Mejora Ambiental en El Uso de Agregados Reciclados de Fraccion Fina Como Materia Prima en La Fabricacion de Mortero de Mamposteria
Mejora Ambiental en El Uso de Agregados Reciclados de Fraccion Fina Como Materia Prima en La Fabricacion de Mortero de Mamposteria
Mejora Ambiental en El Uso de Agregados Reciclados de Fraccion Fina Como Materia Prima en La Fabricacion de Mortero de Mamposteria
ae
The Open Construction and Building Technology Journal, 2017, 11, (Suppl-2, M6) 371-380 371
DOI: 10.2174/1874836801711010371
RESEARCH ARTICLE
Environmental Improvement in Use of Fine Fraction Recycled
Aggregates as a Raw Material in Masonry Mortar Fabrication
Mariano González Cortina1,*, Pablo Saiz Martínez1 and Francisco Fernández Martínez2
1
Architectural Construction and Control Department, Higher Technical School of Building Construction, Universidad
Politecnica de Madrid, España
2
Chemistry and Polymers Department, University school of Technical Industrial Engineering, Technical Universidad
Politecnica de Madrid, España
Received: June 05, 2017 Revised: July 2, 2017 Accepted: July 3, 2017
Abstract:
Background:
Great use of raw material and natural resources as well as generation of huge amount of waste make the construction and building
sector one of the less sustainable human activities.
Objective:
The main aim of this research is to study both technical feasibility and environmental sustainability of fine fraction recycled
aggregates (RA) use in masonry mortar fabrication. Method. The tests were developed using the binder CEM IV/B (V) 32.5 N and
two types of RA: ceramic RA and concrete RA. The substitution percentages were 50%, 75% and 100% and cement-to-aggregate by
dry weight proportions were 1:3 and 1:4.
Results:
Performed tests show that cement-based mortars fabricated with CEM IV/B (V) 32. 5 N can incorporate concrete and ceramic
recycled aggregates, using both cement-to-aggregate proportions, complying with the limits established by the Spanish standards. On
the other hand, carbon footprint calculation of one of the RA used in the research and a comparative study with natural aggregate
(NA) carbon footprint were carried out to analyze environmental sustainability of fine fraction RA. Conclusion. The results show that
the amount of kgCo2eq released into the atmosphere as a result of RA fabrication is significantly lower compared with the emissions
from NA fabrication, and therefore the use of this type of waste reduces greenhouse gas emissions.
Keywords: Waste treatment, Fine recycled aggregate, Recycled mortar characterization, Carbon footprint.
1. INTRODUCTION
Construction and Demolition Waste (CDW) raises an environmental problem due to the lack of prevention in its
production process and the little use of recycled material. According to the European Commission DG ENV [1], 461
millions of tons of CDW is produced in Europe per year. The percentages of recycling and reuse of CDW is very
different for different countries of Europe. For example in Spain only 14% of CDW is being recycled and reused, this
rate is too low as compared to the average recycling rate in Europe which is about 50% [2]. In order to improve this
situation, in the year 2008 the new legislation on the CDW [3] come into force, fostering the recovery of waste at its
end-of-life and incorporating a study on CDW management during the planning process and a plan on CDW
management during the construction phase.
*
Address correspondence to this author at Higher Technical School of Building Construction, Madrid Polytechnic University, Juan de Herrera 6,
28040 Madrid, Spain, Tel: +34913367596; E-mail: [email protected]
Regarding the use if the CDW, presently in Spain it is used mainly as packing for highways stretches and, to a lesser
extent, in concrete fabrication. Derived from the researches carried out in Spain [4], the current Structural Concrete
Code [5] includes a part related to the recycled aggregates which recommend to substitute 20% of natural aggregates
with this type of material.
In spite of the current legislation, Spanish market continues not to include definitively the use of recycled
aggregates into the construction process. The reason is on one side the low cost of natural aggregates because of the
deep crisis of Spanish construction sector, and on the other hand, the lower quality of RA compared to natural
aggregates.
