Resource-efficiency aspects for composites in the construction sector

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1 RWTH, Peter Winandy Resource-efficiency aspects for composites in the construction sector Magdalena Kimm, M.Sc. Institut für Textiltechnik der RWTH Aachen University , CE 2018, Lightweight Technologies Forum

Need for recycling European Demand In 2017: 17.

2 Need for recycling European Demand In 2017: t 1 of Carbon fibres European Waste Types of waste Dry production waste (20-40% of input) 2 End of Life waste with plastic parts 3 aerospace parts: years automotive parts: years Current waste masses: to t/year 2 Estimated waste masses within the next 10 years: t/year 1,4 2 1 Michael Sauer, Michael Ku hnel (CCeV), Dr. Elmar Witten (AVK), Composites-Marktbericht Der globale CF- und CC-Markt, September Michael Ku mmeth, Anita Gottlieb, Juliane Ramerth, Matthias Seitz, Bernhard Hartleitner, Prof. Dr.-Ing. Wolfgang Rommel, Entwicklungsstudie zur Errichtung einer CFK-Recyclinganlage in Bayern,

3 Resource-efficiency on different levels DESIGN for recycling Cloosed Loop PRODUCTION RECYCLING Products with secondary materials 3

4 Approach 1 Design for recycling of carbon concrete composite

5 Design for recycling of carbon concrete composite Deconstruction of test building Mechanical crushing onsite Result Photos beneath: TU Dresden, IBB Jan Kortmann 5

6 Design for recycling of carbon concrete composite Influences on separability Separation method Jaw crushers Hammer mills Impact mills Structural parameters Textile structure Position of textile Materials Fibre material Coating material Concrete mixture.. 6

7 Design for recycling of carbon concrete composite Influences on separability: Separation method 7 Kimm, M., Gerstein, N., Schmitz, P., Simons, M., and Gries, T., 'On the separation and recycling behaviour of textile reinforced concrete: an experimental study', Mater Struct 51 (5 (2018), 122.

8 Design for recycling of carbon concrete composite Influences on separability Separation method Jaw crushers Hammer mills Impact mills Structural parameters Textile structure Position of textile Materials Fibre material Coating material Concrete mixture.. 8

Design for recycling of carbon concrete composite Influences on separability: Coating

Undamaged textile Adhesive concrete Epoxy resin Successful recovery 10 cm 9 Kimm, M.

, 'Characterization of separability of carbon textile reinforced concrete for increased

9 Design for recycling of carbon concrete composite Influences on separability: Coating material Potassium silicate No recovery Styrene butadiene Medium recovery Failure of Roving Undamaged textile Adhesive concrete Epoxy resin Successful recovery 10 cm 9 Kimm, M., Gerstein, N., Weiler, L., Vollpracht, A., and Gries, T., 'Characterization of separability of carbon textile reinforced concrete for increased material sustainability', in 'International Conference on Advances in Construction Materials and Systems (ICACMS), Chennai, India, ,

10 Design for recycling of carbon concrete composite Influences on separability Separation method Jaw crushers Hammer mills Impact mills Structural parameters Textile structure Position of textile Materials Fibre material Coating material Concrete mixture.. 10

11 Approach 2 Closed-loop production process for construction composites

12 Closed-loop production process for construction composites 12

13 Closed-loop production process for construction composites 13

Concrete + Carbon Raw facade element Final facade element

Wet concrete with carbon reinforcement Reject raw & final

14 Closed-loop production process for construction composites Recording of material waste types, masses and sources Concrete Concrete + Carbon Raw facade element Final facade element Mixing Extrusion Storing Sawing Milling Packaging Wet concrete Wet concrete with carbon reinforcement Reject raw & final elements Cut-off waste from edges Small & medium sized cut-off elements 14

15 Closed-loop production process for construction composites Prioritization of material waste types Ratio of waste fractions produced according to... waste mass value 10% 21% Wet Dry 79% 90% In this case study: Focus on dry waste (concrete + carbon reinforcement)! 15

16 Closed-loop production process for construction composites Evaluation of inefficiencies 100% 80% 26% 1% 13% 3% 18% Target Soll-Wert Actual Ist-Wert 60% 40% 74% 16% 35% 26 % Cost reduction potential just by reduction of inefficiencies! 20% 0% 3% 3% 3% 5% 17

17 Closed-loop production process for construction composites Identification of suitable measures Concrete Concrete + Carbon Raw facade element Final facade element Mixing Extrusion Store Sawing Milling Packing Wet concrete Wet concrete with carbon reinforcement Reject raw & final elements Cut off waste from edges Small & medium sized cut-off elements Mobile crushing plant 18

Closed-loop production process for construction composites Identification of suitable measures How does the recyclate influence the properties of the products?

