Recycling and Exploitation of Construction and Demolition Wastes as Additives in Unsaturated Polyester Composite Building and Insulation Materials; Mechanical and Thermal Properties Investigation

Abstract

This research investigates the potential of manufacturing composite materials combining good mechanical and thermal insulation characteristics using C&D wastes (Construction and Demolition waste) in substitution of raw aggregates. Unsaturated polyester matrix composites encapsulating C&D waste of 300 μm and 500 μm as additives, at concentrations of 30%, 40% and 50 (% w/w) respectively, were manufactured. The effects of loading these materials with C&D wastes, in terms of mechanical and thermo-insulating performance were studied. Experimental research revealed the strong interrelation between the mechanical performance of materials and parameters such as grain size and concentration of loading agent. In particular, composites encapsulating 300 μm additives demonstrated improved flexural and shear properties, taking values of 34.59 MPa (30% additives), 35.61 MPa (40% additives) and 30.25 MPa (50% additives) for flexural strength and 3.72 MPa (30% additives), 4.18 MPa (40% additives) and 2.66 MPa (50% additives) for shear strength, compared to corresponding 500 μm loaded composites which flexural strength reached 33.58 MPa (30% additives), 34.6 MPa (40% additives) and 27.47 MPa (50% additives). Similarly shear strength reached 2.81 MPa (30% additives), 3.87 MPa (40% additives) and 2.5 MPa (50% additives) respectively. Composite materials loaded at a concentration of 40% (w/w) using 300 μm C&D waste additives, exhibited optimal mechanical efficiency in terms of flexural and shear strength. Thermo-insulating properties of optimum, in terms of mechanical behavior, composite materials were afterwards investigated. Thermal insulation efficiency was determined by measurement of thermal conductivity coefficient (λ) which was calculated at 0.39 W m-1 K-1, demonstrating good insulating properties compared to common insulation materials. In conclusion, the characteristic attribute of these materials to exhibit adequate mechanical and thermal insulation properties, as validated by the experimental results, indicates their suitability as building and insulation materials in co

Full text

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*Corresponding author: Email: k_bogiatzidis@hotmail.com;
Journal of Materials Science Research and Reviews
1(2): 1-11, 2018; Article no.JMSRR.43628
Recycling and Exploitation of Construction and
Demolition Wastes as Additives in Unsaturated
Polyester Composite Building and Insulation
Materials; Mechanical and Thermal Properties
Investigation
C. Bogiatzidis
1*
, D. Semitekolos
1
and L. Zoumpoulakis
1
1
Research Lab. of Advanced, Composite, Nano-Materials and Nanotechnology, School of Chemical
Engineering, National Technical University of Athens, Greece.
Authors’ contributions
This work was carried out in collaboration between all authors. Author LZ designed the study. Authors
CB and DS performed the experimental analysis. Author CB managed the literature review and wrote
the first draft of the manuscript and managed the analyses of the study. All authors read and
approved the final manuscript.
Article Information
DOI: 10.9734/JMSRR/2018/43628
Editor(s):
(1) Dr. Suraya Hani Bt Adnan, Associate Professor, Department Civil Engineering Technology, Faculty of Engineering
Technology, Universiti Tun Hussein Onn Malaysia, Malaysia.
Reviewers:
(1) Chong Leong, Gan, Universiti Malaysia Perlis, Malaysia.
(2)
A. B. Wahab, Obafemi Awolowo University, Nigeria.
(3)
Nasmi Herlina Sari, Mataram University, Indonesia.
Complete Peer review History:
http://www.sciencedomain.org/review-history/26142
Received 20 June 2018
Accepted 04 September 2018
Published 07 September 2018
ABSTRACT
This research investigates the potential of manufacturing composite materials combining good
mechanical and thermal insulation characteristics using C&D wastes (Construction and Demolition
waste) in substitution of raw aggregates. Unsaturated polyester matrix composites encapsulating
C&D waste of 300 μm and 500 μm as additives, at concentrations of 30%, 40% and 50 (% w/w)
respectively, were manufactured. The effects of loading these materials with C&D wastes, in terms
of mechanical and thermo-insulating performance were studied. Experimental research revealed
the strong interrelation between the mechanical performance of materials and parameters such as
grain size and concentration of loading agent. In particular, composites encapsulating 300 μm
Original Research Article

