SW124C „ / / ENVIRONMENTAI
VVV PROTECTION
AGENGX
U.S. DEPARTMENT OF ' ^ AS
National Technical Information
PB-256
COST ESTIMATING HANDBOOK FOR TRANSFER, SHREDDING
AND SANITARY LANDFILLING OF SOLID WASTE
Booz, ALLEN AND HAMILTON INCORPORATED
PREPARED FOR
ENVIRONMENTAL PROTECTION AGENCY
AUGUST 1976
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BIBLIOGRAPHIC DATA
SHEET
1. Report No.
1396
PB 256 444
4. Tit If .uid Subt it If
Cost Estimating Handbook For Transfer,
Shredding and Sanitary Landfilling of
Solid Waste
5- Report Date-
August 1976
6.
7. Autlior(s)
8. Performing Organisation Kept,
No.
9. Performing Organization Name and Address
Booz, Allen and Hamilton Inc.
Washington, B.C.
10. Project/Task/Work Unit No.
11. Contract/Grant No.
EPA, 68-01-3121
12. Sponsoring Organization Name and Address
EPA, Office of Solid Waste Management Programs
401 M Street, S.W.
Washington, B.C. 20460
13. Type of Report & Period
Covered
Final
14.
15. Supplementary Notes
16. Abstracts
Cost findings for 12 solid waste transfer stations averaged $4.45
per ton for operating costs and $.94 per ton for capital costs in 1975.
Average capital investment was $780,000 per community. Average costs
for 10 shredder facilities in 1975 were $5.61 for operating costs and
$1.69 per ton for capital. Average capital investment was nearly 2
million dollars per facility. Data from 17 landfills indicated operating
costs averaged $2.38 and capital costs 68 cents per ton in 1975. Labor
was the largest operating cost item at all facilities accounting for
55 percent at transfer facilities, 39 percent at shredding facilities
and 50 percent at landfills.
17. Key Words and Document Analysis. 17a. Descriptors
Solid Waste:
Costs
Capital Costs
Operating Costs
Landfill Costs
Transfer Costs
Shredding Costs
Milling Costs
Estimating Costs
17b. Identifiers/Open-Ended Terms
PRICES SUBJECT TO CHANGE
17c. COSATI Field/Group
Solid Waste: Economics, Statistics, Processing,
Landfill, Shredding, Transfer
18. Availability Statement
Release Unlimited
REPRODUCED BY
NATIONAL TECHNICAL
INFORMATION SERVICE
U.S. DEPARTMENT Of COMMERCE
SPRINGFIELD, VA. 22161
NTIS-35 (REV. 3-721
19. Security Class (This
Report)
UNCLASSIFIED
| 21. "No. of Pages
20. Security Class (This
Page
UNf.LASSII-'lf-.D
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COST ESTIMATING HANDBOOK
FOR TRANSFER, SHREDDING AND
SANITARY LANDFILLING OF SOLID WASTE
This final report (SW-l24c) describes work performed for the Federal
solid waste management programs under contract No. 68-01-3121
and is reproduced as received from the contractor with
same deletions and minor editorial corrections.
U.S. ENVIRONMENTAL PROTECTION AGENCY
1976
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This report had been reviewed by the U.S. Environmental Protection
Agency and approved for publication. Its publication does not signify
that the contents necessarily reflect the views and policies of the U.S.
Environmental Protection Agency, nor does mention of commercial products
constitute endorsement or recommendation for use by the U.S. Government.
An environmental protection publication (SW-124c) in the solid waste
management series.
11
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FOREWARD
In response to numerous requests for cost information on selected
solid waste functions, the Environmental Protection Agency initiated a
study with Booz, Allen & Hamilton Inc. to develop cost estimating proce-
dures for use by local solid waste managers in projecting the capital
and operating costs of solid waste transfer, shredding and landfilling
systems in their communities. EPA Contract Number 68-01-3121.
This project is part of a broad technical assistance program being
carried out by the Office of Solid Waste Management Programs in EPA to
help communities improve their solid waste management. It was conducted
under John W. Thompson, Project Manager.
Special appreciation is expressed to the following jurisdictions
for their cooperation in supplying the data used in the preparation of
the handbook:
Transfer Systems
Arlington County, Virginia
Brookline, Massachusetts
Dearborn Heights, Michigan (Central Wayne
County Sanitation Authority)
Detroit, Michigan
Hamilton, Ohio
Hanover, Massachusetts
Hollywood, Florida
Lancaster, Pennsylvania (Lancaster Area Refuse
Authority)
Orange County, Florida
- Pensacola, Florida
Richardson, Texas
Santa Monica, California
Washington, D. C.
Shredders
Charleston, South Carolina
Chemung County, New York
Chicago, Illinois
- Columbus, Ohio
De Kalb County, Georgia
Great Falls, Montana
Harrisburg, Pennsylvania
High Point, North Carolina
- Madison, Wisconsin
Odessa, Texas
Onondaga County, New York
- Tacoma, Washington
Willoughby, Ohio
iii
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Sanitary Landfills
Cape Girardeau, Missouri
- Fairfax County, Virginia
Fresno, California
High Point, North Carolina
Independence, Missouri
Joplin, Missouri
Kenosha, Wisconsin
Lancaster, Pennsylvania (Lancaster
Area Refuse Authority)
Madison, Wisconsin
- Nashua, New Hampshire
Norfolk, Virginia
Odessa, Texas
Raleigh, North Carolina
Richardson, Texas
Toledo, Ohio
Topeka, Kansas
- SHELDON MEYERS
Deputy Assistant Administrator
for Solid Waste Management
Table of Contents
Page
1 Transfer Systems
14 Cost Estimating
21 Shredding
33 Cost Estimating
39 Bulky Item Shredding
48 Cost Estimating
53 Sanitary Landfilling
70 Cost Estimating
IV
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LIST OF TABLES
Table I
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Table fl.5
Table 0.6
Table 17
Table 18
Table 19
Table 20
Table 21
Table 22
Table 23
Table 24
Table 25
Table 26
Table 27
Table 28
Table 29
Table 30
Table 31
Table 32
Table 33
Table 34
Table 35
Table 36
Table 37
Table 38
Table 39
Table 40
Characteristics and Costs of 12 Transfer Systems in 1975
Capital Costs for 12 Transfer Systems in 1975
Annual Operating Costs for 12 Transfer Systems in 1975
Operating Costs Per Ton for 12 Transfer Systems in 1975
Depreciation Periods for 12 Transfer Systems in 1975
Wage and Fringe Benefits Rates for 12 Transfer Systems in 1975
Direct Hauling Costs for 12 Transfer Systems in 1975
Average Daily Tons for Transfer System Personnel
Transfer System Capital Cost Worksheet
Transfer System Operating Cost Worksheet
Characteristics and Costs of 10 Shredder Sites in 1975
Capital Costs of 10 Shredder Sites in 1975
Operating Costs of 10 Shredder Sites in 1975
Operating Costs Per Ton of 10 Shredder Sites in 1975
Depreciation Periods for 10 Shredder Sites
Wage Rates and Fringe Benefits Rates for 10 Shredder Sites in 1975
Direct Hauling Costs for 10 Shredder Sites in 1975
Shredder Capital Cost Worksheet
Shredder Operating Cost Worksheet
Characteristics of 3 Bulky Item Shredders in 1975
Capital Cost of 3 Bulky Item Shredder Sites in 1975
Operating Costs of 3 Bulky Shredder Sites in 1975
Operating Costs Per Ton of 3 Bulky Item Shredder Sites in 1975
Depreciation Periods for 3 Bulky Item Shredder Sites
Wage Rates arid Fringe Benefits for 3 Bulky Item Shredders
Direct Hauling Costs for 3 Bulky Item Shredders in 1975
Bulky Item Shredder Capital Cost Worksheet
Bulky Item Shredder Operating Cost Worksheet
Characteristics and Costs of 17 Landfill Sites in 1975
Capital Costs for 17 Landfills in 1975
Operating Costs for 17 Landfills in 1975
Operating Costs Per Ton for 17 Landfills in 1975
Depreciation Periods for 17 Landfill Sites
Wage Rates and Fringe Benefits for 17 Landfills in 1975
Average Daily Tons for Landfill Personnel
Equipment for 17 Landfills in 1975
Operating and Capital Costs Per Ton for 3 Landfill Sites
Receiving Shredded Wastes in 1975
Land Costs for 17 Landfill Sites in 1975
Landfill Capital Cost Worksheet
Landfill Operating Cost Worksheet
Figure 1
FIGURE
Total Cost Per Ton U.S. Utilization for 10 Shredder Sites in 1975
v
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SUMMARY
Solid Waste processing and disposal have become a major problem
for many local governments in recent years. Primary factors contri-
buting to the problem have been an increasing amount of solid waste,
the need for new disposal sites, rising labor and equipment costs,
and increased public awareness.
In response to these problems, many local officials are developing
and evaluating alternative courses of action. Options under consideration
include the installation of transfer systems, construction of shredder
facilities, and the development of new sanitary landfills.
The purpose of this report is to provide capital and operating cost
data for solid waste systems so that decision makers can evaluate and
assess the estimated costs of alternative options.
Cost findings based on data collected in 1975 are summarized as
follows:
Transfer systems. Operating costs for 12 communities
averaged $4.55 per ton in 1975 and ranged from $1.84 to
$10.72 per ton. Labor costs, including fringe benefits,
averaged 55 percent; vehicular equipment, 34 percent;
stationary equipment, 9 percent; and other, 2 percent.
Capital costs averaged $780,000 per system, and
accounted for an average additional $.94 per ton.
Shredding. Operating costs per ton for 10 communities in
1975 averaged $5.61, ranging from $2.85 to $9.50. Labor
costs averaged 39 percent; stationary equipment, 27 per-
cent; vehicular equipment, 15 percent; and other, 19 per-
cent. The average capital cost was $1,940,000, amounting
to an average additional $1.69 per ton.
Sanitary landfilling. Operating costs for 17 communities in
1975 averaged $2.38 per ton, ranging from $.98 to $5.41 per
ton. Labor costs averaged 50 percent; vehicular equipment,
36 percent; and other, 14 percent. Capital costs averaged
additional $.68 per ton.
VI
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INTRODUCTION
This handbook was developed to help local solid waste officials in
(1) developing cost estimates for planning purposes; (2) developing
budget estimates; (3) evaluating costs of alternative systems; and
(4) evaluating cost proposals for solid waste systems submitted by
vendors.
The cost estimates which may be prepared from this handbook should
be considered preliminary or planning estimates. They cannot replace
the estimates that are developed as part of a detailed engineering
study for a particular system at a particular site. Every solid waste
system is unique, in that no two systems will have identical capital
and operating costs due to differences in land costs, labor rates, site
characteristics, equipment selection, and many other factors.
Two basic assumptions have been made in the report. First, interest
expense, or the cost of capital, has been excluded from the analysis
since this expense was found to be treated inconsistently in the surveyed
sites. Second, except for the section on Sanitary Landfilling, land was
considered to be a nondepreciable asset. The Sanitary Landfilling
chapter provides for situations where land is treated as a depreciable
asset over the expected life of the landfill.
