Reuse of waste iron as a partial replacement of sand in concrete

One of the major environmental issues in Iraq is the large quantity of waste iron resulting from the industrial sector which is deposited in domestic waste and in landfills. A series of 109 experiments and 586 tests were carried out in this study to examine the feasibility of reusing this waste iron in concrete. Overall, 130 kg of waste iron were reused to partially replace sand at 10%, 15%, and 20% in a total of 1703 kg concrete mixtures. The tests performed to evaluate waste-iron concrete quality included slump, fresh density, dry density, compressive strength, and flexural strength tests: 115 cubes of concrete were molded for the compressive strength and dry density tests, and 87 prisms were cast for the flexural strength tests. This work applied 3, 7, 14, and 28 days curing ages for the concrete mixes. The results confirm that reuse of solid waste material offers an approach to solving the pollution problems that arise from an accumulation of waste in a production site; in the meantime modified properties are added to the concrete. The results show that the concrete mixes made with waste iron had higher compressive strengths and flexural strengths than the plain concrete mixes.     

Reuse of thermosetting plastic waste for lightweight concrete

This paper presents the utilization of thermosetting plastic as an admixture in the mix proportion of lightweight concrete. Since this type of plastic cannot be melted in the recycling process, its waste is expected to be more valuable by using as an admixture for the production of non-structural lightweight concrete. Experimental tests for the variation of mix proportion were carried out to determine the suitable proportion to achieve the required properties of lightweight concrete, which are: low dry density and acceptable compressive strength. The mix design in this research is the proportion of plastic, sand, water-cement ratio, aluminum powder, and lignite fly ash. The experimental results show that the plastic not only leads to a low dry density concrete, but also a low strength. It was found that the ratio of cement, sand, fly ash, and plastic equal to 1.0:0.8:0.3:0.9 is an appropriate mix proportion. The results of compressive strength and dry density are 4.14N/mm(2) and 1395kg/m(3), respectively. This type of concrete meets most of the requirements for non-load-bearing lightweight concrete according to ASTM C129 Type II standard.     

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.     

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 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.     

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.     

Physical and mechanical properties of mortars containing PET and PC waste aggregates

Non-biodegradable plastic aggregates made of polycarbonate (PC) and polyethylene terephthalate (PET) waste are used as partial replacement of natural aggregates in mortar. Various volume fractions of sand 3%, 10%, 20% and 50% are replaced by the same volume of plastic. This paper investigates the physical and mechanical properties of the obtained composites. The main results of this study show the feasibility of the reuse of PC and PET waste aggregates materials as partial volume substitutes for natural aggregates in cementitious materials. Despite of some drawbacks like a decrease in compressive strength, the use of PC and PET waste aggregates presents various advantages. A reduction of the specific weight of the cementitious materials and a significant improvement of their post-peak flexural behaviour are observed. The calculated flexural toughness factors increase significantly with increasing volume fraction of PET and PC-aggregates. Thus, addition of PC and PET plastic aggregates in cementitious materials seems to give good energy absorbing materials which is very interesting for several civil engineering applications like structures subjected to dynamic or impact efforts. The present study has shown quite encouraging results and opened new way for the recycling of PC waste aggregate in cement and concrete composites.     

Recycling of waste glass as a partial replacement for fine aggregate in concrete

Waste glass creates serious environmental problems, mainly due to the inconsistency of waste glass streams. With increasing environmental pressure to reduce solid waste and to recycle as much as possible, the concrete industry has adopted a number of methods to achieve this goal. The properties of concretes containing waste glass as fine aggregate were investigated in this study. The strength properties and ASR expansion were analyzed in terms of waste glass content. An overall quantity of 80 kg of crushed waste glass was used as a partial replacement for sand at 10%, 15%, and 20% with 900 kg of concrete mixes. The results proved 80% pozzolanic strength activity given by waste glass after 28 days. The flexural strength and compressive strength of specimens with 20% waste glass content were 10.99% and 4.23%, respectively, higher than those of the control specimen at 28 days. The mortar bar tests demonstrated that the finely crushed waste glass helped reduce expansion by 66% as compared with the control mix.     

