EUSEW 2019 Energy Fair; Brussels (Belgium); June 2019 ... · «Transforming Construction Waste into...

The projects have received funding from the European Union’s Horizon 2020 research and innovation programme.

«Transforming Construction Waste into Energy Efficient

Solutions»

EUSEW 2019 – Energy Fair; Brussels (Belgium); June 2019

Coordinator: CNR-ISAC

Project

„This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 723916”

Innovative pre-fabricated components including different waste construction materials reducing building energy and minimizing environmental impacts


InnoWEE Main Objectives

❑ Develop realistic performant and cost-effective solutions fornew and existing buildings

❑ Create the opportunities for new business and real estatedevelopment

❑ Recycling of Construction & Demolition Waste (CDW) to tomake new eco-friendly secondary raw materials (SRM)

❑ Use of the SRM with geopolymeric technology to producenew insulating and radiating panels with high content of CDWfor higher performace of buildings

❑ Validation of the new panels in different scenarios❑ Testing in real and virtual demo sites❑ Enter the market❑ Evaluation of energy consumption reduction and

environmental sustainability❑ Production with lower environmental impact❑ Guidelines, trainings, workshops to share knowledge❑ Dissemination of the results


InnoWEE ConceptProduction of InnoWEE secondary raw materials (SRM)

1. Selection of CDW → concrete, bricks, mortars, cement2. Crushing and sieving of CDW3. Magnetic separation of metals4. Milling and sieving for required size of InnoWEE SRM → 0 – 2 mm

5. Incorporation of inorganic CDW for high density geopolymwr (HDG) panels production andwood waste for wood geopolymer panels (WGP) production and laboratory / pilot testing

6. Scaling-up and industrial production of the panels7. Introduction of new panels on to the market


Production of geopolymeric insulating and radiating panels for buildings

Demo sites buildings

Pilot house, CNR Area of Padua, Italy

Old city hall of Voulamunicipal, Athens, Greece

Residential Eco-house,Putte-Mechelen, Belgium

Don Orione Residential Care Center, Voluntari, Bucharest, Romania


INNOWEE Project has additional four (4) virtual demo sites buildings located in Italy, Greece, Romania, and Spain.

Results at today

New insulating and radiating panels

prototypes realisation

The panels were designed in their details(dimensions, color, texiture, ancoring….).The panels were produced and the prototypesinstalled in a test wall.

The panels were tested

with different methods

averageΛ - diffusion conductivity of

water vapor (kg/m2 s Pa)2.59 × 10-10

W – diffusion water vapour

permeability (kg/m s Pa)2.08 × 10-12

μ - coefficient of diffusion

resistance to water vapor97.2

Wind and seismic load

FEM simulations

Adhesion/bond strength, Capillary absorption, water vapour permeability, impact resistance, frost resistance, reaction to fire, infrared thermography, etc.


Results at today (cont.)

Production definition and scale up of new panels

The panels were produced at industrial level tobe installed in the different demonstrationsites.

The final panels were distributed

to the different demo sites


Four (4) real demosite buildings

Pilot house, CNR Area of Padua, Italy Old city hall of Voulamunicipal, Athens, Greece

Residential Eco-house,Putte-Mechelen, Belgium

Don Orione Residential Care Center, Voluntari,

Bucharest, Romania

Measurement in progress


The simulations related to the 4 real and 4 Virtual demo sites are in progress

The modelling of energy performance of the different products is in progress in orderto find the best solutions in terms of energy efficiency and indoor comfort.

Three scenario will be analysed:- Scenario 0: current status of the demos,

which will be used as baseline.- Scenario 1: behavior of the demos after the

intervention.- Scenario 2: optimization.

Old city hall of Voula municipalityAthens, Greece


Energy-efficiency and CO2 reductionInnoWEE project proposes use of geopolymers containingconstruction waste for production of the innovative panels.Production of the geopolymer materials emits even 80% lessCO2 than in case of traditional Portland cement.


The radiant panels were tested and designed aiming to obtianthe best possible energy efficiency, while maintaining propermechanical properties.The enthalpy balance method is coupled with thethermographic measurement, that highlights the temperaturedistribution on the active surface.

0

20

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0 5 10 15ΔT (°C)

Cooling-HDG

Cooling-commercial

The radiating panels for indoor application are able to provide more power during both heating andcooling mode then comparedcommercial ones.In case of the radiating panels,the thermal conductivity is thekey parameter as it couldreach values higher than 1 Wm-1 K-1.

