Excavation Waste Recycling: A Sustainable Solution for SAPA

SAPA, an asphalt manufacturer based in Geneva, set out to recycle construction, demolition, and excavation waste instead of sending it to landfill. Terex Washing Systems delivered a complete 100tph washing and recycling solution that transforms waste into saleable sand and aggregates. The system also features advanced water management technology that recycles up to 95 percent of water used. This sustainable and cost-effective approach has reduced disposal costs, increased material recovery, and lowered environmental impact, reinforcing SAPA's commitment to the circular economy. 

 

 

 

Problem

 

SAPA, an asphalt manufacturer based in Geneva, was challenged by the large volumes of construction, demolition, and excavation waste being sent to landfill each year.  To address this, the company set out to:

 

  • Implement a sustainable and a cost-effective recycling solution
  • Transform waste into saleable sand and aggregate products
  • Reduce landfill disposal costs
  • Introduce an advanced water management system to optimise usage and minimise environmental impact

 

Solution

Terex Washing Systems delivered a complete 100tph wash and recycling plant for excavation and demolition waste, designed to maximise material recovery and minimise environmental impact. The system includes:

 

  • A 2-deck Rinser to classify aggregates and sand
  • The Aggrescrub 150 Log Washer for advanced scrubbing
  • A Terex MPS Impact Crusher to size larger stone
  • The FM 120 C-2G Sand Plant for high-quality sand
  • An AquaClear thickener and filter press that recovers 95% of water

Results

SAPA now diverts excavation waste from landfill, transforming it into usable and saleable sand and aggregate products. With a water management system that recycles 95% of process water, the site significantly reduces water consumption and environmental impact. The 100tph processing capacity supports high-volume production with minimal waste, while reduced disposal costs and new revenue streams from recycled materials strengthen SAPA’s operational and financial performance.

 

Johnston Patterson, Product & Applications Manager at Terex Washing Systems, highlighted the success of the project:

 

“The customer is very pleased to have a solution in place to recycle their C&D and excavation waste. The strong partnership between Terex Washing Systems and SAPA has been key to achieving high plant performance.“

 

 

excavation-material-sapa-hero (2)

“We’re very pleased to have a solution in place that allows us to recycle our C&D and excavation waste. The performance of the plant and our partnership with Terex Washing Systems have been key to making this possible.”

SAPA, Geneva