SINERGI Vol. No. October 2025: 845-856 http://publikasi. id/index. php/sinergi http://doi. org/10. 22441/sinergi. Evaluation of recycled steel properties originating from construction steel waste Mohamad Zarif Mirza Alias. Nur Ezzaryn Asnawi Subki. Hazrina Mansor*. Yazmin Sahol Hamid. Nurizzati Hidayah Mohd Afendi. Mazlan Mohd Yusoff. Ellvera De Ermalina Dominic. Nur Saihah Nasurudin Faculty of Civil Engineering. Universiti Teknologi MARA (UiTM) Shah Alam. Malaysia Abstract This research presents an experiment of constructional recycled steel properties that has been remelted into component-shaped specimens using green sand casting. A series of tensile, compressive and toughness tests were conducted. Then, specimens were observed using Scanning Electron Microscopy (SEM) and Energy-Dispersive X-ray (EDX) for microstructure analysis and chemical composition determination. This experiment was done to determine whether the recycled steel quality met the industrial All tests were conducted at Universiti Teknologi MARA (UiTM), providing data on the stress-strain relationship and toughness of recycled steel. The results indicated that recycled steel exhibited tensile characteristics below the standard strength range required by Eurocode. The changes in YoungAos modulus of the steel were attributed to exposure to high temperatures, causing significant vibration within the steel atoms and increasing the distance between atoms, thereby reducing tensile strength. The influence of impurities may also be a factor affecting tensile strength. The tests also concluded that the recycled steel construction waste was a brittle material with an average V-notch toughness of 24J. Keywords: Experimental test. Metallurgical. Recycled steel. Article History: Received: October 15, 2024 Revised: March 20, 2025 Accepted: July 24, 2025 Published: September 5, 2025 Corresponding Author: Faculty of Civil Engineering. Universiti Teknologi MARA (UiTM) Shah Alam. Malaysia Email: hazrina4476@uitm. This is an open-access article under the CC BY-SA license. INTRODUCTION Steel is the most recycled material globally, with approximately 680 million metric tons of recycled scrap recorded in 2021 . Recycled steel products typically originate from a combination of pre- and post-consumer scrap sources . , which can be a challenge. Generally, three common approaches can be utilized in the steel production industry: Blast Furnace (BF). Direct Reduced Iron (DRI), and Electric Arc Furnace (EAF) . , 4, 5, . EAF is notably more aligned with the production of steel, offering lower carbon emissions . , 4, . , in line with the Sustainable Development Goal (SDG). EAF, essentially using electricity to heat metal to a soft state for shaping, requires input materials that are already reduced, which means the process does not directly produce steel from iron ore . Moreover, this EAF approach can be integrated with a hydrogen-based process, known as Aufossilfree steelmakingAy . Conversely. BF technology . % utilizatio. in steelmaking uses coke as a reducing agent and provides heat for the iron ore reduction process . While the DRI method uses fossil carbon-based fuels as the reductant . involves the utilization of natural gas as both fuel and reductant for the iron ore reduction process in a shaft furnace . This method can also be integrated into the EAF process as (DRI-EAF) to replace the traditional BF . Currently, secondary steel constitutes merely 30% of global steel production . Therefore, the EAF production technique via recycled steel serves as a crucial input required for all steelmaking process routes for the future . Hence, expanding the proportion of total steel production derived from secondary sources presents a notable opportunity to mitigate CO2 Alias et al. Evaluation of recycled steel properties originating from construction A SINERGI Vol. Vol. No. October 2025: 845-856 emissions from the iron and steel sector . This can be achieved, in part, by augmenting the portion of end-of-life (EOL) scrap that undergoes Bringing the concept of recycling steel into fruition to reduce CO2 emissions is not a straightforward task . , 12, . As indicated in a study cited by . , there is an inadequate supply of scrap to fulfill the global economy's steel demand . This shortage jeopardizes steel recycling for high-grade applications. Danny in 2021 . , categorized three types of scrap by steel lifespan, namely: . forming scrap, generated during the casting and shaping of intermediate steel such as rods, tubes, and . fabrication scrap, resulting from the cutting of intermediate products into final products. end-of-life (EOL) scrap, coming from fullyutilized products that have reached their service Currently, steel scraps are graded mainly by visual inspection, human interference, and decision, which contribute to issues related to safety and accuracy of grading . This leads to difficulties in processing secondary steel . Steel recycling can degrade steel products quality . In some cases, the alloying elements found in