Generating Saleable Recycled Aggregates from Hydro Vac Truck Waste

Capital City Paving uses the Terex VacRecover plant to turn hydro vac waste into high-quality recycled aggregates, improving efficiency, lowering disposal costs, and supporting sustainable construction across Canada.

Problem

Capital City Paving, a major asphalt and aggregate supplier in Canada, was facing growing challenges with the disposal of hydro vac waste made up of fill, excavation debris, gully waste, and contaminated sludge. The existing approach created:

 

  • Messy and unsafe working conditions
  • Health and safety risks for personnel
  • High disposal costs
  • Limited ability to recover usable materials
  • Environmental impact from landfill use and quarry depletion

 

Solution

To solve its hydro vac waste challenges, Capital City Paving partnered with Terex Washing Systems to install the VacRecover plant, a modular and adaptable washing system designed specifically for this material. Key features of the system include:

 

  • Efficient processing of mixed loads such as mud, sand, rock and organics
  • Rapid unloading with Hydro Vac trucks emptied in just 15 minutes
  • Up to 80% material recovery, converting waste into reusable aggregates
  • Closed water circuit that reduces contamination and conserves water
  • Integrated Deep Cone Thickener and Floc Dosing Unit for high-quality water recycling
  • Compact, flexible design suitable for space-limited or urban sites

 

Results

Key outcomes of the VacRecover system:

 

  • New revenue from turning hydro vac waste into saleable sand and aggregates
  • Reduced environmental impact through landfill diversion, lower transport emissions, and less quarry depletion
  • Safer, cleaner site conditions with lower risk and improved work environments
  • Local job creation and support for nearby suppliers
  • Greater efficiency with fast truck turnaround and minimal downtime
  • Strong positioning as a leader in sustainable material recovery

 

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“With the VacRecover plant, we’ve turned a messy, costly problem into a clean, profitable solution. It’s helped us recover materials we used to throw away—while improving safety and sustainability across our operations.”

Cap City Paving