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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 135
GREEN CAST DEMONSTRATION OF INNOVATIVE LIGHTWEIGHT
CONSTRUCTION COMPONENTS MADE OF RECYCLED ASH FOR
SUSTAINABLE BUILDINGS
Íñigo Larraza1
, Ignacio del Val2
, Alessandro Marseglia3
, Giovanni Giodice4
, Jose Vera-Agullo5
1
ACCIONA Technological Centre, Valportillo II, 8, Alcobendas, Spain
2
ACCIONA Technological Centre, Valportillo II, 8, Alcobendas, Spain
3
CETMA - Engineering, Design & Materials Technologies Center, S.S. 7 – km 706+300, 72100, Brindisi, Italy
4
CETMA - Engineering, Design & Materials Technologies Center, S.S. 7 – km 706+300, 72100, Brindisi, Italy
5
ACCIONA Technological Centre, Valportillo II, 8, Alcobendas, Spain
Abstract
The present article describes the main objectives and outcomes of the GREEN CAST project. This project aims at the
demonstration of an innovative material that has been ideated and developed to be a green alternative to autoclaved aerated
concrete (AAC). The present material is based on geopolymer technology and consists on fly ash activated in an alkaline solution
in the presence of a foaming agent. The mechanical, thermal and acoustic characterization suggests that the properties of the
developed material are similar to those of AAC. The life cycle analyses carried out for both materials reveal that the alternative
technology has a lower environmental impact, associated to the use of the alkaline activator. The material in form of blocks was
used to build a demonstrator and its behavior as thermal and acoustic insulating material was monitored and compared to an
identical AAC made demonstrator. The similar performance of both materials reveals that GREEN CAST is a technical and
environmentally viable alternative to AAC.
Keywords: Lightweight, Fly ash, Autoclaved Aerated Concrete, Geopolymer.
--------------------------------------------------------------------***----------------------------------------------------------------------
1. INTRODUCTION
There is an increasing environmental need to develop new
and more sustainable production technologies to utilize
waste to substitute for raw materials in different industrial
areas and reduce the CO2 released to the atmosphere. In fact,
the European Commission has committed to reduce the CO2
emissions to 90´s levels by 2020. It is a major target to find
alternative construction materials for the construction
industry, because:
 The cement industry is the second one in CO2
emissions to the atmosphere, at least 5% of total
anthropogenic emissions (3.3 billion tons of cement
are produced yearly in the world)
 The extremely large consumption of natural
resources and generation of huge amounts of waste
 Millions of tons of waste potentially useful for the
construction industry are generated in Europe
yearly.
Every year, coal combustion fly ash is produced as a
byproduct of combustion processes in thermal plants
worldwide in large amounts. Although fly ash has not been
classified as hazardous waste, it causes environmental
concern due to the trace concentrations of heavy metals and
crystalline silica that are present in their composition,
limiting the amount that can be landfilled, or be in contact
with water streams. On the other hand, fly ash can be
classified as a pozzolanic material, which means that upon
alkaline activation they harden exhibiting cementitious
properties, and that is why they are mainly reused as a
supplementary cementitious material (SCM) in cement and
concrete composition.
Foamed, cellular or aerated autoclaved concrete (AAC) is
defined as a cement-based material that contains at least
20% air in its structure. This ensures desirable properties
such as low density and good thermal and acoustic
insulation. The main drawback of conventional cellular
concrete production is that has to be carried out in an
autoclave process that involves high temperature and
pressure.
Moreover, in the fabrication process of ordinary Portland
cement (OPC), CO2 is released into the atmosphere in the
same quantity as material that is produced. This CO2 is
produced in the burning of fossil fuels and in the de-
carbonation of limestone which is used as a raw material for
the clinker. So far, in the preparation of cement based
materials, fly ash has partially replaced commercial Portland
cement in several types of OPC up to 35%.
By considering all the facts outlined above, the GREEN
CAST project has emerged as a smart solution that proposes
the full replacement of OPC by fly ash, in order to obtain
non-structural lightweight precast construction elements
with good insulation properties, which is additionally
efficient from an environmental point of view.
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 136
GREEN CAST proposes to use fly ash as the main raw
material, optimizing their management as waste, thus
reducing their exposure to environment and therefore the
associated risks related to their potential toxicity and
environmental impact. Very importantly, compared to OPC,
the CO2 released into the atmosphere will be dramatically
reduced, since neither fossil fuel nor carbonates are present
in the GREEN CAST production process.
The main outcome of this research is the development and
demonstration on an innovative construction product with
good thermal, mechanical and acoustic properties,
economically competitive and with minimized
environmental footprint. The present manuscript relates the
preparation and characterization of the material, as well as
the demonstration step and the life cycle analysis,
demonstrating the environmental benefits of the GREEN
CAST technology with respect to its traditional competitors.
2. MATERIALS AND METHODS
The fly ash used in this project has been supplied by
Cencatra, a waste management company located in Spain.
Sodium hydroxide (50%) and hydrogen peroxide (33%)
were supplied by Panreac. A commercial bubble stabilizer
was used as received. All materials were used as received
without any further purification. The fly ash composition
was analyzed by X-ray fluorescence (XRF). This technique
allows detecting chemical species and their content in a
given sample. The particle size and distribution were
analyzed by granulometry. A Malvern Mastersizer 2000
equipment was used. Measurements have been made after
ultrasonic dispersion of samples by using water as
dispersant.
The materials were homogeneously mixed with a
mechanical stirrer in plastic recipients in the following way:
first the sodium hydroxide solution was diluted and allowed
to cool down at room temperature. Then, the bubble
stabilizer (BS) was added to the solution and stirred. The fly
ash was weighted and placed in the corresponding recipient,
then homogenized mechanically. In each case the aqueous
solution was added and mixed until complete
homogenization. Finally the hydrogen peroxide solution was
added to the mixture and mixed. The liquid mixtures were
then immediately poured into the corresponding mold and
covered with plastic film in order to prevent evaporation.
The foaming process was allowed to take place prior to the
curing stage. For the mechanical analyses, 16x4x4 cm
specimens were prepared in metallic molds. The blocks
were fabricated in PTFE coated wood molds (25x63x7 cm)
with capacity for 5 independent blocks, Figure 1. All the
samples were cured in laboratory furnaces at 80ºC for 16
hours. In order to analyze the foaming process of the
material, a metallic mold with a transparent PMMA face
was built.
