A STUDY OF CONCRETES CONTAINING THERMOPLASTIC

WASTES AS AGGREGATES
S. Gavela (1), C. Karakosta (1), C. Nydriotis (1), V. KaselouriRigopoulou
P. A. Tarantili (1), C. Magoulas (1), D. Tassios (1) and A. Andreopoulos (1)

(1)

, S. Kolias

(2)

(1) National Technical University of Athens, School of Chemical Engineering, Greece

(2) National Technical University of Athens, School of Civil Engineering, Greece
Abstract ID Number: 270
Author contacts
Authors

E-Mail

Fax

Postal address

Stamatia Gavela

gmat@mail.ntua.gr

112, Spartis str, 17675

Athens, Greece

Chariklia
Karakosta

xarak@mycosmos.gr

21-23, Ifigenias str, 17677

Athens, Greece

Constantinos
Nydriotis

nidrioco@yahoo.com

111,
Mesologiou
str,
12131 Athens - Greece

Vasilia Kaselouri vasrig@central.ntua.gr

Rigopoulou

+302107723188

9, Heroon Polytechniou
str, 15773 Athens, Greece

Stilianos Kolias

skolias@cenral.ntua.gr

+302107722404

9, Heroon Polytechniou
str, 15773 Athens, Greece

Petroula A.
Tarantili

taran@chemeng.ntua.gr

+302107723163

9, Heroon Polytechniou
str, 15773 Athens, Greece

Constantinos
Magoulas

mag@chemeng.ntua.gr

+302107723155

9, Heroon Polytechniou
str, 15773 Athens, Greece

Dimitrios Tassios

dtassios@chemeng.ntua.gr +302107723155

9, Heroon Polytechniou
str, 15773 Athens, Greece

Andreas
Andreopoulos

andreo@chemeng.ntua.gr

9, Heroon Polytechniou
str, 15773 Athens, Greece

+302107723163

Contact person for the paper: Gavela Stamatia

Presenter of the paper during the Conference: Gavela Stamatia
9
Total number of pages of the paper (this one excluded):

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A STUDY OF CONCRETES CONTAINING THERMOPLASTIC

WASTES AS AGGREGATES
S. Gavela (1), C. Karakosta (1), C. Nydriotis (1), V. Kaselouri Rigopoulou (1), S. Kolias
(2), P. A. Tarantili (1), C. Magoulas (1), D. Tassios (1) and A. Andreopoulos (1)
(1) National Technical University of Athens, School of Chemical Engineering, Greece
(2) National Technical University of Athens, School of Civil Engineering, Greece

Abstract
In the frame of an extended research program concretes containing various types of
polymer waste as aggregates were studied. The above materials attract a growing ecological
interest especially due to the increasing volume of polymer wastes. Used materials or
industrial wastes from polypropylene (PP) and polyethylene terephthalate (PET) were studied
as alternative replacements of a part of the conventional aggregates. Sieve analysis, specific
gravity tests and water absorption tests were performed in all types of aggregates. There were
two replacement levels, 20% and 30% by volume of aggregates. Reference specimens
without polymeric aggregates were also prepared. Before the molding of all fresh concretes
their specific gravity was measured. The dimensions of specimens for flexural and
compressive tests were 100mm*100mm*500mm. Tests were carried out in accordance to
standard procedures, 7 and 28 days after the specimen preparation. The interface of polymer
aggregate and mortar was examined by Scanning Electron Microscopy. The first results of
this research suggest that PP and PET can be used as concrete aggregates for certain structural
applications taking into consideration their behavior in extremely thermal conditions.
1.

