Lifecycle Perspective of Tech and Prop of RCA by Noguchi.ppt · Lifecycle Perspective Lifecycle...

2010 International Concrete Sustainability Conference, Dubai, UAE 1

NRMCA Concrete Sustainability ConferenceLifecycle Perspective Lifecycle Perspective ofof

Technologies and PropertiesTechnologies and PropertiesTechnologies and Properties Technologies and Properties of Recycled Aggregate of Recycled Aggregate ConcreteConcretein Japanin Japan

Takafumi NOGUCHIThe University of [email protected]

December 13-14, 2010 – Dubai, UAE


NRMCA Concrete Sustainability Conference

Content

•• IntroductionIntroductionHistory of Measures on RecyclingHistory of Measures on Recycling•• History of Measures on RecyclingHistory of Measures on Recycling–– Political MeasuresPolitical Measures–– StandardizationStandardization

•• History of Recycling TechnologyHistory of Recycling Technology–– Recycling technologies for existing structuresRecycling technologies for existing structures–– Completely Recyclable ConcreteCompletely Recyclable ConcreteCompletely Recyclable ConcreteCompletely Recyclable Concrete

•• Conclusions Conclusions



NRMCA Concrete Sustainability ConferenceEnvironmental Problems in Concrete

IndustriesIndustries

•• Global warmingGlobal warmingResource depletionResource depletion•• Resource depletionResource depletion

•• Waste disposalWaste disposal




Building Related CO2 Emission

Housing

construction

Commercial

building

Japan’s totalCO2 emission

1.2 billion

5% construction

6%Building

repair

1%tons Energy for

housing

operationEnergy for

36%36%

Other

industries

64%

11%gy

commercial

building

operation


p

13%



CO2 Emission from Concrete Industries2

Portland cement: 1 tonPortland cement: 1 ton

COCO 0 750 75COCO22: 0.75 ton: 0.75 tonDecarbonation of limestone (60 %)Decarbonation of limestone (60 %)Fossil fuel combustion (30 %)Fossil fuel combustion (30 %)

Concrete: 1 mConcrete: 1 m33

COCO22: 0.35 : 0.35 -- 0.45 ton0.45 tonCement production (0 25 ton)Cement production (0 25 ton)


Cement production (0.25 ton)Cement production (0.25 ton)Others (0.1 Others (0.1 –– 0.2 ton)0.2 ton)



Resource Input into Construction Industries

TotalTotal ConstructionConstruction

Total: 2,000 (million t/year)Total: 2,000 (million t/year) Total: 1,000 (million t/year)Total: 1,000 (million t/year)CONCRETE is the second most widely consumed CONCRETE is the second most widely consumed substances on Earth, after water !substances on Earth, after water !

OthersOthers“LIQUID STONE:NEW ARCHITECTURE IN CONCRETE”“LIQUID STONE:NEW ARCHITECTURE IN CONCRETE”(National Building Museum in Washington D.C.)(National Building Museum in Washington D.C.)

ConstructionConstruction ConcreteConcreteWoodWood


1,000 (million 1,000 (million t/year)t/year)50%50%

ConcreteConcrete500 (million t/year)500 (million t/year)50%50%SteelSteel



Waste Output from Construction Industries

Industrial WasteIndustrial Waste Construction WasteConstruction Waste

Total: 406 (million t/year)Total: 406 (million t/year) Total: 79 (million t/year)Total: 79 (million t/year)

EnergyEnergyOthersOthersA h lA h lWoodWood OthersOthers

EnergyEnergy

AgricultureAgriculture

PulpPulp

SteelSteel

ChemicalChemical Asphalt Asphalt concreteconcreteSludgeSludge

WoodWood

ConstructionConstruction79 ( illi / )79 ( illi / )