TRANSFER SYSTEMS
Transfer systems employ the concept of transferring solid waste
from collection vehicles to larger capacity transfer vehicles for hauling
to a disposal site. Generally, transfer trucks are tandum axle tractor/
trailer vehicles, hauling 15 to 20 tons. Truck transfer systems are in
operation in many areas of the nation where disposal sites are distant
from urban areas and significant time would be spent by collection crews
transporting the solid waste.
Truck transfer systems commonly utilize one of two methods in
transferring wastes. In one, noncompacted solid waste is transferred
directly into a larger transfer truck until capacity is reached. Another
method involves a highpressure packing ram as part of a transfer truck
or a stationary compactor which compresses the material to a fraction
of its original volume. Both methods reduce the number of trips required
to the disposal site.
The overall advantages of a transfer system are: (1) total solid
waste management costs can be potentially reduced since nonproductive
collection time can be cut; (2) communities can change landfill locations
without changing the collection routes. A disadvantage of transfer
systems is that large capital expenditures must be made for land,
facilities, stationary, and vehicular equipment.
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The characteristics of the 12 transfer systems are shown in Table 1.
The sites are similar in that all the transfer stations are publicly
owned and operated, and all but one of the systems employ stationary
compactors. The average daily tonnage ranged from 112 tons to a combined
tonnage of 880 tons for the two separate transfer stations operated by
one jurisdiction. Operating days per year varied from 130 to 36A, and
number of station employees ranged from 1 to 24. The round-trip distance
from the transfer station to the landfill ranged from 20 to 63 miles and
averaged 31 miles.
The annual operating and annualized capital costs of the 12 transfer
systems averaged $5.49 a ton. (Table 1) Operating costs were 82 percent
of total annual costs, or an average of $4.55 per ton. Capital costs
averaged 18 percent of total annual costs, or $.94 per ton. The costs
include the operation of the transfer station and the round-trip truck haul
to the disposal site but not the collection or the disposal costs.
Capital Costs
The average total capital cost per ton for the 12 sites was $.94,
with a range of $.15 to $2.70 per ton. Annualized capital costs 18
percent of total annual costs and ranged from 2 to 42 percent.
The capital costs associated with a truck transfer system include
those incurred in constructing the station and in purchasing the vehicular
equipment in Table 2. Annualized capital costs were calculated for
each cost category (except for land, which was considered to be a
non-depreciable asset) by straight-line depreciation over the depreciation
period (expected useful life) of each capital cost item, assuming zero
salvage value, as follows:
Annualized Capital Cost = Purchase Cost
Depreciation Period (years)
Land. Only 3 of the 12 sites had purchased land on which to locate
the transfer station. The land costs reported by the 3 sites were $13,000,
$4,000, and $9,000. The remaining sites utilized land already owned
by the jurisdiction.
Site Construction. The site construction costs ranged from $.01 to
$.90 per ton, with an average of S.27, for the 11 sites that did not
utilize an existing structure for the transfer station facility. The site
construction category included costs for: engineering design; architec-
tural services; site preparation, including demolition and grading; and
construction of the transfer station facility.
Stationary Equipment. An average of $.11 per ton was spent for
stationary equipment. Costs ranged from $.004 to $.33 per ton. Stationary
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equipment included equipment required at the transfer station, such
as scales, compactors, conveyors, and push pits.
Vehicular Eguipment. Vehicle capital costs averaged $.64 per ton
for 10 sites which did not lease their equipment, with a range of $.18
to $1.67. Sites 1 and 4 leased their vehicular equipment. The vehicular
equipment cost category represented the purchased costs of all vehicles
utilized by the transfer operation, including transfer trucks and
trailers, sweepers, and front end loaders.
Operating Costs
The average operating cost per ton was $4.55, ranging from $1.84
to $10.72 per ton. This was 82 percent of total annual costs, and ranged
from 58 to 98 percent. The annual operating costs of the 12 transfer
sites are shown on Table 3 and the operating costs per ton are given in
Table 4.
Labor. Labor costs averaged $2.52 per ton and ranged from $.63 to
$5.20 per ton. The percentage of labor costs to total operating costs
ranged from 26 percent to 81 percent, averaging 55 percent.
Labor costs included salaries, wages and fringe benefits to those
individuals employed at the transfer station or directly associated with
its operation. These were vehicle drivers, regular, temporary, and
overtime pay. An average of $2.10 per ton was attributed to salaries
and wages, with a range of $.55 to $4.78 per ton.
Fringe benefit costs included social security, hospitalization,
workmen's compensation, and unemployment compensation costs. Fringe
benefits averaged $.42 per ton, and ranged from $.63 to $5.20 per ton.
Sitationa ry Equipme n t. Stationary equipment costs averaged $.18
per ton and ranged from $.01 to $.95 per ton. The stationary equipment
operating costs averaged 4 percent of total operating costs. Operating
expenses associated with stationary equipment included labor costs
for the repair and maintenance of the transfer station equipment and
costs of parts and supplies, such as lubricants. Additional costs
included were for the purchase of shop equipment, small hand tools, and
communication devices.
Vehicular Equipment. Vehicular equipment operating costs were found
to average $1.51, ranging from $.41 to $5.07. On the average, 33 percent
of the total operating costs were directly associated with vehicular
equipment operation, varying from 15 percent to 68 percent. Operating
costs associated with the vehicular equipment category included costs of
repair and maintenance labor, parts and supplies, and fuel and oil. If the
vehicular equipment was rented or leased from a private firm or another
municipal agency, the rental costs were also included.
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Facilities and Site Maintenance. Facilities and site maintenance
averaged $.04 per ton, with a range of $.033 to $.17 per ton. The
facilities and site maintenance category included costs for items such
as painting, fence or road repair, janitorial services, and rodent control.
Utilities. An average utilities cost of $.12 per ton was found,
which varied from $.02 to $.52 per ton. The utilities costs typically
included electricity, gas, water, sewer, and telephone charges incurred
in the operation of the transfer station facility and all associated
equipment.
Administrative Expense. An average of $.07 per ton was reported
for administrative expenses in 10 of the sites surveyed, with a range
of $.01 to $.26 per ton. Two of the sites did not report any adminis-
trative expenses.
Costs associated with the administration of a transfer system may
include a variety of expenses which varies with each system. Typically,
administrative expenses included those incurred for such items as
printing, data processing, postage, paper and forms, uniforms, washroom
supplies, non-capitalized office furniture and fixtures, painting, lawn
care, and office rental.
Other Expenses. Depending on the individual transfer system, expenses
for a number of other items were incurred that were not provided for in
the previous categories. These included consulting engineering services,
insurance, taxes, and security services. Three of the twelve sites
surveyed reported no such expenses, while the remaining nine averaged S.10
per ton, ranging from $.01 to $.31 per ton.
Variations in Cost Elements
Both the capital and operating costs, vary significantly among the
12 transfer system sites. The costs per ton can be influenced by a
number of variables such as: (1) tons processed per day; (2) depreciation
schedules; (3) wage and fringe benefits rates; (4) hauling costs to the
disposal site; and (5) labor utilization.
Tons Processed Per Day. A close relationship between daily tonnage
and operating, capital, and total costs per ton was not in evidence. This
can be explained, in part, by examining the influence of other factors
on the costs per ton. These factors were: (1) start-up operations;
(2) operating days per year; (3) purchase vs. rental or lease of equipment;
(4) transfer station design.
As table 2 indicates, Site no. 3 had high capital costs. This site
operated only six months a year, thus the annualized capital costs per ton
were proportionately higher than for sites operating on a 12-month basis.
-------
An examination of the operating costs indicates that Site Nos.
1, 2, 4, and 12 have significantly higher operating costs per ton than
the average of $4.55. The major factors influencing these variations
were:
(1) Site Nos. 1 and 4 rented or leased the majority of their
vehicular equipment. This resulted in higher operating
costs per ton.
(2) Some sites were based on six months of initial operation and
may not be representative of normal operating costs.
(3) Site No. 12 utilized an existing incinerator facility for
one of its two transfer stations. This station was not
equipped with push pits and compactors, but transferred
waste by means of clam shell cranes. This was a more expensive,
time-consuming operation.
Depreciation Schedules. Examination of the depreciation schedules,
shown in Table 5, reveals that all sites did not depreciate their
facilities and capital equipment in the same manner. Most sites
depreciated their facilities over 20 years, stationary equipment over
10 to 15 years, and vehicular equipment over 5 years.
Depreciation for each transfer system was computed on a straight-
line basis. Although the depreciation period influences the annualized
capital cost, the data did not support a statement concerning this
relationship, since capital costs varied from site to site and depre-
ciation periods did not differ substantially among most of the sites.
Wage and Fringe Benefits Rates. Average hourly wages of the transfer
systems' employees are displayed in Table 6. Supervisors had an average
hourly wage of $6.51; station employees, $4.72; and vehicle operators
$4.98.
These rates help explain some of the operating cost per ton varia-
tions shown in Table 4. For example, Site No. 10, which had the lowest
average hourly wages, had much lower operating costs per ton than sites
with similar daily tonnages. Site No. 1, which had the highest wage
rates also had high operating costs per ton.
The fringe benefits rates averaged 20 percent of salaries and wages,
with a range of 9 to 40 percent. There is a direct relationship between
labor costs and fringe benefits rates since fringe benefits are calculated
by multiplying the cost of salaries and wages by the fringe benefits
percentage.
-------
TABLE 5
DEPRECIATION PERIODS FOR 12 TRANSFER
SYSTEMS IN 1975
Site No.
1
2
3
4
5
6
7
8
9
10
11
12
Average
Site Construction
20
10
20
20
20
--
20
20
20
16
20
10
20
Stationary Equipment
15
10
15
15
12
15
10
20
20
10
14
10
10-15
Vehicular Equipment
5
5
5
--
8
3-5
6
10
5
3-5
6
4
5
TABLE 6
WAGE RATES AND FRINGE BENEFITS RATES
FOR 12 TRANSFER SYSTEMS IN 1975
Site
No.
1
2
3
4
5
6
7
8
9
10
11
12
Supervisor
Avg. Hourly Wage
$8.75
6.48
7.47
—
6.48
--
—
4.50
6.87
4.00
6.46
7.56
Station Employee
Avg. Hourly Wage
$6.06
5.47
5.90
--
5.38
4.16
4.30
3.50
4.35
2.10
5.46
5.26
Vehicle Operator
Avg. Hourly Wage
$6.68
5.41
5.83
--
5.66
4.75
4.60
3.80
5.00
2.10
5.30
5.71
Fringe
Benefits Rate
22%
25
40
40
16
20
14
13
23
14
24
9
Average 6.51 4.72 4.98 20
10
-------
Hauling Costs. The largest cost item in any transfer operation is
hauling to the landfill. As shown on Table 7, costs increase almost in
direct relation to distance hauled. Average costs for 10 firms reporting
were $2.82 per ton for an average round trip haul of 31 miles or about
9 cents per ton mile. On a mile basis truck operating costs, including
labor and depreciation, were $1.36 for a 15 ton load.
It is difficult to establish a typical tractor trailer operating cost.
