Creating markets for recycled resources

CONGLASSCRETE II
Project code: GLA0015-007 1/09/2002 - 31/03/2004 Final Report

Written by: Dr EA Byars, Dr B Morales and HY Zhu

Centre of Cement and Concrete University of Sheffield

Published by:
The Waste & Resources Action Programme The Old Academy, 21 Horse Fair, Banbury, Oxon OX16 0AH Tel: 01295 819900 Fax: 01295 819911 www.wrap.org.uk WRAP Business Helpline: Freephone: 0808 100 2040

March 2004 ISBN: 1-84405-116-1

R&D Final Report: Glass

EXECUTIVE SUMMARY
This document reports the work conducted within the WRAP-funded ConGlassCrete II Project (contract GLA15007). This project has conducted widespread characterisation tests on the chemical properties of glass from the postconsumer, flat, lighting and fibres waste streams. Borosilicate and CRT waste glass are specifically excluded from this work. These results have shown that the chemistry of the glass in the waste streams tested had essentially similar major oxide contents. In addition it was found that the chemistry did not vary significantly between waste streams, nor between clean and contaminated sources of a single waste stream. The widest-ever study of pozzolanic reaction (which allows normally inert materials to contribute to concrete physical and chemical properties) between ground glass and cement was undertaken. 33 recovered glasses from various streams and sources were ground to a range of finesses, used to replace cement in mortar mixes and the fresh and hardened properties measured. The most important results from this work are i) that glass reactivity in cementitious systems is more related to fineness than waste glass stream, source or degree of contamination and ii) that glass ground to a fineness of >300m2/kg, irrespective of source, has a strength activity index equivalent to a conventional concrete pozzolan (fly ash to BS EN 450). A specification for glass as pozzolan in concrete has also been proposed, based on the results obtained in this project and some 250 concrete mixes made and tested in the parallel ConGlassCrete 1 Project. BRE Certification have confirmed the work by overseeing duplicate testing at a UKAS-accredited laboratory and by publishing an independent Pre-Certification Report on glass pozzolanicity, developed from the work at Sheffield. These independent Reports are included in the Appendix D to this report. Three precast concrete products made with recovered glass as aggregate and/or pozzolan, selected from the 19 precast concrete products tested in the ConGlassCrete 1 Project, were subjected to independent 3rd-Party testing to assess their performance relative to control concrete made with no recovered glass and against the appropriate British Standards for the product type. In all cases, the products were compliant with British Standards and there was very little difference between the recovered glass samples and the control. Two independent Reports on these procedures, written by BRE and BRE Certification, are given in Appendix E to this report. Around 200 concrete mixes (100 made in factories as products and 100 made in the laboratory) are being kept in controlled conditions at Sheffield for long-term testing. These are discussed in the body of this report and it is believed that these represent the single largest long-term study of glass in concrete in the world, with very high significance to the market. Currently, no funding is available to ensure that testing of these can be maintained. The information generated in this study has been widely disseminated by a 100-page web site (up to 1,000 hits per day), 6 Newsletters, 2 Seminars and 2 papers.

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Contents
Chapter 1. Introduction
1.1 Background 1.2 Aims and Objectives 1.3 Overview of Project 1.4 Industrial Collaborator and Steering Committee 1 1 1 1 3 4 4 4 4 5 6 8 9 9 10 10 10 12 12 12 12 14 14 15 16 17 17 17

Chapter 2. Literature Review

2.1 Legislative Drivers 2.2 Developing Markets 2.3 Pozzolanic Reactivity of Ground Glass 2.4 Glass Fibres in Concrete

Chapter 3. Dissemination Chapter 4. Scoping Exercises

4.1 Questionnaire 4.2 Cullet Scoping

Chapter 5. Experimental Programme

5.1 Materials 5.2 Test Methods 5.3 Results and Discussion 5.3.1 Characterisation 5.3.1.1 Major Constituents 5.3.1.2 Contamination Levels 5.3.2 Glass Pozzolan in Concrete 5.3.2.1 Initial Setting Times and Water Requirement 5.3.2.2 Activity Index 5.3.2.3 Influence of Washing 5.3.3 Glass Fibres in Concrete 5.3.3.1 Mix Proportions and Testing 5.3.3.2 Flexural Strength

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Chapter 6. Certification
6.1 Glass Pozzolan 6.2 Concrete Products Containing Glass as Pozzolan and Aggregate

19 19 19 22 22 22 22 26 26 27 28

Chapter 7. Long Term Testing

7.1 Concrete Products Study 7.2 Laboratory Parametric Study 7.3 At BRE

Chapter 8. Demonstration Projects

8.1 Contacts for Potential Demonstration Projects

Chapter 9. Conclusions
REFERENCES APPENDIXES
Appendix A ConGlassCrete II Project Subscribers Appendix B - Newsletters Appendix C Scoping Exercise Questionnaire Appendix D Certification of Glass Pozzolan BRE Reports Appendix E - Certification of Concrete Products Containing Glass Pozzolan and Aggregate BRE Reports Appendix F BRE Long-Term Testing BRE Reports Appendix G ConGlassCrete Bibliography

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Chapter 1. Introduction
1.1 Background
Over the next 4 years the targets for waste glass recovery will significantly increase in line with the Packaging Waste [1], End-of Life Vehicle (ELV) [2] and Waste Electrical and Electronic Equipment (WEEE) [3] Directives. Whilst this recovered waste glass could theoretically be reused as 100% feedstock for new glass manufacture [4], due to contamination tolerances and the imbalance between production and arisings of specific waste glass streams in the UK, there is a practical limit. The use of waste glass as an aggregate and pozzolan in concrete manufacture has a huge potential [5] that is not being currently exploited due to a lack of Standards and 3rd-party Certification as well as uncertainly about consistency of supply and price of these emerging new materials.

1.2 Aims and Objectives of The ConGlasscrete II

The main aim of the ConGlasscrete II Project, in collaboration with 28 partners, has been to characterise recovered container, plate, automotive, fibrous and fluorescent tube glass streams and to initiate certification procedures for (i) glass as a pozzolanic material and (ii) concrete products containing glass as a partial replacement of cement and/or aggregates. The specific objectives of the ConGlasscrete II Project were to: i. ii. iii. iv. v. vi. vii. viii. Scope, develop intelligence, encourage working recycling partnerships, raise environmental awareness and develop market opportunities for business in the flat glass, glass fibre and lighting industries. Extend the research work on container glass in ConGlassCrete I to investigate the feasibility of using plate, automotive, fibrous and lighting waste glasses in concrete. Develop technical specifications for the target waste glass streams for use in concrete products. Initiate a certification process for powered glass from the target waste streams for use as a concrete pozzolana. Initiate a certification process for concrete products containing glass pozzolana and aggregate. Link with other WRAP glass projects to extend the intelligence on glass waste arisings, processing techniques and end uses. Establish communication with architects, local authorities and pre-cast concrete companies to encourage the development of high profile projects for glass concrete products. Disseminate the findings of this study by reports, publications, seminars and a web site.

