THE 7th INTERNATIONAL CONFERENCE

"CIVIL ENGINEERING - SCIENCE AND PRACTICE"

GNP 2020 – Kolašin, Montenegro, 10-14 March 2020

Dubravka Bjegovic1, Ivana Banjad Pecur2, Nina Stirmer3, Ana Baričevic4, Marijana Serdar5,
Ivana Carevic6, Marina Bagaric7

INNOVATIVE CONSTRUCTION PRODUCTS: DRIVERS OF

SUSTAINABLE ENGINEERING

Abstract
Construction engineering has a direct impact on the environment due to generated waste and
emission of harmful substances during the production of construction materials. To assure its
sustainability, significant changes need to be introduced starting with the excavation of natural
resources up to the reuse of construction products after their service life. Such changes are
crucial for the future generations, as the current level of pollution will have a significant impact
on their lives. Taking into account that construction industry is one of the world leaders in the
environmental pollution, this paper describes how we can contribute to the sustainable
development by applying innovative construction products and materials. The paper examines
the usage of the alternative materials in the cement and/or concrete production, the substitute of
natural aggregates by recycled aggregate from different sources and reinforcement of concrete
with recycled fibers from waste tires.
Key words
Concrete industry, sustainability, waste, recycled materials, construction products

1
Professor emerita, Department of Materials, University of Zagreb Faculty of Civil Engineering,
dubravka.bjegovic@grad.unizg.hr
2
Professor, Department of Materials, University of Zagreb Faculty of Civil Engineering,
ivana.banjad.pecur@grad.unizg.hr
3
Professor, Department of Materials, University of Zagreb Faculty of Civil Engineering, nina.stirmer@grad.unizg.hr
4
Assistant professor, Department of Materials, University of Zagreb Faculty of Civil Engineering,
ana.baricevic@grad.unizg.hr
5
Assistant professor, Department of Materials, University of Zagreb Faculty of Civil Engineering,
marijana.serdar@grad.unizg.hr
6
PhD student, Department of Materials, University of Zagreb Faculty of Civil Engineering,
ivana.carevic@grad.unizg.hr
7
PhD student, Department of Materials, University of Zagreb Faculty of Civil Engineering,
marina.bagaric@grad.unizg.hr

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1. INTRODUCTION

Sustainability is a way of live, attitude to the overall economic activity in accordance with
the Earth’s eco-system, which needs a vision of development [1]. The developed countries in the
EU developed the strategies in construction at the end of the last century (Figure 1) [2], which
show the difference between the traditional approach and global construction. The basic principle
of sustainable development in construction today is the minimum use of natural resources and
energy and generating the minimum amount of harmful waste for the Earth. The environment
protection and the energy saving have become worldwide issues in all fields of technology
including the construction industry, particularly in the field of the production of concrete.
The concrete industry is the largest consumer of natural resources and one of the largest
producers of waste. Although concrete, compared with other construction materials, is considered
to be an ecologically acceptable material, its components and production technology are not. The
concrete industry uses large amounts of natural resources, and some authors claim that it is
responsible for 7% of greenhouse gas emissions [3, 4]. It is also known that CO 2 emissions in the
environment are the main cause for today’s basic ecological problem – global warming [5 – 10]. In
addition to the problem of energy consumption and the emission of large amounts of CO 2 during
the production of cement, in concrete structures a significant problem is their durability, which
ultimately comes down to the problem of construction waste disposal.
Construction industry, and the industry of concrete within it, have to be capable of dealing
with the challenges of the population growth (150.000 new inhabitants a day globally) and
accordingly to the need for buildings and construction materials, which has an impact on global
warming, so that the demands of sustainable development, both at the level of material itself and its
production and its properties in construction, become primary requirements.
It has been estimated that only in the Republic of Croatia about 1.2 million tons of
construction waste is generated [11, 12]. The research into the technology of concrete has made
progress in the use of recycled aggregate which can be used as a satisfactory substitute for
aggregate from natural sources [13]. Knowledge about the mechanical and durability properties of
concrete produced from recycled aggregate can result in its convenient application, and thereby
increase the value of the material that is currently being used for backfilling or is being discarded at
landfill sites. Also, there are many scientific efforts of using other wastes (slag, glass, tire scrapes,
sewage sludge) as new recycled materials in construction (hot mix asphalt, concrete mixes,
aggregate, soil stabilizer, etc.) [14].

