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Sustainable Construction Products

1. Developing Precast Concrete Products made with Recycled Construction and Demolition Waste (C&DW):• Phase I : Concrete Building Blocks• Phase II: Concrete Paving Blocks and Flags

Funded by:The Onyx (Veolia) Environmental Trust &

Flintshire Community Trust (AD Waste Ltd)5th March 2003

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Sustainable Construction Products

2. North West Construction Knowledge Hub Construction Sustainability Centre:

(a) Recycled demolition aggregates in precast buildingand paving blocks and concrete flags,

(b) Reactive glass powder concrete flags of superior strength,

(c) Cementless “geopolymer” concrete products.

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Sustainable Construction Productsversus

Sustainable Built Environment

3. The Building as Total System

Technology Strategy BoardLow Impact Buildings:  Design and Decision Tool

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Concrete Building Blocks,Paving Blocks & Paving Flags

made with Recycled Demolition Aggregate.

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European Commission - 1991.

• Construction & Demolition Waste (C&DW) amounts to around:• 180 million tonnes per year in the

EU, or• 480 kg/person/year.

• Land-filling of C&DW (72% of the total amount) requires a landfill 10m deep and roughly 13 square km in surface area every year.

Recycling for Profit.Waste Management &

the New Environmental Economics.

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• C&DW accounts for 17% of the estimated annual waste in the UK.

• 220 million tonnes of new construction aggregate are extracted annually.

Construction and Demolition Waste (C&DW).

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There is a need to:• Increase research and

development to improve recycled aggregates quality.

• Demonstrate where recycled products are competitive with natural materials.

• Expand specifications to accept more recycled material where it has been shown to compete technically.

• Facilitate the flow of market information.

Potential uses forC&DW derived (recycled demolition) aggregate.

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• The Veolia Environmental Trust• The Flintshire Community Trust• A.D. Waste Ltd

Invesigators:• The University of Liverpool .

Precast Concrete Manufacturers:• Marshalls Ltd.• FORTICRETE Ltd .• Charcon Ltd.• Cemex Readymix Ltd.• RPC Ltd.

Demolition Contractors:• W.F. Doyle & Co. Ltd.• DSM Demolition Ltd.

Collaborators:Collaborators:

Aggregate Suppliers:• Lafarge Aggregates Ltd.• Hanson Aggregates Ltd.• Aggregate Industries.

Material Suppliers:• Appleby Group Ltd.• United Kingdom Quality Ash Association (UKQAA). Other:• Clean Merseyside Centre.• Liverpool Housing Action Trust.• Liverpool City Council.• Cheshire County Council• Morris Brothers Ltd.

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• contamination affecting reinforcement is not an issue.

• supply of input materials & storage of output are more easily managed.

• local circumstances may make high grade use of C&DW cost effective.• regeneration calls for

demolition and major reconstruction.

•major movements of aggregate from North Wales to North West .

Concrete Building Blocks,Paving Blocks & Paving Flags

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Aggregate Quarry in Merseyside?Now you do not see it……

….but soon you will!

Aggregate Quarry in Merseyside?Now you do not see it……

….but soon you will!

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….and now you do! 15,000 tonnes of waste?

….and now you do! 15,000 tonnes of waste?

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Make waste a resource!Make waste a resource!

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Flows of crushed rock between regions.

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Vibro-Compressor Machine- Factory -

Experimental Work & DevelopmentBuilding Blocks - “Black Art” or Science?

Electric Hammer Drill- Laboratory -

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Replacement Level (%).

0 10 20 30 40 50 60 70 80 90 100

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Strength

CoarseAggregate

FineAggregate

Compressive Strength Versus Replacement Level (%) with concrete derived aggregates.

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Replacement Level (%).

0 10 20 30 40 50 60 70 80 90 100

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Compressive Strength Versus ReplacementLevel (%) with masonry derived aggregates.

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Factory Trials

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FACTORY TRIALSConcrete blocks with masonry-derived

aggregate.

FACTORY TRIALSConcrete blocks with masonry-derived

aggregate.

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Compressive Strengths of:Laboratory cast and factory cast blocks.

Cement content (kg/m3)

100 150 200 250

28 d

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1820/20 MasonryFactoryLab

0/30 ConcreteFactoryLab

'ALL-IN' ConcreteFactoryLab

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Electric hammer onsliding rods

Clamped-on vibrator together with an electric

hammer

Modifications needed for casting:Concrete Paving Blocks

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Concrete Pavement FlagsThe manufacturing process:

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Casting of Concrete Flagsusing the laboratory “mini-press”

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• The claims culture in the UK costs local authorities £500m each year from trip, slip and fall accidents arising from cracked pavements.

• The superior performance of UHPFRC flags indicates that pavements are unlikely to crack even if they are overloaded by unplanned vehicle loading.

Reactive Glass Powder Concrete Paving Flags.Ultra High Performance Fibre Reinforced Concrete

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Reactive Glass Powder Concrete Flagsor:

“Green” flags for “Green” Pavements ?

Transformation of contaminated waste glass of all forms, in a single process, into safe, sterile, sharp free

glass crystals for re-use into alternative high value markets.

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Surface texture Cut surface

Complete replacement of cement by waste materials of high silicon dioxide content, e.g., incinerator ash, basic oxygen

steel slag, disposed ash from coal-fired thermal power plants, together with waste alkali solutions to produce:

“Green” Precast Concrete Products.

Geopolymer “Cementless” Concrete 100% recycled content!

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Every tonne of cement produces a tonne of CO2 !!!

Cement Manufacture – what’s wrong with it?

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What’s the alternative to cement?

• It is estimated that three million tonnes of ash are placed in lagoons for long term storage!

• Approx. 56 million tonnes are already waiting for a new use to be found!

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Embodied CO2 of UK cement,additions and cementitious material:

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Ultra High Performance Fibre Reinforced Cementless Precast Concrete Products:

The project will push the boundaries and knowledge past current leading edge work through developing a better understanding of the reactions between siliceous ashes and waste alkalis and thus enable their use in high volume production through appropriate blending to achieve the required chemical and mineral composition to enable them to react and form a strong matrix equivalent if not better than that achieved with the use of cement.

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Low Impact Buildings: Design and Decision Tools

Eawag Forum Chriesbach, Switzerland

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Sustainable Construction Productsversus

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The Building as Total System

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Sustainable Built Environment ?

• Waste Management &the New Environmental Economics.

Sustainable only if PROFITABLE !!!

– Cementing Concrete Solutions -

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And finally......And finally......

Thank you for your attention.

Are there any questions?