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Department of Mining and Petroleum Engineering, Polytechnic School, University of Sao Paulo. Av. Prof. Mello Moraes, 2373, CEP 05508-030 So Paulo, SP, Brazil
Institute for Technological Research. Av. Prof. Almeida Prado, 532, CEP 05508-901 So Paulo, SP, Brazil
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Department of Construction Engineering, Polytechnic School, University of Sao Paulo. Av. Prof. Almeida Prado, 83, CEP 05508-900 So Paulo, SP, Brazil
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a r t i c l e
i n f o
Article history:
Available online 14 March 2012
Keywords:
Recycled sand production
Construction and demolition waste
Mineral processing
a b s t r a c t
Existing construction waste recycling technologies and standards have long been applied in construction
and demolition waste recycling. However, they have been essentially focused on the production and use
of coarse recycled aggregates. This paper presents a technology that permits the production of high quality recycled sand. The selective removal with a vertical impact crusher of the cement paste attached to
recycled aggregates and the potential improvements in the quality of the recycled sand that is produced
were investigated. The results showed that the proposed method permitted the production of low-porosity sand from construction and demolition waste and may contributes to changing the construction recycling model.
2012 Elsevier Ltd. All rights reserved.
1. Introduction
The composition of construction and demolition waste (CDW) is
dictated by different construction types and their components; in
general, CDW is composed of concrete, asphalt, brick and ceramic
materials [1]. The problems related to waste dumping have dramatically increased with the growth and development of large cities. In the UK, for example, over 50% of landll waste comes from
construction use [2] and the US alone produces around 200
300 million tons of CDW annually [3]. The exhaustion of natural
sand deposits close to large urban centers necessitates the initiative to use CDW as a potential raw material.
Previous studies have shown that the ne fraction (particles
below 4.8 mm) represents about 50% of the weight of the crushed
C&D waste in coarse recycled aggregates production [4]. For a
long time, the ne fraction was disregarded or used as a road
pavement base because it was believed to have low quality
properties. However, regardless of any limitations that may exist,
the use of recycled aggregates in concrete will be essential in the
very near future [5]. As well, recent studies have shown that ne
fraction properties are not that different from coarse fraction
properties, and can even be improved with appropriate processing
[6]. Experimental tests have shown the viability of the partial
replacement of natural sand by crushed bricks in the mortar
production [5,7].
Corresponding author. Address: Departamento de Engenharia de Minas e de
Petrleo da Escola Politcnica da USP, Av. Prof. Mello Moraes, 2373, CEP 05508-030,
So Paulo, SP, Brasil. Tel.: +55 11 3091 5151; fax: +55 11 3091 6037.
E-mail addresses: carina@lct.poli.usp.br (C. Ulsen), henrique.kahn@poli.usp.br
(H. Kahn), gustav@lct.poli.usp.br (G. Hawlitschek), eamfsini@usp.br (E.A. Masini),
scangulo@ipt.br (S.C. Angulo), john@poli.usp.br (V.M. John).
0950-0618/$ - see front matter 2012 Elsevier Ltd. All rights reserved.
doi:10.1016/j.conbuildmat.2012.02.004
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2. Experimental
2.1. Sampling
The investigation was carried out on C&D waste from Urbem Tecnologia Ambiental, a private recycling plant located in the city of Sao Bernardo do Campo in the
Sao Paulo metropolitan region in Brazil. The composition of the waste was basically
low and medium-strength concrete (around 80%) and masonry.
The operational owsheet of the plant is summarized in Fig. 1. It consists of a
vibrating grizzly to remove the fractions below 4.8 mm before crushing (C&D sand
fraction), comminution by impact crusher, magnetic separation to remove the
remaining steel bars, and nally, a two-deck screen to perform the dry sieving
and grading of the products into three size fractions: <6.3 mm, 6.339 mm and
39150 mm. The organic materials such as paper, wood, plastic and others are removed from the mineral fraction by hand sorting, either before or after crushing.
The attained products are commercialized for base pavement applications; fraction
<4.8 mm have limited marked and sometimes are sent to landll.
The sampling procedure was replicated twice a week for 60 randomly selected
days. The samples were collected at the four product stock piles in the same proportions as they are produced (2:5:2:3 as shown in the owsheet). An average sample
of the four products was composed by mixing all aliquots (Urbem CDW). The total
mass collected was about 4 tons.