Use of steel fibres recovered from waste tyres as reinforcement in concrete: Pull-out behaviour,compressive and flexural strength

The increasing amount of waste tyres worldwide makes the disposition of tyres a relevant problem to be solved. In the last years over three million tons of waste tyres were generated in the EU states [ETRA, 2006. Tyre Technology International – Trends in Tyre Recycling. http://www.etra-eu.org]; most of them were disposed into landfills. Since the European Union Landfill Directive (EU Landfill, 1999) aims to significantly reduce the landfill disposal of waste tyres, the development of new markets for the tyres becomes fundamental.Recently some research has been devoted to the use of granulated rubber and steel fibres recovered from waste tyres in concrete. In particular, the concrete obtained by adding recycled steel fibres evidenced a satisfactory improvement of the fragile matrix, mostly in terms of toughness and post-cracking behaviour. As a consequence RSFRC (recycled steel fibres reinforced concrete) appears a promising candidate for both structural and non-structural applications.Within this context a research project was undertaken at the University of Salento (Italy) aiming to investigate the mechanical behaviour of concrete reinforced with RSF (recycled steel fibres) recovered from waste tyres by a mechanical process. In the present paper results obtained by the experimental work performed up to now are reported. In order to evaluate the concrete-fibres bond characteristics and to determine the critical fibre length, pull-out tests were initially carried out. Furthermore compressive strength of concrete was evaluated for different volume ratios of added RSF and flexural tests were performed to analyze the post-cracking behaviour of RSFRC. For comparison purposes, samples reinforced with industrial steel fibres (ISF) were also considered.Satisfactory results were obtained regarding the bond between recycled steel fibres and concrete; on the other hand compressive strength of concrete seems unaffected by the presence of fibres despite their irregular geometric properties. Finally, flexural tests furnished in some cases results comparable to those obtained when using ISF as concerns the post-cracking behaviour.     

Waste tyre rubberized concrete: Properties at fresh and hardened state

The main objective of this paper is to investigate the properties of various concrete mixtures at fresh and hardened state, obtained by a partial substitution of coarse and fine aggregate with different volume percentages of waste tyres rubber particles, having the same dimensions of the replaced aggregate. Workability, unit weight, compressive and flexural strength and post-cracking behaviour were evaluated and a comparison of the results for the different rubcrete mixtures were proposed in order to define the better mix proportions in terms of mechanical properties of the rubberized concrete. Results showed in this paper were also compared to data reported in literature. Moreover, a preliminary geometrical, physical and mechanical characterization on scrap tyre rubber shreds was made.The rubberized concrete mixtures showed lower unit weight compared to plain concrete and good workability. The results of compressive and flexural tests indicated a larger reduction of mechanical properties of rubcrete when replacing coarse aggregate rather than fine aggregate. On the other hand, the post-cracking behaviour of rubberized concrete was positively affected by the substitution of coarse aggregate with rubber shreds, showing a good energy absorption and ductility indexes in the range observed for fibrous concrete, as suggested by standard (ASTM C1018-97, 1997).     

Utilization of municipal solid waste bottom ash and recycled aggregate in concrete

In the combustion process of municipal solid waste (MSW), bottom ash (BA) represents the major portion of the solid residue. Since BA is composed of oxides, especially SiO(2) and CaO, the feasibility of its application in concrete as a substitute for cement was tested. It was found that at the age of 28 days, the flexural and compressive strengths of the binder linearly decrease at the rate of 0.03 and 0.02 MPa per wt% of BA in the binder, respectively. According to the results it may be recommended to replace up to 15 wt% of cement by BA and to use such binder where a low strength of concrete elements is required. Furthermore, the aggregate used for low strength concrete need not be of a very good quality. Therefore, gravel aggregate was partially replaced by recycled aggregate (RA). Consistency measured by slump was significantly reduced (>50%) when BA or/and RA were introduced into the mixture. However, concrete density and compressive strength were not affected and were approximately 2300 kg/m(3) and approximately 40 MPa, respectively.     

