Displaying items by tag: construction and demolition waste
Lafarge Canada completes first phase ECOCycle Technology pilot at St. Constant cement plant
14 August 2023Canada: Lafarge Canada says that it successfully integrated 10,000t of recycled concrete waste in cement production at its St. Constant cement plant in Quebec using its ECOCycle Technology process. The year-long production trial constituted the first phase of Lafarge Canada’s pilot of ECOCycle Technology. The producer says that the achievement solidifies its leading position in North American circular construction innovation. Waste360 News has reported that concrete constitutes 4Mt (40%) of Canada’s 10Mt annual generation of construction and demolition waste.
President and CEO David Redfern said “By reusing construction and demolition wastes in the production of new building materials, we are reducing waste sent to landfill. Across Lafarge Canada, we’re evaluating any opportunity to decarbonise our operations, and circularity is part of this effort. This pilot is critical to demonstrate that we can effectively repurpose concrete waste, which goes a long way to conserve our naturally occurring resources and loops in construction sustainability - building new from old.”
Taiheiyo Cement to dispose of future disaster wastes for Hidaka City and Saitama Prefecture
14 July 2023Japan: Taiheiyo Cement has concluded an agreement to dispose of waste produced by any natural disasters that should occur in Hidaka City and Saitama Prefecture. Under the agreement, Taiheiyo Cement will establish a disposal system with realises the potential of disaster waste as a resource. This will work alongside another recycling programme for conventional wastes. The cement producer says that this will help to build a safe and secure community.
India: The municipal corporation of Kolkata, West Bengal, has enacted regulations requiring landowners to send construction waste from projects on their property to construction and demolition waste recycling facilities. The Telegraph newspaper has reported that the new regulations apply to all construction, demolition and repairs work on plots of land larger than 0.24 hectares. The city authorities have built a 183,000t/yr recycling plant in New Town, Greater Kolkata, to support the increased volumes.
Building new buildings from old ones
19 April 2023Holcim launched its formal take on construction and demolition waste (CDW) this week with the unveiling of its ECOCycle technology platform at the BAU architecture fair in Munich. This amounts to managing the distribution, processing, grinding and recycling of CDW back into new building material products. It claims that its concrete, cement and aggregate products can contain 10 - 100% of CDW with no drop in performance.
It is hard to gauge whether this is marketing for existing operations or the start of something new. Yet, in its 2022 Sustainability Report, Holcim said that it recycled 6.8Mt of CDW back into building products and that it is on track to meet its target of 10Mt by 2025. This target was neatly put into words as wanting “to build more new buildings from old ones.” Ahead of the announcement of the launch of ECOCycle, it added that it was going to roll out its Susteno product around Europe. This product, made from 20% CDW, was originally released in Switzerland in the late 2010s. Notably, recent acquisitions by Holcim that connect to its growing focus on CDW include Poland-based Ol-Trans in July 2022, UK-based Wiltshire Heavy Building Materials in October 2022 and UK-based Sivyer Logistics in April 2023.
As covered by Global Cement Weekly in February 2023, Holcim is not the only heavy building materials company pivoting to CDW. The European Union (EU) set a 70% recovery target for it in 2020 and various cement company sustainability reports have described the region as being receptive to moves into this sector. Cemex set up a global waste management subsidiary called Regenera at the end of January 2023. This division covers both alternative fuels, CDW and industrial by-products, so it is more general than Holcim’s current effort, but it shows intent in the same direction. Cemex previously set a target of recycling 14Mt/yr CDW by 2030.
Heidelberg Materials has been working on developing recycled concrete paste and its ReConcrete-360° concrete recycling process. As of its last sustainability report, this process had been tested at the pilot scale and is now being developed and scaled for industrial application. In addition to acquiring UK-based Mick George Group in December 2022 Heidelberg Materials has also purchased Germany-based RWG Holding in January 2023 and Germany-based SER Group in February 2023. All three companies operate in the CDW sector.
The other notable contribution that Heidelberg Materials has been making is as a partner of the ‘Circular City - Building Material Registry for the City of Heidelberg’ project. When Heidelberg Materials announced its involvement in the initiative in mid-2022 it said it was the first city in Europe to apply the principles of urban mining. The goal of the project is to take an inventory of the city’s buildings and then compile it in a digital material registry. The basis for the registry is the Urban Mining Screener developed by EPEA (Environmental Protection Encouragement Agency). This programme can estimate the composition of buildings based on building data such as location, year of construction, building volume or building type. Circular economy supply chains can then act accordingly when a building is retrofitted, demolished or deconstructed. So, for example, at the start of the project it worked out that a former US Army housing estate conversion site was calculated to contain approximately 466,000t of material, with about half in the form of concrete, a fifth in the form of bricks and 5% as metal.