A recent research carried out in Spain classifies recycled aggregates according to the compounds they are formed of:
concrete RA, mixed RA and ceramic RA, depending on the material that predominates in each fraction [6].
Physical, chemical and mechanical characteristics of RA are determined mainly by pollutant and impurity content
and adhered mortar content [7], [8], in fact, adhered mortar content of RA is the main difference regarding the natural
aggregates. As it was demonstrated by diverse researches that, adhered mortar leads to the lower density and higher
absorption of recycled aggregates, which is the determinant characteristic that decreases the mechanical behaviour of
mortars fabricated with RA [7], [9], [10]. Moreover, this characteristic of RA is more pronounced in smaller fractions
presenting poorer behaviour compared to coarse fraction aggregates [8]. Other factor that impacts directly the quality of
RA is the process of fabrication. The main properties of RA vary according to a fabrication process carried out by a
treatment plants [7], [11], [12] and of course they depend on the source material [13].
Various scientific researches have studied the feasibility of incorporating fine fraction of RA in masonry mortars
production. According to the consulted bibliography, the optimal substitution percentage varies significantly from one
author to another, mainly due to great variability of these materials. For example, Seung-Tae Lee [14] studied the
influence of RA emerging from demolition of concrete structures, using mortar sample in the presence of magnesium
sulphate. The substitution of NA with RA is carried out using the following percentages: 0%, 25%, 50% and 100%,
being the mortar samples with magnesium sulphate exposed to ambient temperature during one year. The obtained
results show that substituting up to 50% of natural aggregates, the mortars withstand harsh environment in the presence
of magnesium sulphate, and water absorption increases using higher substitution percentages.
Silva, J et al. [15] studied the feasibility of incorporation of ceramic RA in masonry mortar fabrication process. The
obtained results proved that at least 20% of this type of material can be used in masonry mortar fabrication.
Braga, M. et al. [16] studied the behaviour of recycled mortars after incorporating very fine fraction concrete
recycled aggregates. Substituting 15% of natural aggregates, improvement of compressive and bond strength could be
observed. Other properties however showed poor performance in recycled mortars (water vapour permeability,
elasticity modulus, water absorption by capillarity). Thus, the use of 15% of RA improves some properties of mortars
compared to conventional mortars.
Fernandez et al. [17] evaluated the possibility to incorporate fine fraction of RA in masonry mortars using CEM
II/BL 32.5 N. The obtained results show that the replacement ratio of 50% can be achieved in mortar for indoor use.
The main aim of this work is the evaluation of recycled mortars properties both in fresh and hardened state using
different replacement percentages of natural sand with three types of RA coming from collaborating recycling plant.
Furthermore, this research includes an environmental study of recycled aggregated fabrication, and a comparison with
the fabrication of natural aggregates. The results of this study present a contribution regarding the published works, and
could help to increase CDW recycling rates.
2.1. Materials
In this research, such basic materials usually used for cement mortars fabrication as cement, aggregate and water
were used. Moreover, it was necessary to use the additive Glenium SKY 604 to obtain a proper consistency of recycled
mortars, due to the high water demand of recycled aggregate compared with natural sand.
The binder used in the study was CEM IV/B (V) 32.5 N, suitable for mortar production and for masonry in general.
The properties of this cement are specified by Spanish and European standard UNE-EN 197-1. The main characteristics
are shown in (Table 1).
Environmental Improvement in Use of Fine Fraction The Open Construction and Building Technology Journal, 2017, Volume 11 373
Physical characteristics
Density (g/cm3) 2.85
Blaine specific area (cm2/g) 4400
Initial set (min) 230
Final set (min) 285
Chemical characteristics
Elements Result (%)
Al2O3 13.40
CaO 35.55
Fe2O3 3.50
K2O 1.80
MgO 2.60
SiO2 31.90
TiO2 0.60
MnO 0.05
P2O5 0.33
NaO2 0.02
Loss on ignition 8.65
Aggregates used for reference mortars fabrication were provided by the Cemex Company. Integrated CDW
Treatment Plant of Madrid Region “El Molar” provided the research with recycled aggregates. Two different samples of
RA were employed: fine recycled aggregates RA-1 and RA-2 originating from the ceramic recycling process and
concrete recycling process, respectively.
