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

www.rewastee.eu

Layman report

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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

Layman report

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

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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:

Layman report

• Plasterboard • Rewastee membrane • Plasterboard • Insula�on • Plasterboard • Rewastee membrane • Plasterboard

• Wood floor • Hanger for wood • Insula�on (op�onal) • Plasterboard • Rewastee membrane • Plasterboard

• Concrete floor • Rewastee membrane & insula�on • Hanger & metallic profile • Insula�on (op�onal) • Plasterboard • Rewastee membrane • Plasterboard

• Waterproof membrane • Insula�on • Rewastee membrane • Deck roof support

Roof - decked roof Floors - Intermediate

Walls - External Facades

• Plasterboard • Rewastee membrane • Plasterboard • Insula�on • Brick wall

Walls - Internal par��ons

• Plasterboard • Rewastee membrane • Insula�on • Rewastee membrane • Plasterboard

• Plasterboard • Insula�on • Plasterboard • Rewastee membrane • Plasterboard • Insula�on • Plasterboard

• Plaster -board • Rewastee membrane • Insula�on • Brick wall

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Performance Data and Tes�ng

For more informa�on, see www.rewastee.eu or contact Biotza Gu�errez (biotza.gu�errez@eurecat.org)

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.

Pilot Demonstra�on

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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.

Local produc�on - tackling a global issue

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.

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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/.

Retailing REWASTEE/TRIMSOUND

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Layman report

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.

…brought to you by:

Summing up