Comparative Life Cycle Assessment (LCA) between standard gypsum ceiling tile and polyurethane gypsum ceiling tile

In this paper, the LCA of two gypsum ceiling tiles is compared, the first one is a traditional gypsum tile and the second is a new eco ceiling tile in which polyurethane foam waste has been incorporated. Both tiles were made at one of the largest gypsum tile factories in Europe. The life cycle assessment has been considered from cradle to grave for which the corresponding production stages have been defined. This includes the extraction and transportation of raw materials, the manufacturing process, transportation to the client, the use of the product and the end of its useful life. The results show that the tile with polyurethane has a better environmental performance than the standard commercial ceiling tile. This is quantified as a 14% reduction in energy consumption, a 14% reduction in CO2 emissions and a 25% reduction in water consumption compared with the standard tile, all the while maintaining the technical performance. An analysis of the results suggests that the new eco product has a competitive advantage on the market thanks to its environmental improvements and good technical performance.This study was carried out within the framework of the LIFEREPOLYUSE Recovery of polyurethane for reuse in eco-efficient materials. LIFE 16 ENV/ES/000254 Project. LIFE 2016. Environment Life Programme. European Commission. The authors are also grateful to the BU070P20 Project funded by the Fondo Europeo de Desarrollo Regional (FEDER) of the EU and the Junta de Castilla y León (Spain). In addition, the authors are grateful to the European Social Fund (European Union) and the Education Board of the Junta de Castilla y León (Spain) for funding the investigation

Characterization properties and fire behaviour of cement blocks with recycled polyurethane roof wastes

In accordance with the European politics of reducing the amount of polymers and plastics wastes, the inclusion of compounds such as roof wastes as recycled and reusable materials to replace variable amounts of aggregates is interesting in the production of new construction materials due to their physical and chemical behaviour. Prefabricated mortar blocks have made with Portland cement, sand, water and grinded roof polyurethane based wastes from the automobile industry that replace in different amounts part or all of the aggregates. To try to avoid the mechanical resistance limitation due to the use of roof wastes, the chemical properties of the binders have been modified with non-ionic surfactants that improve the effect on the hydration of the clinker. This variation produces an important change in the mechanical resistance to achieve recycled structural materials with a density between 18.7% and 62.7% lower compared to conventional lightweight mortars. In addition, these surfactants improve other properties including workability, compaction of the matrix, prevent the disintegration of the particles and help to improve the mechanical properties and durability against fire to reinforce the materials. These eco-mortars have a good behaviour against temperature of the final envelope, measured in terms of non-combustibility test. With these results, the use of roof wastes can be consider as a sustainable alternative to the materials currently used and then with them we can be able to contribute to a more ecological business model in the building sector.The non-combustibility tests were carried out at the AFITI LICOF laboratories in Toledo (Spain), entity recognized by National Accreditation Body (ENAC Accreditation No. 41/LE104 of Reaction to Fire, Fire Resistance and Fire Extinguishing Systems and Equipment tests)

Síntesis, caracterización, propiedades y aplicaciones de nuevas poliamidas aromáticas con subestructuras benzoéter corona y benzopodandos en la cadena lateral

Se describe la síntesis y caracterización de 30 nuevas poliamidas aromáticas que contienen subunidades benzo-12-corona-4, benzo-15-corona-5 y benzo-18-corona-6 y sus homógolos de cadenas abiertas con cadenas oxietilénicas que denominamos podandos. Asimismo, se analiza la formación de geles insolubles bajo las condiciones de polimerización de Yamazaki con algunos de los monómeros diácido sintetizados, que se resuelve disminuyendo la concentración inicial de monómero en la polimerización. También se determinan las propiedades de los polímeros, incluyendo la caracterización química, el comportamiento térmico y mecánico, absorción de agua, morfología resultados de difusión y permeabilidad de las membranas preparadas a partir de estos polímeros. Aprovechando las características de las poliamidas y las de los compuestos corona y relacionados, se han evaluado las posibles aplicaciones de los polímeros sintetizados en extracción selectiva y competitiva de cationes (alcalinos, alcalinotérreos, metales de transición, metales pesados y lantánidos), en transporte de analitos, y en separación de gases. ______________________ We report the synthesis and characterization of 30 novel polyamides containing the benzo-12-crown-4, benzo-15-crown-5 and benzo-18-crown-6 subunit and its dipodal counterpart. The anomalous polymerization of some of the diacid monomers, that leads to insoluble gels under standard Yamazaki polymerization conditions, is described and resolved. Polymer properties are also described, including the chemical characterization, mechanical and thermal behaviour, water sorption, morphology, diffusion data, and permeability of membranes prepared with these polymers. The interaction of alkaline, alkaline earth, transition metal, heavy metal, and lanthanide cations from nitrate solutions with synthetic polyamides as cations host moieties as been described. It is a noteworthy result, which along with the reusability of the solid-phase polyamides points to potentially successful applications in the field of environmental chemistry: the decontamination and elimination of poisoning cations, the separation and modification of cation mixtures, and the development of fixed-site carrier membranes for selective transport or manufacture of cation sensitive sensors