1.3 Overview of Project

An overview of the ConGlassCrete II Project research work, conducted in parallel with its sister ConGlassCrete I Project [6], is shown in Figure 1.1. The ConGlassCrete I Project investigated the fundamental technicalities of using waste container glass in concrete by conducting 20 industrial sub-projects in collaboration with relevant industries across the UK. The ConGlassCrete II Project has extended the ConGlassCrete I Project work to the new glass waste streams (plate, automotive, lighting and fibrous glass). A chemical and physical assessment of the target waste glass streams was conducted. A detailed investigation of the pozzolanic reactivity of ground waste glass samples and the influence of glass source, colour and contamination was also carried out. Based on these studies and coupled with the results emerging from 20 industrial sub-projects [6], the ConGlassCrete II Project has initiated certification procedures for glass pozzolana and concrete products containing glass pozzolan and aggregate.

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CONGLASSCRETE PROJECTS

Assessment of Waste Glass Streams

Post-consumer, plate, automotive, lighting, fibres

Measurement of contamination (selectively)

Pozzolanic Reactivity

20 Full-scale industrial projects

Alkali-Silica Reaction (Laboratory and industrial study) Bottle bank, pub and club collection

Effect of: Source, Colour, Contamination

Clean sources Paving slabs, cast stone, blocks, pavers, flags, kerbs, roof tiles

Contaminated sources

Certification of glass as pozzolan for concrete to BS EN450

Effect of: Colour, Grading, Suppressants

Test methods: ASTM C1260 & C227, BS 812-123 Certification of concrete products containing glass

ConGlassCrete I

ConGlassCrete II

Overlap of ConGlassCrete I & II

Figure 1.1. Overview of ConGlassCrete I and II Projects

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1.4 Industrial Collaboration and Steering Committee

The ConGlassCrete II Project had 28 industrial partners, Table 1.1, all of whom formed part of a Steering Committee to monitor the project progress. Table 1.1. Project Steering Committee members CONGLASSCRETE PROJECT PARTNERS INDUSTRIAL AND IN-KIND FUNDING ORGANISATIONS FUNDING BODIES Academic Glass Industry Trade Association Environmental Body Cement & Concrete Aggregate Industries UK Appleby Group BRE Certification Conways Concrete, CRH Group (Forticrete) H & H Concrete Marshalls Mono Stowell Concrete Tarmac Group Trent Concrete

Fergusson Wild BRE WRAP University of Sheffield CCC Columbia University WAMTECH GTS Mac-Glass Midland Glass Processing Northern Cullet Valpak Ltd BCA British Glass UKQAA

Business Environment Partnership Midlothian Chamber of Commerce Wales Environmental Trust

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Chapter 2. Literature Review

2.1 Legislative Drivers
Container and flat glass are major constituents of the solid waste stream and currently most is still landfilled [7]. Several European Directives have tackled this problem by setting recovery and recycling targets for specific waste glass streams as shown in Table 2.1. The Packaging Waste Directive [1] deals with waste container glass, whilst automotive and lighting glass are dealt by the End-of Life Vehicle (ELV) Directive [2] and the Waste Electrical and Electronic Equipment (WEEE) Directive [3] respectively. Additionally, the EU Landfill Directive [8] and the UK Landfill Tax Regulations [9] now impose fiscal penalties on the landfilling of glass, or indeed any waste, to encourage recovery, recycling and reuse programmes. In addition and specifically in the area of construction, the Aggregate Levy [10] now imposes a tax on the use of virgin aggregates which is forcing the construction industry to seriously consider alternative, fit-for-purpose aggregate materials. Table 2.1. Glass recovery and recycling targets set by European Directives EU DIRECTIVE Packaging End-of Life Vehicle (ELV) Waste Electrical & Electronic Equipment (WEEE) TARGET (%) RECOVERY 60a 85 70-80
b

RECYCLING 55a 80 65-80

b

TARGET DATE 2008c 2006 2006

a- Across all packaging waste streams b- Depending upon waste category c- An earlier date of 2006 has been proposed [11]

Recovered waste glass can be infinitely re-melted without degradation of its physical properties. Nevertheless, 100% recovered glass cannot be used as primary feedstock in glass manufacture due to contamination tolerances, mixed colours and the imbalance of green glass consumption and production in the UK [12]. It has been estimated [13] that with increasing recovery rates there will be at least 400,000 tonnes of surplus container glass, mainly green, by 2008. In addition to this, the UK will soon be obliged to recover and recycle another 1 million tonnes/year [12] to meet the targets of all current Directives [1-3]. Thus, new markets for recovered glass need to be found. The construction sector is an attractive option because of the potential volume of materials involved. In addition, use in concrete may have lower dependency on variations in chemical composition, colour, impurity levels and glass particle size than new glass manufacture [14].

2.2 Developing Markets

Whilst some markets for recycled waste glass already exist in construction [5,13] (200,000 tonnes as aggregate in asphalt, pipe bedding, backfill, loose fill, decorative uses and golf bunkers), there is a huge potential to increase usage in the concrete construction sector. Finely ground glass has the appropriate silica (SiO2) content to react with dissolved calcium hydroxide in the presence of water and form hydrated compounds in a similar way to pozzolanic materials such as pulverized-fuel ash (PFA), ground-granulated blastfurnace slag (GGBS) and microsilica (MS) (see Table 2.2). Alternatively, the physical properties of waste glass make it suitable for use as a concrete aggregate; either as direct replacement for normal concrete aggregates (low value) or as an exposed, decorative aggregate in architectural concrete products (high value). The use of crushed waste glass as a concrete aggregate and the effects on mechanical (strength) and durability properties (alkali-silica reaction, ASR) have been studied widely [15-22]. These studies have shown that glass aggregate in concrete may undergo ASR expansion, the extent of which depends upon glass particle size, content, colour and level of ASR suppressant materials used in the concrete [20,21].

2.3 Pozzolanic Reactivity of Ground Glass

Pozzolans in finely ground form react with Ca(OH)2 and water to form calcium silicate hydrates (C-S-H), which are similar to those formed by hydraulic or cementitious materials [23]. The pozzolanic reaction occurs in several stages. During the initial stage, the Si-O-Si bonds (glassy phases) of pozzolana are hydrolysed by hydroxyl ions (OH-) released from activators (e.g. Ca(OH)2). Once the glassy network is disrupted, reaction takes place between the hydrolysed siliceous material and activator components occurs, forming hydrates that, in part replace the anhydrous grains of the pozzolanic material and in part, fill the space between grains thereby developing bond. 4 Final Report, March 2004

In its simplest form the reaction may be presented as follows [24]: SiO2 + Ca(OH)2 + H2O CaOSiO2H2O Eq 2.1