Bogiatzidis et al.; JMSRR, 1(2): 1-11, 2018; Article no.JMSRR.43628
2
additives demonstrated improved flexural and shear properties, taking values of 34.59 MPa (30%
additives), 35.61 MPa (40% additives) and 30.25 MPa (50% additives) for flexural strength and
3.72 MPa (30% additives), 4.18 MPa (40% additives) and 2.66 MPa (50% additives) for shear
strength, compared to corresponding 500 μm loaded composites which flexural strength reached
33.58 MPa (30% additives), 34.6 MPa (40% additives) and 27.47 MPa (50% additives). Similarly
shear strength reached 2.81 MPa (30% additives), 3.87 MPa (40% additives) and 2.5 MPa (50%
additives) respectively. Composite materials loaded at a concentration of 40% (w/w) using 300 μm
C&D waste additives, exhibited optimal mechanical efficiency in terms of flexural and shear
strength. Thermo-insulating properties of optimum, in terms of mechanical behavior, composite
materials were afterwards investigated. Thermal insulation efficiency was determined by
measurement of thermal conductivity coefficient (λ) which was calculated at 0.39 W m
-1
K
-1
,
demonstrating good insulating properties compared to common insulation materials In conclusion,
the characteristic attribute of these materials to exhibit adequate mechanical and thermal insulation
properties, as validated by the experimental results, indicates their suitability as building and
insulation materials in construction applications.
Keywords: Composite materials; construction and demolition waste; additives; mechanical
properties, thermal properties; insulation; unsaturated polyester.
ABBREVIATIONS
C&D waste : Construction and Demolition waste
EU : European Union
MEKP : Methyl-ethyl-ketone peroxide
1. INTRODUCTION
Civil infrastructure projects and building
construction sectors consume over half of the
material and energy resources [1]. The irrational
consumption model of these activities designated
them as the most inefficient “consumers” [2],
outlining at the same time, the importance of
implementing more sustainable strategies in
every distinct level of materials production and
life-cycle [3-10]. Moreover, recycling and
recovery issues related to construction and
demolition waste (C&D waste) management,
have become crucial and discussed in many
research studies [11-16].
Even though strict environmental standards and
a demanding legislative framework are in force
within the European Union (EU), setting
incredibly high quantitative recycling targets as
far as C&D waste management is concerned, the
average recycling percentage rates in EU
member countries hardly reaches 50% [17-31].
During the last decades, composite materials are
being widely used in a great number of
applications as a result of the outstanding
mechanical properties they exhibit [32-41]. The
need to reduce production costs and keep at the
same time materials' properties in adequately
descent levels designated the positive effects of
various kinds of particulate fillers addition in
composite materials [42-51]. According to
sustainability standards and as far as
environmental awareness increased, many
researchers investigated the possibility of
utilising various wastes or by-products, as
additives in composite materials manufacturing
[52-61]. However, the possibility of exploiting
C&D wastes as raw materials in manufacturing
cheap building materials which are
environmental friendly and present decent
properties, have not been researched yet in great
extent. Research papers concerned with the
issues involved in C&D waste recycling are
concentrated on an investigation of specific C&D
wastes in concrete [63,64], rural roads [65,66]
and mortars construction [67,68].
The aim of this research is to develop new C&D
waste loaded composite materials combining
appropriate mechanical and thermal insulating
properties, enabling them to be used as building
and insulation materials. Besides that, a different
exploiting potential for C&D waste is introduced.
2. MATERIALS AND METHODS
2.1 Raw Materials and Resin System
Construction and Demolition waste containing
various materials such as bricks, cinder blocks,
gravel, tiles, soil, glass, concrete, wall coating
(plaster), produced from demolished buildings,
was collected from a specialised C&D waste
processing facility where they have been guided
for further management. Composition of waste
was determined by means of visual inspection.