Comportamiento térmico de placas ecológicas de yeso con escorias blancas de acería = Thermal behavior of ecological gypsum boards with white steel slag

El presente estudio analiza el comportamiento térmico de placas de yeso fabricadas con adición de escorias blancas de Horno Cuchara LF, con sustituciones progresivas de yeso por escoria del 20%, 40%, 60%, 80%. Se estudia la reacción al fuego, la termogravimetría y la conductividad térmica en placas de yeso de (300 × 400 ×15) mm³. La adición de escorias blancas produce en las placas una variación significativa en los valores de conductividad térmica y del coeficiente de transferencia de calor por convección pared-aire, provocado por el aumento de la densidad y una mayor compactación del material y, por lo tanto, un menor aislamiento térmico. Asimismo, la respuesta frente al fuego y al incremento del calor mejora sustancialmente a medida que se incorpora mayor cantidad de escoria blanca, lo que produce una reducción en los valores de pérdida de masa muy relevante. Esto supone una ventaja para el uso en tabiques o protección en áreas industriales o con ambientes térmicos agresivos.AbstractThis study analyzes the thermal behavior of gypsum boards made with the addition of white slag from Horno Cuchara LF, with progressive substitutions of gypsum for slag of 20%, 40%, 60%, 80%. The reaction to fire, thermogravimetry and thermal conductivity in (300 × 400 × 15) mm³ plasterboard are studied. The addition of white slag produces in the plates a significant variation in the values of thermal conductivity and the coefficient of heat transfer by wall-air convection, caused by the increase in density and greater compaction of the material and, therefore, less thermal insulation. Likewise, the response to fire and to the increase in heat improves substantially as more white slag is incorporated, which produces a very relevant reduction in mass loss values. This is an advantage for use in partition walls or protection in industrial areas or with aggressive thermal environments

Declaration of performance (DOP) and CE marking of cement mortars made with recycled steel waste = Declaración de prestaciones y marcado CE de morteros de cemento fabricados con residuos de acería valorizados

The process of preparing a “Declaration of Performance” is presented for a masonry mortar manufactured with by-products from the steelmaking industry recycled as aggregates, for subsequent CE Marking, with the aim of promoting its commercialization within the European Union. Specific tests are applicable to construction mortars, both for masonry and rendering and plastering, for the verification of their performance, in accordance with harmonized standards EN-998-1 and EN 998-2. The study likewise sets out the Systems of Assessment and Verification of Constancy of Performance (SAVCP): System 4 for Rendering and Plastering Mortars and Systems 4 and 2+ for Masonry Mortars. Special importance in the new procedures for CE Marking is placed on the manufacturers, as they assume responsibility both for determining the properties of the materials and for establishing a control process in the factory. This document describes the technical development of the tests, in accordance with the applicable harmonized standards, for verifying the performance of the mortars designed with steelmaking slags as aggregates. The study concludes with the presentation of a Technical Data Sheet for the preparation of the corresponding CE marking for these new designed mortars.ResumenEste trabajo recoge el proceso de elaboración de una “Declaración de Prestaciones” de un mortero de albañilería fabricado a partir de residuos de acería valorizados como áridos, para su posterior Marcado CE, con el objetivo de facilitar su comercialización en la Unión Europea. Los morteros para construcción, tanto de albañilería como de revoco y enlucido, disponen de ensayos específicos para verificar sus prestaciones, de acuerdo con las normas armonizadas EN 998-1 y EN 998-2. De igual forma, se establece que los Sistemas de Evaluación y Verificación de la Constancia de las Prestaciones (EVCP) serán el Sistema 4 para los Morteros de Revoco y Enlucido, y los Sistemas 4 y 2+ para los Morteros de Albañilería. Los nuevos procedimientos para el Marcado CE en productos de construcción otorgan especial importancia a los fabricantes, ya que son los responsables de determinar las propiedades de los materiales, así como de establecer un proceso de control en fabrica. En este trabajo se describe el desarrollo técnico de los ensayos realizados para verificar las prestaciones de los morteros diseñados con áridos siderúrgicos. El trabajo concluye con la elaboración de la Ficha Técnica de Características para la elaboración del correspondiente distintivo de Marcado CE de los morteros diseñados

Bitumen modified with recycled polyurethane foam for employment in hot mix asphalt