Figure 1. The new approach in global context [2]

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This paper describes how and in what way to contribute to the sustainable construction
engineering by applying alternative materials in cement production and/or as a cement substitute,
by using recycled material as a substitute aggregate in concrete mixture and the use of recycled
fibers from discarded auto tires as a micro reinforcement.

2. ALTERNATIVE MATERIALS AS AN ADDITION TO THE

CEMENT PRODUCTION AND/OR A PARTIAL SUBSTITUTE FOR
CEMENT

In the modern concrete production plants, the largest amount of concrete is made with
supplementary cementitious materials – SCMs – which are either the by-products of various
industries or the materials which can be recycled, and they are numerous [15]. The above materials
vary by origin, chemical and mineral composition and characteristic particles. The application of
alternative materials in concrete mixtures is a well-established methodology for reducing the
clinker factor in cement and developing positive properties of concrete as a construction material.
Some of these materials have been applied for years either as an admixture to cement or as a
substitute for cement in the composition of concrete, such as fly ash, slag, silica fume and
metakaolin. Their application is possible because it has been regulated and standards have been set,
e.g. EN 15167-1:2006 Ground granulated blast furnace slag for use in concrete, mortar and grout,
EN 13263-1:2005+A1:2009 Silica fume for concrete, EN 450-1:2012 Fly ash for concrete. At the
same time, the potential of using numerous other materials as partial or total cement replacement is
studied, which could lead to creation of an enormous number of new binders that could at some
point become available on the market. Some alternative materials are being intensively researched
into, such as sewage sludge [16 - 18], rice flakes ash, copper and zinc slag, waste from the
production of ferronickel, paper sludge, casting sand, sludge from a stone cutters [19], red sludge
[20, 21] and phosphogypsum [19, 22], depending on local availability. There are numerous
industries that create waste materials that could be a new potential by-product for cement and
concrete industry. As a first step in developing alternative binders as new materials for application
in the concrete (ABC – alternative binders for concrete), it is necessary to identify and estimate
potential sources of relevant secondary raw materials in the region and industries that produces
them.

Figure 2. Some of the raw materials evaluated as potential supplementary cementitious materials:
ladle slag, iron silica fines, red mud, fly ash, clay and limestone

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One of material, which is declared as waste but could be use as new material in cement and
concrete industry, is wood biomass ash (WBA). After the full combustion of wood biomass in
power plants, WBA is left as a by-product on landfills [24, 25]. In Croatia estimated costs of WBA
disposal rise from 50 EUR to 180 EUR per tonne which doesn’t not include cost of transport cost
[24]. It the future it can be expected the increase of costs of landfill, as well as the difficulties in
acquiring new landfill sites. These leads to a need of the future strategy for WBA management.
Based on previous scientific research, it was concluded that mostly empirical testing approaches
were used delivering fragment understanding of WBA characterization as a raw material in the
concrete sector and WBA effect on cement composites [25]. This demands the need for wider
WBA characterization in the frame of its use in the cement and concrete industry as a new potential
raw material. Comprehensive research is given by [25] where 21 samples of WBA collected from
different sources in the Republic of Croatia were evaluated based on their chemical (chemical
composition, mineralogical composition, phase-stability characterisation and heavy-metal content)
and physical properties (particle-size distribution analysis, density and particle morphology
analysis). Based on their characterization, WBAs were benchmarked and categorised for the
different resource replacements in production of cement and concrete, Table 3. Such ranking
categorisation can be employed to screen the differences in many WBAs from various sources that
is important in the valorisation of WBAs waste in cementitious materials.
Table 1. Example of WBA´ ranking based on normalisation relative to the limit values for their use
as SCM [25] (data in table are normalized)

