Class of 1976
In the mid 90â€™s, Frank and his wife/business partner Valerie turned their focus to recycling as they were astounded by the amount of recyclables going to landfills. Frank knew that he could produce an aggregate product from the materials being excavated on road reconstruction job sites. As a competitive businessman, Frank possessed the integrity determination, intelligence, ingenuity and ambition to succeed in making construction material recycling a profitable enterprise. Together, the Montecalvos developed a 52-acre site in Woodbridge for a full-scale recycling operation. In 2004, Bayshore Soil Management was launched to remediate non-hazardous petroleum contaminated soil. Frank positioned a low-temperature thermal desorption unit in an existing warehouse and obtained DEP permits to process up to 3,000 tons per day of material. The technology operates similar to an asphalt plant with all material processing and storage taking place indoors or within the equipment, therefore maintaining compliance with New Jerseyâ€™s rigid environmental standards.
In 2005, Frank also spearheaded implementation of a public/private research project to re-engineer dredge material processing and beneficial re-use in partnership with the Port Authority of NY and NJ, the Army Corps of Engineers, Brookhaven National Laboratory, the Department of Energy, the US EPA and the NJDEP. He conceived of the idea to purchase a 730-foot ship and converted it into a mobile dredge material storage and processing platform to demonstrate innovative sediment decontamination technologies. These technologies demonstrated the feasibility of manufacturing valuable products (e.g. soils, cements and road aggregates) from the 4-6 million cubic yards of annual material required to be dredged from waterways to permit safe commercial navigation.
Frank led another public/private partnership with Rutgers University to study and implement the use of crumb rubber in roads and other construction materials. He collaborated with the NJDOT and NJDEP to develop an economic and efficient processing methodology for the high volume re-use of scrap tires. The research proved successful and Frank created a unique design mix for asphalt enhanced with crumb rubber.
Six years ago, Frank launched Coastal Metal Recycling Corp to accept scrap metals including copper, brass, steel, and wire, enabling the Eco-Complex to recycle a wider range of materials.
During the same year, he also started yet another business venture a material recovery/recycling facility for mixed bulky waste and construction debris. The empty warehouses adjacent to the thermal soil operation were perfect to position the Montecalvo Material Recovery Facility. As soon as the business opened, Frank realized that a larger system was needed to process the volume of material accepted (up to 1,000 tons per day per NJDEP permit). He designed a C & D sorting line and processing unit that was unveiled on Earth Day 2010, which recovers approximately 75 percent of the incoming mixed waste into recyclable products. This multi-million dollar system uses both mechanical and manual labor to source separate the material. This "state-of-the-art" system unveiled on Earth Day in 2010, the Montecalvo Material Recovery Facility won the National C & D Recycler of the Year from the Construction Material Recycling Association (CMRA).
A hands-on owner, Frank applies his extensive experience in overseeing the operations, engineering, equipment purchase, quality control and innovation associated with the entire Eco-Complex and Energy Campus on a daily basis.
Frank resides in Highlands, N.J. with his wife and son, Frankie Montecalvo, a professional sports car racer. Daughter Nicole also works for the firm in public relations and marketing and lives in North Jersey. The Montecalvos rescue Mastiff/Great Danes and currently share their home with 5 large dogs. Frank is an avid boater and enjoys living at the Jersey Shore. The Montecalvos support many local charities and will be honored this year by the Central Jersey Chapter of the Juvenile Diabetes Research Foundation for their multitude of philanthropic endeavors.
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