steel scraps are difficult to separate . Melting a mixture of different alloys can result in an unstable composition due to microstructural inhomogeneity. For example, studies on high-entropy and multi-component alloys show that both simulations and experiments yield two-phase or multi-phase mixtures after melting, rather than a uniform solid solution . Additionally, small quantities of non-steel contaminants such as plastic, copper wire, or aluminum are often mixed in due to imperfect separation of materials before melting . While some impurities can be vaporized or removed as slag during melting or refining, others may remain or not be sufficiently eliminated . Recent research conducted by . , introduces a novel oxysulfide electrolyte for electrorefining that significantly improves steel recycling by efficiently eliminating carbon and copper impurities from molten iron. This electrolyte leverages sulfide that is specifically used for copper extraction, resulting from high ionic conductivity with the dilution of molten oxide. This ground-breaking process also produces liquid iron and sulfur as by-products, which potentially reduce emissions and solve issues in secondary steel production. Castro et al. have developed a matrix illustrating which combinations of contaminants and metals in the EAF input mix should be Two primary considerations are to be determined, including the feasibility of eliminating the contaminant from the primary metal during the refining process and the separation of the contaminant from the dust or slag economically. According to Castro et al. findings, aluminum and magnesium mixed with steel must be avoided, while copper, platinum-group metals, stainless steel, and zinc mixed with steel are recommended to be avoided. Other researchers concerning impurity content and it consequences generated from building constructions . hich are commonly contaminated by copper wir. , end the life of vehicle . hich is the most significant source of contaminant. , 27, 28, . Mechanical equipment . Steel in packaging . ith a very thin layer of tin or of chromium and chromium oxide that is retained within the melted stee. has been well reported. Extensive research and literature have been conducted to assess the effect of different manufacturing processes on steel properties, such as the hot dipping aluminizing effect . , the heat rate with the austenitization temperature effect . , and the effect of corrosion on steel properties . Kateusz et al. conducted an experiment to investigate the influence of recycled stainless-steel coatings from mixed scraps under thermal exposures. However, compressive, flexural, and impact strength of recycled steel that is produced by a sustainable method . EAF) has proven to be limited. Therefore, further research is essential to investigate the mechanical properties of recycled steel scrap and identify the properties of steel waste after it has been remelted and recycled. This research aims to conduct a study to assess the mechanical properties, metallurgical, and chemical composition of recycled steel waste used in construction. METHOD The experiment was conducted in phases from Phase 1 to Phase 4. Phase 1: Collection and Preparation Two distinct types of construction steel waste were collected from the waste disposal site at the Heavy Structure Laboratory. College of Engineering. Universiti Teknologi MARA (UiTM) Shah Alam, which included discarded corrugated reinforcement bars with unknown steel grade, featuring a diameter of 12 mm, as well as British Reinforced Concrete (BRC) steel meshes. Alias et al. Evaluation of recycled steel properties originating from construction A p-ISSN: 1410-2331 e-ISSN: 2460-1217 Figure 1. Collected construction steel waste Figure 2. Cutting process and . smaller pieces of steel waste Although the collected materials were originally used for reinforcement, it was categorized as steel waste due to their defects. Cleaning the collected steel waste is important to remove any unwanted particles, such as rust. Then, a visual inspection was performed for initial quality assessment. Figure 1 illustrates the collected construction steel waste. The total weight of collected materials was about 93 kg. The collected construction steel waste was cut into smaller pieces to suit different testing and fit into the small opening size of the Electric Arc Furnace (EAF), which is 40 cm in diameter. In addition, reducing the size of the reinforcement bars also provided better thermal conductivity due to a higher surface-to-volume ratio, which will help to reduce the energy required in the melting process. Figure 2. shows the cutting process of the collected construction steel waste into smaller pieces using a metal cut-off grinder. Figure 2. shows the smaller pieces of BRC steel meshes . , and reinforcement bars . iddle and righ. Before the steel waste can be melted, the mold that will be used for casting the molten steel must be prepared. Phase 2: Pattern Making and Molding Pattern making is typically done