Building construction accounts for a significant proportion of global greenhouse gas emissions, raw material extraction, and waste production. Applying circular economy (CE) principles in the building construction industry would considerably reduce these values. However, uptake by the industry is relatively slow, which is largely attributed to sectoral barriers, including limitations in knowledge and experience. This review paper aims to assess and contribute to diminishing these obstacles by offering a comprehensive review of circular material usage principles and strategies within the construction sector. Opportunities and facilitators of change are also presented, including innovations and emerging technologies in recycling, digitization, robotic systems, novel materials, and processing. Finally, four case studies demonstrate the application of circular theory via a novel block system, recycled aggregate, modular kitchen reuse, and an energy efficiency retrofit. The conclusions show that future efforts should prioritize the development of strong regulatory frameworks, awareness initiatives, and international cooperation. In this regard, the integration of technological advancements, such as AI, robotics, and blockchain, is essential for optimizing waste management efficiency. Furthermore, education on circular practices plays a critical role. Through global collaboration, standardizing circular construction approaches can promote a more sustainable and resilient building construction industry.

The reuse and recycling of construction and demolition waste is becoming an advisable choice to reduce the consumption of key raw materials and the environmental impact generated by the construction of new buildings. This study proposes the introduction of two new stages of recycled aggregate processing that allow redesigning the production process of recycled aggregates towards a more sustainable and eco-friendly system: sieving with secondary crushing and washing. Based on an experimental study, our findings show that the new stages reduce significantly the content of impurities and the water absorption of recycled aggregates, obtaining a better final product (i.e. cement mortar) for buildings. Moreover, the new final product made with treated recycled aggregates also experiences significant improvements in their physical and mechanical properties (i.e.: increased on average, 5% in flexural strength, 6% in compression strength and reduced shrinkage by 2%), in turn reducing both the costs associated with the manufacture of the new product and its environmental impact compared to other products that solely include untreated recycled aggregates. The potential economic and solid waste management implications for firms that choose to deploy the new production system depicted are also discussed.

The high demand for natural resources and increased industrial activity is driving the construction sector to search for new, more environmentally friendly materials. This research aims to analyse plaster mortars with the incorporation of construction and demolition waste (CDW) to move towards a more sustainable building sector. Three types of aggregates (natural, recycled concrete and recycled from ceramic walls) and two types of insulation waste (expanded polystyrene with graphite and mineral wool) have been added to the plaster matrix to evaluate its mechanical and physical properties and its suitability in the elaboration of prefabricated materials. The results show how plaster mortars made with recycled aggregates have higher mechanical resistance than conventional plaster without incorporating sand. The incorporation of crushed mineral wool residues improves the flexural strength of plaster mortars and their application in the execution of prefabricated panels. Likewise, the expanded polystyrene residues reduce the final density of mortars, improving their behaviour against water absorption and reducing the final thermal conductivity of plaster material.

The building sector is currently undergoing a process of change due to concerns about the sustainability of the construction industry. The application of circular economy criteria to develop new, more sustainable construction products has become one of the major challenges for the society of the future. This research advances towards the development of new lightened gypsum composites that incorporate waste from end-of-life tyres and recycled fibres from mineral wool thermal insulation in their composition. The results show how it is possible to reduce the consumption of the original raw materials by replacing them with recycled rubber granular particles, developing new construction products that are lighter, with better water resistance and greater thermal resistance. Additionally, it is shown that the incorporation of recycled fibres from rock wool and glass wool insulation is a good solution to improve the mechanical resistance of lightened gypsum composites, giving these construction and demolition wastes a second useful life by reincorporating them in the process of manufacturing new prefabricated housing products.

The incorporation of rubber recycled aggregates from end-of-life tyres (ELT) in the manufacturing process of sustainable building materials has gained great interest in recent decades as a result of the large volume of this waste being generated annually. In this work, the objective is to make a contribution towards the circularity of construction products by carrying out a physico-mechanical characterisation of new gypsum composites made with the incorporation of these recycled rubber aggregates. To this end, up to 30% by volume of the original raw material has been substituted, analysing the mechanical resistance to bending and compression. Although lower than those of traditional gypsum material, both properties exceed the limits set at 1 and 2 MPa, respectively, by the current regulations. In addition, water absorption by capillarity significantly decreases, and thermal conductivity is reduced by more than 35% with respect to the reference material. Finally, in order to provide the research with a practical application, a prefabricated plate design has been proposed that incorporates the gypsum materials studied and an agglomerated rubber band that increases the thermal resistance and improves the efficiency of the designed construction system. In this way, this research reflects the potential of these novel building materials and explores new avenues for their application in building construction.