open reducer oil vent if clogged.
Six-Months:
1 . Lubricate motor bearings at point E , and motordrive variable shaft bearings
at point Dl of Figure 8-1 .
2. Drain and flush reducer housing.
3. Refill with fresh oil.
4. Check belt of variable speed drive.
C. Bobcat Loader
~KChange crankcase oil and oil filter, air cleaner, hydraulic oil as recommended.
2. Check transmission oil level every two months.
3. Check rear axle oil level every six months.
4. Tuneup as recommended.
78
-------
It is not enough to design a maintenance schedule. A record of maintenance performed
is vital; perhaps a log or checklists would be sufficient. A record of downtimes, re-
placed parts and cost, maintenance labor time and cost, and causes of the trouble are
the information bases for evaluating current production and maintenance procedures.
The control tower operator could have an operating log including startup times, break-
down times and causes, and shutdown times. He could also record bale production.
The data on parts and labor would be the plant supervisor's responsibility.
The maintenance history provides a basis for evaluating present maintenance and
scheduling new maintenance based on production and past maintenance time and costs.
The maintenance history also provides a design parameter for incoming waste storage
area requirements.
2. Transport Trucks. Each morning a pre-starting inspection of the transport trucks was per-
formed. Then the trucks ran all day with stops for gas and minor repairs. Table 8-4
lists the daily and monthly truck maintenance. Included in the maintenance is the
sweeping of the empty truck beds by the balefill equipment operator to avoid
littering the road. Thf« was performed every trip after bales are unloaded from each truck.
The truck drivers kept a log of their activities. This log contained information on
breakdown times and causes. Depending on the maintenance program, a privately
contracted company doing the maintenance or the plant foreman recorded parts and
labor costs.
The St. Paul plant contracted truck maintenance out to a private firm.
3.Fojklift Wheel Loader. Each morning prior to startup, an inspection was performed. Then
the lift ran all day with stops for gas. The balefill had limited fuel storage for this
purpose. Table 8-5 lists the planned maintenance for the lift. The balefill operator
should be keeping a log of his operations including downtimes and replaced parts.
Downtimes, replaced parts and their cost, and labor time and cost are useful as historical
data for designing new systems or improving existing operations.
B. Planned Inventory.
A planned inventory is a stock of replacement parts stored on the site, with some assemblies
preassembled. The basis for a planned inventory is the maintenance history of the
equipment and knowledge of critical parts that are scarce or time-expensive to
reassemble.
79
-------
TABLE 8-4
TRANSPORT NET MAINTENANCE
Transport trucks
Daily:
1 . Check tires, trailer hitch and connections, curtain, and outside accessories.
2. Check oil, water, and windshield fluid.
3. Start engine and let warm up. a
4. Check brakes.
5. Clean off truck trailer bed at balefill, every trip after unloading bales.
Monthly:
1 . Change air cleaner.
2. Check brake fluid level.
3. Check steering travel.
Two-months:
1 . Change oil.
a Common practice is to leave the truck engines running to keep them warm and
at the best operating temperature.
80
-------
TABLE 8-5
BALEFUL EQUIPMENT MAINTENANCE
Fork lift Wheel Loader
Daily:
1 . Check fuel and crankcase oil levels.
2 . Check radiator water level.
3. Start and warm-up engine.
4. Check hydraulic hoses and fittings for wear and tightness.
5. Check bolts for wear and tightness.
6. Lubricate as manufacturer recommends.
Weekly:
1 . Check tire pressure.
2. Check accessories.
3. Clean windows and cab.
4. Lubricate as manufacturer suggests.
As Recommended:
1 . Change crankcase oil and oil filter, air cleaner, hydraulic oil as recommended
by manufacturer.
2. Check transmission oil level every two months.
3. Check rear axle oil level every six months.
4. Tuneup as recommended by manufacturer.
81
-------
American Solid Waste Systems provided a recommended spare parts list based on their
experience in scrap metal baling in St. Paul and elsewhere. From Table C-10, the total
cost of the recommended inventory (fust under $14,000) makes the investment worthwhile
when time savings are calculated.
C. Service and Parts Policy.
Harris Shear and Press, Inc..,claimed to mail any baler part within 24 hours after receiving
an order. This service and an investment in the recommended spare parts should combine
to minimize repair time.
82
-------
SECTION 9
COST STUDY
A. Costs at the St. Paul Baling Plant.
1 . Introduction. Costs are presented separately for the baling plant, transport net,
and balefill.. tliese three operations are almost independent of each other,so that
their individual costs are independent. Thus, alternative operational methods, such as
rail transportation, can be costed and then substituted into the costs for the baling
system.
The costs of each part of the system are divided into fixed, operating, and maintenance
costs. Fixed costs include investment, property tax and insurance, lost interest, etc.
These costs are fixed independently of operating time and production rates. Operating
costs include wages, fringes, utility costs, fuel, rental, etc. These costs are nearly
proportional to operating time and production. Maintenance costs include labor and
parts for both planned maintenance and emergency repairs, but exclude lost production
costs (i.e., the dollar value of production not attained). Due to changed accounting
information during the period 9/23/73 to 6/27/74, the definition of fixed costs is
changed to include fringes.
2. Costs at St. Paul During the Period 10/1/72 to 9/22/73. American Systems of the
Harris Economy Group provided the economic data for Tables 9-1 through 9-4. The
itemized costs are segmented into fixed, operating, and maintenance costs, but are
otherwise as received. During this time period, only minor changes in St. Paul
operations occurred,so that costs reflect the true cost of their operations. Two shifts
were used Monday through Friday, except holidays.
Operating changes that occurred included implementation of sorting of corrugated.
Personnel changes occurred as a new management took over in the spring of 1973,
but this did not affect costs.
Two changes that show up in the year's cost data are a seasonal use of cover soil and a
change to Company-owned trucks from leased trucks for transporting bales. The use of
cover soil was seasonal, with no cover soil applied during some winter months because
the frozen soil was difficult to excavate. In August of 1973 a purchased loader arrived
for use in moving cover soil and, thus, daily cover was applied thereafter. March,
however, shows a large cost for "Grading & Bale Covering" since bales produced during
the winter were covered during this time of spring thaw. The use of Company-employed
drivers and trucks began in April. This lowered costs for transport operations, but with
the observed fluctuations, it is impossible to say exactly how much this cost decreased.
Notice that periodic costs for fuel and oil fluctuate enormously. This follows from bulk
purchase of fuel and oil during one month for use in several succeeding months. The year's
total cost for fuel and oil is accurate on a long-term basis, while periodic costs for
purchase do not necessarily represent expenditures for the respective period. Other
83
-------
TABLE 9-1
HISTORICAL PRODUCTION DATA
FOR THE PERIOD 10/1/72 TO 9/22/73
.Period
Production^ ...
No. of Bales
kkg Baled
Tons Baled
kkg/Bale
fbs/Bale
Hours of Opera-
tion0
^^- ^ Period
Productior?^**^^
No. of Bales
kkg Baled
Tons Baled
kkg/Bale
Ibs/Bale
Hours of Opera-
tion
Oct.
1972
7,565
10,138
11,175
1,34
2,954
341
Apr.
-*v^
4,852
6,363
7,014
1.31
2,891
253
Nov.
7,358
9,986
11,007
1.36
2,992
352
May
4,996
6,576
7,249
1.32
2,902
218
Dec.
6,894
9,127
10,061
1.33
2,919
331
June
6,250
8,207
9,046
1.31
2,895
283
Jan.
1973
7,132
9,273
10,222
1.30
2,867
321
July 1-
Aug. 18
9,791
117764
12,967
1.20
2,649
475
Feb.
6,717
8, 937
9,851
1.33
2,933
312
Mar.
7,677
10,102
11,135
1.32
2,901
355
Aug. 19- Total for
Sept. 22 Year
6,615
7,965
8,780
1.21
2,655
348
75,847
98,438
108,507
1.30
2,861
3,589
Total time for each work shift including downtime, cleanup, etc.
84
-------
u6noi|4|D papiAOjd 4ou 9J9M sajnpgips uoi4Dpajdap puo
4S9J94UI oypgdc; '(sjoaX Ql °* 9 mo*} SS!JDA 4U9wdinb9 J9i|4o ;sjD9A Q£ - bu!P|lnci PUD
Buiioq 9iu ui 4U9Uidmb9 4U9J9j4jp JOj XJDA 59404 4S9J94UI puo uoi4Dp9Jd9Q
•6UIMO|JUI X9UOIU 04 9np 4'PSJ3 UD9UI S9S9q4U9JDJ
p94D|9J puD jO4DJ4SiuitupD 9|6uis 9i^4 gpnpxg ^
33' 9 W5 18* £
09* £ fr9'£ 99*3
Z6*£ 10> £6*3
080 'Ofr 9Z8'?£ 68l'Z3
85>
^i-e
9^'£
£65' L£
69>
*L'£
9K£
£15>£
30' 5
OK£
SZ'£
056 'Z£
9|Dq/$
uo4/$
6>|V$
|D4oj.
8£9'8 Zl9't^ £0£'3
8^6' I 699 8frt' I
813 83 561
9 £
395 'I 688
803' 3 005 '3 Z£9'3
869 'V 8£t^'5 8£t'l
£Zf'l £98' I ll£'L
9C9 16£ 161^
f£3'LL L30'3l £06'6
386'£3 66Z'£3 93f'Zl
063' I 063' L 063' I
fcS9'5 tr69'5 f69'5
091^'Z 09^'Z 09t'Z
•*W 'W ^Df
fZ8'3
9Z8
3LL
3£
930' I
935' 3
£86 >
8*9
WO 'I
396 '6
653' 13
063' L
09*'Z
•03Q
Z9Z'l
655
301
q(39)
081
*£3'3
Of 5' 3
ZIZ
ZSO'l
3Z8'£l
633' 13
903' I
£98 ' L
Z15'IL
•AON
zn's
5lO'l
181
ZLfr
9Z*'3
OZS'*
OSl'L
005
£3£>3
009 '3
Itt
\i \t li C
CQIy Q
3Z6L
90UDU94U.DW
J9M4O
S9.|ddnS
UoTn'
X4piJ408|3
Piuafl
S96UIJ.J
9LUI4J9AQ
DS96DM
93UDJHSUI
X4J3dojc]
UOI4Dp9jd9(]
paxjj
^^
($) INVId ONHVa 3H1 yOd S1SOD IVDI^IOISIH
3-6 319V1
-------
98
•BUJMOJJUJ Xauoiu uoaui
it-9 w-9 ez>
8z*e //> Z9*e
zi> 93*9 we
039yOlt Ol6ylf SZE'9*
zeoy3z es6'9 eet'9
IZ8'8 013 339
9fr6'e ZVZ 839 ' I
08 ~ D(Z l)
389 '8 9Z3y3 391yl
18Z>3 Key3 C98'l
Qno'/r /pr7/ CACy-b
Ov/7 Z.C Z.OC/ G jOj r
C98y9l 3te73 8^9 ' Z
9esyoi tzz ezi'3
8 18 '3fr3 tC3y93 66lyOC
889y6l OOCy3 OOCy3
ZeOy9 639 639
999 y96 C69yOl C69yOl
JD9A 33 Mdas 81 *6nV
*} !D-f°l -61 '6ny -i Xjnp
69>
we
Z9'e
963y63
639 ye
88 L
9CZ
91
ose
006yl
we
0/fr'l
9WyL
OZ3y6
063'9l
ooey3
9&
109 y 9
zze'6
aunp
frfr'6
19'9
8l'Z
Z8lyZt
Z.6yZl
iseyi
8C3
Zl
—
8Wyl
tzzye
090 yl
W9
lZ6yll
ezsy03
063yl
9Zt
I09y9
Z9Cy8
Xoyy
96'Z
09*9
90*9
l09y8C
wz'ei
99
993
SV
069
993y3
L09y3
I83yl
09L'l
396 y 6
063yl
9ZF
C69y9
•jdy
apV$
uo4/$
BW$
,010!
aououa4Uioyy
JSL|4Q
saijddns
auondajaj.
IJQ 'jsn-j
X4jDiJ4oa|g
|D4uail
saSuiJ-j
aiui4jaAQ
saBo//^
6uj4Djado
XD!
aouojnsu,
paxij
X.S4S03
INVld ONHVa 3H1 aOd S1SOD
-------
SS'l
ZO'l
68*1
63'I
zn
£3* I
9£*l
Wl
92' L
6£'L
59' I
sri
698'11 I69y2l
L69'2l
£98VU L69y2l
369y3l 369'3l
Z69'Z[
6ui|nDH
'\IO '
paxjj
.
u
N
-400 pouej
13 N IflOdSNVai 3HI ilOd
S1SOD WDMOISIH
£-6 319V1
-------
£Z*L 9E'l 96*1
12*1 20*1 8KI
ES'l 21 'I £9*1
966'OCL 066'8 F9l'6l
ZOZ'Sl 8re'2 009'9
w'zz
2Z8'S K8 Zgz'l
zzs'9 - 96e'e
Z9gyi si^e Z9i^
ew'si iei> oo9yg
£0£yOLl 862'S 022yll
9867^ Wl'l WI'L
986 > WyL *teyl
joa/^ joj jj ^dag g[ '6ny
(040^ -51 *6ny -[ Xjnp
Sir* I 80*2
62' 1 W I
ir I 65' I
sgo'6 oi^'oi
8W'2 2lZyS
-
89£7l OSO'l
8Z2yl 8Z2yl
ZZ2 VIZ
i2eye ooe'e
W9 2C6y9
99Z 99Z
99Z 99Z
aunf Xoyy
SZ" I 8lDCl/$
02" L u°4/$
2£' L 6>p,/$
9l'/8 P40i
666 8DUDU94UIDyy
W'Z 400^"^-^
et^8 asuaon ^ y|iOy!snJ
?29 |D4uay jajjoj!
902 S36uu.j
16^72 sa6oM
l?9'9 6uj4DjadQ
99Z uoj4Dioaada(]
99Z psxij
•ady \^ s^oD
pouaj -x^^^
13N iilOdSNVJI13HlilOd
S1SOD IVDIilOlSIH
-------
68
•6uiMO|4u; Xauoiu UD9U1
86' L
ze'i
LS't
oe2'si
9V8
8V
Z21
28V'8
028
886
ooe
iev
9Z8'2
2ZO'Vl
n
862
21C
-w
81-1
08'0
88'0
S16'Z
98Z'2
(19)
-
-
VS2
8S9'l
oee
9S2
ose'2
ZIS'V
VI
862
2ie
•qaj
92'1
Z8*0
96'0
OL6'8
868 '2
98C
£2
-
-
Z8V'2
2Z2
6VC
esi'2
ooz's
n
862
2ie
•uop
ZE'I
06*0
66' 0
690'6
Z6S
£2
OS
-
ei2'i
8ZlyV
ZOl
56V
V60'2
091 '8
VI
862
21C
•oao
29' I
80* I
61*1
OC6' 1 1
6C9
V2
911
-
918
oiv'v
§9e
29S
ge9'v
826'0l
-
£9£
£9C
•AON
20*2
ze-i
IS* I
2ie'si
909^
D(61V)
8
IV I as
ezg'9
262
882
V2S'£
ZOV'Ol
-
ooe
ooe
2Z61
•PO
a pq /$
u°4/$
6>|>|/^
P»°I
aouDua4Uioyy
-1944O
S8i[ddn$
LO^ apg ^ BuipojQ
uaoji ^ '\\Q ' \an^
P4uay
saBuj.i-i
aiui4JaAQ
saBDM
6u,40J9d0
XD^
aouojnsu|
uoi4DioajdaQ
paxij
"^--^ 54503
pouej ""\^^
SISOD
V-6 319V1
-------
06
•6u|A\oyuj Xauoui uoaw
ZfrM
COM
MM
ZrcMlL
fr90>l
92fr'C
88C
2CLyZl
002 'V
I6fyie
261 yC
l2Zye
9Z8y62
92fye6
ooe
092
Z6rye
zso>
joa^ joj
JD40!
02M
06*0
66'0
OC6yZ
SC2
-
8
299
26C
9F9y2
99Z
oie
Z9Zy2
OfL'Z
001
L8
we
999
22 *4
(et)
t^89yl
Z21^
6^e
060 ye
28CyOL
001
18
we
999
8L '6nV
-l/|np
22M
WO
C6'0
8C9yZ
(61)
Z68y2
-
-
svz
289 ' I
092
W)2
Z96yL
£F2yZ
001
frl
862
211^
aunp
2KI
86*0
80M
wiyz
2Z
l^
gz
892
z^ye
Z22
w
86C'2
02Zy9
1^1
862
2ie
Aoy\j
2ZM
61M
ICM
6eeys
2ZL
3(2)
-
ess'e
w
8C9M
Z92
eee
2Z6yl
998 'L
n
862
2ie
•jd
8PS/$
uo4/$
6>lV$
ID4°1
a3uoua4uioyy
J9H-*O
saijddng
6UJJ3AO3
ajog *$ BuipojQ
asuaDi-j ^ 'uo 'pnj
p4usy
saBujjj
auij4jaAo
sa6oM
6ui4DjadQ
XDJ.
SDUDJnSU|
/4jadoJcj
110140 pajdaQ
paxij
^^--^^ 54503
V pouad ^^^^
3H1
S1SCO IVDIHOiSIH
(-41103) tr-
-------
16
•passssso 349M saaj pioads 044x3 y>pnj4 at|4 uo BJSM spooB 34iu,M
puo S94J4 j| 'pa||ij ||D 4ou ajaM s>pru4 ai|4 souis 'spjooaj aujn|OA >pru4 oiO4j 340015453 UD
SAjjap 04 apooi SDM 46013440 ou ' UOJ4DAJ3SCJO pnsiA UMO siq soM uouu34o6 31(4 Xq pssn uoj4
-DOIJ4S3 jo pou^aoi ai|4 3oui$ 'papnjoui 4ou 3J3M sni^4 puo 40404 ado 4uojd Buipq 344 oiojj
3|qD|[DAD 40U 343M S98J UO D4DQ -aplU|3A L|OD3 Xq p343AI|3p 34SDM plJOS .JO X4J4UDnb
puo adX4 aij4 04 6ujp4oooo pauoA sjasodsip 34SDM pips 04 paBjoup saaj 4uo|d Buipq auj
•suo[403S snojAajd 31^4 ui paquosap 340 suoj4DJ3do 6uipXo34 jo sjp4ag 'pjooqpjoo 344 djus
puo apq 04 saj4j|po.} 6uipq jo asn puo '4U3aidjnb3 jo 501341 Jouioi jo uoj4D2i4JOOio '30114
,SJ3Joqo| OM4 .jo 4500 344 S4as.jjo UDL|4 ajooi 4a>|JDOi BuipXoaj 30,4 uo p34o6njjoo pspq
'uosp jo sojjd 3Ljj^ -pouad 51^4 6uunp 6ui|pAajd ssoud 36oA|os 344 40 3|qD4yojd s;
pjooqpjDo p34o6njjoo p BuipXosj puo 6uj4Jos pnuooi 4044 sa4Doipui uoj4DOiJO.ju[ sii|j^
•3|qO|IDAD 3J3M D4Dp LJOIIJM 4OJ '^//^ °4 £//8 pOJJad 3L|4 JOJ pJDOqpJDO p34D6aiJO3
6uipXo3J oiojj S4jjpjd puo $4500 Xm4uooi S4uassjd Q[-O a|gpj
pouaj 3U|4 6uunQ poj -4$ +D pjooqpjo^ p34D6njjo^ BuipXosy JQ.J
•spouad Lj4oq JQ.J 54500 sBcusAD sszuooioins o-o 3|qoj^ • pa|Dq 34SDM pijos
jo 4U|6j3M 4jun jad 54500 3t|4 sonpaj UDO Xop J3d 43145 suo uot|4 BJOOI 6uunp uoj4Djado 6uj
-JjnbaJ S3SD3JOUJ 34SDM pJ|OS 4DL|4 SI D4Dp 4500 OIOJ.J UMDJp UOISnpUOO OlSDq SLji ' ||IJpUD|
|Doo| 3Aisu3dx3 ssa| D 40 S34SDM pips papqun jo Buisodsip uo6aq OLJM sjasn paSounoosip
VL6\ u! X|joa. p94Dj4jui saBjoip pasosjouj 'os|y 'psxij paupoisa 54500 .aououa4uiDoi puo
6uj4Djado 9||L|M 'papq 34SDM pips jo X4j4uonb u; dojp 344 SDM asoajoui 4jun
3i|4 jo 4uauodoioo 4uooi.jiu6is ajooi o 4nq ysdsoajoui 4503 pnj puo X4ioij|oe|8 04
-nqiJ4uoo X|4U3Joddo ,,515143 A6jsu3,, ^Ml 'psddo4p 4soo (0404 ijijapq 4nq '^61 6ui4np
4L|6i3M 4jun 43d puo spq 43d sAisusdxs 94001 3Oioo3q pip uoj4P43do 4UD|j • spouad
ai|4 u33M4aq aou34ajjip 4500 aB4D| ou S!343L|^ 'spouaj pjooay o/A| 40 uosuodoto^ '^
•p3AJ3034 SD papnjOUJ U33q 3ADU, dL|^ 'SauDLjO 4SOD
jo 4|ns34 8L|4 34D /uoj4Dioa4dap puD pnj SD Ljons
'54500 aoios jo uoi4Drvpn|j 9t)^ •uosuodoioo 344 ui 54500 poi4ad 3i|4 3AD3| 04 ijBnoua 4uoo
lSUJ 343M S36UDL(0 344 40q 'S34npaOOjd UMOp BuiSOp JO 4|nS34 D SD p3A43SqO 343M
°4 ^Z/92/S) P°!J8d 4SD| 344 6uunp ssBuo^o 4503 -54500 4UD|d Buipq poi4ou jo
aA[4D4UaS34d34 4OU 343M SaBuDLJO 9S9LJ4 Bujjnp S4SOO 9LjJ^ 'p34a|doiOO Bui3q 843M PJ434DOI
Buiui) 43qoiDL|0 s,4apq ai|4 ui ssBuDijO puo suoi4DnpA3 p4U3oii43dx3 aouis papnpxs
8JD tZ/OZA °4 K/Zl/e ^^J POIJSC! 344 Buunp 54503 '4UD|d 43pq 3144 4Oj 400 papiAip
343M S4SOO 30UDU34UpOI pUD 'p9doin| 9J9M MJeL|4O-43l |ddnS-aUOU|dap4|l •Xp4D4DdaS p34S{|
4OU SDM 30II449AO ^psdoiOj S3BUI4J pUD S3XD4 :343M S9IJO 69400 4SOO UI S3BUDI4)3 'S9IJO6
-94DO 4SOO 9LJ4 p3494p 4DLJM3OIOS SdBUDLjO 6ujd99>)>)OOq 4OUIOI '(^-Q ^6nOJL)4
4D3X 4S4IJ 9LJ4 4OJ U3A[6 SD 9OIDS 3L|4 SI 4DOI4OJ 9Lj| 'pOUSd ^^-£/6l 9U,4 JO4
04 op 4500 3|qO|pAD 3i|4 4U3S34d g~6 i|Bno4i]4 g-o S9|qD| -passod pot] 4D3X ||nj puooas
D 34Ojaq uMop pssop uoi4D43do 43|pq 3t|4 4nq '01434 puosss D 4Oj 04 op 4500
osp 501845X5 uDousoiy >^/63/9 °4 ZL/ZZ/6 P°!jsd 9M* Biiung poj -4$ \
•S4SOO JO 4UHOOOD 34D40OOD 4SOO1 3L|4 SI 4D3X 9LJ4 4OJ
(0404 suj -54500 pn4oo 04 S4uooi4SnJpD oins-doin| pus-4D3X L|4jM 5940011453 X|i|4uooi puo
'(•043 '9np 53x04 01494 pauijapa4 'UO^DZ 1440010 jo pud'-a-i) s4U3OiXod oi4ojiunuou 'poijgd
Bu;4unoooD 944 jo L|4Bua| ai|4 ui s>|a9M jo jgqoinu 91)4 403)334 $4500 paxij ui suo;4Dn4on|j
-------
Z6
04 JD4OJ.,, 8^4 Buipnpui '
|Doid/4D so pajou6i si pouad SILJ4 'sniji 'jaujj jaquitxp JjaiJ4 uo suoi4DOi4jpow
p4uauiuadxa 04 anp pouad sji^t Buunp s/op aajij4 4nq J|D u/v\op SDM
4j 9DUJ5 -spousd
•/op 4DLJ4 psnjooo 54500 M9j 'Xopjr^Dc; D SDM
jo 4JD4S puo pua 40 so
9[9'Z
H'l
ZOl'ZF
SU'ZV
WL'ZZ
34DQ 01
568 'Z Z68'2
IC'l ZZ'l
Z16'9 8Z9'£
/ 14,'r ir i 'c
617 a Li» I a
Z2l> O26'e
91 *JDW 6 'q9J
-01 *s8J -9 uor
ZLL'Z W6
9Z'( ZZ'[
IZ9'9 8V9
660 '9 9W
990 'V 996
62/9 9Z/9
- 9Z/9
6Z8'2 206
IC'l 2C
2f6> ?2?
f8Zy£ 956
'2 ...
yz +
'9 +
QZ/V
iz/v - zi/e
'I IS'l
y9 WZ'Z
'V 9V6 '9
9 *uof QC *AON Z2 *4DO
-I "D9a -Z2 '43Q -C2 "4d9S
apq/sq|
apq/6>|>|
papg suoi
pajDg 6>|>|
sapg 40 -o|sj
^S^XSN*.S^ uo iiDnpoj j
apq/sqi
apq/6>)>|
papg suoi
papg 6>|>|
sapg 40 -ON
pouaj -\^
3 HI
viva
5-6 3 19 VI
-------
£6
•4uauu4snlpD joaA 611141100000 40 pug
Zi'S
g9-g
18*9
OC'9
86>
6>iV$
109'OC
P401
9ie'i
sec' z
g
sos
81^0' Z
0
99S
229
061' I
885 'e
SLZ'L
68 L
699
ee6'i
L6Z'6
see' 2
eez'z
zzg'e zie's
9e
gzi'6
oe6'ei
ZOZ'3
886 '9
LIZ
OC3
866'L
ee6'i
886 '9
198
6oe'i
OZ6'9l
VZL
089'L
006'I
998 'e
gie'oi
X4IOU40913
saBuu-j '
LZS'6
IW'Ol
8L6'2l
paxy
91 *JDW
-01
6 *
9 >
oe *
'-PO
54503
INVld
ONIlVfl 3H1 ilOJ S1SOD
9-6
-------
•poiJ9d 5144 S9jou6i osp uwn|co H94DQ 04
• |Doid/4D so pgjouSi sj pougd 5144 'snij^ -J9ui| jgquioip 944 uo
|D4U9uiu9dx9 04 9np pojjgd 5144 6uunp s/op 99.144 4nq |p u/wop SDM
56'9 8Z'9 n'S
C8> 68> We
ee's 6e'£ 06*e
9|Dq/$
UO4/*
6>j>j/$
989yZ22 66fryZ2 665 ^ p4oi
y
W6yei 80£y2 9Wy2
ei8y9 9L 61
oi6yz eei^ 605
4UDJJ
•dinbg sjiqcy^
JO/9AUO3
jgpg
080 '
ezs
93UOU94UIDW
HO ylsnd
002
OZO
08t^
999
C98
01^6
'n
'99
'80L
y6^
'n
94DQ 01
0
69ly6
8Z8y£L
ZZ2"2
OIS'6
(g aunp
-og XoyY
2Z^'2
ieiy9i
C82yZ
8£9'6 *
-L2 *jdV -Zl *JDW
X*la!/i°^
6u]4Dj9do
SSBUU-I 'S9XD1
UOJ4DID9jd9(]
P9XJJ
^^^^^^^ S4S03
pOJJ9d ^^^.^
I^Z/62/9 °4 CZ/82/6 INVId
3Hi ilOd S1SOD IVDIHOiSIH
(•4U03) 9-6
-------
IS'2 2S'2
8Z* 1 VL' I
16*1 26*1
6W'Ol SZ8'6
859 152' I
l9Z'l 628' 2
98Z'2 988' 2
S02'S S9fr'9
1 6£ 9*2
008'2 616
161'C §9l'l
91 'JDW 6 *R9J
-01 'cpj -9 *UDf
86' I 92*2
/£' L 95* I
LS'L 2Z'l
58^'Z 822' LI
126 082'2
859 Ztl'l
696 6*1' I
6L6 W' I
898' L 05Z' I
5 "UDf 08 *AON
-I '03Q -/g '43Q
Zt' I UOV$
29' I 6>lV$
I55'2l ID4°1
££9' I 80UDU3|UlDy^
628 'V !D*uay
Z18 I!O 'lanJ
680'* saBo^
582^6 6uj4DjaaQ
688 ssBuu-i yssxDj_
1^8' I uoi4Dioajda(]
889 'I Pax'.J
Z2 *43O "^*^>^ ^4so^
~82 *4d3S P^!J3d ^"^^^v,.^
3H1
°4 CZ/e2/6 13 N
S1SOD IVDIilOlSIH
Z-6 318V1
-------
96
pouad siij4
pouad siij4 6uijnp sXop
•pajou6i si
||D UMOp SDM 4UD|d ai|J[ ^
Sl'Z
05' I
59' I
09' I 01*2 — 9|D)>j/$
l6f'OZ 109'9 £05' Zl * |D4oj.
SOL
BSO'Z
69C'6 899
VZV '8 691
899
0£2'L
no
Oll'9
fZ/62/9 04 cz/e2/6 13 N
3HI *IOd S1SOD 1VDIHO1SIH
(•4U03) L-6 319VI
09Z
926
'2
'Zl
|D4OJ.
Artf*
wOo
008 '2
os i 'e
62 a"nr
-92 ^W
689
008 'Z
92 ^W 02 *JCV
-12 '-"cV -Zl *JDW
saBuu-j 'SSXDJ^
6uj4DiDajdaQ
paxi-|
^r\
-------
TABLE 9-8
HISTORICAL COSTS FOR THE
BALEFILL 9/23/73 to 6/29/74
^"--x^Period
Costs "~-\^
fixed
Depreciation
Taxes, Fringes
Operating
Wages
Rental
Fuel, Oil
Grading & Bale
Covering
Supplies
Other
Maintenance
Total
$Akg
$/ron
$/bale
Sept. 23- Oct. 27-
Oct. 27 Nov. 30
1,617 2,079
1,124 (72)*
493 2,151
4,978 4,793
2,925 3,054
1,661 1,194
392 499
—
—
46
1,130 1,984
7,725 8,856
1 .00 1 .36
0.90 1.23
1 .30 1 .79
Dec. 1-
Jan. 5
860
498
362
6,693
2,718
3,476
375
124
407
7,960
1.61
1.46
2.10
Jan. 6-
Feb. 9
709
498
211
2,846
1,459
1,056
325
6
684
4,239
0.82
0.75
1.08 /
Feb. 10-
Mar. 16
642
498
144
3,034
1,559
1,036
439
—
754
4,430
0.82
0.74
1.07
End of accounting year adjustment.
S
97
-------
TABLE 9-8 (Cont.)
HISTORICAL COSTS FOR THE
BALEFILL 9/23/73 to 6/29/74
^^^F'enod
Costs "^--x-^^^
fixed
Depreciation
Taxes, Fringes
Operating
Wages
Rental
Fuel, Oil
Grading & Bale
Covering
Supplies
Other
Maintenance
Total
$/kkg
$/ton
$/bale
Mar. 17- Apr. 21-
Apr. 20 May 25
* 687
498
189
* 3,651
2,552
1,035
64
167
* 4,505
0.57
0.52
0.76
May 26-
June 29
627
498
129
5,062
1,541
1,009
213
2,299
559
6,248
1.23
1.11
1.54
Total
To Date
7,221
3,542
3,679
31,057
15,808
10,467
2,307
2,475
5,685
43,963
1.03
0.93
1.34
* The plant was down all but three days during this period. Thus this
period is ignored.
98
-------
o
LU
_J
CO
CO
T
!
C
£"
8
u
-H
V
u.
T
C
n
o
w>
O
U
n
II
*
t
c
15^
o
K
u
•5
o
U
0)
a.
Location
o — CN co
CO CO hs, 00
— CN 0 •«*
CO ^^" ^D 00
00 CN SQ K
O CN O CO
Os -t Q CO
Os CN CO CO
•— CN O >O
o-^R£
O CN O "-fr
Os CN •«*• IT)
if) CO CD Os
CN CO «— sO
sO O WJ ' —
CN CM Os -«t
• • * •
— CO O f>
Fixed +
Operating +
Maintenance
Total
JO
Q_
D)
CO i— sQ Q
CO Os CN IO
O O O —
if) CN ^t • —
O O r- CN
O — O •—
FN O 00 U">
CO O CN sQ
0 — 0 —
IO CN sQ CO
— — CO
0 — 0 —
oo o r^ 10
•^ CO CO r-
O — O CN
rs, »T) r- CO
O •«* CN K
o «— o —
Fixed +
Operating +
Maintenance
Total
^5
Z
I
D
1—
IO SQ CN CO
— sQ — Os
O O O O
3228
O O O —
K CO CO CO
— K •— O
O O O —
•«* «") -^J- co
O Os •— »—
O O O —
CM if) K -^f
CM Os •— CO
000 —
IO CO Os K
O CN — •*
0 — 0 —
Fixed 4-
Operating +
Maintenance
Total
?
o
CO
00 CO O sQ
CN 00 — CN
CN CO — hs.
K CM CO CN
Os •— Os O
O ^ O sQ
CO tX r- .—
"O CN CN O
CN ••* — 00
sO •<* CO CO
O "O O sQ
— ^- ^- sO
CN IX 00 -5
CM IT) IO -
_o
o
^c
I
a.
o
c
o
§
0)
-D
i/>
*^ 2
il^ .2
» o> •£
^CN 8
•g>«
£
• °°
-a
o
0>g
^ CM •-
V) \^ £
i E s
>
+
99
-------
•bO-
Q
C£
^
0
co
Q
<* f£
°u
u_ <->
0 oo Q
J± 1— UJ
| OO I—
ON O <
OJ U O
13 _, ID
co r< oi
2o§
o£ (j
2o
£ Z
x 13
u
u
LU
^
CM °
ON ^>
1
IX O
— CN
\. \y^
CO "tf
1
° NO
X^ ^"
™co"
1
S ON
^CN-
^*X
"~'~ 1
co^
\xt
£- "~
I
CO —
X. C^*
o" • —
1
CO £NJ
CO .
CN
O^
,
"O /
o /
*c /
0) /
0- /
/
/ 1
f -t-
ON IX
ai o
ix" CN"
CO •—
CM
IX
CO
•o"
CM
O CN
ON O
CN O
N N.
lO CN
CO
CO
CN
K,
CO
O IX
(X ON
S, K,
NO —
CO
CN
00
^J"
ir> rx
oo o
••* CM
u-T CN"
R
CN
co"
p —
rx -^-
ix" CN"
ON
CN
00
CO CO
N, N.
r>. - —
CO
00
K
V)
-^- co
00 N§
,
r^
«4-»
(U 1
E a Q-
O *• +-
J 3 1
to -*,
IX <-
CO -^~
ON CO
s. *,
lO iO
— NO
K. ^
lO iO
CM oo
N, ^
lO CN
CM ON
NO fX
^^
IX lO
K S.
ix co
^^ i>sO
N. S.
00 00
«*—
V)
o
15 5> c
-o^ £
oo
00 CM
NO NO
O O
NO "O
• *
o o
3" £
ON CO
O CD
NO O
NQ NO
0 CD
-t rx
rv. NO
CD 0
fX NO
• *
o o
CN IX
lO Tf
CD CD
O) c
-g p
^^
S 2
a. a.
'
•
1)
O
1—
o
^
IT)
NO
-4-
*
in
O
O
ro
"o
_Q
in
_
a.