Some communities were confronted with severe traffic conditions and poor
roads while others had only 1-2 traffic lightjand interstate highways.
Other communities incurred high maintenance costs because transmissions
and axles broke down on sandy landfills. Some communities were able
to purchase used tractors and thru good maintenance keep operating costs
at a minimum.
Labor Utilization. There was considerable variation among transfer
stations on tons handled per employee on an 8 hour day. As shown on
Table 8, tons per station employee per day ranged from 20 to 120 tons and
tons per supervisor ranged from 50 to 2900 a day. A valid comparison of
tons per vehicle driver cannot be made because road and traffic
conditions have a strong effect on productivity.
Several factors contribute to the large variation. Some stations
desired a big crew for peak periods, others maintained extensive cleanup
crews or employees to help collection trucks unload. The most effective
arrangement appeared to be the switching of jobs among all employees.
For example, everyone concentrated on unloading trucks or getting waste
thru the compactors into transfer trucks and then everyone helped with
cleanup. In some instances, drivers and station personnel switched
jobs on a 4 hour basis. One labor saving method was to have the sealer
assign each truck to an unloading bay thus avoiding a spatter on the
dumping floor. Other stations reduced labor requirements by presetting
the compactors for a select number of cycles and not weighing trucks
after loading. Some stations required drivers to open and close tailgates
and run the compactors while other firms had separate specialized personnel
for these operations.
The number of supervisors to a station had a considerable variation.
In general, one man is sufficient for most facilities. Some larger
stations had a supervisor for maintenance and fleet operation, in addition
to station operation which can increase costs substantially. Other
station's used working foremen to operate the facility and the supervisor
only spent part of the day at the station and managed the landfill or
collection vehicles in addition to his transfer station duties.
11
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Cost Estimating
This section presents procedures for developing estimates of the
capital and operating costs of a transfer system. These estimates are
not intended to replace estimates as part of a detailed engineering design
study for a particular transfer station. When available, current local
cost data should be utilized with the procedures.
Capital Costs. Costs for the following categories should be
developed i.n estimating capital costs.
Land. Transfer stations generally require a minimum of two
acres of land. Also, if cost savings are to be maximized from
the operation of the transfer system, it is important that
the transfer stations be located near to collection routes.
Because of the variation in the cost of land, local land costs
should be utilized in estimating the costs in this category.
Estimated land cost.
(2) Site construction. Site construction costs, including site
preparation and development costs, vary greatly depending on
the condition of the land and the type of structure proposed.
In addition, site construction costs will be affected by the
availability of existing structures which can be modified
for use as a transfer station. For example, conversion of
an incinerator facility can reduce construction costs by as
much as 75 percent.
For estimating purposes, $97,000 per 100 tons of daily capacity
can be used, based on the site construction capital costs for
five of the surveyed sites whth enclosed transfer stations.
The annualized site construction capital costs may be computed
by dividing the estimated site construction cost less the
anticipated salvage value by the depreciation period in years.
Most of the surveyed transfer systems used a depreciation
period of 20 years.
Estimated site construction cost (total)
(annualized)
(3) Stationary equipment. Transfer system stationary equipment
typically can include scales, hoppers, compactors, and push pits.
In general, the installation of one or two stationary compactors
is recommended for transfer stations handling up to 200 tons per
day.
14
-------
The surveyed sites had an average total stationary equipment
capital cost of $170,000. Except for one location, the sites
transferring under 225 tons per day had costs under $100,000.
For estimating purposes, $57,000 per 100 tons of daily capacity
may be utilized, based on the surveyed sites.
Annualized stationary equipment capital costs may be calculated
using a depreciation period in the 10 to 15 year range, based
on the survey findings.
Estimated stationary equipment costs (total)
(annualized)
(4) Vehicular Equipment. Vehicular equipment used in a truck
transfer system can be of two general types: equipment used
to haul the solid waste from the transfer station to the disposal
site or equipment used at the station itself.
The number and type of tractor/trailers required in a truck
transfer system depend upon the volume of refuse and the time
and distance to the disposal site.
The number of tractor/trailers required may be estimated as
follows:
Step 1: Number of Daily Tractor/Trailer Loads.
To determine the number of tractor/trailer loads
required each day, the daily tonnage can be divided
by the average trailer load weight of 15 tons.
Step 2: Average Time Required for Each Round Trip.
To estimate the time required to transport each load,
multiply the roundtrip mileage by an average 2.7
minutes per mile. An estimated time for loading, such
as 15 minutes, must then be added.
Step 3: Possible Number of Loads Per Tractor/Trailer
Per Day. To estimate the maximum number of loads
which can be transported by a single tractor/trailer
in a day, divide the number of working hours in a day
by the average time required for each round trip
determined in Step 2.
Step 4: Number of Tractor/Trailers Required.
To estimate the total number of tractor/trailers
required, divide the total number of loads required
per day (Step 1) by the number of loads per tractor/
trailer per day (Step 3), and then add any reserve
tractor/trailers.
15
-------
After the number of tractor/trailers has been determined, the
total costs for transfer vehicles can be calculated by
multiplying the number by current local vehicle prices.
Tractor/trailer costs averaged $42,500 for the surveyed sites.
In addition, this category includes vehicular equipment
used at the station such as front end loaders, sweepers, yard
tractors, back hoes, and other similar equipment. If the exact
requirements are not known, $11,600 per 100 tons of daily
capacity may be used to estimate this item.
In computing the annualized capital costs for vehicular
equipment, five years can be assumed as the depreciation
period.
Estimated vehicular equipment costs (total)
(annualized)
Operating Cos t s. Annual operating costs may be estimated by
developing costs for the following categories.
(1) Labor. This category consists of costs for salaries and wages
and fringe benefits. Three types of personnel generally are
employed in a transfer system: supervisors, station employees,
and vehicle operators. The salaries and wages cost can be
calculated as follows:
Number of x Hourly x Hours x Days of
personnel by wage for worked operation
job category job per day per year
category
Table 8 shows a breakdown of the number of tons per day per
employee for the surveyed sites in each of three categories:
supervisor, station employee, and vehicle operator. Based on
these figures, the following averages can be used for estimating
purposes:
Supervisors—.06 supervisors per 100 tons
Station employees—3 employees per 100 tons
Vehicle operators—3 operators per 100 tons
Using these averages, the number of employees by job
category may be estimated by multiplying the average tons
per day by employees per ton.
16
-------
(2)
(3)
Local hourly wage rates should be used in determining
salaries and wages costs. If these are not available, the
following average hourly wage rates may be used: supervisor,
$6.51; station employee, $4.72; and vehicle operator, $4.98.
The costs of fringe benefits may be developed by multiplying
the local fringe benefits rate by the cost of salaries and
wages. If local rates are not available, an average rate of
20 percent may be used.
Estimated salaries and wages cost
Estimated fringe benefits cost . ,
Stationary equipment. Operating costs associated with stationary
equipment primarily include those for repair and maintenance
and parts and supplies. The purchase of non-capitalized equip-
ment such as hand tools and shop equipment is also included.
Stationary equipment operating costs may be estimated using an
average cost of $.20 per ton.
Estimated stationary equipment cost
Vehicular equipment. The operating costs for vehicular
equipment include those for repair and maintenance, parts and
supplies, fuel and oil, and rental. An average cost of $.54
per ton, or $.50 per mile, as shown in Table 11, can be used
to estimate these costs for systems purchasing most of their
vehicular equipment. If desired, a more detailed estimate
may be developed as described below.
Since costs for repair and maintenance, and parts and supplies
generally are related to usage, these costs can be estimated
on the basis of the total number of hours of operation per year.
The following steps may be followed in estimating these costs,
using an average cost per hour of $9.54:
Daily
transportation
hours
Annual
transportation
hours
Number of daily
tractor/trailer
loads
Daily
transportation
hours
x Average time
for each
round trip
x Operating
days per year
Annual repair
and maintenance
and parts and
supplies cost
= Annual
transportation
hours
x Cost per
hour ($9.54)
17
-------
Annual fuel and oil costs can be estimated on the basis of
the miles traveled. An average of $.11 per mile may be used
for estimating fuel and oil costs. Annual costs may be determined
from the number of daily tractor loads, as estimated previously,
and the round-trip-mileage between the transfer station and the
disposal area.
Costs for rented equipment should be based on current local rates.
Estimated vehicular equipment costs
(4) Facilities and site maintenance. The average cost of $.05
per ton may be used to estimate these costs.
Estimated facilities and site maintenance cost.
(5) Utilities. Utilities costs may be estimated using an average
of $.12 per ton.
Estimated utilities cost.
(6) Administrative expense. This expense can be computed on the
basis of an average of $.08 per ton.
(7) Other Expenses. A provision for other expenses may be
made, if required, by using an average of $.10 per ton.
Estimated administrative expense.
Tables 9 and 10 may be used in developing capital and operating cost
estimates for transfer systems.
18
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&
services, liabili
Consulting and engineering
security services
Other Expenses
Cl
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Totals
-------
SHREDDING
Shredding is a solid waste volume reduction process often referred
to as milling, grinding, or pulverizing. Shredded waste either may be
directly landfilled or used in combination with other processes, such as
pyrolysis or materials recovery.
Advantages of shredding are: (a) the life of a landfill can be
extended since shredding reduces the volume of the solid waste; (b) daily
cover of shredded solid waste may not be required; (c) shredded waste is
easier to compact saving labor and equipment expense; (d) shredding
reduces paper blowing and the fire potential; and (e) shredded waste does
not attract vermin.
Disadvantage is the fact that shredding involves an additional
processing step over landfilling, and additional operating and capital
costs are incurred.
The characteristics of the 10 shredder systems that were surveyed
are presented in Table 11. The sites varied from 64 to 1,042 average
tons per day of operation.
The annual operating costs and the annualized capital costs for
the 10 shredder sites are summarized in Table 11. The sites had an
average operating cost per ton of $5.61 and an average annualized capital
cost per ton of $1.69, resulting in a total cost per ton of $7.30. The
operating costs averaged 77 percent of total costs. All costs reflect the
operation of the shredder facility itself and the transportation of the
shredded waste to a landfill.
Capital Costs
Capital costs are presented in Table 12. The annualized capital
cost per ton for the shredder sites varied from $.80 to $3.10, and
averaged $1.69. Capital costs for the shredder sites were collected in
five major categories: land, site construction, stationary equipment,
vehicular equipment, and other equipment. Annualized capital costs were
calculated for each cost category, except for land, which was assumed to
have infinite life. Annualized capital costs per ton for the 10 sites
averaged 23 percent of total costs per ton, ranging from 14 percent to
36 percent.
Land. The land utilized by the shredder sites varied from 2 to
20 acres. For the five sites where data were available, the cost per acre
ranged from $1,000 to $16,000. All five sites had purchased their land.
21
-------
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23
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Site Construction. Site construction costs for the shredder sites
varied from $.05 to $1.62 per ton, with an average of $.60. Site
construction costs were defined to include: planning and designing costs;
site development costs, including site preparation, roadways; fencing,
and water lines; and all construction costs for shredder facilities and
associated buildings.