ConcreteConcrete35 ( illi35 ( illi

PulpPulp


79 (million t/year)79 (million t/year)17%17%

35 (million 35 (million t/year)t/year)42%42%



Final Disposal Sites for Waste

200

220

in rea

General

Industrial Waste: 412 (million Industrial Waste: 412 (million t/year)t/year)

180

200

e w

aste

posa

l ar

ion

m3 ) Industrial

140

160

Poss

ible

nal d

isp

(mill

i

120

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

P fi


Scarcity of residual capacity of final disposal areas

ResourceResource--recycling recycling societysociety



Content







Recycling Ratio of Concrete

1990RecycleDisposal

Ministry of ConstructionMinistry of ConstructionAction Plan for Construction Action Plan for Construction

ByBy--productsproducts ‘‘9494

1995

ByBy products products 9494Promotion Plan for Promotion Plan for

Construction Waste Construction Waste RecyclingRecycling ’’9797

Basic Law for Establishing aBasic Law for Establishing a

2005

2000

Basic Law for Establishing a Basic Law for Establishing a RecyclingRecycling--based Societybased Society

Construction Material Recycling ActConstruction Material Recycling ActLaw on Promoting Green Law on Promoting Green

PurchasingPurchasing

0 10 20 30 40

Emission of Concrete Lumps (million t)

2005


For road For road subbasesubbaseFor mechanical stabilization For mechanical stabilization

underground underground


NRMCA Concrete Sustainability ConferencePredicted Amount of Future Concrete

WasteWastet)

600

500Concrete Concrete productionproduction

on (

mill

ion

400

300

productionproduction

ConcretConcretD d fD d f

Prod

ucti

o

200

100

ConcretConcreteewastewaste

Demand forDemand forroad road subbasesubbase Greatest part of

future aggregate for concrete

Greatest part of future aggregate for concrete

0

1950 20002050

YearImbalance between Recycling


YearImbalance betweensupply of concrete

wastedemand for road

subbase

RecyclingFrom Quantity-oriented to Quality-oriented



Content







Standardization of Recycled AggregateStandardization of Recycled Aggregate

19771977 Building Contractors SocietyBuilding Contractors Society“Draft standard for the use of recycled aggregate and recycled y gg g y

concrete”

19941994 Ministry of ConstructionMinistry of Construction“Provisional quality standard for reuse of concrete by-products”Quality requirementsQuality requirements

Density:Density: higherhigher19991999 Building Center of JapanBuilding Center of Japan

“Accreditation criteria of recycled aggregate for building concrete”

20002000 Mi i f I i l T d d I dMi i f I i l T d d I d

Density: Density: higherhigherWater absorption: Water absorption: lowerlower

20002000 Ministry of International Trade and IndustryMinistry of International Trade and Industry“TR A0006 (Low quality recycled aggregate concrete)”

20052005--20072007 Japan Industrial Standards CommitteeJapan Industrial Standards Committee“JIS A 5021 5022 d 5023 (R l d f


“JIS A 5021, 5022 and 5023 (Recycled aggregate for concrete, Recycled Concrete)”


NRMCA Concrete Sustainability ConferenceSpecified Values of Recycled Aggregate

in JISin JIS

Coarse aggregate Fine aggregate

Density(g/cm3)

Absorption(%)

Density(g/cm3)

Absorption(%)

JIS A5021(Class H)

2.5 or 2.5 or moremore 3.0 or less3.0 or less 2.5 or 2.5 or

moremore 3.5 or less3.5 or less

JIS A5022 2 3 or 2 2 orJIS A5022(Class M)

2.3 or more 5.0 or less 2.2 or

more 7.0 or less

JIS A5023 - 7 0 or less - 13.0 or


(Class L) - 7.0 or less - less



Applications of Recycled Aggregate

Scope of applicationN li it tiN li it ti t th t d

Class -H

No limitationsNo limitations are put on the type and segment for concrete and structures with a nominal strength of 45MPa or less

