Largest International Airport in the U.S. Boasts Largest Of Carpet Reclamation Projects For Starnet

Local flooring contractor reclaims 70,000 square yards of old carpet from Denver International Airport

The statistics and project logistics alone are mind-boggling. Not to mention the added considerations of airport clearance for installers, security tool checks in and out on a daily basis, delivery of materials down airport runways and up escalators, and limited work periods in between flights and during overnight hours. All taking place in the largest international airport in the United States (by land size) - third largest in the world! These considerations are just a glimpse of the challenges that ReSource Colorado, Inc. is encountering as they replace the carpeting in concourses A & C and parts of the main terminal building at Denver International Airport.

"This has definitely been our most challenging installation to date," says John Stanfield, President of ReSource Colorado, Inc. "From an installer's perspective, things like fingerprinting for security clearance and the logistics of working in a facility that's always very busy aren't normal concerns. None of my guys were certified to drive on an airport runway, but they are now! We've really had to rethink our project management approach." According to Starnet Worldwide Commercial Flooring Partnership, this is one of the largest carpet recovery projects performed by a member to date.

Installation and tear out, which is simultaneous due to the nature of the job and airport passenger safety concerns, began in early April on Concourse C and early May on Concourse A and is expected to run through late October or early November. The month of August is a planned installation hiatus with the expected dramatic increase in passenger traffic due to Denver hosting the Democratic National Convention later in the month.

A total crew of 30, including supply truck drivers, measuring specialists, project managers and 24 full time installers are working two shifts around the clock to complete the job in the specified timeframe. Each of the crew had to be formally fingerprinted and cleared by the Transportation Security Administration (TSA) and was issued a photo ID badge in order to work in the facility. A daily check is conducted when bringing installation tools like carpet knives and razors into the actual airport building. The number of sharp objects is checked in by TSA, recorded onto a log and then checked back out at the end of each shift. The two numbers are required to match.

70,000 square yards of Bentley broadloom carpet will be installed from 12 foot rolls. Parts of the facility don't contain freight elevators, so the ReSource Colorado crew had to get creative in transporting the 650-900 pound rolls of carpet up and down airport escalators. (And you thought navigating your suitcase up an escalator was tricky?) "It's certainly been a challenge," says Tanner DeJonge, Project Manager for ReSource Colorado. "Our guys are good and created their own system for transporting the rolls up the escalators."

The old carpet consists of two types and all will be reclaimed in some manner. The material from Concourse C was manufactured by C & A, who has engineered a reclamation program specifically for their product. The carpet is collected in semi-trailers and shipped to C & A's facility in Georgia. The material is processed and lives a second life as backing for new carpet. The carpet from Concourse A and the terminal is a rubber-backed product. ReSource Colorado has contracted with a cement plant in Sugar Creek, Missouri where the materials will be shipped to and burned for fuel. Built in 2007, the $7 million facility was constructed specifically for this purpose and operates under very specific guidelines. "I was required to send samples of the carpet to the plant so that it could be cleared for acceptance," explains Stanfield. "The material was thoroughly tested according to their specification to be certain it would burn clean and not emit any potentially harmful pollutants."

"I think the biggest thing we've learned during this process is the value of coordination, patience and sound project management skills," says DeJonge. "Coordination with airport management, government security, the mill and reclamation facility are key to this project's timely success. If we can do this, while saving 70,000 square feet of carpet from the landfill, we can do anything."

Denver International Airport - Environmental Impact of Reclamation vs. Landfill

• Quantity diverted from landfills: 630,000 sq. feet
• Equivalent number of pounds reclaimed: 315,000 lbs.
• Overall cubic yards of landfill saved: 1,556 cu. yd.
• Average equivalent BTU's saved: 3,150,000,000 BTUs
• Number of US homes that would supply for 1 year: 18
• Global warming potential averted (CO2 equivalent lbs.): 2,202,480 lbs.
• Water saved: 960,750 gal.

About ReSource Colorado, Inc.

Founded in 1988, ReSource Colorado has been a leader in providing one stop flooring solutions in Denver for twenty years. As a proud Starnet member and full service flooring contractor, they offer a broad variety of carpet choices, as well as resilient flooring, tile, stone, wood, bamboo and cork floor covering options. ReSource Colorado can meet customer flooring needs from installation to maintenance and cleaning services, no matter how great or small. For more information call 303-756-7100 or visit www.resourcecolorado.com.

About Starnet Worldwide Commercial Flooring Partnership

Since 1992, Starnet Worldwide Commercial Flooring Partnership has been a dedicated alliance of commercial flooring contractors throughout North America. Their mission is to provide collective strength, integrity, shared best practices and advocacy of training across the industry. Through strong partnerships with leading flooring manufacturers and related service providers, Starnet members ensure complete customer satisfaction through excellence in project management, installation and service. The membership's combined efforts create an annual volume of nearly two billion dollars. For more information, call 1-800-787-6381 or visit www.starnetflooring.com.