The demolition of buildings insulated with EPS – commonly known as polystyrene – produces EPS waste. Typically, this material still has significant amounts of mineral residues attached, such as plaster and reinforcing mesh. Only when these can be removed quickly and easily is it possible to separate the waste by type for recycling on a large scale.

As part of a pilot project, PORR has deployed an innovative excavator attachment developed by the startup ORBIS Development at two demolition sites in order to separate the insulation material from mineral components such as plaster and reinforcement. The PORR site team was able to dismantle and collect several tonnes of EPS in a clean, single-grade fraction.

PORR CEO Karl-Heinz Strauss: “PORR has been involved in EPS recycling for years. First within the framework of the EPSolutely research project, to which we contributed our extensive expertise in processing and demolition. Now we have seized the opportunity to work with an innovative startup and in close cooperation with our partners along the construction value chain to develop a practical solution for the separation of EPS waste by type. The results speak for themselves”.

Further processing that conserves resources

The insulation waste collected at the pilot construction sites was processed and analysed on a trial basis by Austrotherm. It was found that this method allows façade demolition waste to largely be separated directly on site. This means more resource-efficient further processing, as entire external thermal insulation composite systems (ETICS) no longer need to be transported. In addition, the innovation makes it possible to establish a closed loop for ETICS with EPS, turning old insulation material back into new EPS insulation boards.

At the same time, investigations are underway to determine the extent to which the mineral components from facade demolition can also be recycled – for example, as an aggregate in cement. As part of the pilot project, PORR crushed the plaster layer, which was then tested by Baumit. Further trials on an industrial scale are currently underway.

The client side was also involved from the outset. The development of the excavator attachment was supported by the housing developer Salzburg Wohnbau from the earliest stages.

Important step towards a circular economy

By combining selective demolition with accompanying recycling trials, an important step has been taken towards the systematic development of external thermal insulation composite systems as part of a circular economy. Instead of being sent for disposal, reusable raw materials are recovered from the demolition process.

ORBIS Development founder Paul Spatzenegger: “Based on the project results, we now have a practical approach that can be scaled up and further developed in additional pilot projects. The aim is to work with partners along the value chain – construction companies, waste management firms and recyclers – to establish a demolition and recycling process that is both environmentally sound and economically viable”.

Ongoing pilot projects

For PORR, cooperation with innovative startups is an essential part of its Group-wide innovation and sustainability strategy. This supports decarbonisation goals within the framework of the lever “Avoid – Reduce – Recycle Waste” and strengthens the action field known as “Holistic Circular Economy”.

CEO Karl-Heinz Strauss: “We are continuously piloting applications with equipment manufacturers, construction-material suppliers and technical innovators to make our construction site processes more efficient, more digital and more sustainable. We are open to collaborations with committed partners. The focus is always on whether it can be applied in practice in everyday construction site operations”.