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Sustainable Aggregates from Secondary Materials for Innovative Lightweight Concrete Products

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Sustainable Aggregates from Secondary Materials for Innovative Lightweight Concrete Products Sustainable aggregates from secondary materials for innovative lightweight concrete products Agnese Attanasio 1, Alessandro Largo 1, Iñigo Larraza Alvarez 2, Francesco Sonzogni 3, Lucian Balaceanu 4 1 CETMA - Engineering, Design & Materials Technologies Center, Italy 2 ACCIONA Infrastructure, Spain 3 Magnetti Building Spa, Italy 4 IRIDEX Group Plastic Srl, Romania Large quantities of waste materials are generated from manufacturing processes, industries and municipal solid wastes. As a result, waste management has become one of the major environmental concerns in the world. The increasing awareness about waste management and environment-related issues has led to substantial progress in the utilization of wastes or by-products like plastics as an attractive alternative to disposal. The use of post-consumer plastics in the concrete manufacturing represents an effective solution both to the problem of reducing their environmental impact and to the development of sustainable building industry. The production of new construction materials using recycled plastics is important to both the construction and the plastic recycling industries. In this paper the viability of some secondary plastic materials as aggregates for concrete is assessed. Three different types of plastic scraps (polyurethane foams, tyre rubber and scraps resulting from the sorting of recycled plastics from solid urban wastes) were processed in order to allow their use as aggregates for non-structural concretes. Several mixtures based on recycled aggregates and Portland cement were then manufactured; a large characterization campaign was performed checking how the different amounts of the investigated recycled materials influence the final performances in terms of density, workability, mechanical strength and insulation. The obtained results confirmed that the examined sustainable aggregates could be used for the manufacturing of innovative lightweight concretes products. The potential benefits for industries and society are three: reducing the landfill disposal of several types of solid waste, providing new cost-effective building materials and ensuring the environmental sustainability of the new products. HERON Vol. 60 (2015) No. 1/2 5 Key words: Aggregates from secondary plastics, lightweight concretes, thermal insulation, innovative construction components 1 Introduction A substantial growth in the consumption of plastic is observed all over the world in recent years; this has led to huge quantities of plastic-related wastes [Saikia et al, 2012]. Recycling of plastic waste to produce new materials such as concretes aggregates has economic and ecological advantages and is considered one of the best solution for disposing of plastic waste. The development of new construction materials using recycled plastics is significant for both the construction and the plastic recycling industries. Moreover, post-consumer plastic aggregates can be successfully and effectively used to replace traditional aggregates [Siddique et al, 2008]. Recent studies have reported the promising use of polymers (polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), expanded polystyrene (PS) and others) in the production process of concrete. In particular, the large growth in the use of plastic materials has generated a growing interest worldwide in reusing recycled polymers [Liguori et al, 2014]. Although several studies have demonstrated that waste plastics can be beneficially incorporated in concrete, it is important to observe that not all waste materials are suitable for such use [Zanaib et al, 2008]. The research reported in this paper is focused on the assessment of the viability of secondary plastics as aggregates for concretes. Plastic scraps explored in this study are rigid polyurethane (PU) foams, Mixed Plastic Waste (MPW) coming from the sorting process of Municipal Solid Waste (MSW) and exhausted rubber tyres. The research on the use of rigid PU foam waste as aggregate for concrete, despite the relatively low cost and good chemical compatibility with cement, is very poor and some limitations have been also evidenced [Mounanga P. et al, 2008]; however it has been demonstrated its suitability for non-structural lightweight concretes [Verdolotti et al, 2008]. With respect to aggregate from MPW tested in this research it has a mixed composition (it mainly consists of PE and PP but also PET), therefore its behaviour in concrete might differ from similar plastics tested in other studies. Previous research activities1 have demonstrated the feasibility, processing 1 Carried out by CETMA in collaboration with a company operating in the materials recycling sector. 