Cirmap - CIrcular economy via customisable furniture with Recycled MAterials for public Places


Project Summary

In North West Europe, about 65 Mt of Recycled Fine Aggregates (RFA) are generated yearly from the crushing of Concrete Construction and Demolition Wastes and are disposed in landfills or in banks. In the meantime, 54 Mt of marine sands are extracted in zones where natural aggregate resources are missing, threatening fragile marine spaces. Reusing RFA in concrete would save natural resources.

However, no market exists for RFA owing to rigorous construction standards. RFA is a local resource, with large variability, which is not suited to mass production needing regular materials. But it could be used at a smaller scale, for the manufacture of products needing neither to comply with rigorous construction standards nor to possess high performances. About 5 Mt of RFA could be recycled into concrete for the manufacture of Urban, Memorial or Garden (UMG) furniture, being the starting point of a circular economy loop.

Traditional precast concrete cannot be used for small scale production because of the high share of moulds in the global cost (50 to 80%). However, concrete 3D Printing (3DP) allows manufacturing customized pieces that could be shown by customers as a banner of their identity. UMG furniture are always located in difficult to access zones, reducing their weight by shape optimization and printing them onsite would be easier. Moreover, online control of 3D Printing could be used to compensate materials variability, providing an efficient tool for the valorisation of these resources.

Cirmap will provide a new Mixture Proportioning Method (MPM) for the design of 3DP mortars with RFA and a new Design Methodology for Customized Shapes (DMCS). A new Master Control Command (MCC) for concrete 3DP will be implemented for the equipment of 3DP machines, and an integrated mobile 3D printing unit will be developed for onsite 3D printing of UMG furniture. A Cirmap-network will also be created for lobby and dissemination, leading to a new market for the reuse of RFA. 5 Local Public Authorities in North West Europe will provide public places that will be equipped with 3DP customized furniture.

The CIRMAP Network

In the frame of the Cirmap project, a network is being created in order to gather all the potential stakeholders of the future industrial field that is intended to be created. Entering the Cirmap Network is free and will allow you to get in touch with the latest results of the project. You will be invited to join the Advisory Board of the project in order to share your views and interact with partners, sub partners and associate partners.

Whether you are a private company working on concrete manufacture, production of materials, design, 3D printing machines …, a local public authority interested in new developments in the field of recycling and design, a laboratory, a university … you are welcome to join the network.

 

 

How to join the CIRMAP Network

Simply send your request by email to David BULTEEL (david.bulteel@imt-lille-douai.fr) specifying:


• Your Name, Position, Institution, and your contact details


• The field of activity of your institution


• What is of interest for you in the Cirmap
project

Abstract of the CIRMAP Project

Abstract of the CIRMAP Project Cirmap will provide a new Mixture Proportioning Method (MPM) for the design of 3DP mortars with RFA and a new Design Methodology for Customized Shapes (DMCS). A new Master Control Command (MCC) for concrete 3DP will be implemented for the equipment of 3DP machines, and an integrated mobile 3D printing unit will be developed for onsite 3D printing of UMG furniture. A Cirmap-network will also be created for lobby and dissemination, leading to a new market for the reuse of RFA. 5 Local Public Authorities in North West Europe will provide public places that will be equipped with 3DP customized furniture. Project objectives: CIRMAP aims at finding new opportunities for the valorisation of Recycled Concrete Fine Aggregate through 3D printing of customized shapes. P Total budget : € 6.98 Million EU funding : € 4.19 Million Duration: 36 months (April 2020 – March 2023)

First pilot scale 3D printing of Interreg NWE CIRMAP's project

The first pilot scale 3D printing, within the scope of Interreg NWE CIRMAP, was successfully achieved in May 2021 at IMT Lille Douai (France)! This first 3D printing campaign was jointly led by two CIRMAP partners: ARMINES and Université d’Orléans. The cementitious ink used for printing was developed in the laboratory and contains 100% recycled sand coming from Belgium. The printed shape consisted of a 28 cm height square, and shows the good printability of the ink, as well as the good surface aspect of the mortar at the fresh state and at the hardened state. These promising results will allow to print more complex shapes in the future, suitable for urban, memorial and garden furniture uses.

Second pilot scale 3D printing of Interreg NWE CIRMAP's project

The second pilot scale 3D printing, within the scope of Interreg NWE CIRMAP, was successfully achieved in June 2021 at IMT Lille Douai (France)! This second 3D printing campaign was jointly led by two project partners: ARMINES and ULiège. The cementitious ink used for printing was developed in the laboratory and contains 100% recycled sand coming from Belgium. The pre-saturation conditions of the recycled sand were changed and the blending sequence used was simplified in comparison to the first 3D printing campaign led in May 2021. The printed shapes consisted of a 34 layers height cylinder and a sinuous shape, which will be cut to obtain mortar specimens. These specimens will be used to perform durability and mechanical assessments. These results show that a simplified mortar fabrication protocol still allows to print complex shapes which will be adapted for urban, memorial and garden furniture uses.

Third pilot-scale 3D printing of Interreg NWE CIRMAP's project

In October 2021, CIRMAP carried out a third pilot-scale 3D printing session at ARMINES/IMT Nord Europe (France) in the scope of Interreg NWE CIRMAP. The operation was a success! This third 3D printing campaign was jointly led by two project partners: ARMINES/IMT Nord Europe and UOrléans. For this session, a cementitious ink was formulated using 100% recycled sand from Germany. The printed shape consisted of a 40-layer height cylinder. These results show that the formulations developed in the laboratory allow the printing of various shapes which will be adapted to urban, memorial and garden furniture uses.

Interreg NWE CIRMAP fourth pilot-scale 3D printing session

In March 2022, CIRMAP carried out a fourth pilot-scale 3D printing session at the ARMINES/IMT Nord Europe laboratory (France) in the framework of Interreg NWE CIRMAP. For this session, the cementitious ink used was formulated with 100% German recycled sand, and successfully printed the last letter of "IMT". This impression allows to close the printing of the 3 letters that compose "IMT" Nord Europe, laboratory where different formulations have been developed for the CIRMAP project.

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