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Journal of Cleaner Production 29-30 (2012) 46e52

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Journal of Cleaner Production


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A comparative study on the feasible use of recycled beverage and CRT funnel
glass as fine aggregate in cement mortar
Tung-Chai Ling a, b, Chi-Sun Poon a, *
a
Department of Civil and Structural Engineering, The Hong Kong Polytechnic University, Hung Hom, Kowloon, Hong Kong
b
School of civil engineering, University of Birmingham, Edgbaston, Birmingham, United Kingdom

a r t i c l e i n f o a b s t r a c t

Article history: The rapid development of the electronic industry has led to a growing hazardous waste management and
Received 5 October 2011 disposal problem related to the management of cathode ray tube (CRT) waste. This study aimed to
Received in revised form compare the feasibility of using CRT recycled glass: non-treated funnel glass (n-TFG, crushed without
11 January 2012
treatment) and treated funnel glass (TFG, crushed and treated with acid nitric to remove lead on the glass
Accepted 15 February 2012
Available online 22 February 2012
surface) as fine aggregates in cement mortar. Fresh and hardened properties of the cement mortars,
including their x-ray radiation shielding and potential lead leaching were investigated. The mortar
prepared with crushed beverage glass (CBG, lead-free) was also evaluated for comparison purposes. The
Keywords:
Cathode ray tubes
experimental results show that the use of glass cullets, irrespective of glass type, improved the fluidity
Recycled funnel glass and drying shrinkage but reduced the strength. About 60% enhancement in x-ray radiation shielding
Beverage glass property was achieved with the use of 100% CRT glass in the cement mortar owing to the increase of
Lead leaching mortar density due to the presence of lead in the CRT glass. Furthermore, lead leaching (based on TCLP
Radiation shielding test) from the mortar samples prepared with the TFG complied with the regulatory limits. The results
Mechanical properties have demonstrated that the CRT glass (an original hazardous material) can be treated, processed, and re-
utilized for making cement mortars. The mechanical performance of the cement mortar is comparable to
that made with beverage glass.
Ó 2012 Elsevier Ltd. All rights reserved.

1. Introduction One of the promising ways to identify opportunities for opti-


mizing and reducing environmental impact of this CRT waste is to
One of the biggest technology revolutions in image displays for implement an environmental management system (EMS) stan-
TV and PC monitors was the change from the cathode ray tube dardized by ISO 14001 (Boudouropoulos and Arvanitoyannis, 1999,
(CRT) type to LCD (liquid crystal display) and LED (light emitting 2000). According to Rahman and Subramanian (2012), a recycling
diode). One challenge posed by the revolution is the need to company in Australia (with an ISO 14001 accredited) applied an
dispose of and manage the growing magnitude of CRT waste innovative technology of disassembly which was able to reclaim
(Socolof et al., 2005; Poon, 2008). It was estimated that the amount valuable metals for reuse and divert up to 98% (by weight) from the
of CRT TVs required to be disposed of in United States alone was total discarded 60,000 CRT monitors collected each year. Also, a life
approximately 20 million units each year and the amount was cycle assessment (LCA) methodology complying with ISO 14040
expected to increase beyond the next 10 years (Jefferies, 2006). had been proven to be a reliable approach to assess the entire life
Similar situation are also found in most of the developed and cycle of CRT glass from the environmental perspective (in terms of
developing countries (Nnorom et al., 2011). If the CRT waste is not extraction and treatment of raw materials, production, trans-
handled properly then the lead (or other heavy metals) included portation, reuse, recycling and disposal) as well as its economic and
within the CRT glass may pose serious soil and ground water social point of view (Arvanitoyannis, 2008; Noon et al., 2011;
pollution (Ravi, 2011; Cherry and Gottesfeld, 2009; Nnorom and Andreola et al., 2005).
Osibanjo, 2008). In Hong Kong, a recycling facility has been in existence since
2005 by the Environmental Protection Department (EPD) to recycle
discarded old computer monitors and TV sets. In the facility, the
external components such as electronic, plastic casing and metallic
* Corresponding author. Tel.: þ852 2766 6024; fax: þ852 2334 6389.
parts are first removed from the computer monitors and TV sets.
E-mail addresses: tcling611@yahoo.com, cetcling@inet.polyu.edu.hk (T.-C. Ling),
cecspoon@polyu.edu.hk (C.-S. Poon). The funnel and panel glass from the CRT glass is then separated by

