www.rewastee.eu ECO/13/630286 The REWASTEE Eco-Innovaon Project Recycling steel making solid wastes for added value energy efficiency building products Developing High Performance Thermo-Acousc Construcon Products From Recycled Steel Factory Waste Co-funded by the Eco- innovaon Iniave of the European Union www.rewastee.eu Layman report
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www.rewastee.eu
ECO/13/630286
The REWASTEE Eco-Innova�on Project
Recycling steel making solid wastes for added value energy efficiency building products
Developing High Performance Thermo-Acous�c Construc�on Products From Recycled Steel Factory Waste
Co-funded by the Eco-innova�on Ini�a�ve of the European Union
Introduc�on: REWASTEE was concerned with developing innova�ve, sustainable, added value construc�on products by applying an innova�ve Spanish patent to manufacture a dense (rubber-like) membrane using a binding polymer mix and Electric Arc Furnace Dust (EAFD) (which is a waste by-product from steel produc�on) - a process which also renders the dust non-hazardous. The resul�ng REWASTEE membrane has good (airborne) acous�c insula�on proper�es which presents significant opportuni�es for various soundproofing applica�ons in buildings and beyond. Addi�onally, “phase change material” can also be added during the manufacturing phase to give the membrane thermal iner�a proper�es. This addi�onal product is believed to be the world’s first flexible acous�c membrane with thermal iner�a.
Project aims: The project aim was the industrial valida�on, market deployment and replica�on of a developed technology for recycling steelmaking wastes and the manufacture of mul�func�onal building products. An addi�onal aim was to develop and test construc�ve solu�ons using the new material. All project aims were successfully delivered.
The project team: The REWASTEE project team comprised innova�on and technology development, academic, manufacturing and construc�on sector experts from across the EU as follows: Eurecat (ESP), University of Barcelona (ESP), University of Lleida (ESP), Nobatek (FR), R2M Solu�on (ITA), FCC Construcción (ESP), Trimdelson Trade (ESP) and BRE (UK). The 30 month research project ran from July 2014 to December 2016 and had a budget of €1.387.287 with an EU contribu�on of 50%.
A problem solved: Europe is the world’s second largest steel producer with an average annual produc�on of 165 million metric tonnes. Approximately 40% of this produc�on is made via Electric Arc Furnaces which generate around 15kg of EAFD per tonne of steel produced. Untreated, this dust, amoun�ng to about 1 million tonnes annually, is classed as hazardous waste. The REWASTEE approach offers an alterna�ve to the tradi�onal, costly, iner�za�on, stabiliza�on and recycling of EAFD, that is by encapsula�ng it in a polymer matrix which rendering it non-hazardous.
Introducing REWASTEE
Manufacture: Using a Spanish patent, REWASTEE recycles EAFD from the steel industry into a shape stabilized acous�c insula�on with thermal iner�a provided by embedded phase change materials (PCM). The material is non-hazardous, flexible, durable, highly dense, and offers compelling value for the product cost at the same �me. Furthermore, it solves the environmental challenges associated with trea�ng EAFD. Compact but effec�ve: The resul�ng membrane can considerably improve the ability of external walls, par��ons, floors and roofs to a�enuate airborne noise, even although the membrane is of minimal size (typically 3.5mm or 5mm). Whilst thin, the membrane is dense but s�ll flexible –making it well suited to building applica�ons. It can also be bonded to a variety of building materials (e.g. insula�on or plasterboard). The membrane has applica�ons in private houses, apartment blocks, office buildings, public buildings and industrial buildings.
REWASTEE stands for Recycling steel making solid wastes for added value energy efficiency building products. Rewastee was a research project co-funded by the European Union (ECO/13/630286). REWASTEE has developed a range of innova�ve materials for the construc�on industry. This layman’s report provides a non-technical summary of the project.