0

20

40

60

80

100

120

0 5 10 15 20 25

Spe

cifi

c p

ow

er

(W m

-2)

ΔT (°C)

INNOWEE Project

Project Coordinator Adriana BERNARDINational Research CouncilInstitute of Atmospheric Sciences and Climate (CNR – ISAC)[email protected]

Dissemnation and Exploitation leaderEmil LEZAKIZNAB SPOLKA Z OGRANICZONA ODPOWIEDZIALNOSCIA (IZNAB)[email protected]


mailto:[email protected]



• Topic: EEB-04-2016, New technologies and strategies for thedevelopment of pre-fabricated elements through the reuseand recycling of construction materials and structures

• Duration: 4 years – Start date: 01/10/2016

• Budget: about 5 Million €

• Partners: 15 from 7 European Countries

• Coordinator: Dr. Anna Paraboschi, RINA Consulting S.p.A.,[email protected]

• http://www.veep-project.eu/

« Cost effective recycling of CDW in high added value energy efficient prefabricated concrete components for massive retrofitting of our built environment»

„This project has received funding from the European Union’s Horizon 2020

research and innovation programme under grant agreement No 723582”

http://www.veep-project.eu/


Project objective• The main objective of VEEP is to develop and

demonstrate a series of technological solutions for the massive retrofitting of our built environment, aiming at cost – effectively reducing building energy consumption

• It leads to higher resource efficiency in TWO novel multilayer Precast Concrete Elements (PCEs) through the combination of concrete and superinsulation material manufactured by using, at least, 75% (by weight) of C&DW recycled materials, as raw materials

• The TWO PCEs solutions will be conceived both for new building envelope and for building refurbishment


Project Consortium


VEEP Technological development

• The Advanced Drying Recovery (ADR) is a mobile technology equipped with dynamic air sifter that allows to sift also moist materials

• Normal sieves don’t allow to sift moist materials, but, the ADR technology allows to sift wet materials and develop high quality aggregates

Innovation

• The current ADR installation requires 1 day to dismantle and assemble it again

• ADR can treat both normal weight and lightweight concrete

• Capacity of treatment: 50 t/h

Technical performances


VEEP Technological development

• HAS technology is used for the valorization of the fine fraction aggregates (0-4mm)

• PATENT APPLICATION: Cement waste recycling device and method of recycling cement waste” (Application: N2020846) by TUD – Delft University

Innovation

• A pilot plant (3 ton/hour) has been developed

• HAS and ADR integration has been analyzed by TUD and cost of recycling is estimated @6€/ton of CDW



VEEP materials development

• New concrete & cement formulations have been developed

Innovation

• New green concrete récipes have been developed achieving more than 75% weight CDW aggregates incorporation

• New concretes manufactured with recycled C&DW materials presented @28 days values suitable for the precast concrete elements PCE1New

• Input to EU Standardization committe forEN 197 revision

• New green cement recipies have been developed showing even better characteristics that the reference (with no CDW material)

Technical performances #1


VEEP materials development

• New aerogel using silica based CDW as precurosor

• Patent: Manufacturing process patent (Granted to Keey)

• The technology for the manufacturing of silica Innovative Closed-loop Aerogels by KEEY AEROGELS and TECNALIA, it was awarded with one of the three prizes within the World Material Forum held in Nancy (France) (2017)

• A pilot plant with capacityof 100l/day has been designed and assembled @KEEY

• Aerogel production are <900 €/m³ with a 40% reduction respect to the SoA

Innovation

Technical performances #1


VEEP manufacturing development

• The development of novel plastic (much more lighter and easy to customize than conventional wood ones) formworks has been finalized

Innovation

• The innovative formworks allow the lead time reduction to 4 minutes per square meter, contributing to the achievement of the target +15% daily panels production



VEEP products development

• The development of the design of PCE1 and PCE2 has been finalized

• The preliminary 3D design of a new dismountable anchoring system has been also developed

Innovation

• The new PCEs designed by considering mechanical, thermal, functional and environmental requirements with cost not exceeding 90€/m2

• The design of a new dismountable anchoring between the concrete layers of sandwich panel will allow to facilitate the reuse of concrete layers or their recycling. Also, this new connector will facilitate the separation of the insulation layer from the rest of the element.