Stationary Equipment. The cost per ton of stationary equipment
for the shredder sites averaged $.61, and varied from $.22 to $1.03.
Stationary equipment costs included all fixed equipment purchased for a
shredder site, such as shredding machinery, scales, conveyors, and
stationary packers.
Vehicular Equipment. Vehicular equipment costs for the shredder sites
varied between $.02 and $.91 per ton, and averaged $.46. Vehicular equip-
ment capital costs were the costs of all purchased vehicles associated
with the shredder operation. Typically, these vehicles included transfer
trucks and trailers, front end loaders, dump trucks sweepers, cranes,
dozers, and pickup trucks.
Other Equipment. Where other equipment costs were reported, the
cost per ton for shredder sites ranged from $.002 to $.14, with an average
of $.02. Other equipment capital costs included the costs of all other
purchased equipment that is capitalized and not provided for within the
site construction, stationary equipment, or vehicular equipment cost
categories. Items in the other equipment category included office equip-
ment and maintenance equipment, such as welding equipment and compressors.
Operating Costs
Total operating costs per ton for the surveyed shredder sites
averaged $5.61, ranging from $2.85 to $9.50 per ton. Operating costs
averaged 77 percent of total annual costs, ranging from 64 percent to
86 percent. Annual operating costs, excluding annualized capital costs,
for the shredder sites are presented in Table 13. The operating costs
are grouped into seven major categories: labor, stationary equipment,
vehicular equipment, facilities and site maintenance utilities, adminis-
trative expenses, and other expenses. Operating cost per ton figures
are displayed in Table 14.
Labor. Total labor cost per ton, including salaries and wages and
fringe benefits, for the shredder sites ranged from $1.30 to $4.68, with
an average of $2.21. Labor costs amounted to an average of 98 percent of
total operating costs, ranging from 24 percent to 49 percent.
The labor cost category is composed of both salaries and wages
and fringe benefits costs. The salaries and wages cost provides for
24
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regular, temporary, and overtime compensation paid to personnel directly
involved with the plant operation. Employees typically included were
supervisors, equipment operators, pit loader operators, laborers, transfer
truck drivers, and scalemen. Salaries and wages averaged $1.77 per ton,
ranging from $1.15 to $3.55 per ton.
Fringe benefits provide for those costs incurred for workmen's
compensation; social security; employee hospital, dental, and life
insurance; retirement; and other benefits not paid for by the employee.
Fringe benefits ranged from $.15 to $1.13 per ton, averaging $.44 per
ton.
Stationary Equipment. Stationary equipment costs per ton averaged
$1.52, ranging from $.65 to $2.70. Stationary operating costs averaged
27 percent of total operating costs, ranging from 13 percent to 42
percent.
The stationary equipment cost category is composed of those costs
associated with the repair and maintenance, including parts and supplies
of all fixed equipment at the shredder facility, such as the shredders
and conveyors. The repair and maintenance cost element represents the
labor costs for work performed by shredder facility personnel, such as
maintenance personnel and welders, or fees paid to private firms or to
other organizational units. Parts and supplies include replacement and
maintenance items associated with the stationary equipment, such as
hammers and lubricants. The stationary equipment category also includes
other equipment expenses incurred for non-capitalized equipment. The
other equipment expense cost element provides for miscellaneous items
such as shop supplies, welding supplies, and hand tools.
All shredders surveyed had extensive repair and maintenance facilities,
In many cases, the parts inventory was valued at $50,000 to $100,000.
Vehicular Equipment. Vehicular equipment operating cost per ton
averaged $.82 and had a range from $.29 to $1.62. The average percentage
of vehicular equipment operating costs to total operating costs was
15 percent, ranging from 7 percent to 32 percent.
Vehicular equipment costs include those expenses incurred for the
repair and maintenance, parts and supplies, rental, and fuel and oil for
vehicles. Repair and maintenance costs generally represent labor charges
by other organizational units or by private contractors, but also include
labor costs for major vehicular repairs and maintenance acitivities when
done on a full-time or part-time basis by personnel assigned to the
shredder facility. Parts and supplies include all replacement and
maintenance items utilized for the vehicles, such as batteries, tires,
and lubricants. Rental provides for all expenses incurred when vehicular
27
-------
equipment is rented or leased from another organizational unit or from
a private firm. Fuel and oil includes those costs for gasoline, diesel
fuel, and motor oil used in the operation of the vehicular equipment.
Facilities and Site Maintenance. The cost per ton averaged $.01
and ranged from zero to $.34 per ton. Costs included in the facilities
and site maintenance category are the labor and materials expenses
incurred in maintaining the structures and grounds at the shredder site.
Typical costs are in-house or contracted maintenance and janitorial
services, building materials, road materials, paint, and plumbing supplies,
Utilities. The total utilities cost averaged $.66 per ton, and
ranged from $.17 to $1.96 per ton. The utilities cost category provides
for the electricity, water, gas, sewer, and telephone expenses incurred
in the operation of the shredder facility.
Administrative Expense. Administrative expense averaged $.13
per ton and ranged from zero to $.40 per ton. The administrative expense
category provides for general operating expenses directly incurred by the
shredder facility. Included are costs for office supplies, uniforms
and foul weather gear, travel, training, printing postage, books and
subscriptions, legal and accounting services, and data processing.
Other Expenses. The cost per ton for other expenses ranged as high
as $.77, although the average was $.19 per ton. Costs included in this
category are for those items not provided for in the previous cost cate-
gories. For example, the costs of consulting engineering services,
liability insurance, and security services are considered to be in this
category.
Variations in Costs
Wide variations in costs were observed among the sites visited.
In general, the variations were attributable to (1) tons processed per
day; (2) depreciations schedules; (3) equipment utilization; (4) wage and
fringe benefits rates; (5) distance to landfill or processing area.
Tons Processed Per Day. In general, the costs per ton decrease
with increasing tons processed per day. For shredder sites under 500
tons per day, the average total cost per ton was $8.17 compared with
$5.15 for sites over 500 tons per day. Operating and capital costs
per ton follow the total cost per ton closely, as would be expected.
The percentage of capital cost to total cost remained essentially
the same with increasing tons processed per day, as given in Table 11.
Shredder sites with less than 500 tons per day and sites over 500 tons
per day both averaged 23 percent.
Depreciation Schedules. The total annualized capital cost and the
capital cost per ton is affected by the depreciation method and period
28
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TABLE 15
DEPRECIATION PERIODS FOR 10 SHREDDER SITES
(YEARS)
Site No.
1
2
3
4
5
6
7
8
9
10
Mode
Site Construction
17
20
20
20
20-35
20
20
15
15
18
20
Stationary Equipment
17
20
15
15
20
15
15
15
15
10
15
Vehicular Equipment
3
5
6
3-5
5-10
3-8
8-15
5-10
5
5
5
TABLE 16
WAGE RATES AND FRINGE BENEFITS RATES
FOR 10 SHREDDER SITES IN 1975
Site No.
1
2
3
4
5
6
7
8
9
10
Average
Supervisor
Avg. Hourly Wage
$4.61
5.77
7.83
5.00
6.52
4.28
6.59
--
5.50
5.00
5.68
Site Employee
Avg. Hourly Wage
$2.71
3.32
5.61
3.90
5.80
3.61
5.37
--
4.40
4.20
4.32
29
Vehicle Operator
Avg. Hourly Wage
$3.06
6.76
5.66
4.31
5.55
3.72
5.08
--
4.20
4.20
4.73
Fringe
Benefits Rate
13%
32
20
19
17
12
33
18
38
28
23
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utilized for the facilities, stationary equipment, and vehicular equipment
of a shredder site. Depreciation for all shredder sites was calculated
on a straight-line basis, using the depreciation period being utilized
by the particular site. Table 15 shows the depreciation periods of
items within the site construction, stationary equipment, and vehicular
equipment capital cost categories utilized by the various sites. The
most common depreciation period for site construction was 20 years;
stationary equipment, 15 years; and vehicular equipment, 5 years.
Utilization Ratio. The effect of the utilization ratio, or the
average tons processed per day to the tons of daily design capacity, on
the total cost per ton of shredders is shown in Figure 1. In general,
as the utilization increases, there is a corresponding decrease in the
total cost per ton. The range of the utilization for the shredder sites
was from 16 percent to 62.5 percent with half of the sites falling
between 45.5 percent and 56 percent. Variations in the utilization
percentages can be attributed, in part, to differences in the system
design requirements or the equipment performance. One reason for a
number of the low utilization ratios was that many shredder sites reported
a lower than normal solid waste volume during the period of operation
examined.
Wage and Fringe Benefits Rates. The wage and fringe benefits rates
directly affect the labor cost portion of operating costs of a site.
The average hourly wage rates for supervisor, site employee, and vehicle
operator personnel for each of the shredder sites are presented in Table
16. Table 16 also gives the fringe benefits rates by site. The supervisor
average hourly rate averaged $5.68, ranging between $4.28 and $7.83.
Site employees averaged $4.32 per hour and ranged from $2.71 to $5.80
per hour. Vehicle operators averaged $4.73 per hour, varying from $3.06
to $6.76 per hour. The percentage of fringe benefits to the total
salaries and wages ranged from 12 percent to 38 percent, with an average
of 23 percent.
Distance to Landfill or Processing Area. The distance between the
shredder site and a landfill or an area where other processing occurs
affects the total operating and capital costs per ton. The round-trip
distance for the shredder sites varied between zero and 35 miles. The
direct hauling costs per ton and the round-trip distance for the shredder
sites are presented in Table 17. The total direct hauling costs averaged
$1.47 per ton, ranging from $.67 to $2.53 per ton.
Cost Estimating
There are many differences in the designs and operations of shredder
sites and this is reflected in the operating and capital costs. The
cost differences may be due to the factors discussed in the previous
section, such as volume, degree of utilization, local wage and fringe
benefits rates, and distance to a landfill or processing area. Differences
may also be attributable to other factors, such as equipment performance
and site design.
30
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This section presents procedures for estimating the costs of
shredder installations. The procedures should be used with current
local cost data when available.
Capital Costs. Costs for the following categories should be
developed in estimating capital costs.
(1) Land. The land requirements and the land costs for a shredder
site are very dependent on a particular location. For estima-
ting purposes, it can be assumed that a shredder installation
requires a minimum of three to four acres of usable land. This
land may be purchased, leased, or already owned. It is suggested
that local land costs be obtained in determining the costs for
this category.
Estimated land cost.
(2) Site construction. Site construction costs vary con siderably
due to differences in the required site development and in the
facility design. Based on the survey, shredder sites with an
operating level of 200 tons processed per day or less did not
have costs of more than $600.000. Site construction costs for
all shredders in the survey ranged from $178,000 to $3.3 million.
In general, the sites with the lowest site construction costs
had facilities which were modified from other operations.
Site construction cost estimates can be developed using an
average of $275,000 per 100 tons of daily capacity.
The annualized site construction capital cost can be calculated
by dividing the estimated total site construction costs less
the salvage value by the depreciation period in years. The
most common depreciation period for the site facilities and site
developments of the sites visited was 20 years.