A wide variety of modifiers have been applied to bitumen in order to enhance their properties and performance. Among them, polymers have been mainly used. The aim of this paper is to assess the use of polyurethane foam waste as a bitumen modifier for hot mix asphalts. The polyurethane foam is a by-product of the manufacturing of polyurethane for thermal insulation. From a bitumen with a penetration grade of 50/70, various samples with percentages of waste material in weight ranging from 1% to 5% were produced and tested. Samples with 5% of waste material or more became rough and were refused due to their poor workability. A bituminous mixture with modified bitumen with a 4% of polyurethane was manufactured and compared with a sample with the same aggregates and original bitumen. Results in Marshall test showed that a mix with polymer modified bitumen yielded improvements in stability and a lower deformability. This result suggests that the employment of polyurethane foam waste is a promising bitumen modifier, contributing also to recycle waste materials.Una gran variedad de modificadores se han aplicado al betún para mejorar sus propiedades y rendimiento. Entre ellos, los polímeros han sido principalmente utilizados. El objetivo de este artículo es evaluar el uso del residuo de espuma de poliuretano como modificador de betún en mezclas bituminosas en caliente. La espuma de poliuretano es un residuo que se obtiene durante la fabricación del poliuretano para aislamiento térmico. A partir de un betún de penetración 50/70, se fabricaron y analizaron varias muestras con porcentajes de residuo en peso entre el 1 y el 5 %. Las muestras con porcentajes del 5 % de residuo o superiores produjeron un material áspero y se descartaron debido a su poca trabajabilidad. Se fabricó una mezcla bituminosa con un 4 % de porcentaje de betún modificado con residuo de poliuretano y fue comparado con una muestra con los mismos áridos y el betún original. Los resultados en el test de Marshall mostraron que la mezcla con betún modificado provocaba un aumento en la estabilidad y una menor deformación. Estos resultados sugieren que el empleo de residuo de espuma de poliuretano es un prometedor modificador de betún, contribuyendo además al reciclado de materiales de desecho

Lightweight Recycled Polyurethane Mortar Placement: A Case of Success

The objective of this case study is based on establishing the real possibilities for the placement of cement mortars lightened with recycled shredded polyurethane, and their performance over a very long period of time, several years. Multiple types of mortars have been designed and dosed to be used as masonry base and resurfacing mortars. On site, therefore, it has been used as joint mortar and rendering mortar in a small shed. Mechanical flexural and compressive strength tests have been carried out on the samples made in the laboratory and on the samples taken from the mortar mixed on site. Adhesion tests have also been carried out on mortars applied as coatings, both exterior and interior. Organoleptic and other aptitude tests complete the study. The results show that this type of material is viable for application as a support for traditional coatings and finishes. This is a good advance in the real viability of reusing inert polymeric wastes in the construction sector, with the consequent environmental benefit, and in the line of contributing to the sustainability of the sector applied to construction materials. © 2022, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd

Towards an ecological transition in the construction sector through the production of new eco-efficient products

The economic model of the construction sector is becoming more circular by emphasizing sustainability at all stages from the design, the production phase, the installation, the use, the removal and finally its transport to landfill. This work analyses the influence of added polyurethane foam waste from refrigerated industry on the technical properties (bulk density, water vapor permeability, and reaction to fire performance). The environmental properties were also measured through a comparative Life Cycle Analysis (LCA) between the traditional gypsum ceiling tile and a new organic one. The re-use of polyurethane waste in ceiling tiles causes technical improvements. The most relevant improvements noticed are the decrease in the density (28%), reduction in thermal conductivity (27%) and A1 classification for fire reaction. The comparative (LCA) between both tiles shows that the new product that incorporates polyurethane waste has significant improvement in CO2 (14%) and lower use of energy during the manufacturing process (14%). The following impact categories were also reduced: 9% in the case of the acidification of the ground and water, 9% for eutrophication and 31% reduction for non-hazardous waste. This work intends to reduce the carbon footprint and increase the sustainability of polyurethane gypsum products

Economic sustainability assessment of a gypsum ceiling tile with polyurethane foam waste

The amount of plastics deposited in the environment is constantly increasing. To improve their circularity, numerous research lines emerge, such as the creation of new construction materials that incorporate polymeric waste. This practice manages to extend the life cycle of the waste, avoids the consumption of limited natural resources and gives the product additional characteristics. The re-use of polyurethane foam waste as a substitute for gypsum in ceiling tiles carries technical improvements such as a decrease in the weight of the material and in its thermal conductivity, maintaining a positive fire reaction performance. The goal of this work is to analyse its economic viability. For this, the financial assessments of the PU-Gypsum product and its standard alternative are compared. The results show that the Life Cycle Cost Analysis (LCCA) of the new precast is 6% cheaper. Despite the fact that the waste processing entails an extra cost, this is widely offset by the increase in the factory’s production capacity due to its shorter drying time. The manufacturing stage represents 3/5 of the total cost for both materials. The PU-Gypsum precast is an ideal market alternative to the traditional gypsum one with improved properties and proficient in an economic level

Lightweight structural eco-mortars made with polyurethane wastes and non-Ionic surfactants

The properties of structural lightweight mortars obtained with recovered foam polyurethane wastes have been studied, containing a low fraction of soluble non-ionic surfactant. The characterisation of mechanical properties, bulk density, microstructure and porosity highlights two types of behaviour according to the composition (e.g. hydrolysis grade) of the non-ionic surfactants. By using additives with low hydrophilic–lipophilic balance (HLB) values, the lightweight mortars show more and more high mechanical properties according to the increase of the substitution rate of sand by PU wastes. These non-ionic surfactants seem to promote a homogeneous microstructure and improve the adhesion between PU wastes and cement paste. On the other hand, the mortars mixed with additives showing high HLB values, are more lightweight and macroporous, due to the increase of air entrained driven by the substitution rate of sand by PU wastes. © 2018 Elsevier Lt