0959-6526/$ e see front matter Ó 2012 Elsevier Ltd. All rights reserved.
doi:10.1016/j.jclepro.2012.02.018
T.-C. Ling, C.-S. Poon / Journal of Cleaner Production 29-30 (2012) 46e52 47

a hot wire separation method. Since the lead content of these two Table 1
types of glass are different, they are processed using two different Chemical compositions and physical properties of cement and fly ash.

recycling methods. The recycling process of CRT panel glass mainly Chemical compositions (%) Cement Fly ash
involves the removal of fluorescent powder present on the inner Calcium oxide (CaO) 63.15 <3
surface of the glass by suction, and then using a mechanical crusher Silicon dioxide (SiO2) 19.61 56.79
to break it down into smaller particle sizes in a safe manner. The Aluminium oxide (Al2O3) 7.33 28.21
Ferric oxide (Fe2O3) 3.32 5.31
glass can be used directly as a clean recycled aggregate in
Magnesium oxide (MgO) 2.54 5.21
construction products due to its low lead content. Sodium oxide (Na2O) 0.13 0.45
As for the funnel glass, since it contains a significant amount of Potassium (K2O) 0.39 1.34
lead (PbO) with an average content of 22e25% by wt., a specifically Sulphur trioxide (SO3) 2.13 0.68
designed treatment process (elution) is required before it can be Loss on ignition 2.97 3.90

disposal to landfills or reused as a recycled material. The recycling Physical properties


process for the funnel glass involves crushing, acid washing and Specific gravity 3.16 2.31
Blaine fineness (cm2/g) 3519 3960
water rinsing. The lead present on the surface of crushed funnel
glass is removed by immersing the crushed glass cullets (<10 mm)
in a bath of 5% nitric acid (HNO3) solution for 3 h. After that, the
treated funnel glass (TFG) is removed from the nitric acid bath and The chemical compositions and physical properties of the cemen-
thoroughly rinsed using tap water to remove the remaining acid. titious materials are given in Table 1.
The TFG produced is typically considered safe because the leach-
able lead concentration is below the toxicity characteristic leaching 2.1.2. Fine aggregates
procedure (TCLP) limit of 5 mg L1 as per the requirement of the US All the fine aggregates investigated in this study were of particle
Environmental Protection Department (1992). sizes less than 5 mm. River sand with a fineness modulus (FM) of
A number of previous studies have been conducted to investi- 2.09 was used as the natural fine aggregate (as a control) in the
gate the possibility of using recycled aggregates derived from sand-mortar mix. The CRT recycled funnel glass with relatively
diverse sources as fine aggregates replacement in cement mortars higher fineness modulus than sand (FM ¼ 3.17 for n-TFG and
or concrete for diverse purposes (Ling et al., 2011; Ho et al., 2012; FM ¼ 3.61 for TFG) was obtained from a local CRT Waste Recycling
Mohammed et al., 2012; Pelisser et al., 2012; Richardson et al., Centre. TCLP results of both CRT funnel glass are presented in
2012; Bravo and de Brito, 2012). It was found that the use of glass Table 2. Crushed beverage glass (CBG) derived from post-consumer
aggregate in mortar slightly reduced the strength properties, but beverage bottles was obtained locally from a waste glass recycler.
this negative effect could be reduced when finer glass particles CBG had an of fineness modulus of 3.14. The particle size distri-
(700 mm or less) were employed (Shi et al., 2005). This is because butions and physical properties of all the fine aggregates used are
the pozzolanic property of fine glass powder and its filler role can presented in Table 2. Fig. 1 shows the photograph of sand, recycled
significantly improve the micro-structural and mechanical prop- beverage and CRT glasses.
erties of the cement mortar (Corinaldesi et al., 2005). It is generally
agreed that utilizing recycled beverage glass aggregate in mortar is
a promising and effective method for waste glass recycling (Ling
and Poon, 2011b; Ling et al., 2011). Although a preliminary study 2.2. Mix proportions
has been conducted by the authors to assess the feasible use of
crushed and treated CRT funnel glass for the production of cement All the mortar mixes were prepared with an aggregate-to-
mortar (Ling and Poon, 2011b), a systematic comparison of the cementitious material ratio of 2.5 and a water-to-cementitious
effect of using untreated CRT and other types of glass on the material ratio of 0.45. These mix proportions are common for
properties of the produced cement mortar is still relatively limited. cement mortar applications (Ling and Poon, 2011b; Choi et al.,
The objective of this study is to investigate the feasible use of 2009). 25% of the OPC was replaced by fly ash to mitigate the
untreated funnel glass (n-TFG, crushed without treatment) as fine potential of ASR expansion (Lee et al., 2011). Including the control
aggregates in cement mortar. The effect of using n-TFG as 50% and (sand) mortar mix for comparison, a total of seven mortar mixes
100% replacement of total sand volume on the fresh and hardened were prepared and investigated. The three different types of glass
properties, and the x-ray radiation shielding ability of the cement n-TFG, TFG, and CBG were used to replace 50% and 100% of the sand
mortar were assessed. The expansions due to alkaliesilica reaction (by volume) in the mortar mixes. All the mix proportion mixtures
(ASR) and potential leachability of lead from the cement mortar are shown in Table 3.
were also studied. The cement mortar prepared with treated funnel
glass (TFG, crushed and treated with nitric acid to remove lead on Table 2
the glass surface) and crushed beverage glass (CBG) was also Particle size distributions, physical properties and Pb concentration of fine
studied for comparison purposes. aggregates.