•o"
o
^
U
o
u
0)
c
"o
0)
fl^
D)
V>
J
o
_Q
_0
—
t/5
O
-o
"3
c
o
100
-------
B. Processing and Cost Comparison of Alternative Solid Waste Processing Systems.
1. General Processing Methods. Several alternative solid waste processing systems
are currently in use; these include baling, milling, incineration, and composting. The
former two are physical-mechanical processes; the latter two may be considered thermal
and biological-type chemical processes. Modern incineration which has to meet
stringent air pollution standards is expensive and requires costly pollution
controls. Composting is generally not done because of cost and a lack of markets for
the compost product, particularly near urban areas. Long-distance hauling of bulky
compost to agricultural areas would be costly, even if markets existed. Baling and
milling have advantages in that they are relatively non-polluting to the air and water
and are suited to urban areas due to plant facilities having minimum land requirements
and possibly reduced transportation costs due to lesser waste volumes. Bales and millings
are not expected to affect land any more severely than normal unprocessed solid waste
when disposed to land. These two processes are evaluated with regard to their relative
merits, since they have the similar purpose of increasing the density of landfilled waste.
The analysis summarized in this section compares the following general physical-me-
chanical processing system configurations on the basis of relative cost and describes
potential environmental effects of landfilling alternative types of processed wastes:
a. High-density baling. American Hoist and Derrick Company, Harris high-density
baler with conveyor/front-end loader materials feed system as operated in St. Paul,
Mi nnesota.
b. High-density baling. Harris high-density baler with an overhead crane materials-
feed concept.
c. Milling. The Tollemache and Gondard mill operated as a demonstration plant in
Madison, Wisconsin.
d. Combined milling and low-pressure baling. A mill and American Baling Company
low-pressure baler operated as a demonstration plant by the City of San Diego, Calif.
These four systems were selected due to their being recently or presently in operation on
a full-scale basis as either federal Environmental Protection Agency demonstrations or
pilot plants with relatively good data. Alternative b. has not been operated as a com-
plete system, but the Harris high-density baler is a similar baler to the one used in
St. Paul. Capital, operating, and maintenance cost and technical data presented here
were available for each system at the time the study was completed, and thus provide
a useful comparative assessment of the four system configurations.
Baling and milling processes are generally suitable for application to residential and
commercial solid waste. The -Harris high density baler is also suitable for baling paper
and scrap metal. Economic advantages associated with baling are reduced volume
and reduced soil cover costs and associated landfill placement and maintenance costs
over unprocessed landfilled solid wastes. Bales are easier and less costly to place in
101
-------
the fill than unprocessed and milled wastes, which both require spreading and
compaction to achieve high densities. Milled wastes, which some authorities say
require less soil cover when landfilled, also have some of these aforementioned
economic advantages over unprocessed landfilled wastes. However (obviously), baling
and milling cost more than dumping or plain landfilling. Both baled and milled solid
waste achieve about a 50 percent increase in landfill density over unprocessed solid
waste (see Table 9-22), thus reducing landfill and storage requirements by about one-
third. The higher density also means less settlement (both absolute and differential),
and, thus, a higher potential use for the filled land. If the baler or mill is inoperative
for an extended time, the solid waste could be temporarily disposed into the landfill
unprocessed.
Environmental benefits associated with bale landfills include fewer vectors, less litter,
and minimum odors. This occurs as a result of the reduced surface area of the tightly
packed waste and lack of void passages through which odors can diffuse and birds, flies,
or other vectors can traverse to food. The same environmental benefits were reported for
milling; however, the cause was due to dispersion of finely milled food stuff into the
milled waste so that it was difficult for vectors to forage.
Mechanical processing of solid waste has stimulated salvaging and reclamation. For
example, milled solid waste has been used in a federal EPA demonstration project as
an auxiliary fuel for an electrical power plant. Corrugated cardboard and ferrous
metal segregation and salvage for baling was done by hand at the St. Paul baling plant.
Although most labor-intensive salvage operations were not economically feasible,
more sophisticated ferrous metal segregation, such as using magnetic belts, has been
profitable for shredded waste at several locations. Milling plants can easily
accommodate magnetic segregation on the existing conveyors. Salvage and recycling
operations are omitted from the comparative system analysis, due to local variations in
salvageable materials in the solid waste and the fact that reclamation is presently not
widely practiced. In the future, regional landfills will likely become more important
to reduce costs and provide for economical recycling to meet increased consumption
requirements for dwindling resources. In order to serve more distant regional landfills,
transfer stations will be required, thus providing suitable locations for baling and
milling plants.
Perhaps the greatest disadvantage of either baling or milling is the relatively large
initial capital outlay required for the equipment. This and the high processing rates
necessary to cover the capital costs make baling and milling feasible primarily for
regional or large urban areas.
John J. Reinhardt and Robert K. Ham, Final Report on a Milling Project at Madison,
Wisconsin, Vol. 1 (Milwaukee: Heil, 1973)7
102
-------
2. Systems Comparison.
a. General Assumptions. Comparison of different operating systems using
available data is complicated by local variations in costs (construction, land, supplies,
utilities, and labor), climate, solid waste characteristics, operating plant capacity,
and accounting procedures. If the plants operated during different time periods, the
effects of inflation must be normalized. Granting that these differences exist between
the systems (as operated), a meaningful analysis is possible by equalizing application
of each system in terms of the different cost and operating factors.
The basic year for costing was selected as 1973. This was done because 1973 construc-
tion cost data was available for a high-density Harris baler under construction in Cobb
County, Georgia. The Cobb County costs for construction contingencies and equipment
were used for costing of identical baling plant equipment for comparing the four baling
and milling process configurations. Capital costs for milling were based on the Madison
plant cost analysis, and for combined milling and baling data the San Diego plant
was used. Since each of the four processes systems assume nearly equivalent solid waste
processing rates, similar equipment sizes and costs were used. The Engineering News
Record Construction Cost Index was employed to adjust the Madison and San Diego
reported costs. Standard labor rates were selected as representative of existing landfill,
truck driver, and plant operating personnel in solid waste management at St. Paul and
Madison; available data on Oceanside, California was used as typical of San Diego.
Labor rates in these three cities varied widely and were assumed to be typical of the wide
variations nationally. Interest rates on capital were based on current rates on municipal
bonds. Supplies and other miscellaneous costs were based on data from the St. Paul
baling plant. Operating and maintenance costs were derived from operations at the
three respective plants and adjusted to the standard labor rates.
A standard travel distance of 11 miles one-way between the transfer-processing plant
and landfill, identical to conditions in St. Paul, was assumed for all four systems to
determine transport costs.
Segregation and recycling were excluded from the cost analysis to simplify the direct
comparison of the four alternative processing systems. Segregation oPferrous metals
and corrugated paper for salvage might be feasible for inclusion in all four systems.
b. High Density Baling—System 1. The baling plant operations schematic and
equipment are presented in Figure 9-1. The System ! configuration is the same as
operated in St. Paul. (Equipment specifications are given in Appendix C.) For purposes
of analysis, the current baler model with a 90-second baling cycle was used. The
equipment used is otherwise identical to the St. Paul equipment in size. The System I
baling plant operational conditions are as follows:
• Operating cycle - 1.9 minutes per bale which includes lost time.
• Production rate - 31.5 bales per hour, or 41.6 kkg (45 s tons) per hour.
103
-------
Activities On
Solid Waste
Dump on Floor
errous
1 . Sort^Mix/
Load
I
2. Convey
3. Weigh
i
>
4. Bale
1
5. Eject
f
Load on Truck
Rejects
Storage/
Load
Equipment Used
0. Collection Trucks
1 . Wheel Loader
2. Two Slat Conveyors
3. Automatic Scale
4. Baler
5. Efector
6. Transport Trucks
Sorting for recyclables is possible. Recyclables are baled separately as in the cases
of cans and corrugated.
FIGURE 9-1
HIGH DENSITY BALER SYSTEM 1
OPERATION SCHEMATIC
104
-------
• Bale weight - 910 kg (2,000 Ib) to 1,360 kg (3,000 Ib), average 1 ,320 kg
(2,900lb).
• Bale size -l.lm high by 1 .1 m wide by 1 .4 m long
• Bale density range - 960 kg per cu m to 640 kg per cu m.
• Production schedule - 8 hours per shift, 2 shifts per day, 14 production hours per
day, 49 weeks per year.
Additional peripheral equipment utilized in the plant, but not on the processing activity
line, were an articulated forklift and small "bobcat" wheel loader. These performed
clean-up, equipment and supplied handling,and general transport tasks. It was assumed
that the forklift was not used to lift the bale truck loading platform above the transport
truck bed.
The complete system included four transport trucks (tractors and trailers) to carry bales
to a landfill. Landfill activities and equipment consist of the following:
• De-rigging transport trucks to make bales accessible.
• Unloading and placing bales three-high in the fill with an articulated, wheeled
forklift.
• Excavating soil and covering bales daily with 15 cm (6 inches) of soil using an
articulated, wheel loader.
Landfill operating hours and shifts corresponded to the baling plant operation.
The capital (construction) costs for System I are itemized in Table 9-11 . A 20 percent
contingency is included in accordance with conservative engineering cost practices.
Operating and maintenance costs for System I are defined in Table 9-12. Labor
classifications and manpower levels, and hourly rates are included in Table 9-12. In
order to estimate maintenance costs, a preventive maintenance program was assumed
during two production shifts,with heavier maintenance being performed after the second
shift. Electrical power consumption in kilowatts was estimated using the rated maximum
power requirements of the electrical driven equipment (motors, etc.) and assuming a
constant demand equal to 50 percent of maximum demand. This assumption was necessary
due to a lack of kilowatt-hour power consumption data in St. Paul. Costs for land were
not included due to the assumption that the land value before and after baling or land-
filling would be the same (no net cost). Due to the relative completeness of data from
the St. Paul plant. System I costs are considered more accurate statistically, and are
probably more conservative than the other systems due to the letter's missing items.
c. High Density Baling-System 11.The baling plant operations schematic and equipment
are identified in Figure 9-2. The System II configuration substitutes a travel ling over-
head crane for the front-end wheel loader and conveyor in System I. All other
equipment and baling plant operational conditions, and transport and landfill operations
are as stated for System 1. The loader operator was eliminated. The control tower
105
-------
TABLE 9-11
HIGH-DENSITY BALING SYSTEM I - CONSTRUCTION COSTSa/b
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Item
Baler
Conveyors (2)
Automatic Scales
Hydraulic Bale Loader
Supporting Equipment
a) Wheel Loaders (2)
b) Fork lift
c) Miscellaneous ,,
Building (120 ft x 240 ft) @ $16/ft
Equipment Footing and Pits
Pavement
S ubtotal
Transport Trucks (4)
Articulated Forklift
Wheel Loader
Balefill Building and Fuel Tanks
Site Improvements
Subtotal
Base Total
20 Percent Architecture, Engineering, and
Contingency
Total
Cost ($)
676,200
122,500
40,000
25,000
90,000
10,000
25,000
460,800
120,000
50,000
1,619,500
100,000
10,000
45,000
21,000
0
176,000
1,795,500
359,100
2,154,600
' Based on 1 .9 minute per bale cycle time and 1320 kg /bale (2900 Ibs/bale) weight;
also assumes 4T .5 kkg/hr (45.7 s ton/hour) operating capacity
Based on cost at Cobb County, Georgia, in 1973. Source for most cost data was a
personal communication from the Harris Economy Group of American Hoist and Derrick
Company (November 30, 1973), the cost data for Items 5c and 13 were estimated.
106
-------
TABLE 9-12
HIGH-DENSITY BALING SYSTEM I - OPERATING AND MAINTENANCE COSTS0
1.
2.
3.
4.
Item
Labor Rate ($/hr)
a) Supervisor 6.50
b) Control Tower Operators (1 -1 -0)b 6 .50
c) Loader Operators (1 -1 -0) 6.50
d) Mechanics (1-1-1) 5.50
e) Maintenance Men (1 -0-1 ) 4.50
f) Truck Drivers (2-2-0) 5.50
g) Fill Operators (1-1-0) 6.50
30 percent Cost/Benefits
Subtotal
Electricity
a) Hydraulic Pumps (4) @ 112 kw; (2) @ 19 kw;
(1 ) @ 2 kw
b) Conveyors (2) @ 18 kw
c) Lights
Use @ 50 percent capacity x
Cost@$.015Awhr
$
Fuel/Oilc
Maintenance Parts
Subtotal
Annual Total
Work Week
5 Day/Wk
12,740
25,480
25,480
32,340
17,640
43,120
25,480
182,280
54,684
236,964
487
36
40
563
1,715
965,545
x .015
14,483
16,000
101,000
131,483
(368,447)
368,000
Costs ($)
6 Day/Wk
12,740
30,576
30,576
38,808
21,168
51,744
30,576
216,188
64,856
281,044
563 (kw)
2,058 (hrs)
1,158,654 (kwhr)
x .015
17,380
19,200
121,000
157,580
(438,624)
439,000
Assumes 49 weeks per year, 14 production hrs per day, and 8 hrs per shift.
Numbers in parentheses refer to number of employees required for first, second and
maintenance shifts, respectively.
cAssumes 35,2km(22-mile) round-trip distance to balefill.
107
-------
Activities On
Solid Waste
Cars
0. Unloading Into Pit
Ferrous
1 . Sort
i
1 . Convey
i
2. Weigh
i
3. Bale
'
4. Eject
'
5. Load on
Truck
ReFects
1
Separate Trucking
and Disposal
Equipment Used
0. Collection Trucks
(Weight Station)
1 . Overhead Crane
2. Scale
3. Baler
4. Ejector
5. Transport Trucks
FIGURE 9-2
HIGH DENSITY BALER SYSTEM II
OPERATION SCHEMATIC
108
-------
operator controlled the waste loading and ran the overhead crane.
The construction costs, and the operating and maintenance costs for System II are given
in Tables 9-13 and 9-14, respectively. All cost assumptions are as previously stated
for System 1. The System II configuration reduced construction costs by $200,000, and
operating and maintenance costs by $21 ,000 due to the use of the crane and reduced
labor. It was assumed that maintenance time and cost savings would occur by use of
the travelling crane.
d. Tollemache Mill—System HI. The milling plant operations schematic is given in
Figure 9-3. The System III configuration used the Tollemache hammermill adapted to
shredding solid waste by rearrangement of the "hammers." Each mill can process
12.7 kkg (14 s tons) per hour. For comparison purposes, three parallel line Tollemache
mills were used for System III to provide a total plant capacity approximately equal to
the baling systems. The equipment was otherwise identical to the Madison plant J The
applicable System III milling plant operational conditions were as follows:
• Production rate - 38.1 kkg (42 s tons)
• Production schedule - 8 hours per shift, 2 shifts per day, 14 production hours per
day, 49 weeks per year.
Additional peripheral equipment at the milling plant consisted of a forklift to assist in
lifting heavy objects and segregating items not suitable for milling. Two belt conveyors
were required for each Tollemache mill, one to feed unmilled waste and one to remove
milled waste. A stationary compactor compressed and pushed the milled waste into an
enclosed trailer van. The trailer van had a hydraulic ram to unload the milled waste
at the landfill.
The transport system consisted of four truck tractors and trailer vans. Landfill activities
and equipment consisted of the following:
• Unloading transport trucks using the trailer hydraulic pusher.
^
• Spreading and compacting the milled waste using two steel-wheel loaders. The
milled waste can be placed in the landfill without, or with less, covering of soil,
thus reducing the need for excavating and placing cover soil. Landfill operating
hours and shifts correspond to the milling plant operation.
Construction costs for the milling System III are itemized in Table 9-15 and operating
and maintenance costs in Table 9-16. Labor classifications, requirements and hourly
rates are included on Table 9-16. Construction costs for the mill, conveyors and
compactor were based on projected data in the Madison final report. Three processing
lines (mills) were costed for installation in one building. Mobile equipment, building
1 Ibid.
109
-------
TABLE 9-13
HIGH DENSITY BALING SYSTEM II - CONSTRUCTION COSTS
Item Cost($)Q'b
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Baler
Overhead Crane
Automatic Scales
Hydraulic Bale Loader
Supporting Equipment
a) Medium Wheel Loader
b) Fork lift
c) Miscellaneous „
Building (120 ft x 200 ft) @ $16/ft
Equipment Footings, Pits, & Crane Support
Pavement
Subtotal
Transport Trucks (4)
Articulated Fork lift
Wheel Loader
Balefill Building and Fuel Tanks
Site Improvements
Subtotal
Base Total
20 Percent
Engineering and Contingency
Total
676,200
55,000
40,000
25,000
25,000
10,000
25,000
384,000
160,000
50,000
1,450,200
100,000
10,000
45,000
21,000
,0
176,000
1,626,200
325^240
(1,951,440)
1,950,000
Based on 1.9 minutes per bale cycle time and 1,320 kg/bale (2,900 Ibs/bale) weight;
also assumes 41 .5 kkg/hr (45.7 ton/hour) operating capacity.
Based on cost at Cobb County, Georgia, in 1973. Source for most cost data was a
personal communication from the Harris Economy Group of American Hoist and Derrick
Company; the remaining cost data were estimated for the Cobb County plant.
no
-------
TABLE 9-14
HIGH-DENSITY BALING SYSTEM II-OPERATING AND MAINTENANCE COSTS0
Work Week Basis, Cost ($)
Item
1 . Labor (8-hour shifts) Rate ($/hr)
a) Supervisor , 6.50
b) Control Tower Operators (1-1-0) 6.50
c) Mechanics (1-1-1) 5.50
d) Maintenance Man (1-1-1) 4.50
e) Truck Drivers (2-2-0) 5.50
f) Fill Operators (1-1-0) 6.50
30 percent Cost/Benefits
Subtotal
2. Electricity
a) Hydraulic Pumps (4) @ 1 12 kw; (2) @ 19 kw;
(l)@2kw
b) Overhead Crane ~j 36 kw
c) Lights0
Use @ 50 percent capacity
Cost@$0.15/kwhr
3. Fuel/Oil °
4. Maintenance Parts
Subtotal
Annual Total
5 Day/Wk
12,740
25,480
32,340
26,460
43,120
25,480
165,620
49,686
215,306
487
36
40
~56T
x 1,715
965,545
x .015
14,483
16,000
101,000
131^,483
(346,789)
347,000
6 Day/Wk
12,740
30,576
38,808
31,752
51,744
30,576
196,196
58,858
255,054
563 (kw)
x 2,058 (hrs)
l,158,654(kwhr)
x .015
17,380
19,200
121,000
157^580
(412,634)
413,000
Assumes 49 weeks/year, 14 production hrs/day, and 8 hrs/shift.
b
Numbers in parentheses refer to number of employees required for first, second,
and maintenance shifts, respectively.
Assumes 35.2 km (22-mile) round-trip distance to balefill.
Ill
-------
Activities On
Solid Waste
ODump on
Floor
( Wait )
1. Sort/Load
i
2. Convey
3. Shred
4. Convey
5. Bin Storage
6. Charge/
Compact
7. In to Truck
Ejects
Storage/
Load
Rejects
Equipment Used
O. Collection Trucks
1 . Wheel Loader
2. Belt Conveyor
3. Shredder
4. Belt Conveyor
5. Compactor Storage Bin
6. Stationary Compactor
7. Transport Truck
FIGURE 9-3
MILL SYSTEM
OPERATION SCHEMATIC
112
-------
TABLE 9-15 a b
MILL SYSTEM-CONSTRUCTION COSTS '
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Item
Tollemache Mills (3) with Conveyors
Compactors (2)
Wheel Loaders (2)°
Forkliftc
Miscellaneous «
Building (120 ft x 240 ft) @ $16/ft
Equipment Supports and Pits
Pavingc
Subtotal
Transport Trucks with Compactors (4)
Steel-wheel Loaders (2)c
Millfill Building and Fuel Tanks
Site Improvements
Subtotal
Cost ($)
445,000
47,000
90,000
10,000
25,000
460,000
35,000
50,000
1,162,000
136,000
90,000
21,000
0
247,000
Base Total l,409,00t)
20 percent Architecture,
Engineering, and Contingency 281,800
(1,690,800)
Total 1,690,000
QBased on 12.7 kkg/hr (14 s ton/hr) at Madison, Wisconsin, times three mills.
Assumes 38.1 kkg/hr (42 s ton/hr) operating capacity.
Source: Reinhardt, J. J., and Ham, R. K. Final Report on a Demonstration
Project at Madison,Wisconsin to Investigate Milling of Solid Wastes. Volume I:
1966-1972. E.P.A. Office of Solid Waste Management Programs. March 1973.
pp.104-122.
Based on cost at Cobb County, Georgia, in 1973.
113
-------
TABLE 9- 16
MILL SYSTEM-OPERATING AND MAINTENANCE COSTSC
Work Week Basis, Cost ($)
Hem
1 . Labor (8-hour shifts) Rate ($/hr)
a) Supervisor 6.50
b) Mill Operators (2-2-0)C 5.50
c) Loader Operators (1-1-0) 6.50
d) Mechanics (1-1-1) 5.50
e) Maintenance Men (1-1-1) 4.50
f) Truck Drivers (2-2-0) 5.50
g) Fill Operators (1-1-0) 6.50
30 percent Cost/Benefits
Subtotal
2. Electricity
a) Mills (3) @ 149 kw
b) Conveyors (6)@5.5 kw
c) Compactors (2) @ 20 kw
d) Lights
Use @ 50 percent capacity
Cost@$.015/kwhr
3. Fuel/Oil
4. Maintenance Parts
a) Mills
b) Other
Subtotal
Annual Total
5 Day/Wk
12,740
43,120
25,480
32,340
26,460
43,120
25,480
208,740
62,622
271,362
447
33
40
40
^60
x 1,715
960,000
x .015
14,406
16,000
53,040
45,000
128^446
(399,808)
400,000
6 Day/Wk
12,740
51,744
30,576
38,808
31,752
51,744
30,576
247,940
74,382
322,322
560 (kw)
x2,058(hrs)
l,152,480(kwhr)
x .015
17,287
19,200
63,640
54,000
154J27
(476,449)
476,000
Assumes 49 weeks/year, 14 production hrs/day, and 8 hrs/shift.
Most data modified from St. Paul baling plant annual operating costs for two
five-day shifts. Costs for Items 2 and 4 (a) obtained from Reinhardt and Ham,
op. cit., pp 104-122.
Numbers in parentheses refer to number of employees required for first, second
and maintenance shifts, respectively.
114
-------
and site construction improvement costs were based on the current 1973 Cobb County,
Georgia and updated 1973 construction costs for the other locations. Operating and
maintenance for mobile equipment was costed in an identical manner to the baling
Systems 1 and II, except for the truck trailer vans. Equipment maintenance costs and
electrical power consumption for stationary equipment were derived from the Madison
report. Costs for land were excluded for all the systems.
e. Combined Milling and Low-Pressure Baling—System IV. A schematic depicting the
milling-baling plant operations is given in Figure 9-4. The plant configuration was
identical to the demonstration plant operated by the City of San Diego.' A Williams
No. 475 shredder and American Baler Company Model 12475 baler were used as the
basis for this process confiquration. A materials feed arrangement was used that included
a vertical bucket-type elevator conveyor; it caused operating problems from waste materials
jamming the bucket conveyor mechanism. One milling-baling plant had a capacity of
19.5 kkg (21.5 s tons) per hour based on San Diego operating data. The milling-baling
plant operational conditions were as follows:
• Production rate - 39 kkg (43 s tons) per hour (for two plant process lines).
• Production schedule - 8 hours per shift, 2 shifts per day, 14 production hours
per day, 49 weeks per year.
Other plant equipment consisted of a forklift which was used to move heavy items and
equipment.
The transport system included four tractor-trailer units identical to the high-density
baling Systems I and II bale transport trucks.
Landfill activities and equipment were also identical to Systems I and II, e.g., trucks
were de-rigged, bales were unloaded and placed in the fill by a forklift, and 15.2 cm
(6 inches) of daily cover soil was applied by a loader.
Construction, and operating and maintenance costs (including labor breakdowns) are
given in Tables 9-17 and 9-18, respectively. The San Diego plant operated on a
pilot-scale basis, thus costs were modified for full-scale operation. Two processing
lines are costed for installation in one building. The operating and maintenance cost
summary is considered to be the least accurate due to the experimental type of plant
operated in San Diego.
4. System Cost Comparison. The basic plant production equipment and production rates
for the four systems are summarized in Table 9-19. The plant production rates were
basically equal.
Feasibility of Baling Municipal Refuse. Public Works Department, City of San Diego,
California, October 1968; and Baling Municipal Solid Waste; Technical Evaluation.
Public Works Department, City of San Diego, June 1973.
115
-------
Activities on
Solid Waste
O.Dump on Floor
Rejects
Spillage
10. Load on Truck
10. Storage/
Load
jquipment Used
0. Collection Truck
1 . Wheel Loader
2. Pan Conveyor
3. Shredder
4. Spillage Belt Conveyor
5. Doffer Roller
6. Elevator
7. Baler
8. Baler
9. Roller Conveyors
10. Transport Truck
FIGURE 9-4
MILLING, BALING SYSTEM
OPERATION SCHEMATIC
116
-------
TABLE 9-17
COMBINED MILLING, BALING SYSTEM - CONSTRUCTION COSTS0'b
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Item
American Baler
Shredder
Pan Conveyor
Slider Bed Conveyor
Bucket Elevator
Live Rollon Conveyor
Scale-Section Conveyor
Gravity Conveyor
Air Compressor
Times 2 Plants
Wheel Loaders0 (2)
Forkliftc
Miscellaneous1-
Building (120 ft x 290 ft) @ $16/ft2
Equipment Footings
Paving
Subtotal
Transport Trucks (4)
Articulated Forkliftc
Wheel Loader0
Balefill Building and Fuel Tanks0
Site Improvements
Subtotal
Base Total
20 Percent Architecture, Engineering, and
Contingency
Total
Cost ($)
52,500
86,300
40,600
8,000
21,600
3,000
6,200
1,800
600
220,600
441 ,200
90,000
10,000
25,000
556,800
50,000
50,000
1,223,000
100,000
10,000
45,000
21,000
0
176,000
1,339,000
267,800
(1,606,800)
1,607,000
QBased on 19.5 kkg/hr (21 .5 s ton/hr) in San Diego. Assumes 39 kkg/W (43 s ton/W)
operating capacity.
"Based on 1973 cost descriptions of San Diego Plant. cBased on cost at Cobb County,
Georgia, in 1973. Source: Personal communication, Environmental Protection Agency,
Office of Solid Waste Management Programs, 1973.
117
-------
TABLE 9-18
COMBINED MILLING, BALING SYSTEM - OPERATING AND MAINTENANCE COSTSa'b
Item
1 . Labor Rate ($/hr)
a) Supervisor 6.50
b) Mill Operators (1-1-0) 5.50
c) Baler Operators (2-2-0) 5.50
d) Loader Operators (1 -1 -0) 6.50
e) Mechanics (1-1-1) 5.50
f) Maintenance Men (1-0-1) 4.50
g) Truck Drivers (2-2-0) 5.50
h) Fill Operators (1-1-0) 6.50
30 Percent Cost/Benefits
Subtotal
2. Electricity
a) Mills (2)@373kw
b) Balers (2) @ 112 kw
c) Conveyors
d) Lighfc
Use @ 50 Percent Capacity
Cost@$.015Awhr
3. Fuel/Oil
4. Maintenance Parts
a) Mills0
b) Baler
c) Other
Subtotal
Annual Total
Assumes 49 hrs/year, 14 hrs production/day, and
Work Week Bases
5-Day/Wk
12,740
21,560
43,120
25,480
32,340
17,640
43,120
25,480
221,480
66,444
287,924
746
224
50
40
1,060
x 1,715
1,817,900
x .015
27,268
16,000
38,000
45,000
35,000
161,268
449,192
8 hrs/shift.
Most data modified from St. Paul annual operating costs for two five-day
for item 2 (d) obtained from Reinhardt and Ham,
op.cit., pp!04-122.
, Cost($)
6-Day/Wk
12,740
25,872
51,744
30,576
38,808
21,168
51 ,744
30,576
263,228
78,968
342,296
1,060 (kw)
x 2,058 (kw)
2,181,480 (kwhr)
x .015
32,722
19,200
45,600
54,000
42,000
193,522
535,818
shifts. Costs
Two thirds Tollemache milling value plus $3,000.
118
-------
1
CO
LU
ON 5?
t- <
ON <
J =>
EQ
2§
1—
CO
>-
CO
^
E
0)
1
D ">
a> ro
c c
a —
H
ii
(1)
t
CO
i
^
£
a>
^
CO
D)
C
is
^
c
0)
Is
CO
O)
c
is
E
0)
±:
1 rr\
American, con
tinuous, low-
pressure, tyinc
balers
£
Tollemache
mills
S
£r£
'£ "i
-o !r-
I3 E
'C 0 ON
£ -c '
I °-
0
0)
O)
ii 0)
-21
"•NT
x>
5 'i
m ON
-S •
IJ
45
~
•- J>
•M
D1
u
Z^-
o
4~
O
-D *•
2 £
Q_ C
u. §.
.2- '5
O IT
^LU
1
4-
(U J2
!» ^|2
15 E
•»s
s^
s
« X
Belt conveyor
approximatel
3 foot wide
S
(U
o
u.
u
-D
O
(U
U_
a)
c5
S
0)
-D
'i
"o
o
lil
CO
L.
o
X
0
>
o
u
o
CO
CS
.- N^
•) Belt conveyors
approximatel;
3 foot wide
;£.
t C
c S "D
c 0 o
15 u J
<0 "u i-
o 2|
i_ 4- U
° _x °
o^03 a
CN|,
^
U
4—
L.
O
(U
'aT i
0) -D
U
C3,
t_
0)
"D
D
O
^:
u
L.
4—
1
O
u
.9L
'(U
0)
^
CQ
^
J2
§.
(/)
|
-o
•?
^
UL
^
— jn
E 8.
Large wheel
loader
Enclosed, co
pactor trans
o ^
t
§.
t/i
C
s
•D
(L)
_Q
4-
o
u_
^
55 42
M» ^*
8 8-
c
T O
0) >-
M—
15
o
u.
(U
C3)
5
^^,
tl|i"
32
£
a>
D5
3
•^,
u.
_c
1_
(U
-o
8
"a>
0)
JC
S
l_
rt\
u/
-D
J
~Q)
0)
-C
^^^
U-
a>
f
o-
*\
c
O
vi
s.
i
_*
^
ON
CO
ii
-* o
-iC "
r— ">
' CN
^^
L
^1i
^ o S
D) 4-
2 «• ^
~c ^u
10 ^ NO
js^:
-st -2^ co
^^ i^^
1_
•—
<
c
o
in
r>.
•
in
•5
^^
O
^-5
^^
IO NO
• •
^ CO
(U
4-
s
c
£
-1-
o
i
O-
•
in
4-
*E
3
4«
(U
^Q.
"D
S"
14-
o
0)
_Q
£
D
C
t/>
(U
^_
O
u
^
c
o
119
-------
Summaries of capital and total system costs are given in Tables 9-20 arid 9-21, respec-
tively. Table 9-21 gives costs for five-day and six-day operating work week schedules.
A summary of capital costs is given in Table 9-20. As can be seen, the largest capital
expenditure was for the Harris high-density baler System I. In accordance with the EPA
contract requirements a 10-year amortization period was used.
A total cost summary comparison is given in Table 9-21 . As can be seen, the Harris
high-density baling System II was the least costly of,the four system configurations at
$4.23 per kkg ($3.82 per s ton). System II achieved a $0.32 per kkg ($0.29 per s ton)
savings in cost over the existing St. Paul baling plant transport and landfill operation.
The costs given in Table 9-21 are significantly lower than recorded during demonstration
operation. This resulted from the following factors:
• The demonstration plants incurred extra costs due to research and development
conducted during operation to refine the systems.
• Reduced labor was used for the four system cost estimates.
• Adjustments in labor hourly rates to standard rates.
The existing St. Paul baling plant, for example, was actually operating at a cost of
$6.24 per kkg ($6.88 per ton) in late 1973. The Tollemache mill plant in Madison op-
erated at a cost of $3.97 per kkg ($4.38 per ton) in early 1972. Both plants operated
two shifts daily. Costs at the combined milling-baling San Diego plant were $8.77 per
kkg ($9.67 per ton) in March 1973 on a 6-hour per day operating schedule. The high
San Diego costs were due to the San Diego plant being put together in steps requiring
equipment modifications which resulted in inefficient plant layout and equipment operation,
C. Comparison of Processed Solid Waste Impacts on the Landfill and the Environment.
1. Density. One benefit associated with the processing system is that is increases the
density and the rate of settlement for solid waste in the landfill. The unprocessed and
processed landfill densities, in terms of actual solid waste and effective fn-place
density (includes effect of cover soil), are given in Table 9-22. The Madison unprocessed
waste densities were used because the waste composition and compaction methods were
similar to the milled waste and thus provided a more valid comparison. The density of
this unprocessed waste was on the high end of unprocessed landfill densities normally
achieved, which were about 475 kg (800 Ib) per cu yd. Since moisture contents vary by
location, the most valid comparison of solid waste densities achieved between each of the
four systems and unprocessed waste should have been based on actual dry weight. This
dry weight was often unavailable. The System IV combined mi I led-low-pressure baled
waste had the highest wet or total weight density. The derivation of the noted density
values given in the San Diego project report was based on the total landfill volume plus
soil excavation and less soil cover quantities. Final volumes were determined by sur-
veying, but no indication was given of how soil quantities were measured.
120
-------
1
II
II
X.
20
SUMMARY
O)
c
I
= >
2 E
^^ &_
T3 «
g X
2 ^
E
o
U
_
—
E
(U
"x
CO
ii
'i
I Z *
<* £ .X
uj 2
-1 h=
1=0
-------
o
Z
_j
ul
Q
Z
Q
7
J~*
^f
O
z
> H1
_ a; a;
CM < O
ON 5 7.
• 1 1 ^j ^
CQ | — | —
•< oo
^j -^
z~
oo
to
LU
y
o
rv*
a_
a;*
LU
u_
OO
Z
2
i—
>
E
o NO
X
"U OO
If
O co
U
.5
flj NO
•fe
X
00
D)
•E 'o
"o
CQ
__
O O
IX CM to CO CO
CM CO IX •* 00
•* O IO •— O
q.
.2
.1-
u
1 »°«|°S
t— y y ^^ _-|._
— *- x *• x «
g 0> >> 0> £«-=
2 ^ Q ^ Q eS
c
•^
Ri mQ
CM iolX
O O«00
CM •<* IX
CM "* ^O
r- NO-
CM "* ^
- g
C^ ^4" SO
CO „-
CM ^ *°
00 IX IO
K'vf* ^V I
^^ CN
CN v j ^o
^O csin
^? |^
co ^^ ix
vO CO •*
o ^o rx
CO CO vO
0)
o
c
• • w
*^r c
o •=
8 |
^ri' f± ®O
'^ O)
*; 0 c
O N "*I
U '£ E —
— o O O
CM 00 00 CM W>
. ._ ^^ ._ ^_
^ * ^ ' *
O 00 •— IX CM
r— rx oo CM "O
1 „- ._ ^^
TT «7 n «J U)
IX IO CM CN CM
"* "O "^" *O NO
^ J2> o> £ o
^ *. "t r " 4>
^ a, x a> x
o > ~o ? TJ J5
( J 1_ U. I- l_ L-
(U Q) (1) Q) Q)
*: D. Q. D. Q. Q,
C
^
.
C
"S
0)
Q.
0
C
^
* 0)
TJ
0 u_
0 °
II -§
« s
S> £
^ §
C> y
H a5
« X *;
E 0 g
*•!-*.
x o> -c
co Q- O?
u- u) *m
O ^ >
^ -C 'Q
•4- C 4-
(U O C
"D *"~ d)
i- U P
12 •§ 8.
— Q. "0
ON Tj- IX
— CM
•U ^
~n c
^ -S TJ
-------
0
•jr- oo
o ...
CO
1 1 1
CN —
CN t
1 CO
O Z
UJ LJJ
_J Q
5 ^
< H-
l— co
1
s
N§ Q
E -
3 ?
^ 3
V
»
.. >
u> •—
» 0
•a •£
t/> u-
C UJ
/1\
1
s~ £T
$A ^§
^ <0 CO < !P> ^
•^ **/ ^ * ^ !*) ^—
z Sgo z «^-
Jo §"
CM 10 SQ
«n - osT
KT ^o
^ CN U"> ON
. A oo ^ 10 fv
< S K S o —
z " ^ z - —
^_^
si !i if ??