The calcium silicate hydrate (C-S-H) resulting from pozzolanic reaction is different to that formed by cement hydration. One modification is a reduction in the CaO/SiO2 ratio of the gel due to the consumption of portlandite, Ca(OH)2, during the pozzolanic reaction. This encourages alkali adsorption, especially Na+ [25], which together with the reduction in Ca(OH)2 can cause a decrease in the pore water pH [26]. It is this effect which can decrease the propensity of the system to cause ASR expansion. However, if the pozzolanic material possesses a high level of CaO as with class C fly ash [27], pH reduction may not occur. The effects of using pozzolans in concrete are well-documented [24-31] and when used in the correct proportions can improve workability, cohesiveness, ultimate strength and the durability properties of concrete. Pozzolanicity of powdered glass was first studied in 1973 [32]. However the most important work has been conducted in the last 7 years [14,21,33-39] and has shown that finely ground glass (finer than 300m2/kg [21]) will contribute to concrete strength development, apparently without any detrimental effects. Table 2.2 shows the oxides found in common glass types [40] compared to Ground Granulated Blastfunace Slag (GGBS) [41], Pulverized-fuel Ash (PFA) [42] and Microsilica (MS) [43]. It can be seen from this that the pozzolanic reactivity of ground glass is derived from its high SiO2 content, which, whilst lower than that of microsilica, is higher than that of both GGBS and PFA. Table 2.2. Average oxide contents of container, plate, windscreen and lighting glass [40] compared to common concrete pozzolanic materials [41-43] OXIDE (MASS, %) SiO2 71-74 33-37 48-55 86-94 Na2O 12-16 <0.4 0.7-1.7 <0.5 CaO 6-9 38-43 1-6 <0.4 Al2O3 K2O Fe2O3 MgO 0.1-4 <14 1-2 <1 BaO 0.1-2 B2O3 0.1-0.3 -

POZZOLAN Glass (average) GGBS PFA MS

0.1-6 0.1-2 0.1-0.3 8-14 22-29 <0.5 <0.4 2-4 <0.7 <1 8-13 <0.2

This means that raw, post-consumer glass could be ground to an appropriate fineness and used to replace a percentage of the Portland cement in concrete mixes. Considering the size of the cement industry (over 10 million tonnes/annum in the UK) this would appear to be a potential high volume, economic and environmentally friendly solution to part of the waste glass problem.

2.4 Glass Fibres in Concrete

Concrete is weak in tension and of low ductility [23]. To improve these properties, concrete can be reinforced with glass fibres that bridge cracks, thereby imparting a degree of increased tensile strength and ductility to concrete. Glassfibre Reinforced Cement (GRC) [44] is a mixture of cement, aggregate, water and randomly distributed alkali resistant glassfibres. The main applications of GRC are pre-cast panels, curtain wall facings, sewer pipes, thin concrete shell roofs and wall plaster [44]. The primary concern with using glass fibres in concrete is potential deterioration and loss in strength in the high pH environment, although the use of alkali resistant glass fibres (containing Zirconia) can significantly improve the long-term engineering properties [45]. Currently, the UK production of glass fibres is over 220,000 tonnes/year [46], of which approximately 11,000 tonnes is wasted during production [46]. Most glass fibre waste is not recycled due to its low density, the large variation in glass fibre types, high level of contamination (i.e. surface coating) and variation in moisture content.

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Chapter 3. Dissemination
The ConGlassCrete II Project has undertaken significant dissemination exercises as follows: 1) Continuous updating of the ConGlassCrete web-side (www.wrap.org.uk/conglasscrete). 2) Publication of 6 newsletters to project subscribers (Appendix B) (www.wrap.org.uk/conglasscrete/cgc_newsletter.asp) 3) Publication of conference [18,46] and journal [20,21,47] papers 4) A series of press releases and press articles in the waste management and construction press (www.wrap.org.uk/conglasscrete/cgc_press.asp) 5) Two National Seminars held at the Earth Centre in Doncaster and the Commonwealth Institute in London, which attracted 120 delegates (www.wrap.org.uk/conglasscrete/seminar.asp) 6) Online Reports (www.wrap.org.uk/conglasscrete/cgc_reports.asp). In addition, the ConGlassCrete Projects have some 500 UK company sector subscribers, Table 3.1 (Appendix A), distributed as shown in Figure 3.1. Table 3.1. Companies subscribed to the ConGlassCrete Projects SCOPE OF BUSINESS Glass Collection & Processing Portland Cement Cementitious Materials Concrete Aggregates Ready Mixed Concrete Pre-cast Concrete Local Authorities Education, Research & Development Consultant Engineering Waste Legislation Environmental Other TOTAL No. of COMPANIES 76 21 25 43 28 51 79 71 18 21 16 51 500

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(a)ConGlassCrete Subscribers

(b) ConGlassCrete Partners

Figure 3.1. Geographical distribution of the ConGlassCrete Projects Subscribers and Partners

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Chapter 4. Scoping Exercise

ConGlassCrete II Project has carried out a material scoping exercise to update current tonnages for each target waste stream (plate, end-life vehicle, lighting and fibrous glass) and to encourage potential working partnerships. This exercise was extended to waste container glass, although this stream was not initially considered as part of the Project. Tables 4.1 and 4.2 show the latest published data on UK production, importation, exportation consumptions, arisings and recovery of container glass. The importation and exportation percentages have been estimated from the assumption that most imports are green wine and beer bottles and most of the exports are clear whisky bottles [49]. Table 4.1. UK Production, importation and exportation of container glass in 2001 PRODUCTION IMPORTATION EXPORTATION %d CONSUMPTION 103tonnes/year 1335 -53 Amber Flint TOTAL 272 1,105 +1,700a 16 115 65 +1,154c 10 -472 -525e 90 691 2,329 10 303

GLASS COLOUR

103tonnes/year %b 103tonnes/year %d 103tonnes/year 323 19 1,039 90

Green

a, c, e The source of all these data was British Glass. Biffa Programme on sustainable resource use. Available from URL www.britglass.co.uk/files/documents/BIFFAReport_09012004153824.pdf b WRAP. Developing Markets for Recycling Glass [13] d Estimated based on type of UK imports and exports [49]

In Table 4.2 the potential arisings for container glass have been estimated from a sorting study carried out on bottle bank samples at the CCC. The recovery figures were obtained from literature [13]. Table 4.3 shows the consumptions, arisings and recovery data for flat glass. The automotive glass arisings have been estimated assuming that each of the 1.9 million vehicles scrapped annually [49] has approximately 33 kg of glass [12]. In addition, it has been estimated [50] that car window replacement generates another 15,000 tonnes/year of waste glass. Arisings from building demolition were calculated from the estimation that the glass content of construction and demolition waste (C&D) is 0.7% [49]. Arisings from other flat glass sources (furniture and interior decoration) were estimated assuming that this stream generates arisings similar to those observed for plate and automotive streams (65%). Table 4.2. UK consumption, arisings and recovery of container glass CONSUMPTION 2001 103tonnes/year 1335 303 691 % 57 13 30 2,329 ARISINGS 2002 RECOVERY 2002 %b 52 14 34 No data

GLASS COLOUR

103tonnes/year % 103tonnes/year 1320 286 528 66 2,200a 60 13 24 3 388 105 254 No data 747a

