Valorization of post-consumer waste plastic in cementitious concrete composites

The sheer amount of disposable bottles being produced nowadays makes it imperative to identify alternative procedures for recycling them since they are non-biodegradable. This paper describes an innovative use of consumed plastic bottle waste as sand-substitution aggregate within composite materials for building application. Particularly, bottles made of polyethylene terephthalate (PET) have been used as partial and complete substitutes for sand in concrete composites. Various volume fractions of sand varying from 2% to 100% were substituted by the same volume of granulated plastic, and various sizes of PET aggregates were used. The bulk density and mechanical characteristics of the composites produced were evaluated. To study the relationship between mechanical properties and composite microstructure, scanning electron microscopy technique was employed. The results presented show that substituting sand at a level below 50% by volume with granulated PET, whose upper granular limit equals 5mm, affects neither the compressive strength nor the flexural strength of composites. This study demonstrates that plastic bottles shredded into small PET particles may be used successfully as sand-substitution aggregates in cementitious concrete composites. These new composites would appear to offer an attractive low-cost material with consistent properties; moreover, they would help in resolving some of the solid waste problems created by plastics production and in saving energy.     

Use of selected waste materials in concrete mixes

A modern lifestyle, alongside the advancement of technology has led to an increase in the amount and type of waste being generated, leading to a waste disposal crisis. This study tackles the problem of the waste that is generated from construction fields, such as demolished concrete, glass, and plastic. In order to dispose of or at least reduce the accumulation of certain kinds of waste, it has been suggested to reuse some of these waste materials to substitute a percentage of the primary materials used in the ordinary portland cement concrete (OPC). The waste materials considered to be recycled in this study consist of glass, plastics, and demolished concrete. Such recycling not only helps conserve natural resources, but also helps solve a growing waste disposal crisis. Ground plastics and glass were used to replace up to 20% of fine aggregates in concrete mixes, while crushed concrete was used to replace up to 20% of coarse aggregates. To evaluate these replacements on the properties of the OPC mixes, a number of laboratory tests were carried out. These tests included workability, unit weight, compressive strength, flexural strength, and indirect tensile strength (splitting). The main findings of this investigation revealed that the three types of waste materials could be reused successfully as partial substitutes for sand or coarse aggregates in concrete mixtures.     

Use of waste plastic in concrete mixture as aggregate replacement

Industrial activities in Iraq are associated with significant amounts of non-biodegradable solid waste, waste plastic being among the most prominent. This study involved 86 experiments and 254 tests to determine the efficiency of reusing waste plastic in the production of concrete. Thirty kilograms of waste plastic of fabriform shapes was used as a partial replacement for sand by 0%, 10%, 15%, and 20% with 800 kg of concrete mixtures. All of the concrete mixtures were tested at room temperature. These tests include performing slump, fresh density, dry density, compressive strength, flexural strength, and toughness indices. Seventy cubes were molded for compressive strength and dry density tests, and 54 prisms were cast for flexural strength and toughness indices tests. Curing ages of 3, 7, 14, and 28 days for the concrete mixtures were applied in this work. The results proved the arrest of the propagation of micro cracks by introducing waste plastic of fabriform shapes to concrete mixtures. This study insures that reusing waste plastic as a sand-substitution aggregate in concrete gives a good approach to reduce the cost of materials and solve some of the solid waste problems posed by plastics.     

Mechanical, Thermal and Water Absorption Properties of Kenaf-Fiber-Based Polypropylene and Poly(Butylene Succinate) Composites

The use of composites made from non-biodegradable conventional plastic materials (e.g., polypropylene, PP) is creating global environmental concern. Biodegradable plastics such as poly(butylene succinate) (PBS) are sought after to reduce plastic waste accumulation. Unfortunately, these types of plastics are very costly; therefore, natural lignocellulosic fibers are incorporated to reduce the cost. Kenaf fibers are also incorporated into PP and PBS for reinforcing purposes and they have low densities, high specific properties and renewable sourcing. However without good compatibilization, the interfacial adhesion between the matrix and the fibers is poor due to differences in polarity between the two materials. Maleic anhydride-grafted compatibilizers may be introduced into the system to improve the matrix-fiber interactions. The overall mechanical, thermal and water absorption properties of PP and PBS composites prepared with 30 vol.% short kenaf fibers (KFs) using a twin-screw extruder were being investigated in this study. The flexural properties for both types of composites were enhanced by the addition of compatibilizer, with improvements of 56 and 16 % in flexural strength for the PP/KF and PBS/KF composites, respectively. Good matrix-fiber adhesion was also observed by scanning electron microscopy. However, the thermal stability of the PBS/KF composites was lower than that of the PP/KF composites. This result was confirmed by both DSC and TGA thermal analysis tests. The water absorption at equilibrium of a PBS composite filled with KFs is inherently lower than of a PP/KF composite because the water molecules more readily penetrate the PP composites through existing voids between the fibers and the matrix. Based on this research, it can be concluded that PBS/KF composites are good candidates for replacing PP/KF composites in applications whereby biodegradability is essential and no extreme thermal and moisture exposures are required.     