Fig 1 Mixing process (left) and PTFE coated wood molds
(right).
The density (ρ) of the GREEN CAST samples was analyzed
according to the UNE-EN 772-13 standard. Six specimens
were extracted from different parts of three blocks.
The compressive strength (MC) was determined by
following the standard UNE-EN 772-1. A constant load was
applied at a constant rate of 0.1±0.05 MPa/s. The specimens
were kept at a constant humidity of 6±2% prior to the tests.
The dry density value is obtained from drying the specimens
to constant mass.
The thermal resistance and conductivity was measured in a
NETZSCH HFM 463 Lambda Heat Flow Meter, according
to the UNE-EN 12664:2001 standard. The heat flow meter
was used according to the norm ISO 8301:1991. In order to
do that, 3 specimens were introduced horizontally in a heat
flow meter, being the hot plate in the upper side. Said
specimens were conditioned in a ventilation oven at 105ºC
until constant mass is achieved, then coated with a
waterproof cover which prevents them from moisture. The
state temperature and the average temperature difference
through the specimen were set at 10 and 15ºC, respectively.
The free-thaw resistance was investigated by following the
UNE-EN 15304:2010 standard. Six cubic specimens (7x7x7
cm) were extracted from different parts of two blocks,
saturated and kept for 48 hours in a polyethylene bag for
stabilization and preserve moisture. The samples were
placed in a chamber and exposed to 15 cycles of freeze (-
15±2ºC) for 8 hours and thaw (20±5ºC) and humidity 95%
for 8 hours. Both the mass and compressive strength loss of
the specimens after this test were determined and compared
to that of references taken from adjacent parts of the blocks.
In order to demonstrate the viability of the developed
technology as constructive element, two mockups were
built, one with the produced GREEN CAST blocks and an
identical one built with commercial cement based AAC
blocks. Both mockups were built in ACCIONA´s facilities
in Alcobendas, Spain. The mockups consisted in metallic
structures anchored to onsite casted concrete ground slabs
and the two types of blocks were used to build the walls of
each of the mockups.
For the construction of the reference mockup, Ytong blocks
were used. The dimensions of the blocks were 25x63x7 cm
and the density specified by the supplier 550 Kg/m3
.
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 137
Both mockups possessed one window oriented to the east
and one door oriented to the north. In both cases generic
aluminum/polyurethane sandwich panels were used as
ceilings. The blocks were glued together with
insulating/waterproof mortar. Both mockups were coated
externally with such mortar, and finally, power supply was
installed within them.
The acoustic insulation of the developed material was
studied by in situ measurements of the following
parameters:
-Airborne sound insulation of façades, according to the
standard ISO 140-5:1998. For this experiment, an
omnipower sound source generating a sound field with
a continuous spectrum was placed outside the
prototype at 7 m from the analyzed façade. Then, the
average sound pressure level is measured in a point at
2 m from the façade and 3 different points inside the
prototype. The airborne sound insulation index was
calculated as the difference between pressure levels,
inside and outside, standardized by reverberation time.
The airborne sound insulation index was calculated as
the difference between pressure levels, inside and
outside, standardized by reverberation time.
-Measurement of the sound reduction index. In this
case, an omnipower sound source generating a sound
field with a continuous spectrum was installed inside
the prototype. The average sound pressure level was
measured in a point at 1 m from the façade and 3
different points inside the prototype. Background noise
reduction inside the prototype was recorded too.
The sound measurements were carried out with the
following equipment purchased to B&K: omnipower sound
source 4292, audio power amplifier 2716, microphone 4189,
hand held analyzer 2250 and sound level calibrator.
Fig 2 Measurement of airborne sound insulation of façades:
sound source (left) and microphone (right).
In order to study thermal behavior of the real scale demo-
buildings, a data acquisition system was installed in both the
reference and GREENCAST mock-ups. An Agilent 34972A
Data Acquisition Unit with a built-in 20-bit resolution
digital multimeter was selected as autonomous data logging
system, combined with a pair of Type T thermocouples
(Copper-Constantan) for internal temperature measurement
(sensitivity 40 μV/°C, nominal accuracy ±0.5°C). A Davis
Instruments Vantage Pro2 weather station was used for
external temperature monitoring. Thermal sensors were
previously calibrated using a FLUKE 724 Multi Function
Calibrator, finding differences not higher than 0.1°C.
In order to analyze the environmental impact of the
developed technology, a comparison between the life cycle
assessments, for both the GREEN CAST technology and
generic AAC was carried out, according to the guidelines
given in the ISO 14040-44 series, by using the SimaPro 7
software. For the study a cubic meter of product was defined
as functional unit and an annual production of 50.000 m3
for
both types of materials was assumed. The environmental
impacts of each life cycle stage have been calculated using
the CML impact assessment method, which is a problem-
oriented LCA method developed by the Institute of
Environmental Sciences (CML) of Leiden University, the
Netherlands. The data was directly obtained wherever
possible in the field (primary data), when direct collection
was not possible, derived data (secondary data) have been
used, collecting on purpose data from literature or databases.
3. RESULTS AND DISCUSSION
The ash was characterized by XRF and SEM. As shown in
Table 1, the ashes are mainly composed of SiO2, Al2O3 and
Fe2O3, with a low content in CaO, which corresponds to a F-
class type of ash. The X-ray pattern, shown in Figure 1
reveals the mineralogical phases of this material: Quartz,
Mullite, Hematite, magnetite, Figure 3.
Table 1 Fly ash composition analysis
Al2O3 SiO2 Fe2O3 TiO2 CaO MgO Na2O
% 27.5 44.0 17.3 0.9 4.2 0.9 0.18
Fig 3 Mineralogical phases of the used fly ash.
Figure 4 shows the topology and internal microstructure of
the fly ash. The particles are almost spherical and
amorphous. Some spheres are hollow and others completely
solid. The particles have a big range of sizes from 1.5 to 110
µm. The media size is 33.5 µm.
Fig 4 SEM micrographs of fly ash.
Previous research carried out showed that oxygen peroxide
was the best performing foaming agent, and an optimization
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 138
of the formulation proportions and the production process
was carried out.
Formulations with different proportions of the components
were prepared and tested. Considering the heterogeneous
properties of the fly ash due to its waste origin, the
formulation was optimized in a range of proportions. Table
2 shows a range of accepted formulations.