Sieve size (mm) Percentage passing (%)

River sand n-TFG TFG CBG


2. Experimental details
5.00 99.5 99.9 99.2 99.6
2.36 97.6 87.1 73.3 87.4
2.1. Materials 1.18 89.8 59.0 43.1 53.5
0.60 75.3 28.6 18.9 27.6
2.1.1. Cementitious materials 0.30 39.5 7.6 4.5 12.7
0.15 3.7 0.6 0.3 5.1
Ordinary Portland cement (OPC) of strength class 52.5R
complying with American Society of Testing Materials (ASTM) Type Fineness modulus 1.94 3.17 3.61 3.14
I was used as the primary cementing material in this study. Fly Ash Relative density (g/cm3) 2.62 3.10 2.99 2.49
Water absorption (%) 0.87 w0 w0 w0
complying with ASTM class F was used as a suppressor agent to TCLP leachable Pb concentration (mg/L) e 373.5 2.2 e
prevent expansion due to alkaliesilica reaction (Lee et al., 2011).
48 T.-C. Ling, C.-S. Poon / Journal of Cleaner Production 29-30 (2012) 46e52

Fig. 1. Photograph of sand, recycled beverage and CRT glasses with particle size less than 5 mm.

2.3. Sample preparation 2.4.5. Equivalent compressive strength


According to ASTM C 349 (2008b), the broken pieces (portions
The proportioned materials in all the mortar mixes were mixed of the prisms broken in the flexure strength test) were used for the
for 5 min using a standard laboratory rotating drum type mixer. The equivalent compressive strength test. The broken portions of
fresh mortar mix was then put into steel moulds (size prisms used had a length of not less than 65 mm and were free from
40  40  160 mm and size 25  25  285 mm) in two layers of cracks, chipped surfaces, or other obvious defects.
similar depth. Vibration was applied by a mechanical vibrating
table after filling up each layer. After casting, the mortar specimens 2.4.6. Drying shrinkage
were covered with a plastic sheet in the laboratory at 23  3  C for Drying shrinkage value measurements on the specimens (size of
24 h. After 1 day, the mortar specimens were demoulded and then 25  25  285 mm) were conducted according to the procedures
water cured at an average temperature of 23  3  C until the day of stated in a modified British Standard (BS ISO-Part 8, 2009) method.
testing. After demoulding, the length and initial reading (regarded as zero
reading) of the prisms was measured. The specimens were then
2.4. Test methods transferred to a drying environmental chamber at a temperature of
23  C with a relative humidity of 50%. Subsequent readings were
2.4.1. Fresh properties taken at 1st, 4th, 7th, 28th and 90th days.
The flow table test was used for the determination of fluidity of
fresh mortar mixes. The procedures of the flow table test followed 2.4.7. Expansion due to alkaliesilica reaction (ASR)
ASTM C 1437 (2007b). Three 25  25  285 mm mortar specimens were used for the
alkaliesilica reaction (ASR) test based on ASTM C1260 (2007a).
2.4.2. Hardened density After 28 days of water curing, a zero reading was taken after further
