Research Programme Reuse of End-of-Life Composites
Reuse of End-of-Life Composites is one of the topics studied by the Professorship for Polymer Engineering. It is aimed at the development of a new construction material based on End-of-Life thermoset composites. The programme has been running since 2015 and so far over 80 companies, public and knowledge institutes (project partners), have participated, and more than 100 students have carried out assignments. As befits a practice oriented research group at a University of Applied Sciences, the outcome of this research programme benefits general education and has become part of the curriculum of the minor Composites, minor Production Engineering and master Polymer Engineering.
Subsidies were provided by: SIA KIEMVANG(opens in new tab) (2015-2017), CompoWorld (2015-2017), SIA RAAK (opens in new tab)MKB 1 (2017-2019), SIA RAAK MKB 2 (2019-2022), SIA RAAK MKB 3 (2022-2024), Provincie Overijssel(opens in new tab) (2019-2022) and DCPV (2020-2022).
The Windesheim methodology for Reuse of End-of-Life Composites
This methodology involves machining End-of-Life composite products into strips or flakes for re-use as reinforcing elements which, when combined with virgin resin and fibre, enable the production of a brand-new component. This, in effect, preserves and re-uses the mechanical properties of the original obsolete composite.
Since the start of the programme, the project has aimed at the development of demonstrators to show its potential to the industry. Together with the project partners, specific user cases were identified for this new construction material to develop scientific substantiated computation rules. These rules have made it possible to develop full-scale demonstrators installed all over the Netherlands.
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About our demonstrators
Over the past years, a lot of knowledge was generated based on the development of the full-scale demonstrators using the Windesheim methodology for Reuse of End-of-Life Composites
A summary of these demonstrators as developed in conjunction with the industry can be found below in chronological order, showing the natural evolution of the programme.
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2017 - Retaining walls
This was the first full-scale demonstrator within the programme. The goal was to show the potential of the methodology in real life. In September 2017 80 separate profiles were produced with a tongue-and-groove detailing. At the Beatrix Sluis, the profiles were installed by vibrating into the ground without any damage being incurred on the profiles.More information in chapter 4.1 of ‘Industrieel Hergebruik EoL Composieten’(opens in new tab)
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2017 - Interior paneling rHPL
This demonstrator is the only one produced using a foaming polyurethane resin instead of unsaturated polyester resin and a press in the production of the panels. From these panels, furniture was made, ranging from lockers and tables to kitchen units. These can be founded dotted around the technical faculty since 2017.More information in chapter 4 of ‘Industrieel Hergebruik EoL Composieten’(opens in new tab)
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2018 - Dinzer bridge
In Friesland the renovation of the Stroobosser TrekFaert involved the replacement of 7 traffic bridges, with a clear choice to retain the look of the original hardwood beams. For the Dinzer bridge the choice was made to go for a different, more sustainable solution: Reused Composites. Using the Windesheim methodology, bridge planks were produced for heavy-duty traffic. These planks were tested and approved by the independent consultancy company Royal Haskoning DHV. The planks were produced by Composite Structures. -
2018 - Guiding beams
The Professorship developed guiding beams for the Province of Groningen in 2018 to replace the use of tropical hardwood (azobé) which suffers from fungi attack, limiting the life span of the wood. The company Fiby Products produced 120 meters of these guiding structures, which were installed in 2019 at Groningen Seaport in Delfzijl.More information in chapter 4 of ‘Industrieel Hergebruik EoL Composieten’(opens in new tab)
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2019 - Crane mats
In cooperation with the company Welex, 4 meter wide crane mats were developed consisting of 5 individual beams, replacing tropical hardwood.
More information in chapter 4 of ‘Industrieel Hergebruik EoL Composieten’(opens in new tab)
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2020 - Dutch Railways railway sleeper
By 2030, Dutch Railways aim to have implemented circular purchasing, maximum reuse of materials and zero waste. In a joint development a railway sleeper was developed based on the principle of Structural Reuse of EoL Composites using the interior composite panels from trains as raw material stream for the flakes. For the actual production of the sleepers, Dutch Railways are looking for an industrial partner.
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2021 - Inlay Save Plastics
The company Save Plastics manufactures wood-replacement products like decking boards based on a 100% recycled plastic mix. A demonstrator plank with an EoL composite inlay was developed to study the creep of the combined materials. A vast improvement was found and this opens up new potential end markets. This project is ongoing.
