HB 155—2002

Guide to the use of recycledconcrete and masonry materials

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First Edition

Published December 2002

ISBN 0 7337 4273 4

Author

Commonwealth Scientific and Industrial Research Organisation (CSIRO)

Printing and Binding

Standards Australia

Copyright

2002 Commonwealth Scientific and Industrial Research Organisation (CSIRO)

All rights reserved. Except where the Copyright Act allows otherwise, no part of this publication may bereproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic,mechanical, photocopying, recording or otherwise without the prior written permission of theCommonwealth Scientific and Industrial Research Organisation (CSIRO).

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HB 155—2002

Guide to the use of recycledconcrete and masonry materials

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HB 155—2002

ACKNOWLEDGMENTS

The compilation of this document has been made possible by the support and contributions ofnumerous participants in several recycled concrete projects initiated by CSIRO and other agencies. Inparticular, the contribution of the contents of Chapter 3 by the former Inner Sydney Waste Board isgratefully acknowledged as well as the involvement of several local councils, especially Randwick CityCouncil, NSW. The editorial assistance of Ms Cathy Bowditch and the technical support of theconcrete recycling research group, both of CSIRO Building, Construction and Engineering, are alsogratefully acknowledged.

The support of the following agencies is also gratefully acknowledged:

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HB 155—2002

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CONTENTS

PREFACE .............................................................................................................................................iiiDISCLAIMER ..........................................................................................................................................iv

CHAPTER 1: RECYCLED CONCRETE AND MASONRY MATERIALS1.1 Introduction...................................................................................................................................11.2 The Guide ......................................................................................................................................11.3 Objective of the guide ..................................................................................................................21.4 Terminology ..................................................................................................................................31.5 Concrete recycling .......................................................................................................................3

1.5.1 Feedstock materials ..........................................................................................................41.5.2 Material recycling operations.............................................................................................61.5.3 Foreign material content....................................................................................................91.5.4 Recycled products ...........................................................................................................10

1.6 Recycled aggregates for pavement applications....................................................................111.7 Quality system requirements ....................................................................................................111.8 Masonry recycling ......................................................................................................................121.9 Characterisation of recycled aggregates.................................................................................13

CHAPTER 2: PROPERTIES OF RECYCLED CONCRETE AGGREGATE(RCA) (CLASSIFICATION 1).................................................................................................................192.1 Introduction.................................................................................................................................192.2 RCA – general background .......................................................................................................202.3 Aggregate supply (Class 1 RCA) ..............................................................................................202.4 Material properties......................................................................................................................212.5 RCA handling ..............................................................................................................................212.6 Recycled aggregate concrete (Class 1 RCA) specification....................................................22

2.6.1 Scope………….. .................................................................................................................222.6.2 Definitions……….. ..............................................................................................................222.6.3 RCA properties…................................................................................................................23

2.7 Recycled concrete (RC) .............................................................................................................272.7.1 Concrete production............................................................................................................272.7.2 Concrete production and placement...................................................................................282.7.3 Fresh concrete properties ...................................................................................................292.7.4 Hardened concrete properties ............................................................................................33

CHAPTER 3: PROPERTIES OF RECYCLED CONCRETE AGGREGATE (CLASSIFICATION 2)….393.1 Introduction.................................................................................................................................39

3.1.1 Granular base applications..............................................................................................393.1.2 Embankment or fill applications.......................................................................................40

3.2 Material processing requirements ............................................................................................413.3 Technical specification for RCA use in pavements and other civil works...........................41

3.3.1 Scope...............................................................................................................................413.3.2 Definitions ........................................................................................................................423.3.3 Standards ........................................................................................................................433.3.4 Sources of recycled material ...........................................................................................433.3.5 Material quality.................................................................................................................453.3.6 Contaminants...................................................................................................................453.3.7 Transport .........................................................................................................................453.3.8 Supply from certified stockpiles .......................................................................................453.3.9 Sampling and testing (quality assurance) .......................................................................463.3.10 Conformance with the specification.................................................................................46

CHAPTER 4: RECYCLED AGGREGATES: CASE STUDIES .............................................................47

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HB 155—2002

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4.1 Introduction.................................................................................................................................474.1.1 General recycled concrete serviceability.........................................................................48

4.2 Project 1 – path, Williamstown, Victoria...................................................................................484.2.1 Concrete properties .........................................................................................................494.2.2 Compressive strength......................................................................................................494.2.3 Dimensional stability........................................................................................................504.2.4 Fresh concrete properties................................................................................................504.2.5 Comment .........................................................................................................................51