Sg ^22 §^ g^
C CN<0 OO ^C^ ^"^
O I
•
f
1
fl)
Q
0)
1
£ °.
2 1
o ^
oo >
-c
—
Ls
I W"
u.
£
•fr
• •1
u
a
C
i
•i
<
<
JQ
•
^
>.
Q
1
2
a
i J
- >
3 >
t i
t. >
i
<
_!
j
•«
? o „!
00 JO- SK ^°
?? ^o S'o ^^
AA Ag Ao g-
^ ^ S ^ «o 0 oo
1 tQS »I §1 §1
O
— 0~
gf 2 of g^
?? "o tA 5°.
lg Si §1 §-
1 ^^ W
I
\
<0 T>
— o =u >«»
J3~!R ~" -2 — o — c
•B § E .S E § § |%
ES ajfc « = £ i —
og- ^^ ££ ^i3^
I
8
"5
o
•i—
^
"8j2
M- •—
0 tc
« "O
o S
a> — .
* a
0) J)
CO «
-o ^
•^ -_
-* c
o —
c £
— a)
11
!S O-
o£
•0 M_
TJ 0
S±
*f
~ ^
— co
IZ. ^:
^ E
g>|
.— <-4-
" 1_
0 O
*i i '
.•t = -Q
2«= i
-s-s §
•n "S; ® iL
« 3 ^ _Q
U/ B"^ ^^ i. 1 /
•fi °- X <-
HP c~ £
§.§ -s 5
E ° '5>
8| g 8
0 <3> § '5 1n
O .E *• K O
•T™ ^« C tw ^?"
Q-— O S ^
H > ° I"0
DO g 8 —
£- £ ^
m ui O
S -I 'i * i
«£ .2 E o ^
£•€ -E 18
x > a> co
1 S 8 I •
0 ,fc Q. *- .
— *« "*~ */*
^ c - s
— o • "O /
0 .2 00 o <
D *. CO —
tj " 4_ o ,
£
u
6
V
E
D
"o
>
+
(U
•fc
a
^
TJ
"5
oo
5
>
1
X
z
0)
D
•
J_.
2 O *2 C u-
< Q. <. — LU
o -Q °
Z ^ co to VJ
123
-------
0)
o
O)
0)
(D
I?
D
Q.
£
o
to
O
O
to
<+-
O
X
U)
o
0)
V
-Q
0
CQ
U
C
0
o
c
o
o
JU
o
-Q
0)
8
o
5:1
c
CN
CN
I
Os
CQ
<
8[°
s-
t/>
0)
U
srs
•2|
•5ic
l'°
o
I,.
-c _a
D
O «-
-Q
C
(U «J
^ O
(D U
O
LJJ
D
U
U
0)
c
0)
i-l
'i-i
LU,
1
"5
CQ
81
ii
(U
0) 0)
Qi CQ
fs
ij
2? ^
D O
8«*-
0) O
E <»
C Q)
11
*:.*
OO CO
c i
(U
J
o
.. Os
0) —
s»
Q)
124
-------
On a dry weight effective landfill density basis, Systems I and 11 high-density baling
averaged the highest density.
Density in a bale landfill can be increased by improving the placement of bales or pro-
ducing more regular bales (such as San Diego) to eliminate spaces between bales which
reduce the in-situ density. The extensive compaction by equipment of the landfilled
milled solid waste may have contributed to the reported high density. Heavy compaction
in a landfill of raw refuse will also give excellent densification. However, there are
improvements in average effective dry weight densities of mill processed over unprocessed
solid waste. The increase in processed over unprocessed landfill densification is pre-
sented as follows: Systems I and II, high density baling - 60 percent; System III, milled -
4 percent; and System IV, milled/baled - 53 percent.
2. Landfill Operations. Baled solid waste required no spreading, and less transport
volume and landfill handling than either unprocessed or milled waste. The bales were
placed onto and from transport trucks and located directly into the working face of the
fill. Milled waste required compaction, and the degree of compaction will affect the
in-situ density. Since compaction is not required for bale landfills, less equipment
(no compactors) is required.
The Madison project final report included the assessment that daily cover soil was not
needed for milled solid waste. Operation of a sanitary landfill would by definition
require daily soil covering. Thus, the cover soil requirements for milled waste would
be similar to unprocessed waste less the savings due to increased density. It should be
noted that bale working faces are vertical and 3 m (10 ft) or more in minimum height;
thus only the top horizontal surface is covered daily. Unprocessed and milled waste
are normally placed on a slope in 90 to 120 cm (3 to 4 ft) layers; therefore, soil must
be placed on both horizontal and sloped surfaces which must be covered with 15 cm
(6 in) of clean earth daily. Thus, baled waste should require less soil cover than com-
parable processing on a Ib per Ib basis.
Observations at the St. Paul bale landfill during wet weather indicated no impediment
of mobile equipment operations occurred during heavy rainfalls. Wheeled transport
trucks and landfill equipment were well supported by the solid bale surfaces, even when
the vehicle wheels sank through the 15 cm (6 in) cover soil. It was reported in the
Madison project that wheeled vehicles could travel satisfactorily on the milled waste
due to its compact, uniform surface. Wet weather travel was difficult to impossible in
unprocessed waste landfills based on typical observations.
3. Environmental Impact. Less wind-blown litter was observed at the St. Paul bale
landfill than at normal unprocessed waste landfills. Madison milled waste landfill litter
was also reported as less than for unprocessed waste, but litter fences were required at
Madison to catch plastic film, etc. In the case of the bales, the reduced surface area
of in-situ waste and the adherence of materials within the bales produced the low litter
level.
125
-------
The American Hoisf and Derrick Company stared that no fires had occurred at the
balefill during its two years of operation from 1971 to July 1973. During the twelve
month period between the first field survey of the bale landfill (July 1973) and the
end of the bale landfill monitoring (June 1974), no fires were reported or observed
in the bale landfill. During the same twelve month period, severe I fires were reported,
and one was observed by our staff at a private (Phoenix) landfill, located about one
mile from the bale landfill, that received normal unprocessed solid waste. The Phoenix
landfill received the same type of waste as the bale landfill, some of which was
delivered by St. Paul private collectors who did not want to pay the baling plant fee.
Although the twelve month period of record is relatively short, the similarity in solid
wastes and identical climate at the bale landfill and Phoenix landfill indicate the
possibility that the bales were a factor in reducing the incidence of fires.
The concentrations of various constituents found in the St. Paul bale test cell leachate
were generally less than or in the low end of the range of concentrations for leachate
from normal and shredded waste landfills (see Table 10-5). The relatively short period
of leachate monitoring may not represent long-term trends.
126
-------
SECTION 10
SIMULATION OF BALE SANITARY
LANDFILL IN A TEST CELL
A. Purpose.
Evaluation of the bale sanitary landfill under controlled conditions was conducted in a
test cell constructed at the American Solid Waste Systems divisionof American Hoist
and Derrick Company landfill. The test cell was constructed to permit monitoring and
sampling of gas composition, leachate quantity and quality, settlement, and tempera-
ture. The test cell construction commenced on August 2, 1973, and was completed on
October 5, 1973. The baseline monitoring began on September 27, 1973, and continued
until November 30, 1974.
B. Method of Study.
1. Site Location. The test cell was constructed at the edge of the American Hoist
bale landfill about 12 miles from the bale plant (see Figure D10, Vol. 2). The loca-
tion of the test cell at the bale landfill is shown in Figure Dl 1, Vol. 2. The area
under the test cell was filled with three layers of bales and covered with six to eight
inches of soil. Water drains away from the test cell to the north, east, and west over the
the edge of the fill area toward the Rock Island Railroad tracks. The cell is exposed
to wind and other normal weather conditions. Access to the cell is via the landfill
access road onto the filled area and up a ramp on the south side of the cell (see Figure
Dll, Vol. 2).
2. Test Cell Design and Construction. The test cell design is shown in Figure 10-1.
The inside dimensions of the test cell were 30 by 33 meters in area and 5 meters in
height. The cell walls were constructed of solid waste bales to more closely simulate
the normal bale landfill environment. The cell height of three bales is the same as the
balefill height. The leachate collection sump was located 3 feet outside of the north-
west corner of the north cell wall to prevent damage during placement of bales in the
cell. The sump was installed after filling the cell.
Test cell construction consisted of several steps (see Photograph 10-1):
a. Grading. Initial grading of the test cell area provided a level base for the
cell walls and bottom.
b. Cell Walls. Three walls were built with bales as shown in Figure 10-2: the
east, west, and south walls. The north side was left open to provide access for the
forklift to place bales in the cell.
c. Cell Bottom. The bottom of the cell was filled with clean sandy clay soil of
15 to 46 cm thickness, graded with a one percent slope downward toward the north-
west corner for leachate collection. Three trenches were cut in the cell bottom con-
verging on the leachate sump. The trenches were cut into the cell bottom with a dozer
127
-------
Outer wall
Test cell
inner wall
Jrenches containing 10 cm (4")
f I. D. pipe
J
^> Leachate sump —
f*— Detail
Bales/ below
see Fig. 10-2
for detail
Top View
5 cm (2") I. D. Vertical
Sump Riser
___
28ari (11")
75 mm (3") I.D.
PVC pipe
Vertical
access riser
leachate drain pipe
Grade
Drain
valve
5m (151) Cell bottom
! (polyethylene)
10 cm (4») inlets
2.5 cm (1") outlet
Front Section Detail of Leachate Sump A-ea
FIGURE 10-1
TEST CELL DESIGN
128
-------
b. Polyethylene membrane on cell walls
a. Cell walls in place
c . Protective layer of roofing paper
on polyethylene membrane
d. Polyethylene membrane on cell bottom
showing leachate drain pipe trenches
PHOTOGRAPH 10-1
TEST CELL CONSTRUCTION
129
-------
30m
Cross-section
below
1
33 m
Top View
UUICl
'//=///•=:;/
\
/=y//-i-v/>'E" 'h
1 .
}••• Roofing paper
14kg(30lb)
M Polyethylene
T 380 //m (15 mil)
1 4 kg (30 Ib)
: '.'»- 1_1_;^" •"•''•?••"'••'•-•- ."'" •"-"-'
Sand
y//^/>^777^
Section View
Not to Scale
FIGURE 10-2
TEST CELL WALL
CONFIGURATION
130
-------
blade beginning at grade and reaching a constant depth of 15 cm (six inches) below grade
to protect the leachate drain pipe. The trenches were about 40 cm wide and had an
additional one percent slope toward the northwest corner of the cell. The bottom of the
cell was cleaned of loose rock and other items that might possibly puncture the poly-
ethylene membrane by hand-raking and carrying off the detritus with a "bobcat" loader.
d. Polyethylene Membrane Installation. A layer of 30-lb roofing felt was hung
vertically along the three walls by nailing into the top bales. The 1 -m wide felt was
cut into 4 m lengths and overlapped to protect the polyethylene. Two layers of 15-mil
polyethylene, 4.4 m wide and 31 m long were suspended along each wall by nailing slats
to the membrane edge and driving 10 cm nails into the top bales in front of the slats to
support them. A second layer of roofing felt was then hung from the walls over the
membrane. Scrap roofing felt strips were placed in the trenches to protect the membrane.
The bottom membranes were placed using 2 layers of 15 mil, 4.4 m by 34 m polyethylene
strips overlapped 0.3 to 0.5 m. All seams were sealed with a 15 cm wide layer of
"Henry" brand latex sealant and then taped with 10 cm wide waterproof industrial tape.
The fourth wall was completed after the cell was filled using the same technique as for
the first three walls.
e. Leachate Collection System. A 10 cm diameter flexible, perforated plastic
pipe was laid in each of the three trenches and subsequently connected to three 10 cm
PVC pipes which were connected to the leachate sump (see Photograph 10-2a). The
trenches were filled with 1 cm smooth gravel to protect the perforated pipe. A 60 cm
layer of clean, washed sand was placed on the polyethylene membrane and graded level
for placing bales.
f. Cell Filling. The cell was filled with eight days' production of bales using
the existing forklift placement method. The total number of bales placed in the test
cell was 1,542, which weighed a total of 1.98 million kg (2,179 tons). Probes for
monitoring temperature, settlement and gas (Photograph 10-2b) were placed at five
stations during the placement of bales. The test cell probe locations are shown in
the top view of Figure 10-3.
g. Completion of the Cell. The final membrane section and roofing felt protec-
tion was placed on the exposed north wall of the bales in the test cell. The leachate
collection sump, a 38 long by 30 wide by 20 deep cm box with lid, was placed about
1 m outside the wall in an excavation. The three perforated plastic leachate collection
pipes were epoxy-cemented to three 10 cm PVC pipe extensions, and then the PVC pipes
were epoxy-cemented to three pipe collar openings in the sump box. The polyethylene
membrane was sealed around the three leachate collector pipes at their Juncture with
the extensions to the sump box using the latex adhesive and industrial tape previously
described. A 5 cm 1. D. PVC pipe was fitted to the sump box top and extended
vertically a height of 4 m to protrude 1 m above the top surface of the bales. This
access pipe was provided as a backup to allow the sump to be pumped empty. A 2.5 cm
I. D. PVC pipe was installed in a ditch extending from the sump north to the edge of
the fill at a two degree slope to drain leachate from the sump. A PVC cap was placed
on the vertical user access pipe, and a PVC ball valve was placed on the end of the
131
-------
a. Leochote collection sump and drain pipes b. Monitoring probes in filled
cell
c. View of filled cell
d. Completed cell with soil cover and
access
ramp
PHOTOGRAPH 10-2
TEST CELL INSTALLATIONS
132
-------
Test
Cell
1
£
^
]
M
Ste
4
L_
St
^ 12m
a4
-^ — 6 m ^JSta
1
a 1
i
^
Sta 3
5
E
o
Sta 2
N
Top View
No Sccile
FIGURE 10-3
TEST CELL PROBE LOCATIONS
133
-------
leachate drain pipe. A 7.6 cm I. D. cast- iron sewer pipe was placed around fhe lea-
chate drain pipe for protection from vehicles, and the pipe was covered with 20 cm
of soil. The fourth (north) cell bale wall was placed. An access ramp was constructed
and a 15 to 60 cm cover soil layer was placed on the cell, the varying
depth resulting from variations in bale size. The walls were covered with soil for
aesthetic purposes, and a 30 cm soil berm was built along the outside edge of the test
cell membrane wall. The berm retained water from rain or snow falling on the cell.
The purpose of the berm was to allow direct correlation between precipitation data
and the amount of water that fell and remained on the cell. This eliminated the need
to estimate any runoff. The completed test cell is shown in Photograph 10-3. Cell
construction was completed October 3, 1973.
3. Test Cell Probe Configurations. Five test cell monitoring stations were located as
shown in Figure 10-3. A rain gauge was located near Station 5. The center station
contained only settlement plates and risers (same as Item C below); each of the other
four stations contained all of the probes listed below. The probes in Items a, b, and
c were installed during test cell construction and the lysimeters of Item d at a later time.
a. Gas Probes. Two 1.1 cm I.D. polyethylene tubes at 0.9 m and 2.4 m depths
were perforated at the bottom and used for gas monitoring (see Figure 10-4).
b. Temperature Probes. Three capped 2.5 cm I.D. PVC tubes at depths of 0.6,
1.5, and 2.4 meters were used for housing thermistors. An additional 2.5 cm I.D.
PVC tube at 2.4 m was used for backup temperature monitoring by thermometers.
c. Settlement. Three 0.7 x 0.7 meter metal settlement plates were located be-
low the bottom bale, between the middle and bottom bales, and between the top and
middle bales. Vertical risers of 2 cm I.D. galvanized cast iron pipe were connected
to each plate and rose about 1 m above the test cell cover- soil. Concrete block surface
benchmarks were placed on top of the top bales at each of the five settlement probes.
d. Lysimeters. In addition to the station probes, 16 lysimeters (soil leachate
sampling devices) were installed in the test cell during the period from February 26
through March 10, 1974. The lysimeters were placed at four depths, 0.3, 0.8 or 0.9,
1.4 or 1.5, and 2.3 meters at each of Stations 1 through 4. Variations in depth of
about 1 meter (0.8 and 0.9, 1.4 and 1.5) occurred at several probes due to restrictions
encountered during placement. One lysimeter was inserted to a depth of 3.4 meters.
4. Core Holes. Five holes, 15 cm in diameter, were augered on November 19,
1974, to sample solid waste for biodegradation, moisture and organic content, and
temperature: two at Stations 1 and 3, one in the most recently completed area (filled
June 1974^and two in an older landfill area (filled mid-1972).
5. Test Cell Monitoring. Table 10-1 outlines the test cell monitoring schedule.
Photograph 10-2 illustrates monitoring devices. Sampling and monitoring procedures
and data forms are given in Appendix E. Laboratory analytical methods are given in
Table 10-2. A brief summary of the methods is given below. All analyses were per-
formed in the Ralph Stone and Company laboratory in Los Angeles, California. Samples
were shipped to Los Angeles by air on the day they were taken and analyzed the next day.
134
-------
" ' '
PHOTOGRAPH 10-3
COMPLETED TEST CELL
135
-------
PVC Screw
Cap
Gas Probe
PVC Valve
Gas Probe
See detail below
Side View
0.3 cm (1/8") I. D. Holes
I.I cm @/8")I.D.
Polyethylene
tubing
O „ O O O O
Porous
Polyurethane Foam
Gas Probe Detail
Not to scale.
136
-------
a. Gas sampling, temperature and settlement'
probes, and leachate sump access in place
-
b. Sampling station
d. Rain gauge
c. Portable electric generator
e. Gas sampling apparatus
PHOTOGRAPH 10-4
TEST CELL MONITORING
137
-------
TABLE 10-1
BALE TEST CELL MONITORING SCHEDULE
Monitoring Parameter
Frequency
Constituent
or Units
Gas
Temperature
Settlement
Leachate from
sump
Weekly
Daily during the
first two weeks,
weekly thereafter.
Weekly
Weekly
Weekly
Annually
Lysimeter Moisture Weekly
Weekly
Core Sampling Once
(11/19/74)
Samples analyzed for: CH,, CO9 N ,
02/ H2S, CO. 4 ^ *
Measured in degrees centigrade.
Feet
Quantity, liters.
Samples analyzed for: pH, totgj coliforms,
fecal coliform, BOD., CITSO", sulfides,
TDS, N03/ NH~, Qrg- N.
Composite of weekly samples analyzed for.-
Al, As, Ba, Ca, Cd, Cr, Cu, F~, Fe, Hg,
Mg, Mn, Ni, Pb, Zn.
Quantity, liters.
Samples analyzed for; pH, total coliforms,
fecal coliforms, BOD., Cl ~ SOT, S
sulfides, TDS, NO~>JH3, Org-N.
Samples analyzed for organic content,
temperature, moisture content, decomposition.
138
-------
to
O
TABLE 10-2
ANALYTICAL METHO
>
o E §
- o o
LU o iS **•
i— o ;-; —
gl 3 -3
SI 1 1
-J CQ 1— U-
,— _. ^^ _^^
^ ^ Q^ o^ o^ £i rz
•OCOOCO-— § SS
•^co»oioix'
. <* . .
0.0-0.0-^0-, ^^;
• ••••• **
•D-O"O-O-O"TJ "OT3
IQ In J2 IQ la lo -°78
^o"
o
S
5 c
^ 0
0) •- O
o «
§c a)
L» *^ •.— p
•£ ° Q c 1
5 £ 0 .1 J
£-), 1— 0) *- O
-g 1 ! > 1 i
•£ ° ° •«••*: h( ^3
| '£ '£ ^ Z ^cs g .
s 2 E 1 • .° <.«= -1 §
8 1 1 1 i S ^| 1 1
8 § -§ 8 * | -CN^ * |
O.cQ^niulSx^OS
t/)
-o
"o c g
£ ™ w
(U -n U) n
0° ||l
£ ± .t: 9
g 8 Z Z
^ .2
o o Q t> •- cfl)
"n -fe E n O "D
2 £ -5^8) EE
Z^'o.^uO <^
•^
s
1—
to
(.^
o
_Y
8
CQ
o
c
<
^v
°
0s*
o
—
i/>
X
I
Gas-solid Chromatog
Z
UJ
? c
::
< r
-7 (^
< ^
%
< i
O (^
o
x
3^
K
CO
!N
i.
^J
c
vIC
« L
-o
>-
o
^
§£
4-
to K
tn
C
D
~O
O
"o
D
•°<
gel/molecular sieves
to
1 1 1
j
a.
S
<
to
LU
c£
0
u
^Q
Z
> -^
N
£
«. *v3
^s
1 Q
*0
» to
f
IO
•
,0,
**l^s
s,
V>
J
5 «
^ ™c
)x ^
• -D
O. *-
O
0) "?
t §
2, ft
. s
•*> if
a- fe
i^S
^S
^3
1 «
o a;
^ V
c ~
.2 "6
l£
^
VI
_0
"E
o
o>
"o
^0
t
c
0)
o
O
u
• w
g
*J
o>
6
139
-------
a. Gas Sampling. An illustration of the gas sampling apparatus appears in
Figure 10-5. A portable generator was used to operate the electric pump. A hand
sampling pump was used as a backup for times when snow or mud prohibited automobile
access to the test cell, or when the generator malfunctioned. Separate on-site testing
for hydrogen sulfide was conducted using a calibrated volume-flow hand pump and hLS
detectors manufactured by Mine Safety Appliances (MSA) Company. The H«S
concentrations were also checked on the laboratory gas chromatograph during gas
analyses.
Basically, the procedure consisted of evacuating a 250- or 500-ml sample bottle and
connecting it to the test cell gas sample probe as shown in Figure 10-5. Prior to
sampling, the probe valve was opened, the probe and evacuated bottle were purged by
running the vacuum pump for at least one minute so that about 2,500 ml of sample gas
passed through. The bottle was then pressurized by additional pumping with the down-
stream bottle valve closed, and the upstream valve was closed when about 10 psi of
pressure in the sample was read on the pump gauge.
b. Temperature. Two methods of temperature measurement were used. Stainless
steel thermistors and a telethermometer manufactured by Yellow Spring Instruments
Company were inserted in the 0.6, 1.5 and 2.4 meter deep probes for primary tempera-
ture measurement. Since problems had been encountered with instruments and thermis-
ters on previous landfill monitoring projects, a thermometer backup system was provided.
The backup system consisted of lowering a thermometer in a test tube filled with water
to the bottom of each temperature probe by means of a string and leaving it there for
about 15 minutes so that the water temperature stabilized to the test cell temperature.
The test tube-thermometer was then raised, and the temperature reading was taken
immediately.
c. Settlement. Twenty settlement monitoring points existed: three plates with
risers, and one concrete surface benchmark at each of five stations. Four permanent
benchmarks placed in strategic locations near the test cell were used as fixed reference
elevation points to check the test cell plate risers and benchmark elevations. Although
only one reference benchmark was needed, the extra benchmarks were installed in case
one was inadvertently destroyed. A surveyor's level, at a known elevation, was used to
read the test cell plate risers and concrete surface benchmark elevations on a surveyor's
rod. Since the test cell was constructed on an area previously filled with bales, the
relative change in elevations between the settlement risers beneath the three bale layers
and the surface benchmark were used to determine the differential and total settlement.
d. Surnp Leachate. Leachate samples were taken in one-liter polyethylene sample
bottles (one liter samples were taken if enough leachate was present). The volume of
leachate was determined for small (up to 15-liter)quantities by filling a 19-liter
(5-gallon) graduated container or the one-liter sample bottles. For larger quantities,
the leachate was drained into the 19-liter graduated bucket for one minute to determine
the flowrate. The drain was left open and the flowrate checked periodically until the
flow ceased. The time-averaged flowrate was used to determine the total volume of
140
-------
Gas Flow
0
\
Vacuum-pressure
hand squeeze bulb
(or electric pump)
Moisture Trap
Gas Sample
Bottle
Cover Soil
1
o
Bale
No Scale
FIGURE 10-5
GAS SAMPLING
APPARATUS
141
-------
leachate. Samples were taken from the filled container at different times during flow
so that a representative sample would be analyzed. During cold weather, when the
exposed leachate drain valve and leachate were frozen, leachate was monitored through
the vertical access pipe using a vacuum pump and tube to withdraw a sample.
e. Lysimeter Monitoring. Soil water lysimeters were sampled using a vacuum
hand pump. The quantity of leachate withdrawn was measured and samples analyzed as
indicated in Table 10-2.
f. Core Sampling. Core sampling was undertaken at the test cell, the newest
landfill area, and the oldest landfill area. Temperature, decomposition, organic con-
tent, and moisture content were determined for the samples. In the test cell, the auger
drill sampling was in the top 0.2 meters of bales and at 1.83 m, 2.75 m, and 3.36 m depths.
The 3.36 m depth was determined to be the deepest thah could be reached and still provide
a margin of safety to avoid penetrating the polyethylene liner. At the new and old
landfill areas, the drilling continued until bottom soil or intermediate lift soil was
reached. Samples were taken from the top 0.2 m of the top bales, and at two inter-
mediate depths.
C. Results and Discussion.
When the field test cell was completed, it was monitored at least once each week for
14 months, except that temperature was monitored daily during the first 14 days.
1. Leachate.
a. Sump Leachate Quantity. During the period from November 7, 1973, through
mid-September, 1974, cumulative rainfall on the test cell was 56.13 cm (22.1 in.),
which was equal to about 490,000 liters over the test cell surface area. The days on
which rainfall occurred, the quantity of rain and the daily quantity and cumulative
total volume of rainfall entering the test cell are summarized in Table 10-3.
The daily sump leachate flows are shown in Figure 10-6. Leachate flowrates were level
during each period they occurred. Sump leachate exceeding one liter per day was
initially observed June 1, 1974, about 250 days after filling the cell. This was
attributed to the cell accumulating moisture to the point of saturation, and frozen ground
during the winter months which created a barrier to moisture entry.
The leachate and precipitation trends are plotted on Figure 10-7. As can be seen,
leachate began to be obtained in mid-March in very small quantities, usually less than
1 liter per day. Leachate flow increased during June 1 to August 27, 1974, and then
became negligible (less than one liter per day) in September.
Amass balance evaluation of moisture conditions at the test cell was completed as
follows. The factors involved in moisture behavior in the test cell are expressed in
the equation:
142
-------
TABLE 10-3
TEST CELL PRECIPITATION
Month
Date
Days
Since
Filled
Rainfall,
1973
Nov. '7 40 .15
cm (in.)
Precipitation
Per Event
(Liters)
Cumulative
(liters)
(0.06) 1,278 1,278
Dec.
1974
Jan.
Feb.
Mar.
Apr.
May
20
21
24
26
5
9
14
15
23
24
26
27
9
20
1
2
3
4
5
14
16
8
14
15
22
26
29
30
31
11
12
13
22
27
3
53
54
57
59
68
72
77
78
86
87
89
90
103
114
126
127
128
129
130
139
141
161
167
168
175
179
182
183
184
195
196
197
206
211
217
4.78 0.88)
1.02 ( -4)
.36
.30
.61
(.12)
(.24)
2.03 (-08)
15 (-06)
(.16)
(.28)
.41
.71
.71 (-28)
.46 (.18)
.51 (-20)
.15 (.06)
.41 (.16)
.05 (.02)
.56 (.22)
.30 (-12)
.05 (.02)
.91 (.36)
1.02 (.04)
2.03 (.08)
.05 (.02)
.25 (.10)
.51 (.2)
.15 (.06)
.76 (-3)
.25 (-1 )
.25 (.1)
(.34)
(.12)
(.38)
(.12)
(.04)
(.32)
.86
.30
,97
.30
.10
.8.1
.15
(.06)
1,278
40,042
8,520
2,982
2,556
5,112
1,704
1,278
3,408
5,964
5,964
3,834
4,259
1,278
3,408
426
4,686
2,556
426
7,668
852
1,704
426
2,130
4,259
1,278
6,390
2,130
2,130
7,242
2,556
8,094
2,556
852
6,816
1,278
1,278
41 ,320
49,840
52,822
55,378
60,490
62,194
63,472
66,880
72,844
78,808
82,642
86,901
88,179
91 ,587
92,013
96,699
99,255
99,681
107,349
108,201
109,905
110,331
112,461
116,720
117,998
124,388
126,518
128,648
135,890
138,446
146,540
149,096
149,948
156,764
158,042
143
-------
TABLE 10-3
TEST CELL PRECIPITATION
(Cont.)
Month
1974
May
June
July
Aug.
Sept.
Date
7
8
9
10
12
14
16
18
22
2
3
4
6
9
10
13
19
20
21
1
3
10
12
18
24
2
3
4
10
21
6
9
10
12
Days
Since
Filled
221
222
223
224
226
228
230
232
236
247
248
249
251
254
255
258
264
265
266
276
278
285
287
293
299
308
309
310
316
327
343
346
347
349
Rainfall,
.46
.56
.56
2.48
1.57
.56
.25
.25
.51
1.52
.36
4.52
1.22
.86
3.96
.25
.41
1.47
.81
.05
.15
.30
.76
.15
2.18
3.15
4.83
.05
.41
.61
.15
.61
.25
1.02
cm (in.)
(.18)
(.22)
(-22)
(.98)
(.62)
(.22)
(.10)
(.10)
(.20)
(.60)
(.14)
0.78)
(.48)
(.34)
(1 .56)
(.10)
(.16)
(.58)
(.32)
(.02)
(.06)
(.12)
(.30)
(.06)
(.86)
(1.24)
(1 -90)
(.02)
(.16)
(.24)
(.06)
(.24)
(.10)
(.40)
Precipitation
Per Event
(liters)
3,833
4,686
4,686
20,873
13,205
4,686
21 ,299
2,130
4,260
12,779
2,982
37,912
10,224
7,242
33,226
2,130
3,408
12,353
6,816
426
1,278
2,556
6,390
1,278
18,317
26,411
40,468
426
3,408
5,112
1,278
5,112
2,130
8,520
Cumulative
(liters)
161,875
166,561
171,247
192,120
205,325
210,011
231,310
233,440
237,700
250,479
253,461
291,373
301 ,597
308,839
342,065
344,195
347,603
359,956
366,772
367,198
368,476
371 ,032
377,422
378,700
397,017
423,428
463,896
464,322
467,730
472,842
474,120
479,232
481,362
489,882
Total
56.13 (22.10)
144
-------
NOTE: Leachate flow stopped August 27, 1975
600 i
500 H
0s 400 H
1 300 -
200 -
100 -
i I i i i i [ i i I
10 20 30 40 50 60 70 80 90 100
Days since leqcihaj'e began flowing
June
June 3 to August 27, 1974
I July I August
250
i
Days since cell was completed
350
FIGURE 10-6
SUMP LEACHATE FLOWS
145
-------
Cumulative Precipitation (1,000 liters)
(SJ94JI QOO'l)
3AI4D|nUlfr) pUD UOJ4D4jdl09Jc|
146
-------
(1) I = O+Et+S where: I is inflow (precipitation)
O is outflow (leachate)
Et is evapofranspiration
S is storage (both in transit and as
specific retention)
The total inflow during the period June 1,1974, to August 27, 1974, was 235,142 liters,
and total outflow was 18,810 liters. Outflow was 8 percent of inflow (total precipita-
tion for the period). Specific retention was assumed to be about 10 percent of the total
pore space for the conditions in the cell and the geographical location. Specific reten-
tion, or field capacity, is the proportion of the total pore space in a soil or other
material that will store water. This estimate was provided by the University of Minnesota
Geology Department consultant, Dr. Pfannkuch.
The test cell contained the following distinct materials in layers:
Surface: glacial till, 0.3 m (1 ft) thick, pore space of 35 percent.
Bales: 3.35 m (11 ft) thick, pore space 6 percent.
Sand: Mixed, clean washed sand, 0.3 m (1 ft) thick, pore space 27 percent.
The pore space in the sand and till were obtained from geology data provided by
Professor Pfannkuch. The empty space between bales (bale pore space) was calculated
from bale spacing measurements taken at the balefill during monitoring, and neglects
absorption into the bales. The total available storage space of 327,500 liters was
calculated as: sand - 69,000 liters; bales - 169,000 liters; and till - 89,500 liters.
Ten percent, or 32,750 liters were attributed to specific retention.
Values for evapotranspiration obtained from the Minnesota Geological Survey were
78 to 87 percent in the St. Paul region. A value of 87 percent was assumed for Et.
At 87 percent for Et the volume of 32,750 calculated for available storage space was
filled during the June 3, 1974 rainfall (see Table 10-3), as shown in the following
calculation using equation (1):
precipitation (Nov. 1, 1973 - June 3, 1974) - 0.87 x precipitation = S + O
= 253,461 - 0.87(253,461) = 32,950 liters.
During the summer 1974 months, the rate of sump leachate outflow closely paralleled
the precipitation inflow. Precipitation not accounted for by outflow during June 1
to August 27, 1974, may be assumed to have been absorbed into the solid waste bales or
lost to evapotranspiration and runoff. Precipitation occurring from October 1973 through
May 31, 1974 filled the storage space in the till, bales and sand, and was lost to
evapotranspiration; hence no leachate was observed during this period.
b. Sump Leachate Characteristics. The chemical constituents in the test cell
sump leachate are given in Table 10-4. The analyses of the weekly and monthly
leachate samples from the test cell are given in Figures 10-8 through 10-12.
147
-------
(£>
1/1
Z
LU
*~P
X
u
^^
LU
^r ^
o ^>
»— ._
LU (/)
_J
< £u
"- u
i _,
I •"
to
LU
1 —
LU
1
ca
i
Q_
| —
oo
X
C
B
Z
«/»
o>
~
0)
c
(D
c
s
z
..^
\
D
E
fc
v>
t:
Q)
-[ .
t/1
C
o
U
~E
o
o
v^
Z
§
E
"o
U
Ix _
»*
if*
O
CO
1
U
in
Q
O
CO
mn-i
O
o
O
u_
0
-J-
w Q
J
«
/) ^
X 0)
3 —
£- iZ
in co o o o CN
*•••••
1 1 CN . CO ^D "^d" SO
lii ^^ ^^ L_ ^o fx rx
0s- ?M* CO ix" OO ?^ r— ^-»* fx ^^^ io* ^O *" ^ ^O * — ^ IsT^
f^oo^-o^'r-cNco^'^-^'Tf^-^o^'K^'rx
co O -^- O T}-V d-indin£!-*o£!->iy£i-^~£i.|xGi-
in o "n
• • •
1^ 1 ^3 >O 1
^^ i (SJ «^^ |
CO O CN
" * *
^5 1 to ""O 1
CN 1 CN CN 1
l«O ^-^^ 00 C3
CO CM CO
1
1
o CM •«* in ~^-
o ^o '*o • — in
o ^ in o oo
— CM i— CM —
.....
o o o o p
w V V V v
r- CO O
— o •— o
§ § i? $ M
o up Q in o
tf> — CN
CO 0
CM » >— ^
•—
8 S! - 8
— CM
Al
o •— — co in
ix' ix' rx' >o >o
O "ir? CM "^ *-"v 'f^' tx
x?O-x">J«x"^x?^^£2- o^
148
-------
CO
co
o
U
"E
o
o
x^
Z
Q-
2
,0
"o
u
O
*E
D
0)
o
CO
T
Z
CO
o
Z
CO
Q
1
co
rf
II
O
co
I
U
IT)
Q
O
CQ
~D
u
~5
4-
£
I
(D CL
ix c
^ CO
'"•• in TT
fl) XJ)
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1
O O 00 CO
£ o7 S^ S
•— i— !—
"^ CO CO ^~
T) in 10 o
CN CO CO 00
O CO IT) -«*•
IT) O tX >O
O O O Q
^1 ^ ^ K
CN CM CM CN
CO OO "
'x
o
o
co
I—
E
|
(U
Q.
O
0)
CL
O
10
4>"
C
tO
"o
Jt
^^-
c
^~ '
E •
0 jX
w^ *V
J2 "
E °
3.-0
C
c 8
^1
*> Q»
D 0)
C *-
8 s
.o.E
ul *•
*u *O
S co
O
W
'x
D
D
w
JC
•4—
o
't
0)
Q.
O
*"
(U
D.
E
W>
^o
X
4-
"c
o
o
0)
'o
£T
I
S
"o
o
c
o
4-
D
•o
O
z
J3
149
-------
co
I
0.