18 Closed-loop production process for construction composites Identification of suitable measures How does the recyclate influence the properties of the products? Is it possible to recycle the total production waste internally? Which volume of rcf is possible in a fresh concrete mixture? How high is the fibre volume content after mixing different waste types? Could different volumes apply for different products/applications? 19

19 Approach 3 Products with secondary materials: recycled Carbonfibres for fibre reinforced concrete

20 Shotcrete/ Casting Recycled Carbonfibres for fibre reinforced concrete Fibres and raw materials 21

Recycled Carbonfibres for fibre reinforced concrete (FRC) 55 kt steel fibres per year in Germany 2 Constant demand in the last 5 years 2 90 % of those for constrution sector 2 Largest share of whole

21 Recycled Carbonfibres for fibre reinforced concrete (FRC) 55 kt steel fibres per year in Germany 2 Constant demand in the last 5 years 2 90 % of those for constrution sector 2 Largest share of whole FRC market Fibre Price [ /kg] Tensile strength [GPa] Polypropylene <1 0,4 Steel 1,50 1 AR-Glass 5 1,5 rcarbon ,5 Carbon 25 4 Residential Construction 1% Industrial floors 70% Safes 3% Precast concrete 16% Quantities of steel fibers by application 1 Underground construction 10% 22 1 Thienel, Kustermann (2010), Sonderbetone Faserbeton 2 German assocation of steel fibre producers (vds e.v.)

22 Recycled Carbonfibres for fibre reinforced concrete From Carbon Composite to Recycling to Buildings & Infrastructure Triple tensile strength compared to steel fibres Half to third of the price of new CF Non-flammability Chemical inert, non corrosive, perfect alkali resistance 23

Flexural strength [MPa] Elongation [%] Recycled Carbonfibres for fibre reinforced concrete Flexural tests with 12 mm fibres AR-Glass pyrolized rcf virgin CF + 14 % Flexural

23 Flexural strength [MPa] Elongation [%] Recycled Carbonfibres for fibre reinforced concrete Flexural tests with 12 mm fibres AR-Glass pyrolized rcf virgin CF + 14 % Flexural strength AR-Glass 0.6 Vol-% 15 0,6 kg/m3 Vol-% pyrolized rcf 0.2 Vol-% 4 kg/m3 virgin CF 0.2 Vol-% 4 kg/m3 15 kg/m 3 4 kg/m 3 4 kg/m 3 0,2 Vol-% 0,2 Vol-% - 75 % material input 24

24 Resource-efficiency on different levels - Conclusion Measures for designing recyclable concrete composites DESIGN Recycling technologies for non-traditional construction composite materials for recycling Including material waste as well as on organizational inefficiencies Company-tailored measures for waste minimization Cloosed Loop PRODUCTION RECYCLING Products with secondary materials Applications and market outlook for recycled carbon fibres in concrete materials 25

25 Thank you for your kind attention! Our Partners: Magdalena Kimm, M.Sc. Construction composites Institut für Textiltechnik (ITA) of RWTH Aachen University +49 (0) 241 / magdalena.kimm@ita.rwth-aachen.de ITA TechnologieTransfer GmbH, Aachen Institut für Textiltechnik Augsburg ggmbh, Augsburg ITA Teknoloji Transfer Ltd. Sti., Bursa (Türkei)

List of Abstracts. James Buckwell. ELG Carbon Fibre Ltd. Carbon Fibre Recycling and Quality Management (P1)

List of Abstracts. James Buckwell. ELG Carbon Fibre Ltd. Carbon Fibre Recycling and Quality Management (P1) List of Abstracts James Buckwell ELG Carbon Fibre Ltd. Carbon Fibre Recycling and Quality Management (P1) ELG Carbon Fibre s mission is to industrialise high-volume recycling processes for the low-cost