Complete Resources Co. Meeting the Challenges of Custom Crushing

by Diana Barnum, Correspondent

Butch Cherrington, operations manager for Complete Resources Company.
Photos by Diana Barnum

Ever get one of those “rush” calls? Someone needs concrete or asphalt recycled - now. Can you come out or they’ll get someone else? Sure you can… “If they tell you that someone else said that they can come ‘just like that,’ don’t believe them,” said Butch Cherrington, operations manager for Complete Resources Company. “You have to get permission from the EPA to run a plant somewhere else.”
Complete Resources was opened in Columbus, OH, in 1988, to recycle America’s deteriorated infrastructure. They own two portable Hazemag 1313 HSI (horizontal shaft impactor) crushers. With crews traveling throughout Ohio, Michigan, Kentucky, Indiana, Pennsylvania and West Virginia, they recycle concrete, asphalt and small amounts of industrial silicone carbine grinding wheels. Complete Resources has handled more than a million tons of materials from interstate highway, city street and private demolition projects. And they know the value of successfully handling the challenges that come with custom crushing operations.
“Establish good communication with your EPA contacts early on,” advised Cherrington. “Be above board with them. It could take up to 30 days for approval, so let them know about any tight deadlines to help your business.”
Cherrington said his EPA contacts were good to them and very cooperative in moving their plants around.
Nine semi loads are needed to move one plant. Under ideal conditions, it takes another three days to are break down, travel and set up in another location. Although some operators may tell you that it takes less time, Cherrington advises caution, “It takes a day to get rocks cleaned off that thing. You don’t want a rock to hit a windshield on the highway.”
Annually, Complete Resources crushes and sells an average of 200,000 tons of concrete and asphalt. It costs an average of $4.50 per ton to purchase the recycled materials, with savings for end users, depending upon location, coming from reduced freight.
For example, Complete Resources can recycle in-town. It can be cheaper to recycle old concrete and reuse it than to have virgin materials delivered from a quarry outside of town.
Generally, Complete Resources brings in one or both portable plants, recycles and stockpiles debris, then moves the plant or plants out to other locations for about three months until the stockpile sells.
In two weeks, this season’s recycling will be completed. Then the crusher will be off to Hilltop Basic in Cincinnati crushing virgin aggregate and Ready Mix in the downtown area outside of I-75 near the Cincinnati Reds’ Stadium.
Their number one buyer, the City of Columbus, purchases granular backfill specs. Number two buyers, Miranda and M/I Homes, purchase #2 for driveway bases and for under house footings, and #1 _ (half) minus also known as (ODOT) # 304 to go on top of #2 (then paves on top for drive ways). The private market is their number three buyer, with ODOT pulling up the rear at number four. “Ohio (ODOT) has limited uses for recycled concrete,” explained Cherrington. “Indiana, Michigan and Pennsylvania – all recycle their own concrete and reuse it. Ohio wants virgin aggregate and does not accept recycled asphalt.” Crushed “chunk” asphalt, milled off by small contractors, sells mainly to private industry and is used in 617 berm, temporary roads, parking lots and golf paths. New construction companies like MI, Miranda and Dominion Homes use the materials for homeowners’ driveways.
The percentage of products that are recycled each year varies. Last year, 100% of their work was private industry concrete jobs. This year two-thirds have been concrete, one-third asphalt, with 50% coming from road sites, 50% private industry. In one major project, Complete Resources is recycling 100,000 cubic yards of concrete and asphalt overlays from I-670 construction with parent company Complete General Construction.
In order to concentrate their focus on their recycling operations, Complete Resources is subcontracting the asphalt milling to the Shelly Company, which removes the asphalt with their own equipment. They are recycling 100% of the concrete and reusing it in a sewer project in the Hiawatha/Ohio State Fair area behind the soccer stadium.
Lighter Side
Not all custom crushing challenges are quite so serious. Actually, some can be entertaining, like on a job site that Cherrington remembered off Route 50 south near Huntington, West Virginia. Complete Resources was crushing native sandstone to 3-inch minus to be used in widening Route 50. Driving through the town they were going to stay in, a 1930’s American depression era town in West Virginia, the crew spotted a name scrawled on a piece of plywood in front of an Airstream trailer with the word “lawyer” incorrectly spelled wrong on it. They drove on and rented rooms in a hotel above a bar. The challenge was getting their wake-up call in the mornings. There were no phones in the hotel. Turns out the bar owner had written numbers on the bar ceiling, one corresponding to each room above. When it was time for the wake up call, she banged on that room’s ceiling number with a broom.
Key Facts
Complete Resources Company, 1275 E. Fifth Avenue, Columbus, Ohio 43219. Call: (614) 253-6415; or fax inquiries to: (614) 253-2531
Founded 1988
Crushers: 2 portable Hazemag 1313 HIS crushers
Screens: 16 X 16 Tyler vibrating screen 3-deck Ty-Rocket
Conveyors: 50 units mostly from Grasan from Mansfield
Truck Scales: 4 Absco “Hitless” above ground
Miscellaneous: All Cat equipment from Holt’s Cat 988 F, 980 G, 980 F, four 980 C’s, two 980 B’s – all rubber tire; One Kawasaki 95 rubber tire wheel loader from Reco; Cat 215 Excavator with Stanley hydraulic breaking hammer