U
t/)
o
U
CM 0>
C
00
I
Q.
150
-------
<
UJ I
,8
O
O
oo
Q.
O
u
Q :r
CN
c
to
8
D-
CO
o
o
"O
o
o
o
o
o
o
CO
151
-------
oo
>o
8
CO
o
5
§•
-.8 =
0)
u
c
o
O
-.8
UJ
u_
o
152
-------
-------
CM LU
ii
u, U
a: <
D
to
O
8
JD
a.
o
U
0)
u
c
i/5
V)
X
O
a
CM
sai
154
-------
The data in Figure 10-8 indicate an average pH of 6.7 for all sump leachate samples
which is approximately neutral. Figure 10-9 indicates an initial BOD^ (5/21) of
25 mg/1. Subsequently, the BOD«j level rose to a peak of 545 mg/l about 312 days
after test cell completion.
The nearly neutral pH and low BOD,- values indicate that the biodegradation rate was
low and probably occurred only on tne bale faces. Organic nitrogen levels fluctuated
between about 10 and 20 mg/liter (Figure 10-10). Chlorides (Figure 10-11) and total
dissolved solids show level trends (Figure 10-12).
The St. Paul bale test cell average leachate composition is compared on Table 10-5 with
leachate from other types of solid waste landfills. As can be seen, the bale leachate
is low in BOD^, chlorides, and TDS, compared with values of other landfills.
c. Lysimeter Leachate. Leachate samples were also taken from the lysimeters
located at various positions on the test cell. The measured chemical constituents of the
test cell lysimeter leachate are given in Table 10-6. The trends of lysimeter leachate
analyses are illustrated in Figures 10-13 through 10-17.
Figure 10-13 shows that as the depth increases, the BODc also increases. The total
dissolved solids (TDS) shown in Figure 10-14 is also a function of the depth of the cell:
TDS increases with an increase in depth. Figure 10-15 shows only two depths represen-
ted for organic nitrogen. Quantities of leachate sample were insufficient for organic
nitrogen determination in many cases. High values obtained in March are attributable
to first analysis of the winter's nitrogen accumulations after the first thaw. However,
from the data plotted, quantities of organic nitrogen appeared to increase with an in-
crease in depth. Chlorides also increased with an increase in depth as seen in Figure
10-16. The pH (Figure 10-17) remained at an approximate average of 6.86 for all
depths.
2. Temperature. Figures 10-18 through 10-21 display temperature trends from data
collected at four different test cell stations. For each station, temperatures at three
different levels were recorded. Figure 10-22 shows the station average temperatures
at 0.6 , 1.5 , and 2.4 meter depths, and average ambient air temperatures. With the
exception of an early sharp increase in bale temperatures, trends in the baled solid
waste followed fluctuations in ambient air temperatures. The early increase in bale'
temperatures is a function of initial intense decomposition. Figure 10-23 compares
change in temperatures over time at Oceanside and Spadra, in California, and at St.
Paul. The comparisons are made to illustrate any similarities and differences between
baled and unbaled waste. The Oceanside data on mixed sludge and solid waste is in-
cluded because the potential exists for baling mixed sludge and solid waste (limited
testing was conducted in St. Paul). All curves show at least a slight initial increase in
temperature before decreasing to a levelling trend. Three differences between St. Paul
and other temperature curves are: a higher initial peak temperature; a generally higher
level trend (exceeded only by Spadra Cell B at 3 meters); and more extreme variation
during the "level trend" part of the curve. The higher initial peak temperature and
155
-------
156
-------
•
t
o
U,
10
0
LU
si
<
oQ _*
C R
O O»
-D .—
C
0 ^
-1 o
. c
-< 0)
^ D)
• <
<* c
** rt
« ,°
0) *.
_C 0
CD 0)
— 1 •*-
x Q
D_
-« -—
•^ £
• c
o
•
(/>
*o
c
—
— •
c
0)
•*-
V)
o
(D
_C
O
Z
c
0)
4-
Lo
"5
in
0
8-
5
0)
to
D
^
TJ
• ir
1 ^
•8 ^
c
*"" • >>
y ID 03
— 3 O
i"o -3
6 £ S
O Q I
c 0 -1
S * ^
0
-
;
]
•
/j
•
_
•
x«
)
^
D
l/l
3
;
jj
o
O
0)
5
to
t/>
'i
•^
c
fl\
Ul
-D
5
0
u_
Jl^
2
•
rv<
0 D" «
•-78
1o ^ -
£c^ 8
0 _Q 00
C
D
•™™
">
0
n-
O
•*-
C
0)
E
t
o
Q-
0)
O
E"
o
I .
c
• • —
V <"
^^ c
-sS
1^
D ^
0) C
-x8
Q ss
^3
• "^^
U ^
• c"
^'K
J2 8
— w>
«: |c
.TJ >•
c ^_
_5 "S
_J
v^
x^
b 'S
.•t
D •-
oo c
1 ro
•*• c
0 'C
4— A)
•j— \y
1 2
o .—
D 0)
1 c
— J JJ
«J-
O D
^
51
-8 S
P 2
g •>
2 c
t— MJ
•
CM
157
-------
«o no
fC
o
CO
•o*
CM
n
oo
• • •
ooo
CO
00 o
' -SI - ,
1 'CM CM I
o
00
xO
CM
.
CM— CM
• • .
00 O
If)
l&x
I —10 CO
00 •— CO •—
° - o o d o 5 5 o 2 2 5
8§i
5
00
«©
S i g
v
CM
! !
o
•
o
•*f xQ
. O CM
;
1 O O
i & ' CM I ^ * 00 o xo
1 CM CO CM - CO
lO
V> CO
lO CO
CM O CM
"
CM
V V
co co co co "sj* iro co
V V V V V V
CO COO OOCOCOCOCOCOOxCO^fCO
v vty ^^"vvvvv v
v V V
•ocxo o K oo o
K XQ* VQ* fs*
vf io"
S K P .CM*
O — O CO O
rv K" r>.' rs! N-'
ID
. "> « CO 00 «N 00
CMCOO - CM O o -' d
CM
CM
CM
Ox vo ,- o
-o xo hx K
^ V? G>
CM
00
o
CM ivj
» oo
00 rf CO
• • .
O-o
K
^
KV
OO Tf-
o —"
158
-------
CO
CO
>j
z
LU
t—
(J
<
_l
jV
LU
LU
^^
—
I
LU
U
&
I—
LU
^^
CO
D
o_
CO
D
E
Z
«/i
a
v
_J
\n
D
Cl i
0)
"o
Q
u
1
6
CO
I
Z
CO
o
Z
co
*-
<8
T3
"5
CO
.7*
II
O
CO
1
u
c?
O
ea
"5
o
o
i
15
"o
i
k-
1—
-*•'
E
o
O —
c —
/^ * 1
'^J-
rx
o
•
^
-»t i
IO
• 1
•— 1
fe 2
o d
5 !
V V
,
ON '
•
^~
^ 1
CM '
•O IO
CO 10
"*
^? 7
CO -*
V
8 CM
to
SS S
00 "O
d i—
CM
_
„_
^
•
CO
CO
-.
•~
fe
CD
5
V
f^
^^
CN
CN
O
CO
V
^
IX
VO
10"
ci
oo
CD
5
•o
x^
>
•
10
rf
o
o
>0
R
V
oo
c^
CN
CN
CN
t?
a>
SO
o
10
CN
00
o
fx
CN
CM
^x1
CM
O
"
0
0
^:
CD
1
•*.
V
10
^M>
CN
oo
^
CO
V
CO
CM
Os
•O
«0
•O
^
*
00
CO
o
CM
0
CD
§
V
^
CN
~
8
CO
V
"^
00
VO
to"
d.
00
o
So
CM
00
^x"
IX
00
°:
CN
CN
CD
00
— *"
V
K
1— '
5
JO
10
co
V
00
CM
Os
•o
10
i
>t
~
•
rx
CO
i
i
i
1
V
00
CN
IO
CM
IO
00
CO
V
CO
V
_
IX
tr?
CN,
00
CD
CM
CO
x°
>
CM
1 1 O 1
~
11*1
1 1 O 1
CM CN
1 1 ""•
1 1 O O
>O IO
^-"
V V V V
i i ^- rx
i i _ ,_
i o o co
o o o o
— o 10 o»
>0 •— CN
CO CO CO CO
V V V V
CO CO CO CO
V V V V
— oo o
i rx «o ^
to to « «>
S
0s CD
IO f^
CO CO
CO CO
V V
CO CS
V
oo o
>o rx
•°. "».
S- s.
**. "*
^ ~
1
CO
^
i-
o
'o
a
cr
(U
•o
£
I
•o
o
•5
-o
o
159
-------
i U
UJ-J
IT)
X
X
X
X
X
.--or
Ofc
"-i
to
>-
CQ
Q.
O
U
8 E
0)
U
c
X
D
Q
£;
E
"K.
_JC
"a
0)
-D Q
(U
1
1 1 1 1 1 1
"O" 10"
d"*Vl t~**\ — U 1 ^^
<._;• i_i ^T, C*j,
CO O TT »O
• • • •
o o — •—
• < 4 0
i '
1 1 1 1 - - - 1 1
3 O O O O O
o u-> °- 8 °j 2
O
.0
r—
(J94JI/6UJ)
160
-------
Q_
0)
IT)
-------
CN
O 00
(ja4j|/6ui)
CM
162
-------
<
X
10
G. S
CO O-
• •
O O
O fc
W)
O
O)
0)
O
(J94i|/Bui)
163
-------
CN
if)
H
00 O* "*)• if)
• • • •
o o .— •—
O
• <
0)
a.
o
U
o>
81
Q
O
o
r
00
x
a
164
-------
CO
O-
0)
Q
^ If) 00
o 10 -*r
• . •
O ,— CN
-a
a>
O)
4)
8
o
CO
o
CM
165
-------
Q4
or
Q
10 '•r
• •
0 — CM
O>
(D)
166
-------
CO
z
a
0)
a
to
C^ IT) 00
"O IT) "
-------
04
or
Q
CN,IO oo.
o «o TJ-
• • •
O •— CM
! I
I i
•o
0>
O)
0)
o
U
5
CO
o>
o
c
(D)
168
-------
s<£
CN ^- —>
2i§
-
-------
Q.
Q
I *••> ^—fc.
O I O *O O
,_ CO r- ^ r-
&
E
CN
CN OO
CO
< < CQ co
~w "o> "5 "o>
Q
z
LU
O
LU
C
CJ
0
_J
q
JC
u
C
(
(.
C
1
1 V
v u
)O
1
1
, *
L
^E
is
)
j
3
1
i
U
S
1
to
L
1
^
i
t/
;
3
3
I
U
1
o
Q.
—
O
Q_
j-
oo
00
CN
00
\
•< to
l±J
s-
O LU -i
— C£ <
SLU •-jq
^ £^ LU O
D Qi Q.
lis
Qi Q
LU -,
Q_ £-
a £5
8
lO
•O
(U
•=> 1
O
U
S
8
CO
o
8
o
o
p c
K ^
B 8 ?
C^ ^D
CO CN
O
0)
u
c
co
^s
o
Q
170
-------
higher long-term trend temperature level may be a result of the high bale density,
which will tend to retain more heat per unit volume and have fewer entrapped air void
spaces that are not producing heat.
3. Gas Analysis. Figures 10-24 through 10-31 illustrate gas analyses trends at 0.9
and 2.4 meter depths for each monitoring station. Nitrogen percentages are omitted
since gaseous nitrogen does not play a part in decomposition. Carbon dioxide and
methane levels increased with time, while oxygen remained constant. These effects
were more pronounced at the 2.4 meter depth, possibly due to less entrapment of out-
side air. In all cases, hydrogen sulfide levels remained lower than 0.1 percent.
Sudden, infrequent drops in CO2 concentrations and rises in C^ probably represent
air entry into sample bottles during sampling or shipping, and not actual decreased
CO2 gas generation in the balefill .
Figure 10-32 shows differences between St. Paul balefill generation of COo and
and Los Angeles (conventional) and Oceanside (with sludge) landfill gas composition.
4. Expansion/Settlement. Elevation changes were determined at monitoring stations
1 to 5 by calculating the changes in distance between the elevation of the settlement
riser attached to the plate under the bottom bales, and the elevations of the risers
attached to plates and the concrete benchmark on top of the bottom, middle, and top
bales. The differential elevation measurement method is shown in Figure 10-33.
The results of the elevation measurements averaged over the five stations at each level
are plotted in Figure 10-34. Figure 10-35 compares data from St. Paul with data from
a normal landfill at Spadra and a mixed sludge/solid waste landfill at Oceanside, both
in California. The major points are that the test cell bales expanded during the first
10 days and remained basically stable over the following 12 months. As would be
expected, the bottom bale expanded the least, due to the compressive weight of two
upper bales and six inches of cover soil. The bales appear to provide a stable
foundation which would allow immediate use of the land for light structures. However,
since the duration of the monitoring was only for one year, long-term settlement trends
are not yet known.
5. Core Sampling. The results of a one-time auger sampling are summarized in this
section with regard to temperature, moisture content, organic content, and decomposi-
tion. One borehole in the new landfill was analyzed (180 days old); two boreholes in
the test cell were analyzed (415 days old); and two boreholes in the old landfill were
analyzed (about 730 days old).
a. Temperature. Temperature profiles by depth are given in Table 10-7. The
average temperature decreases with the age of the fill material . This follows the
normal decreasing temperature with age curve in landfills.
Temperatures in all bore holes increased with depth. This is due to the lessened effect
of ambient temperature, and a corresponding higher biodegradation rate. The tempera-
ture increase with depth was greatest in the newest fill material, and least in the oldest
171
-------
T3
-------
CNl
ljfc
< LU
-------
0) ,
S"
u O u
< O n
5
• • ^.
>0 co °l X
^^° t
O >- H- uj
^ -J < Q
L"
-------
CM
UJ
O
|ir>
hfr
O LU
O
O u
0)
O)
ODD
H9
^*
-%~a^r
O
CO
O
CN
auin|0/\ Xq
175
-------
oo
CM CO
D)
-------
LU <. •< LU
-------
CO
o
on O
UJ
$6-5
< o a
aiun|0/\ Xq
178
-------
O 00 O "-
TJ
0)
U)
c
8
O
O
to
8
awn|OA
179
-------
_0
(D
O)
^
to
O
V
E
"JJ Q-
o
z
O
oo
S
180
-------
LEVEL
DIFFERENTIAL SETTLEMENT
Designation
r
Bale 1
r
Bale 2
Bale 3
4 —i
|
-t
T?
*
FIGURE 10-33
DIFFERENTIAL SETTLEMENT SCHEMATIC
181
-------
• *• •
• * •
• > • ~
m > •
m > •
m *• •
• > •
?
O
^1 ~
^J • *• •
II • * •
B
• *
X*"S
T
^. • * •
^Q
|| • ^ A
^
f
£2, ^ •
• ^ A
•D ^ >• •
£ ii »• •
o> •
• •
• »• •
• »• •
• * •
• * •
M ^ •
% / •
|_ - . X ... J .,...._.. f 1 . . . t , 1 . J. , . f
8
^
5?
CO
o
8
g
o
8
o
—
8
•
o
T>
o in o ir>
(LUD) uoisuodxg pi^uajsjjiQ sBojaAy
Z
g
co
Z
Q_
•^ LU
o <
Sz
•^ LI 1
O LU
— LI_
U_ | j
Q
LU
O
LU
**? <^
3- -1
c I—
.2 °
JD
a.
E
8
"3
U jj
O) )5
c 2
._ £
> -C
o u
= S «
0 * c
U_ -C O
1 11
*~ * £
c ^
(1) ,_
1 —
-0 >
T3
-------
CO
uojsuocbq
ui
183
-------
K
O
10
CO
CM
s;
I
184
-------
fill material.
b. Organic Content. Organic content increased with depth in the newest fill,
and decreased slightly with depth in the test cell intermediate age fill (Table 10-8).
The intermediate soil layer in the old fill, a sandy-clay loam, had a negligible organic
content. Immediately overlying it was a layer of paper waste of relatively high organic
content.
The average organic content of the solid waste (excludes soil) in each borehole showed
no discernable trend. In normal landfills, the organic content would be expected to
decrease as the age of the landfill increased due to decomposition. A decreasing
average borehole organic content was found as age increased during a two-year period
(equivalent to St. Paul fill ages) for the test cells and landfill (with and without sludge)
in Oceans! de, California.
c. Moisture Content. Moisture content decreased with depth in Station 3 of the
test cell and in Borehole 1 of the old fill (Table 10-9). Moisture content increased
with depth in the new fill, in Station 1 of the test cell, and in Borehole 2 of the old
fill. The intermediate soil layer in the old fill had a significantly lower moisture
content than that of the overlying paper layer. Average moisture content remained
essentially the same with age of the fill.
Moisture content is dependent on four factors (assuming no aquifer interaction):
(1) weather, (2) topography, (3) permeability of fill, and (4) composition of fill.
All three areas experienced the same weather conditions. The finish topography is
flat for all three areas. The test cell was bermed to prevent runoff. The different
trends in moisture content may be explained as a variation in factors 3 and 4 above. The
landfill areas would have drainage flowing on and off with a minor net drainage
change or percolation difference from the test cell.
d. Decomposition. The decomposition of new versus older bales was examined
qualitatively during the core drilling. Changes related to decomposition such as color,
readability of printed matter (paper print, can and bottle labels, etc.) and material
structure were not observed in the test cell core samples (415 days old). The colors
were true (as in the waste when baled) and printing was readable. The newly placed
bales also were natural in color and had readable printing. The paper waste from old
bales (730 days old) tended to be easily pulled apart indicating some structural change.
Overall, the difference between the newer (180 days old) and older (730 days old)
waste bales was the slight structural change.
185
-------
o
u
cp y
So
LU
LU
C£
O
CO
, °°
CO
50.3
0)
ro
s
o>
61
nation me
O O — •— CN CN CO CO* CO "•*'
0)
15
T3
8
u
D
D)
a>
CO
CN
•58
91
9>
D_Q
186
-------
t-
.z
UJ
H-
z
o
u
II 1
Q£
3
CO
o
2
' UJ
_1
o
UJ
— -x
U£i
o
co
4-
.c
^0
"5
^
o
^
o
8
iv
-o
2>
0)
a.
0
U
^^
I
IL
0)
u
~ m
CO ,_
SI'*
^^
o
f~\
8
,
E
^
_n
4_
o.
0)
o
CN
_W
o
X
£
£
IE
-D
O
2 "~
O ®
o
X
£
4) c
zo
4)
U
£
3
CO
£
_o
4>
CO
•
+•
«=-
vO
1
5^
§
^
^™"
•w
t:
•^
§
i
c
5
•••
t
•••
^
V
^
|
V
v
\
<
^
'1
^
i *
i
i 3
j ^
\
•o
lie Surface
i<^2 \\
00 «
/
Z
1
|
$
.4
\
i
\
<
i
i
*0
•o
CN
j^°
r
to
• ,—N
•— CN
$5
0 O
0 ^
1- t^w
• • «v
N CS( sJ-\
">• *-|
7
0
N
"> ^ co \ •*
c? ft 9 \ S
^ M
>. CN CO CO
• • • •
30-^- ^ >O
» CO CN CO
CO CO O.
• • •
"* Ch Q
IO CO ^
•O Os
CO CO
CN *Q
^^oco'epS'-'cN"^'
^^ ""^ >~' "**" * Z^, ^. ^- C^-
CNCOTT'O1O'
-------
Term
Activity Network
Balefill
SECTION 11
GLOSSARY
Definition
Statistical measure of production rate. Ability of a system is
measured as a probability distribution of production rates.
Statistical measure of production time availability. Accessi-
bility of a system is measured by the maximum number of hours
a day that the system can be scheduled for production.
Schematic visualization of the sequential states occupied by a
given machine.
A land disposal site that receives baled solid waste, with or
without binding, for disposal on land by an engineered method
in a manner that minimizes environmental hazards by stacking the
highly compacted bales to achieve the smallest practical
volume, and applying and compacting cover material on the
top of the bale lift at the end of each operating day.
A machine used to compress solid waste, primary materials,
or recoverable materials, with or without binding, to a density
or form which will support handling and transportation as a
material unit rather than requiring a disposable or reusable
container. (Source: WEMI Baler Subcommittee)..
The start-to-finish sequence of operations by the baler that
produces one solid waste bale.
A nine-kilogram composite sample of unbaled solid waste
received from collection vehicles and obtained at daily
intervals during the five-day study. The sample was composed
of waste materials accumulated during bi-daily solid waste
sortings, and was composed to correspond with percentages of
constituents found in the bi-daily sortings.
Baler Liquid Squeezing Liquid samples obtained once or more per day during the five-
Samples day study; collection occurred directly below the baler base.
Both unstrained and strained (through mesh screening) samples
were taken.
Baler
Baler Cycle
Baler Feed Solid
Waste Samples
Baler Operator
The baling plant employee responsible for control of the con-
veyor, scale, and baler equipment operation (see Control
Tower Operator).
188
-------
Term
Definition
Control Tower Operator Employee responsible for supervising bale production, cycling
the baler, measuring the baler charge, allowing transports to
switch on time, and keeping the conveyor full.
Conveyor
Forklift
Gantt Chart
Gate Attendant
Interference
Loader
Loader Operator
Maintenance Man
Two conveyors are employed at the baling plant to move solid
waste from the unloading area to the scale platform. The first
conveyor is horizontal, and the second is inclined; both are
2-bar slat conveyors.
Machine that removes bales from the bale discharge platform
inside the baling plant; these bales are composed of special
materials such as corrugated paper or selected metals. The
forklift also removes broken bales from the platform and de-
posits them onto the incoming solid waste pile, as well as
lifts up the edge of the loading platform to allow the transport
vehicle to fit under its edge.
A schematic method of illustrating relative times occupied by
processes within a given sequence.
Employee responsible for directing incoming traffic and charg-
ing and collecting fees from incoming solid waste collection
vehicles.
Statistical measure of the time one machine in a network is
forced to be idle while waiting for a second machine to
complete its task.
Mobile apparatus used in the baling plant to pile incoming
solid waste, load refuse onto the horizontal pit conveyor,
mix solid waste, scrape the unloading floor and sort large
metal objects and corrugated paper. The loader operator is
the employee responsible for running the loader. A small
"bobcat" loader is also employed at the baling plant for
general operations.
Employee responsible for operation of the forklift and general
purpose loader inside the baling plant.
Employee keeping baling plant equipment in operating con-
dition, repairing minor breakdowns, used for filling-in for
missing personnel, and assisting in transport-vehicle rigging
and floor sweeping.
189
-------
Pusher
Queueing
Reliability
Rigging
Segregator
Util ization
Definition
A metal plate pushing solid waste across the scale and into
the baler charging box.
Hydraulic apparatus moving baled solid waste onto transfer
vehicles. Pusher one is activated every baler cycle, while
pusher two is operated every other baler cycle.
Procedure of organizing and processing vehicles in waiting
lines. Applied to describe where one or more collection
trucks are attempting to or actually are unloading solid
waste at the bal ing point.
Statistical measure of ability to maintain production.
Reliability of a system is measured as the probability
distribution for the fraction of time producifng divided by
scheduled operating time.
Procedure by which bales are covered within transport
trucks prior to departure from the baling plant. Nylon mesh
curtains are pulled over the bales and attached to the
bottom of the truck trailer bed with hooks. The tailgate is
placed and secured following curtain rigging.
Employee responsible for separating corrugated paper and
selected metals from the baler feed solid waste.
Statistical measures of the use made of each machine in a
network. To obtain percent utilization of a machine for a
given state, the amount of time spent in that state per
cycle is divided by the machine total cycle time.
190
-------
t-
ZUJ
D 3
X 5
§2
M 7^7
rH O -^
a ZO
O UJ co
B o£
w *^
w U Z
20
tu
D
i
~o>
^
UJ
£
3
o
2
o
15
^~,
.*-
c
j)
s
._ « 0) 0)
§- SB *. "Z t> -5 -5 -5 -5
«:= E §L£.E.S.E.E
i/i CM O •— tv, -^ O» ^t
^
S
C ^ r- -n PTIOC-
D 0)
«— D I-
S-ST£ §
«- o sr
oo co rx o
co -^ o
Z) O CM O^
-
*~ 0)
£ b
D D
D D-
o- «
" u->
>o in
N. r-
o o
,—
8
o
^- d
CM
y
O
. 8 sr
L.
<0
"5
JE
•4—
V
0) °
L. O
o S:
•f= °
Uc ^
OJ S-
5 o 8
*r «
c "O "O
— U 0
13 »— •—
CT^5 -Q
0) D 3
. « «
LO O •—
^- CO
D co -
£
-Q o
-B-8
0
± 1
c *"
^
0)
-o
_c
.*- o
0) C
0) —
•«*- 0
.22
•S 3
o __
CO 5
IT) O
CO O
o
o 8
•— o
• •
- o o
CO
u
1- U
0 o
E 0
O ">
« D 0
w> -0 0
o
•fr-
ft\
\u
• — •
0) S
fc 8
^^ . ^
.. w O
(1) .— .—
>jr o _Q
-------
-7
H-J
is
~^ __i
S *^
^yj i^
_J _,
(0 Z,
zo
LU C5
•- >
uz
50
.^
•^
D
.-
"^3>
C
LLJ
§
§
3*
"^
U
•4-
_
,_
D
cr
I
•3
^>
"D
g T
M
Q *0
3 "if
O ^
CO
, —
hi 1
<"i 8
O — CO hs
sQ O CM CO CN
CN — O O O
u>
~~ t
I-S §•£
D CD cr .-
-Q Q.QQ Q.
«t ^ S ^
00 r~f O^ '
CN — O O
v>
(I) in
*- j CO) -C
(I) O C U U C
<*- i*- .— c C • —
0 0 O '~ '" O
.— ._ ._ (j U •—
D D D 15 15 D
O O
CO IT) CN ^
IT) CO O • — O O
CO O — O O O
•o
258
o o •— o o o
•~
3 -§ _ =5 "o "E
£• o o) £ a?
"o — *~ ~ —
t3 _g fc ^ '•§ £=
_c -D :r -D o *E
c
0)
O t/>
> TJ «
*5 •Sauoo^-'-C
ffg §|§ § i'E'E'l
^j ^i1 1^^ OO i«O CO '^J1 l^^
• ^) ^J ^^ ^^^ OO '^1* l^S ^^
« r— ^- CS| LO CO ^5 U} ^~ O
a>'— OCNCOOO — OO
O C^
E
'x
o
D
H-
X
(0 *^ ' —
UJ D •— O O
^ roooooo^ooo
_ ,. o o o o .—
Q ^5 o o o —
^ 5> 8 8 "~"
-g o •—
00 § •— '
•< c
s
c
o
'^ t E
'> o ro
2! i- co o
^ -^r O) O} O O) D? ^^
_f> "^i o~ — ^ . *~ "u O) ~o o £
o
._! EE§ EO§
'E0"^^?^) S~^)D)
D '-t .E o5 13 ^ i 'o '€ =
O «^ fli Oi i— • fl) d) *^
C y ^^ _C" "T^ O5 ™^O C) C
.
w>
."t:
c
3
^_
c
"o
§•
,^:
"5>
c
LLJ
.»«
4—
C
0)
0
._
3
CJ"
(U
to
13
i)
X
_Q
"E
u
o>
E
IE.
m^^
^
a
192
-------
EVALUATION OF SOLID WASTE BALING AND BALEFILLS
VOLUME II: TECHNICAL APPENDICES
-------
TABLE OF CONTENTS
Page
TABLE OF CONTENTS iii
LIST OF FIGURES iii
LIST OF TABLES v
LIST OF PHOTOGRAPHS vii
APPENDIX A: FIVE-DAY BALING PLANT AND TRANSPORT 1
MONITORING DATA FORMS
APPENDIX B: AMERICAN HOIST AND DERRICK COMPANY BALING 23
PLANT AND OPERATIONS DATA FORMS
APPENDIX C: BALING PLANT EQUIPMENT DESCRIPTION 37
APPENDIX D: BALING PLANT AND BALEF1LL DETAILS 57
APPENDIX E: BALING PLANT SYSTEM AND HUMAN PERFORMANCE 72
ANALYSIS
APPENDIX F: YEAR-LONG SYSTEM MONITORING DATA FORMS 117
APPENDIX G: LANDFILL OBSERVATIONS AND TEST-CELL 133
MONITORING DATA
LIST OF FIGURES
Figure No.
D-l BALING PLANT FLOOR PLAN 58
D-2 BALING PLANT CONTROL PAN EL SCHEMATIC 59
D-3 CONTROL PANEL-MIDDLE SECTION 60
D-4 CONTROL PAN EL-RIGHT SIDE 61
D-5 CONTROL PANEL-LEFT SIDE 62
D-6 BALER DETAILS 63
D-7 CONVEYOR DETAILS 64
D-8 LOADING DOCK SCHEMATIC 65
D-9 BALING PLANT TRANSPORT VEHICLE 66
D-10 BALE TRANSPORT TRUCK ROUTE TO BALEFILL 67
D-l 1 BALEFILL TOPOGRAPHY AND TEST CELL LOCATION 68
E-l STATE UTILIZATION BY MACHINE 75
E-2 GANTT CHART OF MACHINES 78
iii
-------
LIST OF FIGURES (CONT.)
Figure No. page
E-3 BALING PLANT GATEMAN ACTIVITY NETWORK 80
E-4 BALING PLANT LOADER ACTIVITY NETWORK 81
E-5 BALING PLANT CONVEYOR ACTIVITY NETWORK 82
E-6 BALING PLANT SCALE ACTIVITY NETWORK 83
E-7 BALING PLANT BALER ACTIVITY NETWORK 84
E-8 BALING PLANT PUSHER ACTIVITY NETWORK 85
E-9 BALING PLANT TRANSPORT ACTIVITY NETWORK 86
E-10 BALEFILL FORKLIFT ACTIVITY NETWORK 87
E-ll GATEMAN MOVEMENTS DURING FEE COLLECTION 97
E-12 DAILY DISTRIBUTION OF WASTE VEHICLE ARRIVALS 98
E-13 WEEKLY DISTRIBUTION OF VEHICLE ARRIVALS 99
E-14 DISTRIBUTION OF VEHICLE ARRIVALS BY VEHICLE 100
SIZE
E-15 LOADER MOVEMENT FOR PLACING WASTE ON 105
CONVEYOR
E-16 CONTROL TOWER LAYOUT 108
E-17 BALE TRANSPORT TRUCK LOAD-UNLOAD POSITION 112
LAYOUTS
E-18 CORRUGATED SORTER WORK STATIONS 114
E-19 MANPOWER UTILIZATION 116
G-l BALE EXPANSION - 9/20/73 139
G-2 BALE EXPANSION - 9/21/73 140
G-3 BALE EXPANSION - 9/24/73 141
G-4 BALE EXPANSION-9/25/73 142
G-5 BALE EXPANSION - 9/26/73 143
G-6 FLY EMERGENCE TRAPS 147
IV
-------
LIST OF TABLES
Table No. Page
A-l BALING PLANT ACTIVITY CHART 1-A 2
A-2 BALING PLANT ACTIVITY CHART 1-B 3
A-3 TRANSPORT NET ACTIVITY CHART II 4
A-4 LANDFILL ACTIVITY CHART III 5
A-5 DAILY BALE COUNT 6
A-6 TENTH BALE DATA 7
A-7 PLANT MONITORING GATE ATTENDANT FORM 8
A-8 INCOMING WASTE DENSITY 9
A-9 SORTING DATA FORM 10
A-10 BALE CORE SAMPLE DATA 11
A-ll PRESSED WASTEWATER SAMPLES 12
A-12 EQUIPMENT MAINTENANCE LOG 13
A-13 ACCIDENT REPORT 14
A-14 WEEKLY LABOR REPORT 15
A-l5 WEEKLY STATIONARY EQUIPMENT COST 16
A-16 WEEKLY MOBILE EQUIPMENT COST 17
A-17 MONTHLY OPERATIONS SUMMARY 18
A-18 CAPITAL INVESTMENT REPORT 19
A-19 TOTAL COST SUMMARY FOR PLANT 20
A-20 TOTAL COST SUMMARY FOR TRANSPORTATION 21
A-21 TOTAL COST SUMMARY FOR BALEFILL 22
B-l OFFICE EMPLOYEE TIME CARD 24
B-2 PLANT EMPLOYEE TIME CARD 25
B-3 MAINTENANCE WORK-ORDER 26
B-4 INTER-PLANT WORK ORDER 27
B-5 GATEMAN CASH RECEIPT 28
B-6 TRUCK DRIVER DAILY LOG 29
B-7 PURCHASE REQUISITION 30
-------
LIST OF TABLES (Cont.)
Table No. page
B-8 SUPPLEMENTARY RECORD OF OCCUPATIONAL 31
INJURIES AND ILLNESSES
B-9 INVOICE FORM 35
B-10 PREVENTATIVE MAINTENANCE PROCEDURE FORM 36
C-l EXISTING 137-SECOND CYCLE BALER DESCRIPTION 38
C-2 90-SECOND CYCLE BALER DESCRIPTION 43
C-3 EQUIPMENT DATA FORM: FORKLIFT 48
C-4 EQUIPMENT DATA FORM: BOBCAT LOADER (ON LOAN) 49
C-5 EQUIPMENT DATA FORM: BOBCAT LOADER (IN REPAIR) 50
C-6 EQUIPMENT DATA FORM: ELECTRIC SWEEPER 51
C-7 EQUIPMENT DATA FORM: LOADER 52
C-8 EQUIPMENT DATA FORM: GENERATOR 53
C-9 RECOMMENDED SPARE PARTS LIST 54
E-l MACHINE INTERFERENCE BY MACHINE 77
E-2 PROCESS SEQUENCE ON UNIT OF SOLID WASTE BALED 88
E-3 REDUCED BALED SOLID WASTE NETWORK 89
E-4 MOVEMENT OF STANDARD TIMES FOR GATEMAN AND 90
LOADER
E-5 MOVEMENT OF STANDARD TIMES FOR CONVEYOR 91
AND SCALE
E-6 MOVEMENT OF STANDARD TIMES FOR BALER AND PUSHER 92
E-7 MOVEMENT OF STANDARD TIMES FOR TRANSPORTS 93
E-8 GATEMAN TASKS 96
E-9 LOADER OPERATOR TASKS 102
E-10 CONTROL TOWER OPERATOR TASKS 106
E-ll TRUCK DRIVER TASKS 109
E-12 TRANSPORT VEHICLE RIGGING TIME 111
E-l3 SORTER TASKS 113
F-l FIELD ACTIVITIES LOG 118
F-2 WEEKLY DATA REPORT SUMMARY SHEET 119
F-3 LANDFILL OPERATION RECORD 120
F-4 LANDFILL ENVIRONMENTAL RECORD 122
VI
-------
LIST OF TABLES (Cont.)
Table No. Page
F-5 TOTAL COST SUMMARY FOR PLANT 124
F-6 TOTAL COST SUMMARY FOR TRANSPORTATION 125
F-7 TOTAL COST SUMMARY FOR LANDFILL 126
F-8 PERIOD BALE PLANT STATIONARY EQUIPMENT COST 127
F-9 PERIOD BALE PLANT MOBILE EQUIPMENT COST 128
F-10 PERIOD TRANSPORT EQUIPMENT COST 129
F-ll PERIOD LANDFILL EQUIPMENT COST 130
F-12 PERIOD OPERATIONS SUMMARY 131
F-13 PERIOD LABOR REPORT 132
G-l TENTH BALE DIMENSIONS AT 10 MINUTES AND ONE HOUR - 134
9/20/73
G-2 TENTH BALE DIMENSIONS AT 10 MINUTES AND ONE HOUR - 135
9/21/73
G-3 TENTH BALE DIMENSIONS AT 10 MINUTES AND ONE HOUR - 136
9/24/73
G-4 TENTH BALE DIMENSIONS AT 10 MINUTES AND ONE HOUR- 137
9/25/73
G-5 TENTH BALE DIMENSIONS AT 10 MINUTES AND ONE HOUR- 138
9/26/73
G-6 BALE SPACING RESULTS 144
G-7 LITTER COUNT RESULTS 146
G-8 FLYING INSECTS COLLECTED IN THE BALEFILL FLY 149
EMERGENCE TRAPS
G-9 LAND DISPOSAL EVALUATION SHEET 150
LIST OF PHOTOGRAPHS
Photograph
No.