Development of rice husks-plastics composites for building materials

In this paper, a new effective recycling method for rice husks and waste expanded polystyrene is developed by using a combination of both wastes. A styrene solution of waste expanded polystyrene is used as a binder for rice husks-plastics composites. The composites are prepared with various mix proportions by a hot press molding method, and tested for apparent density, water absorption, expansion in thickness, and dry and wet flexural strengths. From the test results, the apparent density of the composites is increased with increasing binder content and filler-binder ratio. Their flexural strength and wet flexural strengths reach maximums at a binder content of 30.0% and a filler-binder ratio of 1.0. Their water absorption and expansion in thickness are decreased with increasing binder content and filler-binder ratio. Since the composites have a high flexural strength and water resistance, their uses as building materials are expected.     

Recycled lightweight concrete made from footwear industry waste and CDW

In this paper two types of recycled aggregate, originated from construction and demolition waste (CDW) and ethylene vinyl acetate (EVA) waste, were used in the production of concrete. The EVA waste results from cutting off the EVA expanded sheets used to produce insoles and innersoles of shoes in the footwear industry. The goal of this study was to evaluate the influence of the use of these recycled aggregates as replacements of the natural coarse aggregate, upon density, compressive strength, tensile splitting strength and flexural behavior of recycled concrete. The experimental program was developed with three w/c ratios: 0.49, 0.63 and 0.82. Fifteen mixtures were produced with different aggregate substitution rates (0%, 50% EVA, 50% CDW, 25% CDW–25% EVA and 50% CDW–50% EVA), by volume. The results showed that it is possible to use the EVA waste and CDW to produce lightweight concrete having semi-structural properties.     

Use of plastic waste (poly-ethylene terephthalate) in asphalt concrete mixture as aggregate replacement.

One of the environmental issues in most regions of Iran is the large number of bottles made from poly-ethylene terephthalate (PET) deposited in domestic wastes and landfills. Due to the high volume of these bottles, more than 1 million m3 landfill space is needed for disposal every year. The purpose of this experimental study was to investigate the possibility of using PET waste in asphalt concrete mixes as aggregate replacement (Plastiphalt) to reduce the environmental effects of PET disposal. For this purpose the mechanical properties of plastiphalt mixes were compared with control samples. This study focused on the parameters of Marshall stability, flow, Marshall quotient (stability-to-flow ratio) and density. The waste PET used in this study was in the form of granules of about 3 mm diameter which would replace (by volume) a portion of the mineral coarse aggregates of an equal size (2.36-4.75 mm). In all prepared mixes the determined 6.6% optimum bitumen content was used. In this investigation, five different percentages of coarse aggregate replacement were used. The results showed that the aggregate replacement of 20% by volume with PET granules would result in a reduction of 2.8% in bulk compacted mix density. The value of flow in the plastiphalt mix was lower than that of the control samples. The results also showed that when PET was used as partial aggregate replacement, the corresponding Marshall stability and Marshall quotient were almost the same as for the control samples. According to most of specification requirement, these results introduce an asphalt mix that has properties that makes it suitable for practical use and furthermore, the recycling of PET for asphalt concrete roads helps alleviate an environmental problem and saves energy.     