RECYCLING RATE

Green Amber Flint Other TOTAL

29.4 36.7 48.8 No data 38.3

a WRAP. Recycling Glass Market Study & Standards Review [12] b WRAP. Developing Markets for Recycling Glass Presentation [13]

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Table 4.3. UK consumptions, arisings and recovered data of flat glass RECYCLING RATE % No data No data No data 24.5

FLAT TYPE

CONSUMPTION 2001 ARISINGS 2002 RECOVERY 2002 103tonnes/year %b 10 70 20 103tonnes/year 103tonnes/year 78c 508d 150e 736 No data No data No data 180f

AUTOMOTIVE PLATE OTHER* TOTAL

115 805 230 1,150a

* including furniture and interior applications a WRAP. R&D to improve site practises for collection and clean separation of composite (glass) materials in the construction demolition industry. Available URL www.wrap.org.uk/publications/C_and_DGlass.pdf b British Glass. Biffa Programme on sustainable resource use. Available URL www.britglass.co.uk/files/documents/BIFFAReport_09012004153824.pdf c (1.9 millions of scrapped car * 33kg) +15,000=78,000 d 72.5 million tonnes/year [50] of CD waste *0.7=508,000 e 230*0.65 f WRAP. Recycling Glass Market Study & Standards Review [12]

Estimates for arisings of waste fluorescent tubes range from 12,000 to 20,000 tonnes/year [12]. In addition, there are approximately 600 tonnes/year of waste glass from compact fluorescent and high intensity discharge lamps. At present, lighting glass is not being recycled due to the possible mercury contamination and difficulties separating glass from other component of the bulb or tube. The UK production of glass fibres is around 220,000 tonnes/year [46] and approximately 11,000 tonnes/year [46] are wasted during the manufacture of glass fibre-based products. These glass fibres waste are rarely recovered.

4.1 Questionnaire
A questionnaire which could be used to conduct a significant information-gathering exercise as the emerging new markets for recovered glass take force, is given in Appendix C. This questionnaire has been designed to be market-sector specific and it is hoped that it could be included in the WRAP website for online information gathering exercises.

4.2 Cullet Scoping

The ConGlassCrete Projects have contacted every local Authority in the UK in an attempt to gain intelligence about a potential collaborative glass recycling scheme between the concrete and glass collection sectors. The responses were not encouraging and the majority indicated that collection contracts were already in place. One of the major pre-cast concrete partners to the project followed up some of the more positive responses, but concluded that it would be unfeasible to progress at this stage due to diverse availability and high price.

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Chapter 5. Experimental Programme

The experimental programme of the ConGlassCrete II Project focused on two main areas: (i) an extensive characterisation of target waste glass streams (plate, end of life vehicle, container and lighting fibres), including determinations of the main oxides (SiO2, CaO, Na2O, Al2O3, MgO, Fe2O3) and possible contaminants (Cr, Pb, chloride, sulfur, loss on ignition and sugars). (ii) an examination of the fresh and hardened properties of mortar and concrete containing ground glass pozzolana. This was intended to establish parameters that define the pozzolanic contribution of ground glass in concrete. This has been done by assessing the influence of glass fineness, type, source and contamination level on the initial setting times, water requirement and strength activity index. All CCC work has been validated in an UKAS certificated laboratory under the supervision of Building Research Establishment (BRE).

5.1 Materials
A total of 34 glass samples, Table 5.1, supplied by glass collectors and processors across the UK have been tested. The sample library includes plate glass (rejected by the glass industry), delaminated windscreens (rejected and post-consumer), post-consumer side and rear car windows, green and amber container glass (rejected), a large selection of post-consumer mixed-colour container glass from bottle banks and pub and club collections (various contamination levels), post-consumer fluorescent tubes and 1 sample of light bulb glass (rejected). In addition, 2 glass fibre samples have been used to determine their effects on the tensile properties of concrete.

5.2 Test Methods

Table 5.2 shows the test methods used throughout the ConGlassCrete II experimental programme. Table 5.2. Parameters and test methods used in the experimental programme

PARAMETERS

TEST METHODS

Oxide content and Cl Sugars LOI Fineness Initial setting time Water requirement Pozzolanic reactivity

XRF (semi-quantitative) AMS CRD-C 213-92 [51] BS 2646-1 [52] and BS 196-2 [53] Laser technique* BS EN 196-3 [54] BS 3892-1 [55] BS EN 450 [56]

*Used widely in the cement industry, but usually correlated to the Blaine method [57]

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Table 5.1. ConGlassCrete II Project waste glass sources SAMPLE NUMBER Flat Glass 1 2 3 4 5 6 7 8 9 10 11 12 Plate Plate Plate Plate Plate Windscreens Windscreens Windscreens Windscreens Side & rear Side & rear Side & rear Northern Cullet Northern Cullet Northern Cullet All Glass All Glass Northern Cullet Viridor Viridor Viridor Autoglass Autoglass Autoglass R R R R R R PC PC PC PC PC PC 806 575 262 747 391 575 473 390 370 695 293 278 TYPE SOURCE WASTE STREAM SURFACE AREA (m2/kg)

Container Glass 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Green Amber Pubs & Club Pubs & Club Pubs & Club Bottle bank Bottle bank Bottle bank Bottle bank Bottle bank Bottle bank Bottle bank Bottle bank Bottle bank Lighting Glass 27 28 29 30 31 32 FL. Tubes FL. Tubes FL. Tubes FL. Tubes FL. Tubes Light bulbs Glass Fibres 33 34 Fibre Fibre Owens-Corning Owens-Corning Manufacturing Manufacturing Holden MacGlass Mercury Recycling Mercury Recycling Mercury Recycling GTS PC PC PC PC PC R 989 300 281 313 312 587 Northern Cullet Northern Cullet Valpak Valpak Valpak Conways Conways Conways Glass Recycling MacGlass Day Aggregate Day Aggregate Day Aggregate Day Aggregate R R PC PC PC (Washed) PC PC PC (Washed) PC PC PC PC PC PC 458 362 848 263 787 876 290 798 653 257 240 268 240 240

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5.3 Results and Discussion

5.3.1 Characterisation
5.3.1.1 Major Constituents
Table 5.3 shows the SiO2, Na2O, CaO, Al2O3, K2O, Fe2O3 and MgO contents of various samples from the flat, container and lighting waste stream. No significant differences were observed between the oxide contents of samples from the same waste stream. However, it was seen that the CaO, Al2O3, K2O, Fe2O3 and MgO contents varied between waste glass streams while the SiO2 and Na2O contents were similar for all waste glass streams. In particular, the CaO contents of lighting glass were approximately 50% of that in flat and container glass and the Al2O3 contents in flat samples were around 50% of that in container and lighting glass. The K2O and Fe2O3 were similar for flat and container glass and MgO contents were similar for flat and lighting glass. Additionally, it was observed that flat and container samples from the post-consumer stream had marginally lower SiO2 content compared to those rejected directly from glass manufacturing. This is clearly attributed to contaminations in the post-consumer streams, see Table 5.5. Table 5.4 shows the average oxide contents of all samples tested compared with a generic average for container, flat and lighting glasses [40] and with common concrete pozzolanic materials [41-43]. The oxides of all samples tested were within the generally accepted range for clean glass. The higher Na2O content in glass, compared to pozzolanic materials, is probably the most significant departure from conventional concrete pozzolan chemistry and could be a concern for long-term ASR. This underscores the need to extend the long-term testing exercise that this project has initiated (See Chapter 7). Table 5.4. Average oxide contents of all glass tested compared to an average of container, flat and lighting glasses and concrete pozzolanic materials OXIDE (MASS, %) SiO2 70.1 Na2O 13.9 CaO 9.0 Al2O3 1.6 K2O 0.6 Fe2O3 0.5 MgO 2.2

