How Concrete Recycling Works: Process, Equipment, and Costs

The EPA estimates 600 million tons of C&D debris hit the waste stream every year in the United States. Concrete makes up the biggest share by weight. Most of it still goes to landfills at $25 to $80 per ton in disposal costs.

That concrete is not waste. It is raw material. A jaw crusher and a vibratory screener turn demolished concrete into recycled concrete aggregate (RCA): sized, graded base material that meets DOT spec for road construction, backfill, pipe bedding, and structural fill. The process works at fixed recycling plants and directly on the demo site with portable equipment.

This guide walks through every step of concrete recycling, from demolition to finished product. Costs, equipment, environmental numbers, and state DOT acceptance are all covered.

Step 1: Demolition and Collection

Concrete recycling starts the moment the excavator pulls its first slab. The material needs to be broken into feed-sized pieces before it hits a crusher.

Hydraulic breakers mounted on excavators crack slabs, footings, and walls into chunks small enough for the crusher jaw opening. For a compact jaw crusher like the Evortle CT-535, that means pieces under 20 inches across. For a production machine like the Evortle CT-850, the jaw accepts material up to 32 inches wide.

Sorting happens at the pile. Excavator operators separate concrete from wood, drywall, roofing, and other C&D waste streams. Clean concrete (no contaminants, no mixed debris) produces the best aggregate and commands the highest reuse value. Mixed loads with soil, wood, or trash require more screening passes and produce lower-grade output.

Stockpile the feed material. The excavator stages broken concrete in a feed pile near the crusher. On large jobs, this pile grows continuously as demolition progresses. On smaller jobs, the full teardown may happen before crushing starts.

Step 2: Rebar Removal and Pre-Processing

Reinforced concrete has steel rebar embedded in it. Every commercial foundation, bridge deck, and structural wall contains reinforcement. That steel needs to come out before the aggregate is usable.

Two methods handle rebar removal:

Overband magnets on jaw crushers pull rebar, tie wire, and steel fragments from the crushed material automatically during processing. The CT-850 includes the magnet as standard equipment; on the CT-535, it is an available option. The magnet sits above the discharge conveyor. As crushed material exits the jaw chamber, the magnet grabs ferrous metal and drops it into a separate scrap pile. This is the standard method on portable crushing operations.

Manual pre-processing involves cutting exposed rebar with a torch or hydraulic shears before material enters the crusher. This adds labor time but reduces wear on jaw plates. On jobs with heavy reinforcement (number 8 bar and above, or post-tensioned cable), pre-cutting rebar improves feed rate and extends jaw liner life.

The scrap steel has value. Ferrous scrap prices fluctuate, but rebar pulled from a concrete recycling operation typically sells for $150 to $250 per ton to local scrap yards. On a 500-ton concrete job with 2% steel content by weight, that is 10 tons of rebar worth $1,500 to $2,500 in scrap revenue.

Step 3: Primary Crushing

This is where concrete becomes aggregate.

The excavator or wheel loader feeds broken concrete into the crusher hopper. Jaw plates close on the material and crush it to the set CSS (closed-side setting). CSS controls the maximum particle size in the output. Set the CSS to 0.8 inch on the CT-535 for road base aggregate. The CT-850 produces 1-inch minus material at its tightest setting. Open the CSS to 1.5 inches on either machine for larger base material.

Jaw crushers handle concrete, rock, brick, block, and masonry. They do not process asphalt. Asphalt requires an impact crusher, which uses a different crushing action. See our crusher types guide for the full breakdown on jaw vs. impact vs. cone crushers.

Two equipment tiers cover most recycling volumes:

Not sure which model fits your project? Estimate your tonnage first using our demolition sizing guide.

Throughput depends on three things: material hardness, rebar density, and feed consistency. Clean unreinforced concrete crushes faster than heavily reinforced structural walls. Consistent feed sizes (no oversized chunks jamming the chamber) keep production steady. An experienced excavator operator who manages the feed rate makes a measurable difference in daily output.

Step 4: Screening and Grading

Raw crusher output is a mix of particle sizes from dust to the CSS maximum. For many applications (road base, backfill, haul roads), this crusher run material works as-is. The blend of fine and coarse particles interlocks and compacts well.

For spec work that requires specific gradations, screening separates the crusher output into sized products.

A vibratory screener takes the crusher output and sorts it across two screen decks into three size fractions. Common separations:

• 3/4-inch clean: Coarse aggregate for concrete mix, drainage layer, and structural applications
• 3/8-inch clean: Fine aggregate for concrete mix, bedding, and surface course
• Minus 3/8-inch fines: Fill material, base fines, and blending stock

Each fraction has a different market value and a different set of end uses. Screening adds a processing step but creates multiple saleable products from a single feed source.

