Circular economy in construction : introduction of washed recycled aggregatesinto precast concrete products, from recyclingto upcycling

Thibault MARIAGE, QHSE Director, Tradecowall SC

II International Forum Circular Economy, 25th of November 2019

Constatation

We need building materials

Construction in the broad sense consumes between 40 and 50 % of natural ressources for building materials,

Construction uses and consumes 40 % of the energy usedand produces almost 40% of the CO2 emissions

Sustainable development

Constatation

We need building materials

Concrete : more than nine billion tons

(= 30.000 Arches of La Defense)

Gravel : 4,7 billion tons (670 Chéops pyramids)

Sand : 2,2 billion tons (22 million wagons = 264000 km long train)

Cement : 1,3 billion tons (17000 « Norway » liners = 2,34 billion tons of limestone and clay)

Water : 800 billion liters (23 times the daily flow of the river Seine)

Sustainable development

Constatation

We produce waste

Sustainable development

Constatation

We produce construction and demolition (C&D) waste :

• Mixed waste : concrete, bricks, ceramics, natural stones, tiles etc.

• Concrete waste (armed or not).

• Bitumen/asphalt waste from the roads.

Sustainable development

Eco-bénéficience

SOURCE: S. BECKERS (d’après M. BRAUNGART –EPEA, Cradle to Cradle)

Sustainable development

Eco-bénéficience

SOURCE: S. BECKERS (d’après M. BRAUNGART –EPEA, Cradle to Cradle)

Sustainable development

Recycling of C&D Waste

The use of recycled aggregates is usually limited toapplications such as bases and sub-bases for roads andbuildings, this process is called recycling but the finaladded value is relatively poor.

The goal of the SeRaMCo project is to achieveUPCYCLING which means giving the recycled productmore added value.

Partnership:11 Partners3 Sub-Partners3 Associated Partners

17 Partners from 5 EU countries (Germany, France, Netherlands, Belgium, Luxemburg)

Crushing / Screening and preparation methods

Aggregates

StructuralElements

Non-str. Elements

Cement 3 pilot projects

WP T1

WP T2

WP T3

Project overview

C&DW ofunknown origin

C&DW of known origin

SandConcrete

mixesCement mixes

Recycling of C&D Waste

MIXED WASTE

FROM THIS ….

WASHED MIXED RECYCLED AGGREGATES

TO THIS !

Recycling of C&D Waste

Step 1: Conveyor belt EDGE

WASHING PROCESS

Recycling of C&D Waste

Step 2: Screen cleaner Terex Finlay 683

3 roles :- Screening- Overband for sorting ferrous metals- First washing = Shower for waste

ZOOM

Recycling of C&D Waste

• Screening

63+ mm rejected

0/63mm

0/4 mm hydrocyclones(Step 7)

4/63 mm pallet milling machine(Step 3)

Step 2: Screen cleaner Terex Finlay 683

Recycling of C&D Waste

Step 3: Palet milling machine : Logwasher 206 Terex Finlay

Second washing = washingmachine

Wash water loaded withsludges

4/63mm Screen rincer Morgensen(Step 4)

Screen drainer Sotrès(Step 6)

Recycling of C&D Waste

Step 4: Rinsing Screen Mogensen

Thirdwashing = rinsing

Step 5: Screen Warrior 1400

3 different sizes sorted out :- 4/20mm- 20/31,5mm- 31,5/63mm

0/4mm hydrocyclones(Step 7)

4/63mm Warrior screen (Step 5)

Recycling of C&D Waste

Step 6: Screen drainer Sotrès

Step 7: Hydrocyclones Sand master Terrex C15

• Wash water

Floating materials Valorisation

Precipitating materials hydrocyclones (Step 7)

• Fraction 0/4mm + Wash water

Sands High frequency wiper screen

Sludges settling pond (Step 8)

Recycling of C&D Waste

Step 8 : Clarification containers

• Wash water+ sludges

Floculated sludges « Sand bed » (Step 9)

Clear water Reserve pond

Recycling of C&D Waste

Step 9 : “Sand bed” (= settling pond) and reserve pond

Recycling of C&D Waste

Recycling of C&D Wastes

Sands :

- 0/4 mm mixed

- 0/4 mm concrete

Aggregates :

- 4/6 mm mixed

- 4/6 mm concrete

- 6/14 mm mixed

- 6/14 mm concrete

- 14/20 mm mixed

- 14/20 mm concrete

Finished products

Recycling of C&D Waste

Expectations from washing aggregates:• Constrain grain size distribution

• Decrease fine content

• Decrease the quantity of unwished components (floating, clay, plaster...)

• Increase resistance to fragmentation

Effect of washing on aggregates quality

Methodology

WashedUnwashed

Concrete aggregate 0/20

Mixed aggregate 4/20

Concrete aggregate 4/20

Mixed aggregate 0/20

Aggregates washing conclusion

Expectations from washing aggregates:• Constrain grain size distribution

• Decrease fine content

• Decrease the quantity of unwished components (floating, clay, plaster...)

• Increase resistance to fragmentation

1. Hollow Core Floor Slab

2. Urban SeRaMCo Elements

3. Sound Absorbing L-Wall

4. Façade Cladding

5. Salty Concrete

6. Rammed Concrete

7. Energy Sound Barrier

8. Foam Concrete Insulated Wall

9. Cooling Wall

10. Energy Bench

10 Product designs

1. Hollow Core Floor Slab

2. Urban SeRaMCo Elements

3. Sound Absorbing L-Wall

4. Façade Cladding

5. Salty Concrete

6. Rammed Concrete

7. Energy Sound Barrier

8. Foam Concrete Insulated Wall

9. Cooling Wall

10. Energy Bench

10 Product designs

1. Hollow Core Floor Slab

2. Urban SeRaMCo Elements

3. Sound Absorbing L-Wall

4. Façade Cladding

5. Salty Concrete

6. Rammed Concrete

7. Energy Sound Barrier

8. Foam Concrete Insulated Wall

9. Cooling Wall

10. Energy Bench

10 Product designs

Parkour Park – Parc des MarêtsCity of Seraing - Belgium

Project supported by the European Union within the framework of Interreg NWE

SeRaMCo