using materials made from metal or wood. In this study, the patterns replicating the final product of the cast material were first prepared using plywood and wooden sticks. The plywood was cut into a dimension of 300 mm x 200 mm with a thickness of 16 mm, replicating a final product of a solid rectangular steel plate . ee Figure 3. The plywood edges were chamfered to ease the removal work. Then, three similar wooden sticks . ee Figure 3. ) were cut into a length of 75 mm with a diameter of 25 mm that replicates the final product of solid cylindrical steel in compliance with ASTM E9-19 . The sand-molding method was utilized to produce the recycled steel specimen. A sand mold, as shown in Figure 4, was created using green sand, which is composed primarily of sand and clay, and an adequate amount of moisture to facilitate binding effects. The preparation of the sand mold involved two parts: the drag . ottom flas. and the cope . op flas. , as depicted in Figure 4. The drag flask was prepared as indicated in Figure 5. by first placing the plywood pattern at the bottom of the flask and then adding the green The green sand surrounding the plywood design was firmly compacted with a hand rammer until it was strong enough to form a cavity wall that could sustain the pattern when it was removed. When compacting green sand, it is crucial to keep the pattern in place and proceed with caution to avoid trapping air bubbles in the mold during pouring, which could result in blow defects. Subsequently, the drag flask was inverted, and the plywood pattern was carefully removed. Two runners were created next to the mold cavity, as seen in Figure 5. These runners connect the pouring sprue and riser to the mold cavity . efer to Figure . Two conical tubes, which would function as the pouring sprue and the riser . ee Figure . were positioned appropriately before the green Figure 3. A plywood and . a wooden stick Figure 4. Sand-molding components Alias et al. Evaluation of recycled steel properties originating from construction A SINERGI Vol. Vol. No. October 2025: 845-856 Figure 5. Construction of sand mold: . Preparation of sand mold in drag flask, . constructing runners beside the mold cavity, . preparation of sand mold in cope flask, and . complete construction of sand mold. sand was poured into the cope flask . efer to Figure 5. Vents, or ventilation holes, were made by penetrating steel rods all the way through the cope flask, as shown in Figure 5. This will let air circulate more easily during pouring. After the green sand was thoroughly compacted, the conical tubes were carefully removed. The cope flask was then gently positioned atop the drag flask and tightened with bolts to provide stability . ee Figure 5. To enable the green sand to consolidate even further, the sand mold was left for a day. Similar steps . efer to Figure . were repeated by replacing the plywood with three wooden stick patterns for solid cylindrical steel products in a mold. Phase 3: Melting and Casting The melting process of construction steel waste was conducted at the Foundry Laboratory. College of Engineering. Universiti Teknologi MARA (UiTM) Shah Alam, using the Electric Arc Furnace (EAF), as shown in Figure 6. The temperature of the furnace was raised to 1550 AC, which is the melting point of steel. The melting process was carried out in batches, using about 45 kg of construction steel waste in each batch. aid in the melting process, 15 kg of steel scrap were fed into the furnace as it was gradually heated to the required temperature. Once the molten steel was visible, the furnace was gradually filled with construction steel waste . ee Figure 6. Simultaneously, ferrosilicon was added to improve the fluidity of molten steel, which in turn made casting easier. 200g of carbon riser was also added to the furnace during the casting process to increase its carbon content, which reduced the steel porosity. During the melting process, slag coagulant was consistently introduced into the furnace to separate impurities and non-metallic compounds from the molten This resulted in the formation of slag Figure 6. Electric Arc Furnace, . construction steel waste in the furnace, . slag particles formation, and . recycled steel after particles, as shown in Figure 6. , which were then removed from the furnace. The molten steel was kept at 1545 AC for a few hours before it was poured into two different mold shapes: One for a solid rectangular plate and the other for a solid cylindrical mold that had been prepared earlier. The molten steel was left for 24 hours at room temperature to allow for cooling and solidification before the mold could be opened. After 24 hours from casting, the recycled steel specimens were shaken out of the sand mold for the sand shot blasting process, whereby any remaining sand was removed from the recycled steel specimens. Figure 6. shows the recycled steel specimens after they were removed from the sand molds. The recycled steel specimens, involving rectangular- and cylindrical-shaped specimens, then