ECO/13/630286
Co-funded by the Eco-innova�on Ini�a�ve of the European Union
As well as the standard REWASTEE membrane, a unique selling point is that Phase Change Material (PCM) can be added during the patented manufacturing process to provide an op�onal thermal buffering capacity. PCMs work by absorbing heat energy and releasing it some�me later. The addi�on of PCM within the REWASTEE membrane can therefore help designers deliver improvements in indoor thermal comfort as well as energy (hea�ng/cooling) savings within buildings as heat can be absorbed at �mes when indoor temperatures are high, resul�ng in a reduc�on in space cooling loads. The REWASTEE membrane which includes PCM is known as ‘REWASTEE PLUS’. The manufacturing process cons�tuents for the PCM inclusive membrane are outlined below. The resul�ng membrane is also presented.
Our research suggests that REWASTEE PLUS is the first soundproofing acous�c membrane in the marketplace with integrated thermal iner�a.
REWASTEE has delivered to the sustainable construc�on market, two unique and specialist flexible membranes (manufactured from recycled content) for acous�c insula�on (‘REWASTEE’) and the world’s first flexible acous�c membrane incorpora�ng phase change materials (PCM) (‘REWASTEE plus’) which provides thermal buffering.
Similar to a dense rubber in composi�on, both membranes are of high density, provide good airborne sound a�enua�on and have been produced in two thicknesses (3.5 mm and 5 mm). Both membranes can be used as either a simple membrane for coa�ng (e.g. applying directly to surfaces) or layering applica�ons. Alterna�vely, they offer the poten�al to be integrated into manufactured building products (complex products) such as sound insula�on panels and mul�layer wall par��ons.
A wide variety of applica�ons were inves�gated and those offering greatest poten�al (i.e. sound insula�on boards, mul�layer wall par��ons, roof deck, etc.) formed the basis of subsequent product and project development including development of commercial exploita�on, replica�on and cer�fica�on strategies. Relevant laboratory performance tes�ng and demonstra�ons were also progressed.
Thermal Iner�a—a world’s first for an acous�c membrane
Products
Layman report
www.rewastee.eu
Applica�ons REWASTEE and REWASTEE PLUS can be used in a variety of wall, floor, and ceiling / roof applica�ons. The following shows common examples where REWASTEE products can be incorporated in to (i) internal par��on walls, (ii) external wall façades, (iii) intermediate floors and (iv) decked roofs:
For more informa�on, see www.rewastee.eu or contact Biotza Gu�errez (biotza.gu�[email protected])
As well as undertaking formal tes�ng, we conducted pilot trials and launched technical datasheets for the new product. The datasheets present a comprehensive record of the proper�es and technical performance of the REWASTEE and REWASTEE-plus products, and they were produced to inform designers and specifiers. A product range catalogue was also developed, available to download from the project website, to aid dissemina�on. The catalogue introduces the range of REWASTEE products, explains their performance and benefits, and provides extensive details of how REWASTEE and REWASTEE-plus can be integrated with common construc�ve solu�ons in order to provide improved sound a�enua�on and/or thermal capaci�es via the phase change material. The datasheets are available to download from the project website here: www.rewastee.eu/informa�on/
A successful pilot installa�on of the REWASTEE membrane was carried out in a non-domes�c property refurbishment in Spain. The property, owned by FCC Construcción, was well suited as it was subject to a noisy external environment being on an industrial site. The installa�on of REWASTEE was completed quickly and easily and REWASTEE was found to do a great job in reducing airborne noise pollu�on. FCC Construcción, who completed the installa�on reported that the REWASTEE sheet was easy for their installers to handle and enabled easy cu�ng (which makes it easy for users to adapt the sheet to diverse applica�ons). They also reported no significant or unexpected problems during the installa�on process. Overall, FCC Construcción are very sa�sfied with the material’s performance, its installa�on and the acous�c benefits obtained .
Layman report
We conducted independent laboratory tes�ng of the REWASTEE products. This showed that the product was very effec�ve in providing soundproofing over a wide range of frequencies. The tests are aligned to a cer�fica�on strategy developed earlier in the project that iden�fied all appropriately cri�cal tests, cer�fica�ons and approvals necessary to provide a suitable route to market. In this study, different solu�ons were designed and tested. The reason for this is that the acous�c performance of any mul�layer configura�on is not the sum of the acous�c performance of each individual layer. Different mechanisms, such as the mass-spring resonance and the influence of the couplings between the different layers affect the global sound insula�on of the par��on. As a result, a representa�ve configura�on has to be defined to evaluate the sound insula�on.
