From Waste to Sustainable Architectural Resource: Particle Packing-Based Design of Recycled Aggregates for Small-Scale Circular Construction

The transition towards a circular economy in architecture requires new methods for reusing construction and demolition waste as a material resource. Recycled aggregates are a promising alternative to natural aggregates, although their variable porosity and particle grading often limit practical application. This study evaluates the suitability of recycled concrete aggregate (RCA) and recycled ceramic aggregate for small-scale architectural elements such as street furniture. Three comparative mixtures were analysed using particle size distribution data, the Modified Andreasen model, and the EMMA (Elkem Materials Mix Analyzer) tool. Two mixtures contained recycled aggregates, while one reference mixture was based on natural aggregates. The assessment focused on particle packing, water demand, and binder content. The recycled concrete aggregate mixture showed results closest to the reference mix, with water content of 180 kg/m3 and a water-to-cement ratio of 0.50, compared with 170 kg/m3 and 0.50 for the natural aggregate mixture. The ceramic aggregate mixture required the highest water content (200 kg/m3) and cement dosage (380 kg/m3) due to its higher porosity (15–18%) and finer particle fraction. By adjusting aggregate proportions within the packing model, satisfactory particle structuring was still achieved in all mixtures (q = 0.31–0.35). The study shows that particle packing methods, commonly used in concrete technology, can also support early-stage architectural material selection. Recycled aggregates, particularly RCA, may therefore be considered a viable substitute for natural materials in benches, seating panels, and other small-scale circular design applications.