PQI NQI RANG

SAMPLE PozOx d50 LOI Na2Oeq SO3 P2O5 MgO CaO free HMI

Cement 2.34 0.21 0.40 0.33 1.11 0.04 0.50 1.00 1.00 1

F9 2.35 2.68 0.48 0.58 0.22 0.70 0.70 0.33 2.66 2

F7 2.43 1.60 0.42 0.93 0.91 0.36 2.07 4.87 0.90 3

F1 5.07 0.61 1.57 1.48 0.60 0.68 1.24 4.33 2.15 4

F10 3.55 0.40 1.41 0.94 1.32 0.81 1.18 5.87 2.10 5

F8 5.32 0.16 4.03 1.04 1.47 0.70 2.07 3.87 2.20 6

B5 5.38 1.55 1.49 0.96 0.75 0.33 1.01 7.73 1.23 7

F6 5.37 0.96 1.53 1.32 1.19 0.37 0.94 9.00 0.70 8

M1 9.90 0.89 1.57 1.38 0.70 0.69 1.28 5.93 1.41 9

F4 5.70 0.40 1.49 2.18 1.59 0.52 1.20 5.73 3.16 10

B4 8.26 0.75 1.58 1.03 0.54 0.46 1.04 10.53 1.20 11

B2 11.31 1.13 2.01 1.94 0.19 0.50 1.05 11.27 0.66 12

F2 13.04 0.69 2.12 0.74 0.42 0.55 1.08 15.67 0.85 13

F3 24.56 0.09 2.39 3.52 2.91 0.59 1.25 5.20 1.68 14

F5 18.77 0.13 2.31 4.67 4.12 0.50 0.92 7.20 4.11 15

>70 <6.5
Limit <45µm <9% <5% <3% <5% <4% <1.5%
% %

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3. RECYCLED MATERIALS AS SUBSTITUTE AGGREGATE

Construction and demolition waste (CDW) is one of the most extensive waste streams
generated in the EU. It accounts for about 25 % - 30 % of total waste produced in the EU and
consists of numerous materials, including concrete, bricks, gypsum, wood, glass, metals, plastics
and earth, many of which can be recycled. In Europe, 200 million tons of construction and
demolition waste is produced annually [26]. There is a high potential for CDW recycling and
reuse, since some of its components have a high value. Specifically, there is a market for
aggregates obtained from CDW in road and drainage construction, in the production of
prefabricated elements and other construction projects. Therefore, proper waste management,
including proper handling of hazardous waste, can have considerable benefits in terms of
sustainability and quality of life. For this reason, the EU has drawn up a Protocol [27] that
complies with the construction strategy 2020. [28]. The technology for the separation and reuse of
construction and demolition waste is well developed, and thanks to research new technologies are
being found [29]. Construction waste recycling mainly produces aggregates for concrete, and the
most widely used technology for recycling concrete is the one which produces all fractions [30]. In
the studies conducted within two master’s theses at the Department of materials at the Faculty of
Civil Engineering, Zagreb, it has been proved that the most profitable is the application of fraction
16-31.5 mm [31, 32].
One of the possible applications of recycled aggregate in concrete is in the industry of
prefabricated elements, Figure 3. One of example is developed of an innovative Structural
Concrete Insulated Panel, called ECO - SANDWICH® [33-36]. The ECO-SANDWICH® wall
system is innovative prefabricated wall panel with integrated core insulation allowing very low
energy design and retrofit of buildings. It consists of two precast concrete layers interconnected
through stainless steel lattice girders, Figure 3. The inner (load bearing) layer of the ECO-
SANDWICH® is made of recycled concrete aggregates while the outer façade layer is made of
recycled brick aggregates. After mechanical and durability testing [34], it was decided that inner
layer of ECO-SANDWICH® panels will be made with 50% of recycled concrete aggregates while
the outer façade layer will be made with 50% recycled brick aggregates. Layer of thermal
insulation 20 cm thick is free formaldehyde Ecose® based mineral wool. To prevent possibility of
water vapour condensation, layer of ventilated air is placed between layer of thermal insulation and
outer façade layer. Upscaling recycled aggregate concrete (RAC) from laboratory material
experiments to full scale construction product implementation requires proof-of-concept of RAC’s
suitability for energy high-performing, moisture safe, durable and sustainable building envelopes.
To investigate this suitability, experimental monitoring of very low-energy family house built with
ECO-SANDWICH® panels is being carried out; whereby its hygrothermal performance when
exposed to real climate conditions und under the real occupants’ use is captured [36]. Results
suggest that naturally ventilated air in cavity provides passive cooling of envelope in summer
periods, which is particularly present in case of south-facing panel. No moisture problems were
detected in panels and their high thermal mass potentially can lead to lower energy consumption in
buildings [36].