The REWASTEE business model ac�vi�es iden�fied 5 key stakeholders groups as outlined below. Through the project each of these groups were engaged to aid the development of the project. In addi�on, the project team also disseminated key project or product informa�on to stakeholders in a wide variety of ways including, one-to-one mee�ng, events, conferences, news and press ar�cles, journals and technical papers, dedicated construc�on industry-focussed workshops and the project website. Project flyers, banners, technical datasheets and 6 monthly newsle�ers where also produced to aid the promo�on.
Stakeholder engagement and dissemina�on
Layman report
With 70% recycled content, using REWASTEE can bring addi�onal thermal and acous�c comfort, help gain LEED credits, increase BREEAM scores and / or meet regulatory requirements.
Introducing TRIMSOUND
REWASTEE has been rebranded as TRIMSOUND to ensure that prospec�ve customers instantaneously recognises that TRIMSOUND is a sound-reducing acous�c product. This change also coincides with the transi�on of the products from its successful research project beginning to its exci�ng new commercial phase! Now customers and building designers can all trim-sound with our eco-innova�on product, to improve our built environment and acous�c wellbeing!
Stakeholder Groups · Steel producers · EAFD recycling points · Governing bodies · Construc�on material producers · Construc�on stakeholders
- It doesn’t smell - It doesn’t crack - All-temperature friendly – i.e. s�ll pliable in the winter and not “gummy” in the summer - Customizable thicknesses - A 2mm product is really 2mm and not 1.8mm.
Industry Feedback
[REWASTEE] provides added value and is a differen�a�ng factor in the current highly compe��ve market.
No other acous�c solu�on product on the market includes Phase Change Materials.
The REWASTEE density is very similar to [tradi�onal] commer-cial products however an advantage with REWASTEE is the environment benefit due to the recycled EAFD dust.
Sales & Distribu�on Agreement Located in the Barcelona area, Partner Trimdelson Trade is the manufacturer of REWASTEE. Taking its first step towards the interna�onalisa�on of the REWASTEE family of products, Trimdelson Trade reached an agreement with R2M Solu�on for sales and distribu�on in Italy. R2M specialises in the commercialisa�on of new technologies and is located in the city of Pavia near Milan. “New norms related to energy efficiency and acous�c performance point to a growth scenario for these types of solu�ons in Italy. In addi�on, Italy has a proud history of steel produc�on and the Italian recycling point for EAFD has taken a keen interest in our work. We look forward to seeing TRIMSOUND on Italian dwellings in the near future.” (Tom Messervey, CEO, R2M Solu�on).
Enric Torres (le�) of Trimdelson Trade and Thomas Messervey (right) of R2M Solu�on formalise agreement for product sales in Italy.
www.rewastee.eu
Layman report
Sales and distribu�on
Next steps for REWASTEE/TRIMSOUND?
The membrane has proved a success. What is next? One step is working with leading construc�on materials suppliers to integrate TRIMSOUND into prefabri-cated roofing and wall applica�ons. Discussions are already underway. Another step is to expand the use of the membranes to addi�onal sectors outside of construc�on. We are sure that you’ll be reading more about the TRIMSOUND membrane in the near future!
Local produc�on has always been a key project goal and it is a compe��ve advantage for REWASTEE because there are only a few recycling centres in Europe capable of handling EAFD. As such, steel makers are currently required to transport EAFD across mul�ple EU countries to recycling facili�es.
How much dust? Europe is the second largest steel producer worldwide, producing approximately 165 million metric tons annually. Given that about 40% of steel produc�on uses the Electric Arc Furnace which results in about 15kg EAFD per ton of steel produc�on – approximately 1 million tons of EAFD (500,000m3) is ending up in landfills. That’s a lot of dust!