Table 2 Range of weight percentages of each component in
the mixture
Fly ash NaOH Water H2O2 BS
67-71 6-8 20-25 0.4-1 0-0.15
The foaming process was investigated. A metallic mold with
a transparent PMMA face was built and the successive
mixtures were observed. It was found out that in the
optimized range of proportions, the foaming process lasted
for approximately half hour, and then it was allowed to
stabilize for another one and a half hour prior to the curing
step at 80ºC. Figure 5 shows the foaming process over 30
minutes.
Fig 5 Foaming process at 0, 10 and 30 minutes.
By following this procedure, 400 blocks were produced,
some of them were kept for characterization.
The material was prepared in form of blocks and their
properties were measured. In Figure 6 it is possible to
appreciate a SEM micrograph of the porous structure of the
material. The foaming agent added to the formulation
generated a regular cellular structure that is the responsible
for the low density of the material and its good insulating
properties.
Fig 6 SEM micrograph of the GREEN CAST material (scale
bar is 1 mm).
The main parameters of the samples were measured. The
dry density was measured in 18 specimens extracted from 3
blocks. The measured density values are collected in Table
3. The average density was found to be 790±21 Kg/m3
.
Table 3 Density values for the analyzed specimens.
ρ (Kg/m3
)
Block 1 Block 2 Block 3
774 811 801
764 803 813
767 784 798
762 795 810
765 799 805
766 803 812
Similarly, the compressive strength was measured by taking
6 specimens from 6 blocks; the values are shown in Table 4.
The average compressive strength for the tested samples
was 4.8±0.5 MPa.
Table 4 Compressive strength values for the analyzed
specimens. B is for block.
MC (MPa)
B 1 B 2 B 3 B 4 B 5 B 6
4.1 4.7 4.2 5.1 6.0 5.9
5.1 5.5 4.7 4.7 4.4 5.0
4.2 5.4 4.0 4.7 4.7 4.8
4.7 5.3 5.0 4.5 3.9 5.1
4.9 5.0 4.7 4.7 5.7 5.1
4.4 4.0 4.9 4.4 4.0 4.3
The thermal properties of the materials were studied through
the measurement of the thermal resistance and the thermal
conductivity. Three specimens were tested and the results
are shown in Table 5.
Table 5 Thermal resistance (R) and thermal conductivity (λ)
of the analyzed samples
Sample R (m2
K/W) λ (W/mK)
1 0.3788 0.1880
2 0.3635 0.1955
3 0.3649 0.1648
Average 0.369±0.008 0.183±0.016
In the case of a cellular material, such as AAC, the thermal
conductivity is directly related to its density, since the air
present in the structure, lightens the material and reduces the
thermal conductivity, therefore improving the insulating
behavior. Conventional AAC presents typical λ values of
0.1-0.2 W/mK). The reference AAC used in this work, with
a density of 550 Kg/m3
presents a λ value of 0.16 W/mK
according to the supplier. The slightly greater value of
thermal conductivity obtained for the GREEN CAST
material has been associated to its larger density.
The durability of the materials was analyzed by carrying out
freeze/thaw cycles on the samples, measuring the mass and
compressive resistance loss after said cycles. The
temperature program consisted in cooling down to -15± 2ºC,
keeping at that temperature for 8 hours and heating up to
20±5ºC, keeping at that temperature for 8 additional hours.
Table 6 summarizes the dry mass and compressive strength
loss after 15 cycles compared to the references taken prior to
the analysis.
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 139
Table 6 Mass and compressive strength loss after 15
freeze/thaw cycles.
Mass loss (%) MC loss (%)
B1 S1 0.7 8.8
S2 0.9 5.1
S3 0.5 6.1
S4 1.5 9.2
S5 0.2 7.7
S6 0.1 1.8
B2 S1 0.5 7.0
S2 1.0 12.9
S3 0.4 12.8
S4 0.3 16.9
S5 0.5 2.8
S6 0.2 2.3
B is for block and S for specimen
For the tested samples, the average dry mass loss was
0.6±0.4 and the compressive strength loss was 7.0±4.0.
In order to demonstrate the constructive viability of the
developed material, as well as its insulating behavior, a
mockup was built with the GREEN CAST blocks and its
performance was monitored. An identical mockup built with
reference AAC blocks was built and monitored in the same
way. Figure 7 shows pictures of the constructive process of
both prototypes, as well as a picture of both finished ones.
Fig 7 Mockups being built with GREEN CAST blocks (left)
and Ytong ones (center). Both mockups finished (right).
The acoustic insulation of the developed material was
analyzed by in situ measurements. This method allows
characterizing the developed technology as part of a
constructive system. In order to enable the comparison with
a reference, the same measurements were carried out for the
reference mockup.
The sound insulation index (D2m,nT,Atr) is used to measure the
level of sound insulation provided by a structure. This
parameter can be expressed by a global value and by third
octave bands. The results obtained for each of the façades of
both mockups are shown in Table 7.
Table 7 Airborne sound insulation for the measured façades
D2m,nT,Atr (dB)
GREEN CAST Reference
North (door) 21.8 22.7
West 28.0 28.2
South 28.8 28.0
East (window) 25.1 26.4
In both prototypes the highest values for the sound
insulation index were found in the West and South façades.
This is because those walls do not contain elements with a
low sound insulation such as windows. For this reason, these
façades could be the most representative element of the
prototype.
The sound reduction index of a material characterizes the
sound insulation properties of such material or the
constructive system itself. It was obtained from a modeling
of the acoustic field. The results obtained for each of the
façades is collected in Table 8.
Table 8 Sound reduction index (RW) obtained for the
measured façades.
RW (dB)
GREEN CAST Reference
North (door) 21 23
West 32 30
South 33 31
East (window) 25 25
Identically, West and South façades presented the best RW
global values and in both cases both demonstrators showed
very similar behavior.
Figure 8 depicts mockups internal temperature and external
temperature from 7th August 2013 at 11 pm to 14th August
2013. Internal temperature for a given time is the result of
averaging the output of two internal thermocouples placed at
two different positions in the xy plane, keeping the height
fixed at 1.5m
Fig 8 Mockups internal and external temperatures measured
in a period of one week.
