Evaluation of concrete recycling system efficiency for ready-mix concrete plants

The volume of waste generated annually in concrete plants is quite large and has important environmental and economic consequences. The use of fresh concrete recyclers is an interesting way for the reuse of aggregates and water in new concrete production. This paper presents a study carried out for over one year by one of the largest ready-mix concrete producers in Brazil. This study focused on the evaluation of two recyclers with distinct material separation systems, herein referred to as drum-type and rotary sieve-type equipment. They were evaluated through characterization and monitoring test programs to verify the behaviour of recovered materials (aggregates, water, and slurry). The applicability of the recovered materials (water and aggregates) was also evaluated in the laboratory and at an industrial scale. The results obtained with the two types of recyclers used were equivalent and showed no significant differences. The only exception was in terms of workability. The drum-type recycler generated fewer cases that required increased pumping pressure. The analysis concluded that the use of untreated slurry is unfeasible because of its intense negative effects on the strength and workability of concrete. The reclaimed water, pre-treated to ensure that its density is less than 1.03g/cm(3), can be used on an industrial scale without causing any harm to the concrete. The use of recovered aggregates consequently induces an increase in water demand and cement consumption to ensure the workability conditions of concrete that is proportional to the concrete strength level. Therefore, the viability of their use is restricted to concretes with characteristic strengths lower than 25MPa.