From Waste to Resource Using Recycled Stone in 3D-Printed Building Elements

The environmental impact of conventional construction materials, particularly those reliant on traditional stone extraction and processing methods, is substantial. Key data points highlight carbon emissions from stone extraction, waste generation, energy-intensive processing, transportation-related emissions, and habitat destruction. Construction and mining are critical economic sectors, jointly producing 65% of waste on a European scale (EEA – European Environment Agency (2023). Tracking waste prevention progress — A narrative-based waste prevention monitoring framework at the EU level, EEA Report no 2. http://eea.europa.eu/publications/tracking-waste-prevention-progress. Accessed 06 March 2024). Stone waste, a by-product of mining and manufacturing, poses environmental challenges during disposal. In fact, in the stone sector, up to 71% of material becomes waste, with mining waste accounting for 51% and processing waste for 41% of raw production quantity (Italian Trade Agency (2020). Nota di mercato – Settore lapideo, Miami (US). [Online] Available at: ice.it/it/sites/default/files/inline-files/Nota di Mercato - Lapideo - Aprile 2020.pdf. Accessed 06 Oct 2023; Montani, C. (2017). XXVIII Rapporto Marmi e Pietre nel Mondo – 2017 – Marble and Stone in the world, Aldus, Carrara. [Online] Available at: issuu.com/marmonews/docs/rapporto_2017_screen. Accessed 10 Oct 2023). To address this, an innovative approach to design and production process is essential to reintegrate scrap material into the production cycle (Baratta. Agathón | International Journal of Architecture, Art and Design, 9:32–41, 2021), enhancing product flexibility and customization. This study explores the potentiality to transforming this waste into a valuable resource through 3D printing, contributing to the circular economy. Successful case studies demonstrate recycled stone waste as a sustainable alternative for 3D-printed architectural elements, reducing greenhouse gas emissions associated with traditional stone extraction and processing, also the transportation. Recent research encourages experimenting with structural and nonstructural modular elements, decorative wall cladding, and urban furnishings made with additive manufacturing processes. However, surface finish and mechanical performance of these components need improvement. Furthermore, it is also fundamental evaluating component disposal and transformation prospects, by analyzing their recycle potentialities. By analyzing component performance achievable with this technology and processing times, we can assess the environmental impact. This research demonstrates that the components made by 3D print may become complementary to natural stone elements, recovering 80% of waste material. This could be reduced excavation and pollution. Shifting design paradigms allow creating them from waste, minimizing energy consumption and long-distance transportation.