Gradation matters for DOT work. State DOT specifications define exact sieve analysis requirements for base course, sub-base, and aggregate products. Running a crusher and screen together lets you hit those gradation targets on-site. Refer to our crushed stone sizes guide for standard size designations.

Step 5: Stockpiling and Quality Control

Crushed and screened material goes to stockpile areas organized by product size. Proper stockpiling prevents contamination between grades and keeps the product clean for end use.

Stockpile management basics:

• Separate each product grade with at least 10 feet of clearance
• Build conical piles, not flat windrows (less surface area exposed to rain and contamination)
• Keep stockpiles on clean, compacted ground or geotextile fabric
• Label each pile with size designation and test date

Testing and spec compliance matter when selling aggregate or using it on DOT projects. Standard tests include:

• Sieve analysis (ASTM C136): Confirms gradation meets target specification
• LA Abrasion (ASTM C131): Measures hardness and durability. RCA typically scores 30-45% loss (spec maximum is usually 50%)
• Soundness (ASTM C88): Tests resistance to freeze-thaw cycles
• Specific gravity and absorption (ASTM C127/C128): RCA absorbs more water than virgin aggregate (typically 4-8% vs. 1-3%). This affects concrete mix design ratios.

For base course and backfill applications, sieve analysis alone is usually sufficient. For concrete mix aggregate, the full test suite applies.

Fixed-Plant vs. Portable On-Site Recycling

Concrete recycling operations run two ways. The economics are different for each.

Fixed-Plant Recycling Yards

Permanent facilities with stationary crushers, multi-deck screens, stockpile areas, and scale houses. Contractors haul demolition concrete to the yard, pay a reduced tipping fee ($8 to $15 per ton vs. $25 to $55 at a C&D landfill), and the facility processes it into graded products for resale.

Pros: No equipment rental needed. Drive in, dump, leave. Works for small jobs where mobilizing a crusher does not make economic sense.

Cons: You still pay trucking and tipping fees. You lose the material value (the recycling yard keeps the aggregate). Wait times during peak hours cost you driver time. And you need a recycling yard within economical haul distance of your site.

Portable On-Site Crushing

A jaw crusher and vibratory screener come to your demo site. You process the concrete where it sits. No trucks leave the site. No tipping fees. The aggregate stays on your project.

Pros: Zero haul trips. Zero disposal fees. You keep the aggregate for backfill, base course, or resale. Works on any site with enough space for the crusher footprint.

Cons: Equipment rental cost. Need an excavator or loader to feed the crusher. Requires space for the crusher, screen, and stockpiles. Minimum volume of around 50 tons to break even vs. hauling.

For a full cost comparison, see our on-site crushing process and cost guide.

Recycled vs. Virgin Aggregate: Side-by-Side Comparison

The key difference: RCA absorbs more water and has slightly lower abrasion resistance. For base course, sub-base, and fill applications, these differences do not affect performance. For structural concrete mix, most specs limit RCA to 20-30% of total aggregate content.

State DOT Acceptance: Southeast States

Every state DOT has its own specifications for recycled concrete aggregate. Acceptance varies by application. Here is where SE states stand.

All six SE states accept RCA for base course work, which is the most common end use for recycled concrete on contractor jobsites. For structural concrete mix applications, state policies differ. Check the current edition of your state DOT standard specifications before bidding work that depends on RCA acceptance.

Environmental Impact of Concrete Recycling

Concrete recycling has measurable environmental benefits. These numbers matter for LEED certification, green building compliance, and increasingly for public bid scoring.

The real environmental win is eliminating truck trips. A 500-ton demo job hauled out at 20 tons per truck is 25 round trips. At an average 25-mile distance, that is 1,250 miles of truck travel eliminated. At roughly 6 miles per gallon for a loaded tri-axle, that is 208 gallons of diesel saved on trucking alone.

What Concrete Recycling Costs

The cost depends on whether you haul to a recycling facility or process on-site.

