DEMONSTRATION OF TECHNIQUES AND PRODUCTS
DEVELOPED IN IRCOW PROJECT WITHIN THE EXTETION
OF A PENITENTIARY CENTER IN TERUEL (SPAIN)
Rocío Barros García
rocio.barros.garcia.ext@acciona.com
DESCRIPTION OF CASE STUDY:
DEMOLITION & NEW BUILDING
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•
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IRCOW Project: Innovative technologies and eco design recommendations for reuse and
recycling of C&D waste, with special focus on technologies for onsite solution)
ACCIONA Infraestructuras has been in charge of the Case Study “Demonstration of
techniques and products developed in IRCOW project within the extension of a penitentiary
center in Teruel (Spain)”.
The Penitentiary Center Project has been selected as the most suitable case study for IRCOW
purpose. This construction site included the demolition of old buildings and the construction
of new modules. This construction site allowed the validation of advanced recycling
technologies together with the demonstration of products and components developed in the
IRCOW project.
DESCRIPTION OF CASE STUDY:
DEMOLITION & NEW BUILDING
The case study is located in Teruel (Aragón)
The exiting building was built in 1951 and is located in the west part of Teruel and close to
the downtown. The area where the extension of the Penitentiary Center has been carried
out was the same as the current prison area. The objective of the project was the
expansion of the nominal capacity of the current center.
The work is executed in phases ensuring that the prison is in operation with the current
capacity during the course of the construction site. The design is absolutely conditioned by
the building process (construction, demolition, construction).
The first phase of demolition started in 2011 (before CS-4 started; blue),
The second phase consisted of wall demolition and their foundations (green).
The final phase started in 2013 and it consisted of building demolition (red).
DESCRIPTION OF CASE STUDY:
DEMOLITION & NEW BUILDING
• The work plan included:
C&DW MANAGEMENT
CASE STUDY C&DW MANAGEMENT OVERVIEW
ACCIONA Infraestructuras is a large construction company whose image is largely based on their
Innovation potential. Being pioneers in developing and applying new technologies is for ACCIONA
a marketing strategy for staying ahead of competition in the construction market.
ACCIONA already recycles part of the demolition waste generated within their demolition and
construction project as low-grade material for filling applications (e.g. in embankments), but
wants to increase their actual recycling rates as well as move from low-grade applications to
high-grade applications.
The recycling targets, which are a general objective for the company, have been validated in the
case study. Main Targets They have connection with ACCIONA current business model and
European targets according Horizon 2020’s goal (70% waste recycling), in line with Art 11 of
Directive 2008/98/EC and Roadmap to a Resource Efficient Europe.
C&DW Management Plan was modified in order to increase the percentage of waste recycling.
The viability of the applied solutions in new building construction, which is a general objective for
the company, was verified by a techno-economic analysis (DAPP).
C&DW MANAGEMENT
DEMOLITION OF OLD LARGE BUILDING
• Selective demolition:
Waste separation, before and during demolition, in order to prevent material mixing
and contamination of recyclable material.
Fractions:
- Metal
- Wood
- Plastic
- Gypsum
- Paper and cardboard
According to
Spanish Standard:
RD 105/2008
Article 5.5
C&DW MANAGEMENT
DEMOLITION OF OLD LARGE BUILDING
• Intensive demolition: in part of the building to obtain mixed C&DW material
(concrete, ceramic,…)
RECYCLING TECHNIQUES
RECYCLING TECHNIQUES FOR C&DW STONY FRACTION
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Mixed fraction from building intensive demolition
Stony fraction waste resulting from the demolition of the old building was treated on site
(crushed and sieved - particle size 0/60). Recycled mix aggregates were used for rehabilitation
and maintenance of the plot.
A total of 7,619.50 tons were recovered from demolition activities.
On- site
treatment
of stony
fraction:
Recycled
aggregates
for low grade
application
RECYCLING TECHNIQUES
RECYCLING TECHNIQUES FOR C&DW STONY FRACTION
•
Mixed fraction from building intensive demolition
Approximately 25 tons of the
resulting C&DW was separated offsite using the advanced sorting
systems (NIR-Sorting Tech) in order
to validate the sorting technology
and algorithms developed and to
assess the costs of this process.