Wood Polypropylene (PP) Composites Manufactured by Mango Wood Waste with Virgin or Recycled PP: Mechanical,Morphology, Melt Flow Index and Crystalline Behaviour

Compositions of wood-polypropylene composites (WPCs) are prepared through melt compounding followed by injection moulding. WPCs are formulated for eight compositions with a different weight ratio of wood, virgin or recycled polypropylene and coupling agent. WPCs compositions are compared in terms of Melt Flow Index, Tensile, FESEM images, Flexural and crystallinity index for same operating variable conditions. From the results, recycled polypropylene based WPCs are superior in comparison to virgin polypropylene based WPCs. With the addition of 5 % coupling agent in recycled polypropylene-based composites for 45:50 composition, tensile and flexural values of WPCs are higher in comparison to all composition and neat virgin or recycled polypropylene. This work stands for the utilization of waste wood with recycled plastic for replacement of wood and virgin plastic.     

Properties of lightweight aggregate concrete prepared with PVC granules derived from scraped PVC pipes

This paper aims to investigate the fresh and hardened properties of lightweight aggregate concretes that are prepared with the use of recycled plastic waste sourced from scraped PVC pipes to replace river sand as fine aggregates. A number of laboratory prepared concrete mixes were tested, in which river sand was partially replaced by PVC plastic waste granules in percentages of 0%, 5%, 15%, 30% and 45% by volume. Two major findings are identified. The positive side shows that the concrete prepared with a partial replacement by PVC was lighter (lower density), was more ductile (greater Poisson's ratios and reduced modulus of elasticity), and had lower drying shrinkage and higher resistance to chloride ion penetration. The negative side reveals that the workability, compressive strength and tensile splitting strength of the concretes were reduced. The results gathered would form a part of useful information for recycling PVC plastic waste in lightweight concrete mixes.     

Leaching and mechanical behaviour of concrete manufactured with recycled aggregates

The reuse of debris from building demolition is of increasing public interest because it decreases the volume of material to be disposed to landfill. This research is focused on the evaluation of the possibility of reusing recycled aggregate from construction or demolition waste (C&D) as a substitute for natural aggregate in concrete production. In most applications, cement based materials are used for building construction due to their cost effectiveness and performance; however their impact on the surrounding environment should be monitored. The interstitial pore fluid in contact with hydrated cementitious materials is characterized by persistent alkaline pH values buffered by the presence of hydrate calcium silicate, portlandite and alkaline ions. An experimental plan was carried out to investigate concrete structural properties in relation to alkali release in aqueous solution. Results indicate that the presence of recycled aggregate increases the leachability of unreactive ions (Na, K, Cl), while for calcium the substitution resulted in a lower net leaching. In spite of the lower mechanical resistance (40% less), such a waste concrete may be suggested as more environmentally sustainable.     

Multi-regime transport model for leaching behavior of heterogeneous porous materials

Utilization of secondary materials in civil engineering applications (e.g. as substitutes for natural aggregates or binder constituents) requires assessment of the physical and environment properties of the product. Environmental assessment often necessitates evaluation of the potential for constituent release through leaching. Currently most leaching models used to estimate long-term field performance assume that the species of concern is uniformly dispersed in a homogeneous porous material. However, waste materials are often comprised of distinct components such as coarse or fine aggregates in a cement concrete or waste encapsulated in a stabilized matrix. The specific objectives of the research presented here were to (1) develop a one-dimensional, multi-regime transport model (i.e. MRT model) to describe the release of species from heterogeneous porous materials and, (2) evaluate simple limit cases using the model for species when release is not dependent on pH. Two different idealized model systems were considered: (1) a porous material contaminated with the species of interest and containing inert aggregates and, (2) a porous material containing the contaminant of interest only in the aggregates. The effect of three factors on constituent release were examined: (1) volume fraction of material occupied by the aggregates compared to a homogeneous porous material, (2) aggregate size and, (3) differences in mass transfer rates between the binder and the aggregates. Simulation results confirmed that assuming homogeneous materials to evaluate the release of contaminants from porous waste materials may result in erroneous long-term field performance assessment.     

Pyrolysis of plastic packaging waste: A comparison of plastic residuals from material recovery facilities with simulated plastic waste

Pyrolysis may be an alternative for the reclamation of rejected streams of waste from sorting plants where packing and packaging plastic waste is separated and classified. These rejected streams consist of many different materials (e.g., polyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), aluminum, tetra-brik, and film) for which an attempt at complete separation is not technically possible or economically viable, and they are typically sent to landfills or incinerators. For this study, a simulated plastic mixture and a real waste sample from a sorting plant were pyrolyzed using a non-stirred semi-batch reactor. Red mud, a byproduct of the aluminum industry, was used as a catalyst. Despite the fact that the samples had a similar volume of material, there were noteworthy differences in the pyrolysis yields. The real waste sample resulted, after pyrolysis, in higher gas and solid yields and consequently produced less liquid. There were also significant differences noted in the compositions of the compared pyrolysis products.     