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2021 - Guide beam with rubber insert
Like glass fibre composites, passenger car tyres are difficult to recycle. To study if interesting mechanical properties could be achieved by a combination of the two, parts of a tyre were used to add a spring-type inner lining to a guide beam of EoL composite material (left image). A second demonstrator beam was developed based on a 100% recycled plastic mix in combination with an elastomer foam strip (shock absorbance). This demonstrator was installed in the town of Ronduite and is currently being tested.
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About our partners
This programme would not have been possible without a great number of partners from the industry. Please find an overview below.
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RAAK MBK 1
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RAAK MBK 2
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RAAK MKB 3
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About our research topics
The programme for Structural Reuse of End-of-Life Composites consists of various research topics, each addressing a specific topic. An overview of the results can be found below: End-of-Life Composites waste streams, end products, mechanical behaviour, leaching of heavy metals or salts and long-term behaviour.
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Mechanical behaviour of strips of reused composites
The most extreme form of a high L/D ratio are strips. The production of these strips is explained in the publication 'Reuse of thermoset composites', including how they can be produced by machining them on an industrial scale and the mechanical properties that can be obtained as a raw material for the Reuse of EoL Composites. It appeared to be possible to generate a well-functioning construction material with a higher bending strength than soft-wood (coniferous) and hardwood. Links to the studies can be found below, chapters 2, 3 and 5 of the second publication (in Dutch).
Publication 'Hergebruik van thermoharde composieten'(opens in new tab)
Publication 'Industrieel hergebruik van EoL thermoharde composieten'(opens in new tab)
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Mechanical behaviour of reused composites using flakes/needles
Flakes with a high L/D ratio can be produced using industrial shredders. Depending on what End-of-Life composite object is used, a raw material for reuse is obtained in needle shape or flake. Using these needles or flakes, the mechanical properties of the new composite will depend on the weight ratio of the EoL flakes and orientation. Links to the studies can be found below, in chapters 2, 3 and 5 of the second publication (in Dutch).
Publication 'Hergebruik van thermoharde composieten'(opens in new tab)
Publication 'Industrieel hergebruik van EoL thermoharde composieten'(opens in new tab)
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Leaching of dangerous chemicals
Since the start of the programme, old boats were used as the input for EoL raw materials. These boats were once produced using resins specifically developed for the marine industry, and now at the end of their lives were processed into flakes for the EoL Structural Reuse programme. It was extremely important to study if any leaching of chemicals or heavy metals took place from the composites parts made from the flakes and strips. The results can be found in the table 3 on page 14, chapter 7 (in Dutch). Very minimal to no leaching of heavy metals and salts was detected. The levels remained far below the maximum allowable limit.
Publication 'Mogelijke uitloging in hergebruikt composiet'(opens in new tab)
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Long term behaviour
To determine the LCA, it is vital to know the long term behaviour of the material. Preliminary accelerated tests are being carried out at 25 °C and 40 °C in the context of a set of lock gates intended for Groningen Seaport.
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About the Life Cycle Assessment
The Windesheim methodology for structural reuse of End-of-Life composites can only be labelled truly circular if the carbon footprint is lower than the alternatives. A first study was performed using 1 m running length of retainer wall as the functional unit (static load). The preliminary results showed that it is extremely important to produce these composite parts in an automated, industrial way because this leads to a low resin content and high stiffness of the products and an economically feasible process. More information can be found in chapter 6.3 of the study in the link below (in Dutch).
Publication 'Industrieel Hergebruik EoL Composieten'(opens in new tab)
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About our awards
Since the start of the programme in 2015, the following prizes have been awarded to our research programme.
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JEC Innovation Award 2022, Civil Engineering category
Each year, since its creation more than 20 years ago, the JEC Composites Innovation Awards(opent in nieuw tabblad)(opens in new tab) celebrate successful projects and cooperation between players in the composites industry. In 2022 the programme for Structural Reuse of EoL Composites was awarded the prize in the category Building and Civil Engineering.
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RAAK Award 2021
Each year, the Taskforce for Applied Research SIA awards a prize for the best practice based research project: the RAAK Award(opens in new tab). The winning project is recognized as a showcase for research carried out at the Universities of Applied Sciences. On the 25 November 2021 at the SIA conference, project manager Albert ten Busschen was awarded the RAAK award 2021 for the programme Hybrid Reuse of End-of-Life Plastics and handed a cheque for € 10.000,-!