Recycled mortars were prepared using the superplasticizer additive Glenium Sky 604 by BASF Company. This is a
high-activity water reducing/superplasticising additive based on polycarboxylates.
Glenium SKY 604 was prescribed by BASF Company technical department to improve consistency of recycled
mortars.
Dosage
Type Dosage 1:3 c/a Dosage 1:4 c/a
50% 75% 100% 50% 75% 100%
RA-1 0.58 0.66 0.70 0.75 0.86 0.90
RA-2 0.58 0.66 0.70 0.75 0.86 0.90
NA - - 0.55 - - 0.62
Note: 1% of additive over the weight of cement
Compressive and flexural strength were analyzed using prismatic specimens of 40x40x160 mm, being cast and
cured in a humid chamber at 20ºC. Flexural and compressive strength were determined following the technical
prescription of the UNE-EN-1015-11 standard.
In the second part, the possibility of RA incorporation in masonry mortar fabrication was studied. To this end, one
type of binder was used: CEM IV/B (V) 32.5 N. There were suggested three substitution percentages to replace natural
sand with two types of recycled aggregates: 50%, 75% and 100%, and cement-to-aggregate by dry weight proportions
374 The Open Construction and Building Technology Journal, 2017, Volume 11 Cortina et al.
were 1:3 and 1:4. Recycled aggregates obtained from treatment plants were sieved in the laboratory, eliminating
material retained on the 4 mm sieve and material passed through 0.063 mm sieve, because of poorer characteristics of
aggregates of this fraction.
The following code was employed for the mixes identification:
RA-Nº-X
Where RA= Recycled aggregates,
Nº = Recycled aggregate type (1 = ceramic recycled aggregate and 2= concrete recycled aggregate),
X%= Recycled aggregates substitution percentage.
In the third part, ceramic recycled aggregate carbon footprint was measured keeping in view the environmental
feasibility of this material. This study was based on the standard UNE-EN 15804 collaborating with the company
responsible for the CDW management and for RA fabrication which is called TECNOLOGIA Y RECICLADO S.L.
(TECHNOLOGY AND RECYCLING L.S.)
As it can be observed from the results presented in Table (3), the main difference of recycled aggregates compared
with natural sand is their high absorption and lower density. As the result of this high absorption, recycled mortars need
significantly bigger quantity of water for mixes elaboration, what negatively affects their mechanical properties.
Recent researches carried out in Spain [6] conclude that there are no pure RA, considering concrete RA as an
aggregate that contains at least 90% of this material. In case of ceramic RA, there is an established minimum percentage
of 60%. For this reason, the rest of the physical characteristics, with the exception of absorption, show similar results
for both types of studied recycled aggregates.
Fig. (1) shows particle size distribution curve analysis of different types of aggregates used in the research
according to the requirements established by the UNE-EN-933-2 and the UNE-EN-933-1. As it can be observed in Fig.
(1), RA present continuous size distribution curve which is an important characteristic for the elaboration of masonry
mortars as it facilitates a good consistency of this material [7].
Below, in Table (4) the results obtained in the X-ray diffraction test are shown.
Table 4. X-Ray Diffraction.
X-ray diffraction pattern was measured using the Cu-Ka radiation (l ¼ 1.540598 Å) with a Siemens D500
diffractometer equipped with a graphite monochromator. Data were collected at 300 K over an angular range of 10º <
2θ < 110º by scanning in steps of 0.05º and counting times of 10 s. 40 kV voltage and 20 mA current were used.
As it can be observed in the Table (3), the principle and more crystalline founded phases are quartz and calcite.
Other obtained phases, such as gypsum, phlogopite and sanidine do not show high crystalline behaviour and show low
intensities in the carried out tests.