Bogiatzidis et al.; JMSRR, 1(2): 1-11, 2018; Article no.JMSRR.43628
3
The resin used as a matrix for composites was
unsaturated thixotropic polyester PE6/TC system
of Neotex Co., which is available in the market as
a complete set (resin and curing agent).
2.2 Preparation of Additive Substance
from C&D Waste
After removing contaminants which could not be
processed (such as steel reinforcement parts),
by means of hand-sorting and initial weighing of
collected waste, consecutive stages of sampling
through laboratory splitter to ensure sample’s
maximal homogeneity, were performed. Crushing
in a jaw-crusher took place afterwards to bring
C&D waste in a more manageable size and
enable further processing. The initial crushing
product was placed for 24 hours in the oven to
remove contained moisture. After de-
humidification, a sequence of sieving routines,
were executed. Additional splitting-sampling
steps took place and powders of two
granulometric sizes, 300 μm and 500 μm, were
finally prepared through grinding in a pulverising
mill.
2.3 CDW-loaded Polyester Composites’
Mechanical Behaviour Analysis
Mixture of unsaturated thixotropic polyester PE
6/TC adding the appropriate quantity (≈3% w/w)
of curing agent, Methyl-ethyl-ketone peroxide
(MEKP) and loaded with C&D waste additives of
granular size 300 μm and 500 μm at
concentrations of 30%, 40%, and 50% (w/w)
respectively, were prepared after continuous
stirring the ingredients in a pot for 5 minutes.
Weight measurements required were performed
using an electronic weighing machine. Final
mixture was carefully poured into a mould
suitable for flexural and shear strength according
to the standards. A thin layer of wax was applied
on mould’s surfaces to enable easy and
undamaged removal of specimens. The mould
containing the poured mixture was placed in a
laboratory oven and thermally cured at 60
o
C for
20 minutes. Flexural and shear tests of
unsaturated polyester C&D waste loaded
composites, were conducted according to the
three-point method by ASTM D 790 [69] and
ASTM D 2344 [70] (see Fig.1). The distance
between the supporting basis of three-point
bending test machine was set at 10 cm for
flexural strength measurements and 1 cm for
shear strength measurements respectively.
2.4 CDW-loaded Polyester Composites’
Thermal Insulation Properties
Thermo-insulating properties of composites were
defined by determination of thermal conductivity
coefficient, λ, using Eq. 1
(1)
Where;
Φ : Capacity resistance of heating surface,
S
m
: Composites’ average thickness (m),
A : Composites’ average surface area (m
2
),
Θ
wm
: Composites’ warm surfaces av. Temp. (
ο
K),
Θ
cm
: Composites’ cold surfaces av. Temp. (
ο
K).
Fig. 1. Schematic of the three-point test

Bogiatzidis et al.; JMSRR, 1(2): 1-11, 2018; Article no.JMSRR.43628
4
Fig. 2. Thermal conductivity measurement apparatus
Experimental measurement of composites
thermal insulation efficiency was carried out by
means of a guarded-hot-plate apparatus [71-73]
according to ASTM C177 [74]. The set-up of the
apparatus used is presented in Fig. 2.
Discoid composite specimens with identical
dimensions to those of heating and cooling
components of the experimental set-up were
prepared. Materials to be tested were
manufactured following the same procedure,
based on composition characteristics of optimum
(in terms of mechanical behaviour) composites,
as far as polyester/ curing agent proportions,
additives grain size and w/w concentration is
concerned (see Fig. 3 and Fig. 4, section 3.1).
After mixing, the final blend was poured in a tray
and cured in the oven at 60°C for 20 min. Wax
was again applied to ease composites removal
from the moulding tray. Specimens to be tested
were placed in the spaces between the heater
and the two cooling plates of the hot-guarded-
plate. The experimental set-up (heater, cooling
plates, and test specimens) after being
assembled was appropriately insulated.
Error involved in measurements of thermal
conductivity’s coefficient, λ, is ±5%. Required
calculations were performed according to the
literature [75].
3. RESULTS AND DISCUSSION
3.1 C&D Waste Particle-Filled Polyester
Composites
3.1.1 Flexural strength
Flexural strength of composites under
investigation is presented in Fig. 3. Pure
polyester materials are represented in light green
coloured column, 300 μm and 500 μm C&D
waste loaded composites are represented in blue
and orange coloured columns respectively.
Composites incorporating 30% w/w additives,
demonstrated a decrease in flexural strength of
55.4% once 500 μm is used as filler and 54.1%
in the case of 300 μm additive respectively,
compared to flexural strength recorded for pure
unsaturated polyester materials. Increasing filling
agent’s percentage to 40% acts on inversely. At
this specific concentration of additive flexural
strength of composites is improved by 2.95%
(500 μm filler) and 2.86% (300 μm filler) in
comparison to materials incorporating 30% of
C&D waste additive. Further increase of filler’s
concentration from 40% to 50% leads to
significant decrease of flexural strength about
20.6% for composites loaded with 500 μm
powder and 15.1% for 300 μm loaded ones
respectively, compared to those loaded with 40%