Effect of microsilica addition on compressive strength of rubberized concrete at elevated temperatures

An experimental investigation was carried out to study the effects of various percentages of fine/coarse tire waste and microsilica at various temperatures on the compressive strength of concrete. The compressive strength of concrete mixtures made with tire rubber was assessed statistically with those of concrete containing microsilica and conventional concretes in order to evaluate the usefulness of recycling rubber waste as a component of concrete. Results confirmed that the recipe and processing temperature of concrete cubes influence the compressive strength values. Generally, the use of microsilica or fine rubber mixed with microsilica as aggregate replacement of 5% by volume improved the compressive strength of concrete processed at a temperature of 150°C. The addition of coarse rubber did not achieve any increase in strength when used as an aggregate replacement at any percentage. Moreover, the reductions in the compressive strength of concrete mixes at higher temperatures were much smaller for the fine rubber with 5 vol% microsilica than those for control and coarse rubber mixes. The specimens made with fine rubber and 5 vol% microsilica at elevated temperatures above 400°C appeared to show very similar compressive strength values. The use of fine rubber in building construction could help save energy and reduce costs and solve the solid waste disposal problem posed by this type of waste.     

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.     

Reuse of municipal solid wastes incineration fly ashes in concrete mixtures

This study is aimed at assessing the feasibility of concrete production using stabilized m.s.w. (municipal solid waste) incineration fly ashes in addition to natural aggregates. The tested fly ashes were washed and milled, then stabilized by a cement-lime process and finally were reused as a "recycled aggregate" for cement mixture production, in substitution of a natural aggregate (with dosage of 200-400 kg m(-3)). These mixtures, after curing, were characterized with conventional physical-mechanical tests (compression, traction, flexure, modulus of elasticity, shrinkage). In samples containing 200 kg(waste) m(-3)(concrete), a good compressive strength was achieved after 28 days of curing. Furthermore, concrete leaching behavior was evaluated by means of different leaching tests, both on milled and on monolithic samples. Experimental results showed a remarkable reduction of metal leaching in comparison with raw waste. In some cases, similar behavior was observed in "natural" concrete (produced with natural aggregates) and in "waste containing" concrete.     

Use of recycled plastic in concrete: a review

Numerous waste materials are generated from manufacturing processes, service industries and municipal solid wastes. The increasing awareness about the environment has tremendously contributed to the concerns related with disposal of the generated wastes. Solid waste management is one of the major environmental concerns in the world. With the scarcity of space for landfilling and due to its ever increasing cost, waste utilization has become an attractive alternative to disposal. Research is being carried out on the utilization of waste products in concrete. Such waste products include discarded tires, plastic, glass, steel, burnt foundry sand, and coal combustion by-products (CCBs). Each of these waste products has provided a specific effect on the properties of fresh and hardened concrete. The use of waste products in concrete not only makes it economical, but also helps in reducing disposal problems. Reuse of bulky wastes is considered the best environmental alternative for solving the problem of disposal. One such waste is plastic, which could be used in various applications. However, efforts have also been made to explore its use in concrete/asphalt concrete. The development of new construction materials using recycled plastics is important to both the construction and the plastic recycling industries. This paper presents a detailed review about waste and recycled plastics, waste management options, and research published on the effect of recycled plastic on the fresh and hardened properties of concrete. The effect of recycled and waste plastic on bulk density, air content, workability, compressive strength, splitting tensile strength, modulus of elasticity, impact resistance, permeability, and abrasion resistance is discussed in this paper.     