100
90
80
70
% passing
60 NA
50
40 RA-1
30
20 RA-2
10
0
4 2 1 0.5 0.25 0.125 0.063
Sieve size (mm)
3.2.1. Phase 1
Table (5) shows the results obtained in the tests of flexural and compressive strength.
Table 5. Flexural and compressive strength test.
Dosage
Recycled mortar
1:3 1:4
RA Type Test(MPa) 50% 75% 100% 50% 75% 100%
Flexural 5.13 4.77 4.02 3.47 3.24 3.02
RA 1
Compressive 17.62 15.44 14.70 12.51 10.11 9.23
Flexural 5.44 5.12 4.78 3.78 3.21 3.27
RA 2
Compressive 20.34 17.86 15.23 12.67 11.91 10.42
Flexural - - 5.74 - - 4.12
NA
Compressive - - 23.11 - - 17.52
In all the studied dosages it can be observed that compressive and flexural strength lowers with the increase of RA
incorporation rate, observing the most significant decrease in the mixes with 100% of RA and 1:4 cement-to-aggregate
proportion, as expected. In all the studied mixes, the obtained compressive strength values comply with the limits
required for the class M 7,5 MPa established by the standard UNE-EN 998-1. As a result, these recycled mortars
elaborated with 100% of RA are valided to be used as masonry mortars after analyzing this property. Regarding the
376 The Open Construction and Building Technology Journal, 2017, Volume 11 Cortina et al.
flexural strength, masonry mortars do not have to comply with any minimum value, thus the obtained results are
accepted as valid.
3.2.2. Phase 2
Table (6) shows the rest of the tests carried out with recycled mortar fabricated with 100% of RA using 1:4 dosage
which completes the characterization of recycled mortar.
Table 6. Recycled mortars characterization.
RA Type
Test
RA 1 RA 2 NA
Wet density (gr/cm3) 2.09 2.13 2.18
Dry density (gr/cm3) 1.73 1.79 1.97
Real density (gr/cm3) 2.10 2.12 2.26
Bond strength (N/mm2) 0.42 0.40 0.51
Shrinkage (mm/m) 0.112 0.096 0.031
Water abs. capillarity (kg/m2*min0.5) 0.77 0.69 0.60
Water vapour permeability -12 -12
5.61 6.44 3.09-12
(kg/m.s.Pa)
Both dry density and real density (UNE-EN 1015-10) depend on the density of compound materials, particle size
distribution and water-to-cement proportion. Generally, dry density and real density are lower in recycled mortar as
compared to mortars fabricated using natural sand and it has repercussion on the mechanical properties of recycled
mortar because of its higher porosity.
Results of bond strength test (UNE-EN 1015-2) and shrinkage test (measurements taken during 72 hours) show
worse behavior of recycled mortars as compared to the reference ones. Bond strength, among other factors, is a
consequence of formation of crystals produced by binder hydration. In any case, obtained values are higher than the
limit of 0.30 N/mm2 established by the UNE-EN-998-1 standard for this type of mortar.
As it can be seen in Table (6), water vapor permeability values for mixes containing RA are higher compared to
mixes elaborated with natural sand (UNE-EN 1015-19). This characteristic enables the evacuation of water vapor
existing inside a building avoiding in this way the condensation in internal enclosure walls layers.
Regarding absorption by capillarity (UNE-EN 1015-18), mortars fabricated using recycled aggregates show values
that are significantly higher than those of conventional mortars. This occurs due to the higher absorption of recycled
aggregates that leads to the fabrication of mortars with less density and porous, facilitating the circulation of water in
the sample capillaries.
from the construction and demolition works to the point when the product is valid to be placed on the market.
Fig. (2) shows the general scheme of recycling plant and different processes that recycled aggregates undergoing
prior to sale. To simplify the scheme, different materials that are obtained in the plant are grouped into processes and
only those relevant to ceramic recycled aggregates fabrication are shown.
