Remanufacturing construction and demolition waste and incineration ashes into eco-blocks: Quantitative sustainability assessment

Abstract

This study performed a sustainability evaluation of a proposed business for remanufacturing concrete materials from construction and demolition waste (CDW) and ash from the combustion of municipal solid waste (MSW) to produce eco-blocks for construction applications. Six possible industrial remanufacturing alternatives are proposed based on commercially available industrial machinery and their economic sustainability was compared by a cost and profit feasibility study. Furthermore, the technical feasibility was evaluated by considering the maturity of the selected machinery based on the relationships among the cost–productivity, power–productivity, and number of workers–productivity pairs. The proposed remanufacturing business achieves a maximum profit of 17,643 USD/day with a minimum remanufacturing cost of 30.65 USD/t for the production of 529 t of eco-blocks in an 8-h factory shift. A quantitative environmental sustainability assessment was performed using the remanufacturing cost, profit, concrete savings, energy savings, CO2 emission savings, and eco-cost savings as criteria based on demographic statistics from the literature for current and predicted CDW and MSW generation. CDW and incineration ash are widely available, so the proposed process is viable worldwide. Based on the technical, economic, and environmental sustainability results, a final sustainability index of 0.874 was calculated, which exceeds literature thresholds for a sustainable business, indicating that the proposed eco-block remanufacturing process has the potential to generate substantial profits, while positively contributing to reducing waste and energy usage by recovering valuable resources and producing value-added products. The remanufactured eco-blocks are prepared in the same way as typical concrete blocks and can be used for all of the same residential, commercial, and industrial construction and landscaping applications. The remanufactured eco-blocks have several advantages over typical concrete blocks, including a much lower manufacturing cost (∼50 % lower), significant environmental and resource savings by avoiding the use of new sand and gravel resources, and improved mechanical properties.