Suitable CDW types, were selected, investigated and assessed to obtain Secondary Raw Materials (SRM) for geopolymer formulations. A cost analysis of SRM was carried out, and the methodology LCA was established according to current standards. Based on global cost analysis, different LCC scenarios were proposed.
Properties of high-density geopolymer (HDG) binders with 50% by weight of inorganic CDW were investigated and optimized to achieve a formulation that yielded satisfactory prototypes and met requirements of an industrial-like pilot production. An innovative manufacturing process for geopolymer-bonded wood particleboards (WGP) was developed to obtain components with up to 40-50% of wood. A geopolymer adhesive to bond WGP to HDG was formulated. The performance of geopolymer binders and panels was investigated in terms of mechanical/physical properties, thermal output and durability, with a preliminary appraisal of the potential of HDG as recycled aggregate.
For a sound upscaling strategy and with the support of specific tests and simulations, the design of panels was accomplished by considering: industrial feasibility; characteristics of demo buildings; geometric features; fastening systems and installation methods; aesthetics (joints, surface colour and texture, etc. Items for demo sites, with surface properties enhanced by a multifunctional coating, were manufactured and tested, while the best solutions for easy installation and dismounting were identified. The promising results set the basis for their future industrialization/commercialization.
InnoWEE solutions were installed in 4 real sites, a pilot in Padua (Italy), Bucharest (Romania), Athens (Greece), and Putte (Belgium), covering different climatic zones. A monitoring in all sites was carried, before and after the installation to assess: indoor micro-climatic conditions; thermo-hygrometric comfort; thermal consumption of heating systems; thermal transmittance.
Modelling of 4 virtual demo sites, Piazzola sul Brenta (Italy), Paros (Greece), Bucharest (Romania), Bilbao (Spain), and validation of the real demo sites, were performed completing a European scenario. Simulations showed the beneficial impact of InnoWEE solutions on the energy demand of buildings.
The LCCA, mainly affected by production line and labour cost, demonstrated that costs can be competitive to similar commercial products. Compared to the pilot plant production, a cost reduction of 53–65% is expected at the industrial scale. The LCT considered aesthetics, promotion of selective demolition process, LCA and deconstruction. Social impacts of the new products (S-LCT) revealed strengths and opportunities for the improvement of production process and stakeholder’s involvement.
The TCO (Total Cost of Ownership of the product), compared to similar available solutions, demonstrated a sensible cost reduction.
An exhaustive exploitation and final business plans with risk assessment were elaborated, identifying 10 Key Exploitable Results (KER).
Numerous communication and dissemination actions were undertaken: logo; website; leaflet and brochures – general and technical – in 8 languages; newsletters; Social Media; videos; congresses, conferences and workshops; fairs; scientific publications and press releases. Joint activities with the cluster of projects focused on geopolymers and CDW were done.