That last example compares to a European Commission estimate that, as a whole, Europe generates around 450 - 500Mt/yr of CDW. A third of this is concrete. As with alternative fuels and slag previously, this may be money going into the ground. Recycling building materials is not new but any significant increase in reusing CDW that can reduce the clinker factor of cement (and the cement factor of concrete) offers a potentially cheaper route to building materials decarbonisation than carbon capture and utilisation/storage at current costs. Hence the continued interest.
Switzerland: Holcim has launched ECOCycle, its initiative to recycle construction demolition materials into new building products. It says it can recycle construction demolition materials across a broad range of applications, from decarbonised raw materials in low-carbon cement formulation, to aggregates in concrete and fillers in road construction.
Jan Jenisch, the chief executive officer of Holcim, said “Across all metropolitan areas where we operate, we are at the forefront of driving circular construction to build new from the old. With our ECOCycle technology we can build cities from cities, recycling 100% of construction demolition materials into new solutions, so everything gets reused and nothing gets lost. With our world’s growing population and urbanisation, circular construction is essential to build a future that works for people and the planet.”
The building materials producer is deploying its ECOCycle technology across its range of products to scale up circular construction. It says that its process enables concrete, cement and aggregates to contain from 10 - 100% recycled construction and demolition waste with no change in performance. The initiative is supported by distributing, processing, grinding and recycling construction and demolition materials into new building material products.
ECOCycle brings together previous work Holcim has conducted in the field such as launching a cement in Switzerland made with 20% demolition and construction waste. The company is now launching this product elsewhere in Europe. In France it is building an affordable housing complex using 100% ECOCycle recycled concrete. In the UK it is building a residential area with 50% ECOCycle aggregates that have been made from 100% recycled construction demolition materials.
Holcim publishes Climate Report 2023
06 April 2023Switzerland: Holcim has published its Climate Report 2023, detailing the company’s progress towards meeting its sustainability commitments up to the end of 2022. The cement producer recorded net specific CO2 emissions per tonne of product of 562kg/t, down by 1.7% year-on-year from 572kg/t in 2021. In line with its 1.5°C climate change-aligned targets, Holcim is committed to 420kg/t specific CO2 emissions by 2030 and net zero by 2050.
Overall, the group’s Scope 1 CO2 emissions from cement production fell by 2.5% to 77Mt from 79Mt, while its Scope 2 emissions remained at 5Mt and its Scope 3 emissions fell by 11% to 47Mt from 53Mt. Its cement had an average clinker factor of 73%, down from 73.6% in 2021. Holcim processed 6.8Mt of construction and demolition waste, up by 3% from 6.6Mt. Meanwhile, its thermal substitution rate of alternative fuel (AF) rose to 28% from 26%.
CEO Jan Jenisch and chief sustainability officer Magali Anderson said “With our successful transformation, we reduced our CO2 per net sales by 21% in 2022, and commit to reducing it by over 10% in 2023. Accelerating the shift to net-zero cities requires deep partnerships across our value chain. In 2022 we engaged with public authorities to evolve building standards, with cities to scale up green demand in their projects, and with architects and engineers to specify sustainable solutions in their designs. We did this as a key partner for our customers, bringing solutions that help them achieve their sustainability goals.”
Holcim acquires Sivyer Logistics
06 April 2023UK: Holcim has acquired leading London construction and demolition waste (CDW) recycling company Sivyer Logistics. Sivyer Logistics produced 500,000t of recycled aggregates and manufactured soils from 1Mt of CDW across its six sites in 2022. Holcim says that the acquisition represents a step towards realising its target of 10Mt/yr of construction and demolition waste in Holcim products by 2025.
The group’s Europe regional head Miljan Gutovic said “Sivyer Logistics is an excellent addition to help us drive circular construction.” He added “I look forward to welcoming all employees of Sivyer Logistics and investing in our next era of growth together.”
India: Antony Waste Handling Cell Limited (AWHCL) has won a US$124m contract for construction and demolition waste management services in Mumbai. Press Trust of India News has reported that the contract covers nine municipal subdivisions of the city and will last until 2044. AWHCL said that the contract will enable it to develop the circularity of cement and concrete within the local economy. It expects to commission 600t/day-worth of waste processing capacity by March 2023. The waste management company expects a recovery rate of 25% recyclable materials.
AWHCL chairman and managing director Jose Jacob said "This sub-segment of solid waste management provides tremendous growth opportunities given the number of infrastructure development projects underway, and the government's push to accelerate the economic growth with infrastructure being one of the important growth pillars."