underwent finishing processes, which involved the removal of excess steel components . uch as risers and runner. , cutting the connections between the specimens, and polishing of the steel surfaces using a grinder. solid rectangular steel plate and three solid cylindrical steel plates were ready for the testing Subsequently, three . steel specimens were extracted from the solid rectangular steel plate through waterjet cutting to get the desired shape, while milling and grinding to achieve the necessary thickness. Phase 4: Experimental Testing Three . mechanical tests were conducted, compression, and Charpy Impact test to determine the mechanical behavior of the recycled steel specimen under different stress states. Also, the recycled steel specimen was observed using Alias et al. Evaluation of recycled steel properties originating from construction A p-ISSN: 1410-2331 e-ISSN: 2460-1217 Figure 7. Dog bone-shaped specimens for the tensile test and rectangular specimens for the toughness test Figure 9. Dimension of solid cylindrical compressive test specimen in accordance with ASTM E9-19 . Scanning Electron Microscope (SEM) to analyze the microstructure of recycled steel and Energy Dispersive X-ray (EDX) to assess the chemical composition of recycled steel. For the uniaxial tensile test, three . dog bone-shaped specimens were cut from the solid rectangular steel plate . efer to Figure . and designated as ST1. ST2 and ST3. The sampling method and uniaxial tensile test procedure were conducted in accordance with ISO6892-1:2019 . The dimensions of a tensile test specimen can be seen in Figure 8. This test was performed using the Universal Testing Machine (UTM). The strain rate control testing method, also known as Method A2 in ISO6892-1:2019 . , was employed with a single strain rate approach. This approach is suitable for determining various key parameters such as yield strength, fracture strength, and others. The tensile test was executed in a quasi-static manner at a constant loading rate of 0. 025mm/s with A20% tolerance. On the other hand, three . solid cylindrical specimens were lathed for better surface finishing and prepared for the uniaxial compression tests, such as SC1. SC2, and SC3. The procedures for conducting a uniaxial compression test, including specimen preparation, were referred to as ASTM E9-19 . Based on the standard, short specimens are generally utilized for compression tests of bearing Medium-length specimens are usually used for establishing the general compressive strength properties of metals. Long specimens are best suited for determining the elastic modulus in compression of metals. Specimens with an L/D . ength/diameter rati. 5 or 2. 0 are best suited for determining the compressive strength of highstrength materials. This test was conducted mainly to determine the general compressive strength of recycled steel. Thus, only a mediumlength design was selected for the compressive test specimens. The dimensions of solid cylindrical steel specimens can be seen in Figure Then, three . rectangular specimens were extracted from the solid rectangular steel plate . efer to Figure . for the Charpy Impact test, with each specimen designated as SI1. SI2, and SI3. This test was conducted to assess the toughness of recycled steel specimens. Material toughness quantifies the maximum amount of energy that a material can absorb before it fractures, which is helpful to determine whether a material is ductile or brittle. The sampling method and test procedure were conducted in compliance with ISO1481:2016 . Detailed dimensions of the rectangular specimen with the presence of Vnotch can be seen in Figure 10. The test was executed using the impact testing machine which consists of a pendulum hammer and a scale measuring energy. The Charpy impact test procedure involves releasing the pendulum hammer from a state of free fall until it contacts the sample, causing it to break. The energy required to break the sample essentially represents the toughness of steel material, which is commonly expressed as the impact strength . energy per Figure 8. Dimension of a dog bone-shaped tensile specimen in accordance with BS EN ISO6892-1:2019 . Alias et al. Evaluation of recycled steel properties originating from construction A SINERGI Vol. Vol. No. October 2025: 845-856 Figure 10. Dimension of rectangular specimen with V-notch unit area of the notc. Note that the energy capacity of the testing machine was 300J. Then, a specimen with dimensions of 10 mm x 10 mm and a maximum thickness of 40 mm was cut from the solid rectangular plate using an angle grinder. This recycled steel specimen was placed under a Scanning Electron Microscope (SEM) for microstructural observation. The specimen preparation and operating procedures were conducted in compliance with ASTM E311:2017 . Image outputs were observed at different magnifications, including 1000x and In conjunction with SEM analysis. Energy Dispersive X-ray analysis was performed to determine the chemical composition of