Estimated site construction cost
(3) Stationary Equipment. The total costs for stationary equip-
ment associated with a shredding facility, such as the shredding
machinery, conveyors, scales, and packers, vary with manufacturer,
equipment capacity and features, and other factors. For estimating
purposes, an equipment design to operating capacity factor of 2
might be used to develop equipment requirements. For example,
if it is estimated that the shredder facility would have to
process an average of 100 tons per 8 hours day, two shredders,
each with a 25 ton per hour design capacity, might be selected.
It is recommended that a minimum of two spearate shredders
be included at a single conventional shredder site in order
to minimize the effects of down time due to shredder repair
and maintenance activities.
33
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If shredder equipment costs are not readily available from
manufacturers or other sources, they can be roughly esti-
mated by multiplying the desired equipment design capa-
city in an 8 hour day by $1,400. This figure is based on
the average of stationary equipment costs per ton of de-
sign capacity in an 8 hour day for the surveyed sites.
In calculating annualized capital costs for stationary
equipment, the depreciation period can be assumed to be
15 years.
Estimated stationary equipment cost (total)
(annualized)
(4) Vehicular equipment. The vehicular equipment capital
costs include the costs of all purchased vehicles that are
utilized in the shredder facility itself, such as front end
loaders and sweepers, and in the transportation of the
shredded waste to a landfill or to another area for further
processing. The number of transfer tractor/trailers re-
quired by a shredder operation depends on factors such as
distance and time to the landfill or processing area, volume of
solid waste, and the capacity of the trailers. Information
on estimating the number and costs of tractor/trailers required
is presented in the chapter on Transfer Systems. Costs of any
other required vehicular equipment can be then added to deter-
mine the total vehicular equipment capital cost.
Alternatively, the vehicular equipment capital costs for
shredder sites can be roughly estimated by multiplying the
estimated average tons processed per day by $685. This is
based on the average of the vehicle equipment cost to tons
processed per day for the surveyed shredder sites.
The annualized capital cost for vehicular equipment is deter-
mined by the method described for site construction capital
costs. Five years can be assumed as the depreciation period
for vehicular equipment if other estimates are not available.
Estimated vehicular equipment cost (total)
(annualized)
(5) Other equipment. The estimated costs for equipment not provided
for in the previous equipment categories may be included in
this category. Annualized capital costs can be calculated us-
ing a depreciation period in the typical range from 10 to 20
years.
Estimated other equipment cost (total)
(annualized)
34
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Operating Costs. Annual operating costs may be estimated by develop-
ing costs for the following categories.
(1) Labor. The salaries and wages and fringe benefits costs for all
personnel involved in the shredder site operation are provided
for in this category. The personnel typically included are
supervisors, site employees, and vehicle operators. The salaries
and wages cost can be calculated as follows:
Number of personnel x Hourly wage x Hours x Days of
by job category for job worked operation
category per day
The number of personnel required for the operation of a shredder
site depends on a number of factors, such as number of shifts,
time and distance to a landfill or processing area, and site
design. Based on the survey, the number of shredder site
employees required, such as equipment operators, laborers, and
pit loader operators, can be approximated by using an average
of 31 tons processed per day per site employee.
If the hourly wage rates are not known, average wage rates may
be substituted, as determined by the survey. These are as
follows: supervisor, $6.03 per hour; site employee, $4.75 per
hour; and vehicle operator, $5.07 per hour.
The fringe benefits cost is calculated as follows:
Total salaries and wages cost x Fringe benefits rate
If the fringe benefits rate is not known, an average rate of
21 percent may be used.
Estimated salaries and wages cost
Estimated fringe benefits cost . .
Total, estimated labor cost . .
(2) Stationary equipment. The stationary equipment operating cost can
be estimated by using an average cost per ton of $1.52.
Estimated stationary equipment cost
(3) Vehicular equipment. An average cost of $.67 per ton for shredders
located at a landfill or $.89 per ton for shredders not located
at a landfill may be used for approximating the vehicular equip-
ment operating costs, if most of the equipment is not rented.
Estimated vehicular equipment cost
(4) Facilities and site maintenance. The costs for facilities and
site maintenance may be estimated by using an average cost of
$.17 per ton.
35
-------
Estimated facilities and site maintenance cost
(5) Utilities. The utilities cost category includes the costs for
such items as electricity, water, gas, sewer, and telephone at
the shredder facility. The electricity cost for shredder sites
using electric-driven shredders can be estimated as $.60 to
$.70 per ton. The cost of all other utilities can be calculated
assuming $.13 per ton.
Estimated utilities cost
(6) Administrative expenses. The administrative expense can be esti-
mated using an average cost per ton of $.13.
Estimated administrative expenses
(7) Other expenses. The other expenses cost category provides for
those items not otherwise provided for in the other operating
cost categories. A provision for these miscellaneous expenses
can be made by using an average cost of $.21 per ton.
Estimated other expenses
Tables 19 and 20 may be used in developing capital and operating cost
estimates for shredder sites.
36
-------
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38
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BULKY ITEM SHREDDING
In a typical residential solid waste stream, about five percent of the
waste will be bulky items such as furniture, stoves, water heaters, tires,
etc. Because these items do not compact easily and are difficult to land-
fill, several cities have installed shredders for these items to facilitate
landfilling.
The characteristics and costs of three bulky item shredders processing
31 to 63 tons per day are shown on Table 20. The sites had an average
operating cost per ton of $12.14, or 72 percent of the total cost per ton,
and an average atmualized capital cost per ton of $4.55. All costs reflect
the operation of the shredder facility itself and the transportation of the
shredded waste to a landfill or to the next processing area.
Capital Costs
Capital costs for the three bulky item shredder operations are presented
in Table 21. The sites had an average annualized capital cost per ton of
$4.55, ranging from $4.01 to $5.62. Capital costs for the shredder sites
were collected in five major categories: land, site construction, station-
ary equipment, vehicular equipment, and other equipment. Annualized
capital costs were calculated for each cost category as described in the
chapter on Transfer Systems, except for land, which was assumed to have
infinite life. The annualized capital cost per ton to total costs per ton
averaged 28 percent, ranging from 19 percent to 35 percent.
Land. Land costs were not available from the three bulky item shredder
sites which were surveyed.
Site Construction. Site construction costs for the bulky item shredder
sites averaged $1.79 per ton, ranging from $.23 to $3.18 per ton. Site
construction costs were defined to include: planning and designing costs;
site development costs, including site preparation, roadways, fencing, and
water lines; and all construction costs for shredder facilities and
associated buildings.
Stationary Equipment. The cost per ton of stationary equipment for
bulky item shredder sites ranged from $.52 to $3.41 per ton and averaged
$1.91. Stationary equipment costs included all fixed equipment purchased
for a shredder site, such as shredding machinery, scales, conveyors, and
stationary packers.
Vehicular Equipment. Vehicular equipment costs for bulky item shredder
sites varied between $.12 and $.82 per ton, and averaged $.40. Vehicular
equipment capital costs included the costs of all purchased vehicles
associated with the shredder operation. Typically, these vehicles included
transfer trucks, front end loaders, dump trucks, sweepers, cranes, dozers,
and pickup trucks.
39
-------
TABLE 20
CHARACTERISTICS OF BULKY ITEM SHREDDER SITES IN 1975
Site No.
Average
Characteristics
Average Tons/Day Processed
Tons/Year Processed
Days/Year of Operation
63
16,457
260
31
8,060
260
62
11,759
190
Number of Shredders
Shredder Type/Capacity (TPH) Vert/60 Hor/25 Hor/40
Site Acreage 2.5 — 10
Storage Capacity (Tons) -- 150 0
Resultant Particle Size (Inches) 3.6 3 14.4
Roundtrip Distance to Landfill 13 0 1
(Miles)
Number of Shifts 1 1 1
Number of Supervisors 2 5 1
Number of Site Employees 452
Number of Vehicle Operators 2 0 1
Cost
Total Operating Costs: 281.7
Total/Year (1,000 dollars) 17.12
Cost/Ton (dollars) 81
% of Total Cost
83.1
10.32
65
105.6
8.98
69
12.14
72
Total Annualized Capitol
Costs:
Total/Year (1,000 dollars)
Cost/Ton (dollars)
% of Total Cost
65.9
4.01
19
45.3
5.62
35
47.4
4.03
31
4.55
28
Total Cost:
Total/Year (1,000 dollars) 347.6
Cost/Ton (dollars) 21.12
128.5
15.94
153.0
13.01
16.69
40
-------
TABLE 21 ,
CAPITAL COSTS OF 3 BULKY ITEM
SHREDDER SITES IN 1975
Site No.
Cost Item
Average
Land
Total Cost (1,000 dollars)
Site Construction
Total Cost (1,000 dollars) 1,048 238 27
Annualized Cost (1,000 dollars) 52.4 15.9 2.7
Cost/Ton (dollars) 3.18 1.97 .23
1.79
Stationary Equipment
Total Cost (1 ,000 dollars) 128 412 211
Annualized Cost (1,000 dollars) 8.5 27.5 21.1
Cost/Ton (dollars) .52 3.41 1.79
1.91
Vehicular Equipment
Total Cost (1,000 dollars) 12 10 48
Annualized Cost (1,000 dollars) 2.0 2.0 9.6
Cost/Ton (dollars) .12 .25 .82
.40
Other Equipment
Total Cost (1,000 dollars)
Annualized Cost (1,000 dollars)
Cost/Ton (dollars)
Totals
Total Cost (1,000 dollars)
Annualized Cost (1,000 dollars)
Cost/Ton (dollars)
15
3.0
.18
0
0
0
140
14.0
1.19
.46
1,203
65.9
4.01
660
45.3
5.62
426
47.4
4.03
4.55
41
-------
Other Equipment. Two bulky item shredder sites had other equipment
costs of $.18 and $1.19 per ton, with an average for the three sites of
$.46. Other equipment capital costs included the costs of all other
purchased equipment that is capitalized and not provided for within the
site construction, stationary equipment, or vehicular equipment cost
categories. Items in the other equipment category included office equip-
ment and maintenance equipment, such as welding equipment and compressors.
Operating Costs
Total operating costs per ton averaged $12.14 for bulky item shredder
sites. The range in operating costs per ton was from $8.98 to $17.12.
Operating costs averaged 72 percent of total annual costs, ranging from
65 percent to 81 percent. Annual operating costs, excluding annualized
capital costs, are presented in Table 22 The operating costs are grouped
into seven major categories: labor, stationary equipment, vehicular equip-
ment, facilities and site maintenance, utilities, administrative expenses,
and other expenses. Operating cost per ton figures are displayed in Table 23
Labor. Total labor cost per ton, including salaries and wages and
fringe benefits, varied from $2.46 to $6.06, averaging $4.42 per ton. Labor
costs amounted to an average of 36 percent of total operating costs, ranging
from 27 percent to 46 percent.
The labor cost category is composed of both salaries and wages and
fringe benefits costs. The salaries and wages cost provides for regular,
temporary, and overtime compensation paid to personnel directly involved
with the plant operation. Employees typically included were supervisors,
equipment operators, pit loader operators, laborers, transfer truck drivers,
and scalemen. Salaries and wages averaged $3.85 per ton, ranging from
$2.17 to $5.44 per ton.