The hardened density was determined according to ASTM C 642 storing the prisms in distilled water at 80  C for 24 h. The mortar
(2006). The presented results are the average values of the three bars were then transferred and immersed in 1 N sodium hydroxide
specimens. (NaOH) solution at 80  C until testing time at 1st, 4th, 7th, 14th and
28th days.
2.4.3. Water absorption
The water absorption values of the specimens were determined 2.4.8. X-ray radiation shielding
according to ASTM C 642 (2006) and the results are the average The x-ray radiation shielding test was performed in an x-ray
values of the three specimens. laboratory designed for medical diagnostic examination. The
laboratory was installed with a medium frequency x-ray unit
2.4.4. Flexural strength (Toshiba, KXO-30R). The distance between the target of the diag-
The flexural strength of the specimens was tested at 1, 4, 7, 28 nostic x-ray tube (DXB-0324CS-A) and the test samples
and 90 days after casting based on ASTM C 348 (2008a). The mortar (100  100  5 mm) was kept at 700 mm. The radiation dose at
bar specimens (40  40  160 mm prisms) were placed under a point in free air beneath the samples was measured by a 6 c.c.
a central line load with simple support over a span of 120 mm. A ionization chamber linked to a radiation monitor controller (Model
displacement rate of 0.1 mm min1 was used. The reported results 9015, Radcal Corporation). The sensor was placed 100 mm beneath
are the average values of the three specimens. the test samples.

2.4.9. Toxicity characteristic leaching procedure (TCLP)


Table 3 The toxicity characteristic leaching procedure (TCLP) test was
Mix proportions of mortar mixtures (kg/m3). used to identify the leaching of lead from the tested samples. The
No Mix notation Cementitious materials Fine aggregate Water
TCLP test was conducted according to the US Environmental
Protection Agency method 1311 (1992). The samples were taken
Cement Fly ash Sand n-TFG TFG CBG
after the mechanical testing at the 28th day and were crushed to
1 Control 456 152 1519 0 e e 273 pass through a 10 mm sieve before the test. This is intended to
mortar (CM)
2 n-TFG50 456 152 759 867 e e 273
simulate the potential lead leaching to assess whether the
3 n-TFG100 456 152 0 1734 e e 273 material would be classifiable as hazardous waste. An extraction
4 TFG50 456 152 759 e 867 e 273 solution with a pH value of 2.88 was prepared using glacial
5 TFG100 456 152 0 e 1734 e 273 acetic acid. As per the TCLP test protocol, 400 mL extraction
6 CBG50 456 152 759 e e 722 273
solution was added into plastic containers containing 20 g of
7 CBG100 456 152 0 e e 1446 273
crushed samples and the mixtures were then tumbled by
T.-C. Ling, C.-S. Poon / Journal of Cleaner Production 29-30 (2012) 46e52 49

250 0% 50% 100%


0% 50% 100% 10
200
8

Water absorption (%)


Flow table value (mm)