INTRODUCTION

Handling and safe disposal of industrial and domestic waste has become a major concern
in the European Community which attempted to organize all Member States by setting
common targets. Reuse of bulk wastes is considered the best environmental alternative for
solving the problem of disposal. The fraction of plastic wastes in household wastes is large
and increases with time. In each country the waste composition is different, since it is
affected by socioeconomic characteristics, consumption patterns and waste management
programs, but generally the level of plastics in waste composition is high. The major users of
plastic are the packaging industries. The largest component of the plastic waste is
polyethylene, followed by polypropylene, polyethylene terephthalate and polystyrene.
The large volume of materials required for construction is potentially a major area for the
reuse of waste materials. Recycling in concrete has advantages since it is widely used and has

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a long service life (exceeding 50 years), which means that the waste is being removed from
the waste stream for a long period. Because the amount of mineral aggregates required in
concrete is large, the environmental benefits are not only related to the safe disposal of bulk
waste but also to the reduction of environmental impacts arising from the extraction of
aggregates which include the visual intrusion and the loss of countryside.
Polymers in concrete have received considerable attention over the past 25 years.
Polymer-impregnated concrete (PIC) was the first concrete polymer composite to receive
widespread publicity and it was produced by impregnating hydrated Portland cement concrete
with a low viscosity monomer which was subsequently polymerized by radiation or thermal
catalytic techniques. Polymer concrete (PC) became well known in the 1970s, consists of
aggregate with a polymer binder and contains no Portland cement or water. Polymer
modified concrete (PMC) has been in use since the 1950s and consists of Portland cement
concrete with a polymer modifier [1, 2]. Also, thermoplastics [3, 4] and thermoset plastics [5]
have been used as aggregates in concrete in order to produce concrete with enhanced
characteristics.
In the present study industrial wastes from polypropylene (PP) and polyethylene
terephthalate (PET) were studied as alternative replacements of a part of the conventional
aggregates.
2.

EXPERIMENTAL PROCEDURE

Table 1: Sieve analysis results.

Sieve size

sand

gravel

% passing % passing

PP

PET

% passing

% passing

" (12.5mm)

100

3/8" (9.5mm)

62.2

100

" (6.3mm)

20.4

100

81.8

No 4 (4.75mm)

100

88

69.4

No 8 (2.36mm)

81.4

0.2

18.1

74

0.1

2.9

No16 (1.18mm)

57.1

0.7

0.4

No 30 (0.6mm)

39

0.1

No 40 (0.43mm)

36

No 100 (0.15mm)

25

No 200 (0.08mm)

21.2

No 10 (2mm)

The materials used in the research were cement type CEM IV/B 32.5N, coarse and fine
aggregates, industrial wastes from polypropylene and polyethylene terephthalate and

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superplasticizer. ASTM standard sieves ranging from sieve No 1/2" (12.5mm) to sieve No
200 (0.08mm) were used to obtain the grading of coarse (gravel), fine (sand) and polymer
aggregates (since those were used as aggregate replacement). Two sieve analysis tests for
each material were carried out and their average results were considered. The gradations
obtained are shown in Table 1.
The determination of specific gravity and water absorption of the aggregates were
performed according the European Standard EN 1097-6. The results are shown in Table 2.
Table 2: Physical properties of aggregates.
Specific gravity (kg/m3)

Water absorption (%)

Gravel

2720

1.4

Sand

2690

1.94

PP

1022

PET

1226

Material

Table 3: Proportions for mixes containing PP aggregates.

Mix component
Plastic aggregates-PP
(volume replacement of
conventional aggregates)
water (kg/m3)

w/c=0.5

w/c=0.6

20%

30%

20%

200

230

200

400

460

333.3

sand (kg/m3)

1138.3

970.9

1175.8

gravel (kg/m3)

265.5

163.6

274.4

PP aggregates (kg/m3)

133.1

184.5

137.5

cement (kg/m3)

Five concrete mixes were made to investigate the engineering properties of concrete
containing plastic aggregates. The by volume replacement of conventional aggregates was
20% and 30%. The concrete mixes were made with two water-to-cement ratios: 0.5 and 0.6.
The percentage of superplasticizer was 1% b.m of cement. Details of the mix proportioning
are given in Table 3 for mixes containing PP and in Table 4 for mixes containing PET. Two
different reference mixes with w/c=0.5 were also made. Their mix proportions are shown in
Table 5. Before the molding of all fresh concretes their bulk density was measured.
A total of 42 100mm*100mm*500mm concrete specimens, six from each mix, were cast.
The specimens were left to cure for 24h, then demoulded and put in constant conditions: 19oC
and RH>95%. Flexural and equivalent cube compressive tests were carried out 7 and 28 days
after the specimen preparation. Before these tests ultrasonic testing for each specimen was
performed to obtain an estimation firstly of the continuity of the material and secondly of the
modulus of elasticity.

