The Need

The rapid worldwide growth of the  construction industry during recent decades has resulted in an enormous increase in the global production of  Construction and Demolition Waste (CDW), placing an enormous strain on the environmental. The industry urgently needs to implement changes to economic policy and decision-making criteria to address this issue and to safe-guard the environment.

Some challenges to be overcome –

  • CDW contains a complicated combination of bulky and heavy materials such as concrete (40%–67%), wood, asphalt, gypsum, metals, bricks, glass, and plastics
  • There is currently 850 million tons of CDW in Europe (31% of total waste generation)
  • The global cement industry produces 1.6 billion tons of CO2 annually (8% of total emissions)
  • There is 39 kg of construction waste in every square metre of building
  • The recent financial crisis impacted on the building and construction (B&C) sector with increased unemployment and increased pressure on sub-sectors such as construction materials, distribution channels and logistics
  • EU targets set for 2020 and 2050 (reducing CO2 emissions by 80-95%) create an increased need for efficient, affordable and deep refurbishment by a factor of 2 to 3 times the current rate
  • Deep refurbishment is difficult due to the level of time and capital investment required, and inadequately optimised technologies

The Project


6 integrated layers – high structural performance – insulation – comfortable healthy indoor environment – high aesthetic value – CO2 capture – grey & storm water management – easy installation – light weight – recyclable & reusable – over 70% CDW – energy and resource efficient – based on extrusion – cost effective – no specialized labour required

Competitive advantages

  • Sustainable and cost effective through the use of CDW – more than 70% of net weight
  • Reduced installation and production times – Installation 15% and production 30% faster
  • Reduced weight – 30% lighter than conventional envelope walls of the same size
  • Safety and energy efficiency – meets Eurocode standards for fire safety, thermal insulation with U value of 0,14 W/m2.°C and acoustic insulation coefficient of 55-60dB
  • Cost efficient products and new supply chains – Green technologies such as on-site grey and storm water management through integration of a vertical green wall
  • Customisation potential – Multi-layered, modular & prefabricated building block for new and old building
  • Comfortable, healthy and productive environment – C2C strategies

Work Packages

WP1: Coordination & Management

The objective of this work package is to ensure the smooth running of the project including the communication between the consortium and the European Commission (EC), so that all knowledge generated under the project is created, managed and disseminated in a coordinated and coherent manner. Project management, financial and legal aspects will be orchestrated to high standard and in accordance with GA terms.

  • Establishment and follow-up of consortium agreement
  • Taking responsibility for communication within the consortium
  • Control project progress and time schedules
  • Review milestones and deliverables.
  • Generate and publish regular and special reports such as the mid-term, summary and exploitation reports
  • Overview financial and technical management

WP2: Consolidation of Specifications

The focus of WP2 is on the analysis of the specifications for the final products based on user and technical requirements. WP2 aims at defining standardisation and demonstration specifications.

The activity will take into account aspects related to the social acceptance of the products and also environmental, technical and aesthetic issues connected with the proposed solutions. The aim here is to define standards related to the demonstration activities.

  • Analyse end-user requirements and finalise product specification
  • Define product technical requirements
  • Identify the most suitable certification strategies related to demonstration activities

WP3: Module and Building Design

  • Develop an architectural design for the Green INSTRUCT building envelopes
  • Prepare a construction project development plan
  • Design the prefabricated building block from a functional, structural and aesthetic perspective
  • Optimise the structural and thermal performance of the building block using CFD
  • Devise a sustainable C2C (Cradle to Cradle®) strategy for the Green INSTRUCT building block
  • Develop 2D and 3D Building Information Models (BIM)

WP4: Optimisation of Recovery Process and Life-cycle Assessment (LCA)

  • Identify additional CDW streams that can be incorporated in the recovery process
  • Design, implement, monitor and optimise a CDW recovery process tailored to the project’s material flow requirements
  • Coordinate the material characterisation techniques employed within the project

WP5: Harvesting of CDW and processing of materials

  • Process and produce reinforcing fibres from PET, PVC, PE, wood and textile
  • Encapsulate Phase Change Materials (PCM) in concrete aggregates
  • Produce a recycled structural aluminium frame
  • Integrate recovered CDW with structural adhesives

WP6: External panel development

  • Enhance plastic compounding to meet plant substrate requirements
  • Weave fibres into the geopolymer matrix
  • Optimise amendments to the geopolymer for reinforcement and property enhancement
  • Establish a method for reliable water treatment
  • Include automation of water treatment
  • Evaluate the properties of the external panel

WP7: Internal panel development

  • Recycle and process polymers for application as lubricants during the extrusion of geopolymer and MOC
  • Recycle and process polyurethane from CDW into an insulating foam
  • Develop and extrude an eco-friendly minimum oxygen concentration (MOC) structural layer integrated with PCMs and reinforcing fibres
  • Develop TiO2powders through sol-gel and perform doping to enable indoor photocatalytic activity
  • Integrate the TiO2powder with innermost surface coating

WP8: Integration and validation

  • Integrate and assemble working prototypes
  • Optimise structural performance of prototypes
  • Optimise thermal and acoustic insulation of prototypes
  • Conduct on-site modifications

WP9: Demonstration activities

  • Demonstrate Green INSTRUCT building block performance in two experimental stations
  • Monitor system performance in variable heat, humidity and wind conditions
  • Demonstrate quality of indoor environment

WP10: Dissemination, Exploitation and Communication activities

We are committed to the transfer of generated knowledge through the dissemination of technology developed during previous WPs as widely as possible. All project results will be formulated and compiled in protect-able format and necessary patents and copyrights will be filed.

  • Promote developed techniques and maintain a technology transfer program
  • Ensure widespread use and awareness of the project’s developed technology within the building and construction industry to maximise exploitation opportunities for partners and stakeholders
  • Take appropriate action for the protection of Intellectual Property Rights (IPR) where relevant
  • Compliance of project results to national, EU and market standards and regulations, contributing to emerging standards (especially regarding CDW utilisation in the B&C industry and prefabricated construction)
  • Assure inter-operability with existing standards in CDW separation, material processing and component & product development, identifying legislative barriers and opportunities incumbent in the national and European regulatory systems
  • Assess socio-economic impact of the generated knowledge and technology, and broadcasting of the technology’s potential applications to the wider community
  • Seek out and identify further sources of funding and create a development plan for post-project investment

WP11: Ethics requirements

  •  Ensure compliance with the ethics requirements as provided for within the project