4.3 Project 2 – path, Werribee South, Victoria...............................................................................514.3.1 Concrete properties .........................................................................................................514.3.2 Compressive strength......................................................................................................514.3.3 Dimensional stability........................................................................................................524.3.4 Comment .........................................................................................................................53

4.4 Project 3 – parking bay, driveway and footpath, Kensington, NSW .....................................534.5 Project 4 – footpath, Werribee South, Victoria ........................................................................54

4.5.1 Compressive strength......................................................................................................554.5.2 Comment .........................................................................................................................56

4.6 Project 5 – kerb and channel, Altona, Victoria ........................................................................564.6.1 Compressive strength and drying shrinkage ...................................................................56

4.7 Project 6 – footpath, Randwick, NSW.......................................................................................564.8 Project 7 – footpath, Maroubra Beach, Randwick, NSW ........................................................574.9 Project 8 – footpath, Randwick, NSW.......................................................................................574.10 Conditional survey results ........................................................................................................58

4.10.1 Concrete finishability .......................................................................................................594.10.2 Weathering ......................................................................................................................604.10.3 Pop-outs ..........................................................................................................................614.10.4 Discoloration ....................................................................................................................614.10.5 Cracks..............................................................................................................................624.10.6 Subsidence ......................................................................................................................654.10.7 Joints ...............................................................................................................................65

CHAPTER 5: SECONDARY RECYCLED MATERIALS.......................................................................675.1 Introduction.................................................................................................................................675.2 General background – glass cullet ...........................................................................................67

5.2.1 Glass cullet as a construction materials ..........................................................................685.2.2 Cullet applications in construction ...................................................................................685.2.3 Overview of glass cullet utilisation...................................................................................69

5.3 Recycled glass as construction aggregate .............................................................................705.3.1 Glass cullet classification: crushed cullet sand (CCS) ....................................................705.3.2 Material requirements......................................................................................................715.3.3 Crushed cullet aggregate ................................................................................................725.3.4 Material storage and handling .........................................................................................725.3.5 Cullet crushing .................................................................................................................725.3.6 Cullet feedstock ...............................................................................................................735.3.7 Typical contaminants in recycled glass ...........................................................................735.3.8 Safety...............................................................................................................................735.3.9 Glass aggregate dust ......................................................................................................74

5.4 Secondary materials...................................................................................................................745.4.1 Slags................................................................................................................................755.4.2 Mining and quarrying wastes...........................................................................................755.4.3 By-products from power plants........................................................................................765.4.4 Reclaimed asphalt material .............................................................................................76

RELEVANT AUSTRALIAN STANDARDS AND ROAD AUTHORITY STANDARDS………………....77

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HB 155—2002

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PREFACE

The use of recycled materials in the building and construction sector has been occurring over the pastfew years, with varying degrees of success. This development has generated a strong industryawareness and public interest in the use of recycled materials and recycling as it relates toconstruction. Increasingly, government, regulatory bodies and various industry sectors are beginningto account for and find ways to increase their use of recycled materials. As a result, we have seen anembryonic recycling industry move towards becoming a viable value-adding component of the buildingindustry.

The objective of key stakeholders within the building sector is to reduce waste and to incorporatewaste and recycled materials into construction operations and activities. To achieve this goal, it isessential to demonstrate safety, economic benefits and the technical performance of recycledmaterials, and their fitness for purpose compared to virgin alternatives.

The primary purpose of this Guide is to assist those who have an interest in using recycled materialsto increase their understanding of the types of waste and by-product materials in constructionapplications. It is intended to provide the potential user general guidance on engineering evaluationrequirements, environmental issues and economic considerations for determining the suitability andcurrent uses of recycled concrete and masonry materials. Success in the marketplace for productsderived from recycled materials has been underpinned by the technical work carried out by researchinstitutions such as CSIRO, and the willingness of users of such materials to trial such products.

This Guide comprises a total of five chapters.• Chapter 1 presents an overview of material and processing requirements of recycled concrete

and masonry products.• Chapters 2 and 3 provide general guidelines for the specification and use, respectively, of

Classes 1 and 2 recycled concrete aggregate products.• Chapter 4 reviews case studies of construction works involving recycled aggregates.• Chapter 5 deals with emerging and conventional secondary materials.

A list of the documents referred to in this Guide can be found in Appendix A.

This Guide to the Use of Recycled Concrete and Masonry Material attempts to consolidate availableinformation needed for the technical consideration of recycled concrete and masonry materials inconstruction applications. Hence, it is hoped that the document will provide engineers withfundamental product specification information and the tools required for conventional design withgraded recycled construction and demolition waste material.

Kwesi Sagoe–CrentsilCSIRO Sustainable Materials Engineering

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