This task was performed in close
collaboration with TOMRA and a
Spanish C&DW recycling plant
where NIR technology was
implemented (BTB, Bilbao, 480 km
of distance from Teruel).
Pre-treatment before testing
Traditional treatment on BTB plant: washing, removing light materials by air classification and electromagnetic metal separator
NIR-Sorting test
Sorting of problem fractions: gypsum, non-inert material (wood, plastic and metal)
RECYCLING TECHNIQUES
RECYCLING TECHNIQUES FOR C&DW STONY FRACTION
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Concrete fraction from a wall foundation
The recycled concrete aggregates were
obtained from the demolition of a wall
foundation located in the Penitentiary
Centre. This demolition was executed
during the Phase 1 as a preliminary work.
The construction and demolition waste
material from the wall foundation was
100% concrete waste.
The recycled concrete aggregate was
processed (crushed and sieved - traditional
treatment) off-site with the collaboration
of the Concrete manufacturer EMIPESA.
RECYCLING TECHNIQUES
RECYCLING TECHNIQUES FOR C&DW STONY FRACTION
The stony fraction composition and quantities are listed in the table below.
RECYCLING TECHNIQUES
RECYCLING TECHNIQUES FOR C&DW STONY FRACTION
• Recycling technologies for C&DW organic fraction:
A possible list of materials derived from the Case Study was selected for Wood Plastic
Composites (WPC) decking board manufacturing:
- Wood (EU Waste Code: 17 02 01)
- Polymers (EU Waste Code: 17 02 03),
- Mineral Wool (EU Waste Code: 17 06 04)
- Gypsum (EU Waste Code: 17 08 02)
Following the quality criteria (recovered material 100% free of nails, screws and hard metals)
established by CONENOR, mineral wool that was rejected due to quality reasons, was the only
material finally used for the WPC decking manufactured by CONENOR.
DEMONSTRATION EFFICIENCY OF PRODUCTS
CONCRETE: NEW FORMULATIONS
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Recycled concrete for structural applications
Recycled concrete aggregates (C100/0CRA) from previous
demolition of a wall foundation (100% concrete) waste were
used to manufacture structural concrete.
The optimal dosages defined during IRCOW activities were
studied and adapted for the case study in order to achieve
the construction site specifications. Different formulations
were optimized and thereafter applied for two applications:
slab foundation with 20% of replacement of coarse
aggregates (Slab-20%) and slab foundation with 50% of
replacement of coarse aggregates (Slab-50%).
The following figures show compressive strength results:
DEMONSTRATION EFFICIENCY OF PRODUCTS
CONCRETE: NEW FORMULATIONS
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Recycled concrete for Structural applications
Slab-20%
(20% substitution of coarse fraction)
Slab-50%
(50% substitution of coarse fraction)
DEMONSTRATION EFFICIENCY OF PRODUCTS
CONCRETE: NEW FORMULATIONS
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Recycled concrete for Non-structural applications
Coarse mixed recycled aggregates (C80/20CRA: Coarse recycled aggregates (80% coarse recycled concrete +
20% coarse recycled ceramics) obtained from the demolition of the building and previously treated off-site and
sieved, were used to manufacture concrete for non-structural application.
The optimal dosage was defined following the results on IRCOW project and it was executed on the
construction site for lean concrete with 100% of replacement of the coarse fraction (non-structural
application).
The compressive strength at 7 and 28 days was respectively 16.2±0.8 (N/mm2) and 21.4±0.9 (N/mm2).
DEMONSTRATION EFFICIENCY OF PRODUCTS
CONCRETE: MULTILAYER PANEL FOR BUILDING ENVELOPE
Acciona manufactured and installed acoustic insulation boards elaborated with recycled gypsum
and multilayer component for building envelope elaborated with recycled aggregates and
recycled plastic.
The element is composed of:
o Multilayer component:
• External thermal insulation layer made of cement mortar with EPS
• Internal structural layer made of concrete with 100% recycled coarse aggregates
o Recycled gypsum acoustic boards indoor assembled.