the recycled steel specimen. A high energy electron beam in a range of 10 to 20 keV was bombarded on the specimen, and X-rays emitted from the specimen were collected by an energy dispersive The energy of the X-rays generated represents characteristics of the atomic structure of elements from which it is emitted and hence presents the elemental details of the recycled steel For comparison, the chemical composition of the collected construction steel was identified by using a handheld X-ray Fluorescence (XRF) before going through the melting process. RESULTS AND DISCUSSION Results of tensile, compressive and toughness tests were presented and discussed in this section. Tensile Properties of Recycled Steel The uniaxial tensile test results of recycled steel originating from construction steel waste were presented in Figure 11 and summarized in Table 1 The initial stiffness of recycled steel specimens, or known as the YoungAos modulus, was estimated to be E = 2583 MPa on average, given in Table 1. Figure 11. Tensile stress-strain properties of the recycled steel specimen. The YoungAos modulus of the recycled steel specimen was significantly lower than mild steel . E = 210 GP. , but quite comparable to the commonly adopted strain hardening stiffness of mild steel . Esh = 0. 01E = 2100 MP. as specified in EN1993-1-5:2006 . The changes in YoungAos modulus of the steel were attributed to high temperature exposure, causing significant vibration within the steel atoms and increasing the distance between atoms, thereby reducing tensile As shown in Figure 11, the initial stiffness of the recycled steel specimen dropped after surpassing the proof yield strength at fy,0. 2 = 194. MPa on average . ee Table . The post-yielding stiffness of the recycled steel material, also known as strain hardening stiffness, was estimated to be Esh = 988 MPa on average . ee Table . Essentially, the initial stiffness of the recycled steel specimen declined by 38% on average . Esh = 38E). As given in Table 1, the recycled steel specimen fractures at the nominal strain of A = 0% with an average fracture strength of ff = 9 MPa. The significant drop in stiffness, which is also called stiffness degradation, occurred due to the microstructural changes during recycling processes, including melting and casting. It can be seen in Figure 12 that the steel was oxidized throughout the melting process, with an abundance of ferric oxides observed under SEM. The presence of pores and voids is also contributing to lower steel strength and density. Without the addition of 200g of carbon riser and 300g of ferrosilicon as catalysts, the steel porosity will be higher, which can make the steel even The idea of carbon riser addition was to ensure that the carbon is uniformly distributed throughout the molten steel and increase its strength, while the addition of ferrosilicon was to remove unwanted oxides and reduce the porosity of steel. Alias et al. Evaluation of recycled steel properties originating from construction A p-ISSN: 1410-2331 e-ISSN: 2460-1217 the carbon content of the recycled steel specimen This shows that the addition of a carbon riser was inappropriate for molten steel during the melting process. In comparison to mild steel that is commonly used in the steel industry, the yield and ultimate strength of recycled steel are significantly lower than mild steel, as in Table 2. Figure 12. SEM images of . raw reinforcement bar, and . recycled steel specimen under 50m Table 1. Summary of key parameters on the tensile behavior of recycled steel specimens Specimen YoungAos modulus. E (MP. Strain stiffness. Esh (MP. Proof yield strength, fy,0. (MP. Fracture strength, ff (MP. Proof, yield strain. Ay,0. 2 (%) Fracture strain. Af (%) ST1 ST2 ST3 Average Besides, decarburization occurs during the steel melting process with the presence of oxygen or hydrogen, as steel loses carbon atoms, hence, reduced in strength and toughness . efer to . This is also related to the impurities, such as rust that are rich in oxygen. Rust or iron oxides can combine with other elements in the steel to form other metallic compounds, thus weakening the yayceycC ya = yayce yaycC This can be seen through the XRF and EDX results of raw construction steel and recycled steel specimens, respectively, as in Figure 13 which presents the elemental details of raw construction steel and recycled steel specimens. The percentage of carbon atoms in raw construction steel was higher compared to that carbon atoms in the recycled steel specimen. This proves that the removal of carbon atoms through decarburization has occurred in the steel melting The optimum amount of carbon for mild steel is typically between 0. 05% and 0. But Compressive Properties of Recycled Steel The compressive test results of recycled steel originating from construction steel waste were presented in Figure 14 and summarized in Table 3. The compressive strength of the recycled steel specimen was found to be 183. 