Selective demolition and recycling of Dutch infrastructure concrete

This study advances understanding of how selective demolition combined with advanced recycling techniques affects the quality of recycled concrete aggregates (RCA) from Dutch infrastructure concrete under industrial conditions. A 60-year-old highway viaduct in the Netherlands was selectively demolished, including T-beams, columns, abutments, and foundations. Powder, fine, and coarse RCA fractions were produced from these preselected members using a conventional impact/rotor crusher and two advanced recycling technologies (Smart Liberator and Mangeler) and compared with RCA obtained from unknown-origin concrete rubble. Experimental relationships were established between adhered mortar content and key physical, mechanical, and chemical properties of RCA across particle size fractions. Selective demolition combined with advanced recycling produced materials with substantially improved performance. Fine RCA (0–4 mm) exhibited water absorption values of 2–6%, compared to approximately 8% for fine RCA from unknown-origin concrete rubble, while coarse RCA (4–22 mm) reached 1.5–4%. These improvements were accompanied by the high-performance characteristics of RCA produced using the Smart Liberator, including a Los Angeles abrasion value of approximately LA15 and particle density up to 2610 kg/m 3 . The results highlight the importance of both parent concrete selection and the choice of comminution technique in achieving high-quality RCA. Unlike conventional high-energy impact crushing, advanced recycling relies on controlled friction, shearing, and selective abrasion, which preserves aggregate integrity and allows efficient removal of adhered mortar. The resulting RCA exhibits mechanical and physical performance comparable to natural aggregates and meets Eurocode 2 requirements. This study demonstrates, at full industrial scale and within a single reinforced concrete structure, how selective demolition combined with advanced recycling enables direct control over adhered mortar content and aggregate performance, narrowing the gap between conventional RCA and natural aggregates for high-performance structural applications. • Industrial-scale selective demolition of a 60-year-old highway viaduct was implemented in combination with advanced recycling techniques. • Combining selective demolition with advanced recycling narrows the gap between recycled and natural aggregates for high-performance structural applications. • A mechanistic understanding of the differences between advanced and conventional recycling processes is provided. • A guideline for parent concrete selection is proposed to assess its suitability for selective demolition.