How much membrane? About 30% of EAFD has low zinc content making it less a�rac�ve for zinc extrac�on processes. Targe�ng this 30% (300,000 tons of EAFD), suggests ~75 million m² of the standard TRIMSOUND 3mm product could be produced. That would cover 75 km² or almost all of Paris. At current market prices of similar products, this equates to an approximate €500 million annual turnover opportunity.
Can we use it? Assuming 250m² for a household installa�on, annual produc�on of 75 million m² would equate to 300,000 households. Europe has approximately 220 million households (Eurostat). The EU target for renova�on is 3% (6.6 million homes per annum). The EU is adding 2 million new households to its housing stock each year. So yes, REWASTEE provides a great solu�on and this is before we consider domes�c refurbishment or commercial and industrial building applica�ons.
A landmark outcome of the project was the establishment of a commercial agreement which will lead to the distribu�on of TRIMSOUND through DeCinque Linear House in San Salvo, Italy. Part of the DeCinque Group (who build and construct homes and offer support for the thermal and acous�c isola�on of homes), DeCinque Linear House started in 1978 and has become the leading construc�on retail center in its area www.de5linearhouse.it/.
EURECAT is the major private RTO in Catalonia and 2nd in Southern Europe. It provides unique technology and advanced knowledge to industry in order to solve its needs for innova�on and empower compe��veness. Eurecat brings to REWASTEE its exper�se on industrial sustainability and manufacturing scalability. www.eurecat.org Universitat de Barcelona (UB) was founded in 1450. REWASTEE co-patent holder. Today it boasts of a student body of 84,370 and a research staff of 4,548 members. Degrees are offered in 73 different areas of teaching with numerous postgraduate and doctorate programs as well as con-�nuing educa�on courses. The university is a co-patent holder of the REWASTEE technology and has expert knowledge regarding its chemistry, produc�on, environmental issues and recycling. www.ub.edu Universitat de Lleida is a REWASTEE co-patent holder. The university is a public university that combines its success as a long-standing university with a young and dynamic structure com-mi�ed to high quality training based on advanced methods. www.udl.cat Nobatek provides exper�se on sustainable construc�on, paving the way for developing RE-WASTEE as a building material, through to assessment of market feasible construc�ve solu�ons and building components, taking into account key aspects concerning sustainability in building products. www.nobatek.com R2M is a well-recognized private company with broad experience in bridging the gap between applied research results and its market uptake. R2M provided exploita�on exper�se, leading business development and exploita�on ac�ons, coordina�ng all directly related to ensure tech-nology commercializa�on and market uptake of REWASTEE building products. www.r2msolu�on.com TRIMDELSON is a Spanish based manufacturer of rubber materials and led the produc�on of REWASTEE product Trimdelson were responsible for managing EAFD as raw material, but also to produce the REWASTE products at commercial scale, defining both a standardized and replicable industrial methodology and producing the building products. www.trimdelson.com FCC is a major EU construc�on company and thus poten�al key end user of REWSATEE products. FCC provided expert industry insight to assist the rapid market entry of REWASTEE, by tailoring the produc�on of REWASTEE products, according the needs of a major end user. www.fcc.es The Building Research Establishment (BRE) is the UK’s leading centre for research and consultan-cy on the built environment with exper�se in construc�on quality, products, processes and produc�vity; tes�ng; cer�fica�on; environmental impact of construc�on, sustainability and whole-life performance; energy efficiency of buildings; renewable energy in buildings. www.bre.co.uk
has…
· introduced to the market an innova�ve new building material product range including the world’s first flexible acous�c membrane with thermal iner�a.
· established the industrial methodology and know-how required for the efficient processing of steelmaking electric arc furnace dust waste, whilst evalua�ng its posi�ve environmental impact.
delivers (for the construc�on market)…
· acous�c and thermal comfort poten�al for buildings, and an associated reduc�on in carbon footprint through its use. · great performance from an eco-innova�on product with significant recycled waste content.
delivers (for the steel and waste handling industries)…
· an effec�ve means of reducing or elimina�ng the economic cost associated with tradi�onal EAFD waste management. · a reduc�on of risks (for persons and the environment) associated with the handling and landfilling of EAFD.