Depolymerization of Waste PET with Phosphoric Acid–Modified Silica Gel Under Microwave Irradiation

Chemical recycling of waste poly(ethylene terephthalate) (PET) using phosphoric acid–modified silica gel as a solid catalyst is reported. Advantageously, microwave irradiation was used to progress the depolymerization of PET. In this study, depolymerization of PET with a small amount of water is suggested as a suitable method. The depolymerized product, terephthalic acid was obtained and assigned by ¹H NMR and FT-IR spectroscopy. Finally, over 90 % conversion to terephthalic acid was achieved when waste plastic bottles were treated with the method. This results confirm the importance of the microwave power technique as a promising recycling method for plastic bottles made from PET, resulting in monomer recovery in addition to substantial energy saving.     

Use of mix of clay/solid waste from steel works for civil construction materials.

The present study focuses on the use of solid waste generated by the steel works in Brazil for manufacturing clay-based structural products. The waste sample was characterized regarding chemical composition, X-ray diffraction, particle size, morphology, specific surface and plastic properties. The waste was added in gradual proportions to a kaolinitic clay from zero up to 3 wt.%. Ceramic bodies were formed by vacuum extrusion and fired at 950 degrees C. The physical-mechanical properties (linear shrinkage, water absorption, apparent density and flexural strength) of the resulting clay/solid waste mixtures were determined. In addition, leaching tests were performed according Brazilian Standards as well as a preliminary analysis of gases evolved during the thermal process. It was found that the solid waste is formed by irregular particles, ranging in size from 1 to 500 microm. The test results indicate that solid wastes generated by steel works can be used as filler in construction materials, thereby increasing reuse in an environmentally safe manner.     

Synthetic aggregates from combustion ashes using an innovative rotary kiln

This paper describes the use of a number of different combustion ashes to manufacture synthetic aggregates using an innovative rotary 'Trefoil' kiln. Three types of combustion ash were used, namely: incinerated sewage sludge ash (ISSA); municipal solid waste incinerator bottom ash (MSWIBA-- referred to here as BA); and pulverised fuel ash (Pfa). The fine waste ash fractions listed above were combined with a binder to create a plastic mix that was capable of being formed into 'green pellets'. These pellets were then fired in a Trefoil kiln to sinter the ashes into hard fused aggregates that were then tested for use as a replacement for the natural coarse aggregate in concrete. Results up to 28 days showed that these synthetic aggregates were capable of producing concretes with compressive strengths ranging from 33 to 51 MPa, equivalent to between 73 and 112% of that of the control concrete made with natural aggregates.     

Recycled blocks with improved sound and fire insulation containing construction and demolition waste

The environmental problem posed by construction and demolition waste (C&D waste) is derived not only from the high volume produced, but also from its treatment and disposal. Treatment plants receive C&D waste which is then transformed into a recycled mixed aggregate. The byproduct is mainly used for low-value-added applications such as land escape restoration, despite the high quality of the aggregate. In the present work, the chemical composition properties and grading curve properties of these aggregates are defined. Furthermore, the resulting recycled concrete with a high proportion of recycled composition, from 20% to 100% replacement of fine and coarse aggregate, is characterized physically and mechanically. An environmental study of the new construction material when all aggregates are substituted by C&D waste shows a low toxicity level, similar to that of other construction materials. The new material also has improved properties with respect to standard concrete such as high fire resistance, good heat insulation, and acoustic insulation.     

Effects of Waste Paper Sludge on the Physico-Mechanical Properties of High Density Polyethylene/Wood Flour Composites