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The principle of the method is based on the relationship between the elastic properties of
concrete and the velocity of the transmission of waves through its bulk body. The waves are
produced by an ultrasonic device. A pulse is produced by a transmitter which is being put in
contact with the one side of the specimen. After going through the known length of the
specimen the pulse is converted to electrical signal from a receiver which is being put at the
other side of the specimen. By appropriate electric circuits the time (t) that is demanded for
the pulse to go through the length of the specimen (L) is determined and the velocity is found.
It is known that the ultrasonic pulse velocity is directly proportional to the modulus of
elasticity E.
Table 4: Proportions for mixes containing PET aggregates.
Mix component

w/c=0.5

w/c=0.6

(volume replacement of
conventional aggregates)

20%

30%

water (kg/m3)

200

200

cement (kg/m3)

400

333.3

1138.3

1085.4

265.5

182.8

159.6

247.4

Plastic aggregates-PET

sand (kg/m3)
3

gravel (kg/m )
3

PET aggregates (kg/m )

Table 5: Proportions of the reference mixes.

Mix component

Reference mix 1 Reference mix 2

(RM1)
(RM2)

Water (kg/m3)

200

230

Cement (kg/m3)

400

460

Gravel (% by volume
of aggregates)

15

10

Sand (% by volume of
aggregates)

85

90

3.

RESULTS AND DISCUSSION

3.1
Bulk density
The bulk density of concrete containing 20 and 30 percent plastic aggregates is shown in
Table 6. There is a decrease in the bulk density as the plastic aggregates content was
increased. Density reduction is attributable to the lower unit weight of the plastic.

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Table 6: Bulk density.

Bulk density (kg/m3)
RM1

2250

RM2

2359

20%PP

2100

30%PP

1950

20%PET

2262

30%PET

2130

3.2

Ultrasonic testing

Table 7: The results of the ultrasonic testing.

Velocity at 7d Velocity at 28d
(cm/sec)
(cm/sec)
RM1

0.43

0.74

RM2

0.42

0.72

20%PP, w/c=0.5

0.41

0.63

20%PP, w/c=0.6

0.59

0.63

30%PP, w/c=0.5

0.35

0.49

20%PET, w/c=0.5

0.65

30%PET, w/c=0.6

0.54

The results of the ultrasonic testing are shown in Table 7. Ultrasonic pulse velocity - and
consequently modulus of elasticity decreases as the proportion of plastic aggregates in the
mix increases for both 7 and 28 days old specimens. This can be attributed to the formation
of the products of the hydration of cement which fill any voids of the material that happen to
exist. It is also noted that the pulse velocity - and by inference - the modulus of elasticity
decreases by 14% and 33% for 20% PP and 30% PP by volume in the mix respectively.
3.3
Compressive strength
The compressive strength of concrete made with different w/c and varying percentages of
plastic aggregates is shown in Table 8. There is a decrease in compressive strength when the
plastic aggregates content is increased. At a given plastic aggregates content (20% PP by
volume of aggregates) the compressive strength was found to decrease when the w/c was
increased. There was no statistically significant difference in strength for mixes containing
20% PP or 20% PET.

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Table 8: Compressive strength

7 days (MPa)

28 days (MPa)

RM1

33.4

40.2

RM2

31.5

40.6

20%PP, w/c=0.5

25.6

33.3

20%PP, w/c=0.6

20.9

25.8

30%PP, w/c=0.5

18.5

23.5

20%PET, w/c=0.5

26.7

35.1

30%PET, w/c=0.6

19.0

24.0

3.4
Flexural strength
The flexural strength of concrete made with different w/c and varying percentages of
plastic aggregates is shown in Table 9. There is a decrease in flexural strength when the
plastic aggregates content was increased. At a given plastic aggregates content (20% PP by
volume of aggregates) the flexural strength was found to decrease when the w/c was
increased. The flexural strength does not seem to have a significant difference between mixes
with 20% PP and 20% PET.
Table 9: Flexural strength.
7 days (MPa)

28 days (MPa)