JIS A 5308 (ReadyJIS A 5308 (Ready mixed concrete)mixed concrete) allowingH JIS A 5308 (ReadyJIS A 5308 (Ready--mixed concrete)mixed concrete) allowing to use Class-H RA for normal strength concrete

Members not subjected to drying orMembers not subjected to drying orClass -

M

Members not subjected to drying or Members not subjected to drying or freezingfreezing--andand--thawing actionthawing action, such as piles, underground beam, and concrete filled in steel tubes


steel tubes

Class -L

Backfill concrete, blinding concrete, and Backfill concrete, blinding concrete, and leveling concreteleveling concrete



Content






NRMCA Concrete Sustainability ConferenceClassification of Recycling

TechnologiesDemolished Concrete LumpsDemolished Concrete Lumps

Jaw CrusherJaw Crusher

Technologies

Jaw CrusherJaw Crusher

Impact CrusherImpact Crusher

Vibratory SievesVibratory Sieves Cone CrusherCone Crusher

Vibratory SievesVibratory Sieves Heating TowerHeating Tower

Coarse Aggregate ScrubberCoarse Aggregate Scrubber

Road Road SubbaseSubbase,,BackfillBackfill

Vibratory SievesVibratory Sieves

Low Quality Low Quality RecycledRecycled

Fine Aggregate ScrubberFine Aggregate Scrubber

Low Quality Low Quality RecycledRecycled

Vibratory SievesVibratory SievesRecycledRecycledCoarse Coarse

AggregatesAggregates

RecycledRecycledFine Fine

AggregatesAggregates High Quality High Quality Recycled Recycled CoarseCoarse


High Quality High Quality Recycled FineRecycled Fine


PowderPowder


(a) Road (a) Road SubbaseSubbase (b) Low Quality(b) Low QualityRecycled AggregatesRecycled Aggregates

(c) High Quality(c) High QualityRecycled AggregatesRecycled Aggregates


NRMCA Concrete Sustainability ConferenceProblems in Conventional Technology

to Produce High-quality Recycled Aggregateto Produce High quality Recycled AggregateRepeated crushingRepeated crushing••Recovery percentage Recovery percentage d id i

5-10mmnot less

Water Absorption (%) Recovery Percentage

(%)Recycled Fine Aggregate

Size of SuppliedConcrete Lumps

decreasingdecreasing••Fines generation increasingFines generation increasing

than10mm

Recycled CoarseAggregate

GravelAggregate

Powder

Sand

Cement Paste


No 1st 2nd 3rd

Number of Crushing Treatment

No 1st 2nd 3rd OriginalConcrete

Crushing Treatment


NRMCA Concrete Sustainability ConferenceMechanical Scrubbing Equipment for

High-quality Recycled Aggregate

ConcreteConcretelumpslumps

High quality Recycled Aggregate

EccentricEccentrict b lt b l illill

ExternalExternalcylindercylinder

tubulartubular millmill

MotorMotor

Scrubbing

TransmissionTransmission


TransmissionTransmissiongeargearRecoveryRecovery


NRMCA Concrete Sustainability ConferenceApplication of Mechanical Scrubbing

MethodMethod

Old apartment Houses12 x 4-storiedConcrete lump: 11,500 t

New apartment Houses7 x 9-19-storiedRecycled coarse aggregate: 3,000 t


Recycled concrete volume: 3,000 m3

( Total concrete volume:40,000 m3 )