The objective of this work was to determine some physical and mechanical properties of the high density polyethylene (HDPE) composites reinforced with various mixtures of the paper sludge and the wood flour, and to evaluate the coupling agent performance. The waste sludge materials originating from two different sources including paper making waste water treatment sludge (PS) and ink-eliminated sludge (IES) were characterized in terms of physico-chemical properties. In the experiment, four levels of paper sludge (20, 30, 40 and 60 wt%), three levels of wood flour (20, 40 and 60 wt%), and two levels of coupling agent (MAPE) content (2 and 3 wt%) were used. The flexural properties of the composites were positively affected by the addition of the sludge. Especially, tensile modulus improved with the increase of paper sludge content. With the addition of MAPE, flexural properties improved considerably compared with control specimens (without any coupling agent). The results showed that the water absorption (WA) and thickness swelling (TS) values of the samples decreased considerably with increasing sludge content in the composite, while they increased with increasing wood flour content. It is to be noted that with incorporation of MAPE in the composite formulation, the compatibility between the wood flour and HDPE was enhanced through esterification, which reduced the WA and TS and improved the mechanical properties. Composites made with IES exhibited superior physico-mechanical properties compared with the PS filled composites. Overall results suggest that the waste paper sludge materials were capable of serving as feasible reinforcing fillers for thermoplastic polymer composites.     

Use of recycled fine aggregate in concretes with durable requirements

The use of construction waste materials as aggregates for concrete production is highly attractive compared to the use of non-renewable natural resources, promoting environmental protection and allowing the development of a new raw material. Several countries have recommendations for the use of recycled coarse aggregate in structural concrete, whereas the use of the fine fraction is limited because it may produce significant changes in some properties of concrete. However, during the last decade the use of recycled fine aggregates (RFA) has achieved a great international interest, mainly because of economic implications related to the shortage of natural sands suitable for the production of concrete, besides to allow an integral use of this type of waste. In this study, the durable behaviour of structural concretes made with different percentage of RFA (0%, 20%, and 30%) is evaluated. Different properties related to the durability of concretes such as absorption, sorptivity, water penetration under pressure, and carbonation are determined. In addition, the results of compressive strength, static modulus of elasticity and drying shrinkage are presented. The obtained results indicate that the recycled concretes have a suitable resistant and durable behaviour, according to the limits indicated by different international codes for structural concrete.     

Chemical depolymerisation of PET complex waste: hydrolysis vs. glycolysis

The huge increase in the generation of post-consumer plastic waste has produced a growing interest in eco-efficient strategies and technologies for their appropriate management and recycling. In response to this, PROQUIPOL Project is focused on developing, optimizing and adapting feedstock recycling technologies as an alternative for management for the treatment of complex plastic waste. Among the different plastic wastes studied, PROQUIPOL Project is working on providing a suitable treatment to the highly colored and complex multilayered post-consumer waste fractions of polyethylene terephthalate (PET) by chemical depolymerisation methods. Glycolysis and alkali hydrolysis processes have been studied with the aim of promoting the transformation of PET into the bis(2-hydroxyethyl) terephthalate monomer and terephthalic acid, respectively. In both cases operational conditions such as temperature, reaction time, catalyst to PET rate and solvent to PET rate have been considered to optimize product yield, achieving values near to 90 % and monomer purities over 95 % in both processes. This paper presents results obtained for each treatment as well as a simplified comparison of technical, economic and environmental issues.     

Flammability Properties of Virgin and Recycled Polycarbonate (PC) and Acrylonitrile–Butadiene–Styrene (ABS) Recovered from End-of-Life Electronics

Acrylonitrile–Butadiene–Styrene (ABS), Polycarbonate (PC) and their alloys are widely used in automotive industry, computer and equipment housings. With increasing disposal of end-of-life electronic equipment, there is also an increased demand for recycling of these materials so that they do not pose environmental challenge as solid waste. One of the recycling approaches is mechanical recycling of these thermoplastics where recycled plastic is melt blended with virgin materials to obtain a high quality product. Besides obtaining desirable mechanical properties, such blends should also conform to fire safety standards. In this work, a series of blends were prepared using PC and ABS recovered from discarded computers and virgin materials using a twin-screw extruder. Their flammability properties were evaluated using burner flammability tests and Ohio State University (OSU) release rate tests. It was found that the extinguishing time, burning extent and weight loss appears to progressively decrease with the addition of both virgin or recycled PC to virgin or recycled ABS. It was also seen that the addition of the 70% of PC, virgin or recycled, to ABS virgin or recycled, appears to significantly decrease heat release and smoke evolution. The results of this study indicate that recycled polycarbonate can be used as an additive for virgin or recycled ABS, as a means of giving flame resistance to ABS in high-value applications. This result is significant when related to the result obtained by a separate study indicating that up to 25% of recycled material can be used without degradation of mechanical properties in the presence of 15% short glass fiber reinforcement.