MATERIALS

Waste Glass Average (measured) Glass Average (theoretical) GGBS PFA MS

71-74 33-37

12-16 <0.4

6-9 38-43 1-6 <0.4

0.1-6 8-14 22-29 <0.5

0.1-2 0.1-0.3 <0.4 2-4 <0.7 <1 8-13 <0.2

0.1-4 <14 1-2 <1

48-55 0.4-1.7 86-98 <0.5

5.3.1.2 Contamination Levels

Table 5.5 shows the levels of Cr2O3, PbO, SO3, LOI, Cl and sugars in selected glass samples. These compounds were identified as those being of greatest potential detriment to fresh and hardened concrete properties and/or environmental health. The Cr2O3 contents ranged between from 0.05 to 0.23%, excluding one post-consumer sample with Cr2O3 content greater than 1%. These Cr2O3 contents are higher that those in Portland cement clinkers, but they are low enough not to cause any detrimental effect to concrete [41]. The PbO contents for all samples were below 0.05%, which is the content generally found in clinker [41]. The SO3 contents ranged from 0.05 to 0.12% and were significantly lower that those found in common concrete pozzolanas. The measured LOI was significantly dependent upon the maximum ignition temperature (550C and 975C), but always less than 1.5%. Chloride contents in the post-consumer samples were lower than the upper limit in cement standards [58]. The sugar levels of samples ranged from less than 2ppm to 50ppm and at these levels did not affect cement paste setting times. 12 Final Report, March 2004

Table 5.3. Major constituents of the target waste streams examined NUMBER GLASS TYPE Flat glass 1-3 4-5 6 7 8 10 11 Plate (R) Plate (R) Windscreen (R) Windscreen (PC) Windscreen (PC) Side & rear (PC) Side & rear (PC) Average Container glass 13 14 15-16 17 18-19 23 24 25 26 Green (R) Amber (R) Cullet (PC) Cullet (PC-washed) Cullet (PC) Cullet (PC) Cullet (PC) Cullet (PC) Cullet (PC) Average Lighting glass 27 29 30 32 Fluor. tubes (PC) Fluor. tubes (PC) Fluor. tubes (PC) Light bulb (R) Average 70.79 71.03 70.89 70.52 70.8 16.07 15.89 16.16 15.60 15.9 5.25 5.36 5.55 5.72 5.5 1.85 1.75 1.77 1.65 1.8 1.06 1.00 0.90 0.86 1.0 0.30 0.50 0.89 1.40 0.8 3.14 3.33 3.26 3.53 3.3 71.03 71.27 68.39 68.13 70.50 69.5 69.5 69.6 69.3 69.3 13.35 13.41 12.49 12.42 13.00 14.40 14.20 13.90 14.10 13.5 10.44 9.85 12.72 12.69 10.80 11.40 11.30 11.40 11.30 11.7 1.59 1.98 1.56 1.60 1.90 1.75 1.91 1.95 2.00 1.8 0.71 0.77 0.56 0.54 0.67 0.63 0.62 0.66 0.63 0.6 0.49 0.53 0.56 0.43 0.34 0.33 0.33 0.39 0.47 0.4 1.62 2.12 1.18 1.26 1.50 1.41 1.5 1.44 1.46 1.4 71.25 71.27 69.5 69.71 69.29 68.52 68.91 69.8 13.44 13.34 14.58 14.80 13.98 15.00 15.31 14.3 9.15 8.89 8.75 8.90 9.25 9.79 9.15 9.1 1.15 1.09 1.10 1.00 0.89 0.90 0.99 1.0 0.47 0.55 0.41 0.45 0.54 0.33 0.25 0.4 0.40 0.36 0.22 0.32 0.65 0.72 0.40 0.4 3.05 3.41 3.97 4.31 4.24 4.26 3.96 3.9 OXIDE (MASS, %) SiO2 Na2O CaO Al2O3 K2O Fe2O3 MgO

13 Final Report, March 2004

Table 5.5. Cr2O3, PbO, SO3, LOI, Cl and sugar levels for selected glass samples CONTENT (%) Cr2O3 Flat glass 1 4 7 10 Plate 1 (R) Plate 2 (R) Windscreen 1 (PC) Car windows 1 (PC) Container glass 13 14 16 18 23 24 25 26 Green (R) Amber (R) Cullet 1 (PC) Cullet 2 (PC) Cullet 3 (PC) Cullet 4 (PC) Cullet 5 (PC) Cullet 6 (PC) Lighting glass 27 32 31 Fluor. tubes (PC) Light bulb (R) *1000ppm=0.1% <0.05 0.15 <0.05 <0.05 0.17 0.23 <0.05 0.06 1.13 0.12 0.11 0.14 0.12 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 0.05 0.12 0.05 0.22a 0.19a 0.83a 0.65a 0.52a-0.94b 0.46a-0.82b 0.65a-1.00b 0.66a-1.00b 50.9 21.7 46 12 <2 <2 <2 <2 <0.05 <0.05 <0.05 0.05 <0.05 <0.05 <0.05 <0.05 0.10 0.25a 0.38a 0.21a-0.28b 0.23a-0.41b <2 28 PbO SO3 LOI CONTENT (ppm*) Cl Sugars

NUMBER

GLASS TYPE

a to BS 2646 (550C, 1h)

b to BS 196-2 (975C, 2h)

5.3.2 Glass Pozzolan in Concrete

5.3.2.1 Initial Setting Times and Water Requirement
Table 5.6 shows the initial setting time and water requirement of mortar mixes made with 30% ground waste glass as a partial cement replacement, compared to a control OPC mortar mix. It was found that ground glass increased the initial setting times of pastes, but within the limits allowed by BS EN 450 PFA [56]. The automotive samples (samples 9 and 10) exhibited higher initial setting times than those observed in other samples. The water requirement of mortars containing 30% of ground waste glass as a partial cement replacement were similar to those made with 100% Portland cement and showed variation of +1.3% and -4.5% respectively.