Fringe benefits provide for those costs incurred for workmen's compen-
sation; FICA; employee hospital, dental, and life insurance; retirement;
and other benefits not paid for by the employee. Fringe benefits averaged
$.57 per ton, ranging from $.28 to $.80 per ton.
Stationary Equipment. The cost per ton averaged $3.38, with a range
from $2.00 to $5.23. Stationary equipment operating costs averaged 27
percent of total operating costs, ranging from 22 percent to 31 percent.
The stationary equipment cost category is composed of those costs
associated with the repair and maintenance, including parts and supplies,
of all fixed equipment at the shredder facility, such as the shredders
and conveyors. The repair and maintenance cost element represents the
labor costs for work performed by shredder facility personnel, such as
maintenance personnel and welders, or fees paid to private firms or to
other organizational units. Parts and supplies include replacement and
42
-------
TABLE 22
OPERATING COSTS OF 3 BULKY ITEM SHREDDER SITES IN 1975
(1,000 DOLLARS)
Cost Item
Labor
Salaries and Wages
Fringe Benefits
Total , Labor
Stationary Equipment
Repair and Maintenance
Parts and Supplies
Other Equipment Expense
Total, Stationary Equipment
Vehicular Equipment
Repari and Maintenance
Parts and Supplies
Rental
Fuel and Oil
Total, Vehicular Equipment
Facilities and Site Maintenance
Utilities
Electricity
Other
Total, Utilities
Administrative Expense
1
89.5
10.1
99.7
60.1
25.9
0
86.0
0
0
52.0
0
52.0
0
15.6
8.4
24.0
20.0
Site No.
2
31.8
6.5
38.3
11.7
11.8
0
23.6
.3
.2
0
1.0
1.5
5.5
6.7
1.7
8.4
3.0
3
25.5
3.3
28.9
21.8
1.7
0
23.5
7.8
0
17.5
.4
25.7
.01
5.6
.2
5.8
15.9
Total
281.7
83.1
105.6
43
-------
TABLE 23
OPERATING COSTS PER TON OF 3 BULKY ITEM SHREDDER SITES IN 1975
(DOLLARS)
Cost Item
Labor
Salaries and Wages
Fringe Benefits
Total , Labor
Stationary Equipment
Repair and Maintenance
Parts and Supplies
Other Equipment Expense
Total, Stationary Expense
Vehicular Equipment
Repair and Maintenance
Parts and Supplies
Rental
Fuel and Oil
Total, Vehicular Equipment
Facilities and Site Maintenance
Utilities
Electricity
Other
Total , Utilities
Administrative Expense
Other Expenses
1
5.44
.62
6.06
3.65
1.58
0
5.23
0
0
3.16
0
3.16
0
.95
.51
1.46
1.22
0
Site No.
2
3.95
.80
4.75
1.47
1.46
0
2.92
.04
.02
0
.12
.18
.68
.84
.03
1.04
.38
.36
3
2.17
.28
2.46
1.86
.14
0
2.00
.66
0
1.49
.03
2.19
.001
.48
.01
.49
1.35
.50
Average
3.85
.57
4.42
3.38
1.84
.34
1.00
.98
.29
Total, Operating Cost/Ton
17.12
10.32
8.98 12.14
44
-------
maintenance items associated with the stationary equipment, such as hammers
and lubricants. The stationary equipment category also includes other
equipment expenses incurred for non-capitalized equipment. The other equip-
ment expense costs element provides for miscellaneous itmes such as shop
supplies, welding supplies and hand tools.
Vehicular Equipment. Vehicular equipment operating cost per ton averaged
$1.84 and had a range of $.18 to $3.16. The average percentage of vehicular
equipment operating costs to total operating costs was 15 percent, ranging
from 2 percent to 24 percent.
Vehicular equipment costs include those expenses incurred for the
repair and maintenance, parts and supplies, rental, and fuel and oil for
vehicles. Repair and maintenance costs generally represent labor charges
by other organizational units or by private contractors, but also include
labor costs for major vehicular repairs and maintenance activities when
don.e on a full-time or part-time basis by personnel assigned to the shredder
facility. Parts and supplies include all replacement and maintenance items
utilized for the vehicles, such as batteries, tires, and lubricants. Rental
provides for all expenses incurred when vehicluar equipment is rented or
leased from another organizational unit or from a private firm. Fuel
and oil includes those costs for gasoline, diesel fuel, and motor oil used
in the operation of the vehicular equipment.
Facilites and Site Maintenance. The cost per ton averaged $.34 and
ranged from zero to $.68 per ton. Costs included in the facilities and
site maintenance category are the labor and materials expensesd incurred
in maintaining the structures and grounds at the shredder site. Typical
costs are in-house or contracted maintenance and janitorial services,
building materials, road materials, paint, and plumbing supplies.
Utilities. The total utilities cost averaged $1.00 per ton, varying
between $.49 and $1.46 per ton. The utilities cost category privides for
the electricity, water, gas, sewer, and telephone expenses incurred in
the operation of the shredder facility.
Administrative Expenses. Administrative expenses averaged $.98 per
ton, varying from $.38 to $1.35 per ton. The administrative expense
category provides for general operating expenses directly incurred by the
shredder facility. Included are costs for office supplies, uniforms and
foul weather gear, travel, training, printing, postage, books and subscrip-
tions, legal and accounting services, and data processing.
Other Expenses^ The cost per ton for other expenses averaged $.29
per ton and ranged from zero to $.50 per ton. Costs included in this
category are for those items not provided for in the previous cost cate-
gories. For example, the costs of consulting engineering services,
liability insurance, and security services are considered to be in this
category.
45
-------
Variations in Costs
Primary sources of variation in the capital and operating costs of
the three shredder sites were: (1) tons processed per day; (2) deprecia-
tion schedules; (3) wage and fringe benefits rates; (4) distance to land-
fill or processing area.
Tons Processed Per Day. The three bulky item shredder sites, rang-
ing from 31 to 63 tons per day, had an average total cost per ton of $16.69.
The total cost per ton figures for the bulky item shredders, each of which
handled fewer tons per day than any of the regular shredders described
in the previous chapter, were higher than for any of the regular shredders.
Depreciation Schedules. The depreciation method and period utilized
for the facilities, stationary equipment, and vehicular equipment of a
shredder site affects the total annualized capital costs and the capital
costs per ton. Depreciation for all shredder sites was calculated on a
straight-line basis, using the depreciation period being utilized by the
particular site. Table 24 shows the depreciation periods of items within
the site construction, stationary equipment, and vehicular equipment
capital cost categories utilized by the various sites.
Wage and Fringe Benefits Rates. The labor cost portion of operating
costs is directly affected by the local wage and fringe benefits rates.
The average hourly wage rates for supervisor, site worker, and vehicle
operator personnel for each of the shredder sites are presented in Table 25•
Table 28 also gives the fringe benefits rates by site. The supervisor
average hourly rate averaged $7.09, ranging between $5.77 and $8.19. Site
employees averaged $6.03 per hour and vehicle operators averaged $6.60
per hour, varying from $3.57 to $7.64 and $6.15 to $7.05, respectively.
The percentage of fringe benefits to the total salaries and wages ranged
from 11 percent to 20 percent, with an average of 15 percent.
Distance to Landfill or Processing Area. The distance between the
shredder site and a landfill or an area where other processing occurs
affects the total operating and capital costs per ton. The round-trip
distance for the bulky item shredder sites varied from zero to 13 miles.
The direct hauling costs per ton and the round-trip distance for the
bulky item shredder sites are presented in Table 26. The total direct
hauling costs averaged $3.65 per ton, ranging from $2.65 to $4.65 per
ton. Site No. 2 had no direct hauling costs because the shredded waste
was fed directly into an incinerator.
Cost Estimating
This section presents procedures for estimating the costs of bulky
item shredder installations. The procedures should be used with current
local cost data when available.
46
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TABLE 24
DEPRECIATION PERIODS FOR 3 BULKY ITEM SHREDDER SITES
(YEARS)
Site No.
1
2
3
Range
Site Construction
30
15
10
10-30
Stationary Equipment
15
15
10
10-15
Vehicular Equipment
5
5
5
5
TABLE 25
WAGE RATES AND FRINGE BENEFITS RATES
FOR 3 BULKY ITEM SHREDDER SITES IN 1975
Site No.
1
2
3
Average
Range
Supervisor
Avg. Hourly Wage
8.19
5.77
7.31
7.09
5.77-8.19
Site Employee
Avg. Hourly Wage
7.64
3.57
6.87
6.03
3.57-7.64
Vehicle Operator
Avg. Hourly Wage
7.05
6.15
6.60
6.15-7.05
Fringe
Benefits Rate
11
20
13
15
11-20
TABLE 26
DIRECT HAULING COSTS FOR 3 BULKY ITEM
SHREDDER SITES IN 1975
Item
Characteristic
Round Trip Distance
to Landfill (Miles)
Tons /Year
Direct Hauling Cost/Ton
(dollars)
Operating Cost/Ton
Capital Cost/Ton
Total Cost/Ton
1
13
16,457
4.65
0
4.65
Site no.
2 3
0 1
8,060 11,759
2.65
0
2.65
Average
3.65
0
3.65
47
-------
Capital Costs. Costs for the following categories should be developed
in estimating capital costs.
(1) Land_. The land requirements and the land costs for a shredder
site are very dependent on a particular location. For estimat-
ing purposes, it can be assumed that a shredder installation
requires a minimum of three to four acres of usable land. This
land may be purchased, leased, or already owned. It is suggested
that local land costs be obtained in determining the costs for
this category.
Estimated land cost,
(2) Site construction. Site construction costs vary considerably
due to differences in the required site development and in the
facility design. Bulky item shredder site construction costs
can be estimated using an average of $8,400 per ton of daily
capacity.
The annualized site construction capital cost can be calculated
by dividing the estimated total site construction costs less
the salvage value by the depreciation period in years. A
depreciation period of 20 years may be used for items in the
site construction category.
Estimated site construction cost (total)
(annualized)
(3) Stationary equipment. The total costs for stationary equip-
ment associated with a shredding facility, such as the shredding
machinery, conveyors, scales, and packers, vary with manufacturer,
equipment capacity and features, and other factors.
If shredder equipment costs are not readily available from
manufacturers or other sources, they can be roughly estimated
by multiplying the desired equipment design capacity in an
eight hour day by $1,000 for bulky item shredders. This figure
is based on the average of the stationary equipment costs per
ton of design capacity in an eight hour day for the sites in
the survey.
Operating Costs. Annual operating costs may be developed by estimat-
ing costs for the following categories.
(1) Labor. The salaries and wages and fringe benefits costs for
all personnel involved in the shredder site operation are pro-
vided for in this category. The personnel typically included
48
-------
are supervisors, site employees, and vehicle operators. The
salaries and wages cost can be calculated as follows:
Number of personnel x Hourly wage x Hours x Days of
by job category for job worked operation
category per day
The number of personnel required for the operation of a shredder
site depends on a number of factors, such as number of shifts,
time and distance to a landfill or processing area, and site
design. Based on the survey, the number of bulky item shredder
site employees required, such as equipment operators, laborers,
and pit loader operators, can be approximated by using an average
of 14 tons processed per day per site employee.