150 6

100 4

2
50

0
0 n-TFG mortar TFG mortar CBG mortar
n-TFG mortar TFG mortar CBG mortar
Fig. 4. Effect of n-TFG, TFG and CBG on water absorption of cement mortars.
Fig. 2. Effect of n-TFG, TFG and CBG on the flow table value of the fresh cement
mortars.
respectively. The higher density could be related to the relatively
a rotary shaker. After 18 h, the leachable heavy metals in the high specific gravity of lead present in the funnel glass. As noticed,
solution were then analyzed using atomic absorption spectro- the density of TFG mortars was slightly lower than n-TFG mortars.
photometer (AAS). This is understandable because the TFG cullets were slightly lighter
than n-TFG cullets due to the removal of lead through the acid
treatment process. On the other hand, the hardened density for the
3. Results and discussion
control (sand) mortar and CBG mortar were lower.
3.1. Fresh properties
3.3. Water absorption
Fig. 1 shows the flow table test results of the fresh mortar mixes.
The flow table values increased with increasing glass content, The water absorption results are shown in Fig. 3. The control
regardless of the glass type. The improvement in fluidity of the mortar shows the highest water absorption value and the water
fresh mortar could be due to the impermeable and smooth surface absorption reduced with increasing glass content. This could be due
of the glass cullets used (Kou and Poon, 2009). Comparing the to the nature of glass which does not absorb water.
influence of glass type, the flow values of CRT (both the n-TFG and
TFG) mortars were slightly higher than CBG mortar, probably due to 3.4. Flexural and compressive strength
the higher fineness modulus of recycled CRT glass that led to
a reduction in total surface area per unit volume which required The flexural strength test results are shown in Fig. 4. The 90-day
less water to enwrap the solid particle. flexural strength of the control mortar, n-TFG50, TFG50 and CBG50
mortars were 9.0 MPa, 6.7 MPa, 7.9 MPa and 7.8 MPa, respectively. It
can be seen that the flexural strength of mortar was reduced by
3.2. Hardened density
approximately 13% when 50% of the sand was replaced by TFG and
CBG, respectively. The strength reduction is probably due to the
Fig. 2 shows the effect of n-TFG, TFG and CBG content on the
poorer bond strength between the smooth surface of the glass
hardened density of cement mortars. The hardened density of n-
cullets and the cement paste (Ismail and AL-Hashmi, 2009; Ling
TFG and TFG mortars increased with increasing glass content. The
and Poon, 2011a). As for n-TFG50, a greater reduction (approxi-
hardened density for n-TFG100 and TFG100 mortar mixes were
mately 25%) in 90-day flexural strength was observed, probably due
2,546 kg m3 and 2472 kg m3, an increase of 14.6% and 11.2% in
to the retardation effect of lead on the hydration of cement (Shi
comparison to the control mortar, respectively. In other words, the
et al., 2005; Cheeseman and Asavapisit, 1999). The results show
density of the mortars was increased by 7.3% and 5.8% for every 50%
replacement of sand n-TFG and TFG used in the cement mortar,

2600
0% 50% 100%
Hardened density (kg/m3)

2400

2200

2000

1800
n-TFG mortar TFG mortar CBG mortar

Fig. 3. Effect of n-TFG, TFG and CBG on hardened density of cement mortars. Fig. 5. Flexural strength of cement mortars with 50% and 100% n-TFG, TFG and CBG.
50 T.-C. Ling, C.-S. Poon / Journal of Cleaner Production 29-30 (2012) 46e52

0.40
Contro mortar
0.35 n-TFG50
TFG50
0.30

ASR expansion (%)


CBG50
0.25 n-TFG100
TFG100
0.20 CBG100

0.15

0.10

0.05

0.00
0 5 10 15 20 25 30
Curing age (day)

Fig. 8. Expansion due to alkaliesilica reaction of cement mortars with 50% and 100%
Fig. 6. Compressive strength of cement mortars with 50% and 100% n-TFG, TFG and
n-TFG, TFG and CBG.
CBG.