14 Final Report, March 2004

Table 5.6. Initial setting times and water requirement of concrete containing 30% of cement replacement with powered waste glass FINENESS (m2/kg) 806 575 262 370 695 458 362 240 268 240 240 989 281 INITIAL SETTING WATER REQUIREMENT (min.) (%) (30% cement replacement) +12 +18 +30 +48 +90 +12 +18 +36 +42 +42 +22 +6 +18 95.5 95.5 100.0 100.0 100.0 97.8 97.8 101.3 100.0 100.0 101.3 97.8

SAMPLE ID

Plate 1 (R) Plate 2 (R) Plate 3 (R) Windscreen 9(PC) Car windows 10 (PC) Green 13 (R)) Amber 14 (R) Cullet 23 (PC) Cullet 24 (PC) Cullet 25 (PC) Cullet 26 (PC) Fluor. 27 Tubes (PC) Fluor. 29 Tubes (PC)

5.3.2.2 Activity Index

Figure 5.1 shows the strength development of 25% cement replacement ground glass mortars, relative to OPC cement control. Mortars were made as described in BS EN 450. Container (10 samples), plate (6 samples), endlife vehicle glass (4 samples) and lighting glass (5 samples, including 1 light bulb and 4 fluorescent tubes) were used with surface areas ranging from 257 to 989m2/kg. The key finding of this experiment was that when the glass is ground to a surface area greater or equal to 300m2/kg, the test mortars generally exceeded the minimum strength required for a BS EN 450 fly ash at both 28 and 90 days. This result appeared to be independent of glass type used and may prove to be a useful processing target for full-scale production of glass pozzolans.

15 Final Report, March 2004

 Lighting
115

Container

Plate
115

End-life vehicle
(b) 90 days of curing Surface area > 300m2/kg achieves BS EN 450 strength compliance

(a) 28 days of curing 105 Relative strength (%)

95

Surface area > 300m /kg achieves BS EN 450 strength compliance

105

95

85

85 BS EN 450 minimum relative strength

75

BS EN 450 minimum relative strength

75

65 200

300

400

500

600

700
2

800

900

1000

65 200

300

400

500

600

700
2

800

900

1000

Surface area (m /kg)

Surface area (m /kg)

Figure 5.1. Influence of glass fineness on relative strength at (a) 28 and (b) 90 days

5.3.2.3 Influence of Washing

The effect of washing post-consumer cullet prior to grinding on the pozzolanic reactivity is shown in Figure 5.2. Two post-consumer cullet sources (from pub & club and bottle bank collection), washed and unwashed prior to grinding were tested for pozzolanicity in mortars as detailed in Table 5.2. The results suggest that washing the post-consumer glass does not lead to a clear and significant increase in the compressive strength of concrete. Table 5.8 compares relative strength of washed and unwashed glasses in mortars to BS EN 450 and it can be seen that the target strength activity index at 28 and 90 days (75% and 85% respectively) was significantly exceeded in all cases.

70 Compressive strength (N/mm ) 60

2

(a) Pub and Club collection Washed

70 60

(b) Bottle Bank collection Washed

50 40 30 20 10 0

Unwashed

50 40 30 20 10 0

Unwashed

28

90

180

365

28

90

180

365

Age (days)

Age (days)

Figure 5.2. Compressive strength of mortar made with 25% glass pozzolan as cement replacement, from (a) Pub & Club collection and (b) Bottle Bank cullet

16 Final Report, March 2004

Table 5.8. Relative strength of mortar made with 25% washed and unwashed glass pozzolan from Pub & Club and Bottle-Bank collection cullet RELATIVE STRENGTH (%) 28 days 91.6 85.96 81.8 79.0 90 days 95.2 97.8 90.0 104.8 180 days 92.2 89.2 93.5 98.5 365 days 100.0 91.4 98.1 98.6

SOURCE

PROCESS

SURFACE AREA (m2/kg)

Pub & Club

Washed Unwashed Washed Unwashed

787 848 798 876

Bottle-Bank

5.3.3 Glass Fibres in Concrete

5.3.2.1 Mix Proportion and Testing
A minor study of the effects of mixing waste glass fibres into concrete was conducted to evaluate the influence of the fibres on concrete tensile strength and ductility. The waste glass fibres were supplied by Owens-Corning as continuous alkali-resistant filaments originating from the production of roving strands. The filaments were chopped into 13mm fibres and added to the concrete mixes made with OPC or High Alkali Portland Cement (HAPC), with PFA, Table 5.9. The mixes made with waste glass fibres were dosed with 2% (by binder weight) of super-plasticizer to maintain equivalent slump (medium). Table 5.9. Mix proportion for concrete specimens containing glass fibres BINDER (kg/m3) MIX OPC 374.1 374.1 374.1 374.1 PFA 160.3 160.3 160.3 160.3 FIBRE 32 32 WATER W/B AGGREGATE (kg/m3) FINE 621.5 621.5 621.5 621.5 COARSE 1015 1015 1015 1015

OPC/PFA OPC/PFA/FIBRE HAPC/PFA HAPC/PFA/FIBRE

190 190 190 190

0.35 0.35 0.35 0.35

5.3.2.2 Flexural Strength

The flexural strength of the concrete mixes was measured to BS 1881 BS EN 12390-5 [59] at 3, 7 and 28 days. It can be seen from the results, Figure 5.3, that in both cases glass fibres increased the flexural load-carrying capacity of concrete. However, the increase appears to be greater when OPC, rather than HAPC, is used. Clearly, this area requires additional study and it would be useful to examine the ductility of glass-fibre-reinforced concrete over time to assess the durability of the system. In addition, further testing on the ASR susceptibility of individual fibres would provide guidance on the potential for using waste glass fibres as either a short or longterm means of increasing concrete tensile strength and ductility. In either case, benefit to concrete could be realised, for example, by use in permanently improved systems or to effect temporary tensile strength improvements for early-age handing of pre-cast products.

17 Final Report, March 2004

12

Flexural strength (N/mm )

10

OPC/PFA OPC/PFA/FIBRE HAPC/PFA HAPC/PFA/FIBRE 0 5 10 15 Age ( Days) 20 25 30

Figure 5.3. Influence of using glass fibres on flexural strength of concrete

18 Final Report, March 2004

Chapter 5. Certification
This project has sought and achieved 3rd party pre-certification for glass as a pozzolan and for concrete products containing glass pozzolan and aggregate.