In the analyzed period, GREENCAST showed an attenuated
thermal wave amplitude with respect to the reference one
(3°C), maintaining the frequency. In both cases the
temperature wave amplitude was found to be narrower than
that for the measured external temperature, evidencing the
insulating behavior of the materials. The insulating
properties of both types of blocks showed to be practically
identical, corroborating GREEN CAST as an alternative to
current commercial solutions.
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 140
The ultimate aim of this work is to obtain an alternative to
AAC with a lower carbon footprint. In order to quantify the
environmental impact of the developed technology, LCA
was performed for both technologies: GREEN CAST and
the reference one. During the LCA study only the
manufacturing phase was considered, performing a cradle to
gate analysis, from raw materials acquisition through
manufacture. The aim of a cradle-to-gate analysis is to
assess potential environmental impacts associated with all
the stages of manufacturing phase, without taking into
account the subsequent phases crossing the gate. Fly ash is a
by-product from coal combusted power therefore part of the
environmental impacts of the electricity production should
be allocated to the fly ash. In the case of by-products, two
allocation procedures can be chosen: mass allocation or
economic allocation. For this study the economic allocation
procedure was used. According to Chen et al. [9] in the case
of fly ash obtained in the production of power, the allocation
by economic value for fly ash is 1% and 99% for electricity.
For this study, five impact categories were analyzed: global
warming, ozone layer depletion, photochemical oxidation,
acidification and eutrophication. Table 9 summarizes the
numerical results for each investigated impact category.
Table 9 Summary of impact categories values for generic
AAC and GREEN CAST.
Impact Category Unit AAC GREEN
CAST
Global warming Kg CO2 eq 182 80.5
Ozone layer depletion Kg CFC11 eq 2 E-5 7.45E-6
Photochemical
oxidation
Kg C2H2 eq 0.0208 0.0176
Acidification Kg SO2 eq 0.449 0.431
Eutrophication Kg PO4
3-
eq 0.037 0.03
As it has been evidenced, the potential impacts for
acidification, eutrophication and photochemical oxidation
categories are very close to those of AAC due to the
emissions of sulphur and nitrogen oxides. It was found that
the most significant parameter in both cases is the global
warming, which is defined as the index used to translate the
level of emissions of various gases into a common
measurement to compare their contributions to the
absorption by the atmosphere of infrared radiation.
Although all the parameters were studied in detail, only the
global warming has been included in this report due to its
relevance in the present study. In the case of the traditional
AAC, the major contributor to the global warming
parameter is the cement, which acts as the binder and
typically represents 20% of the weight of AAC. Individual
contributions to this parameter for the GREEN CAST
material are collected in Table 10.
Table 10 Contributions to global warming in the GREEN
CAST technology.
Process Unit Quantity (Kg CO2 eq)
Fly ash 0.08
H2O2 8.43
NaOH 44.8
Water 0.03
Raw material silos 0.1
Mixer 1.8
Blocks cutting 0.83
Oven 20.7
Blocks storage 0.83
Transport System 2.9
Total 80.5
Among all the contributions to the global warming, the most
representative one is that from sodium hydroxide, followed
by hydrogen peroxide.
In sight of the present analysis, it is possible to conclude that
the developed alternative material possesses a lower
environmental impact than conventional AAC associated to
the absence of cement in its formulation.
4. CONCLUSIONS
A green alternative to AAC, in total absence of OPC, has
been satisfactorily produced by the alkaline activation of fly
ash in the presence of a foaming agent at relatively low
temperatures and atmospheric pressure in a range of
formulations. The physical properties have been measured
under their corresponding international standards. The
density, compressive modulus, thermal conductivity and
durability properties were found to be very similar to
traditional AAC. The viability of the GREEN CAST
material as constructive element was demonstrated. Two
identical mockups were built with each type of blocks and
thermal measurements were carried out and compared to the
exterior temperature for a period of one week, showing
similar performance. Similarly, in situ sound insulation
measures were carried out and the experimental data reveal
the GREEN CAST material as good acoustic insulator as the
commercially available AAC. A life cycle assessment was
carried out for both types of materials, showing that the
alternative material possesses a lower environmental impact
and global warming index than AAC due to the absence of
cement in its formulation.
It can be highlighted that a cellular material based on alkali
activated fly ash, and in total absence of OPC, has been
developed and compared to traditional AAC, showing a
similar performance as constructive material and a lower
environmental impact, standing out as a solid alternative to
it.
ACKNOWLEDGEMENTS
The authors acknowledge the European Commission for
funding the GREEN CAST project within the CIP Eco-
Innovation First Application and market replication projects
framework.
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 141
REFERENCES
[1]. Construction and Building Materials 2008, 22, 2393-
2399.
[2]. ACI Materials Journal 2004, 6, 467-472.
[3] Resources, Conservation and Recycling 2011, 55, 669-
685.
[4]. Journal of Hazardous Materials 2009, 172, 1049-1060.
[5] World of Coal Ash (WOCA) Conference, 2011
[6]. Cement and Concrete Research 2011, 41, 1244-1256.
[7]. Construction and Building Materials 2012, 28, 493-498
[8]. 2005 World of Coal Ash (WOCA), April 11-15, 2005,
Lexington, Kentucky, USA.
[9]. Journal Resources, Conservation and Recycling 2010,
54 (12) 1231–1240
BIOGRAPHIES
Dr. Íñigo Larraza has a PhD in Polymer Science and
Technology (2012), has published 5 articles and holds a
patent. Project manager of the Concrete Group of
ACCIONA´s R&D Center. His background is in polymer
nanocomposites and alternative construction materials for
energy efficient buildings. He coordinates the GREEN
CAST project (CIP Eco-Innovation)
Dr. José Vera-Agulló is Chemical Engineer by the
University of Alicante (Spain) and received is PhD in
nanotechnology topics in 2008. He has published more than
10 papers in international journals and holds three patents.
He is the head of Concrete group in the R&D department of
ACCIONA.
Ignacio del Val obtained his BSc in Physics from the
Universidad Autónoma de Madrid in 2010. He works in the
Advanced Materials Group in ACCIONA´s R&D center,
being the responsible for the demonstration and monitoring
activities in 8 European funded projects related to energy
efficiency in buildings.
Dr. Alessandro Marseglia, graduated in Materials
Engineering in 1999 at University of Lecce. He has
published 4 papers in international journals and holds one
EU patent about plastic recycling in concrete. Currently he
is the coordinator of two European CIP Eco-Innovation
projects: ECOPLASBRICK and PROWASTE.