D-l BALE PLACEMENT IN HORIZONTAL TIERS 69
D-2 LANDFILL BALE HANDLING EQUIPMENT 70
D-3 COVER SOIL LOADER 71
G-l FLY EMERGENCE TRAPS 148
Vll
-------
APPENDIX A
FIVE-DAY BALING PLANT AND
TRANSPORT MONITORING FORMS
-------
TABLE A-l
BALING PLANT ACTIVITY CHART 1-A
.50
.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
2.75
3.00
3.25
Gate
a.
Loader
£t 8£t|.8
=6 8 EK 8 1 g
£ -D S 5'
E|l2 E"<
H C '"'•II !«•!
—T-
.25
.50
.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
2.75
3.00
Continued to 5.25
-------
TABLE A-2
BALING PLANT ACTIVITY CHART 1-B
.25
Cf\
,oU
.75
1.00
1.25
1.50
1 T\
1 . /O
2 00
.25
2.50
2.75
3.00
H.V.1)
Co
c.
u_
nv
§
oo
JS.
s
0)
1
Q.
O
CO
8
'i
e
t"c
'o
o
_o
a
D
0)
_o
0
1
.r
"o
O)
o.
E
£
Ba
o
|
o
o
ler
o
0)
=tfc
a.
cs
*:
Q-
JJ
.25
CA
.50
.75
i An
1 . UU
1 .25
.50
1 75
2.00
.25
2.50
.75
3f\f\
.00
3OC
.25
Continued to 5.25
-------
LU
CO
f—
X
U
< JO)
1— 0
UJ •-
Z a?
NSPORT
V
2
t—
c
(D
O
U
D
II
4-
W
D
O
X
(U
D)
C
i
u
>ymbols
mi
i, wheels/2 =
ii .°
s £
Qi o)
.:.- &•
II
u
•o
D)
i!
II
\ «n
— JH
3} o
t2 -Q
ii Z
oZ
*- ••
0 •>
_0) JJ
5
>^
>
3
3)
3)
- X
5 ~o
B.E
•» ^ K
j .1
j .t:
^ !
5 ^o
3 *n
u g
(U
0 T3
§ L5
C
£
c ^_
*5 a
2 z
s
0)
c ff
i s
•*" 7^
J
V
"D
£ LU
•- \
O "
"c j_
5
-a
LU
O-2
c ® o
o ^ ^
V
T3
0) LU
JV
C/1
•a o
....
CM
CO
,
"O
o
00
Os
o
, ^™
-------
U
i*
3§
££, <
< -I
D
z
O£
o
g
t
__i
5
o
I—
8£
£2
E
D
"S
C£
31
0)
•o
o
6
Q.
E
D
Q
X
L.
t_
D
U
-D
D
3
_0>
2
T3 -*
II
Q>
>
o
i
E
D
"5
0£
i-5
O- 4.
-o
0
_o
c
X
£
U
•§
.3
J)
2
I
1
1
;
1
:
<
;
>
i
—
'
J^
U
*-
?i
t£
4.
1
II
00
•
U
••—
E
II
IX
.E?
n
c
II
O
•
•4-
• •~
O
II
«o
w>
D
U)
II
^-
"o
_ _i<:
S "
5 i
afl,
" S
« E
II
^ 0
_Y , —
D
? ^
U
II P
1X1 t
O
^ 8-
— 0)
£ 5
v>
" II
^- o
-------
Date:
TABLE A-5
DAILY BALE COUNT
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
TIME
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Weight Lbs.
j
i
No.
42
43
44
45
46
47
48
49
50
TIME
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
TIME
76
77
78
i 79
i 80
81
Weight Lbs.
j
No.
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
TIME
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
Weight Lbs.
I
j
No.
123
124
125
TIME
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
TIME
151
152
; 153
154
155
156
157
158
159
160
161
162
Weight Lbs.
i
-------
TABLE A-6
TENTH BALE DATA
f —
VI
0)
_c
u
c
to
z
o
to
z
LU
-£
LU
_J
2i
Tim
Bal
Tim
Ran
4)
D
C
ii
Min
. Max
Min
L - Length
Comments
W - Width
H - Height
-------
?0
II
o
^Q
Q
.3
o
.&
o
_c
o
"o
£ ^
^5 E
i
M
3 ~
c 'C
1
c
(U
.-5-5
t/) •—
0) *•
a;
to-
0)
1?
^5 3
<>0
(/>
^
u
L.
0)
.a
E
D
z
o
u
•s!
0)
_E
P
i
I
I
1
i
i
I
|
4
I
i
1
i
•
I
8
-------
UJ
1
!
i
1
1
|
|
|
1
v_
>-
{— \
CO
UJ
Q
UJ
oo
•^
^^
*^
O
5
o
u
z
- --
trt
•*—
c
0)
£
£
o
U
<•»••— "->*'«---••"
X
4-
tfl
c ^
D
_o> y
OL. ^"^
£ -Q
a -J
CO
•
•^ ui
o) 3|
^^
o ^^
CO
•«-
0) .
i^^
a
X
a
O
<-»_
o
01
_£
P
"o
Q
-. ,^
1
*->«-—«-»»).«._>.
— i
i
i
t
i
i
!
!
j. * , ^
;
i
|
i
i
[
|
'•
'
!
!
~"
.,
|
I
i
1
I
i
.. .. }
j
1
|
i
1
|
1
t"^' "*** ' "
.,„«--
!
i
i
4
1 w"
L
P
!.
-------
TABLE A-9
SORTING DATA FORM
S.
•2
\ IE i—
ll
"o -o t
J §5
1|
.0
g -T3 E
O ° o
-------
en
o
D_
X
I
o
U
o
c
o
(N
CO
CO
O
CO
o
00
o
o
O
a
s
o
o
(U
o
-o
93
0)
J3
in
0)
u
o
0)
I
>M—
J)
CL
I
-------
"O
u
U.
O)
o
a.
X
co
X
c
D
a.
J
c
a
o
I
CO
ro
O
CO
o
-o
o
8
•4-
c
o
U
LU
\
oo
LU
£
^3
LU
1—
oo
<
^
Q
LU
OO
OO
LU
Q_
•4—
C
9)
E
E
8
L.
9)
_Q
E
D V
ZJ
3*+.
g°
Q-
0)
I
3 TJ
"5 g e
> 8 ju
"p gin
X
£5
"o
0>
.§
P
0)
li
00
X
o
Q
OO
r—
CM
OO
-
oo
CM
OO
CM
CN
•
00
CO
CN
OO
CO
CO
OO
1
CM
oo
^
oo
CN
OO
IT)
IO
a>
a;
c.
o
_x
(U
-4»
o
*x
2
a.
a.
o
0)
_Q
O
-------
TABLE A-12
EQUIPMENT MAINTENANCE LOG
Date started Date ended_
Time started Time ended_
Machine name Sheet *
No. Model Mfrs.
Downtime Action Taken
Date Start End Problem, Labor, Parts, Special Tools Signature
13
-------
TABLE A-13
EPA CONTRACT NO. 68-03-0332/AMERICAN HOIST COMPANY
ACCIDENT REPORT
Date
Person to contact
Employee's nqme_
Job description
Type of injury
Date of accident
Effect on employee
(permanent/partial/tempo rary)_
Lost time
Therapy
Time
Initial cost
Therapy cost
Reason for accident
Conditions at time of accident (time, weather, fatigue, equipment)
Signature of person completing form
14
-------
Qi
2
LU
LU
LU
£
D
3 J2
T3 D
1 £
c
^~
c
vO
o
Q 0
— •>
vi
3
lO O
< _Q
o o
— >
{2
^d" "^
> X
< -Q
L_J Q
J2
D
CO O
^1
V)
CM O
>- <^
°?
V)
t— D
O
< J3
^
CM
*-
*-•—
•™*
CO
V
X *
-2 i
E Z
LU
H-
z
^
0.
Z
o
I—
vNSPORTA
g
t
nidQNVl
c
2J
D OJ
4-
D> t
•1 8.
L.
O 1>
"~^ JJ
:§ ^<
C 0)
0 0
X c
^_ D
_D £
Q- .E
1 °
r> ^0
C
D
(U „,
*** "5
-o i
4-
•-!
.— * i/^
C
.2 D)
"o .£
Q-'5
° J
i!
C! •"
-3^
i
J3o1
•o
o
OJ
O
_Q
O
15
-------
1—
o
U
S
5
1
TABLE
STATIONAR
>i
LU
LU
£
§
•4- 'r-
1 8
£ JT
CL •—
D C
cr .
O
"50.*-
2 Di 1—
CM
>-
D
|1|
CO
>
0
•fb
^ V O
^
>
0
^2 *-
.E '5 -5
n D- 4-
^ 0) 0
V>
>-
Q
^ Q) "5
^ o: I—
O
>~
O
16
-------
TABLEA-16
WEEKLY MOBILE EQUIPMENT COST
Vehicle
License No.
M+ R*
af
Total
M + R*
Fuel
DAY 2 Oil
Total
M + R*
Fuel
DAYS Oil
Total
M+R*
Fuel
DAY 4 Oil
Total
M + R*
Fuel
DAYS Oil
Total
M + R*
Fuel
DAY 6 Oil
Total
Individual
Totals
Comments
Daily Total
Daily Total
Daily Total
Daily Total
Daily Total
Daily Total
1
!
!
M + R denotes Maintenance and Repair
17
-------
TABLE A-17
MONTHLY OPERATIONS SUMMARY
LABOR COST
Plant
| Transport
'Landfill
I Total
Week 1
Mobile
Stationary
Total
Week 2
Week 3
Week 4
EQUIPMENT MAINTENANCE
Week 5
Gas
Electric
Water
Telephone
Other
Total
Identify
Total
UTILITIES COST
MISCELLANEOUS COST
FIXED COSTS
Plant
Transport
Landfill
Total
Subtotals
18
-------
TABLEA-18
CAPITAL INVESTMENT REPORT
Description
PLANT:
Land
Surveys
Preparation
Roads
Buildings
Baler
Scales
Bins
Motors
Pumps
Conveyor
Loader
Fork Li ft
Control Unit
Other
TOJA|
TRANSPORT:
1
2
Trucks 3
4
5
Other
TOTAL
LANDFILL:
Land
Surveys
Preparation
Roads
Fork Lift
Loader
Generator
Other
TOTAL
TOTALS
Size,
Amount
etc.
X
Date
Put In Use
X
Est. Total
Life
X
Cost
New
Deprec
Yearly
X
iation
Monthly
X
1
i
19
-------
TABLE A-19
TOTAL COST SUMMARY FOR PLANT
If em
Tons of Waste Received
Number of Bales Produced
Total Operating Cost
Total Financing Cost
Total Cost
TOTAL COST PER TON
REVENUES:
Private Collectors
Public Collectors
Salvage:
Cardboard
Metals
OTHER
TOTAL REVENUES
TOTAL REVENUES PER TON
NET COST (PROFIT)
NET COST PER TON
NET COST/TON/DAY
For This Period
i
Budget
This Period
Year
To Date
Budget
Year to Date
20
-------
TABLE A-20
TOTAL COST SUMMARY FOR TRANSPORTATION
Item
Tons of Waste Hauled
No. of Bales Hauled
Total Operating Cost
Total Financing Cost
Total Cost
Operating Cost Per Ton
Financing Cost Per Ton
Total Cost Per Ton
Total Cost Per Ton Per Day
For This
Period
Budget
This Period
Year
To Date
Budget
Year to Date
21
-------
TABLE A-21
TOTAL COST SUMMARY FOR BALEFILL
Item
Tons of Waste Received
No. of Bales Received
Total Operating Cost
Total Financing Cost
Total Cost
Operating Cost Per Ton
Financing Cost Per Ton
Total Cost Per Ton
Total Cost Per Ton Per Day
For This
Period
Budget
This Period
Year
To Date
Budget
Year to Date
22
-------
APPENDIX B
AMERICAN HOIST AND DERRICK COMPANY
BALING PLANT AND OPERATIONS DATA FORMS
23
-------
TABLE B-l
OFFICE EMPLOYEE
TIME CARD
1ST VltK
2ND V-ltV
4TII HIKK
51H >VFKK
101AI
IHH KS ilill KS ti.'.l !A
RH.LI VK 'TIMIfllMI- IliOCr'lh 7I\!F
TOT\I.
RATE
AWrsr.MFNT
TIME ALLOWED
TI?.:E LOST
APPROftP— PUT. llf\D
DATE
MflR.M.NC;
IN
Ol'T
IN
Ol'T
OVlhTIMF
IN T OLT
TotaJj
ID
1-1?
3-19
4-20
5-21
6-22
7-23
8-24
9-25
10-26
11-27
15-31
NO. 6 — 030"56
AMERICAN HOIST & DERRICK CO.
ST. PAUL 1, MINN.
24
-------
Q
5
HI
o
o
CO IL)
< -
"I
z
5
Q.
'IVi
1
!i
<
«/
ce
3
'lUJ
s
<3
•(JOl'J
eei
9SV
ca
-204066
ttttttbS
25
-------
UJ
Q
Qi
O
< z
•- <
UJ
*<
0 N
UI0
K*
t-
a
a z
uj u
x -J
ua
aaaao »aoM 'INIVW
26
-------
O£.
UJ
Q
O£.
o
To
-,*
i/i
y;
01
^
ill
«
IS««Z
i-
0
bu
o
1-
z
_l
0.
1 ACCOUNT NUMBER
}_
<
Q
z
o
CL
1 EQUIPMENT DESCRI
LU
•^
H-
riNTERTLANT
1 WORK ORDER #
[
X
u
l~
*
J
X
Q.
X
u
Ul
•s.
-
u
Ul
Ul
| CARP.
Ul
Z
o
a
Ul
ta
[DESCRIBE WORK TO
O
t- .
. z
q o
S h
u Z
m X
U h
§3
u c
o o
c u.
u .
2 H
U 0.
lu tt
h b
o. z
u u
u .
X J
u a.
>-
CD
0
O
—j
1 PHONED IN BY:
y
q
u!
0
in
0
pi
0.
27
-------
O-
D
LU
1—
O 2
DC
O
Q_
DC
£ O
LU f )
U ^
II 1 ^^
f^ ™^"*
^
V)
V9
>• <^»
s
^o-o-cr?
co co ,« a.
LU LU Jij X
P P ^
O*: < £j
(i — =:
~> ^ al f-
< ^ < O
LU LU
? <
I Z
o as
CO $
_: O
t/5 U
< 3
V
u
O
^M»
^
0£
J^S 1 I
CO
z
o
oc
LU
^
LO
fs
K
^
u
0
O
Z
y
Z =3
** *^ ~ ^ ** ^ ^
z P
o
8
^>
LU LU LU
MM Z M
00 CO _ O °°
i —
1 5 K 1
-**" 1 — LU _j
Q_ Cki °° — 0-
U» ^^ ^.^ wj> x>
O O « ^ uj O
r^ »— ^ U f- ^-
ff^ Br Q£
£z=?OO^ Xu
(jUJ^i_|_JL COOJ
^o^<
-------
Date
TABLE B-6
TRUCK DRIVER DAILY LOG
Truck No.
Driver
Time Start-
Time Fin.
Lunch from
to
Total Hr.
List below every step: time started, finished; weight; unloading time; delays and reasons
Time
From To Explanation (loading, unloading, etc.) Trlr.
No.
Load Min.
29
-------
TABLE B-7
PURCHASE REQUISITION
PAGE OF
REQUISITION DATE
PHARGE TO ACCT.
P. Oo NO,
P. 0, DATE
DATE REQUIRED
VENDOR ;
TERMS
P.OTTTING
DELIVER TO
QTY
SHIPPING PL 'NT
FOB POINT
ITEMS
PRICE
i
SEND YELLOW ORIGINAL TO PURCHASING DEPARTMENT
SJGfcEr APPROVED
30
-------
"5
0
'•»
zrD
D
'c1 >•
Z 3 £
1 s^? g
a
CC
**-
c
1 ^fi s
:r™ *™ (D t"
« -Q — —-
-Q
S 1DD i
00
1
CQ
LLJ
1
t—J
rf\ »
^r 1"^
•^ ft f*
P t/>
O
I
«/>
«
'hi
3
'E*
fc "w
i S
= o
7 ^^
H •£
_ CO
z a
** 3
u. o
>• O O
< fe °
5r EC
< o •»=
20. O
••g AMERICAN
RICAN & DERRICK CO
^ffi SUPERVISOR'S 48 HOUR RE
No. 101
r File No. - — _
Supplementary Record
.OYER
i
!
i
1
V)
is?
'o
0
(/]
. Man aaaress (No. and street) '
Location, if different from mail address
RED OR ILL EMPLOYEE
f
r
j
T
y—
u
s
*
o
i _0)
,T rtj
± E
0)
LL
D
jO)
(0
2
D
i **
I 1
^ o>
u
5 x
« o>
1 W
» i ^'
- fl)
F
•— (A
£
•o
•o
(D
.
3
'E1
"o
a
to
ai
c
§
O
i
(D
ffi
5. Occupation — — — -
Enter regular job title, not the specific activity hi
>
6
|
(^
e
£
a
01
iS
£i
>•
ID
E
0>
£
j:
01
3
O
j:
c
0)
S
1
X
o
a
i
>
te
1
V)
'i 2?
« m
S Z
a J
? .J
2. J
^ <
« > Z
€| 0
). Department — _ : — -
Enter name of department or division in which
working in another department at the time of inj
ACCIDENT OR EXPOSURE TO OCCUPATI
£ « S
Sis
11"
». _ fl)
fii
£*• -n
Q'=?
rj£ " c
£S fe £
^ c-e •£
o <• E ^
8«g |
•-§> ?
£•2-0 ?
Hi? i
2 tu: '
' Q.— «i
CM £ «
'- fc » n 5
IP Z 5
91 O m *-
Ja-S PI "c*
•S E *: u 0-5
'3 S ° 'S S
~ «-S c ?^
s ~ S £ S
Si!" , ffi -S-o
WS8S ^ &S
°="si n "E
>. « t * . U 5 «
~ D. 3 S » >£ •£
— "S o-5 " *
a ° ? i -^ | P
S c a) Q. !S -C c
ills 1 :-•
S o -w P t; "C
o ^. ^ *•• CO ai
§"£•5 « J5»
•|r«S a |?
y* ^J (Q 3 (A (J> O)
.8 IS 8 | Sif
E| > S g- 13?
P -S 2 — — ">
sa~ S >• a r--=
Su.^-S.a E •PS
3. Place of accident or exposure-p^-^^^
If accident or exposure occurred on employer':
departmenr or division within the plant or esta
give that address. If it occurred on a public hii
provide place references locating the place of inj
1. Was place of accident or exposure on ei
2 What was the employee doing when injure
Be specific. I f he was using tools or equ ipment (
-
X
r-
31
-------
*.
> c
C V
™:2
;£
Q. >
a >
JC >;
«- 2
||
~— to
H =
^ 0
SJ5
'— "c ? «
• .° = -s
"t ~_ T
~ (0 (D __
O c c 3
Ura.o--
-— >w 0)
— - aS >
00 a$ oO
m og|
UJ w o|
^ S£.t
< -S-ls
• .. n\
I-™ s
ra jc
v_ *-• >
S.E£
K^;
03 «- 0
= 3f
-Kg
ss?
(J -C ™
8*1
*- « ^
c JF o
a) 5 >
S 8.5
'o
m ^ ^
™ " c
0) > ra
«II
sta
'€&
g 8J3
O o> o
IQ.S.
CO
I
i
i
i
a
0)
~n
C
s
**
t
1 Z
o
M
f (D
1 E
! 1
; TJ
*
• o>
"SI
•*-< *•
Is
.^6
i "5 a
: >."S
i
1
I
T3^
f $
o;
t: °
nj 5,
0-D
J8 li
^ st-
1 (DC
~i .y o
= TJ-"
. C-D
»J C
< -a 8
? c S
0 "2
» ."^ TO
1- £ %
<
O
3j
+-
TS
$
5
(fl
1
i_
o
•p ci
d> t-t
1
ra <" :
1? i
*= 1
i: D
c a
8_i
?
'5-c
a«-
L_ ^ —
o »
k. 5
§ s
«£
> ^
... en
i
1
*c i
• " £ '
$60,
>S £
^f -
D. 0 0
E|S
<" S „•
's5
o «2
11!
j: t> c
sr substance whi'-
achine or thing he
•ritated his skin; or
y ? u
15. Name the obje
For example, th
or radiation whii
i
1
1
•- > >-
SfeS
:• £ o Q
S; ? a«
2 E E-c
° S S.21
XQ.H--J
(/)
s
c
ODD
OJ
>»
M-
—
O
^.
a
~~* +j
"S !Q
C ~
V
C7i
rc
c
<0
5
c
«J
a
03 IX
~ ! > 9- S i
Q.
V)
o
o
y,
0}
w
T3
T3
ro
•D
C
ro
a>
e
i- .£ S ii
0 T3 £ .
>• 0) TI "o"
!- 0) T3 0)
-J >- TO NJ
:§• -i ? =5
,,_ D. C <-•
^ E ro 'a
_% flj 0) w>
Is § J
Q Q 2 *•
DC -
«o ^' ii! od c3i
i -a £• O 1
•ggH
ro 2
o
S
a.
1
1
atments (sutures, -.-,
"V I
Date of reoort.
de details on medical
a
D
^)
i
y
CM
is.
^^
IO
i
X.
»-l
o
(N
IT
L d
2
g - - - £ - - 1 Ig |
32
-------
«»
(D
.Q
3
W h_
— 0 C
P\l *•** T*
1 C y
III
n "8 3 o E c
>t- "S 5 u oi ° c
• 23 «> o § to 'C g>
$ O01 o c t .£ 5 .£
3 P> 0 .0) n3 — •?"
O> 2 n-^'Sm-Dojiaa)
,S OS™u'«--j51»-»-»5
3 uicc'*-5n'5-5^
& JJ[£DQDIDDD
'I IDDDDDDDD
^0 D'-cMnn-mtor-co
. -{J
j- n
c s
o
^J
CO
CO
i — •£ c
CO [-1 S » o
£
S
h.
^
a
*4^
1
T
"n
^t
'v
5
X
C
c
t
'>
a
i
c
c
<
K
1.
n
>
L
c
0)
E
a
(U
a *
8.8
c 2
n »
s t
c w
1 1
b> ° °
C c C
jZ Z .2 .2
2O ^D flj
£ E "c ? Q.
n) Q c c D
§ 0 1 -D E E 5
°ol!5£885
CUJ CC CC U.
tt ^DDDDDD
10 z . ...
§> *~
u
0)
o
O rv
a) aj
5 'i
! '.s
"H> *~
£ E
4-* *—
™ -K
iUIDES TO CORRECTIVE ACTION
lased on the cause checked above, indii
INSAFE ACT
. D Stop the Worker
. D Study the Job
. D Instruct (Tell-Show-Try-Check)
. D Follow Up
. D Enforce
Vhat are vou actually doing to prevent
33
-------
I
00
CO
1
.2
1
What further recommen
\
1
1
1
Eyewitnesses
S
O
IM
|
U
£
2
3
V
C
n
*•
* *
£ o
a t;
i s
^
«- o>
0 =
C 3
o!
11
5l
S o
£ **
i!
it
(1) Only one "X" can be i
(2} There can be several "
s.
J
0
UJ
Cfl
|
UJ
CC
<
2
UJ
0
_i
UJ
z
z
o
cc
U
0.
Employee's address
5
§
C
'i
Q)
?
S
"8
&
o>
4-t
to
O
2-
3
'JET
Date employee reported
0)
**3
>
«
S
.?
T^
u
1
tt
UJ
VI
.i
is
u
TJ
"<5
0
First day off work
Dates of previous injurie'
vt
|
^
(D
Qp
».
0
o.
s
•1
c
£
V
E
£
a
E
E £ 8
8O «
•=. 2
•E § or
s s •
'E 'E c
0) 0) «
M to E
0
E
CN
T^
1.
Q.
u
n
M
tT c
a c
™ o
l« -•>
> 01
n O
c J
« *•
c o
* o
fi
a<5
£o
. V
n JC
u **
Is
E t
S5
c c
Number of first aid cases
Date of employment
Service in department
NOTE: Submit photos, sketc
NOTE: Carry this informal
34
-------
7 o
1 u_
<* LU
LU y
<1
DC
DC
LU
O
00
&
O
i M
ffl ffi
§ 1
z 5
D
U~>
O
Z
-
O
8
y
>•
cr
z
<
a.
x
LU
Ot
LU
os
°
Q-
1
5
CL.
x
D
I 1
z z
Q O
00 CO
— ct
•A 2
< o
§
u
LU CO
•< CO
^ in
< S
Z Q
O
CO — '
35
-------
Q
LU
U
O
O-
LU
o U
T Z
OQ <
LLJ Z
_l LLJ
I
Z
LU
I
a.
3A/S
3K1X
idlHS
o
*
w
w
&
o
M
PS
w
cu
m
CM
f— 4
m
LLt
t-l
rs
t~H
rf*^
ta
o
i— i
0*
CO
r.
*
*
~3r
rn
CN
i— i
WORK PERFORMED BY DEPT #
ex
3
cr
4-1
O CO
-o
c -i
O pq
-U
a.
•H
o -1-1
« a.
0) CJ
O Q
vD
i/
O
O
Pt
> H
O
Pi
S
u-i'
in
£
O
Work Description:
36
-------
APPENDIX C
BALING PLANT EQUIPMENT DESCRIPTION
37
-------
TABLE C - 1
EXISTING 137 - SECOND CYCLE BALER DESCRIPTION
HARRIS PRESS & SHEAR CORPORATION
SALES OFFICE 63 SO ROBERT STREET. ST HAUL. MINNESOTA 55IO7
DATE: rr~.T—i
SUBSIDIARY OF Ar.tVIU N HOIST
PROPOSAL SPECIFICATION: 710925
AirrOMATIC BALING PRESS MODEL: SlVC-2528-36x36
STYLE: Offset Box
GENERAL LAYOUT DRAWING: 4A-S588
APPLICATION:
A CAPACITY AND RATING:
Al WEIGH HOPPER LOADING DIMENSIONS:
Carefully selected solid waste material
suitable for packer truck handling
A2 CHARGING BOX OPENING:
A3 PRESS BOX DIMENSIONS:
A4 PRESS BOX CAPACITY:
A4.1 BALE CHAMBER:
A4.2 CHAMBER CAPACITY:
AS BALE SIZE:
A6 BALING FORCES:
A6.1 FIRST COMPRESSION RAM FACE:
A6.2 SECOND COMPRESSION RAM FACE;
A6.3 THIRD COMPRESSION RAM FACE:
A7 BALE WEIGHT:
A7.1 COMPRESSED:
A7.2 EXPANDED:
A8 BALING CYCLE:
COMPONENTS:
Bl ELECTRIC MOTORS:
Bl.l MAIN SYSTEM:
144" wide x 36" deep x 228" long
(684 cubic ft)
68" x 228"
68" wide x 60" deep x 280 1/2" long
680 cubic feet
70" wide x 123" deep x 36" long
179 cubic feet
36" x 36" x variable
172 p.s.i.
1450 p.s.i.
2740 p.s.i.
Average 2000-3000 Ib
2500 Ib average, 36"x 3>6"x 48"
2500 Ib average, 38" x 38"x 60"
137 seconds (44 cycles/hour)
.Three (3) 150 HP, 1750 IIPM, 460 volt,
Ip, 60 Hertz, protected.
AREA CODE 612 • TELEPHONE 2Zq 4236
C-2
38
-------
B COMPONENTS: (Continued) «wswtss*sK«n. ..- .
TABLE C-l (Cont.)
Bl ELECTRIC MOTORS: (Continued)
B1.2 PILOT SYSTEM: One (1) 25 HP, 1750 RPM, 230/460 volt,
3<5, 60 Hertz, protected.
B1.3 COOLING SYSTEM: One (1) 3 HP, 3500 RPM, 230/460 volt,
3j5, 60 Hertz, protected.
B1.4 SUPERCHARGE SYSTEM: One (1) 25 HP, 3500 RPM, 230/460 volt,
3(5, 60 Hertz, protected.
B2 ELECTRIC CONTROL SYSTEM:
B2.1 One (1) NEMA Class 2, Type C, NEMA 1A enclosed motor control center
equipped with combination circuit breakers and across-the-line motor
Starters for 440 to 600 volt power with control transformers.
B2.2 One (1) operator's station enclosure to include oil tight control
switches and signal lights, wired to terminal strips.
B3 HYDRAULIC SYSTEM:
B3.1 MAIN PUMPS: Three (3) Vickers 75 GPM and 3500 psi max.
Three (3) Vickers 150 GPM and 2000 psi max.
B3.2 PILOT PUMP: One (1) Vickers 18/7 1/2 GPM and 2000/750 psi
B3.3 HEAT EXCHANGER: One (1) 75 GPM and 20 psi
B3.4 SUPERCHARGE PUMP: One (1) 320 GPM and 50 psi
B3.5 VALVES: Harris or equal
B3.5.1 Individual relief valves protect each pump from
overload pressure.
B3.5.2 Directional valves are electrically controlled and
hydraulically operated.
B3.6 CYLINDERS: Harris double acting all places; Teflon protected pistons in
honed bores; rods flame hardened, ground and polished; stand-
ardized rod wipers, chevron packing and "0" ring gaskets.
B3.6.1 FIRST COMPRESSION: 16" bore, 352 tons
B3.6.2 SECOND COMPRESSION: 36" bore, 1780 tons
B3.6.3 THIRD COMPRESSION: 36" bore, 1780 tons
B3.6.4 BALE GATE: 12" bore, 113 tons
B3.6.5 HOPPER: 10" bore, 78 tons
B3.6.6 COVER: 12" bore, 113 tons
C-3
PROPOSAL SPECIFICATION - SWC-2528-36x36 Page 2 of 5
-------
TABLE C-l (Cont.)
B COMPONENTS: (Continued)
B4 FILTERING AND COOLING SYSTEM:
B4.1 Filtering is by combination of screens, tank magnets and
replaceable cr.rtridge type micronic filters.
B4.2 Standard cooling system is oil to water type heat exchanger.
C OPERATION:
Cl There are three modes of operation: Manual, semi-automatic and automatic
repeat. Manual operation is provided primarily for set up and maintenance
purposes. Semi-automatic is usually preferred in conjunction with batch
feeding. Automatic repeat mode is normally synchronized with conveyor or
other automatic methods of charging waste and handling finished bales.
C2 With weigh hopper'the charging sequence is as follows: All waste is
weighed by the hopper and dumped from the hopper into the press. When
the press is being operated in the semi-automatic mode, the hopper is
dumped by manual pushbutton and the baling cycle is initiated by manual
pushbutton, each from the operator's station. When the press is operated
in the automatic repeat mode, the hopper dumping cycle is synchronized
with the baling cycle and interlocked with the scale so that the press
is charged only when the baling cycle is in the correct phase and the
proper weight of waste is in the hopper. Dumping of the hopper also
initiates the subsequent baling cycle of the press.
C3 At the start of a baling cycle the first compression ram extends fully
forward; the second compression ram extends to the fully down position
and the third compression then extends to complete the bale. The bale
door opens and the bale is ejected by the third compression ram. In
proper sequence, the third compression ram retracts, the bale door closes,
the second and first compression rams retract to complete one baling cycle.
D CONSTRUCTION:
Dl The Model SWC-2528-36x36 design follows established Harris standards.
02 Major sub-assemblies are heavy plate and structural weldments, stress
relieved before machining to design dimensions.
D3 Final assembly is bolted and keyed in accordance with good engineering
practices.
D4 Press box, baling chamber and ram wear surfaces are fitted with replaceable
wear plates of heat treated alloy steel.
US All liner plates are sectional design for ease of replacement.
D6 The compression faces of all rams are fitted with replaceable wear plates
of heat treated alloy steel.
D7 All replaceable wear plates are securely fastened with Harris patented
screws' and through bolts.
C-4
PROPOSAL SPECIFICATION - SIYC-2528-36x36 Page 3 of 5
40
-------
TABLE C-l (Cont.)
D CONSTRUCTION: (Continued) •-».--•
D8 All rams arc box type steel weldments, stress relieved and machined to
design dimensions.
D9 Hopper is single weldmcnt from steel plate and structurals.
D9.1 Weighing means is by load cells.
D10 All pipe is electrically welded and securely anchored.
Dll Pipe flanges are steel, bolted type, with "0" ring gaskets.
D12 Each Harris machine is completely assembled, operated and tested before
shipment.
D13 Standard'paint is machinery enamel over primer coat.
D14 Shipping weight: 740,000 Ib, approx
E GENERAL:
El Layout and foundation prints show above grade dimensions and conditions.
Below grade soil conditions, piers, piling, footings and associated com-
ponents are matters of local determination for which Harris can accept
no responsibility.
•E2 Harris technical services are available on a free advisory basis to assist
in determining the location and material flow conditions best suited to
utilize the high production of Harris equipment.
E3 This proposal also includes the services of a qualified installation specialist
for 10 eight-hour working days. He will supervise the unloading and assembling
of the press, place the press in operation and instruct your operator in recom-
mended operating and maintenance procedures. (Transportation and sustenance
outside the continental United States is for the purchaser's account.)
F EXPENSES ASSUMED BY THE PURCHASER TO COMPLETE THE MACHINE INSTALLATION!:
Fl Railroad freight from Cordele to destination.
F2 Preparation of foundation.
F3 Unloading and assembling the press.
F4 Wiring from power source to electric control panel.
F5 Wiring from panel to main and auxiliary motors, also control wiring from
panel to junction boxes and to pushbutton station.
F6 Furnishing all fuses.
F7 Making connections to filter and cooler.
F8 Furnishing approximately 1800 gallons of hydraulic oil for the hydraulic
system.
C-5
PROPOSAL SPECIFICATION - SWC-2528-36x36 Page 4 of 5
-------
MflRMtS PM $*•• 6, 3-l£fiH C!>MiHAT.jrrf
TABLE C - ] (Cent.)
G WARRANTY:
Gl The seller guarantees its product for the period of six months after date
of delivery FOB Cordele, Georgia, against defects in material and workman-
ship for use within the capacity defined in Section A. No guarantee shall
exist if unauthorized alterations have been made by the owner or user, or
stated capabilities of machine exceeded. In case any material or workman-
ship shall prove defective, the seller's liability will be limited to
repairing any defect in workm.inship or replacing defective part packaged
for shipment FOB Cordele, Georgia. All outside purchased equipment and
accessories are guaranteed only to the extent of the original manufacturer's
guarantee, shear blades included, no exceptions. Manufacturer reserves the
right to change the design and construction of the product when in their
opinion it represents an improvement of any part or the entire product.
Seller-shall have no liability or responsibility for consequential damages
of any kind including damage or injury to persons or property arising out
of use or operation of said article.
C-6
PROPOSAL SPECIFICATION - SWC-2S28-36x36 Paie 5 of
42
-------
SW-IO
TABLE C - 2
90 - SECOND, CYCLE BALER DESCRIPTION
PROPOSAL NO
J»AG1_
PROPOSAL SPECIFICATION: 71100U
AUTOMATIC BALING PEESS MODEL: SWC-2528-36 x 36 -
STYLE: Offset Box
GENERAL LAYOUT DRAWING: ltA-5588
APPLICATION:
A CAPACITY AND RATING:
Al WEIGH HOPPER LOADING DIMENSIONS:
A2 CHARGING BOX OPENING:
A3 PRESS BOX DIMENSIONS:
A^ PRESS BOX CAPACITY:
AU.l BALE CHAMBER:
A^.2 CHAMBER CAPACITY:
A5 BALE SIZE:
A6 BALING FORCES:
A6.1 FIRST COMPRESSION RAM FACE:
A6.2 SECOND COMPRESSION PAM FACE:
A6.3 THIRD COMPRESSION RAM FACE:
A7 BALE WEIGHT:
A7.1 COMPRESSED:
A7-2 EXPANDED:
A8 BALING CYCLE:
B COMPONENTS:
Bl ELECTRIC MOTORS:
Bl.l MAIN SYSTEM:
Solid vaste material suitable for
packer truck handling.
lUU" wide x 36" deep x 228" long
(68U cubi.c ft.)'