Possibility of using waste tire rubber and fly ash with Portland cement as construction materials

The growing amount of waste rubber produced from used tires has resulted in an environmental problem. Recycling waste tires has been widely studied for the last 20 years in applications such as asphalt pavement, waterproofing systems and membrane liners. The aim of this study is to evaluate the feasibility of utilizing fly ash and rubber waste with Portland cement as a composite material for masonry applications. Class C fly ash and waste automobile tires in three different sizes were used with Portland cement. Compressive and flexural strength, dry unit weight and water absorption tests were performed on the composite specimens containing waste tire rubber. The compressive strength decreased by increasing the rubber content while increased by increasing the fly ash content for all curing periods. This trend is slightly influenced by particle size. For flexural strength, the specimens with waste tire rubber showed higher values than the control mix probably due to the effect of rubber fibers. The dry unit weight of all specimens decreased with increasing rubber content, which can be explained by the low specific gravity of rubber particles. Water absorption decreased slightly with the increase in rubber particles size. These composite materials containing 10% Portland cement, 70% and 60% fly ash and 20% and 30% tire rubber particles have sufficient strength for masonry applications.     

Properties of concrete blocks prepared with low grade recycled aggregates

Low grade recycled aggregates obtained from a construction waste sorting facility were tested to assess the feasibility of using these in the production of concrete blocks. The characteristics of the sorted construction waste are significantly different from that of crushed concrete rubbles that are mostly derived from demolition waste streams. This is due to the presence of higher percentages of non-concrete components (e.g. >10% soil, brick, tiles etc.) in the sorted construction waste.In the study reported in this paper, three series of concrete block mixtures were prepared by using the low grade recycled aggregates to replace (i) natural coarse granite (10 mm), and (ii) 0, 25, 50, 75 and 100% replacement levels of crushed stone fine (crushed natural granite <5 mm) in the concrete blocks. Test results on properties such as density, compressive strength, transverse strength and drying shrinkage as well as strength reduction after exposure to 800 °C are presented below. The results show that the soil content in the recycled fine aggregate was an important factor in affecting the properties of the blocks produced and the mechanical strength deceased with increasing low grade recycled fine aggregate content. But the higher soil content in the recycled aggregates reduced the reduction of compressive strength of the blocks after exposure to high temperature due probably to the formation of a new crystalline phase. The results show that the low grade recycled aggregates obtained from the construction waste sorting facility has potential to be used as aggregates for making non-structural pre-cast concrete blocks.     

Mechanical properties of concrete containing a high volume of tire-rubber particles

Due to the increasingly serious environmental problems presented by waste tires, the feasibility of using elastic and flexible tire-rubber particles as aggregate in concrete is investigated in this study. Tire-rubber particles composed of tire chips, crumb rubber, and a combination of tire chips and crumb rubber, were used to replace mineral aggregates in concrete. These particles were used to replace 12.5%, 25%, 37.5%, and 50% of the total mineral aggregate's volume in concrete. Cylindrical shape concrete specimens 15 cm in diameter and 30 cm in height were fabricated and cured. The fresh rubberized concrete exhibited lower unit weight and acceptable workability compared to plain concrete. The results of a uniaxial compressive strain control test conducted on hardened concrete specimens indicate large reductions in the strength and tangential modulus of elasticity. A significant decrease in the brittle behavior of concrete with increasing rubber content is also demonstrated using nonlinearity indices. The maximum toughness index, indicating the post failure strength of concrete, occurs in concretes with 25% rubber content. Unlike plain concrete, the failure state in rubberized concrete occurs gently and uniformly, and does not cause any separation in the specimen. Crack width and its propagation velocity in rubberized concrete are lower than those of plain concrete. Ultrasonic analysis reveals large reductions in the ultrasonic modulus and high sound absorption for tire-rubber concrete.     

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.     

Utilization (recycling) of iron and steel industry by-product (GGBS) in concrete: strength and durability properties

Due to exponential growing in urbanization and industrialization, byproducts from industries are becoming an increasing concern for recycling and waste management. Ground granulated blast furnace slag (GGBS) is by-product from the blast-furnaces of iron and steel industries. GGBS is very useful in the design and development of high-quality cement paste/mortar and concrete. This paper covers the properties of GGBS, reaction mechanism, and its effect on strength and durability properties of concrete. Properties covered are sorptivity, microstructure, compressive strength, splitting tensile strength, flexural strength, permeability, sulfate resistance, freezing and thawing resistance, corrosion of concrete.