Funded project – A new mortar design enabling the reuse of demolished bricks
Although bricks are ideal for reuse in a circular economy, they are rarely recycled because removing the mortar that bonds them is difficult and costly. This project focuses on developing a new type of mortar that can be easily removed from demolished bricks, enabling their reuse.
Introduction
Australia's construction and demolition industry generates significant brick waste, with most demolished bricks being downcycled into low-value applications rather than being reused. The primary obstacle has been the difficulty and cost of removing traditional mortar without damaging the bricks, leading to resource depletion and increased greenhouse gas emissions from new brick production.
This challenge demanded an innovative solution, bringing together the expertise of RMIT University, the University of Newcastle, and Brickworks in a pioneering collaboration. Each partner brought distinct capabilities: RMIT's advanced facilities and sustainable construction expertise, the University of Newcastle's material science knowledge, and Brickworks' industry insights and practical experience.
The project team actively engaged with brick recyclers across Victoria and New South Wales, incorporating real-world insights into their research. This comprehensive approach ensured that the developed solution would be both scientifically sound and practically implementable within existing industry workflows.
| 31/01/2024 | Project kick-off |
| 28/08/2024 | Concept design of mortar mix |
| 30/06/2024 | Developing and testing mortar mix with reducing strength and bonding |
| 30/10/2024 | Small scale trials of developed mix |
| 30/11/2024 | Architectural design and translation into real building application |
| 15/12/2024 | Final project reporting and documentation |
Outcomes – what worked?
The project successfully developed two groundbreaking mortar formulations that enable brick reuse in construction: one for non-structural applications (suitable for marine exteriors and non-marine interiors when used with general-purpose bricks), and one for structural applications (suitable for marine interior and exterior applications when used with protected bricks). Both formulations achieved the required compressive strength while significantly reducing bond strength, making demolition easier.
Other key achievements of the project:
Extended Product Lifespan
As the newly developed mortars enabled efficient brick recycling, this project has the potential to extend brick lifespans up to eight times their current use.
Reduced Carbon Emissions
The environmental impact analysis revealed promising results.
In Victoria, 59% of houses use brick and mortar construction, with plans for 283,300 new homes by 2029 (approximately 33,430 brick homes per year). The standard mortar with new bricks typically generates an embodied carbon footprint of 305 million kgCO₂eq each year for these builds. The new mortar solution could reduce this by up to 93 million kg of CO₂-equivalent annually, saving up to 465 million kgCO₂eq by 2029.
Challenges
The project had a short timeframe, and limited access to facilities required the team to adapt their testing procedures and conduct several experiments in alternative settings. This required additional effort in experimental setup and coordination to ensure consistency in results.
Insights to share with other business
Success in circular economy projects relies heavily on strong collaborative partnerships between industry, research institutions, and government bodies. Organisations should focus on identifying sector-specific challenges and developing solutions that balance economic and environmental benefits. Starting with pilot projects, maintaining openness to innovation, and ensuring early stakeholder engagement are crucial factors for success.
What’s next?
The project has successfully progressed from TRL level 1 to TRL 4, demonstrating significant potential for commercial application. The team has recently won over $600,000 in additional funding through Australia's Economic Accelerator (AEA) Ignite to support continued research and development over the next 12 months. This next phase will focus on systems laboratory testing, on-site validation, and translation into real building applications, moving closer to commercialisation.
From the grantee
"We prioritise sustainability and circularity because they are essential to addressing traditional construction practices' environmental challenges. Construction and demolition waste significantly contribute to waste generation and carbon emissions, and transitioning to circular practices offers a solution to mitigate these impacts."