NRMCA Concrete Sustainability ConferenceHeated Scrubbing Equipment for

High-quality Recycled Aggregate

Hot Hot ElevatorElevator

High quality Recycled Aggregate

Rotary Rotary

22ndnd Scrubbing MachineScrubbing MachineDust Dust ChamberChamber

11stst Scrubbing Scrubbing MachineMachine

ElevatorElevator

yyKilnKiln

SieveSieve

Filler TankFiller Tank R l d CR l d CRecycled Coarse Recycled Coarse


l dl d5mm5mmRecycled Fine Aggregate Recycled Fine Aggregate --5mm5mm

20mm20mmAggregate 5Aggregate 5--20mm20mmdd

PowderPowderByBy--product product PowderPowder



Mechanism of Heated Scrubbing

H ti t R bbiHeating at 300°C

Rubbing process

Concrete rubbleWeakening of

hardenedRemoval of powdered


hardened cement paste

powdered cement hydrate



Application of Heated Scrubbing MethodStorehouse : ・Upper structure : SRC 6-storey・Basement structure : RC 1-storey・Building area : 12,800m2g ,・Total floor area : 62,100m2

Total volume of recycled concrete: 25,000m3




Content







Problems in Current Recycling

ExistingForward-

Existing technology

process production

•• Nosotropic technologyNosotropic technologyNo recycling-conscious design applied– No recycling-conscious design applied

– Materials diffused into a wide range of industries– Finally disposed

• Quality degradation Unstable supply Unstable price


• Quality degradation, Unstable supply, Unstable price, Unstable distribution, Increasing environmental impact


NRMCA Concrete Sustainability ConferenceConcept of Completely Recyclable

Concrete

NewNew technologytechnology

Concrete

gygy

•• Proactive TechnologyProactive TechnologyUpstream (inverse) processes incorporated– Upstream (inverse) processes incorporated

– Components of concrete completely recycled into concrete

– Resource conserved


Resource conserved– Resource circulated in a closed system



Cement-recovery Type Completely Recyclable Concrete

Crushing &• Concrete whose binders,

additives and aggregates are all made of cement or Operation

DemolitionCrushing &Milling

Calcination

materials of cement, and all of these materials can be used as raw materials f t ft

Semi-closed-loop

Construction

ClinkerGypsum

Recycled cementof cement after hardening

Productionof CRC

Aggregate

y




Changes in CO2 Emissions and Dumped Concrete

200200

5% of concrete replaced withcement-recovery type CRC every year

150150

CO2 EmissionDumped concreteCO2 Emission

Dumped concrete

50

100

50

100Dumped ConcreteDumped Concrete

COCO22 EmissionEmissionC l i dC l i d

0

50

0 50 100 150 200 250El d

0

50

0 50 100 150 200 250El d

CalcinedCalcinedlimestone never limestone never emits COemits CO22..


Elapsed year(2) Production of CRC

Elapsed year(1) As it is



Application of Cement Recovery Type CRC for “Eco-Pole”

Remove andTransportation

Use andOperation

Supply of Pole

Closed Recycle ofConcrete Pole

Manufacture of Pole

Crushing andClassifying

SteelRecycling

Placing of concretePlacing of concrete

Limestone Supply

Raw Material for Cement

Cement Supply

Steam curedSteam cured


Limestone Mining

Circulation of Cement

Manufacture of CementRemoval of formRemoval of form



Aggregate-recovery Type CRC

Chemical treatmentDemolition

Crushing& Si i

Operation

Demolition & Sieving

CalcinationRecycled

t

Physical treatment

Closed-loop

Construction

Clinker

Recycledcement

aggregate

Productionof CRC

Surfacemodifiedaggregate

cement



NRMCA Concrete Sustainability ConferenceRecovery and Mechanical Property of

Aggregate-recovery Type CRCAggregate recovery Type CRC

90%)

No treatment Chemical Physical

60

No treatment Chemical Physical

W/C=60%

60708090

ry r

atio

(%

W/C=40%

30405060

gth

(MPa

)