87 MPa on Due to high porosity, the compressive strength of the recycled steel specimen was notably lower than mild steel . fu = 250 MP. Based on the 0. 2% plastic strain, the recycled steel specimen SCM-1 has a yield strength value 758 MPa, specimen SC-2 was 38. 803 MPa, while SC-3 was 43. 28 MPa. Toughness of Recycled Steel The results of the Charpy Impact test are summarized in Table 4. Assuming that the energy loss due to friction was negligible, the average energy loss due to breakage of the V-notch specimen was KV = 24J (Refer Table . The failure mechanism of V-notch specimens involved the splitting of the specimens into two pieces, which is commonly referred to as the cleavage The surface fracture exhibited a shiny look with a combination of white and grey hues. The visual examination of the specimens confirms that the recycled steel specimen exhibited brittleness, which further supports the findings of the monotonic tensile test. Table 2. Comparison of recycled steel specimens to mild steels available in the industry Specimen YoungAos Modulus (GP. Yield Strength (MP. Ultimate Strength (MP. Recycled S275 . Reclaimed steel by wall-saw cutting . Reclaimed steel by wire-saw cutting . Alias et al. Evaluation of recycled steel properties originating from construction A SINERGI Vol. Vol. No. October 2025: 845-856 Figure 13. Elemental details of: . raw construction steel using handled XRF, and . recycled steel specimen using EDX analysis Figure 14. Compressive stress-strain of the recycled steel specimen Alias et al. Evaluation of recycled steel properties originating from construction A p-ISSN: 1410-2331 e-ISSN: 2460-1217 Table 3. Summary of key parameters on compressive properties of the recycled steel Specimen Ultimate Compressive Strength, fu (MP. Yield Compressive Strength, fy (MP. SC1 SC2 SC3 Average Table 4. Key parameters on impact strength of the recycled steel specimens. Specimen Energy loss due KV (J) Impact (J/mm. SI1 SI2 SI3 Average Table 5. Comparison of impact strength of the recycled steel specimens to S275JR grade mild steel at room temperature . AC). Specimen Recycled steel S275JR . Energy loss due to KV (J) Impact (J/mm. In comparison (Refer Table . , a typical impact strength of an S275 grade mild steel is 0. J/mm2, which is slightly higher than the recycled steel specimen. This may be due to the density difference between recycled steel and S275JR mild steel. A lower impact strength indicates that the recycled steel has poor toughness and is more susceptible to brittle fracture under impact loading Several possible causes of its low impact strength include the presence of impurities and the inappropriate rapid cooling rate of molten steel after the melting process. Thus, the recycled steel specimen cannot be used for applications where a minimum of S275JR is specified. CONCLUSION In summary, the study successfully achieved its objectives. Based on the findings, it is evident that none of the recycled steel specimens met the requirements for conventional steel All the test specimens exhibited brittle behavior under different stress states, which are characterized by brittle fracture without any visible necking before reaching the fracture point. This behavior could be attributed to the presence of voids that lead to high porosity, the residual impurities are not totally removed such as rust, and the decarburization of steel during melting process which has reduced the carbon content of remelted steel as proven through SEM and EDX In terms of toughness, the tested specimens demonstrated an average energy loss of KeV 24J due to the breakage of V-notch specimens, with the V-notch specimens splitting into two pieces, indicating an expected cleavage These findings suggest a significant deviation from the standards of conventional steel Therefore, the output from this study highlights the need for further improvement in future research. For future investigations, it is essential to segregate the quality of the recycled steel waste used according to its sources. Additionally, to prevent defects such as porosity, voids, and the formation of honeycomb, an optimum amount of carbon riser and ferrosilicon should be added during the melting process. Precautionary steps during melting and casting, such as setting the holding temperature above the flow point, can help prevent impurities in the finished product. Finally, enhancing the number of samples tested and sorting them according to the category of recycled steel waste would further enhance the validity of the research. Finally, it is beneficial if a network of advanced steel recycling facilities in Malaysia is equipped with technologies for refining and enhancing the quality of recycled steel to meet industry standards while developing a guideline to ensure uniformity in dealing with steel recycling. ACKNOWLEDGMENT The Authors would like to thank Universiti Teknologi MARA (UiTM) for their facilities and experts in completing this research successfully, and Geran Insentif Penyeliaan (GIP) for financial support to the author throughout this research REFERENCES