Abstract:
A Circular Economy is an economic system that values resources by keeping materials in use as long as possible, while reducing the generation of waste. Modular design a product design approach grouping similar products into independent module. The aim of this research is to show the development framework of circular modular pavement using high density polyethylene, coffee husk and phenol formaldehyde resin adhesive, to find the optimum geometry for axial load distribution to the neighboring bricks and load distribution vertically to the ground, volume and topology optimizing to reduce material consumption. The methods to complete this research starts from comparative ANSYS analysis between nine different commonly used shape with same top area but different shape and then optimizing the volume using multi objective optimization by genetic algorithm (GA) and Artificial Neural Network (ANN), the load distribution optimization is done using Response surface method (RSM) optimization. The life of the product is done by interpolating the stress with the corresponding life. Finally, the life cycle assessment method is used to assess the potential environmental impact using open LCA software Recipe Midpoint (H) 2016 method. Results in the round dumble shape have better axial load transfer efficiency having equal length and width of 288mm and thickness 54mm and optimum internal cavity dimensions of side cover thickness (19.77684mm), mid flange thickness (19.68045mm), bore depth (32.4127mm), vertical side fillet radius (20.5074mm), flange vertical fillet radius (20.44337mm), horizontal fillet radius (16.42463mm), Maximum Equivalent Stress (0.260922MPa). High density polyethylene and coffee husk modules will serve for 7 sand 3 years respectively. And at last the percentage reduction of Freshwater ecotoxicity (99%), Global warming (99.99%). Human carcinogenic toxicity (99.8%), Marine eco toxicity (99.99%), and Terrestrial acidification (98.2%) in the life cycle impact of these ecofriendly pavement brick. It can be concluded that using high density polyethylene and coffee husk wastes for brick production will significantly reduce or eliminate the potential environmental impact and substituting lack of cement, sand, and aggregate material and its high environmental impact. Key words: Circular Economy, Modular Design, Life Cycle Assessment, Topology Optimization, Response Surface Optimization, Open LCA.