Highly Commended CRUK award winner Gt Recycling has been a member of Carpet Recycling UK for around 6 years already and reprocesses approx. 500 tonnes of waste carpet waste annually,  with most of this waste regarded as ‘non-recyclable’ and previously destined for landfill.   G T Recycling joined CRUK and from its links with the non-profit membership association, has been able to understand potential end uses for recycled carpet in its domestic market, and be a part of a “Best Practice” industry organisation in that area.   The company accepts clean installation offcuts, new factory offcuts, rejects and end of run waste at its recycling plant in Geelong, Victoria, Australia where the waste is sorted into four classifications – nylon, polypropylene, wool, and PET.

GT Recycling will launch a new product GT FibreCrete 100 onto the Australian market in 2021, to be used in the application of carpet fibre-reinforced concrete which includes the use of PET carpet fibres as a strengthening component.    Doug McLean, Business Advisor for GT Recycling says “GTR’s innovative reprocessing method and subsequent new product has been developed over six years in a Research and Development collaboration effort with Deakin University, Geelong.   This collaboration has successfully proven the suitability and benefits of this new product innovation, and we believe that a new and Australian first product has been established”.

“Together with Deakin University, a significant amount of work has been undertaken to prove the workability of the Carpet Fibre Reinforced Concrete (CFRC) in areas covering ease of placement, compaction and finishing. Our research also proved amongst a range of other things, positive results for compressive strength, flexural strength and drying shrinkage strain of the CFRC compared to plain concrete, together with optimum size and blend.  In essence, it provides 3-dimensional reinforcement to minimise open cracking of concrete”.

“The processing method includes waste carpet being shredded to meet optimum size requirements.  This process in itself required researching a range of shredding options and screen sizes and configurations, whilst at the same time maintaining the flexibility to process a range of other products recycled by the company.    The end product, GT FibreCrete 100 will be packaged in convenient and recyclable packaging for ease of mixing in concrete batches”.

“In September 2014, two high traffic trial sections of industrial driveway were laid, with both carpet fibre reinforcing and plain concrete for comparison.  Results to date have showed positive evidence of crack resilience with the carpet fibre reinforced section.    Now that we have proven this product in trial high traffic sections, our next step is to trial sections of industrial hardstand areas and local council footpaths and cycle paths.”

“GT Recycling has taken a previously non-recyclable waste problem, undertaken significant R&D with specialist researchers at Deakin University, to deliver a sustainable recycling solution for Australia’s largest carpet manufacturer, whilst having a positive impact on the environment and reducing the volume of waste destined to landfill.  Our experience helped us recognise the synergies with recycling carpet polymer fibre and our existing plastic recycling operations, and we have subsequently diversified our operations to accommodate this innovative recycling solution.  This Australian first has scale to significantly reduce landfill locally and globally, creating new markets to accept and apply this waste solution”.

Applications for the CFRC include residential slab on ground and driveways, footpaths and cycle paths, and industrial hardstand areas, creating a wide market of residential, industrial and local council end consumers.

GT Recycling identified a gap in the country’s capabilities to recycle waste carpet in a commercially viable and sustainable fashion.  With limited established domestic markets for recycled carpet, and the absence of WTE options in Australia, the company embarked on a journey, together with its stakeholders Godfrey Hirst Carpets and Deakin University, to develop new recycled product options suitable for local markets.

GT FibreCrete, with minimal waste created in the recycling process, certainly meets the criteria in driving carpet waste up the hierarchy.

There has been significant interest in the carpet fibre concrete reinforcing product, particularly from Councils, who see potential benefits and cost savings in areas of pavement crack management, with potential lower maintenance requirements, and reduced public liability aligned to reduced trip hazards.

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Photos

• GT Recycling Team Tim, Trevor and Andrew McLean proudly displaying their Carpet Recycling UK member award for highly commended recycler of the year 2020, taken at the ground of Australian Football League side Geelong.
• A new replacement section of cycle path using FibreCrete as a trial section.
• Retail and bulk packaged Fibrecrete.