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Our publications
Please find below a list of Dutch and English publications and reports published over the years. There are more reports available on HBO Kennisbank(opens in new tab).
2017 - Structural re-use of end-of-life thermoset composites, Elsevier, Reinforced Plastics
A. ten Busschen, 'Structural re-use of end-of-life thermoset composites' Elsevier, Reinforced Plastics, volume 61, number 3 May/June 2017.Download the publication(opens in new tab)
2017 - Revolutionary re-use of polyester boats, The Report
A. ten Busschen 'Revolutionary re-use of polyester boats', The Report, September 2017, issue 81 blz 50-55.Download the publication(opens in new tab)
2020 - Industrial re-use of composites, Elsevier, Reinforced Plastics
A. ten Busschen 'Industrial re-use of composites', Elsevier, Reinforced Plastics, volume 64, number 3, May/June 2020.Download the publication(opens in new tab)
2020 - Characterisation of Glass Fibre Reinforced Expoxy (GRE) Composites in hot/wet Conditions
A. ten Busschen; M. Bennink, report, November 20202021 - Industrial re-use of composites, Chapter in Current topics in Recycling
A. ten Busschen 'Industrial re-use of composites', chapter in Current topics in Recycling, August 2021.
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Articles in the Dutch press
Throughout the years, this research programme has been highlighted several times by the national press. A list of online articles can be found below, organized into three categories: RAAK-award, Wind energy & yachts and Railway sleeper.
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Wind energy and yachts
Publications on the wind turbine blades, as part of the research into the reuse of end-of-life composites.
- Jachtbouw Nederland (2016, in Dutch)(opens in new tab)
- Kunststof & Rubber (2017, PDF in Dutch)(opens in new tab)
- Jachtbouw Nederland (2018, in Dutch) (opens in new tab)
- Stentor (2019, in Dutch)(opens in new tab)
- Algemeen Dagblad (2019, in Dutch) (opens in new tab)
- Composites World USA (2021)(opens in new tab)
- Reformatisch Dagblad (2022, PDF in Dutch)(opens in new tab)
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Raak Award
Publications about the RAAK Award, which associate lector Albert ten Busschen won together with all researchers with the research on Reuse of Composites.
- Composites NL (2021, in Dutch)(opens in new tab)
- Kunststof Magazine (2021, in Dutch)(opens in new tab)
- NRK (2021, in Dutch)(opens in new tab)
- NJI (2021, in Dutch)(opens in new tab)
- Regieorgaan SIA (2021, in Dutch)(opens in new tab)
- Science Guide (2021, in Dutch)(opens in new tab)
- RTV Focus (2021, in Dutch)(opens in new tab)
- Stentor (2021, in Dutch)(opens in new tab)
- RTV Oost (2021, in Dutch)(opens in new tab)
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Railway sleepers
Publications about the railway sleepers, a demonstrator we delivered in cooperation with the Dutch Railways as part of the research on reuse of end-of-life composites.
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Programme manager Albert ten Busschen
Associate professor Albert ten Busschen is an expert in the field of development and production of composite products and building products. Both his master’s degree in mechanical engineering and his PhD studies were spent studying the mechanical properties of fibre reinforced plastics (FRP). For 7 years he worked as head of the Reinforcement Evaluation Centre of PPG Fiber Glass in Hoogezand, evaluating the performance of glass fibre products as reinforcement in various end applications. In the years that followed, he became head of the department 'Houtproducten voor de Bouw' (Wood Products for the Built Environment) at SHR Hout Research in Wageningen, followed by a period where he worked as research manager at Tech-Wood Nederland in Rijssen. From 2005 till 2022, Albert was the technical director for Poly Products in Werkendam. From 2005 till 2013 he was the chairman of the composites federation in the Netherlands, VKCN (now CompositesNL). In June 2015 he became associate professor for Polymer Engineering at the Professorship for Polymer Engineering at Windesheim University of Applied Sciences in Almere and Zwolle. Here he started his work on his methodology for Structural Reuse of End-of-Life Composites.
Want to know more?
If you want to get in touch with us to discuss a new project, please contact us: kunststoftechnologie@windesheim.nl(opens in new tab).
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