Optimal design of a post-demolition autoclaved aerated concrete (AAC) recycling network using a capacitated, multi-period, and multi-stage warehouse location problem

Autoclaved aerated concrete is a popular building material in constructing one- and two-family houses because of its low thermal conductivity and fire resistance. Since autoclaved aerated concrete production rose significantly in the 1960s and 1970s, increasing post-demolition volumes can be expected in the following decades. However, these are currently landfilled as high-quality recycling options are still to be established.

This study develops a new capacitated, multi-period, and multi-stage network model for optimising a Germany autoclaved aerated concrete recycling network. The multi-period character of the model enables the precise consideration of increasing post-demolition volumes by constantly allowing the move of recycling plants or opening new ones throughout the planning horizon. Additionally, the multi-stage formulation facilitates incorporating an optional second recycling step, which involves additional effort and higher revenues. The model aims to find a cost-minimised recycling network and identify optimal network transformations until 2050. Results show that recycling is preferred over landfilling. The optimised recycling network uses large recycling plants for economies of scale and opens new plants in the future to handle the expected increase in post-demolition autoclaved aerated concrete. Transport costs account for the largest share of total costs (50%), while fixed costs reach around 40%, and revenues offset approximately 20% of all costs. The total costs of the network reach about 2200 M€ until 2050, which is 4600 M€ (68%) less than without establishing recycling. The results offer new insights into cost-minimal network structures and their future development to encourage decision-makers to promote autoclaved aerated concrete recycling.