6 specific mixed plastic scraps, to obtain recycled aggregates (referred to as “Remix”) in both lower and higher density (NUMIX project “High performance lightweight aggregate for concrete from recycling of plastic waste”, CIP-ECOINNOVATION 2008, Project n. ECO/08/239110/SI2.535262); however their potential for concretes manufacturing still need to be fully validated. As far as concerns the use of recycled tyre rubber aggregates some practical applications have been proposed but it was also evidenced that their incorporation into concretes was not always successful due to rubber-cement paste incompatibility [Shu et al, 2014]. In other studies the use of recycled rubber tyres for concretes with good thermal insulation performance has been demonstrated [Cairns et al, 2004]. These three waste materials have been selected since they are available in quantities large enough for feeding the concrete industry and, at the same time, represent a socio- economic problem as there are low chances for their re-use in more added-values applications. The availability, across Europe, of these waste streams to be converted into aggregates has been quantified in [Arena et al., 2015] together with the analysis of rules for re-use and integration of recycled aggregates in concrete at European level. The use of sustainable aggregates from specific secondary materials in conventional cement binder systems is one of the goal of the SUS-CON project (“SUStainable, innovative and energy-efficient CONcrete, based on the integration of all-waste materials”, FP7/2007- 2013, Grant Agreement No. 285463). The main outcomes related to the development of these aggregates and their integration within lightweight concretes are reported in this paper. The first part of this work is focused on the secondary materials investigated, their processing to obtain eco – friendly lightweight aggregates and the relevant characterizations to assess their suitability for concretes production. The second part of the work deals with the use of the sustainable aggregates with traditional binders to make lightweight concretes. Several mixtures have been studied and the relation among design parameters and concretes performance (i.e. workability, mechanical and insulating behaviour) have been discussed. The concretes have been developed first on the lab scale and then, for assessing their integration in traditional production cycles, on the industrial level. On the basis of the performances achieved, real non-structural applications have been proposed for these lightweight eco – friendly concretes with recycled plastic aggregates; their performances have been finally compared with those of similar commercial products. 7 2 Production of lightweight aggregates from secondary materials 2.1 Rigid Polyurethane foams aggregates Recycled Polyurethane (PU) aggregates are made from rejected, non-conform parts or scraps of rigid polyurethane foams. A typical manufacturing process basically consists in mechanical breaking the material to allow size reduction. The first step consists in crushing the raw material into small pieces and then feeding them into the shredding mill. Finally, the material is sieved and separated in different grades. 2.2 Mixed plastics aggregates The remaining plastic debris from the sorting of plastics from Municipal Solid Waste (MSW), commonly defined Mixed Plastic Waste (MPW), are the basis of these aggregates that mainly consist of PE and PP but also PET. Aggregates, herein referred as Remix (RX), have been produced in two different forms, Remix HD (high density) and Remix LD (light density) respectively. Remix HD is obtained by an extrusion process, while Remix LD by an extrusion/foaming process (using foaming agents also from waste) applied on Remix HD. 2 Polyurethane Mixed plastic waste Tyre rubber Figure 1: Secondary raw materials for producing aggregates 2.3 End-of-life rubber tyres aggregates Recycled tyre rubber (TR) recycled aggregates are fabricated trough the processing of scraps resulting from the sorting of end-of-life vehicles tyres. A typical production process begins with the removal of metallic and textile fibers from the tyres, followed by mechanical fragmentation. The tyres are firstly crushed with a system of knives and then enter to a granulator where are processed into aggregates of different gradings. 2 The process for producing expanded granules (Remix LD) has been patented by CETMA, these aggregates, in combination with extruded aggregates (Remix HD), have been never tested in other studies. 8 3 Characterization of lightweight aggregates from secondary materials In order to assess the suitability of the lightweight aggregates from secondary materials (PU, RX, TR) for concretes manufacturing, physical, mechanical and chemical characterizations have been carried out according to specific standards3 (Table 1): • loose
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