If the hourly wage rates are not known, average hourly wages rates
may be substituted as follows: supervisor, $7.09; site employee,
$6.03; and vehicle operator, $6.60.
The fringe benefits cost can be calcualted by multiplying the
total salaries and wages cost by the fringe benefits rate. If
the local fringe benefits rate is not known, an average rate of
15 percent may be utilized.
Estimated salaries and wages cost.
Estimated fringe benefits cost . .
Total, estimated labor cost . .
(2) Stationary equipment. The stationary equipment operating cost can
be estimated by using an average cost per ton of $3.38.
Estimated stationary equipment cost.
(3) Vehicular equipment. An average cost of $1.84 per ton may be used
for approximating the total annual vehicular equipment operating
costs if most of the equipment is not rented.
Estimated vehicular equipment cost
(4) Facilities and site maintenance. The costs for facilities and
site maintenance may be estimated by using an average cost of
$.34 per ton.
Estimated facilities and site maintenance cost
(5) Utilities. The utilities cost category includes the costs for
such items as electricity, water, gas, sewer, and telephone at
the shredder facility. The cost of utilities can be calculated
assuming an average of $1.00 per ton.
Estimated utilities cost.
49
-------
(6) Administrative expense. The administrative expense can be esti-
mated using an average cost per ton of $.98.
Estimated administrative expense.
(7) Other expenses. The other expenses cost category provides for
those items not otherwise provided for in the other operating cost
categories. A provision for these miscellaneous expenses can be
made by using an average cost of $.29 per ton.
Estimated other expenses,
Tables 27 and 28 may be used in developing capital and operating cost
estimates for bulky item shredder sites.
50
-------
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52
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SANITARY LANDFILLING
Sanitary landfilling is a disposal method whereby solid wastes are
spread in thin layers over a prescribed area of land, compacted, and
covered each day with a required amount of cover material. Generally,
the depth of cover material is established by state or local regulations.
Regardless of whether the solid wastes are processed or not, the solid
waste or waste residue generally must be landfilled.
A variety of landfilling methods may be followed, depending upon
the type and volume of the solid wastes and the physical condition of
the land. Both operating and capital costs vary with the landfilling
method and with the waste composition and volume. For example, if
primarily residential and commercial solid wastes are landfilled, a high
compaction ratio is possible. This reduces the volume and extends the
life of the landfill. If bulky wastes, such as construction debris,
trees, and stumps, form a large portion of the refuse, a lesser compaction
ratio is attained.
The advantages of sanitary landfilling are: (1) it is generally the
least expensive method of solid waste disposal; and (2) capital invest-
ment is low. The disadvantages are that land meeting all environmental
requirements may not be available and that cover material may be expensive
to obtain.
The characteristics of the 17 sanitary landfill sites which were
surveyed are shown in Table 29. The landfills differ in daily tons re-
ceived, ranging from 99 to 1,014 tons per day. The number of operating
days per year, varied from 260 to 360 days. The landfills differed signif-
icantly in number of employees needed to place and cover 100 tons of
solid waste and in the type and amount of equipment used. The landfills
are similar in that all are publicly owned and operated.
The annual operating and annualized capital costs of the 17 landfill
sites are summarized in Table 30. Operating costs averaged $2.38 per ton,
or 78 percent of total annual costs. Annualized capital costs averaged
$.68 per ton, or 22 percent of total annual costs, resulting in an
average total cost of $3.06 per ton.
Capital Costs
The capital costs reported by each of the 17 landfill sites are
presented in Table 30. The average annualized capital cost per ton was
$.68, with a range of $.07 to $1.55 per ton. Annualized capital costs
averaged 22 percent of total annual costs, ranging from 4 percent to 46
53
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percent. Capital costs associated with a sanitary landfill include the
purchasing and preparing of the land, constructing the necessary buildings,
fences, and roads, and purchasing of stationary and vehicular equipment
required for the operation.
Land. Annualized land capital costs averaged $.13 per ton, with a
range of $.02 to $.42 per ton. Land costs were annualized using the
estimated expected life of the landfill, based on the anticipated capacity.
The price per acre averaged $1,896, varying from $163 to $10,000 per acre.
Fifteen of the seventeen survey sites had purchased land for use as a
sanitary landfill. Two of the sites leased the required land for approxi-
mately $6,000 per year. Most sites in the survey deposited from 15,000 to
35,000 tons per acre.
Site Construction. Annualized site construction capital costs averaged
$.13 per ton, and ranged between zero and $.88 per ton. Site construction
costs include: design costs, site preparation costs (surveys, demolition,
grading, and excavating), and construction costs for roads, fences, and
utilities. Three of the sites did not report any site construction costs.
Three of the sites incurred significant costs for roads.
Stationary Equipment. Annualized capital costs for stationary equip-
ment averaged $.01 per ton, varying between zero and $.04 per ton. Station-
are equipment includes scales, air compressors, and maintenance equipment,
such as welding and vehicle repair equipment. Five of the survey sites
reported no capital investment for stationary equipment. In most cases,
these sites weighed the solid waste at a transfer station or shredder
facility.
Vehicular Equipment. The annualized capital costs per ton for
vehicular equipment averaged $.39, and ranged from zero to $1.16 per ton.
Vehicular equipment items purchased by the landfill sites included dozers,
loaders, graders, compactors, and scrapers. The vehicular equipment category
was the largest capital cost category for the majority of the landfill sites.
One site leased all vehicular equipment.
Operating Costs
The operating costs of the 17 landfills averaged $2.40 per ton, or
78 percent of total annual costs. Individual sites varied between an operat-
ing cost of $.98 and $5.41 per ton. Operating costs to total costs ranged
from 54 percent to 96 percent.
The annualized operating costs are displayed in Table 31 and operating
costs per ton are shown in Table 32. The operating data are presented in
eight categories: labor, stationary equipment, vehicular equipment, facilities
and site maintenance, utilities, cover material, administrative expense, and
other expenses.
58
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Labor, The total labor cost per ton averaged $1.20, with a range
from $.41 to $2.36 per ton. On a percentage basis labor costs to total
operating costs averaged 50 percent, ranging from 26 percent to 75 percent.
Labor costs include salaries and wages paid to employees, and the
associated fringe benefits costs. Salaries and wages include regular,
temporary, and overtime pay to those persons employed at the landfill or
directly associated with its operation. Such persons may include super-
visors, scale operators, and equipment operators. Salaries and wages costs
ranged from $.36 to $1.88 per ton, averaging $.99 per ton.
Fringe benefits costs include expenses for social security, medical
and dental insurance, workmen's compensation, and unemployment compensa-
tion. Fringe benefits averaged $.21 per ton, with a range of $.05 to
$.53 per ton.
Stationary Equipment. Stationary equipment operation costs per ton
averaged $.04, ranging from zero to $.31 per ton. The percentage of
stationary equipment operating costs to total operating costs ranged from
zero percent to 6 percent, averaging 1 percent. Only 11 of the 17 sites
surveyed reported operating costs for stationary equipment.
Operating expenses associated with stationary equipment primarily
involve the costs for repair to scales, maintenance labor, replacement parts,
and operating supplies, such as lubricants. The purchase of non-capitalized
equipment such as shop equipment, hand tools, and communication devices
can also be included in this cost category. Examples of stationary equip-
ment items utilized at a landfill site are scales, air compressors, two-way
radios, and "credit card" readers.
Vehicular Equipment. The vehicular equipment operating costs averaged
$.84 per ton, with a range of $.21 to 2.63. The percentage of vehicular
equipment operating costs to total operating costs ranged from 16 percent
to 56 percent, with an average of 36 percent.
Costs associated with the operation and maintenance of vehicular
equipment at a landfill include those for maintenance labor and parts and
supplies. This category also included costs for equipment that was rented
or leased from another agency or from a private concern. In addition,
fuel and oil costs are provided for in this category.
Facilities and Sjite Maintenance. An average cost of $.16 per ton was
computed for facilities and site maintenance costs. These costs ranged
between zero and $1.52 per ton. The percentage of these costs to total
operating costs had a range of zero percent to 53 percent, with an average
of 6 percent. This category provides for the costs of such maintenance
activities as road repair, painting, rodent control, and landscaping.
61
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Utilities. Utilities costs averaged $.01 per ton, ranging from zero
to $.02 per ton. Utilities costs typically included electricity, gas,
waste, sewer, and telephone charges directly associated with the operation
of the landfill.
Cover Material. The two sites which purchased cover materials reported
costs of $.07 and $.81 per ton. Fifteen of the surveyed sites obtained
cover material from the landfill itself. A six-inch cover requirement
was common for landfills receiving non-shredded wastes.
Administrative Exp ense. Administrative expenses averaged $.05 per
ton, ranging from zero to $.19 per ton. Costs associated with administering
a sanitary landfill can include a variety of expenses and differed signif-
icantly with each operation. Typically, administrative expenses can include
costs for printing, data processing, billing, accounting services, paper
and forms, uniforms, postage, and cleaning supplies.
Other Expenses. Other expenses ranged from zero to $.24 per ton,
and averaged $.05 per ton. Examples of costs included in this category
are consulting engineering services, insurance, security services, and taxes.
Variations in Cost Elements
The operating and capital costs per ton vary substantially among the
17 survey sites. Five major variables influencing landfill costs are:
(1) tons received per day; (2) depreciation schedules; (3) wage and fringe
benefits rates; (4) characteristics of the land and (5) shredded wastes.
Tons Placed Per Day. As shown on Table 32, operating costs per ton
varied from $.98 cents to $5.41 per ton. Most of this variation is
attributed to economy of scale. In general, large landfills had lower costs
than small landfills. The average operating cost per ton for sites under
400 tons per day was $2.56, while the average for those sites over 500 tons
was $2.07 per ton.
Noticeable cost differences exist among the sites within these two
ranges, however. Some differences can be explained by examining the influence
of other factors on the cost per ton. In the under 500 tons per day range,
for example, Site No. 5 had a very high operating cost per ton; this was
due primarily to high vehicular maintenance costs. Also, Site No. 4,
which reported a very low operating cost per ton, received only shredded
waste. This reduced the maintenance costs for the landfill equipment.
Site No. 2, which receives over 1,000 tons per day, showed higher
costs than for the other sites in that range. This was attributable
to the relatively high wage rates and to the fact that cover material
was purchased.
64
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Depreciation Schedules. A shorter depreciation period results in
a higher annualized capital cost. Site Nos. 1, 10, and 12 have comparatively
high costs per ton. These sites use shorter depreciation periods than the
mode, as given in Table 33, whereas, Site Nos. 13, 17, and 3, reporting
low capital costs per ton, use depreciation periods longer than most of
the sites. Table 33 shows the depreciation periods used by all of the
surveyed landfills for site construction, stationary equipment, and
vehicular equipment categories.