Hauling to a recycling yard:

• Tipping fee at the recycling facility: $8-$15/ton (lower than C&D landfill rates)
• Trucking: $5-$8/ton (varies by haul distance)
• Loading and staging: $2-$4/ton
• Total: $15-$27/ton

On-site portable crushing:

• Equipment rental (crusher): varies by model and market
• Equipment rental (vibratory screener, if needed): varies
• Fuel: varies by material hardness and hours run
• Operator (if not using existing crew): varies
• Total: $5-$12/ton (see full breakdown in our on-site crushing cost guide)

Value of the recycled product:

• RCA base material sells for $6-$15/ton at recycling yards
• Self-produced RCA replaces purchased virgin aggregate at $15-$30/ton
• Scrap rebar recovery: $150-$250/ton of steel

On a 300-ton commercial demo job in Atlanta, on-site crushing at $8/ton costs $2,400 to process. That same 300 tons would cost $12,000 to $24,000 to haul and dump at a C&D landfill. And you keep the aggregate on-site instead of buying $6,000 worth of new base material.

The break-even point for on-site crushing sits around 50 tons. Below that, hauling to a nearby recycling yard is usually cheaper. Above 50 tons, the economics tip sharply toward on-site processing. For detailed math at different job sizes, see our disposal cost comparison.

The Step-by-Step Process: Summary Table

LEED and Green Building Credits

Concrete recycling directly contributes to LEED certification under the Materials and Resources (MR) category. In LEED v4.1, the Construction and Demolition Waste Management credit rewards projects that divert C&D waste from landfills.

Two paths to credit:

• Path 1 (Diversion): Divert 50% of total C&D waste (by weight) for 1 point. Divert 75% for 2 points. On-site concrete recycling counts 100% toward diversion because the material never leaves the site.
• Path 2 (Reduction): Reduce total C&D waste generation below an established limit. Less common on demo projects but applicable on new construction.

For contractors bidding LEED-certified projects, on-site concrete recycling is one of the easiest MR credits to earn. The documentation is straightforward: weigh your feed material, weigh your output, document the reuse. No third-party recycling facility records needed when you process on-site.

Frequently Asked Questions

Is recycled concrete as strong as virgin aggregate?

For base course and sub-base, yes. RCA compacts and performs at equivalent levels to virgin crushed stone when properly graded. The California Bearing Ratio (CBR) for well-graded RCA typically exceeds 80%, which meets or exceeds most DOT base course specifications. For structural concrete mix, RCA is approved in limited percentages (typically 20-30% of total aggregate) because its higher water absorption affects the water-cement ratio.

Can recycled concrete go under a building?

Yes. Recycled concrete aggregate is approved for structural backfill and foundation sub-base in all six SE states. It compacts to 95%+ Modified Proctor density, which meets standard structural fill requirements. Many commercial and residential foundations sit on RCA base course. The key is proper gradation and compaction testing, the same requirements that apply to virgin aggregate.

What about rebar in the concrete?

Jaw crushers process rebar-reinforced concrete without issues. An overband magnet pulls steel from the crushed output automatically (standard on the CT-850, optional on the CT-535). The steel goes to a scrap pile and the aggregate exits clean. Heavy rebar (number 8 and above) slows the feed rate and increases jaw liner wear, but the machine handles it. Pre-cutting exposed rebar on heavily reinforced material reduces wear and improves throughput.

How much does recycled concrete cost?

Three price points depending on how you get it. Purchased from a recycling yard: $6 to $15 per ton. Self-produced on-site with portable crushing equipment: $5 to $12 per ton processing cost. Hauled to a recycling facility for disposal: $15 to $27 per ton all-in (tipping plus trucking). The cheapest option is producing it yourself on jobs over 50 tons. See our concrete disposal cost guide for the full math.

Do DOTs accept recycled concrete aggregate?

Yes. All six Southeast states (GA, FL, NC, SC, TN, AL) accept RCA for base course, sub-base, and pipe bedding. Acceptance for structural concrete mix aggregate varies by state and typically allows RCA at 20-30% of total aggregate content. Always check the current edition of your state DOT standard specifications. Acceptance criteria include sieve analysis, LA Abrasion, and soundness testing. See the state acceptance table above for specific spec references.

Can you sell recycled aggregate?

Yes. Contractors who produce more RCA than they need on a job sell the surplus to neighboring projects, landscaping suppliers, and aggregate yards. Market price for RCA ranges from $6 to $15 per ton, depending on gradation and local supply. Clean, well-graded 3/4-inch base material commands the highest price. This turns a disposal cost into a revenue stream. Some contractors run concrete recycling as a side business, processing rubble from other demo companies and selling the output.

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Skip the recycling yard. A portable jaw crusher and vibratory screener on your demo site turn concrete rubble into DOT-spec base material. No haul trips. No tipping fees. No waiting in line at the transfer station.

GrinderCrusherScreen connects contractors with portable crushing and screening equipment across the Southeast. Browse concrete crushers on our main site or check rental availability on the crusher rental page. Call 770-433-2670 to talk through your project. We have been matching contractors with the right equipment since 1973.