4050

Crushed stone Gravel

Reco

ve

1020

Crushed stone Gravel

Stre

ng•• TTraderade--off relationshipoff relationship remainedremained

– Aggregate recoverability increasedincreasedM h i l ti f t d dd d


– Mechanical properties of concrete decreaseddecreased


NRMCA Concrete Sustainability ConferenceAdvanced Aggregate Recovery-type

CRC

Surface modification treatment

CRC•• Concrete strength Concrete strength

enhancementenhancement– Aggregate surface modification

I b di f b

Aggregate

Mortar– Increase bonding force between

coarse aggregate and mortar• Fine SCM: pozzolanic reaction• Mineral powder: mechanical

f i ti 330330°C at 10at 10secsec610610°C at 30at 30secsecfriction 330330 C at 10at 10secsec610610 C at 30at 30secsec

•• AAggregate recggregate recoverabilityoverability– Inclusion of dielectric material – Selective heating by microwave


< After microwave heating >< Microwave heating >

g y– Weakening aggregate surface– Recovery of aggregate with low

energy


NRMCA Concrete Sustainability ConferenceMechanical Properties in Advanced

Aggregate Recovery-type CRCAggregate Recovery type CRC

Increase



NRMCA Concrete Sustainability ConferenceAggregate Recovery Ratio in Advanced

Aggregate Recovery-type CRCAggregate Recovery type CRC

Original coarse aggregate Fine aggregate Paste

80100120

io (

%) Decrease

406080

very

rat

i

020

O1 O2 O3 SP80

Reco

v

Increase


O1 O2 O3 SP80



CO2 Emission in Concrete Recycling Process

3540

ete)

20253035

/t-c

oncr

e

OthersScrubbingMicrowaveh i

Decrease

5101520

ssio

n (k

g/ heating

05

Heated-

scrubbing

Mechanical-

scrubbing

30sec 60sec 90sec

CO2

emis


scrubbing scrubbing


NRMCA Concrete Sustainability ConferenceSustainable Resource Recycling Concrete

SocietySocietyDemolition Demolition

and recoveryand recovery

Recycled coarse aggregateRecycled coarse aggregate

Complete Complete separationseparation

Concrete structureConcrete structure

Long-lived Recycled coarse aggregateRecycled coarse aggregate

Recycled Recycled finefine aggregateaggregate(under technology development)(under technology development)

HHighigh--purity purity CaCaMicrowavMicrowave heatinge heating

g

Coarse Coarse aggregateaggregate MModifiedodified

coarsecoarse

ModificationUse as cement raw material

Little Little COCO22emissionemission

FineFineaggregateaggregate

coarse coarse aggregateaggregate

FineFineaggregateaggregate Demolition and Demolition and

CCement ement factoryfactory


ByBy--product product powderpowder CementCement

CCompleteompletellyy recyclrecyclaable ble structurestructure

recoveryrecovery



Content







Conclusion

•• Toward Toward sustainable resourcesustainable resource--recycling societyrecycling societyConcrete recycling inConcrete recycling in closed systemclosed system–– Concrete recycling in Concrete recycling in closed systemclosed system

•• Current method: Some technical and social problemsCurrent method: Some technical and social problems

–– Adoption of technology enhancing Adoption of technology enhancing resource resource conservabilityconservability at the stage of designat the stage of designconservability conservability at the stage of designat the stage of design

•• Completely recyclable concreteCompletely recyclable concrete•• New technology with New technology with aggregate surface modification aggregate surface modification and and

microwave radiationmicrowave radiation–– Overcoming inherent conflicting properties in concrete recycling Overcoming inherent conflicting properties in concrete recycling –– Achieving high performance of concreteAchieving high performance of concrete–– Energy saving and Energy saving and small COsmall CO22 emission emission in concrete recyclingin concrete recycling–– Fully recoveringFully recovering original aggregateoriginal aggregate


–– Generating cement raw materials which Generating cement raw materials which never emit COnever emit CO22



Thank you for your kind Thank you for your kind استماعكم حسن على استماعكمأشكرآم حسن على !!أشكرآم y f yy f yattention!attention!م ن ى م مر ن ى م !!ر


[email protected]@bme.arch.t.u--tokyo.ac.jptokyo.ac.jp

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