• The innovative components were implemented in a real building. A storage module was
selected like the most suitable alternative to develop demonstration activities.
DEMONSTRATION EFFICIENCY OF PRODUCTS
CONCRETE: MULTILAYER PANEL FOR BUILDING
ENVELOPE
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Multilayer component
Coarse recycled concrete aggregates (6-12 mm)
The new formulations developed in IRCOW project, together with the
eco-design requirements, were used to develop, at industrial scale, a
multilayer element for building envelope.
The element is composed of:
• Internal structural layer made of concrete with 100% recycled
Fine recycled ceramic and concrete aggregates (0-4 mm)
coarse aggregates
• External thermal insulation layer made of cement mortar with EPS
Fines of ceramic fraction (0-12mm)
Flakes of recycled expanded polystyrene (EPS)
DEMONSTRATION EFFICIENCY OF PRODUCTS
CONCRETE: MULTILAYER PANEL FOR BUILDING ENVELOPE
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Acoustic insulation boards
ACCIONA, together with TECNALIA, manufactured and installed acoustic
insulation boards elaborated with recycled gypsum.
DEMONSTRATION EFFICIENCY OF PRODUCTS
MULTILAYER COMPOSITE DECKING BOARD
WPCs using recycled plastic (not from C&DW) and different mixtures of filler from C&DW, such
as mixture of gypsum plaster board, mineral wool insulation and mixed wooded materials by
using a new multilayer extrusion technology.
The raw materials are used in the following indicative composition (which may be tailored case
by case according to the actual type and origin of the waste):
• Fibers and inorganic fillers 60% (wood, gypsum, wool);
• Recycled plastic 35% (e.g. from rigid consumer packaging and films);
• Additives 5%.
DEMONSTRATION EFFICIENCY OF PRODUCTS
PRODUCTS INSTALLATION
• Multilayer Panel
DEMONSTRATION EFFICIENCY OF PRODUCTS
PRODUCTS INSTALLATION
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Wood plastic composite decking board
CONCLUSIONS
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Difficulties during the case study:
o Demolition (change of the initial selected project and definition of a new project,
selection of recycling plants: low availability in the site neighbourhood, etc)
o Construction of new buildings (selection of adequate recycled products and
adequacy to the project, shipment cost, manufacturing difficulties and delays,
construction and installation difficulties, etc).
o These difficulties were solved without delay in the project and introducing minor
modifications.
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Benefits: lower cost of concrete elements, energy and raw materials savings and
thermal insulation properties that eliminates energy losses
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Other advantages include environmental benefits from minimal waste, better quality
control for recycled products, and an efficient use of material.
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Demonstration of viability for recycling techniques and recycled products
BUSINESS MODEL
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ACCIONA Infrastructure intends to foster its image of innovative enterprise delivering
cutting-edge and environmentally-friendly solutions through the introduction of novel
practices aimed at the recycling of C&D waste in high-grade applications.
Within the IRCOW project, ACCIONA Infrastructure has successfully demonstrated that
the recycling of C&D waste into high-grade applications is feasible not only from a
technical point of view but as well from an industrial and organizational point of view.
BUSINESS MODEL
Deployment of A NEW INTEGRATED SERVICE aimed at the recycling of C&D waste into
high-grade applications:
• ACCIONA Infraestructuras is able to offer structural as well as non-structural recycled
concrete applications through the definition of new concrete mixes.
• ACCIONA Infraestructuras is able to coordinate the whole supply chain that is
necessary for the purpose, which encompasses demolition companies, concrete ready
mix manufacturers and C&DW treatment plants as well as treatment aimed at
recycling.
C&DW
TREATMENT
PLANTS
CONCRETE
READY MIX
MANUFACTURERS
DEMOLITION
COMPANIES
THANK YOU FOR YOUR ATTENTION
Rocío Barros rocio.barros.garcia.ext@acciona.com
Blanca Juez blanca.juez.sanchez@acciona.com
ACCIONA INFRAESTRUCTURAS
R&D Technological Center. Biotechnology and Environmental Group.
Material Area