Upcycling of End-of-Life-Vehicle (ELV) plastics as a replacement for natural fine aggregate in concrete

End-of-life vehicle (ELV) plastics pose technical challenges in conventional recycling due to their diverse polymer compositions. Consequently, landfilling remains the prevailing disposal method. This study explores an innovative approach by upcycling ELV plastics as a substitute for natural sand in concrete. The study investigates the physical, mechanical and economic performance of ELV plastic-containing concrete. Plastic aggregates were prepared from real-world ELV plastics, featuring particle sizes below 4.75 mm, with over 90 % falling within the range of 1.18–4.75 mm. The research involves replacing natural sand with ELV plastics at varying volumes (0 %, 15 %, 25 %, 35 %, and 40 %) and examines the effect of sand replacement on various concrete properties. The results suggest that as the replacement ratio increases, the workability, density, and strength of concrete decrease. However, the 28-day compressive strength of concrete at the maximum replacement rate of 40 % was found to be 39 MPa, which suffices for certain non-structural strength applications, such as traffic routes, shared-use paths, local streets and curbs. In addition, compared to previous studies using mixed commodity plastics, ELV plastics lead to significantly lower strength reductions at high replacement ratios. Scanning Electron Microscopy (SEM) analysis reveals a distinctive rough and fibrous aggregate morphology, which enhances physical binding and provides bridging effects within the concrete matrix, potentially mitigating strength loss. Moreover, the economic analysis highlights a significant potential to commercialize ELV plastics for concrete applications. This study demonstrates that ELV plastics can be effectively used at high replacement rates (up to 40 % by volume) in non-structural applications.