Dr. Giovanni Giodice received a University degree in
Aerospace Engineering at Polytechnic University of Turin in
2002. Since 2003 he has been working as a researcher at the
CETMA in the field of industrial design and scientific
research. Main activities: Rapid Prototyping, Geographic
Information System, Life Cycle Assessment, Environmental
Analysis and Sustainable mobility.

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Green cast demonstration of innovative lightweight construction components made of recycled ash for sustainable buildings

  • 1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 135 GREEN CAST DEMONSTRATION OF INNOVATIVE LIGHTWEIGHT CONSTRUCTION COMPONENTS MADE OF RECYCLED ASH FOR SUSTAINABLE BUILDINGS Íñigo Larraza1 , Ignacio del Val2 , Alessandro Marseglia3 , Giovanni Giodice4 , Jose Vera-Agullo5 1 ACCIONA Technological Centre, Valportillo II, 8, Alcobendas, Spain 2 ACCIONA Technological Centre, Valportillo II, 8, Alcobendas, Spain 3 CETMA - Engineering, Design & Materials Technologies Center, S.S. 7 – km 706+300, 72100, Brindisi, Italy 4 CETMA - Engineering, Design & Materials Technologies Center, S.S. 7 – km 706+300, 72100, Brindisi, Italy 5 ACCIONA Technological Centre, Valportillo II, 8, Alcobendas, Spain Abstract The present article describes the main objectives and outcomes of the GREEN CAST project. This project aims at the demonstration of an innovative material that has been ideated and developed to be a green alternative to autoclaved aerated concrete (AAC). The present material is based on geopolymer technology and consists on fly ash activated in an alkaline solution in the presence of a foaming agent. The mechanical, thermal and acoustic characterization suggests that the properties of the developed material are similar to those of AAC. The life cycle analyses carried out for both materials reveal that the alternative technology has a lower environmental impact, associated to the use of the alkaline activator. The material in form of blocks was used to build a demonstrator and its behavior as thermal and acoustic insulating material was monitored and compared to an identical AAC made demonstrator. The similar performance of both materials reveals that GREEN CAST is a technical and environmentally viable alternative to AAC. Keywords: Lightweight, Fly ash, Autoclaved Aerated Concrete, Geopolymer. --------------------------------------------------------------------***---------------------------------------------------------------------- 1. INTRODUCTION There is an increasing environmental need to develop new and more sustainable production technologies to utilize waste to substitute for raw materials in different industrial areas and reduce the CO2 released to the atmosphere. In fact, the European Commission has committed to reduce the CO2 emissions to 90´s levels by 2020. It is a major target to find alternative construction materials for the construction industry, because:  The cement industry is the second one in CO2 emissions to the atmosphere, at least 5% of total anthropogenic emissions (3.3 billion tons of cement are produced yearly in the world)  The extremely large consumption of natural resources and generation of huge amounts of waste  Millions of tons of waste potentially useful for the construction industry are generated in Europe yearly. Every year, coal combustion fly ash is produced as a byproduct of combustion processes in thermal plants worldwide in large amounts. Although fly ash has not been classified as hazardous waste, it causes environmental concern due to the trace concentrations of heavy metals and crystalline silica that are present in their composition, limiting the amount that can be landfilled, or be in contact with water streams. On the other hand, fly ash can be classified as a pozzolanic material, which means that upon alkaline activation they harden exhibiting cementitious properties, and that is why they are mainly reused as a supplementary cementitious material (SCM) in cement and concrete composition. Foamed, cellular or aerated autoclaved concrete (AAC) is defined as a cement-based material that contains at least 20% air in its structure. This ensures desirable properties such as low density and good thermal and acoustic insulation. The main drawback of conventional cellular concrete production is that has to be carried out in an autoclave process that involves high temperature and pressure. Moreover, in the fabrication process of ordinary Portland cement (OPC), CO2 is released into the atmosphere in the same quantity as material that is produced. This CO2 is produced in the burning of fossil fuels and in the de- carbonation of limestone which is used as a raw material for the clinker. So far, in the preparation of cement based materials, fly ash has partially replaced commercial Portland cement in several types of OPC up to 35%. By considering all the facts outlined above, the GREEN CAST project has emerged as a smart solution that proposes the full replacement of OPC by fly ash, in order to obtain non-structural lightweight precast construction elements with good insulation properties, which is additionally efficient from an environmental point of view.