Bogiatzidis et al.; JMSRR, 1(2): 1-11, 2018; Article no.JMSRR.43628
5
w/w additives. Adding filler of different grain
size led to modifications in composites
bending strength. In particular, composites
filled with 30%, demonstrated a decrease of
2.92% in flexural strength once 500 μm filling
powder is used, compared to these in which 300
μm filler is used. Similarly, composites loaded
with 40% presented a decrease of 2.84% in
flexural strength and composites encapsulated
50% C&D waste additive, demonstrated a
reduction of 9.19% respectively. Optimum
flexural strength values were presented by
composites loaded with 40% w/w using 300 μm
additives compared to all loading scenarios
studied.
3.1.2 Shear strength
Fig. 4 presents shear strength of manufactured
composites. As in the case of flexural
strength graphical illustration, unloaded
composites (pure polyester) are represented
in light green coloured column and those
filled with additives of 300 μm and 500 μm
are represented in blue and orange
coloured columns. Adding 30% w/w of filling
agent in the polyester composites, led to the
decrease of shear strength by 79.9% for
composites incorporating 500 μm additives and
73.3% for those containing 300 μm additives
respectively, compared to the shear strength
values measured for pure polyester specimens
(matrix). Increasing the concentration of filling
agent to 40% had an inverse result, since shear
strength composites was improved by 27.4%
(500 μm filler) and 11% (300 μm filler) compared
to those loaded at a concentration of 30% w/w.
Further increase of loading concentration from
40% to 50% led to an even greater reduction of
shear strength values about 35.4% (composites
incorporating 500 μm additives) and 36.4%
(composites with 300 μm additive), in
comparison to 40% w/w loaded composites. An
enhancement in shear strength was exhibited by
composites encapsulating 300μm C&D waste
additives at 40% w/w, in comparison to all other
additive incorporating composites examined.
Additive’s granular magnitude is of great
importance as far as shear strength is
concerned. Analytically, encapsulation of
additives at 30%, led to the reduction of
shear strength by 24.5% while 500 μm filler is
used in place of 300 μm. Correspondingly,
composites containing additive at concentration
of 40% presented a shear strength reduction of
7.42% and those containing 50% of filler
demonstrated a downsizing of 6.01%
respectively, once the 500 μm C&D waste
additive was used to load composites, instead of
300 μm.
Fig. 3. CDW-filled composites’ flexural strength
(Note: All Measurements include +/- 7% of error)

Table 1. C&D waste loaded polyester composites versus common insulation materials
Material
Polymer matrix
Polyester/ MEKP (% w/w)
C&D waste-loaded composite*
Commercial Unsat. Polyester*
60
100
Expanded Polystyrene (XPS)
Extruded polystyrene (EPS)
100
100
Polyurethane foam (PUR) 100
Unsat. Commercial Polyester
*** Experimentally determined value
Bogiatzidis et al.;
JMSRR
6
Table 1. C&D waste loaded polyester composites versus common insulation materials
-
Coefficients of thermal conductivity
Polymer matrix
Polyester/ MEKP (% w/w)
Additive (filler)
CDW (% w/w)
Coefficient of thermal
conductivity, λ
(W m
40
-
0.39
0.2664*
-
-
0.029-0.041**
0.025-0.035**
- 0.020 -0.027**
0.24
***
* Experimentally determined
** Values found in literature
*** Experimentally determined value
of pure polyester found in the literature
Fig. 4. CDW-filled composites’ shear strength
(Note: All Measurements include +/- 7% of error)
JMSRR
, 1(2): 1-11, 2018; Article no.JMSRR.43628
Coefficients of thermal conductivity
Coefficient of thermal
(W m
-1
K
-1
)
Granular magnitude
of filler (μm)
300

Bogiatzidis et al.; JMSRR, 1(2): 1-11, 2018; Article no.JMSRR.43628
7
3.2 Thermal Insulation Properties
The effects of loading on thermal insulation
properties of composites were assessed by
estimation of thermal conductivity coefficient, λ.
Thermal conductivity coefficient took
characteristic values which are presented in
Table 1. Analytically, thermal conductivity
coefficient of C&D waste loaded polyester
composites was calculated at 0.39 W m-1
K-1. This value appears to be increased
compared to corresponding λ values of
polystyrene based (0.025-0.041 W m-1 K-1)
and polyurethane foam (0.020-0.027 W m-1 K-1)
materials that are widely used as insulators
[76]. Thermo-insulating efficiency of composites
was affected by C&D waste addition decreasing
by 31% compared to the experimentally
determined value obtained for pure polyester
specimens. The measured thermal conductivity
coefficient was almost identical in comparison to
pure polyester λ values found in literature [77].
Encapsulation of C&D waste fillers led to
manufacturing of materials with low thermal
conductivity combining sufficiently good
mechanical strength.
4. CONCLUSIONS
In the present study the effect of incorporating
C&D wastes on polyester matrix in terms of
mechanical performance and thermo-insulating
efficiency of the resulting composites was
studied. The optimum manufactured composites
were those loaded with C&D wastes of 300μm at
concentration of 40% (w/w), exhibiting
adequately good mechanical performance. The
thermo-insulating properties were slightly
affected compared to the pure polyester,
resulting in reduction of the thermal conductivity
coefficient, λ. Those results along with the
recycling of the wastes indicate that they are
appropriate and can be utilized as building and
insulation materials in construction applications.
COMPETING INTERESTS
Authors have declared that no competing
interests exist.
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