Update on construction and demolition waste, February 2023
01 February 2023Cemex launched a new waste management division called Regenera this week. Cemex describes Regenera as a “business that provides circularity solutions, including reception, management, recycling, and coprocessing of waste.” The Mexico-based company has a long and leading history with sourcing and using alternative fuels in the cement sector and the new organisation looks set to utilise this experience. What is notable though is how the business is targeting three waste streams: municipal and industrial; industrial by-products; and construction, demolition and excavation waste (CDEW). Bringing the three waste streams together in this way appears to be novel for the heavy building materials sector, particularly the inclusion of CDEW, which we will explore further here.
CDEW is split into fractions, just like the municipal and solid waste streams that end up as alternative fuels at cement plants, but the biggest fractions are generally concrete, followed by bricks. The recycled concrete is then typically used as an aggregate, either in new concrete production or in areas like road construction and earthworks. The use of recycled aggregates (RA) made from CDEW goes back to at least the 1930s in its current form although ‘reusing’ materials from structures such as castles and churches goes back far further. Recycling and reusing CDEW gained a boost in 2020 when the European Union (EU) set a 70% recovery target. However, within the EU the CDEW recycling rates vary considerably and that 2020 target includes the use of CDEW in backfill applications.
In its launch statement for Regenera, Cemex noted that it operates a dock in Paris, where it receives a variety of materials, including construction debris, excavated material and inert soil. These materials are sorted, processed and then transformed into recycled aggregates or organic material used to restore quarries. Cemex then promptly followed up the official launch of Regenera on 30 January 2023 with the acquisition of a majority stake in Shtang Recycle, an Israel-based CDEW recycling company. It added that Shtang Recycle is preparing to build a recycling plant with a production capacity of 0.6Mt/yr of CDEW waste materials. The output from the plant will be used as raw materials for aggregate production.
The focus on CDEW recycling was flagged up at Cemex’s investor event in November 2022. It said that it was targeting a recycling rate of 14Mt/yr of construction and demolition waste by 2030. Other managed waste stream goals included doubling the amount of municipal and industrial waste it manages, to achieve a 50% to fossil fuel substitution rate, and increasing its usage of alternative raw materials and by-products by 30%, thereby eliminating 13Mt/yr of extracted materials.
Cemex is not alone in targeting the CDEW waste sector. Holcim’s recent work in the area goes back to at least 2016 when a recycling unit near its Retznei cement plant in Austria started processing 130,000t/yr of CDEW. It announced in December 2022 that it was setting up a similar recycling centre, also in Austria, at its Mannersdorf cement plant. In October 2022 Holcim acquired Wiltshire Heavy Building Materials in the UK. This company recycles 150,000t/yr of construction and demolition waste into aggregates and concrete. Holcim linked the acquisition to its Strategy 25 target of recycling 10Mt/yr of construction and demolition waste by 2025.
Activity by other cement companies includes the commissioning of a construction waste recycling plant at Gennevilliers in France by CRH-subsidiary Eqiom in April 2022. It was aiming for a target of 50,000t in 2022. In November 2022 Heidelberg Materials agreed to acquire RWG Holding based in Berlin, Germany. Then, in December 2022, it announced a deal to buy Mick George Group in the UK. Both proposed acquisitions are subject to competition authority approval. Heidelberg Materials’ current target is to offer circular alternatives for half of its concrete products by 2030.
The moves by the bigger cement companies into the CDEW sector follow sustainable thinking and the waste hierarchy. Yet the big prize here is to gain a route to dispose of some of their CO2 emissions through recarbonation and this has been flagged up in several net-zero roadmaps for the cement sector such as those by Cembureau and the Global Cement and Concrete Association (GCCA). Holcim has been involved in the FastCarb project in France, running a pilot at its Val d’Azergues cement plant in 2021. Heidelberg Materials has been testing its own process with so-called recycled concrete paste. The development now appears to be that utilising CDEW has entered the sustainability strategies for some of the big cement-concrete-aggregate producers, targets have been set and acquisitions are happening.
For more information on Heidelberg Materials research into concrete recycling read the January 2023 issue of Global Cement Magazine
Lafarge Zement to establish Recycling Centre Mannersdorf
14 December 2022Austria: Lafarge Zement plans to invest Euro8m in the establishment of the Recycling Centre Mannersdorf at its 1.2Mt/yr Mannersdorf cement plant in Lower Austria. Niederösterreichische Nachrichten News has reported that the facility will process demolition waste into alternative raw materials for use in the cement producer’s operations.
Plant manager Helmut Reiterer said “The Recycling Centre Mannersdorf is of great importance for the construction industry. It enables people to build in a much more environmentally friendly way, increases the recycling rate and strengthens the domestic circular economy.”