68" x 228"
68" wide x 60" deep x 280 1/2" long
680 cubic ft.
70" wide x 123" deep x 36". long
179 cubic ft.
36" x 36" x variable
172 p.s.i.
1U50 p.s.i.
27^0 p.s.i.
Average 2000-3000 lb.
2500 lb. average, 36" x 36" x U8"
2500 lb. average, 38" x 38" x 60"
90 seconds (1*0 cycles/hour)
Four (1*) 150 HP, 1750 RPM, 1*60 volt,
3^, 60 Hertz, protected.
AMERICAN
SYSTEMS
63 SO. ROBERT ST. • sr PAUL, MINNESOTA 55107
DIVISION OF AMERICAN HOIST & DERRICK COMPANY
C-7
CPI
43
-------
TABLE C -2 (Conf.)
PROPOSAL NO..
B COMPONENTS; (Continued)
Bl ELECTRIC MOTORS: (Continued)
B1.2 PILOT SYSTEM:
B1.3 COOLING SYSTEM:
Bl.lt SUPERCHARGE SYSTEM:
B2 ELECTRIC CONTROL SYSTEM:
One (1) 25 HP, 1750 MM, 230/^60 volt,
3^, 60 Hertz, protected.
One (1) 3 HP, 3500 MM, 230/U60 volt,
3^, 60 Hertz, protected.
One (1) 25 HP, 3500 MM, 230/**60 volt,
3^, 60 Hertz, protected.
B2.1 One (l) NEMA Class 2, Type C, NEMA 1A enclosed motor control center
equipped with combination circuit breakers and across-ths-line motor
starters for MtO to 600 volt power with control transformers.
B2.2 One (l) operator's station enclosure to include oil tight control
switches and signal lights, wired to terminal strips.
B3 HYDRAULIC SYSTEM:
B3.1 MAIN PUMPS:
B3.2 PHOT PUMP:
B3.3 HEAT EXCHANGER:
B3.lt SUPERCHARGE PUMP:
B3-5 VALVES: Harris or equal
Four (k) Vickers 75 GPM and 3500 psi max.
Four (It) Vickers 150 GPM and 2000 psi max.
One (1) Vickers 18/7 1/2 GPM and 2000/750 ps
One (1) 75 GPM and 20 pal
One (1) 320 GPM and 50 psi
B3.5-1 Individual relief valves protect each pump from
overload pressure.
B3-5-2 Directional valves are electrically controlled and
hydraulically operated.
B3-6 CYLINDERS: Harris double acting all places; Teflon protected pistons in
honed bores; rods flame hardened, ground and polished; stand-
ardized rod wipers, chevron packing and "0" ring gaskets.
B3.6.1 FIRST COMPRESSION:
B3.6.2 SECOND COMPRESSION:
B3.6.3 THIRD COMPRESSION:
16" bore, 352 tons
36" bore, 1780 tons
36" bore, 1780 tons
SYSTEMS
AMER 1C AN
63 SO. KOBfKT ST. • ST. PAUL, MINNCSOTA 55/07
DIVISION OF AMERICAN HOIST i, DERRICK COMPANY
C-8
44
-------
TABLE C-2'CCont.)
PROPOSAL NO. PAGE
B COMPONENTS: (Continued)
B3.6 CYLINDERS: (Continued.)
B3.6A BALE GATE: 12" tore, 113 tons
B3.6.5 HOPPER: 10" bore, ?8 tons
B3.6.6 COVER: 12" bore, 113 tons
BU FILTERING AND COOLING SYSTEM:
B1*.! Filtering is by combination of screens, tank magnets and
replaceable cartridge type micronic filters.
B^.2 Standard cooling system is oil to water type heat exchanger.
C OPERATION:
Cl There are three modes of operation: Manual, semi-automatic and automatic
repeat. Manual operation is provided primarily for set up and maintenance
purposes. Semi-automatic is usually preferred in conjunction with batch
feeding. Automatic repeat mode is normally synchronized with conveyor or
other automatic methods of charging waste and handling finished bales.
C2 With weigh hopper the charging sequence is as follows: All waste is
weighed by the hopper and dumped from the hopper into the press. When
the press is being operated in the semi-automatic mode, the hopper is
dumped by manual pushbutton and the baling cycle is initiated by manual
pushbutton, each from the operator's station. When the press is operated
in the automatic repeat mode, the hopper dumping cycle is synchronized
with the baling cycle and interlocked with the scale so that the press
is charged only when the baling cycle is in the correct phase and the
proper weight of the waste is in the hopper. Dumping of the hopper also
initiates the subsequent baling cycle of the press.
C3 At the start of a baling cycle the first compression ram extends fully
forward; the second compression ram extends to the fully down position
and the third compression then extends to complete the bale. The bale
door opens and the bale is ejected by the third compression ram. In
proper sequence, the third compression ram retracts, the bale door closes,
the second and first compression rams retract to complete one baling cycle.
D CONSTRUCTION:
Dl The Model SWC-2528-36 x 36 design follows established Harris standards.
D2 Major sub-assemblies are heavy plate and structural weldments, stress
relieved before machining to design dimensions.
D3 Final assembly is bolted and keyed in accordance with good engineering
AMERICAN jjjjjjjjjls Y S T E I
63 SO. ROBERT ST. • ST PAW, MINNESOTA 55TO/
DIVISION OF AMERICAN HOIST & DERRICK COMPANY
sw.io C-9
45
-------
TABLE C-2 (Cent.)
PROPOSAL NO. PAGE.
D CONSTRUCTION: (Continued)
Eh Press box, baling chamber and ram wear surfaces are fitted with replaceable
wear plates of heat treated alloy steel.
D5 All liner plates are sectional design for ease of replacement.
D6 The compression faces of all rams are fitted with replaceable wear plates
of heat treated alloy steel.
D7 All replaceable wear plates are securely fastened with Harris patented
screws and through bolts.
D8 All rams are box type steel weldments, stress relieved and machined to
design dimensions.
D9 Hopper is single weldment from steel plate and structurals.
D9-1 Weighing means is by load cells.
D10 All pipe is electrically welded and securely anchored.
Cll Pipe flanges are steel, bolted type, with "0" ring gaskets.
D12 Each Harris machine is completely assembled, operated and tested before
shipment.
D13 Standard paint is machinery enamel over primer coat.
DlU Shipping weight: 750,000 lb., approximate
E GENEBAL:
El Layout and foundation prints show above grade dimensions and conditions.
Below grade soil conditions, piers, piling, footings and associated com-
ponents are matters of local determination for which Harris can accept
no responsibility.
E2 Harris technical services are available on a free advisory basis to assist
in determining the location and material flow conditions best suited to
utilize the high production of Harris equipment.
E3 This proposal also includes the services of a qualified installation specialist
for 10 eight-hour working days. He will supervise the unloading and assembling
of the press, place the press in operation and instruct your operator in recom-
'mended operating and maintenance procedures. (Transportation and sustenance
outside the continental United States is for the purchaser's account.)
F EXPENSES ASSUMED BY THE PURCHASER TO COMPLETE THE MACHINE INSTALLATION:
Fl Railroad freight from Cordele to destination.
F2 Preparation of foundation.
AMERICAN /,^^~? SYSTEMS
63 SO. ROBERT ST. • ST PAUL, MINNESOTA 55107
DIVISION Of AMEBICAN HOIST 4 DEHKICPC COMPANY
C-10
46
-------
TABLE C -2 (ConM
PROPOSAL MO. PACE_
F EXPENSES ASSUMED BY THE PURCHASER TO COMPLETE THE MACHINE INSTALIATION: (Continued)
F3 Unloading and assembling the press.
FH Wiring from power source to electric control panel.
F5 Wiring from panel to main and auxiliary motors, also control wiring from
panel to junction boxes and to pushbutton station.
,F6 Furnishing all fuses.
F7 Making connections to filter and cooler.
F8 Furnishing approximately l800 gallons of hydraulic oil for the hydraulic
system.
G WARRANTY:
Gl The seller guarantees its product for the period of six months after date
of delivery FOB Cordele, Georgia, against defects in material and workman-
ship for use within the capacity defined in Section A. No guarantee shall
exist if unauthorized alterations have been made by the owner or user, or
stated capabilities of machine exceeded. In case any material or workman-
• ship shall prove defective, the seller's liability will be limited to
repairing any defect in workmanship or replacing defective part packaged
for shipment FOB Cordele, Georgia. All outside purchased equipment and
accessories are guaranteed only to the extent of the original manufacturer's
guarantee, shear blades included, no exceptions. Manufacturer reserves the
right to change the design and construction of the product when in their
opinion it represents an improvement of any part or the entire product.
Seller shall have no liability or responsibility for consequential damages
of any kind including damage or injury to persons or property arising out
of use or operation of said article.
AMERICAN U-g SYSTEMS
63 SO. ROBERT ST. • ST PAUl, MINNESOTA 55107
DIVISION OF AMERICAN HOIST & DERRICK COMPANY
sw-io ~ CM
47
-------
TABLE C -3
EPA CONTRACT NO. 68-03-0332/AMERICAN HOIST COMPANY
EQUIPMENT DATA FORM
Equipment name Fork lift
Use Remove cardboard bales, lift wood/ lift parts, etc.
Manufacturer Clark Equipment Company
Model Clarklift CF 40 Type G Serial CF 40B-149-2052 069
Size NA Class NA
Mfrs.max. load 4,000 Ibs (1,816 kg) Mfrs. max, rate 2,000 Ibs (908 kg)
Bale plant design load 4,000 Ibs (1,816 kg) Bale plant design rate 2/000 Ibs (908 kg)
Utilities ]) None 2) 3)
(Voltage, pipe size, flow capacity)
4) 5)
New price_ Depreciation rate period
Overhaul price Setup price_
Parts inventory
Backup equipment
Specs: Weight 3,940 Ibs Dimensions 38" W x 84" H x 118" L
,, . _ ~.(1,78? kg) ~"T (0.97 m V2713 m x 3.0 m)
Mounting Rubber tires Power
Auxiliary equipment/
fittings/too Is/attachments None
48
-------
TABLE C-4
EPA CONTRACT NO. 68-03-0332/AMERICAN HOIST COMPANY
EQUIPMENT DATA FORM
Equipment name Bobcat Loader (On Loan)
Use Push segregated cardboard to store; feed conveyor, cleanup
Manufacturer International Harvester
Model 3200 A Serial
Size Class
Mfrs.max. load 1,500 Ibs (13cu ft) Mfrs. max. rate Speed 0-8 mph (0- 5 km/h)
(681 kg) (0.36 cum)
Operating capacity 1,250 Ibs Bale plant design rate
(568 kg)
Utilities 1) 2) 3)
(Voltage, pipe size, flow capacity)
4) 5)
New price Depreciation rate period
Overhaul price Setup price
Parts inventory __
Backup equipment
(1.09mx 1.42m x 295m)
Specs: Weight 3.620 Ibs Dimensions Overall W - 43" x 56" Hx 116" L
(1643 kg) (with bucket)
Mounting Rubber tires (4) Power 30 brake horsepower
A. ... . 4/ @2,800rpm
Auxiliary equipment/
fittings/tools/attachments Engine: Wisconsin VH 4D. 4 evl. 4 r
49
-------
TABLE C-5
EPA CONTRAa NO. 68-03-0332/AMERICAN HOIST COMPANY
EQUIPMENT DATA FORM
Equipment name Bobcat - Wheeled loader (in repair during monitoring)
Use Segregate to stack cat-board & metal; general cleanup; pile solid waste; feed baler
Manufacturer Melroe Div. Gwfnner, No. Dakota
Clark tquipment Company " ~
Model 600 Serial 70393
Size Class NA
Mfrs.max. load 1/2 cu yd (.38 cu m) Mfrs. max. rate NA
Bale plant design load 1/2 cu yd (.38 cumfrale plant design rate NA
Utilities 1) 2) 3)
(Voltage, pipe size, flow capacity)
4) 5)
New price Depreciation rate period
Overhaul price Setup price
Parts inventory
Backup equipment
(16.4 m x 16.4 m x 29.5 m)
Specs: Weight Dimensions 5 ft Hx5ftWx9ftL
Mounting Wheeled - rubber tire -4 Power Wisconsin; heavy duty air-coo led,
A M- • */ M^6' VF4D (8 26
Auxiliary equipment/ .. , / , l°.£° cm x
fittlngs/tools/attachments C' ^." .1 0220^0
Serial no. 4905230
Wisconsin Motor Corp.
Milwaukee, Wisconsin
50
-------
TABLE C-6
EPA CONTRACT NO. 68-03-0332/AMERICAN HOIST COMPANY
EQUIPMENT DATA FORM
Equipment name 42 E Sweeper
Sweep up tipping floor
Manufacturer Tennant Co. f Minneapolis,. Kft]
Model 42 Heavy duty _(42E-Hd\ Serial
„ Overall-62" L x 35" W x 34" H (1 .5 m x.,.89
„ . m x.,. m x .86 m)
Size sweeper area on floor - 2T7' W x 12" I Class NA
Mfrs.max. load
(68.6 cm x 30.5 cm)
NA Mfrs. max. rate
NA
NA
Bale plant design load
Utilities 1) 24 volt _ 2)
(Voltage, pipe size, flow capacity)
4) _ 5)
Bale plant design rate NA
3)
New price
Overhaul price
Parts inventory
Depreciation rate
Setup price
period_
Backup equipment Truck sweeper
Specs: Weight 150 Ibs (68 kg) Dimensions See size above
Mounting Rubber wheels 9" P.P. x 1 1/2" Thd
Auxiliary equipment/ (22.9 cm x 3.8 cm)
Power Wall socket for charging
bc*tery
fittings/too Is/attachments Electric cord for charging battery
51
-------
TABLE C-7
EPA CONTRACT NO. 68-03-0332/AMERICAN HOIST COMPANY
EQUIPMENT DATA FORM
Equipment name Loader
Use Feed solid waste to conveyor
Manufacturer Caterpillar
Model 930
Size See dimensions below
_Serial_
Class
o
Mfrs.max. load 2? cu yd (1 .72 m ) Mfrs. max. rate NA
19,700 Ib (8,930kg)
Bale plant design load NA
Utilities 1) 2)_
(Voltage, pipe size, flow capacity)
4) 5)
Bale plant design rate NA
3)
New price $31,781
Overhaul price
Parts inventory
Depreciation rate
Setup price
period
Backup equipment
Specs: Weight 20,494 Ib
Mounting
(9,220 kg)
Auxiliary equipment/
fittings/too Is/attachments
15'6i"H X20'6" L
Dimensions (4.74 m X 6.25 m)
PoweHOP flywheel horsepower @
2,200 rpm
52
-------
TABLE C-8
EPA CONTRACT NO. 68-03-0332/AMERICAN HOIST COMPANY
EQUIPMENT DATA FORM
Equipment name Portable Light Generator
Use 4 mercury vapor load lights
Manufacturer Onan _^
Model 6DJB-3E2236 Serial #1170268978
Size 6 KW 120/240 A.C. Class 60 cycle 1 800 rpm Battery = 12V
Mfrs.max. load A»C- Amp = 25 Mfrs. max. rate Diesel 220 V
Bale plant design load Bale plant design rate
Utilities 1) 2) 3)
(Voltage, pipe size, flow capacity)
4) 5)
New price $2,1 85.00 Depreciation rate period
Overhaul price Setup price
Parts inventory
Backup equipment
Specs t Weight 485 Ib (218kg) Dimensions 343/4" Lx 17 1/8" W x 27 1/4" H
(88cm
Mounting Power
(88 cm x 43 cm x 69 cm)
PC
Auxiliary equipment/
fittings/tools/attachments
53
-------
TABLE C-9
RECOMMENDED SPARE PARTS LIST
Item Qi
No. Hi
jan-
y Part No.
Part Name
Price
FIRST COMPRESSION - GATHERER
1 1
2 2
3 1
4 1
5 1
6 1
7 1
1118-M1
2119-H5
818956
21643-AO
4289-AO
20527-GO
818950
Rod Packing
Rod Bushings - Inner & Outer
Rear Head "O" Ring (1700.25)
Bolting Flange
Packing Ring
Packing Ring Dowel £"xl"
"O" Ring (1300.25)
$ 67.37
175.61
5.31
689.74
824.55
J4
3.65
SECOND COMPRESSION & THIRD COMPRESSION
8 2
9 2
10 2
n 2
12 2
13 1
14 1
15 1
16 1
1118-S1
5834- A 1
818970
818971
818885
6104-AO
7937-AO
20527- FO
818969
Rod Packing
Rod Bushings - Inner & Outer
Rear Head "O" Ring (3500.25)
Rear Head "O" Ring (3600.25)
Back- Up Washer (3600. 25B)
Bolting Flange
Packing Ring
Packing Ring Dowel ^"x3/4"
11 0" Ring (3200.25)
110.72
265.25
7.62
11.60
87.26
910.05
1,204.73
.56
9.23
BALE DOOR & LID CYLINDERS
17 2
18 2
19 2
20 3
21 1
22 1
23 1
24 1
1118-H1
1102-B5
1I02-C5
81 8949
5188-A2
4083-A5
20527- DO
818945
Rod Packing
Rod Bushing - Outer
Rod Bushing - Inner
Cylinder Head "O" Rings (1200.25)
Bolting Flange
Packing Ring
Packing Ring Dowel 3/8 x 2
"O" Ring (1000.25)
28.43
15.18
15.18
3.34
133.15
359.84
.14
1.78
"O" RINGS & SEALS FOR ROTARY VALVES & SHIFTER CYLINDERS
25 4
26 2
27 8
28 4
818937
81 9273
818942
818847
"O" Ring (700.13)
U-Cup Seal
"O" Ring (900.13)
U-Cup Seal
.87
2.47
1.69
3.81
54
-------
TABLE C-9(Cont.)
RECOMMENDED SPARE PARTS LIST
Item
No.
29
30
31
32
33
wuan-
itiry
12
6
12
12
12
Part
Number
81 8888
81 8892
81 8901
811671
818925
Part Name
Back- Up Washer (100.13 B)
"O" Ring (100.13)
"O" Ring (200.13)
"O" Ring (275.13)
"O" Ring (375.13)
Price
.06
.13
.20
.25
.36
PIPING "O" RINGS
34
35
36
37
38
39
12
12
5
11
12
12
805403
810787
818912
811517
818936
818941
"O" Ring (275.19)
"O" Ring (388.19)
"O" Ring (488.19)
"O" Ring (500.13)
"O" Ring (675.25)
"O" Ring (875.25)
.24
.29
.56
.60
1.14
2.66
MISCELLANEOUS COMPONENTS
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
1
1
1
1
1
1
1
1
1
1
818380
833519
819456
833520
819457
818439
818586
818410
818409
818412
81 9326
819851
819114
833556
825532
Vickers Piston Pump PFA50-30-R-12
Vickers Vane Pump 50V100A-1 C-10L
Vickers Vane Pump 2520V12A-5-100-10
2,998.27
670.34
341.19
Vickers Vane Pump 4535V60A38-1 AC-10-L 553.13
Vickers Solenoid Valve DG454-016-CH-50 190.70
Vickers Solenoid Valve DG454-012-AH-50 122.00
Vickers Solenoid End Assembly 195053
Dual Snap Pressure Switch 604-PR-21
Dual Snap Pressure Switch 604-PR-31
Dual Snap Pressure Switch 604- GR-11
Allen Bradley Limit Switch ASC2-1
Sier-Bath Pump Coupling C2
Sier-Bath Pump Coupling C2
Sier-Bath Pump Coupling C2
Electric Motor, 150 HP, Frame 445 TCZ
50.63
68.20
76.19
47.40
30.48
38.05
104.35
90.05
3,270.05
55
-------
TABLE C-9(Cont.)
RECOMMENDED SPARE PARTS LIST
Item
No.
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
Quantity
12
12
12
12
12
12
12
12
12
5
12
12
12
8
12
12
12
12
Part-
Number
5582-J
(20753- J 2)
819966
5582- C5
5582- D5
5582- E5
5582-F5
5583- D4
5583- E4
5583- F4
5583- L4
5583-R4
5584-D5
5584- E5
5584- F5
5586- Dl 3
5586- El 3
5586-F13
5586-G13
Part Name
Capscrew 1 "-8 unc x 4" Ig. 50° fl. hd.
Lock Nut l"-8 unc-2B
Capscrew l"-8 unc x 2\" Ig. 50° fl. hd.
Capscrew 1 "-8 unc x 2]" Ig. 50° fl. hd.
Capscrew 1 "-8 unc x 2-3/4" Ig. 5CT fl. hd
Capscrew l"-8 unc x 3" Ig. 50° fl. hd.
Capscrew H"-8 un x 2-3/4" Ig. 50° fl. hd
Capscrew U"-8 un x 3" Ig. 50° fl. hd.
Capscrew U"-8 un x 3]-" Ig. 50° fl. hd.
Capscrew U"-8 un x 6" Ig. 50° fl. hd.
Capscrew U"-8 un x 8^" Ig . 50° fl. hd.
Capscrew l£"-8 un x 3|" Ig. 50° fl. hd.
Capscrew U"-8 un x 4" Ig. 50° fl. hd.
Capscrew l£"-8 un x 42L" Ig. 50° fl. hd.
Capscrew 2"-8 un x 5" Ig. 50° f 1 . hd.
Capscrew 2"-8 un x 5£" Ig. 50° f 1 . hd.
Capscrew 2"-8 un x 6" Ig. 50° fl. hd.
Capscrew 2"-8 un x 6^" Ig. 50° f I . hd.
I
1 Price
4.89
.52
4.66
3.25
4.09
4.13
5.97
6.49
10.32
10.38
23.44
13.02
13.32
12.66
24.82
22.72
17.42
24.08
MISCELLANEOUS CAPSCREWS
73
74
75
76
77
78
79
80
12
12
12
8
12
12
12
8
809554
812053
818038
818039
818051
2445-A19
2445-N19
2444- El 8
Capscrew 3/4 "-10 unc x 1-3/4" Ig. soc. hd
Capscrew 3/4"-10 unc x 2j" Ig. soc. hd.
Capscrew l"-8 unc x 4j" Ig. soc. hd „
Capscrew 1 "-8 unc x 5" Ig. soc. hd.
Capscrew H"-7 unc x 4" Ig. soc. hd.
Capscrew 2"-8 un x 9-3/4" Ig. Harris hd.
Capscrew 2"-8 un x 10" Ig. Harris Hd .
Capscrew 2j"-8 un x 6^" Ig. Harris hd.
.64
.82
2.45
2.73
6.39
36.42
53.95
24.64
TOTAL:
$ 13,931.01
56
-------
APPENDIX D
BALING PLANT AND BALEFILL DETAILS
57
-------
T H- Z
i
Q
Qi
D
o
58
-------
O)
ofl «— in
i- O O
o> x i
0)
Jr Q.
JJ E
O =
CO Q-
I*
-'
CN
LLJ
D
O
U
Q- ULJ
CO
CN
(U
0)
1
cs
0)
u.
« D)
0) .—
CO U_
CN
CN
oo u_
59
-------
Martin
Decker
Scale
Dial
(w)
Power on
Semi-auto
Auto
Hand
(A)
In weight
range
(G)
Controls on
(GJ
Cycle start
Hopper
dumping
R ))
Emergency
stop
Cyc Pe stop
JL
Hopper
dump
Legend:
A - Amber
G - Green
R -Red
W-White
Q = Light
\C\= Button
FIGURE D-3
CONTROL PANEL- MIDDLE SECTION
60
-------
I
®
Open
®
Opening
®
Closing
®
LTd
c losed
Close
J/
Open
Lid
©
Gatherer in
differential
©
Gatherer
forward
®
Advancing
®
Retracting
®
Retracted
Fwd
J2
Ret
Gatherer
High pressure
©
Tramper in
differential
©
Tramper
down
®
Moving
down
®
Moving
up
®
Up
UP n
A
Down
Tramper
©
Long ram in
differential
©
Long ram
forward
®
Advancing
®
Retracting
®
Retracted
Fwd
/?
Ret
Long ram
Bale
complete
(B)
Bale door
open
®
Opening
®
Closing
®
Closed
Open
J?
Close
Bale door
©
Conveyer 2
Run
©
Conveyer 2
start
©
Conveyer 2
stop
©
Conveyer 2
slow
@
CoMveyer 2
Fast
©
Conveyer 1
Run
©
Conveyer 1
start
©
Conveyer 1
stop
©
Conveyer 1
slow
©
Conveyer 1
Fast
Legend:
A - Amber
B - Blue
G - Green
R - Red
W - White
Y- Yellow
o =
Light
Button
FIGURE D-4
CONTROL PANEL - RIGHT SIDE
61
-------
Microphone
>*- Face of
X^ scale
dial
©
Start
Forward
Refract
0
Stop
Forward
Retract
©
Heater on
©
Blowers on
©
Cooler/heater
circ. pump on
_ .Off.,
Cool xr-k Heat
Oil temp.
control
©
Main pump
*1 run
Start
Stop
Low oil
©
Pilot pump
run
Start
Stop
©
Main pump
#2 run
t
Sop
Supercharger
pressure
©
Supercharger
pump run
Start
oFop
©
Main pump
^3 run
Start
Stop
Legend:
A - Amber
G - Green
R -Red
O •
Light
Button
FIGURE D-5
CONTROL PANEL - LEFT SIDE
62
-------
-J.
I
<3
o
-o
o
£
C 0)
-------
HI
CD
c
J
o
X
a)
6
n
CO
LU
ID iu
o>
Eo
u
VI
0)
0)
o -
*- c
*- 0)
o >
Z'6>
O
z
64
-------
_*
U O)
0 C -Y
l_ •— [)
S]2
D -1
Eg
u
-
N v*
I //Y/
TO
C
O 0
O_ 9)
i~
!<
I
V
D) o
.- P
-------
LU
Q;
LU
U
as:
2
to
Q.
o
«L
«
|
CN
•
CN
1
/I
J
/
•8 d
o
3
O
0)
TJ
I/)
— F
-Q
?
1
^ c
1V^ CO
O -'
v
(
^_^/
Lu
£ >
CN
•
oc
">
1 LU
Q
\r>
J CO
•
0-7
Q_
O
z
w >-
s L- 3
-E h—
. o-
CN w
*
_o ixi
I >
J)
5
66
-------
Scale:
1" = 1 mile
Route 1 - Highway 52
Route 2 - Highway 56
67
FIGURE D-10
BALE TRANSPORT
TRUCK ROUTE TO BALE FILL
-------
68
-------
— ±i to
Q I- UJ
Z i—
^i 111 ^^
°<£
o?2
I- <*- N
O "J £
?^O
c
o
o
1
o
c/l
69
-------
. ••*. ^*5!*j5S!L&*K
- - » n ^^j»>-*
-------
PHOTOGRAPH D-3
COVER SOIL LOADER
71
-------
APPENDIX E
BALING PLANT SYSTEM AND
HUMAN PERFORMANCE ANALYSIS
72
-------
APPENDIX E
Appendix E details the system and human performance facets of the time and method
study, as specified in Section 7. These analyses were the basis for the plant perform-
ance evaluation within Section 7.
A. System Performance.
In order to analyze the baler plant, transport net and balefill, eleven machines were
defined. Each machine was used in processing solid waste, and each had a network
description with average time per state. The eleven machines were the gateman,
loader, conveyor, scale, baler, pusher, four transport trucks, and forklift. The machines
represented one man and ten items of equipment in the system.
Each machine had a set of defined operating states. The states were complete and
sequential in that one and only one state exists for a single machine at each instant.
Thus, according to the network model, a machine spends time in a state, shifts instantly
to a new state, spends time in the new state, etc. Each sequence of states was
constrained.
The gateman and loader were located inside the front door. Together they handled
incoming solid waste. The gateman had six defined states that were task-oriented, in
that, for example, no mention was made of how he directed the dumping or measured
truck volume. The break points between his tasks were those instants when he finished
one task or started another, as indicated by his eyes and body movements. The defined
operating states of the loader were also task-oriented. The baling plant description
illustrates how the loader operates in each state. The break points for loader states
were consistent; the stopping of the four wheels, shifting into gear, contact of the bucket
with waste, and raising of the bucket were four break points delineating "unload,"
"return," "travel," "load," "mix," "carry," and "clean floor" states.
The conveyor, scale, baler, and pusher states were identified by control panel lights
connected to sensors on these machines. Again, the defined states were task-oriented;
Section 2 of this report included machine layouts and other aids for visualizing the
physical system. These states identified the processing of the solid waste through the
central part of the baling system.
The conveyor had two simple states of "run" and "idle." Idle time was often due to
some delay in another machine. The scale was more complex in concept and operation;
"load," "idle/loader," "idle/conveyor," "idle/baler," "dump," and "return" states
were separately distinguished. During the "load" and "idle/. . ." states the scale
platen was in place and possibly locked down to prevent large waste items from jarring
the scale load cells. The load time was the time from when the conveyor started a new
load cycle until the desired waste charge was measured out, less periods over 0.2 minutes
when the conveyor was stopped. Idle time was blamed on interference by other machines;
the basic distinction is that idle time while loaded is due to the baler, and idle time
73
-------
while unloaded is due to the loader or conveyor. The baler had a cycle of item states,
but the states worked in a simple, steady, repetitive sequence. The states were
indicated by panel lights showing the release and application of hydraulic and mechan-
ical locks.
The transports were logged by the two truck drivers as to arrival, departure, gas, repair,
and lunch times. The time intervals were labeled "idle/load," "transport," idle/unload,"
"return," "gas," and "repair." "Rigging" and "lock tailgate" times were stop-watch
measured by Ralph Stone and Company, Inc.,engineers daily. In the transport truck data
presentations, the average time in each state would be that for all four trucks. It can be
assumed that at any instant one transport was in each of the four states of "idle/load,"
"transport," "idle/unload," and "return," as this was usually the case.
The balefill forklift was also timed by stop-watch in "load," "carry," "unload,"
"position," "return," "travel," "handwork," and "idle" states during weekly monitoring.
The breakpoint between most states was marked by the motion of the fork lift's wheels.
"Return" and "travel" were distinguished by the subsequent state: whether the forklift
returned to load another bale or went elsewhere.
At any instant, the processing system was identified by the eleven instantaneous states
of the eleven defined machines. Processing time was represented as the average machine
cycle time, or as the sum of average state times for the sequence of states used. These
times are presented in the following sequence of presentations. The first three parts are
basic descriptive summaries of time performance. The later presentations are more
sophisticated network models. For the final presentation, average time values are
subtotaled by four plant operating conditions of manual or automatic baler control and
dry or wet solid waste. This is done to show the stability of the average state processing
times under fluctuating conditions.
1. Utilization. Utilization is a statistical measure of the use made of each machine.
By definition, the sum of the percent utilization of all machine states is 100 for each
machine. Figure E-l presents state utilization by machine, except those at the balefill.
These values were derived by dividing the average measured time in a defined state per
machine cycle by the average measured cycle time of the respective machine. This
information was specific to each machine.
The significance of percent utilization lies in comparing design and actual use. Thus,
the percent idle time per cycle shows the percent decrease from maximum production.
Yet the total lack of idle time in a single machine conversely indicates a bottleneck in
production. Both extremes are undesirable.
The utilization of each state signifies the relative time-cost of each operating state.
The costliest states will yield the greatest improvements in system performance for a
percent improvement in the state performance.
74
-------
Utilization (percent)
o
J
CN
I,
O
J>-2 CO
-o c
— D
CN
C
CO
o
g.
O
C
_c
v>
D_
\ \
o.
D
Q
u
a
O
Q.
O
U
a.
D
4)
"I
a.
O
SL
0)
a>
-o
UJ
u
£2£
o
LLJ
_E
O
\ \
$2
Volume 1
o
Q.
E
D
Q
O c
.2 £ 0
2 O CN
-_ J
T
lO
cs
O
O
75
-------
2. Interference. Interference is a statistical measure of the time one machine waits
idle for another machine in the sequence. For example, the baler sometimes waits for
the conveyor to load the scale platen and the conveyor sometimes waits for the baler
lid to open. In interference terms, the conveyor interferes with the conveyor another
time. Thus, A interferes with B for X percent of B's cycle, and B interferes with A for
Y percent of A's cycle. This concept can be viewed as blaming some of B's idle time
on A, and some of A's idle time on B. This is valid since A was waiting until B
finished its operations, and B waited on A at other times. Thus, all of A's and B's idle
time can be blamed on the machines in the system.
Table E-1 presents the interference between seven different machines in the plant.
Notice the pusher and transports did not interfere with other machines; it is possible
for the plant to stop due to the pusher or transport, but this did not occur under measured
operating conditions. The gateman was a different case, though, in that he could not
interfere with any subsequent machines. The forklift is not considered here since the
results would be valid only at St. Paul.
The best-designed machines will interfere due to statistical fluctuations. The pattern of
interference is an indicator of conditions. The condition of matched production rates
results in matched interference values; in other words, X interferes with Y the same
amount that Y interferes with X. The condition of integrated machines in a sequence
also results in small interference values for all the machines. At the plant, the
machines formed a balanced production system, with the conveyor causing the most
interference.
3. Gantt Chart. In order to visualize the dynamic operation of the plant, a Gantt
Chart is presented in Figure E-2. The seven defined machines are represented by their
operating states for a hypothetical six-minute period of plant operation. The results
are considered typical of any six-minute period. Notice that the scale, baler, pusher,
and transports were highly structured in their cycles and operating times. The gateman
and loader were very unstructured in their cycles; they depended on random incoming
trucks and stockpiled solid waste to determine their necessary operations. The conveyor
was semistructured , depending on the height of solid waste piled on by the loader
operator, with possible stop-starts in the load cycle.
The times on the Gantt Chart are from the average observed times for each state; random
number tables were used to choose a specific value for each mean and standard deviation.
Basically for each state two numbers from 0 to 99 were picked from a column of random
numbers. The first number fixed the sign of the deviation by being greater than or equal
to or less than 50. The second number picked the magnitude of the deviation in percent
of the confidence level; for example, la is 65 percent, 20 95 percent, and 3a
99 percent. Notice that normal distributions are assumed in these approximate, but
representative, random times.
76
-------
*
D-
f»\
S.
previous s
•
§
-o
C
o
v>
_*
O
E
*~
i_
£
U)
_c
*.£
>
t/J
_c
o
-o
(U
I/)
4
0)
Q.
D
0)1
*^
JC
0
o
E
o
c
•c
«£
Tl
0)
C
• •—
£
Q
•T"
Li
(U
"c
u
a
0)
•*•
0)
-o
•^
a>
a
c
|
<
II
_
^
i
i
CO
^
a>
•4—
c
D)
C
5
_Q
0)
u
X
u
0)
D)
e
i
Q)
C
•—
U
O)
^
*—
Iw
(U
u-
t_
0)
c
£
a.
•r
a>
t
u
t.
a
0)
E
"
«
I,
•—
0)
CT
S
<
•<
II
T3
»
5
5
—
?>
D
a>
^
^
u
o
^
o
0)
u
>x
u
0)
a.
a>
E
'^
0)
-D
P
O
a)
ro
S
2
<
o
X
>
I
u—
-D
0)
II
Z. LLJ
X
77
-------
«0
c
'§
CN
LU
z
o
u
I—
I—
z
o
c
J.
0)
78
-------
4. Machine Networks. Each machine is described herein as a network of complete
sequential states. Mean observed time and standard deviation for each state are listed
in the activity networks, Figures E-3 through E-10. These times represent standard
times for the defined operations. This is a basis for evaluation and comparison with
alternative methods and different systems. These standard times represent the current
state-of-the-art in the St. Paul baling plant.
Some machines possess simple network descriptions. Examples are the conveyor, scale,
baler, pusher, and transports; these are simple sequential machines with highly structured
operations. Conversely, the gateman and loader have complicated network descriptions
of their relatively unstructured operations. At the St. Paul baling plant a number of
alternative cycle paths was indicative of operating consistency, and the ratio of the
standard deviation time over the mean time for any state indicates the time uniformity
of that operation over many cycles. For example, some states of the baler were very
uniform, such as "lid open" and "lid close;" conversely, the states of the gateman were
constantly changing each cycle. The times presented in Figures E-3 through E-9 are based
on observations by Ralph Stone and Company, |nc.,.engineers on September 20 through
28, 1973. The times in Figure E-10 result from long-term field observations over one year.