Concrete sandwich panel

with new connector

Concrete sandwich panel

dismounted thanks to the new

connector


Conclusions

The fine (0-4 mm) fraction of the recycled concrete, accounting for roughly 40% of the recycled concrete, still faces technical barriers to be incorporated into new concrete

CDW fines aggregates

• the development of the integrated ADR+HAS technologies movable system which has demonstrated to improve the mechanical properties of the cement obtained can lead to overcome such barrier

The positive results about the addition of CDW aggregates in concrete as coarse and fine aggregates can result in better concrete and cement performance

CDW concrete & cement

• TEC/UNE proposal for standard revision which can also foster the CDW adoption

PCEs eco-design finalizedPCEs design

• The ecodesign of panels and development of easy to adopt connectors can also foster the PCEs further commercialization

VEEP Project

Project CoordinatorAnna PARABOSCHIRINA Consulting [email protected]



Project number 723825

Project value 4.99 million €

Starting month October 2016

Project Duration 42 months

Work Programme topics

addressed:

EeB-04-2016 New technologies

and strategies for the development

of pre-fabricated elements through

the reuse and recycling of

construction materials and

structures


Prof. Xiangming ZHOUBrunel University London

Department of Civil and Environmental Engineering

[email protected]

«Prefabrication for refurbishment from a modular perspective by way of a universal building block with customization potential»

„This project has received funding from the European Union’s Horizon 2020

research and innovation programme under grant agreement No 723825”

Motivation

850 million tons of waste in the EU

construction sector

31% of the total EU waste generation

40%–67% of the Construction and

Demolition Waste is concrete

1.6 billion tons of CO2

each year globally

Construction of new buildings alone generates an average of 39kg of construction waste per m2 of a

building.

Ageing building stock is consuming an ever increasing amount of energy-deep renovation and shifting

energy requirements of the buildings closer to zero is often out of reach for economic and technical

reasons!


Our Proposal

Prefab structural building block

suitable both for retrofitting as well as new construction

>70% per weight of

CDW30% lighter

than conventional

envelope walls

U-value of 0.14

W/m2ºC

Acoustic insulation in the 55-

60dB

Vertical Green Wall

Continuous manufacturing

using extrusion


Objectives

Efficient, robust, eco-friendly and replicable

processes

Cost efficient products and new supply chains

Safe and energy efficient buildings

Comfortable, healthy and productive

environment

Sustainability and cost savings through CDW

sourced materials & C2C


Impact

High CO2 and energy inputs savings during the

fabrication and operation processes

High rates of CDWs recycle and reuse during

building blocks fabrication

Re-entry into production lines with coherent

design strategies

Reduction of uncertainty linked to the use of recycled products

Incorporation of the safety-by-design

approach


• Tackle CDW harvesting & separation based on supply chain optimization & establish a new value chain with high business potential;

• Develop high performance insulating materials from PU waste & also extract rheology modifiers to co-extrude with MOC cement & geopolymer;

• Develop novel reinforcing fibres & functional additives from CDW (i.e. wood, textiles, polymers etc.) to reinforce MOC cement, geopolymer & PU;

• Develop PCM-encapsulated aggregates with high & smart energy efficiency workable under different climates

• Develop doped TiO2 coating for MOC cement panels that is able to clean indoor air pollution;

• Explore geopolymer matrix with precursor from CDWs that is able to accommodate green wall & to be extruded;

• Develop & optimize MOC cement composites to mimic natural wood with elegance, thermal insulation, light-weight, high fire resistance etc.;

Aims


Aims

• Develop vertical green wall for aesthetic, microclimatic, CO2 capture, biodiversity & acoustic insulation as well as for treatment of storm & grey water;

• Build CFD model for integrated multi-layer Green INSTRUCT modular panel to guide materials & components research & development for highest energy efficiency;

• Create architectural & BIM model to guide Green INSTRUCT modular panel design, installation, repair/replace & dismantling;

• Demonstrate integrated Green INSTRUCT multi-layer modular panels in two climate zones for minimizing on-site work as well as structural, thermal, acoustic & climatic performance; and


Project Organisation



Polyurethane Insulating Foam

Produced by extrusion4-6 mm thickness

Eurocode 9 compliant

Polyurethane Insulating Foam from PU waste with additives and reinforcing

fibers50-100mm thickness

Magnesium Oxide CementMOC with Fibers, Aggregates and

PCMs20-40 mm thicknessDensity 1-1.2 g/cm3

Photocatalytic LayerDoped TiO2 coating for indoor

activation

Reinforced FibersReinforcing Fibers from wood

and textiles

Green Wall

Geopolymer Layer

Reinforcing Fibers

Air Gap

Reinforcing Fibers from PVC, PET and textiles2-5% loading

30-60 mm

Geopolymer Matrix from CDW: clay, wood, glass, bricks, gypsum and tiles 20-40 mm thicknessDensity 1-1.7 g/cm3

