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The concrete waste is crushed in a way that maintains the natural structure of the aggregates to keep their performance properties. The goal is, to remove as much cement paste from the aggregates as possible.
Technology beyond concrete recycling: the everox upcycling process
Recovering the raw materials in concrete
everox introduces an advanced approach to handling construction waste: a patented concrete upcycling plant. The process that recovers the primary materials in concrete waste and transforms them into four high-performance, drop-in materials for gravel, sand, fine inert filler, and most importantly, cement.
Innovation that makes a difference
This fundamentally differs from conventional concrete recycling, which is widely used but typically downcycles materials into lower-quality outputs with limited applications, such as road base, soil stabilization or even landfill.
By contrast, the everox process upgrades concrete waste into consistent, high-quality resources that can be reused in newly produced construction materials, unlocking significantly higher value and enabling real CO₂ reduction.
R&D center 'everox Garden'
The advantages of the process at a glance
Zero waste
all four everox output materials can be reused in newly produced concrete
CO2 reduction
The upcycled cement ‘Activated Cement Paste’ can replace up to 30% primary cement in concrete or can be blended with cement as a low carbon SCM. It is processed with 11 Kg CO2 per ton, which is more than 90% less compared to primary cement.
Local value chains
The plant enables the creation of local value chains, as it upcycles the concrete waste where it is needed: next to urban centers, reducing logistic costs and transport related CO2 emissions.
Protection of natural habitats
Concrete waste is provided from urban mining which protects natural habitats, like ocean floors (sand) and river beds (gravel) from further extraction.
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Crushing
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Separation
The Ballistic Separator belongs to the everox IP and divides the crushed material into three material streams, of which the Recycled Coarse aggregates are the first final output material. Material containing too much cement paste is detected by the sensor and camera system and redirected to the crushing unit. The finer particles, sand, fine inert filler and cement paste move on to the next step.
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Liberation
In this process step, the material is shock heated for a short period. The thermo-mechanical reaction cracks the cement paste off the sand, which is the second output material after this step.
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Acitvation
The very fine particles are processed in a closed system to the activation phase, where they are separated into cement paste particles, which is transformed into Activated Cement Paste and Fine Inert Filler.
Activated Cement Paste (ACP)
Activated Cement Paste is a reactive supplementary cementitious material (SCM) produced through the thermomechanical activation of recycled concrete fines. The everox process selectively removes inert mineral fractions and reactivates the cementitious phases, resulting in a material with high specific surface area (~5000 cm²/g) and enhanced pozzolanic reactivity.
With controlled particle size distribution (<63 μm), low chloride and sulphate content, and consistent quality, ACP enables partial clinker replacement in accordance with EN 197-6 (CEM II/X and CEM VI systems). It is suitable for ready-mix concrete, precast applications, and cement blending, enabling reduced CO₂ emissions while maintaining mechanical performance and durability.
Technical data sheet
Recycled Coarse Aggregates (RCA)
Recycled Coarse Aggregates (RCA) are produced from end-of-life concrete through controlled crushing and advanced fraction separation. The resulting material, with particle sizes of 4–16 mm and bulk density of approximately 2300 kg/m³, complies with EN 12620 and demonstrates low water absorption (<4%).
Due to consistent grading, low impurity content, and stable physico-mechanical properties, RCA is suitable for structural and non-structural concrete, precast elements, and infrastructure applications. It provides a technically reliable alternative to primary aggregates while reducing demand for virgin gravel and lowering environmental impact.
Technical data sheet
Recycled Fine Aggregates (RFA)
RFA are fine mineral fractions (0.25–4 mm) derived from concrete waste through everox separation technology. The process ensures low moisture content, minimal sulphates and chlorides, and the absence of swelling clay minerals, resulting in stable and predictable behavior in concrete applications.
With a bulk density of approximately 2400 kg/m³ and controlled water absorption (<6%), RFA is suitable for use in ready-mix concrete, precast elements, and dry mortar systems. It serves as a compliant replacement for natural sand under EN 12620, contributing to resource efficiency and circular material use.
Technical data sheet
Fine Inert Filler (FIF)
Fine Inert Filler is a quartz-rich micro-filler (<0.25 mm) produced from concrete waste and designed to optimize particle packing in cementitious systems. With low moisture content and minimal chloride and sulphate levels, FIF functions as a non-reactive filler that enhances matrix densification and reduces permeability.
Due to its uniform fineness and controlled particle size distribution, FIF improves rheology and contributes to increased durability in concrete and mortar applications. It is suitable for use in ready-mix concrete, precast elements, and dry construction materials, supporting both technical performance and material efficiency.
Technical data sheet
Deep expertise build up in the R&D center 'everox Garden' in Rotterdam
Understanding circular construction materials
As the demand for sustainable construction and concrete recycling solutions grows, so does the need for a deeper understanding of material recovery and performance. everox combines more than a decade of scientific research with industrial testing and real-world deployment to advance the field of concrete upcycling.
The everox Garden: R&D for both - innovation and economical viability
At the core of everox’s expertise is the everox Garden. An integrated testing and development operated facility combining laboratory research, pilot-scale processing, and material validation, at the Port of Rotterdam.
The everox Garden is designed as a platform to:
- Testing concrete waste samples of international partners and customers
- Validate concrete mixes and predict material performance
- Demonstrate the full concrete upcycling process
- Test and optimize materials across the full value chain
- Develop new hardware, sensors, and process control systems
It includes advanced analytical equipment such as XRD, XRF, calorimetry, rheology testing, and strength testing, enabling precise characterization of recycled materials and their behaviour in concrete applications.
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- Partners can bring or send concrete waste to the Garden
- The facility processes and analyzes these samples at lab and pilot scale
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- The Garden includes a laboratory specifically for analyzing the upcycling behavior of concrete waste
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- The process can be demonstrated and executed at pilot scale
- Materials can be produced from the tested waste
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- The Garden produces material samples that can be provided to partners for further testing
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- Based on testing and analysis, the Garden predicts material yields and performance of outputs
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The facility supports studying concrete mixes and predicting performance outcomes
From academic research to industrial application
The foundations of everox were laid through long-term research in concrete recycling and material science, including work at TU Delft between 2009 and 2022, where the principles of advanced concrete separation and cement recovery were developed.
Early proof points followed with pilot applications such as the Sustainable Bridge at The Green Village (TU Delft), demonstrating the feasibility of circular concrete materials in real construction environments.