Wage and Fringe Benefits Rates. Average hourly wages paid to landfill
supervisors and employees are displayed in Table 34. The variations in
these rates can be used to explain some of the differences in operating
costs. For example, Site No. 1, which had the lowest employee hourly
wage rate of $3.19, had an operating cost per ton of $1.77. This was 31
percent lower than the average wage rate of $2.63 for all sites receiving
under 500 tons per day. Site Nos. 6 and 10, paying wages of $5.88 and
$6.86, respectively, had operating costs over 10 percent higher than other
sites in the same daily tonnage range. Table 34 also shows the fringe
benefits rate reported by each of the sites. The average rate was 19
percent, with a range between 7 percent and 33 percent.
There was a wide variation in tons placed per employee and supervisor
which contribute significantly to high labor cost per ton. As shown on
Table 35, tons per production employee ranged from 25 to 173 tons on an
8 hour basis. Often the low worker productivity was the result of inadequate
equipment. The use of 2 or 3 small dozers instead of 1 large compacter
contributed to low tons per employee on sites 2, 5, 6, 8 and 16. The
use of several dump trucks to move cover material on sites 1, 6, 7, 11, 12
and 16 instead of 1 or 2 large scrapers increased the labor force and
resulted in higher labor costs than necessary. In one instance at site
2, the use of 3 supervisors instead of the customary one contributed to
low productivity.
Characteristics of the Land. A significant factor affecting landfill
operating and capital costs is the physical condition of the land, i.e., the
availability of cover material, the relative difficulty of excavation, and
the necessity of grading or landscaping and of controlling ground water
pollution and methane production. This factor can have a significant
influence on costs, including capital costs for equipment and operating
costs for equipment usage, labor, and cover material.
Two of the surveyed sites reported costs for the purchase and transpor-
tation of cover material. Site No. 2, which purchased some cover material
from an outside source, and hauled other cover material from distant areas
of the landfill, reported a cover material cost per ton of $.81. Site
No. 7 reported $.07 per ton for the handling of cover material.
Landfills with excavation and grading problems can have higher
capital costs and operating costs per ton than other landfills within the
same tons per day range. The types of equipment used at each site is
65
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TABLE 33
DEPRECIATION PERIODS FOR 17 LANDFILL SITES
(YEARS)
Site No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Mode
Range
Site
Construction
20
16
20
__
5-10
--
7
16
__
5
15
20
--
10
10
15
13
10-15
5-20
Stationary
Equipment
*m —
10
8
—
10
10
10
10
--
5
10
3
--
--
10
—
13
10
3-13
Vehicular
Equipment
3-6
5-10
8
5
5
5
8
5
6
6-10
5-8
3
5-27
5
5
5-8
7
5
3-27
66
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TABLE 34
WAGE RATES AND FRINGE BEiNEFITS RATES
FOR 17 LANDFILL SITES IN 1975
Site
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Average
Range'
Supervisor
Avg. Hourly Wage
$4.18
7.32
9. 58
3.90
5.44
8.96
6.50
--
8. 19
8. 19
4.15
5.14
5.00
5.31
4.00
__
5.75
5.96
3.90 - 9.58
Employee
Avg. Hourly Wage
$3.19
4.56
8.34
3.90
4.44
5.88
5.10
5.70
7.72
6.86
4.15
3.94
3.62
4.13
3.87
--
4.48
4.99
3.19 - 8.34
Fringe
Benefits Rate
7%
15
14
12
13
14
23
14
33
33
26
19 .
18
25
14
24
30
19
7-33
67
-------
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68
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TABLE 36
EQUIPMENT FOR 17 LANDFILL SITES IN 1975
Site Scales Dozers
No.
1
223
3 1 3
4
5 1 3
6 1 2
7 1
8 1 2
9
10 1 1
11 1
12 2 7
13 1
14 1
15 1 2
16 6
17 1 3
Loaders Compactors Scrapers Misc.
Equip.
1 1 1
2 3 41 dragline
1 grader
1 water
truck
3 air com-
pressors
1 2 1 water
truck
1 1 11 water
truck
1 1
1 1 11 water
truck
2 1 1
1 1 11 water
truck
1
4 1 2
1 1
2 1 2 draglines
1 water
truck
1
2 1 11
1 1 2 draglines
1 grader
1 water
tractor
2 1 1
Misc.
Vehicles
1 pick-up
4 dump trucks
3 pick-ups
1 packer truck
1 lawn tractor
1 industrial
tractor
1 pick-up
2 pick-ups
1 dump truck
1 pick-up
1 dump truck
2 dump trucks
1 tire cutter
1 pick-up
4 open body
trucks
1 1 owboy
tractor
tra i 1 er
1 1/2 ton
truck
1 3/4 ton
truck
3 pick-ups
1 trash pump
1 lowboy
tractor
trailer
1 sweeper
5 dump trucks
1 pick-up
69
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presented in Table 36. It reveals that Sites Nos. 2, 10, 12, and
16 utilized scrapers, draglines, and graders. This equipment is
typically found at landfills where excavation and grading problems
exist. Each of these sites show higher capital costs and operating
costs than other sites within the same daily tonnage range.
Shredded Solid Waste. At three of the survey sites, over 60
percent of the solid wastes received were shredded. The use of
shredded solid wastes at a landfill typically has the following cost-
effective advantages:
0 The life of the landfill can be extended since shredding
reduces the volume of solid waste.
0 Daily cover of shredded solid waste may not be required.
0 Shredded waste is easier to compact at a landfill, saving
labor and equipment expense.
0 Shredded waste does not attract vermin, blow as freely,
or cause fires, thereby reducing site maintenance costs.
The operating and capital costs per ton for the three sites
receiving shredded solid wastes is presented in Table 37. The dif-
ference between the cost per ton of each site and the average of the
remaining 14 sites is shown as a positive or negative percentage.
The three sites averaged a total cost per ton 45 percent lower than
landfills receiving non-shredded solid wastes.
A comparison of the cost reported by Sites Nos. 9 and 10 reveals
a distinct cost difference between landfilling shredded and non-
shredded wastes. Site Nos. 9 and 10 are, in fact, two separate land-
fills that are operated by the same municipality. Site No. 9, which
receives shredded waste, had a total cost per ton of $2.62 compared
with $4.41 for Site No. 10, which receives non-shredded wastes.
Cost Estimating
This section presents procedures for estimating the capital and
operating costs of a sanitary landfill. When available, current local
cost data should be utilized with these procedures.
Capital Costs. Costs for the following categories should be
developed in estimating capital costs.
(1) Land. The capital cost for land can vary greatly,
depending upon the location, condition, and amount of
the land. Land costs for the surveyed sites are shown
70
-------
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in Table 38 It is recommended that local land value be
used in estimating the cost category.
Land can be treated as a depreciable or non-depreciable
asset in developing the capital costs of a sanitary
landfill. If the land is considered to be a depreciable
asset, the annualized capital cost is determined by
dividing the land cost less its salvage value by the
expected life of the landfill in years. If the land is
considered to be a non-depreciable asset (the land cost
equals its salvage value), the annualized capital cost would
be zero.
Estimated land cost (total)
(annualized)
(2) Si_te_ construction. Site construction costs vary with each
landfill, depending upon the condition of the land, the availability
of existing roads, and other factors.
It is recommended that local site construction estimates be
utilized. If not available, an average cost of $370 per ton of
daily capacity may be utilized.
Annualized site construction capital costs can be determined by
dividing the estimated total site construction costs less any
salvage value by the depreciation period in years. Periods from
10 years to 15 years are common for items in the landfill site
construction cost category.
Estimated site construction cost (total)
(annualized)
(3) Stationary equipment. Stationary equipment utilized at a land-
fill can include scales and other equipment. Generally, station-
ary equipment investment is a very small percentage of total
capital costs. Most surveyed sites reported costs between $6,000
and 12,000.
In calculating annualized capital costs for stationary equipment,
a depreciation period of 10 years can be used.
Estimated stationary equipment cost (total)
(annualized)
(4) Vehicular equipment. The purchase of vehicular equipment tends
to be the largest capital expense at a landfill. Typically, only
one compactor is required for landfills receiving under 500 tons
per day. Compactors may not be required at landfills receiving
only shredded wastes. Also, only one scraper is required at land-
fills operating under 800 tons per day.
73
-------
Local costs should be utilized in estimating vehicular equip-
ment costs. The total vehicular equipment capital costs for
most of the surveyed sites receiving under 500 tons per day was
from $37,000 to $200,000. Sites receiving more than 500
tons per day had a vehicular capital cost between $225,000
and $575,000.
Annualized vehicular equipment costs may be calculated using a
five year depreciation period.
Estimated vehicular equipment cost (total)
(annualized)
Operating Costs. Annual operating costs may be estimated by develop-
ing costs for the following categories.
Labor. This category consists of the costs of salaries and
wages and fringe benefits. The annual salaries and wage costs
can be estimated as follows:
Number of x Hourly x Hours x Days of
personnel by wage for worked operation
job category job per day per year
category
Generally, only one supervisor is required at a landfill. The
number of employees can be estimated using an average of one
employee per 73 tons of daily operation.
Local hourly wage rates should be used when available. If they
are not available, the following average rates may be used:
supervisor, $5.96 per hour; and employee, $4.99 per hour.
The fringe benefits cost if determined by multiplying the salaries
and wages cost by the local fringe benefits rate. If this is not
available, an average rate of 19
The fringe benefits cost is determined by multiplying the salaries
and wages cost by the local fringe benefits rate. If this is not
Estimated fringe benefits cost.
Total, estimated labor cost.
(2) Stationary equipment. An average of $.05 per ton can be used
for estimating stationary equipment operating costs.
Estimated stationary equipment cost
(3) Vehicular equipment. An average cost of $.83 per ton can be used
to estimate vehicular equipment operating costs for landfills
purchasing most of their equipment. If a more detailed estimate
74
-------
is desired, one can be developed as described below, in terms
of costs for repair and maintenance, parts and supplies, and fuel
and oil.
Costs for vehicular equipment repair, maintenance, parts and
supplies can be calculated using the following average costs
per ton based on the surveyed sites:
0 Landfills receiving shredded wastes—$.28 per ton
0 Landfills receiving non-shredded wastes of under 500
tons per day—$.65 per ton
0 Landfills receiving non-shredded wastes of over 500
tons per day—$.33 per ton
Fuel and oil costs can be determined using an average $.15
per ton.
Estimated vehicular equipment cost
(4) Facilities and site maintenance. An average cost per ton of $.19
can be used to estimate costs of facilities and site maintenance.
Estimated facilities and site maintenance cost
(5) Utilities. Costs for utilities can be provided for by using an
average $.01 per ton.
Estimated utilities cost
(6) Cover material. The need to purchase or transport cover
material depends on each situation. An estimate for this
category should be made based on the site requirements and
local costs of cover material.
Estimated cover material costs
(7) Administrative expense. Administrative expenses may be estimated
utilizing an average of $.06 per ton.
Estimated administrative expense
(8) Other expenses. A provision for other expenses may be made based
on the average of $.06 per ton.
Estimated other expenses
Tables 39 and 40 may be used in developing capital and operating
cost estimates for landfill sites.
75
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Labor - Salarie
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