that the flexural strength was further reduced by 19.5% as the n-TFG 3.6. Expansion due to alkaliesilica reaction
content was increased from 50% to 100%.
Fig. 5 shows the compressive strength results. As can be seen, Fig. 7 shows the expansion due to alkaliesilica reaction (ASR) of
a similar trend to that of flexural strength was observed. The the cement mortars. It can be clearly noticed that the expansion of
detrimental effect of n-TFG was again shown, particularly at the the mortar bars containing glass cullets was higher than that of the
100% replacement level. control mortar. The higher the glass content the higher the
expansion. This is consistent with the results reported by Park and
Lee (2004).
For a given glass content, the ASR expansion of the n-TFG and
TFG mortars was relatively higher than that of the CBG mortar. A
3.5. Drying shrinkage reason for this is believed to be the higher solubility (higher %
weight loss in 1 N NaOH) of CRT glass than that of CBG glass,
Fig. 6 shows the effect of glass type and replacement level on the resulting in higher amount of dissolved glass available in solution
drying shrinkage of the cement mortars. During the first 4 days, the for ASR gel formation. This results and hypothesis had also been
difference of drying shrinkage of all the cement mortars was confirmed by other studies (Saccani and Bignozzi, 2010; Trocellier
insignificant. From the 7th up to the 90th day, the positive effect of et al., 2005). The highest ASR expansion was found in the n-
using glass cullets as fine aggregates in reducing the drying TFG100 mortar mix. Except for the n-TFG100 mortar, at the age of
shrinkage became more obvious. The possible reason for this may 14 days, all the mortar bar mixes showed ASR expansion below the
be the lower absorption capacity of the glass cullet when compared permissible limits (0.10%) according to ASTM C1260 Fig. 8.
with natural river sand.
Comparing Fig. 6(a) and (b), it can be clearly observed that the 3.7. Radiation shielding properties
drying shrinkage decreased with increasing replacement
percentage of glass cullets. This is consistent with the results of Ling The X-ray radiation shielding properties of the mortar mixes are
and Poon (2011b). For a given replacement level, the mortar shown in Table 4. The linear attenuation coefficient of the samples
prepared by using n-TFG showed the greatest reduction in drying was significantly increased when sand was replaced by either n-
shrinkage. This might be due to the retardation effects of lead on TFG or TFG. This could be attributed to the dense atomic structure
cement hydration and is consistent with the strength results. in both types of CRT funnel glass actively interacting with x-ray
radiation, thus reducing its energy and the depth of radiation
penetration (Calabrese et al., 1996). However, the mortar mixes
0.08 prepared with CBG had no significant effect on the attenuation
Contro mortar
0.07 n-TFG50 coefficient.
TFG50
CBG50
0.06 n-TFG100
Drying shrinkage (%)

TFG100
CBG100 Table 4
0.05 Linear attenuation coefficients, half-value layer and tenth-value layer of cement
mortars.
0.04
Sample Linear attenuation Thickness (mm) HVL (mm) TVL (mm)
0.03 coefficient (mm1) 1 mm lead Eq.
Standard 4.010 1.0 0.2 0.6
0.02 lead sheet
CM 0.069 57.7 10.0 33.1
0.01 n-TFG50 0.121 33.2 5.7 19.1
n-TFG100 0.171 23.4 4.0 13.4
0 TFG50 0.118 34.1 5.9 19.6
0 20 40 60 80 100
TFG100 0.167 24.1 4.2 13.8
Curing age (day) CBG50 0.069 58.2 10.1 33.4
CBG100 0.069 58.5 10.1 33.6
Fig. 7. Drying shrinkage of cement mortars with 50% and 100% n-TFG, TFG and CBG.
T.-C. Ling, C.-S. Poon / Journal of Cleaner Production 29-30 (2012) 46e52 51

Table 5 density of the mortar which in turn enhanced the shielding


TCLP results of crushed mortar samples. properties.
Number Crushed mortar sample Pb (mg/L) 5. The alkaline environment in the cement mortar matrix was
1 Control mortar 0.41 able to reduce the leaching of lead. The TCLP results of the
2 n-TFG50 14.65 cement mortar prepared with the treated CRT glass complied
3 n-TFG100 32.72 with the regulatory standard.
4 TFG50 0.54
6. For the untreated CRT funnel glass, adjustments to the cement
5 TFG100 0.75
6 CBG50 0.46 binders used is necessary to provide additional immobilization
7 CBG100 0.57 of lead to satisfy the TCLP limit.

Acknowledgement
The half-value layer (HVL) and tenth-value layer (TVL) were also
computed, and they show that the HVL provided by the n-TFG100 The authors would like to thank the Environment and Conser-
and TFG100 mortars were about 4.0 mm and 4.2 mm, respectively, vation Fund and the Woo Wheelock Greed Fund, and The Hong
which was about 60% more than the attenuation provided by the Kong Polytechnic University for funding support.
control sand mortar. This shows that the mortar prepared with the
recycled funnel glass had a superior performance in shielding References
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