Recycled Aluminum FrameGreen INSTRUCTat a glance

Panel Development (Materials)

Sourcing of CDW’s and other raw materials

Fibres


Panel Development (Materials)

Geopolymer

PU Foam


Magnesium Oxychloride cement

PCM impregnated aggregates

Panel Development (Green Wall)


Panel Development (Modelling)


Panel Development (Connection)


Project Coordinator

Prof. Xiangming ZHOUBrunel University London

Department of Civil and Environmental Engineering

[email protected]

Dissemnation and Exploitation leader

Thomas PARISSISCenter for Technology, Research & Innovation (CETRI)

[email protected]

Technical Manager

Dr. Glikeria KakaliNational Technical University of Athens

School of Chemical Engineering

[email protected]

Green Instruct Project


This project has received funding from the European Union’s Horizon 2020

research and innovation program under grant agreement No. 723583

Work Programme topics addressed:

EeB-04-2016 New technologies and strategies for the

development of pre-fabricated elements through the reuse and

recycling of construction materials and structures

Project number: 723583 Project cost: 4.81 million €

Starting month: September 2016 Project Duration: 42 months

REuse and REcycling of CDW materials and structures in energy efficient pREfabricated

elements for building REfurbishment and construction

www.re4.eu

RE4 PROJECT


https://www.linkedin.com/company/15155876/

https://twitter.com/RE4_project

https://www.facebook.com/re4project

https://twittehttps/www.youtube.com/channel/UCVjtZ3lyoEvw6O3LYnzwHAwr.com/RE4_project

http://www.re4.eu/

Motivation

40

Development of innovative technologies & reliable strategies

• Increase % reuse &recycling from CDW

• Increase CDW technical& economic value

• Minimise future CDWfrom next generation ofbuildings

• Increase building energyefficiency


41

RE4 is developing an innovative approach to reuse and recycling of construction demolition waste materials

and structures.


Aim of the project

42

Develop prefabricated energy-efficient building concept

• Easily disassembled / assembled for future reuse

• Containing up to 65% by weight of recycled materials from CDW

• Reusable structures will range from:

• 15-20% for existing buildings• 80-90% for the RE4

prefabricated building concept


Objectives

43

• Maximise recycled CDW amount & value by using advanced sorting technologies

• Innovative RE4 CDW sorting system based on an automated robotics system

• Assess properties of CDW-derived materials for building elements• Compliance check

• Quality variability evaluation, quality classes & optimal recycling strategy definition


Objectives

44

• Development of prefab. elements and innovative design concepts for pre-fabricated building components

• Design for modular/smart installation & disassembly/re-use


Objectives

45

• RE4 demonstration in an industrial environment

• For new constructions & refurbishment

• Demonstration of strategy for disassembly & reuse

• Enhance sustainability & future applications of RE4 prefab. products

• 30% CO2 savings & 20% energy savings

• Resource efficiency: min. 65% recycled materials in final product

• Less waste generation & disposal


Objectives

46

• Development of a BIM-compatible DSS and platform for CDW estimation andmanagement

• Support owners & Construction/demolition companies

• Development of business models for industrial exploitation• Enhance replication potential• Economic assessment to evaluate profitability, understand

future cash flows, & highlight need for additional funding/investment


Project partners

47

UK

Belgium

Italy

Spain

Sweden

Germany

Czech Republic

Coordinator

Taiwan


Demonstration

48

• Two specifically constructed mock-ups (residential or non-residential) in two different climatic regions (UK, Spain).

• Demonstration of refurbishment solutions in the demo siteavailable at STRESS.

• Strategy for disassembly and reuse materials demonstrated inthe Acciona demo park.

• High replication outside EU through demo building in Taiwan.


Timeline

49

Assessment of CDW streams across Europe

CDW separating system based on weight criteria

CDW sorting system based on robotic

NIR sensors

Design development of components for easy

installation & disassembly

Large-scale production of the selected

products & elements

Demonstration buildings &

performance analysis

Project start

Project end

1 2 3 4 5 6


This project has received funding from the European Union’s Horizon 2020

research and innovation program under grant agreement No. 723583

The sole responsibility of this publication lies with the author. The European Union is

not responsible for any use that may be made of the information contained therein.

REuse and REcycling of CDW materials and structures in energy efficient pREfabricated elements for building REfurbishment and construction

Project coordinator: Alessandro Largo, CETMA [email protected]

Dissemination leader: Petra Colantonio, FENIX [email protected]




Thank you for your attention!


«Transforming Construction Waste into Energy Efficient Solutions»

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