RM1

4.64

5.34

RM2

4.66

6.07

20%PP, w/c=0.5

3.98

5.03

20%PP, w/c=0.6

3.06

4.14

30%PP, w/c=0.5

2.83

2.89

20%PET, w/c=0.5

4.05

4.79

30%PET, w/c=0.6

2.87

3.27

3.5
SEM Analysis
It is generally accepted that a weak interfacial zone exists between aggregates and matrix
in all cement based materials [6]. Over the years, this zone, whose thickness depends on the
size and shape of the sand particles [7], has been analysed from different aspects and it has
been concluded that its properties have a significant influence on the short-term and long-term
behaviour and performance of concrete materials. A weak interfacial zone may have many
serious influences on a range of properties of concrete. Water and harmful ions will easily

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penetrate into the concrete resulting in the deterioration of both the concrete and the
reinforcement. Therefore, it is essential for the long-term performance of concrete that the
interfacial zone should be as dense as possible, having a strong bond between the aggregate
and the cement matrix.

Figure 1: SEM of the polymer aggregate mortar interface.

Figure 2: EDX analysis at the interfacial zone.

In figure 1 the aggregate mortar interface in a specimen containing 20% PET (90 days of
hydration) is shown. It is observed that the zone is dense enough without cracks and with a
relatively good adhesion between the aggregate (on the left) and the binder (on the right).

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That is also confirmed by energy dispersive X-ray (EDX) analysis at the point marked of
figure 1 which shows that the very near grains to the interface are grains of hydrated concrete.
4.

CONCLUSIONS
Plastic aggregates can be used successfully to replace conventional aggregates in
concrete. Laboratory testing showed that the 28-day compressive strength of concrete
containing 20% and 30% by volume of aggregates ranged from 35.1 to 23.5 MPa while
the flexural strength ranged from 5.03 to 2.89MPa.
The decrease in 28-days flexural and compressive strength of mixes containing PP was
similar to this of mixes containing PET. This means that for the type of polymers
examined the polymer type does not influence the strength, only the percentage of
replacement does.
The drop in compressive and flexural strength due to the addition of plastic aggregates
may be attributed to lower bond between the cement paste and the plastic aggregates
and to the low strength of plastic aggregates.
Although there is a reduction in strength the material can be considered to be potentially
interesting for certain applications such as pavements, where the reduction of the
modulus of elasticity may be considered beneficial. However, more research is needed
concerning strength, modulus of elasticity and creep at various temperatures and with
various percentages of replacement.

ACKNOWLEDGEMENTS
The specimens were prepared and tested for strength in the Laboratory of the Hellenic
Cement Industry Association by the first three authors. The authors would like to express
gratitude for the facilities provided.
REFERENCES
[1] D. W. Fowler, 'Polymers in concrete: a vision for the 21st century', Cement & Concrete
Composites 21 (1999) 449-452.
[2] Yoshiko Ohama, 'Recent Progress in concrete polymer composites', Advanced Cement Based
Materials 5 (1997) 31-40.
[3] Parviz Soroushian, Abdulrahman Alhozaimy and Aly I. Eldarwish, 'Recycling of plastics in
concrete to enhance toughness characteristics and resistance to shrinkage cracking', Proceedings
of the symposium on recovery and effective reuse of discarded materials and by-products for
construction of highway facilities sponsored by federal highway administration and EPA, Denver,
Colorado, October, 1993, p. 5-41 to 5-53.
[4] A A. Al-Manaseer and T. R. Dalal, 'Concrete containing plastic aggregates', Concrete
International 19 (8) (1997) 47-52.
[5] Mohamed M. Ziara, Hasan S. Dweik and Mohammed S. Hadidoun, 'Engineering properties of
concrete made with ground melamine-formaldehyde thermosetting plastics as sand replacement',
Proceedings of the 6th International conference on concrete technology for developing countries,
Amman, Jordan, October, 2002, p. 233-242.
[6] Sinan Caliskan, 'Aggregate/mortar interface: influence of silica fume at the micro- and macrolevel', Cement & Concrete Composites 25 (2003) 557-564.
[7] P. J. M. Monteiro, J. C. Maso and J. P. Ollivier, 'The aggregate mortar interface', Cement &
Concrete Research 15 (1985) 953-958.

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