6.1 Glass Pozzolan

The first step in the pre-certification process was to review existing specifications for similar materials (BS EN 450[56], BS 3892[55] and ASTM C 311 [60]) to develop a working specification for glass pozzolana. BS EN 450, which addresses the physical, chemical and strength performance criteria for fly ash for use in concrete was selected as the most appropriate model for glass pozzolana. Based on this, Table 6.1 gives the proposed parameters, criteria and test methods to ensure the quality and performance of glass pozzolan in concrete. Values for chloride content, SO3, strength activity index, soundness and initial setting times given in BS EN 450 have been retained for glass pozzolan, but others, such as the SiO2 and LOI have been modified to values typically found in post-consumer glass samples that perform at an appropriate level in concrete. New criteria such as fineness (surface area) and lead content have been adopted to ensure the material reaches the BS EN 450 criteria for strength activity index and prohibits contamination by cathode ray tubes (CRTs). Pre-certification of glass pozzolana was conducted in partnership with BRE, who supervised the UKASaccreditated testing on selected samples of ground glass pozzolana to corroborate the CCC results. BRE certification have now produced a pre-certification report stating that ground glass pozzolana is suitable for use as a pozzolanic cement replacement material at levels up to 25% by weight of cementitious material (Appendix D, Report Numbers 216-515 and BC2197). Table 6.1. Parameters, criteria and methods to guarantee the pozzolanic reactivity of waste glass for use in concrete PARAMETERS SiO2, min % Fe2O3, Al2O3, Na2O, K2O, CaO and MgO Chloride, max % Sulfur trioxide (SO3), max % Loss on ignition, max % Surface area, min m2/kg Activity index, min Soundness, max expansion Initial setting time, max Lead, max % CRITERIA 68 To be provided 0.1 3 1.5 300 75% at 28 days 85% at 90 days 10mm 2h more than control 0.1 METHODS BS 196-2 BS 196-2 BS 196-21[58] BS 196-2 BS 196-2 BS 196-6 BS 196-1 BS 196-3 BS 196-3 BS 6748[61]

6.2 Concrete Products Containing Glass as Pozzolan and Aggregate

A pre-certification process for concrete products containing glass aggregate and pozzolan which were made as part of the ConGlassCrete I Project [6], was based on positive compliance of these products with relevant British Standards [62-64] and on the results of 1 year ASR testing to BS 812-123 [65]. The selected products, Figure 6.1 and Table 6.2, were chosen to give as wide a range of applicability to the use of crushed and powdered glass in concrete as possible and included low value grey blocks, pigmented paving blocks and high value architectural masonry units. 19 Final Report, March 2004

The pre-certification of these concrete products was conducted in partnership with BRE and BRE certification. The BRE conducted UKAS-accredited testing of the concrete products (Appendix E Report Number 216-519) and showed that the concrete products complied with corresponding British Standards. Based on this, BRE certification have concluded (Appendix E Report number BC 3562) that selected concrete products made with glass pozzolana and/or aggregate generally performed in the short term as well as the control products with no waste glass present. The report also recommends further investigation work to test long-term durability properties such as freeze/ thaw resistance and ASR expansion.

(a) Grey Blocks (Stowell)

(b) Paving Units (Aggregate Industries UK)

(c) Masonry Units (CRH Forticrete Group)

Figure 6.1 Concrete products selected for certification

20 Final Report, March 2004

Table 6.2. Full-scale ConGlassCrete products under compliance testing

COMPANY

PRODUCT

GLASS REPLACEMENT LEVEL (%) Pozzolan 14 25

PROPERTIES

Stowell Concrete Ltd

Dimensional check, compressive strength and drying shrinkage

Grey blocks Aggregate

Shape and dimensions, Aggregate Industries UK tensile strength, Paving blocks Pozzolan 24 visual aspects, slip/skid and weathering resistances Dimensional check, Aggregate 53 compressive strength and drying shrinkage

Forticrete Ltd

Architectural masonry units

21 Final Report, March 2004

Chapter 7. Long Term Testing

Three long-term testing programmes have been initiated by this project, as described below.

7.1 Concrete Products Study

117 concrete products, Table 7.1, made and reported in the ConGlassCrete I Project [6] have been retained at the University of Sheffield and will be tested to an age of 5 years. Funding is currently being sought to cover this cost.

7.2 Laboratory Parametric Study

The laboratory specimens made for ASR testing to ASTM C1260 [66] and C 227 [67] and as a part of the ConGlassCrete I Project [6] have been retained in high-temperature storage for long-term testing, Table 7.2 and 7.3. Funding is currently being sought to cover the cost of testing these samples.

7.3 At BRE
A long-term testing programme to evaluate the effects of various suppressants on ASR expansion of 6-12mm flint glass aggregate has been initiated by BRE. The study includes 11 concrete mixes made with different suppressants (metakaolin, PFA, GGBS and glass pozzolana), at different replacement levels, and using four cements with alkali contents of 2.68, 4.84, 5.5 and 7.0 kg/m3 Na2O eq. The standard mix design [69], initial assessment and a proposed future testing programme are included in Appendix F.

22 Final Report, March 2004

Table 7.1. The industrial sub-projects concrete products in the long-term testing at Sheffield SUBPROJ. NO. 1 2 3 4 5 6 7 8 9 Marshalls Mono 10 11 12 Tarmac Group 13 14 15 16 17 18 19 20 Glass Pozzolan and Sand in Low-Grade Ready-mix Concrete Assessment of Crushed Glass Product (Analysed by GTS) Glass Pozzolan and Aggregate in Semi-dry Concrete Blocks Glass Pozzolan and Aggregate in Semi-dry Concrete Blocks Glass Pozzolan and Aggregate in Wet-Pressing Concrete Kerbs Glass Pozzolan and Aggregate in Semi-dry Cast Concrete Feet Decorative Exposed Glass Aggregate Concrete Products Glass Pozzolan and Sand in Cast Concrete Roof Tiles TOTAL MIXES 6 2 5 6 3 6 8 7 117 Glass Pozzolan in Wet-Casting Concrete Paving Glass Pozzolan in Hydraulic Wet-Press Concrete Paving Glass Pozzolan in Low-Grade Ready-mix Concrete 3 3 7 Aggregate Industries UK CRH (Forticrete) NO. OF TRIALS

COMPANY

DESCRIPTION

H&H

Glass Aggregate and Pozzolan in Pre-cast Concrete Paving Slabs Glass Pozzolan and Glass Sand in Semi-dry Cast Concrete Stone Glass Pozzolan in Semi-Dry Cast Concrete Grey Blocks Glass Aggregate and Pozzolan in Medici Architectural Masonry Glass Pozzolan in Fielding and Platt Process Slabs Glass Pozzolan and Aggregate in Fielding and Platt Process Slabs Glass Pozzolan in Semi-Dry Cast Block Pavers Glass as Exposed Aggregate in Concrete flags Glass Pozzolan in Semi-Dry Cast Block Paving

8 3 3 9+6 6 6 6 5+5 2+2

Stowell Concrete

Conways Aggregate Industries UK Stowell Concrete Trent Concrete CRH (Forticrete)