The experimental owsheet is shown in Fig. 2 and described below, as are the
characterization procedures.
2.2. Crushing
The total sample (about 4 tons) was comminuted in a laboratory jaw crusher
with a closed circuit screen to obtain a product below 19 mm (3/400 ), which was
homogenized by horizontal elongated piles [19]. A secondary sampling was performed for the attainment of three representative and equal aliquots.
Each aliquot (below 19 mm) was crushed by a vertical shaft impact crusher
(VSI) at different rotor speeds, respectively 55, 65 and 75 m/s, with a closed circuit
with a 3 mm aperture screen. The tests were conducted on a Barmac 3000 at the
Metso Process Technology Centre in the city of Sorocaba, So Paulo, Brazil.
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The CDW head sample represents the aggregates after the second crushing stage at Urbem recycling plant (crushed < 19 mm).
Around 50% of this products weight is below 4.8 mm (sand fraction) and 6% is below 0.15 mm. Regarding just the fraction bellow
3 mm of head sample, named as CDW-sand, it has 15% of its weight
below 0.15 mm.
The comminution of the CDW head sample in a vertical shaft
impactor (VSI) at three different rotor speeds produced sand with
similar grading (Fig. 3), and featured a subtle decrease in the ne
fraction percentage at the lowest speed. Furthermore, the VSI tertiary crushing did not noticeably increase the amount of nes, so it
can be concluded that the sand produced by tertiary crushing at
VSI has quite a similar size distribution to the CDW-sand fraction
(Fig. 3).
3.2. Shape analysis
The shape analysis results of VSI products and the CDW-sand
fraction are summarized by the frequency of particles with certain
EQPC (diameter of a circle of equal perimeter) for each class of
sphericity. Comparative results are shown in Fig. 4.
Since the sphericity of particles for the three crushing conditions is very similar, the effects of rotor speed on the VSI crushed
sand are very subtle. On the other hand, the sphericity of CDWsand is rather different from the VSI crushed sand. In conclusion,
rock-on-rock crushing improved the morphology of recycled sand
as compared to the sand fraction from C&D waste. However, the rotor speed did not greatly inuence particle shape.
3.3. Chemical composition of the main oxides
The composition of fractions of the recycled aggregates above
0.15 mm is represented mainly by silica (6575%), calcium oxide
(711%), alumina (610%) and iron oxide (around 2.5%). Loss on
ignition is around 6 to 9% on average. Minor compounds are
Na2O (0.52%), K2O (1.53%) and MgO (12%). Adding together
the SiO2, Al2O3, Fe2O3, CaO and LOI grades exceed 90% of the total
composition. The fractions bellow 0.15 mm represents between
15% (CDW-sand) and 20% (VSI-sand) of the total weight and has
a different composition with a remarkable decreasing on silica content (4853%) and increasing on calcium oxide (1517%) and LOI
(1215%).
The sum of the silica, alumina and iron oxide grades can be correlated to the content of silicates from natural rock phases, sand
and ceramics while the sum of the grades of calcium oxide and
the loss on ignition is directly related to the binder content [4].
Fig. 3. Particle size distribution of each product. CDW head sample; CDW-sand
fraction <4.8 mm from the head sample, VSI-55, 65, 75 sand produced from
tertiary crushing by VSI crusher in different rotor speed.
Fig. 4. Sphericity classes of recycled sand from CDW; absolute and cumulative
frequency of particles.
Fig. 5. Comparative weight, CaO + LOI grades and distribution. Grade (or content) is
the percentage weight of each constituent; distribution means the proportion
(percentual values) of each constituent in such fraction or product.
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Fig. 7. Relative proportion between quartz and aluminum silicates for CDW-sand
and VSI-sand.
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Fig. 10. Weight percentage of high density products for each size fraction.
Fig. 12. Images from SEM (a) backscattered images, (b) composition mapping, and (c) Ca cement paste mapping.
Acknowledgments
The authors gratefully acknowledge the nancial support provided by the Brazilian National Council of Technological and Scientic Development (CNPq, Process 478142/2009-9 and 550437/
2010-0), Fundao de Apoio Pesquisa no Estado de So Paulo (FAPESP, Process 2010/15543-1 and 09/54007-0) and the Polytechnic
Engineers Association (AEP). The technical support provided by
Sympatec, Urbem Tecnologia Ambiental and Metso Minerals was
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