Once the different processes performed in the recycling plant are explained, it is necessary to know the energy
consumption associated with each one of them to be able to classify that determined percentage of electricity and total
diesel oil consumption are attributable to each resultant material.
Assignment of light and diesel to each material obtained in the plant was carried out in the following way: The
consumption of kW and diesel oil was distributed in each of the processes depending on the machinery involved and
was distributed proportionally to the obtained materials depending on the annual production. For the rest of the
elements under analysis of inventory, 3.18% was assigned to the mixed RA according to the obtained annual
production.
Table (7) shows energy the consumption of different processes of recycling plant.
Energy Consumption
Process
Diesel oil (l) kW
1 100% screening -
2 52.41% (diesel screening) 33.94% (electrical screening)
3 - 35.24% (electrical screening)
53.35% (trommel)
4 12.03% (diesel screening) 7.80% (electrical screening)
47.59% (diesel screening) 25.29% (mill)
23.02% (electrical screening)
5 74.40% (diesel screening) 34.85% (trommel)
74.70% (mill)
The analysis of life cycle inventory studies, all the energy recourses used for ceramic RA fabrication, as well as the
consumption of different products derived from this activity. All the data is referred to the functional unit and all the
calculations were drawn from the meeting with managers of the company TEC-REC. (Table 8) shows this life cycle
inventory data.
378 The Open Construction and Building Technology Journal, 2017, Volume 11 Cortina et al.
Once the quantity of kgCO2.eq produced by ceramic recycled aggregates fabrication is obtained, this value is divided
by the quantity of this fabricated material obtained in a way that the value of carbon footprint is of 0.001336
kgCO2.eq/kg. Comparing this value with natural aggregate carbon footprint: 0.0181 kgCO2.eq [18], it can be concluded
that environmental impact of recycled aggregates is significantly lower than that derived from the exploitation of
natural aggregates.
CONCLUSION
Experimental study carried out in this research leads to the following conclusions:
1. Particle size distribution curve of RA is continuous and suitable for masonry mortar fabrication.
2. Main phases obtained in the X-ray diffractogram are quartz and calcite. Other founded phases show low
crystalline behavior.
3. In terms of characterization, there are no significant differences between ceramic RA and concrete RA.
Nevertheless, recycled mortars fabricated with concrete recycled aggregates show better results in the carried
out tests.
4. Real density of recycled mortar is lower compared to mortar elaborated using natural sand as a result of lower
density of RA. It causes a slight decrease in building permanent loads.
5. Generally, recycled mortar shows poorer mechanical behavior compared to the reference mortar. Shrinkage is
one of the most affected properties. Nevertheless, recycled mortar complies with all the standard requirements
taken as a reference.
6. Carbon footprint of recycled aggregates fabrication is significantly lower than that of natural aggregate
fabrication. As a result, the use of this type of aggregate reduces Co2 emissions and contributes in the
development of more sustainable construction.
7. As a final conclusion, it can be stated that masonry mortar fabricated using CEM IV with 1:3 or 1:4 compounds
proportion can incorporate 100% of two types of RA complying with the requirement established by the Spanish
standards.
UNE-EN 197-1. Cement. Composition, specifications and conformity criteria for common cements.
UNE-EN 933-1:2012. Tests for geometrical properties of aggregates - Part 1: Determination of particle size
Environmental Improvement in Use of Fine Fraction The Open Construction and Building Technology Journal, 2017, Volume 11 379
CONFLICT OF INTEREST
The authors declare no conflict of interest, financial or otherwise.
ACKNOWLEDGEMENTS
The authors gratefully acknowledge the support of the Architectural Construction and Control Department´s
laboratory of the Technical University School of Architecture (Madrid Polytechnic University) and the Chemistry and
Polymers Department´s laboratory of the University School of Technical Industrial Engineering (Universidad
Politecnica de Madrid, España) and the TEMA Research Group. The authors are also grateful to the BASF Construction
Chemicals Spain S.L. for their technical support. The authors would like to show their gratitude to the recycling plants
“El Molar” and “TEC-REC” for their collaboration in the research development.
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