  • 2. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 136 GREEN CAST proposes to use fly ash as the main raw material, optimizing their management as waste, thus reducing their exposure to environment and therefore the associated risks related to their potential toxicity and environmental impact. Very importantly, compared to OPC, the CO2 released into the atmosphere will be dramatically reduced, since neither fossil fuel nor carbonates are present in the GREEN CAST production process. The main outcome of this research is the development and demonstration on an innovative construction product with good thermal, mechanical and acoustic properties, economically competitive and with minimized environmental footprint. The present manuscript relates the preparation and characterization of the material, as well as the demonstration step and the life cycle analysis, demonstrating the environmental benefits of the GREEN CAST technology with respect to its traditional competitors. 2. MATERIALS AND METHODS The fly ash used in this project has been supplied by Cencatra, a waste management company located in Spain. Sodium hydroxide (50%) and hydrogen peroxide (33%) were supplied by Panreac. A commercial bubble stabilizer was used as received. All materials were used as received without any further purification. The fly ash composition was analyzed by X-ray fluorescence (XRF). This technique allows detecting chemical species and their content in a given sample. The particle size and distribution were analyzed by granulometry. A Malvern Mastersizer 2000 equipment was used. Measurements have been made after ultrasonic dispersion of samples by using water as dispersant. The materials were homogeneously mixed with a mechanical stirrer in plastic recipients in the following way: first the sodium hydroxide solution was diluted and allowed to cool down at room temperature. Then, the bubble stabilizer (BS) was added to the solution and stirred. The fly ash was weighted and placed in the corresponding recipient, then homogenized mechanically. In each case the aqueous solution was added and mixed until complete homogenization. Finally the hydrogen peroxide solution was added to the mixture and mixed. The liquid mixtures were then immediately poured into the corresponding mold and covered with plastic film in order to prevent evaporation. The foaming process was allowed to take place prior to the curing stage. For the mechanical analyses, 16x4x4 cm specimens were prepared in metallic molds. The blocks were fabricated in PTFE coated wood molds (25x63x7 cm) with capacity for 5 independent blocks, Figure 1. All the samples were cured in laboratory furnaces at 80ºC for 16 hours. In order to analyze the foaming process of the material, a metallic mold with a transparent PMMA face was built. Fig 1 Mixing process (left) and PTFE coated wood molds (right). The density (ρ) of the GREEN CAST samples was analyzed according to the UNE-EN 772-13 standard. Six specimens were extracted from different parts of three blocks. The compressive strength (MC) was determined by following the standard UNE-EN 772-1. A constant load was applied at a constant rate of 0.1±0.05 MPa/s. The specimens were kept at a constant humidity of 6±2% prior to the tests. The dry density value is obtained from drying the specimens to constant mass. The thermal resistance and conductivity was measured in a NETZSCH HFM 463 Lambda Heat Flow Meter, according to the UNE-EN 12664:2001 standard. The heat flow meter was used according to the norm ISO 8301:1991. In order to do that, 3 specimens were introduced horizontally in a heat flow meter, being the hot plate in the upper side. Said specimens were conditioned in a ventilation oven at 105ºC until constant mass is achieved, then coated with a waterproof cover which prevents them from moisture. The state temperature and the average temperature difference through the specimen were set at 10 and 15ºC, respectively. The free-thaw resistance was investigated by following the UNE-EN 15304:2010 standard. Six cubic specimens (7x7x7 cm) were extracted from different parts of two blocks, saturated and kept for 48 hours in a polyethylene bag for stabilization and preserve moisture. The samples were placed in a chamber and exposed to 15 cycles of freeze (- 15±2ºC) for 8 hours and thaw (20±5ºC) and humidity 95% for 8 hours. Both the mass and compressive strength loss of the specimens after this test were determined and compared to that of references taken from adjacent parts of the blocks. In order to demonstrate the viability of the developed technology as constructive element, two mockups were built, one with the produced GREEN CAST blocks and an identical one built with commercial cement based AAC blocks. Both mockups were built in ACCIONA´s facilities in Alcobendas, Spain. The mockups consisted in metallic structures anchored to onsite casted concrete ground slabs and the two types of blocks were used to build the walls of each of the mockups. For the construction of the reference mockup, Ytong blocks were used. The dimensions of the blocks were 25x63x7 cm and the density specified by the supplier 550 Kg/m3 .
  • 3. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 137 Both mockups possessed one window oriented to the east and one door oriented to the north. In both cases generic aluminum/polyurethane sandwich panels were used as ceilings. The blocks were glued together with insulating/waterproof mortar. Both mockups were coated externally with such mortar, and finally, power supply was installed within them. The acoustic insulation of the developed material was studied by in situ measurements of the following parameters: -Airborne sound insulation of façades, according to the standard ISO 140-5:1998. For this experiment, an omnipower sound source generating a sound field with a continuous spectrum was placed outside the prototype at 7 m from the analyzed façade. Then, the average sound pressure level is measured in a point at 2 m from the façade and 3 different points inside the prototype. The airborne sound insulation index was calculated as the difference between pressure levels, inside and outside, standardized by reverberation time. The airborne sound insulation index was calculated as the difference between pressure levels, inside and outside, standardized by reverberation time. -Measurement of the sound reduction index. In this case, an omnipower sound source generating a sound field with a continuous spectrum was installed inside the prototype. The average sound pressure level was measured in a point at 1 m from the façade and 3 different points inside the prototype. Background noise reduction inside the prototype was recorded too. The sound measurements were carried out with the following equipment purchased to B&K: omnipower sound source 4292, audio power amplifier 2716, microphone 4189, hand held analyzer 2250 and sound level calibrator. Fig 2 Measurement of airborne sound insulation of façades: sound source (left) and microphone (right). In order to study thermal behavior of the real scale demo- buildings, a data acquisition system was installed in both the reference and GREENCAST mock-ups. An Agilent 34972A Data Acquisition Unit with a built-in 20-bit resolution digital multimeter was selected as autonomous data logging system, combined with a pair of Type T thermocouples (Copper-Constantan) for internal temperature measurement (sensitivity 40 μV/°C, nominal accuracy ±0.5°C). A Davis Instruments Vantage Pro2 weather station was used for external temperature monitoring. Thermal sensors were previously calibrated using a FLUKE 724 Multi Function Calibrator, finding differences not higher than 0.1°C. In order to analyze the environmental impact of the developed technology, a comparison between the life cycle assessments, for both the GREEN CAST technology and generic AAC was carried out, according to the guidelines given in the ISO 14040-44 series, by using the SimaPro 7 software. For the study a cubic meter of product was defined as functional unit and an annual production of 50.000 m3 for both types of materials was assumed. The environmental impacts of each life cycle stage have been calculated using the CML impact assessment method, which is a problem- oriented LCA method developed by the Institute of Environmental Sciences (CML) of Leiden University, the Netherlands. The data was directly obtained wherever possible in the field (primary data), when direct collection was not possible, derived data (secondary data) have been used, collecting on purpose data from literature or databases. 3. RESULTS AND DISCUSSION The ash was characterized by XRF and SEM. As shown in Table 1, the ashes are mainly composed of SiO2, Al2O3 and Fe2O3, with a low content in CaO, which corresponds to a F- class type of ash. The X-ray pattern, shown in Figure 1 reveals the mineralogical phases of this material: Quartz, Mullite, Hematite, magnetite, Figure 3. Table 1 Fly ash composition analysis Al2O3 SiO2 Fe2O3 TiO2 CaO MgO Na2O % 27.5 44.0 17.3 0.9 4.2 0.9 0.18 Fig 3 Mineralogical phases of the used fly ash. Figure 4 shows the topology and internal microstructure of the fly ash. The particles are almost spherical and amorphous. Some spheres are hollow and others completely solid. The particles have a big range of sizes from 1.5 to 110 µm. The media size is 33.5 µm. Fig 4 SEM micrographs of fly ash. Previous research carried out showed that oxygen peroxide was the best performing foaming agent, and an optimization
