Development of extrusion based artificial lightweight aggregates from sand-plastic waste composite for sustainable concrete production: Performance evaluation and Life Cycle Assessment

The growing global challenges of plastic waste management and the depletion of natural aggregates in construction necessitate innovative sustainable solutions. To address these, this study investigates a sustainable solution by introducing novel artificial lightweight aggregates developed by extruding a 1:1 mix of polypropylene plastic waste and sand. The developed aggregates were used to replace natural coarse aggregates (NCA) at 0 %, 30 %, 50 %, 70 %, and 100 %. At 30 % replacement, the concrete retained 84.5 % compressive strength (18.6 MPa), suitable for structural use, while 100 % replacement reduced strength by 52 % (10.5 MPa), suitable for nonstructural applications. Tensile strength and flexural strength showed 34.17 % and 20 % reduction at full replacement, respectively. A comprehensive Life Cycle Assessment (LCA) demonstrated potential for reducing the overall environmental impact of concrete production such as a 54.83 % reduction in Global Warming Potential. This research demonstrates an innovative valorization of extrusion technology for effective plastic waste recycling for sustainable production and consumption in the construction industry.