5. System Network. Table E-2 presents the sequence of operations that solid waste
undergoes during processing at the plant. There are 24 defined operations on the solid
waste. Operations not performed on solid waste, such as lid opening, are lumped in
idle categories. Notice that the times are average observed times per bale. Thus, the
times for operations two through six were changed to reflect 2.7 loader-tractor cycles
per baler cycle. The time for step one was the average observed time to dump, times
the average observed number of trucks, divided by the average observed number of bales .
Sections 3 and 4 of this report contain these truck and bale figures. The time waste is
stored on the plant floor varied greatly, depending on the rates of incoming solid waste
and bale production, but never ran longer than 72 hours, the weekend figure. Usually,
solid waste was processed the same day, yielding a storage time of less than 16 hours
on the floor. The minimum processing time per unit of solid waste baled, using mean
times, was 48.85 minutes.
The reduced plant network in Table E-3 sums up the system performance as twelve distinct
operations on the solid waste. This is a general level of activity useful when com-
paring the existing plant with redesigned plants. The defined operations are the minimum
number necessary. Therefore, they are basic to baled solid waste systems rather than
specific to the St. Paul plant.
The time values in the two tables follow directly from the observed mean times. Two
Ralph Stone and Company engineers measured these times as described below.
6. Movement of Standard Times. The information presented so far has been average times
and standard deviations with the resulting percentages, as measured during nine hours of
observation. The present discussion presents the observed time data subtotaled by plant
conditions and totalled. Tables E-4 through E-7 present the mean times and standard
deviations that were used to calculate all previous figures and tables. The standard
79
-------
**i
>-El
. o c
l< g
I
"o
••»
0
X
0)
J5
o
•0
o'
a.
E
D
TJ 10
+- Ns
go'
10
1^"\
**)
0*
s
-sO
0^
"° y
r~
\£
Ck£
O
z z
?fe
n
LU
UJ °- =
S ^5^
o
u_
•
,8
8
•
IT)
^t
•
£ U
^ ^ <
^ z
<
o
-
in X
n u
p
o •*- •
U CTJ
U
-------
X
•*—
•—
^>
u
-
oj Q. t
U
• —
I
o
0)
>
*
/
__
0)
>
D
1w
1—
O
CN
0
io
i ••"
•or
P
^•^v
^p
O^
CM
5,
•
C
• ^
E
o
•~
il
CD
w
^~
*
O
(I
V
E
•<—
•1—
jj
u
X
u
-D
D
.3
X
0) O
c —
og-
.E
a) a>
U 0
a5 2
a. a.
81
-------
X
0)
V
CN"
—
•£.o
.± E o
.> .£ >
« g-8
< l-°
E 1/5
co"
v>
o
2
S >o o
o"00 K *
0) 0 c5
2
!
— — — —
„, Oi 0 ^
)"
\
^
C
J
i
1
1
3-
z ,.
4
O
•
O
)
»
)
)
•
c
o
n
•
o
<
c
1
>
1
1
•)
>
>
!
•^
,_. "7
uLS
m c
c D
\ CN — ^
^00
0
TO
0 §
X >
i S5 « §
x_§ "^ E
°"^ ^ I
9 & o ;
O i/» X o
-o « « c
«- E ? *s:
« *: S
ft. 8 "o
m X ° 0)
o § S3 =
• C £ Q. D.
c: o fc E
'EISA'S 8
•o g^e g5 "
°! f g 5 i
« o S- >
u D OJ
11 II n o) 5o
C 0)
c101^ Eli^°fc
§ — "° .- f 1 > ^ '^ 3
• — 0 c •- 0
1 J JJ E > g
^ 'f -i
" D -Dtfi
is 1 * |1
iji zo^
^
0£
O
>
z
o
u
82
-------
c
X'E
4!
§
15
v
-o
O
h- UJ
•o z z
03 UJ
* L
IT
c
O
I
0)
-o
"2
D
•O
D
"fc
D
0)
«/»
0)
I
8
o
£
o
0)
O.
o
,E S
UJ
jj
O x
Z u
O
1
)
o
in
O
83
-------
D
0)
D
V)
O
O
^
"o
O
0
~
E
p
t3
0)
o
(O
D
O
to
-Q
84
-------
8
«
-a
T3
v>
4.°
is
a.
o
0
o
— 10
2^
CO
l_
o
N
iS
r"
o
i—
o
o
•=8
2 °
JD
u
o
o
-Q
X
CM
•
o
FIGURE E-8
BALING PLAN
ER ACTIVITY NE
0)
-o
o
-o
I
(A
O
4)
2 «
C vi
•- O
C L Q
2 £
o
o ~o
n £
£
o
Q>
O
-------
X C
•*- ••—
'> £
£ c
o •—
< c
o
i
1
"S
0)
-D
*
IS.
VI
X
0)
o >
M
D ^
OCN
*•«•
C
'E
i— (-O
CM
D)
>
D
,
0)
§)
2%
^ •
J
i
°>8
^co*
o
CO
•
I
8
•
M
C£
O
z
!-£
CN / ^"
uli 0)
/It ^^
O D-
^ i i If
"* CN CO _ *•
^ co 10 50 i:
-C^Q P
CN CN „ O^.
u
X
o
u
:*§.
o 5
Z<
•r 0) o
? 0- Q.
86
-------
O
E m
Jo
00
•
o
c
.2 n
So
Q-
CN
O
u
£.
">
"o
D
"• .£
II O
o> ^£
E «
oj fe o
o % &
-7 < D-
^- O
87
-------
TABLE E-2
PROCESS SEQUENCE ON
UNIT OF SOLID WASTE BALE D
Machine
Operation on Solid Waste
Mean Time (min.)
Collection 0 Enter Plant
Trucks. 1 Dump
2 Idle on Floor
3 Mix on Floor
Loader 4 Load Bucket
5 Carry
6 Unload Bucket
7 Setting on Conveyor
Scale 8 Load Scale
9 Idle Waiting on Balerd
1 0 Dump into Charging Box
11 Lid Close
12 Gather
13 Tramp
Baler 14 Compact
15 Door Open
16 Eject
17 ldled
Pusher 18 Push No. 1
19 ldled
20 Push No. 2
21 Idle on Truck Bed
Transport 22 Rig
23 Lock Tailgate
24 Leave Plant
0.00
2.40a
b
0.15
0.30
0.55
0.15
12.70C
1.50
0.55
0.20
0.15
0.30
0.35
0.50
0.10
0.35
e
0.40
1 .85e
0.90
21 .00
3.50
.95
0.00
Total Time From Enter to Leave Plant
48.85 + Step 2
^j
i Estimated from video tapes.
Usually less than 16 hours, max. up to 3 days over weekend.
Estimated from 39 meters of travel at 6 meters per minute, with idle percent at
,49 for conveyor.
^Waiting on lid to open, runs to retract, and possibly other baler operations.
•^ of 17 and 1 9 is 1 .85, averaged for two bales.
-------
TABLE E-3
REDUCED BALED SOLID WASTE NETWORK
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Cycles Per
Operation Baler Cycle
Dump on Floor
Store/ Mix
Load Conveyor 2.8
Convey 1
Measure Charge 1
Bale 1
Load Trailer 0.5
Wait on Trailer 0.07
Transport
Wait on Trailer
Stack
Cover
Average F
Per Bale
2.40°
-
1.50
3.00
0.05
3.05
3.15
21.0
2.0
25.0
-
-
'rocess Times (min.)
Per 1,000 Kilograms
1.90
-
1.20
2.35
0.04
2.40
2.50
16.5
1.6
19.7
-
-
Estimated from video tapes.
89
-------
cog
UJ <.
c*. Z
«
CO
CO LU
|2
LLJ
O
£
o
••o
«x
^f
CN
O
lO
CN
1
cs
ir>
.— CN O «"> i ~*t
. . . . •
^ o o o —
in if) O IT) O
CN 0 O IX 1 10
... 1 .
^ O .— O —
•o •<• in co o oo
CO CO CN "3-
in o o in in
•o »t rx o i ir>
^t o o o o
IT) OO O O
.— IXr- 00 1 00
• • • • 1 •
^r o — ° °
o co ro oo o o
o oio o o
ro Of) IO 1 OO
.... 1
CO O O O —
IT) OO O O
in oo- co • rx
... . J .
f*> o o o •—
O — • O -^ O r-
in O O O
— 1 «O CO —
* 1 * * 1 *
«•> O O It—
IT) O O O
O > — IX I in
. 1
in — O .—
o OCN oo o CN
o ir> in o
Jr; • rx m rx
1 i i • i •
CO O O ' •—
O in O in
CN IX CO | CO
• . . 1 .
^ 0 o £ .t .^
ZT O 0) •— O 1?
2 > a! Q 08 ^
UDLU94D0
Q
CO
'X
Z
Q
CO
IX
Z
Q
CO
IX
Z
Q
CO
IX
Z
*
CO
IX
z
3
—
CN
-
3
s
o
o
CN
rx
(X
o
o
IX
o
CO
S
-
8
r—
rx
CN
o
o
8
•o
Machine ldle|
8
CO
o
in
—
CO
o
o
in
o
CN
s
o
IX
o
o
00
o
•0
-
o
CO
—
CO
o
o
8
•o
0)
CN
o
o
o
rx
I™
1
1
1
1
0
in
CN
o
in
o
m
o
CO
o
o
o
0
CN
i
i
i
o
1
in
CN
o
o
CO
—
CO
1
o
CO
o
-
1
1
o
8
o
in
r-
CN
1
1
!
o
IE
i
o
in
o
o
CN
o
CN
CN
3
o
o
o
CO
o
CN
o
in
CN
o
CN
in
o
o
CO
o
00
CO
o
0
in
CO
0
rx
i_
o
s
U
in
o
o
o
o
IX
8
o
o
o
in
in
o
o
in
o
o
•0
8
o
0
o
CO
rx
o
0
o
0
m
0
o
o
o
CN
o
CN
CN
CN
o
o
2
o
3
in
o
o
CN
o
CN
•o
o
o
o
CN
o
Fx
o
o
in
CN
o
o
8
o
8
o
CN
CO
CN
8
o
in
0
o
CN
m
8
o
in
o
o
s
8
O
0
o
rx
in
o
0
8
o
CO
in
o
o
o
CN
0
CO
CN
CN
8
o
in
o
4
0
O
o
CN
O
o
in
o
o
o
CN
o
o
in
o
0
in
o
in
^Q
^^ O c
o ~c "S3
u ^ cL
japotv]
o
o
o
CN
0
%
o
o
o
CN
O
CN
O
O
0
CN
O
o
CN
0
r-"
o
0
CN
O
00
CN
i2
0
o
CN
O
O
CN
~o5
|
in •
o '
o
CO ;
O ;
in
o
o '
in
CN
o
i
CN
O
O
CN
O
^
in
o
o
CO
o
2
o
CN
O
§
O
o
X
2
E
co
O
90
-------
«-)
LU
LU
_J
CO
LU U
< ee.
QO
oo
o
0
"o
h-
j
•O
N
•*
N
• ON
IO
CN
1
ON
00
^
*fr
CM
o*
1
s
CN
O
£
0
O
•
Q
•
oo
Iv
Z
•
Q
•
to
iv
KN.
Z
•
Q
•
oo
IX
Z
•
Q
oo
IV
Z
•
Q
•
oo
IX
Z
Columns
81 O O T>
1 r— CO NO
• • • •
.— o o o
o o 10 o 10
r- •— CN ~
CN CN CN — CO «•>
* 1 • • •
o ' o o o
O O IT) O
O | CO CO —
• 1 • • •
— ' 0 0 —
O O O O Os
CO CO CO CN
U")
§
IJ
a>
2
0
-o
CN
•
o
IO
CO
o
CN
k.
0)
4
JJ
2
3I
8
o
o
iO
—
IO
ON
o
IV,
•
o
IO
CN
—
CN
CN
IO
CN
o
IO
CO
—
CO
CN
iO
NO
o
IO
NO
-
ON
CN
o
IO
•
o
IO
IV
—
r™
CN
J
-o
J
DO
8
0
0
CN
o
8
IO
o
•
o
IO
o
IO
CN
8
0
o
CN
o
IO
CN
8
o
o
CN
o
CO
CO
8
•
o
o
CN
o
CN
CN
Q
0-
E
o
Q
s
1
IO
o
!
1
w>
0
1
1
10
o
!
1
IO
o
1
1
!
IO
o
!
o
3
•fr-
0)
a£
JU
I
SL
0)
o
O
E £
D C
OO
-------
oo
LU
2
OO
uj S Q
3|5
*!s
oo <^
u_ co
O &
z"-
UJ
£
0
<5
if)if>iOlOOif)if>
oorx
00 CO IO I r— r— r— COCOlf).— TfrOO
CD O O ' O O O O O CD O O CD
OCNCNOlOlO'OtXOCNCN'— 1
CN CN CN CNCNCNCNCNCNCNCN 1
ir> if>u-)if)'otf>if>u">if)if>
— r-OOOOOOOO
01 IOOOOOOCD'OOI
if) if)OOlf)Olf)if)Olf)if>
CO| ICOi— CN — COCOf).— COCO
o1 OO'OOOOCD'O'OO
CNOOcN' if) if)if>iO«")U")Oif)O
00^"* lOOOOOr- CN —
O'CJCD" i OOCD'OOOO'O' i
OOO , lOOOiOiOOOOiO
so — in j •— CN-— cocoiOr— Tj-co
OOOOCNCOCO^ — O- CO O O- t
COCOCO COCOCOCOCNCNCNCN 1
o oioioioiQiQ0^""*
•Ol IvOCDCDOOOr—OcD
O OOOO'OO^DOO1
if) lOiOOlOOlOOOiTjlT)
COI ICO — CM — COCOlOr- COCO
O ' ' O O O O O* CD O O O O
CNOOCNCOCMCNCN — •— CNCN 1
CN CNCNCNCNCNCNCNCNCNI
- N ^
S
2 jo^iO^u ^r^r^
Q
oo
IX
Z
Q*
oo
IX
Z
Q
•
oo
IX
Z
Q
oo
IX
Z
Q
•
oo
IX
Z
Columns j
. . , , if) O
I i I I ° "~
1 I 1 1 • •
o o
.Q -Q _L> _£>
O IO U-) O O O
CN 'O O CN ^f CN
CN r— CM O O
! i i i >ON wo
1 1 1 1 IX CO
1 , j , 8 2
0 0*
! ! ! i 9 8
• *
o o
1 1 1 1
1 1 1 1 CO CO
IT) O
CD •—
1 1 1 1 • •
1 1 1 1 CD O
j j , , S cS
o o'
| | | | OO CN
1 1 1 1 1~~
lO «*>
1 1 1 1 O O
1 1 1 1 . •
O 0
,,,,?£
1 1 1 1 O O
1 | { 1 00 CN
CM i —
O O
! i i i """• "~*
1 1 1 1 O O
«f) O
1 1 1 1 - —
r- CM
0°- = = ^
(D Q) 0) (D "^ *^~
2 2 2 2 cE £§
(U
I
D
8
a>
E
u
(1)
0)
T3 O
*. E
Z *
oZ^
92
-------
co
LLJ
H-
D
co
LLJ
_ °°
rx *~ at.
. Q O
UJ 0£. y
<
O
I—
z
LLJ
LLJ
O
"o
>o
CN
O
•O
CN
1
CN
CN
1
CN
fSJ
*\^
O
CN
1
Os
.
o
Q
!
i
•
.
O
•
CO
IX
z
n
CO
IX
z
Q
•
CO
IX
7
•
cj
CO
IX
Z
Q
CO
IX
Z
c
D
O
u
vO IO O tx CM CM
— CN CO
oo o rx co o ,—
•3- • — CN
r— CN — CN
o o
CO CO
r— O
O IO
LO CN
ro* o*
CN IO
D
O IO
> CO
do
O IO
M 00
* •
CM o
** IO
o to
"O CM
* •
r- O
IO IO
CN r-
co ^~
rx 10
O IO
rx CM '
0 0
IO IO
00 CN
CO O
» 10
0}
•o o
_ O CO
^ -t- O —
n <— — •—
4 M E -5 I
rno;
2ji:2^O(Sc2-3
S4JodsuDJj^
O
o
E
i/>
0)
D
U
CN
O
93
-------
times and percentages are averages of over nine hours of observation recorded on
activity charts.
In order to measure how much the plant operation usually varied each day, the data were
subtotalled into four groups. The four subtotals are for four different conditions. Group
one on 9/20 and 9/21 is for automatic control and dry waste; group two on 9/24 and
9/28 is for automatic control and wet waste; group three on 9/25 is for manual control
and moist waste; and group four is manual control and wet waste. Tables E-4 through
E-7 present these subtotals, as well as the totals presented previously.
The four groups cover four disparate conditions, but other possible conditions were not
included in the present data. A fuller view must include downtime, described in the
subsequent section of this report on maintenance. This time and method study measured
operating conditions, not the downtime conditions. It should be understood that these
standard times are for the running system; no conclusion is drawn to how long machines
run between breakdowns.
Figures 4-1 and 4-2 show the time that every 10th and 25th bale was produced on the
days of September 20th to 26th. On any given day, the production rate varied due to
the effects of breakdown and changing conditions, such as fatigue and incoming waste"
composition.
B. Human Performance.
This section presents information on present human performance at five full-time positions.
These positions are production jobs: gateman, loader operator, control tower operator,
transport driver, and sorter. Notice that four positions were not studied: superintendent,
balefill lift operator, maintenance man, and plant forklift operator. The five positions
studied are general to baled solid waste system design. The superintendent, maintenance
man, and plant lift operator are not integral to the baler production system.
This information is presented as defined tasks, sub-tasks, skills, and human factors.
Based on official job descriptions and actual observations, each position had a set of
responsibilities or tasks. In order to perform these defined tasks, a man performed a
sequence of subtasks, providing detailed performance descriptions. This is a macro-
motion level of analysis in that many micromotions of a man's body are lumped together.
Activity Charts I-A and |-B (see Appendix A) and videotapes were used to develop
standard times. Based on the observed behavior and environment of each position,
needed skills and human factors were identified.
Tasks were divided into production, information, and safety categories. This distinction
between meaningful areas allows positions to be compared and methods to be redefined.
Subtasks divided each task into a network of meaningful operations that reflect physical
activity. At the subtask level, standard times were given.
94
-------
Skills were divided into physical, mental, and task skills. This is a natural distinction
allowing specifications of a position in these terms. Basically, strength, endurance,
visual acuity, hearing, and muscular control were physical characteristics listed as skills.
Ability to read, knowledge of machines and procedures, and understanding of work
environment were basic mental skills. Task skills were defined as the ability to perform
the stated tasks in the standard times with the stated results. Physical and mental skills
were general abilities usually present before employment, while tasks' skills would be
developed for specific positions during employment.
Human factors are factors affecting production, part of the man-machine interface.
Human factors were divided in this discussion into areas affecting perception, machine
control, fatigue, and wasted motion. For example, instrument meter location and
design had human factors in all four areas; scale precision, force size, numbering,
distance from operator, and location relative to other items are factors improving or
hindering operator performance. Since labor is a relatively expensive and sensitive,
yet powerful tool for production, human factors must be identified and considered in the
system design. Human factors were identified for each position.
1. Gateman. Tasks, subtasks, skills, and human factors for the-gateman are described
below. These tasks divided this position's activity into areas of production, information,
and safety. Tasks relating to maintenance and other areas were not defined for two
reasons: first, these were minor activities with few controls and little conscious effort;
and second, these areas of responsibility were specific to just one set of conditions,
subject to many changes.
a. Tasks. A gateman worked on each shift; his job description included
responsibility for checking customer credit, filling out data on each ticket, taking
money from customers without charge accounts, filing cash and charge tickets, manag-
ing incoming waste truck movements, cleaning gate area, and reclaiming pallets and
metal.
Table E-8 lists the gateman's tasks and subtasks in production, information, and safety
categories. The times are mean times measured from video tapes and Activity Chart 1-A.
Gateman task movement is illustrated in Figure E-ll. In actual performance the gate-
man did not work in a set sequence. Depending on many factors, he may not have
directed a specific truck into the dump area. Thus, incoming trucks were completely
or partially directed to their dumping point; this depends on whether the gateman was
already busy, the truck driver was experienced at the baler plant, or the loader
operator saw the truck waiting outside. As in the task "directing dump," the safety
task of watching the front floor area was only a partially completed task. Thus, at times,
the gateman missed the activity on the floor, but when possible he monitored activity
to avoid collisions and helped organize the solid waste piles on the floor.
The activity of the gateman was largely dependent on the distribution of vehicle arrivals.
Figures E-12 and E-13 show daily and weekly arrival distributions during the survey period.
Figure E-14 shows the distribution of arrivals by vehicle size.
95
-------
TABLE E-8
GATEMAN TASKS
Production Tasks?
A.
Direct dump
1 . Guide to door
2. Guide through door
3. Direct loader clear
4. Guide to stop
Task Time (min.)
Mean
0.75
•
-
-
-
Std. Dev.
0.55
b
b
b
b
Information Tasks:
B.
Charge fee
1. Walk to booth
2. Obtain ticket
3. Walk to front of truck
4. Estimate volume (12 percent)
5. Fill In vehicle data
6. Walk to cab
7. Charge fee & driver sign
8. Walk to booth
9a. Record transaction ]
9b. Make change |
9c. File ticket v
9d.Walk to truck0
9e.Give change I
1.10
0.20
0.05
0.15
0.65
0.25
0.05
0.30
0.20
0.05 or
0.30°
0.60
-
-
-
0.25
mm
-
-
-
-
C. Prepare tickets
1. Walk to booth
2. Fill in dates
Safety Tasks.-
D. Monitor front floor
1. Monitor incoming trucks
2. Monitor loader tractor
1.50
1.45
b
b
Continuously
b
b
Special subtasks for private vehicles.
Unobserved or highly random times.
96
-------
Gcrteman's
LJV-J Booth
S. £ -*
JQ 0 U
o j, 2
> — H-
o
u
I
L-
O
o
o
U
O
CN
•
O
0>
o
U
NOTE:
All inside building.
FIGURE E-11
GATEMAN MOVEMENTS
DURING FEE COLLECTION
97
-------
o
CM
(jscjiunu) spAj
98
-------
00
Di
LU
_J
y
x
UJ
LU ^
Si
I—
c 5
CO
D
O
(U
E
04
00
03
I
CO
o
4)
O
z
99
-------
38.0 -57.0
6.0 -37.2
CO
*E
8 0.8-3.0
c
3.8- 10.6
9.8% (38 vehicles)
Legend:
Arrivals on 9/20, 21, 22,
24, 25 and 26, 1973,
combined.
7.3% (28 vehicles)
44.6%
(171 vehicles)
25.1% (96 vehicles)
13.2% (50 vehicles)
I
I
J_
10 20 30 40 50 60
Incoming Vehicle Arrivals (percent)
70
FIGURE E-14
DISTRIBUTION OF VEHICLE ARRIVALS BY VEHICLE SIZE
100
-------
b. Skills. The necessary physical skills required for the gateman are good vision
and hearing, and endurance to stand all day. About 20/30 vision (corrected or un-
corrected) is needed to see the location of vehicles, license numbers, items of solid
waste, and the print on tickets and schedules. Hearing plays an important role in ful-
filling the gateman's responsibilities: he can monitor vehicle location, speed, and
direction while filling out forms. Although strength is not necessary for a gateman, he
must be able to ambulate and stand all day. During the monitoring the gateman was
sometimes overloaded with incoming trucks, but he was idle 55 percent of the day.
Mental skills are: 1) ability to read and write at a high school level, 2) ability to
visualize in two dimensions using visual and auditory inputs, 3) ability to understand
the operation of incoming trucks and the loader tractor, and 4) ability to understand
and manage the size, shape, and location of the solid waste on the floor. Actually,
the gateman must understand the basic operations of the loader and trucks; he manages
the dumping of the solid waste and so affects the efficiency of the incoming dump trucks
and loader tractor. The gateman faced no crucial task skills in that much of his task
behavior was writing. Directing dumps, charging fees, and monitoring operations were
not time-intensive tasks.
c. Human Factors. The gateman used little equipment: pen, clipboard, tickets,
file drawer, and cash register.
The most time-intensive activity was walking. Thus, floor layout was the primary factor
in his productivity. The location of his work area is shown in Figure E-ll.
The structure of the booth was a second factor of his performance. The booth was heated,
with a counter near elbow height and with all forms and equipment located together in
front of the gateman. Large windows allowed unobstructed vision of the working floor,
but no window provided direct vision outside. Thus, he could always see trucks waiting
outside. The forms he used are a third factor, especially in processing trucks; in order
to handle all the trucks that arrive at once, he had to process them quickly. Basically,
booth location, booth heating, inside and outdoor visibility from the booth, booth
counter, drawer and cash register arrangement, and the forms were primary factors
affecting the gateman.
2. Loader Operator. The description of the leader operator does not include main-
tenance and other relatively unstructured activities.
a. Tasks. A loader operator worked each shift. His position was defined as
responsibility for keeping the conveyor full, keeping the front floor clear of solid waste
so that incoming trucks could maneuver, mixing the solid waste so it baled properly,
and removing rejects and recyclables. Activity Chart 1-A and videotapes were used to
record and measure time data.
Table E-9 lists production and safety tasks. Since the operator and his machine were
integral, the defined tasks for this position were listed as machine operations. The
sequences of subtasks were fixed by material handling constraints, but many factors
101
-------
TABLE E-9
LOADER OPERATOR TASKS
Production Tasks:
A. Load conveyor
1 . Load bucket
2. Carry
3. Unload bucket
4. Return
B. Mix solid waste
1. Mix
2. Travel
C. Clear floor
1. Clear floor
2. Travel
D. Reject /recycle items
1. Separate from solid waste
2. Pull out of pile with bucket
3. Push to side of floor
4. Travel
lime
Mean
0.55
0.10
0.20
0.05
0.20
0.50
0.30
0.20
0.40
0.20
0.20
—
(min.)
itd. Dev.
0.15
0.05
0.10
0.05
0.10
0.20
0.15
0.10
0.50
0.50
0.10
b
E. Direct dump
1. Point to correct door
2. Point to stopping point
Safety Tasks:
F. Monitor front floor
1. Watch gateman
2. Watch trucks
3. Watch front doors
Continuously
b
b
b
aOccas?onal task when gateman is busy.
Unobserved or highly random times.
102
-------
affected standard times. The "load," "mix/1 and "clean floor," tasks have been
previously defined. The "reject/recycle items" task is an occasional task performed
when appropriate items are found by the loader operator. The safety tasks were
constantly performed as neck and eye motions to detect obstacles and thus avoid collision.
Occasionally, when many trucks arrived simultaneously, the loader operator directed
these trucks from his cab.
b. Skills. Necessary physical skills are stringent: good vision (corrected or
uncorrected) and hearing, body strength, endurance, good body coordination, and
flexibility in neck and back. Basically this operator must have the physical strength,
endurance, and coordination to operate an articulated loader on a relatively simple
ground layout. The actual skill involved is the ability to watch the entire front floor
area while working. The avoidance of collision with other trucks depends heavily on
this operator. The loader operator constantly turned his head and twisted at the waist
to view rear areas. Hearing is very important in locating other trucks and recognizing
verbal warnings.
Necessary mental skills are 1) understanding of the dumping operation, 2) understanding
of the need and reasons for mixing solid waste and rejecting and recycling items, 3)
ability to manage the piles of solid waste so that trucks can move in and out, and 4)
the ability to load the conveyor to the correct height. The loader operator worked
the waste piles so that the incoming trucks could move in and out quickly. He mixed
the waste sufficiently so that the bales were stable. He was responsible for identifying
rejects and recyclables. The loader operator, in loading the conveyor, greatly
affected the time for scale loading. He stacked the conveyor to the proper height,
and positioned large items correctly, avoiding both long load times and heavy weights
falling hard on the scale.
Task skills were typical operating skills of a loader operator under dirt loading and
grading operations. He operated at the design efficiency of the loader while observing
the floor, waste pile, conveyor, gateman, and other trucks. It is important that he was
able to operate at standard time rates with his mind free to observe the surrounding
environment. Usually a well-experienced operator was needed to perform under these
constraints.
c. Human Factors. The human factors of the loader operator deal with: the loader
instruments and controls; the overall layout of the solid waste pile, conveyor, gateman
and trucks; and the method of working the face of the pile.
The loader itself was a single unit. The choice of loader was based on other than human
factors, such as capacity and cost. Thus, the only loader factors mentioned here are
operator visibility over 360 and a heated cab. The manufacturer has presumably
optimized instrument and control factors in the loader.
103
-------
The physical layout of the front area and the method of working the waste pile were two
important factors in performance of both incoming trucks and the loader. Basically,
time idle, fatigue, and collision-possibility were affected. For example, working one
side of the conveyor at a time, while trucks dump on the other side, avoided the need
for the operator to wait on these trucks. A procedure keeping obstacles from behind
the loader eliminated many twisting motions of the operator. Basically, layout affected
possible travel routes, patterns of head motion, methods of mixing and loading at the
face of the pile, and waiting on incoming trucks. And the method of working the waste
pile determined the effects, such as fatigue, on the operator.
The past pattern of loading is presented in Figure E-15.
3. Control Tower Operator. Tasks, subtasks, skills, and human factors for the control
tower operator are described. Only tasks relating to work in production, information,
and safety systems are defined.
a. Tasks. A control tower operator worked each shift. Tasks are listed in Table E-10,
and involve supervising production on the shift, cycling the baler, measuring the charge,
getting the transports switched on time, and keeping the conveyor full. The control tower
operator worked under three sets of conditions - automatic, semiautomatic, and manual
sequence control of the conveyor-scale-baler-pusher.
Figures D-2 through D-5 illustrate the control panel. Under automatic operation,the
operator merely watched and listened to the machines, and stopped the conveyor when a
full charge was on the scale. Under typical semiautomatfc operation, the operator used
the stop-start buttons for the conveyor, the dump toggle for the scale, and the push No. 1
and No.2 buttons for the pusher. Under manual operation the operator manually switched
all operations. He used the bottom row of toggle switches, the conveyor buttons, and
the pusher buttons.
Under all conditions, the control tower operator watched the transport and conveyor as
he controlled the conveyor-scale-baler-pusher sequence. If the conveyor was empty, he
directed someone to start loading the conveyor. If the transport was full,he informed the
driver and lift operator by the P. A. system speaker. He recorded data on time, weight
of bales, and reasons for shutdowns.
b. Skills. Physical skills center on perception, in that the control operator mainly
observed and pushed buttons. Good vision, about 20/20 (corrected or uncorrected) was
necessary to observe the machines and floor from the control tower. Hearing was important
in monitoring the machines; an experienced operator received much auditory information.
The mental skills of this operator were the tightest constraint. He has to understand the
limits and abilities of the machines in the baling sequence, be able to decide waste charge
sizes and bale dimensions, locate jams in the conveyor, pressure losses, jammed bales,
and general equipment problems; and to coordinate the central operations of the plant,
including directing the activities of other employees.
104
-------
Entrance
Doors
NOTE:
All inside building.
FIGURE E-15
LOADER MOVEMENT FOR
PLACING WASTE ON CONVEYOR
105
-------
TABLE E-10
CONTROL TOWER OPERATOR TASKS
n i • T i Standard Times (m|n.)
Product.on Tasks: (Machine TFmes)
A. Cycle baler 3.05
1. Open fid 0.15
2. Dump platen 0.20
3. Return platen 0.15
4. Close lid 0.15
5. Gatherer forward/differential 0.30
6. Tramper forward/differential 0.35
7. Compactor forward/differential 0.50
8. Bale door open 0.10
9. Compacter forward/differential 0.35
10. Return all rams and close bale door 0.35
B. Load scale
1. Start conveyor
2. Monitor weight and volume of waste 1.50
3. Stop conveyor
C. Load transport
1. Push No. 1 fora bale 0.40
2. Push No. 1 for a second bale 0.90
3. Push No. 2 for both bales 0.90
Information Tasks:
D. Switch transports
1. Monitor number of bales on transport
2. Call driver and lift operator on P. A.
E. Keep conveyor full
1. Monitor conveyor load
2. Call for action on P. A.
F. Record production
1. Write bale numbers
2. Write reasons for downtime
Safety Tasks: Continuously
1. Watch floor
2. Watch machines
106
-------
The task skills of the control operator deal with the control panel, scale dial, scale,
platen, and conveyor. The operator must be able to locate controls without looking;
once located, the controls are easy to activate. He must instantly read the scale dial
by the needle angle. He must estimate the volume of waste on the scale and conveyor,
and the impact force of waste falling onto the scale. He must constantly observe the
transport being loaded and floor areas. His degree of involvement varied under the
possible modes, automatic to manual, of operation.
c. Human Factors. The human factors revolved around instrument and control
location and design, and the operator's perspective and visibility from the tower. The
control panel contains all of the instruments and controls except the scale meter.
The panel layout was critical in that the operator had to keep his eyes on the plant
operations while using the controls. Basically, all necessary controls were within reach
at the bottom of the panel, spaced far enough apart to avoid interference during
actuation. Modifications of the controls were undertaken in stages. Thus, the panel
had been extended on the left and right sides. The pusher controls were at the far left,
while the conveyor controls were at the far right. The new operating scale meter was
on the left wall. (See Figure E-16 for the layout.) Operator speed and fatigue were
influenced by meter and control location. The control tower floor was five meters
(17 feet) above the plant floor. The tower enclosure was glass from the waist to the
ceiling. The tower was higher than the conveyor, platen, and charging box, allowing
direct observation into these critical areas.
4. Truck Drivers. Tasks, subtasks, skills, and human factors for the truck drivers are
described. Only tasks relating to production, information, and safety are defined.
a. Tasks. Two truck drivers worked each shift. They were responsible for driving
transport trucks to and from the balefill, rigging and de-rigging the trucks, positioning
trucks at the pusher platform, gassing and light maintenance on the trucks. Table E-ll
lists the tasks. Each driver was rigidly constrained to the basic sequence of switch trucks at
plant, transport, switch trucks at balefill, and return, with occasional stops to gas up
and morning chek-outs of equipment on the trucks. Unscheduled repairs were handled
by the driver if minor; otherwise, the driver phoned the plant for instructions. (Major
repairs were scheduled by a maintenance contract with a private company.)
b. Skills. Physical skills were related to driving a transport. Vision, hearing,
strength, and endurance are basic physical qualities. The truck drivers needed to pass
the usual medical tests of physical ability. Mental skills also revolved around driving.
Reading, mechanical understanding, understanding of the loading and unloading
operations, and understanding of the operation of the transports were basic. Task skills
were driving the transports, backing down a 33 meter (100-foot) straight path to the baler
ejection platform, and rigging and de-rigging the curtain.
c. Human Factors. The human factors of this position revolved around the transports.
The truck was designed for driving, and so had factors presumably optimized for productive
use. The curtain and tailgate were specially designed for the St. Paul bale-haul con-
ditions. The design of the curtains and tailgate required two men to draw and retract
107
-------
Scale
Dial
(Operator)
Scale View
Conveyor View
(and Sorters )
Front Floor
Area View
FIGURE E-I6
CONTROL TOWER LAYOUT
108
-------
TABLE E-11
TRUCK DRIVER TASKS
lime irnintL
Production Tasks: Mean STcLue
A. Switch trucks at plant
1. Position at ramp (truck 1)
2. Rig using two men , , ?,
3. Pull out (truck 2)
3'5
4. Back in (truck 1)
5. Lock tailgate (truck 2) 1.0 0.3
B. Transport 36 22
1. Drive (truck 2) 29 5
2. Gas (8 percent)0 26 21
3. Repair (12 percent)0 41 32
C. Switch trucks at bale fill b
1. Pull in (truck 2)
2. De-rig using two men
D. Return 35 24
1. Drive (truck 3) 28 7
2. Gas (8 percent) 26 21
3. Repair (12 percent) 41 32
Information Tasks:
E. Driver's log - b
1. Record times of arrival and departure
Safety Tasks;
F. Check truck - b
1. Tires
2. Oil
3. Accessories
4. Brakes
Special subtasks performed as needed.
Unobserved times.