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a) b) c)

Figure 3: Closing material loop for strengthening construction industry: a) Model of ventilated
prefabricated RAC wall panel with positions of installed sensors; b) Construction of family house
using ventilated RAC wall panels; c) hygrothermal monitoring results accessed in customized
computer system

Larger fractions of secondary waste of metallurgical industry, such as slag, zinc,

ferronickel, aluminium, also could be used as substitute aggregate fractions [19, 37]. During
waste tyre recycling, rubber granules can be obtained. Within the EU RUCONBAR project
[38-42], it has been proved that concrete can incorporate rubber granules from recycled tires
to form a porous noise-absorptive layer of road and railway noise barriers (RUCONBAR). By
incorporating 40% rubber granules recycled from waste tyres recovered from end-of-life
vehicles, innovative solution as absorbing layer in production of noise barriers was
developed, once more proving that innovative materials could be drivers for sustainable
construction sector.

4. RECYCLED MICRO REINFORCEMENTS

0,1 30 0,1 30
Early age deformations (‰ )

Early age deformations (‰ )

0,08 0,08
25 25
0,06 0,06
Temperature (
C)

Temperature (
C)

0,04 20 0,04 20
0,02 0,02
15 15
0 0
-0,02 0 10 20 30 10 -0,02 0 10 20 30 10
-0,04 -0,04
5 5
-0,06 -0,06
-0,08 0 -0,08 0
Time (hours) Time (hours)

Figure 4. Recycled tire steel fibers Figure 5. Average results of the early age shrinkage
(RTSF) and recycled tire polymer fibers measurement for: a) referent mix; b) mix with 5
(RTPF) kg/m3 of cleaned RTPF [45]

During recycling of tyres, besides rubber granules, recycled tire steel fibers (RTSF) and
recycled tire polymer fibers (RTPF) can be obtain (Figure 4) and use in design an eco-friendly
cement-based composites [43-47]. Currently, RTPF are mainly sent to landfills or valorized as an
alternative fuel during cement production. The main challenge when using RTPF is storage, since
they are extremely flammable, and their low weight allows them to be easily carried by the wind.
Following the performance-based logic and considering the RTPF properties, RTPF can be used in
the concrete industry (independently to its rubber contamination level) as a replacement for
monofilament polypropylene (PP) fibers as their contribution to the improvement of concrete
behaviour in early age and during exposure to aggressive environments , Figure 5. The RTPF is

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usually heavily contaminated with residual rubber particles that can influence the concrete
properties. Therefore, a small-scale cleaning device [45] for RTPF cleaning was developed at the
Faculty of Civil Engineering, University of Zagreb, unclosing the possibility for establish the new
sector/industry that will assure the constancy of a new recycled waste as a new material in the
construction sector.

5. CONCLUSIONS
The construction industry slowly adopts new techniques, materials and technologies, and
our traditional building methodologies rely on traditional skills and unskilled labour. Today, this is
the reason for lagging behind and for the negative impact on the whole sector, and for the growing
gap between the traditional, aged working force and younger, technologically advanced
generations selected by other industries over construction one. However, a smart era, innovative
building methods are “round the corner” precisely because the main attention is paid to minimize
the impact on the environment by using innovative materials which can be durable and extremely
cost-effective. Examples in this paper shows various researches at the different technology
readiness levels (TRS) that are focus on implementation the concept of sustainability, respectively
reducing high energy consuming and negative environmental impacts in the concrete and cement
industry. This paper show potential of wastes from other industries as new materials in the new
developed construction products in order to overcome economic and ecological challenges, making
them as drivers for sustainable construction sector.

ACKNOWLEDGMENTS

Parts of the work presented in this paper were performed in the scope of the following
projects: “Transformation of Wood Biomass Ash into Resilient Construction Composites” (IP-
2016-06-7701) and “Alternative Binders for Concrete: understanding microstructure to predict
durability, ABC” (UIP-05-2017), funded by the Croatian Science Foundation.

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