  • 4. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 138 of the formulation proportions and the production process was carried out. Formulations with different proportions of the components were prepared and tested. Considering the heterogeneous properties of the fly ash due to its waste origin, the formulation was optimized in a range of proportions. Table 2 shows a range of accepted formulations. Table 2 Range of weight percentages of each component in the mixture Fly ash NaOH Water H2O2 BS 67-71 6-8 20-25 0.4-1 0-0.15 The foaming process was investigated. A metallic mold with a transparent PMMA face was built and the successive mixtures were observed. It was found out that in the optimized range of proportions, the foaming process lasted for approximately half hour, and then it was allowed to stabilize for another one and a half hour prior to the curing step at 80ºC. Figure 5 shows the foaming process over 30 minutes. Fig 5 Foaming process at 0, 10 and 30 minutes. By following this procedure, 400 blocks were produced, some of them were kept for characterization. The material was prepared in form of blocks and their properties were measured. In Figure 6 it is possible to appreciate a SEM micrograph of the porous structure of the material. The foaming agent added to the formulation generated a regular cellular structure that is the responsible for the low density of the material and its good insulating properties. Fig 6 SEM micrograph of the GREEN CAST material (scale bar is 1 mm). The main parameters of the samples were measured. The dry density was measured in 18 specimens extracted from 3 blocks. The measured density values are collected in Table 3. The average density was found to be 790±21 Kg/m3 . Table 3 Density values for the analyzed specimens. ρ (Kg/m3 ) Block 1 Block 2 Block 3 774 811 801 764 803 813 767 784 798 762 795 810 765 799 805 766 803 812 Similarly, the compressive strength was measured by taking 6 specimens from 6 blocks; the values are shown in Table 4. The average compressive strength for the tested samples was 4.8±0.5 MPa. Table 4 Compressive strength values for the analyzed specimens. B is for block. MC (MPa) B 1 B 2 B 3 B 4 B 5 B 6 4.1 4.7 4.2 5.1 6.0 5.9 5.1 5.5 4.7 4.7 4.4 5.0 4.2 5.4 4.0 4.7 4.7 4.8 4.7 5.3 5.0 4.5 3.9 5.1 4.9 5.0 4.7 4.7 5.7 5.1 4.4 4.0 4.9 4.4 4.0 4.3 The thermal properties of the materials were studied through the measurement of the thermal resistance and the thermal conductivity. Three specimens were tested and the results are shown in Table 5. Table 5 Thermal resistance (R) and thermal conductivity (λ) of the analyzed samples Sample R (m2 K/W) λ (W/mK) 1 0.3788 0.1880 2 0.3635 0.1955 3 0.3649 0.1648 Average 0.369±0.008 0.183±0.016 In the case of a cellular material, such as AAC, the thermal conductivity is directly related to its density, since the air present in the structure, lightens the material and reduces the thermal conductivity, therefore improving the insulating behavior. Conventional AAC presents typical λ values of 0.1-0.2 W/mK). The reference AAC used in this work, with a density of 550 Kg/m3 presents a λ value of 0.16 W/mK according to the supplier. The slightly greater value of thermal conductivity obtained for the GREEN CAST material has been associated to its larger density. The durability of the materials was analyzed by carrying out freeze/thaw cycles on the samples, measuring the mass and compressive resistance loss after said cycles. The temperature program consisted in cooling down to -15± 2ºC, keeping at that temperature for 8 hours and heating up to 20±5ºC, keeping at that temperature for 8 additional hours. Table 6 summarizes the dry mass and compressive strength loss after 15 cycles compared to the references taken prior to the analysis.
  • 5. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 139 Table 6 Mass and compressive strength loss after 15 freeze/thaw cycles. Mass loss (%) MC loss (%) B1 S1 0.7 8.8 S2 0.9 5.1 S3 0.5 6.1 S4 1.5 9.2 S5 0.2 7.7 S6 0.1 1.8 B2 S1 0.5 7.0 S2 1.0 12.9 S3 0.4 12.8 S4 0.3 16.9 S5 0.5 2.8 S6 0.2 2.3 B is for block and S for specimen For the tested samples, the average dry mass loss was 0.6±0.4 and the compressive strength loss was 7.0±4.0. In order to demonstrate the constructive viability of the developed material, as well as its insulating behavior, a mockup was built with the GREEN CAST blocks and its performance was monitored. An identical mockup built with reference AAC blocks was built and monitored in the same way. Figure 7 shows pictures of the constructive process of both prototypes, as well as a picture of both finished ones. Fig 7 Mockups being built with GREEN CAST blocks (left) and Ytong ones (center). Both mockups finished (right). The acoustic insulation of the developed material was analyzed by in situ measurements. This method allows characterizing the developed technology as part of a constructive system. In order to enable the comparison with a reference, the same measurements were carried out for the reference mockup. The sound insulation index (D2m,nT,Atr) is used to measure the level of sound insulation provided by a structure. This parameter can be expressed by a global value and by third octave bands. The results obtained for each of the façades of both mockups are shown in Table 7. Table 7 Airborne sound insulation for the measured façades D2m,nT,Atr (dB) GREEN CAST Reference North (door) 21.8 22.7 West 28.0 28.2 South 28.8 28.0 East (window) 25.1 26.4 In both prototypes the highest values for the sound insulation index were found in the West and South façades. This is because those walls do not contain elements with a low sound insulation such as windows. For this reason, these façades could be the most representative element of the prototype. The sound reduction index of a material characterizes the sound insulation properties of such material or the constructive system itself. It was obtained from a modeling of the acoustic field. The results obtained for each of the façades is collected in Table 8. Table 8 Sound reduction index (RW) obtained for the measured façades. RW (dB) GREEN CAST Reference North (door) 21 23 West 32 30 South 33 31 East (window) 25 25 Identically, West and South façades presented the best RW global values and in both cases both demonstrators showed very similar behavior. Figure 8 depicts mockups internal temperature and external temperature from 7th August 2013 at 11 pm to 14th August 2013. Internal temperature for a given time is the result of averaging the output of two internal thermocouples placed at two different positions in the xy plane, keeping the height fixed at 1.5m Fig 8 Mockups internal and external temperatures measured in a period of one week. In the analyzed period, GREENCAST showed an attenuated thermal wave amplitude with respect to the reference one (3°C), maintaining the frequency. In both cases the temperature wave amplitude was found to be narrower than that for the measured external temperature, evidencing the insulating behavior of the materials. The insulating properties of both types of blocks showed to be practically identical, corroborating GREEN CAST as an alternative to current commercial solutions.