109
-------
the curtain while the drive handles the tailgate alone. In practice the rigging was done
once before the transport left the plant; the de-rigging was done once after the transport
arrived at the balefill. Rigging times measured during the survey period are shown in
Table E-12. The average time to rig was 3.5 minutes, and the average time to lock the
tailgate is 0.95 minutes.
Figure E-17 shows the layout of the loading dock and balefill. In both cases, the truck
being processed was in position two or three as the next transport arrived at position one.
At the loading dock, rigging was done at position two before moving, while the tailgate
was put on at three. At the balefill, de-rigging was done at position two; notice that
the balefill loader operator swept the bed of the empty transport at position two or three.
5. Resource Recovery. Tasks, subtasks, skills and human factors related to segregation
of corrugated paper are described in this section. It should be noted that segregation
was not necessary to baling solid waste and could have been discontinued if salvage
corrugated paper prices declined significantly.
a. Tasks. Segregation by sorters for recycling was organized to use two men on
each shiffT ATused, the sorters recycled only corrugated paper. Other items were to
have been considered for sorting in the future. The only task of the sorters was to
segregate the corrugated paper (see Table E-13). They worked either at the top of the
conveyor, one on each side, or on the floor piles. From the conveyor sides they reached
over to pull out large, dry, clean pieces of corrugated paper. They then turned about
12 degrees and dropped the items down a chute to the floor.
b. Skills. Physical skills were medium-acuity vision and hearing, muscular
coordination, and endurance to stand for several hours. The sorter stood on a small
platform high in the air; thus, he needed to have a good sense of balance. The ability
to identify and fudge corrugated paper items required little mental activity. The job
required no training or skill development.
c. Human Factors. Figure E-18 illustrates the sorter layout. Factors affecting
human performance are sorter platform height relative to the conveyor, the distance the
sorter needed to reach, the use of mechanical tools such as hook poles, and the location
of the place corrugated paper was dropped.
As performed, the sorters used their hands. This required that they reach farther than
the length of their arms at the shoulder. Then they needed to bend forward. Then they
twisted 120 degrees and placed the corrugated paper in a chute 180 degrees from the
conveyor side of their standing position. Sorters could not reach the middle of the
conveyor.
Metal poles 1.9 meters (6 ft) long with hooks were used to reach corrugated paper in
the middle of the conveyor. The hook poles also allowed one sorter to remove items
from almost the entire width of the conveyor. These poles were not used while the five-
day study was conducted.
no
-------
TABLE E-12
TRANSPORT VEHICLE RIGGING TIME
Date
1973
9/20
9/21
9/24
9/25
9/26
Average
Standard
Time
9:00 A.M.
9:50 A.M.
10:14 A.M.
7:00 A.M.
7:50 A.M.
8:38 A.M.
11:05 A.M.
11:45 A.M.
2:50 P.M.
7:15 A.M.
8:35 A.M.
9:20 A.M.
9:58 A.M.
10:43 A.M.
12:40 P.M.
1:40 P.M.
7:55 A.M.
8:34 A.M.
9:30 A.M.
10:00 A.M.
9:25 A.M.
12:58 P.M.
Deviation
Rigging Place- No.
(man -m inures) Men
7.60
6.20
6.50
10.40
7.48
8.19
6.40
8.98
4.80
6.72
3.82
10.66
6.40
8.25
6.50
4.50
2.20
—
"
6.36
5.20
6.69
2.06
2
2
2
2
2
2
2
2
2
2
2
2
2
3
1
1
2
2
"
2
2
1.95
0.39
Tailgate In- No. Bales Loaded
tman-mTmjfes) Men per Truck
«
--
1.20
1.16
0.88
—
0.86
0.53
1.35
2.76
0.89
1.10
1.50
0.98
~
1.19
0.61
1.00
"
1.56
1.22
1.17
0.51
—
—
1
1
1
_.
1
1
3
2
1
1
-V-
1
1
^^
1
1
2
2
1
1.29
0.61
14
16
14
14
14
14
14
16
14
14
14
14
14
14
16
14
14
14
14
14
14
14
14.3
0.73
— Data missing because person taking data was occupied taking tenth bale
measurements.
Ill
-------
A Load Position
Bale
v Loading
Dock
\
Legend ••
1 Approach
2 In position
3 Leave
Working area
below face ofbalefill
Fork lift
^\}r\\ oading bales
/ / / ///////// / /
B Unload Position
No Scale
FIGURE E-17
BALE TRANSPORT TRUCK LOAD-UNLOAD
POSITION LAYOUTS
112
-------
TABLE E-13
SORTER TASKS
Time (min.)
Production Tasks:
A. Sort corrugated paper
1 . Retrieve one or two items
2. Drop on a pile
Mean
0.25
0.20
0.05
Std. Dev.
0.11
0.10
0.05
113
-------
Cardboard
Pile
Guard
Baler Charging Box
Scale
Platen
r-*-*-*-^v-/"V. •
Cardboard
Pile
Guard
Plate
Sheet Metal
Chute for
Segregated
Cardboard
Horizontal
Conveyor
Section
Inclined
Conveyor
Section
-V
Chute
for Segregated
Cardboard
Top View of Conveyor
Note: Not to scale.
FIGURE E-18
CORRUGATED SORTER
WORK STATIONS
114
-------
6. Utilization of Positions. Figure E-19 presents the percent utilization of the five
position: gateman, loader operator, control tower operator, driver, and sorter. The
first three men were observed during plant operations as recorded on Activity Charts
1-A and 1-B. The truck drivers were timed by their logs, video tape, and stopwatch
observations. The sorters were video taped for 20 minutes of continuous operation
with the conveyor working at the normal rate.
The utilization of the control operator was not totalled. This operator did little physical
work, but he continuously watched the machines. Thus, it is very difficult to identify
when he was monitoring or idle. In fact, even when all the machines were idle, he was
monitoring conditions from his position. Thus his time had been divided to show running
utilization of the baler and conveyor. The sorter was watching the conveyor 84 percent
of his time. Contrary to the control operator who controlled equipment, the sorter
accomplished nothing during the 84 percent watching time. The utilization for the truck
driver was obtained from the utilization of the transports. Each driver handled one
and a half transports, so that the mean times were increased by 50 percent.
Figure E-19 shows utilization percentages of the average times for each operation. It
is important to note that this ignores idle time due to machine breakdowns; if all
machines run as designed, the utilization would be as shown. Also, startup and shutdown
procedures have been ignored. The time observations were of steady-state operating
conditions only. Downtime was analyzed in Section 8.
115
-------
Utilization (percent)
o
to
z
O
N
±
i—
ID
\
t
§•
c
D
CM
E
^ to
0> CN
.C
0.0
0)
e
a. a)
S .>
E
i—
10
_x
l_
Q) "n
O
-------
APPENDIX F
YEAR-LONG SYSTEM MONITORING
DATA FORMS
117
-------
TABLE F-l
FIELD ACTIVITIES LOG
Observer(s)
Hours: start
Date
end Checked
METEOROLOGICAL:
Ambient1 Temperature
Wind: Speed
Direction
Humidity
C Weather:
Precipitation in,.
Cloud cover
Other and comments:
TEST CELL
Work Tasks
Q 1. Survey settlement D3. Temperarure D 5. Lysimeter samples
Q 2. Gas samples D 4. Collect leachate GO. Rain gage
Work task no's.
Date
Time
Shipper
Samples mailed:
Equipment condition
Comments
{Continue on back of page)
LANDFILL
Work Tasks
G 1 • Surface water Q 4. Bale spacing G 7. Dust G 10- Fly traps
13 2. Cover soil D 5. Time studies C 8. Odor QH. Data mailed
G 3. Litter G 6- Broken bales G 9. Vectors to R. S. & Co.
Truck unload, time
Landfill operator(s)
Activities
min. Bales, no. Bale unload, time
Equip, in use
mm.
Comments on operations
(Continue on back of page)
118
-------
LU
to
>
%
•?
5
— J 1 1 1
cZ ?
^ ^
LU LU
LU
LU
CO
o
"o
oo
CM
Q
•4-
to
"o
to
•i-
c
V
JQ
'D
Q
&.
0
CO
/•>
I
CO
Q
2
to
CO
O
i
-
o
O-
Q-
O
z
u
a.
oo
ca
D
>*-
>
0)
_c
o
c
(U
c
(U
(U
1
(U
D
Q.
oo
/
/O
_a>
D3
<
U>
^
CM
1
/
8
D
U-
^
_J
5*
•^~
_J
^
i
^
_i
^
_i
>.
"*
-
^
-•
^
J
s
-1
/
ci
D
Q
n
LU
O
1—
!
0
\J
^£
o
(U
O)
o
o
ai
L.
0)
•«—
D
^^
(U
U
D
5
.1
(U
"o
Q
in
-C 0
*- _r-
ol
0
1_ -U-
n^
^^
r^ ,
*d o
^ y
* u
Jc3
^
°. 1
o o
o
c^
0) -CT
D •
CO O
'
-a
i» -_
o C-
> c
o
Z
o
^
Z
LU
_J
_J
u-
Q
o
X —
l_ t**" "
O i \ O
-E a> Z
O oo"^'
it
« CT
0 0«
0 ^1 >
v i Q
i*-
c
£
_2
0
U
to
D
D
t_
^
^
4
L. ^y7
CO
o
q ^
Jc *-^
"5 ii^
X
0
3
D
U
vi
0
U
U
«^£
0
0
-Q
_O
0
ca
0
_E
0
D
Q
i
i
119
-------
TABLE F-3
LANDFILL OPERATION RECORD
Date
4/22
4/28
5/20
5/27
6/9
6/16
6/26
7/2
7/8
7/16
7/25
7/30
8/6
8/14
8/21
8/27
7/3
9/17
9/25
10/14
10/27
10/28
1 1/1/73
11/8
11/15
11/25
urface Water
No.
Puddles
2
4
2
2
16
Aycj.Size
Ft^xFt)
75 x 1
70x2.5
750x0.5
S00x0.6
~Area .
Coy^red
1
15
10
4
7
Broken
Bales
(N/100)
1
7
2
0
3
1
No.
buckets
3
Cover Soil
Yi£
Bucket
3
Coveragi
(Ft2)
200
Depth
(In )
8
5"
5-1/2
120
-------
TABLE F-3 (Cont.)
LANDFILL OPERATION RECORD
Date
12/1
12/9
12/15
12/27
1/4/74
1/13
2/11
2/17
2/21
3/3
3/10
3/20
3/23
3/31
4/7
4/13
Surface Water
No.
Puddles
5
3
7
4
1
Avg.Sizt
(F&Ft)
20x50
3500x2.5
10x0.12
10x7
1600x0.5
Area
Ca^rec
3-5
65-70
5
3
15
Broken
Bales
(N/lOOj
2
4
2
0
1
Cover Soil
No.
Buckets
Ydj
Bucket
Coverage Depth
(Ft 2) (In )
6"
121
-------
TABLE F-4
LANDFILL ENVIRONMENTAL RECORD
Date
11/1
11/8
11/15
11/25
12/1
12/9
12/15
12/27
1/4
1/13
2/7
2/17
2/24
3/3
3/10
3/20
3/23
3/31
4/10
4/13
4/22
4/28
5/21
5/27
6/9
6/16
Time
0800
1100
1400
1000
1400
1030
1600
1000
1320
1200
1500
Litter
Below
1
68/1 (X
67/100
9/100
2/100
48/1 OC
69/1 (X
14/10C
81/100
10/100
17/100
70/100
68/100
24/100
47/100
35/100
301/oo
12<^0
4%
31/10C
Above
10/101
2Voo
9/100
4/100
3Yoo
3Yoo
2Yoo
27roo
1(ft6
1 W
%
27/00
Access
2%o
Yoo
2%>
Moo
24oo
Dust
Cause
car
Heighi
(Ftl
7
Area
(%)
Od
tf|eng
med.
n
mod.
light
slight
mod.
med.
med.
slight
n
n
n
med,.
med.
mod.
mod.
med.
mod.
strong
n
or
Typ
gar
9og
n
n
ii
n
n
n
n
ii
n
n
M
n
n
n
n
n
n
M
Vectors
Birds
100
5
3
30
24
6
5
Flies
Other
122
-------
TABLE F-4 (Cont'd)
LANDFILL ENVIRONMENTAL RECORD
Date
6/26
7/2
7/8
7/16
7/25
7/30
8/4
8/6
1
Time
Litter
Below
%0
20%o
4/100
6/100
Above
YM
1(Voo
3/100
Access
Voo
1/100
Dust
Cause
truck
truck
ir
K
car
car
Height
fa)
4
12
10
6
8'
6
6
Area
\(%)
5
Odor
>
-------
Period
From
TABLE F-5
TOTAL COST SUMMARY FOR PLANT
By
To
Page
Checked
Of
No. of Days
Item
Tons of Waste Received
Number of Bales Produced
Total Operating Cost
Total Depreciation/Interest
on Investment
Total Cost
Operating Cost Per Ton
Financing Cost Per Ton
Total Cost Per Ton
For This Period
Year
To Date
i
1
.
^ -j
Comments:
124
-------
TABLE F-6
TOTAL COST SUMMARY FOR TRANSPORTATION
Period
From
To
No. of Days
Page
By
Of
Checked
Item
For This
Period
Year j
To Date
Tons of Waste Hauled
1_
No. of Bales Hauled
Total Operating Cost
Depreciation and Interest
on Capital Investment
Total Cost
; Operating Cost Per Ton
Financing Cost Per Ton
Total Cost Per Ton
L_
Total Coit Per Ton Per Day
125
-------
Period
From
To
No. of Days
TABLE F-7
TOTAL COST SUMMARY FOR LANDFILL
Page
By
Item
Tons of Waste Received
No. of Bales Received
Total Operating Cost
Depreciation and
Interest on Capital
Total Cost
Operating Cost Per Ton
Of
Checked
For This
Period
Year
To Date
Financing Cost Per Ton
Total Cost Per Ton
Total Cost Per Ton Per Day
126
-------
t/1
o
u
I—
LU
5
O
UJ
c£
t 2
u. Q
LU —
CD <
< H-
co
O
O
T 1
o .
"D
(1)
_y
0
V
6
0)
D)
D
O.
X
DQ
O
i
u,
(D
3
"U
.2 E
cD 2
D_ u-
r n
1
!
i £
; 0
15
i to
i
i
i
i
i *,
! c
_D
0.
CM
O
^•t
cu
c
o
o
1_
o
X
o
>
s
U
*
X*-
D C
1"M
o
* *-
*• •- £ __
.E 0 QJ D
n CU o *-
IcSo^
e >i88M
^o
*r .•- a
r* n *— —
.E D 0) 0
o °- CL *-
-§ <" rt °
^ oi U »—
y >j39M
!
i
i
!
i
i
1
i
1
1
1
jt
^ \
O
\J 1'
1— 1
I
1
o
II
ro
c
II
•JC *-
D in
O
" -g
c 3
O "
8.2
0-5
s i!
£ *-
o c
T3 JO
-g o-
0)
-o > E
JJ-o «
D > Sf>
c
=>
:&-
— DC
8,^°
rS II
CD
11 fi-
s-
X
11
127
-------
M
"•o
o
u
Q_
5
a >
LU CQ
I CO
O
CQ
a
O
a;
LU
Q_
1
aJ
3
.2 E
o?2
o
£
_Q
D
CO
o^
u—
32
o
u_
+_
o
o
-£l
O
CO
*
1_
0
"D
D
O
C
*-.2
C4T
(U D
E.S
>Di£
•11
12
§
-' -- 1
.£ 5 £ o
-i S'n''5
5 a: U f—
I >i39M
o
-' •- 's -
.- D Q) D
llo°-3
S >i89M
•
to
1 .1
. '-^ j . •*-
*- .i: o [ •*- .h P _
.S D a> o
-i »n-°
5: a: O H-
e >!99M
•- R « o
,5 S-^-S
5: o; U t-
: f -i9aM
[
j
1
l
i
i
.
— ^n
o
4-
O
o»
CM
10
o
CQ
LL.
O
CO °
^ -o
-------
TABLE F-10
PERIOD TRANSPORT EQUIPMENT COST
Period Covered
From
By
To
Page
Checked
of
Vehicle
License No
Lease
- M + R*
-------
Period G
From
•ed:
TABLE F-ll
PERIOD LANDFILL EQUIPMENT COST
By
To
Page
Checked
of
Vehicle
License
No.
Lease
_ M + R*
•% Fuel
| Oil
Total
Lease^
cs M + R
~ai Fuel
i Oil
Total
Lease
2 M + R*
S Fuel
^ Oil
Total
Lease
^ M + R*
•8 Fuel
^ Oil
Total
Lease
2 M + R*
§ Fuel
£ Oil
Total
Individual
Vehicle
Totals
Forklift . , +JL i _ J Trailer, Lights,
. , + Loader ! Dozer •' j <~ ^
Loader , and Generator
.
r
ti
|i
ii
i
ii
!!
!
|
-
]
;
;
1
Weekly
Total
i
|
Forkfift, al-ticulated, Allis Chalmers Model 840, deisel
ntenance and Repair
Loader, articulated, Trojan Model 4000
130
-------
TABLE F-12
PERIOD OPERATIONS SUMMARY
Period Covered
From to
By
Che "'-d
Plant
Transport
Landfill
Total
Mobile
Stationary
Total
Gas
Electric
Water
Telephone
Other
Total
identify
Total
Mant
'ransport
.andfiil
ota I
ub Totals
Page
LABOR COST
Week 1
Week 2
Week 3 I Total for Month
EQUIPMENT MAINTENANCE
UTILITIES COST
MISCELLANEOUS COST
FIXED COST
131
-------
a>
-^
u
(D
^:
U
x
ca
0)
ff
a.
O
Q_
LU
< Q
o:
LU
"§
0)
3
.2 E
Q- LU
-o IF
0 ^
Comments
(Include shift hour
changes, causes of
sences, changes in
number of laborers,
-8s
~~> o
10 3
_^j O
^ O
— >
i
^. O
|\
—1
V)
CO 3
^ O
— )
to
CM *-
_y O
0) \
o
— 1
~
O
I
O ^
—I Q-
to
(U
132
-------
APPENDIX G
LANDFILL OBSERVATIONS AND
TEST-CELL MONITORING DATA
133
-------
TABLE G-l
TENTH BALE DIMENSIONS AT 10 MINUTES
AND ONE HOUR- 9/20/73
Meters
10 Minutes
Max. Height 1.13
Min. Height 1.05
Max. Width 0.99
Min. Width 0.96
Max . Length ] . 34
Min. Length 1.27
Ave. Height 1.Q9
Ave. Width 0.97
Ave. Length 1.30
One Hour
Max. Height
M?n. Height
Max. Wfdth
Min. Width (
Max. Length
Min. Length
Ave. Height
Ave. Width
Ave. Length
.14
.05
.02
).97
.38
.28
.10
.00
.33
Mean
Inches
44.33
41.23
39.05
37.70
52.63
50.00
42.78
38.37
51.32
44.96
41.36
40.11
38.25
54.39
50.36
43.16
39.18
52.37
St.
Meters
0.052
0.025
0.023
0.018
0.106
0.107
0.056
0.024
0.047
0.058
0.036
0.047
0.025
0.106
0.111
0.064
0.033
0.072
Dev.
Inches
2.06
1.00
0.91
0.73
4.19
4.22
2.19
0.95
1.86
2.29
1.41
1.86
1.00
4.17
4.36
2.55
1.31
2.85
134
-------
TABLE G-2
TENTH BALE DIMENSIONS AT 10 MINUTES
AND ONE HOUR-9/21/73
10 Minutes
Max. Height
Min. Height
Max. Width
Min. Width
Max. Length
Min. Length
Ave. Height
Ave. Width
Ave. Length
One Hour
Max. Height
Min. Height
Max. WTdth
Min. Width
Max. Length
Min. Length
Ave. Height
Ave. Width
Ave. Length
Meters
1.20
1.09
1.06
1.00
1.48
1.39
1.15
1.03
1.43
1.17
1.07
1.03
0.98
1.43
1.35
1.12
1.01
1.39
Mean
Inches
47.29
43.04
41.64
39.36
58.11
54.68
45.16
40.50
56.39
46.04
42.07
40.46
38.71
56.39
53.14
44.05
39.59
54.77
St.
Meters
0.097
0.068
0.070
0.042
0.152
0.155
0.076
0.041
0.061
0.087
0.052
0.035
0.029
0.142
0.137
0.071
0.031
0.058
Dev.
Inches
3.81
2.66
2.74
1.67
5.98
6.10
3.00
1.62
2.42
3.42
2.05
1.39
1.15
5.61
5.39
2.80
1.24
2.30
135
-------
TABLE G-3
TENTH BALE DIMENSIONS AT 10 MINUTES
AND ONE HOUR - 9/24/73
Mean
Meters Inches
St.
Meters
Dev.
Inches
10 Minutes
i i
Max.
Mm.
Max.
Min.
Max.
Min.
Ave.
Ave.
Ave.
Height 1
Height i
Width 1
1.16 45.71
1.06 41.68
1.04 41.00
Width 0.98 38.68
Length ]
Length 1
Height 1
Width 1
Length 1
1.38 54.43
1.23 48.46
1.11 43.70
1.01 39.84
1.31 51.45
0.064
0.027
0.033
0.029
0.072
0.083
0.072
0.042
0.107
2.55
1.08
1.29
1.14
2.83
3.26
2.85
1.64
4.22
One Hour
i i
Max.
Min.
Max.
Min.
Max.
Min.
Ave.
Ave.
Ave.
Height i
Height 1
Wfdth 1
Width (
Length 1
Length '
Height 1
Width 1
Length i
1.21 47.57
1.08 42.71
1.08 42.36
).99 39.14
1.44 56.86
1.26 49.71
1.15 45.14
1.04 40.75
1.37 53.29
0.074
0.036
0.055
0.032
0.099
0.085
0.087
0.058
0.128
2.93
1.41
2.15
1.25
3.88
3.33
3.43
2.27
5.05
136
-------
TABLE G-4
TENTH BALE DIMENSIONS AT 10 MINUTES
AND ONE HOUR - 9/25/73
10 Minutes
Max. Height
Min. Height
Max. Width
Min. Width
Max. Length
Min. Length
Ave. Height
Ave. Width
Ave. Length
One Hour
Max. Height
Min. Height
Max. Wtdth
Min. Width
Max. Length
Min. Length
Ave. Height
Ave. Width
Ave. Length
Meters
1.19
1.14
1.09
1.04
1.38
1.31
1.16
1.06
1.35
1.22
1.18
1.13
.07
.47
.40
.20
.10
.36
Mean
Inches
46.82
44.86
42.91
40.91
54.50
51.45
45.81
41.91
52.98
48.09
46.32
44.50
42.21
57.77
55.09
47.20
43.33
53.43
Meters
0.052
0.047
0,036
0.040
0.170
0.181
0.035
0.036
0.054
0.078
0.051
0.048
0.046
0.149
0.151
0.032
0.041
0.048
St. Dev.
Inches
2.04
1.85
1.41
1.59
6.70
7.12
1.38
1.41
2.15
3.10
2.00
1.90
1.81
5.85
5.96
1.25
1.62
1.90
137
-------
TABLE G-5
TENTH BALE DIMENSIONS AT 10 MINUTES
AND ONE HOUR - 9/26/73
10 Minutes
Max. Height
Min. Height
Max. Width
Min. Width
Max. Length
Min. Length
Ave. Height
Ave. Width
Ave. Length
One Hour
Max. Height
Min. Height
Max. W?dth
Min. Width
Max. Length
Min. Length
Ave. Height
Ave. Width
Ave. Length
Meters
1.18
1.05
1.17
1.06
1.44
1.31
1.11
1.11
1.38
1.22
1.06
1.18
1.05
1.51
1.36
1.14
1.11
1.43
Mean
Inches
46.61
41.17
46.00
41.67
56.72
51.72
43.89
43.83
54.22
47.89
41.72
46.39
41.33
59.28
53.61
44.81
43.86
56.44
St.
Meters
0.060
0.035
0.108
0.061
0.081
0.093
0.098
0.078
0.136
0.049
0.021
0.068
0.054
0.125
0.140
0.111
0.091
0.102
Dev.
Inches
2.37
1.39
4.24
2.41
3.17
3.67
3.85
3.06
5.36
1.93
0.83
2.69
2.11
4.92
5.52
4.36
3.57
4.01
138
-------
_
0)
0)
X
D
-
ro
r-
o
CM
O
X
D
O
O
CM
|OA Xq o/0) uoisuodxg
139
-------
0)
e
o
R
O
LU
O
I
Z
O
to
Z
X
LU
LU
co
X
o
-o
o
o
CO
o
CN
(•JOA Xq %) uoisuodxg
140
-------
_
0)
OJ
CO
I
CO
o
Z
O
x
o
o
o
o
CN
(•|OA Xq %) uojsuodxg
141
-------
=1 «
CO
o
UjO
x
•8
<
CQ
O
O
CO
O
CN
(• |OA Ac\ %) uojsuodxg
142
-------
0)
"^
I O^
°4
UJ O
oe. rr
O
X
LU
LU
j
o
CO
o
CM
(•|OA Xq %) uoisuodxg
143
-------
TABLE G-6
BALE SPACING RESULTS
Spacing Between Bales, cm
Date
1974
1/4
1/13
2/7
2/17
2/24
3/10
3/20
3/24
3/31
4/22
4/28
5/21
5/29
6/19
6/16
6/26
Maximum
Width
10.2
3.8
2.5
6.4
8.9
6.4
6.4
7.6
6.4
15.2
6.4
0
** 15.2
2.5
** 5.1
7.6
15.2
** 1.3
17.78
** 15.24
Length
30.5
99.0
55.9
17.8
—
20.3
61.0
63.5
30.5
43.2
17.8
20.3
1.3
20.3
3.8
3.8
16.5
17.8
30.48
5.08
Minimum
Width
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Length
0
1.9
8.9
0
—
2.5
0
3.8
1.3
0
0
0
0
0
0
0
0
0
0
0
Average
Width
4.6
0.6
1.1
0.6
2.2
1.0
1.2
2.5
1.4
4.8
0.9
0
4.8
0.5
1,7
2.3
2.4
0.1
1.9
4.3
Length
13.4
16.0
24.8
10.2
—
8.0
7.7
15.4
9.8
15.3
10.0
7.0
0.1
7.2
0.4
0.5
5.2
6.1
5.5
0.8
Std. Deviation
Width
3.7
1.2
1.0
1.9
2.7
2.0
2.1
2.3
2.2
4.6
2.0
0
6.0
0.8
2.0
2.9
4.6
0.4
5.3
4.5
Length
8.3
27.9
15.6
6.2
—
5.4
17.3
16.9
8.6
13.8
6.7
6.3
0.4
6.6
1.1
1.2
5.3
5.6
9.8
1.5
** Working Face
144
-------
TABLE G-6(Cont.)
BALE SPACING RESULTS
Spacing Between Bales, cm
Date
1973
10/10
10/14
10/16
10/17
10/18
10/20
10/27
11/3
11/10
11/15
12/1
12/9
12/15
12/27
Maximum
Width
20.3
20.3
7.8
6.4
5.1
76.2
61.0
1.3
1.3
2.
15.2
3.8
5.1
15.2
Length
— —
— -
—
58.4
15.2
38.1
61.0
35.6
25.4
25.4
25.4
30.5
21.6
22.9
Minimum
Width
0
1.3
0
0
0
0
0
0
0
0
0
0
0
0
Length
__
--
—
0
0
0
0
0
1.3
0
0
0
0
0
Average
Width
6.6
8.4
3.1
2.2
1.3
14.8
17.8
0.1
0.1
0.4
2.8
0.9
1.0
2.7
Length
__
—
—
17.8
6.0
7.9
21.6
8.4
11.4
10.7
8.8
7.5
9.8
7.9
Std. Deviation
Width
7.2
6.2
5.3
2.3
1.5
22.3
17.1
0.4
0.4
0.9
5.3
1.3
1.8
4.7
Length
__
—
—
17.5
5.5
10.6
17.9
9.7
6.3
8.7
9.1
9.2
7.3
6.8
145
-------
TABLE G-7
LITTER COUNT RESULTS
No. Observations
Range
, no. pieces.
{ ibo ft ^ ' ~'
Average
/ no. pieces \
1 100ft2 '
No. Observations
Excluding
Values > 100
Range
, no . pieces'*
( 100ft2 '
Average
( no. pieces^
v Too ft 2" ;
Below Face
25
2 to 425
81
20
2 to 70
48
Above Face
15
3 to 207
39
13
3 to 50
21
Access Road
7
1 to 82
22
6a
1 to 27
12
No values > 100; excludes the 82 value, which appeared to be erranf considering
the range of other values.
-------
rlvi
CANVAS
COVER
O
BLACK PAINTED
CANVAS COVER
2-INCH
PACKED
SOIL SEAL
SCREEN
1-QUART
FLYTRAP
BOTTLE
Not to Scale
FIGURE G-6
FLY EMERGENCE TRAPS
147
-------
b. Trap:
a. Trap Placement
PHOTOGRAPH G-l
FLY EMERGENCE TRAPS
148
-------
TABLE G-8
FLYING INSECTS COLLECTED
IN THE BALEFILL FLY EMERGENCE TRAPS*
MAY
JUNE
Traps on
Cover Soil
C
E
F
A
E
F
Families
Metopiidae
(bottle flies)
Asilidae
(robber flies)
None
collected
Scarabacidae
(dung beetles)
Silphidae
(carrion beetles
Metopiidae
)fosophilidae
(fruit flies)
Silphidae
Staphylinidae
Asilidae
Scatopsidae
(scavenger
flies)
Metopiidae
Drosophilidae
Culicidae
(mosquitos)
Mycetophilidae
Metopiidae
Scatopsidae
Mycetophilidae
Traps on
Bales
A
B
R
D
C
Families
Specimens
mangled
None
collected
Staphylinidae
(scavenger beetles
Mycetophilidae
(fungus gnats)
Silphidae
Staphylinidae
* Trap D was destroyed by the loader during placement of cover soi
149
-------
TABLE G-9
LAND DISPOSAL EVALUATION SHEET
Points St. Paul
L EMPLOYEE FACTORS Possible Site
1.Facilities
a. Adequate shelter, hygiene facilities ( 3) *
b. Adequate shelter-minimal hygiene facilities ( 2) ~~2
c. Inadequate shelter, hygiene facilities ( 0)
2. Communications
a. Radio or telephone on-site ( 2)
b. Telephone or radio within 3-miles ( 1) j
c. No communications ( 0) '
3. Accident Prevention and Safety
a. Periodic training given, equipment provided with
safety features, first aid readily available on-site ( 2) 2a
b. Periodic training given, equipment provided with
safety features, first aid available within 3-miles
of site ( 1)
c. No training, no first aid available ( 0) ~
d. Unsafe equipment and/or practices (-5) ~
4. Fire Protection
a. Adequate water supply, local fire company
available on call, open burning prohibited (3) „
b. Poor fire protection, open burning prohibited ( 2)
c. No fire protection, open burning allowed ( 0) "
5. Parking Facilities and Access Road Conditions
a. All weather, adequate parking ( 3) gb
b. Al! weather, Inadequate parking ( 2)
c. Negotiable only in good weather ( 0)
Sub Total (T3) ]]
OPERATIONAL FACTORS
1. Weighing Facilities
a. Fixed or portable scales available on-site ( 2) 2C
b. Scale available near site ( 1)
c. No weighing facilities nearby ( 0) ~
2. Access Limited
a. Access by unauthorized vehicles and pedestrians
prohibited and prevented (3) 3
b. Access prohibited except during day ( 2)
c. Uncontrolled access to site ( 0)
150
-------
TABLE G-9 (Cont.)
LAND DISPOSAL EVALUATION SHEET
Points St. Paul
Possible Site
a. nmum -
b. Minimum depth - 2 ft poor soil and grading ( 5)
c. No final cover, or poorly constructed and
poorly graded ( 0)
151
3. Solid Waste Unloading Control
a. Controlled, area restricted ( 2) ^
b. Controlled, area unrestricted ( 1)
c. No control ( 0) ~"
4. Working Area
a. Size of v/orking area small, but adequate for
peak traffic (2) 2
b. Working area larger than necessary to handle traffic ( 1)
c. Much larger working area than necessary and/or '
uncontrolled dumping ( 0)
5. Waste Spreading and Compacting
a. Refuse spread evenly and adequately compacted ( 5) 5
b. Refuse spread, but not compacted ( 2)
c. No spreading or compacting ( 0) "
6. Depth of Waste
a. If waste compacted in cells of 8 ft depth or less (5) 5
b. If waste compacted in cells less than 12 ft depth
but more than 8 ft (2) _
c. If uncompacted or cells greater than 12 ft deep ( 0) ~~
7. Daily Earth Cover
a. If cover material is of good quality and is compacted
In unbroken layers no less than 6 in. deep (20)
b. If cover material is of poor quality, but is
compacted well (15)
c. If cover is not earth material (e.g., incinerator ash)
but is greater than 6 in. thick (10) Q
d. No cover provided ( 0)
8. Intermediate Cover
a. One foot or greater thick, good quality ( 4)
b. One foot or greater thick, poorer quality ( 3) ""*"'
c. One foot or greater thick, not soil (1)
d. No intermediate cover or, if so, poor application ( 0)
9. Final Cover and Grading
a. Minimum depth - 2 ft good soil and grading (8)
-------
TABLE G-9(Cont.)
LAND DISPOSAL EVALUATION SHEET
Points c. D ,
.. , St. Paul
Possible Site
10. Equipment Maintenance
a. Maintenance facilities available on-site or standby
equipment reedy ( 2)
b. Routine maintenance equipment available,, service
arrangements made for major repairs ( 1) 1
c. Nonexistent or inadequate maintenance-
facilities available ( 0}
11. Hazardous, Liquid and Bulky V/aste Handling
Provisions
a. Procedures adopted for handling hazardous, liquid,
and bulky products ( 4)
b. Hazardous and liquids excluded from site ( 1) ]
c. Such materials accepted without special handling
provisions ( 0)
«*^™««
12. Record Systems
a. Complete daily records are maintained (e.g., type
of waste, location of deposition, total weight,
number of vehicles served) (3) 3
b. Inadequate records are kept ( 1)
c. No records maintained ( 0)
111. ENVIRONMENTAL FACTORS Sub Total (60) 32
1. Blowing Litter
a. Fences or other barriers control blowing litter ( 4)
b. Some litter control exercised, but results are poor ( 2) ~~^
c. No controls established ( 0)
• I. !• I
2. Burning
a. No burning allowed any time (3) 3
b. Burning allowed ( 0)
3. Salvage
a, No salvage at disposal site proper allowed (3) 3
b. Controlled salvage practiced ( ])
c. Scavenging allowed ( 0)
I ••!!•••
4. Vector Control
a. Not practiced because unnecessary (2) 2
b. Proper vector control supplied ( 1)
c. Vectors (rats, flies, etc.) present, but no control ( 0)
MM^V*
152
-------
TABLE G-9(Cont.)
LAND DISPOSAL EVALUATION SHEET
polnts St. Paul
Possible Site
5. Dust Control
a. Not required, or suitable control measures
are supplied ( 2)
b. Control provided, but inadequate ( 1)
c. Necessary, but not provided ( 0)
6. Placement of Solid Wastes in Groundwater
a. Refuse placement above high groundwafer mark ( 5)
b. Intermittent contact possible ( 3)
c. Refuse deposited in water ( 0)
7. Surface Drainage
a. Surface waters diverted from fill area; no
ponding present ( 6)
b. Occasional water runs onto surface ( 4)
c. No surface water control, cover scouring
and erosion ( 0)
8. Animal Feeding
a. No animal feeding allowed, fencing provided
to prohibit animals (2) 2
b. Animal feeding allowed ( 0)
Sub Total (27) 23
Total (100) 66**
* Indicates points to be assigned if condition is met
** Score of 85 is rated acceptable by EPA
Score of 70-85 is rated marginally acceptable
Score of 55-70 is rated minimally acceptable
Score less than 55 is rated unacceptable
° First aid limited to kit in trailer.
All weather access for trucks, not cars.
Weighing facilities at baler.
Bales compacted to greater density permitting greater cell depth.
eLitter control consists of periodically scraping work area. Not much blowing litter.
pal 280
153
------- |