Sustainable Construction Products 1 Developing Precast Concrete Products

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) 5 th March 2003

Sustainable Construction Products 2. North West Construction Knowledge Hub Construction Sustainability Centre: (a) Recycled demolition aggregates in precast building and paving blocks and concrete flags, (b) Reactive glass powder concrete flags of superior strength, (c) Cementless “geopolymer” concrete products.

Sustainable Construction Products versus Sustainable Construction Products Sustainable Built Environment 3. The Building as Total System Technology Strategy Board Low Impact Buildings: Design and Decision Tool

Sustainable Construction Products Concrete Building Blocks, Paving Blocks & Paving Flags made with Recycled Demolition Aggregate.

Sustainable Construction Products Recycling for Profit. Waste Management & the New Environmental Economics. Priority Waste Stream Programme 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 10 m deep and roughly 13 square km in surface area every year.

Sustainable Construction Products Construction and Demolition Waste (C&DW). • C&DW accounts for 17% of the estimated annual waste in the UK. • 220 million tonnes of new construction aggregate are extracted annually.

Sustainable Construction Products Potential uses for C&DW derived (recycled demolition) aggregate. 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.

Sustainable Construction Products Collaborators: Funding Bodies: • The Veolia Environmental Trust • The Flintshire Community Trust • A. D. Waste Ltd Aggregate Suppliers: • Lafarge Aggregates Ltd. • Hanson Aggregates Ltd. • Aggregate Industries. Invesigators: • The University of Liverpool. Material Suppliers: • Appleby Group Ltd. • United Kingdom Quality Ash Precast Concrete Manufacturers: • Marshalls Ltd. • FORTICRETE Ltd. • Charcon Ltd. • Cemex Readymix Ltd. • RPC Ltd. Demolition Contractors: • W. F. Doyle & Co. Ltd. • DSM Demolition Ltd. Association (UKQAA). Other: • Clean Merseyside Centre. • Liverpool Housing Action Trust. • Liverpool City Council. • Cheshire County Council • Morris Brothers Ltd.

Sustainable Construction Products Concrete Building Blocks, Paving Blocks & Paving Flags • 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.

Sustainable Construction Products Aggregate Quarry in Merseyside? Now you do not see it…… …. but soon you will!

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

Sustainable Construction Products Make waste a resource!

Sustainable Construction Products Flows of crushed rock between regions.

Experimental Work & Development Sustainable Construction Products Building Blocks - “Black Art” or Science? Vibro-Compressor Machine - Factory - Electric Hammer Drill - Laboratory -

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

Sustainable Construction Products Compressive Strength Versus Replacement Level (%) with masonry derived aggregates.

Sustainable Construction Products Factory Trials

FACTORY TRIALS Sustainable Construction Products Concrete blocks with masonry-derived aggregate.

Sustainable Construction Products Compressive Strengths of: Laboratory cast and factory cast blocks.

Sustainable Construction Products Modifications needed for casting: Concrete Paving Blocks Electric hammer on sliding rods Clamped-on vibrator together with an electric hammer

Sustainable Construction Products Concrete Pavement Flags The manufacturing process:

Sustainable Construction Products Casting of Concrete Flags using the laboratory “mini-press”

Reactive Glass Powder Concrete Paving Flags. Sustainable Construction Products Ultra High Performance Fibre Reinforced Concrete • The claims culture in the UK costs local authorities £ 500 m 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.

Sustainable Construction Products Reactive Glass Powder Concrete Flags or: “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.

Sustainable Construction Products Geopolymer “Cementless” Concrete 100% recycled content! 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.

Sustainable Construction Products Cement Manufacture – what’s wrong with it? Every tonne of cement produces a tonne of CO 2 !!!

Sustainable Construction Products 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!

Sustainable Construction Products Embodied CO 2 of UK cement, additions and cementitious material:

Sustainable Construction Products 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.

Low Impact Buildings: Design and Decision Tools Sustainable Construction Products Eawag Forum Chriesbach, Switzerland

Sustainable Construction Products versus Sustainable Construction Products Sustainable Built Environment The Building as Total System

Sustainable Construction Products Sustainable Built Environment ? • Waste Management & the New Environmental Economics. Sustainable only if PROFITABLE !!! – Cementing Concrete Solutions -

Sustainable Construction Products And finally. . . Thank you for your attention. Are there any questions?