We promote the recovery of end-of-life tires in Manresa: an example of the circular economy 

A new generation of urban surfaces—from playgrounds and running tracks to bike lane dividers—is being built with a surprising ingredient: recycled rubber from discarded tires. In Spain, where annual ELT production reaches approximately 300,000 tons, this material has the potential to turn waste into opportunity. Since 2016, our Granulated Rubber Project (GRP) plant in Manresa (Barcelona) has been leading the way, turning discarded tires into high-value products while showcasing how innovation and sustainability can go hand in hand in modern industrial practices.

Cutting-edge technology at the service of recycling

The Manresa facility, known as the Granulated Rubber Plant (GRP), combines two dedicated production lines with advanced processing equipment designed for high efficiency and precision. The operation begins with primary shredding, which reduces end-of-life tires (ELTs) into fragmented material while preparing them for further refinement. In the secondary stage, high-capacity mills further grind the fragments, simultaneously liberating and separating steel and textile fibers from the rubber matrix.

Following this, the rubber granules pass through a series of screening and particle size classification systems, enabling precise calibration of the final product to meet the specifications required for diverse industrial and urban applications. Depending on their intended use, the processed granules are either bagged in large-volume sacks for storage or transported in bulk to downstream users. Every stage of this workflow is carefully engineered to maximize material recovery, ensure consistent product quality, and minimize the loss of valuable resources, illustrating how advanced technology can transform complex waste streams into high-value industrial inputs.

Two outlets for the same waste

The Manresa facility processes rubber into two distinct output materials. One stream consists of chips and fragments designated for energy recovery. These are supplied directly to our cement plant in Sant Vicenç dels Horts (Barcelona), where they are employed as an alternative kiln fuel. Particle size is meticulously defined through combustion analyses carried out by the R&D department, a process designed to optimize thermal efficiency and reduce emissions in line with best practices for sustainable clinker production.

The second stream consists of granules of varying sizes, engineered for diverse industrial and urban applications. These include safety pavements for playgrounds, running tracks, artificial turf infill, road surfaces, and even elements of urban furniture such as bike lane dividers. This wide spectrum of uses underscores how a complex waste stream can be revalorized into high-value products, advancing circular economy practices within the sector.

Nine years of results with millions of recycled tires

In nearly a decade of continuous operation, the Manresa plant has processed almost 20 million end-of-life tires (ELTs), recovering thousands of tons of rubber, steel, and textile fibers for reintroduction into the value chain. The facility operates through a five-stage treatment system—primary shredding, initial screening, secondary grinding, secondary screening, and final separation of components—designed to maximize resource recovery and ensure that every tire is utilized to its full potential.

The Manresa project was conceived to achieve a dual purpose: divert end-of-life tires (ELTs) from landfills and reduce dependence on finite natural resources. By converting ELTs into energy, the facility supplies alternative kiln fuels that partially replace fossil inputs, while its material recovery process produces high-quality secondary raw materials for a range of industrial applications. This integrated model positions the Manresa plant as a reference point for circular economy practices within the cement and broader materials sector.

A key driver of the project’s operational efficiency is its strategic proximity to our cement plant in Sant Vicenç dels Horts, just a few kilometers away. This close location minimizes transport requirements, cutting both logistics costs and CO₂ emissions associated with distribution. By coupling advanced resource recovery with reduced environmental impact along the supply chain, the Manresa facility enhances our overall sustainability footprint while demonstrating that industrial-scale circular economy initiatives can deliver both ecological and economic value.

The contribution to the Sant Vicenç dels Horts cement plant has been particularly impactful. Today, 55% of the energy consumed in its kilns is derived from alternative fuels, with ELTs representing one of the most relevant inputs. This substitution not only decreases reliance on traditional fossil fuels such as petroleum coke but also plays a decisive role in lowering the carbon intensity of clinker production. By integrating ELT-derived fuels into its process, we advance both its decarbonization roadmap and the sector’s broader commitment to sustainable cement manufacturing.

ELT recycling as part of a broader sustainability vision

End-of-life tire recycling represents just one pillar of our comprehensive sustainability strategy. The company is firmly committed to incorporating recycled and alternative materials across all areas of its business, a vision exemplified by the Alternative Raw Materials Plant inaugurated in Barcelona in 2022.

This facility specializes in the treatment of construction, demolition, and industrial waste, converting it into high-quality secondary raw materials that can be reintegrated into new products. In a little over two years of operation, it has already recovered more than 193,000 tons of material, with a 25% year-on-year increase recorded in 2024 alone. Beyond diverting large volumes of waste from landfill, the plant plays a critical role in reducing reliance on natural resources, while ensuring that the recovered inputs meet the performance standards required by the construction industry.

Together, the Manresa tire recycling plant and the Barcelona Alternative Raw Materials Plant illustrate our dual commitment to technological innovation and the principles of the circular economy. Both initiatives demonstrate how industrial processes can be reconfigured to close resource loops, reduce environmental impact, and add long-term value to the construction supply chain.

Building a more sustainable future for construction

The Manresa facility offers a concrete example of how the sector can respond to the challenges of the 21st century. By transforming a complex waste stream into a valuable resource, the project generates environmental benefits while simultaneously creating new business opportunities, fostering technological advancement, and reinforcing the resilience of the construction ecosystem.

For us, sustainability is not a peripheral activity but a core industrial driver. By integrating research, innovation, and social responsibility, the company is proving that circular economy models can be scaled effectively within heavy industry. In this sense, the Manresa project goes far beyond being a recycling plant: it is a proof point that sustainable construction is not a distant goal but a reality already in motion.

Published in International Cement Review.