  • 6. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 140 The ultimate aim of this work is to obtain an alternative to AAC with a lower carbon footprint. In order to quantify the environmental impact of the developed technology, LCA was performed for both technologies: GREEN CAST and the reference one. During the LCA study only the manufacturing phase was considered, performing a cradle to gate analysis, from raw materials acquisition through manufacture. The aim of a cradle-to-gate analysis is to assess potential environmental impacts associated with all the stages of manufacturing phase, without taking into account the subsequent phases crossing the gate. Fly ash is a by-product from coal combusted power therefore part of the environmental impacts of the electricity production should be allocated to the fly ash. In the case of by-products, two allocation procedures can be chosen: mass allocation or economic allocation. For this study the economic allocation procedure was used. According to Chen et al. [9] in the case of fly ash obtained in the production of power, the allocation by economic value for fly ash is 1% and 99% for electricity. For this study, five impact categories were analyzed: global warming, ozone layer depletion, photochemical oxidation, acidification and eutrophication. Table 9 summarizes the numerical results for each investigated impact category. Table 9 Summary of impact categories values for generic AAC and GREEN CAST. Impact Category Unit AAC GREEN CAST Global warming Kg CO2 eq 182 80.5 Ozone layer depletion Kg CFC11 eq 2 E-5 7.45E-6 Photochemical oxidation Kg C2H2 eq 0.0208 0.0176 Acidification Kg SO2 eq 0.449 0.431 Eutrophication Kg PO4 3- eq 0.037 0.03 As it has been evidenced, the potential impacts for acidification, eutrophication and photochemical oxidation categories are very close to those of AAC due to the emissions of sulphur and nitrogen oxides. It was found that the most significant parameter in both cases is the global warming, which is defined as the index used to translate the level of emissions of various gases into a common measurement to compare their contributions to the absorption by the atmosphere of infrared radiation. Although all the parameters were studied in detail, only the global warming has been included in this report due to its relevance in the present study. In the case of the traditional AAC, the major contributor to the global warming parameter is the cement, which acts as the binder and typically represents 20% of the weight of AAC. Individual contributions to this parameter for the GREEN CAST material are collected in Table 10. Table 10 Contributions to global warming in the GREEN CAST technology. Process Unit Quantity (Kg CO2 eq) Fly ash 0.08 H2O2 8.43 NaOH 44.8 Water 0.03 Raw material silos 0.1 Mixer 1.8 Blocks cutting 0.83 Oven 20.7 Blocks storage 0.83 Transport System 2.9 Total 80.5 Among all the contributions to the global warming, the most representative one is that from sodium hydroxide, followed by hydrogen peroxide. In sight of the present analysis, it is possible to conclude that the developed alternative material possesses a lower environmental impact than conventional AAC associated to the absence of cement in its formulation. 4. CONCLUSIONS A green alternative to AAC, in total absence of OPC, has been satisfactorily produced by the alkaline activation of fly ash in the presence of a foaming agent at relatively low temperatures and atmospheric pressure in a range of formulations. The physical properties have been measured under their corresponding international standards. The density, compressive modulus, thermal conductivity and durability properties were found to be very similar to traditional AAC. The viability of the GREEN CAST material as constructive element was demonstrated. Two identical mockups were built with each type of blocks and thermal measurements were carried out and compared to the exterior temperature for a period of one week, showing similar performance. Similarly, in situ sound insulation measures were carried out and the experimental data reveal the GREEN CAST material as good acoustic insulator as the commercially available AAC. A life cycle assessment was carried out for both types of materials, showing that the alternative material possesses a lower environmental impact and global warming index than AAC due to the absence of cement in its formulation. It can be highlighted that a cellular material based on alkali activated fly ash, and in total absence of OPC, has been developed and compared to traditional AAC, showing a similar performance as constructive material and a lower environmental impact, standing out as a solid alternative to it. ACKNOWLEDGEMENTS The authors acknowledge the European Commission for funding the GREEN CAST project within the CIP Eco- Innovation First Application and market replication projects framework.
  • 7. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 03 Special Issue: 13 | ICNTCC-2014 | Sep-2014, Available @ http://www.ijret.org 141 REFERENCES [1]. Construction and Building Materials 2008, 22, 2393- 2399. [2]. ACI Materials Journal 2004, 6, 467-472. [3] Resources, Conservation and Recycling 2011, 55, 669- 685. [4]. Journal of Hazardous Materials 2009, 172, 1049-1060. [5] World of Coal Ash (WOCA) Conference, 2011 [6]. Cement and Concrete Research 2011, 41, 1244-1256. [7]. Construction and Building Materials 2012, 28, 493-498 [8]. 2005 World of Coal Ash (WOCA), April 11-15, 2005, Lexington, Kentucky, USA. [9]. Journal Resources, Conservation and Recycling 2010, 54 (12) 1231–1240 BIOGRAPHIES Dr. Íñigo Larraza has a PhD in Polymer Science and Technology (2012), has published 5 articles and holds a patent. Project manager of the Concrete Group of ACCIONA´s R&D Center. His background is in polymer nanocomposites and alternative construction materials for energy efficient buildings. He coordinates the GREEN CAST project (CIP Eco-Innovation) Dr. José Vera-Agulló is Chemical Engineer by the University of Alicante (Spain) and received is PhD in nanotechnology topics in 2008. He has published more than 10 papers in international journals and holds three patents. He is the head of Concrete group in the R&D department of ACCIONA. Ignacio del Val obtained his BSc in Physics from the Universidad Autónoma de Madrid in 2010. He works in the Advanced Materials Group in ACCIONA´s R&D center, being the responsible for the demonstration and monitoring activities in 8 European funded projects related to energy efficiency in buildings. Dr. Alessandro Marseglia, graduated in Materials Engineering in 1999 at University of Lecce. He has published 4 papers in international journals and holds one EU patent about plastic recycling in concrete. Currently he is the coordinator of two European CIP Eco-Innovation projects: ECOPLASBRICK and PROWASTE. Dr. Giovanni Giodice received a University degree in Aerospace Engineering at Polytechnic University of Turin in 2002. Since 2003 he has been working as a researcher at the CETMA in the field of industrial design and scientific research. Main activities: Rapid Prototyping, Geographic Information System, Life Cycle Assessment, Environmental Analysis and Sustainable mobility.