23 Final Report, March 2004

Table 7.2. Laboratory concrete mixes undergoing long-term testing at Sheffield TEST REGIME AND RESULTS MIX CODE DESCRIPTION C1260 OPC/Amber OPC-1/Amber OPC/PFA30/Amber OPC/Flint OPC/PFA30/Flint OPC/CPFA30/Flint OPC/Blue OPC/PFA30/Blue OPC/CPFA30/Blue WPC/Amber WPC/PFA30/Amber WPC/CPFA30/Amber WPC/Blue WPC/MK20/Blue WPC/SPFA20/Blue WPC/Flint WPC/PFA20/Flint WPC/MK20/Flint OPC, ASTM grading amber cullet OPC, ASTM grading amber cullet OPC with 30% PFA, ASTM grading amber cullet OPC, ASTM grading flint cullet OPC with 30% PFA, ASTM grading flint cullet OPC with 30% CPFA, ASTM grading flint cullet OPC, ASTM grading blue cullet OPC with 30%PFA, ASTM grading blue cullet OPC with 30% CPFA, ASTM grading blue cullet White cement, ASTM grading amber cullet White cement with 30% PFA, ASTM grading amber cullet White cement with 30% PFA, ASTM grading amber cullet White cement, ASTM grading blue cullet White cement with 20% MK, ASTM grading blue cullet White cement with 20% SPFA, ASTM grading blue cullet White cement, ASTM grading flint cullet White cement with 20% PFA, ASTM grading flint cullet White cement with 20% MK, ASTM grading flint cullet Pass Pass Pass Pass Pass Pass Fail Pass Pass C227 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass 40oC water Ongoing Ongoing Ongoing Ongoing 60oC, 98% RH Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing 80oC, 98% RH Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing

24 Final Report, March 2004

Table 7.3. Laboratory concrete mixes undergoing long-term testing at Sheffield TEST REGIME AND RESULTS ASTM C227 Pass Fail Pass Pass Fail Pass Pass Fail Pass Pass Pass Pass Fail Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Fail Ongoing Ongoing 60oC, 98% RH Ongoing Ongoing Ongoing Ongoing 80oC, 98% RH Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing Ongoing 25 Final Report, March 2004

MIX CODE HAPC/Normal Sand HAPC/Amber HAPC/PFA30/Amber HAPC/CPFA30/Amber HAPC/Blue HAPC/PFA30/Blue HAPC/CPFA30/Blue HAPC/Flint HAPC/PFA30/Flint HAPC/CPFA30/Flint HAPC/PFA20/Flint HAPC/SPFA20/Flint HAPC/GP20/Amber HAPC/GP30/Amber HAPC/PFA-I 20/Amber HAPC/PFA-II 20/Amber HAPC/PFA20/Amber HAPC/PFA25/Amber HAPC/SPFA20/Amber HAPC/MK20/Amber HAPC/GGBS30/Amber HAPC/GGBS30/Amber HAPC/GGBS50/Amber HAPC/GGBS30/Flint HAPC/GGBS40/Flint HAPC/GGBS50/Flint HAPC/GGBS30/Blue HAPC/GGBS40/Blue HAPC/GGBS50/Blue

DESCRIPTION High alkali cement, ASTM grading normal sand High alkali cement, ASTM grading amber cullet High alkali cement with 30% PFA, ASTM grading amber cullet High alkali cement with 30% CPFA, ASTM grading amber cullet High alkali cement, ASTM grading blue cullet High alkali cement with 30% PFA, ASTM grading blue cullet High alkali cement with 30% CPFA, ASTM grading blue cullet High alkali cement, ASTM grading flint cullet High alkali cement with 30% PFA, ASTM grading flint cullet High alkali cement with 30% CPFA, ASTM grading flint cullet High alkali cement with 20% PFA, ASTM grading flint cullet High alkali cement with 20% SPFA, ASTM grading flint cullet High alkali cement with 20% green pozzolan, ASTM grading amber cullet High alkali cement with 30% green pozzolan, ASTM grading amber cullet High alkali cement with 20% UK PFA-I, ASTM grading amber cullet High alkali cement with 20% UK PFA-II, ASTM grading amber cullet High alkali cement with 20% replacement of PFA, ASTM grading amber cullet High alkali cement with 25% PFA, ASTM grading amber cullet High alkali cement with 20% SPFA, ASTM grading amber cullet High alkali cement with 20% MK, ASTM grading amber cullet High alkali cement with 30% GGBS, ASTM grading amber cullet High alkali cement with 40% GGBS, ASTM grading amber cullet High alkali cement with 50% GGBS, ASTM grading amber cullet High alkali cement with 30% GGBS, ASTM grading flint cullet High alkali cement with 40% GGBS, ASTM grading flint cullet High alkali cement with 50% GGBS, ASTM grading flint cullet High alkali cement with 30% GGBS, ASTM grading blue cullet High alkali cement with 40% GGBS, ASTM grading blue cullet High alkali cement with 50% GGBS, ASTM grading blue cullet

Chapter 8. Demonstration Projects

The ConGlassCrete 2 Project has, throughout its duration, sought to develop appropriate Demonstration Projects in collaboration with industry. This has been done by the use of the 100-page web site, 6 newsletters, 2 online reports and 2 National Seminars. Enquiries have come in over the course of the Project from a variety of sources. However the issue that has arisen in every case has been the lack of Standards, specifications or certified products that industry would require prior to using glass in concrete construction. With the publication of this report and the ConGlassCrete 1 Project Report [6], the industry now has tentative specifications and pre-certification reports that may increase confidence in glass as a material that can be used in concrete. It is the intention of the ConGlassCrete team to retain an interest in demonstration projects beyond the term of this project. To that end, a series of demonstration units to be placed at strategic high-profile sites, is planned in conjunction with the project partners.

8.1 Contacts for Potential Demonstration Projects

The 250 companies within which individuals have expressed interest in ConGlassCrete are listed in Appendix A. The individuals cannot be named in this Report because of the Data Protection Act, but full e-mail addresses have been supplied to WRAP under separate covers.

26 Final Report, March 2004

Chapter 9. Conclusions
The main conclusions that can be drawn from the ConGlassCrete 2 are given below: 1. The chemical characterisation exercises conducted during this project on the container, plate, lighting, automotive and lighting waste glass streams has shown that: a) the target waste glass streams of this project (with the exception of glass fibres) are chemically very similar and differences between them are not considered significant with respect to their effects in concrete. levels of contamination were not as high as originally perceived, even in very fresh cullet obtained straight from a pub and club collection source.

b)

2. All target waste glass streams tested in this study, whether from contaminated or relatively clean sources, demonstrated pozzolanic reaction when tested in mortars tested for strength activity index to BS EN 450. 3. The main parameter affecting the degree of reaction was ground glass fineness. A fineness of 300m2/kg is required to give strength activity index in concrete equivalent to a BS EN 450 fly ash. 4. None of the waste glass streams tested in this study, irrespective of contamination level, retarded concrete set by more than 2 hours. 5. A specification for glass as a pozzolan has been proposed, based loosely around the requirements of BS EN 450 with modifications to suit a glass material. The Sheffield data upon which the specification is drawn has been checked by testing in a UKAS-accredited laboratory under the supervision of BRE. 6. The glass as a pozzolan in concrete specification set by this project for has been given 3rd-Party accreditation by BRE Certification. 7. Selected pre-cast concrete products containing glass as aggregate and pozzolan have also received accreditation from BRE Certification. 8. Samples for long-term ASR testing have been prepared at Sheffield (over 200 mixes) and at BRE (11 mixes). These probably represent the largest glass in concrete sample library in the world and funding is now being sought to ensure that ongoing tests can be conducted to at least 3 years.

27 Final Report, March 2004

REFERENCES

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