- Article
End-of-life mattresses constitute a bulky waste stream whose valorisation is constrained by material heterogeneity, large unit volume, and the intensity of dismantling and separation operations. Based on the experimental campaign conducted within the pilot project RESTBUILT: Valorisation of Used Mattresses as Construction Materials, this study evaluates the hypothesis that mechanical processing intensity can be treated as a design variable governed by the requirements of the receiving product. Post-consumer mattresses were selected typologically at a waste treatment facility. Starting from whole mattress shredding, two complementary experimental routes were developed, not conceived as a controlled comparative experiment: Route A, involving low-intensity processing based on coarse shredding and lightweight panels, and Route B, involving more intensive processing, with milling to ≤2 mm and incorporation of the waste into mineral matrices. In Route B, specific milling energy consumption was estimated from the rated power of the equipment and the recorded processing time, yielding 3.27–6.29 kWh/kg at laboratory scale. Volumetric substitutions of 5–10% in gypsum mortars maintained compressive strengths close to the reference (22.40–23.01 MPa versus 22.25 Mpa), although flexural strength decreased at the 10% dosage and thermal conductivity increased relative to the reference mortar. In Route A, reducing binder content prevented the formation of a continuous cementitious matrix and visually preserved a greater proportion of the porous structure of the shredded material. A non-standard comparative thermal test using a cold chamber was used as a preliminary comparative assessment of panel behaviour. Overall, the results support the feasibility of minimal processing as a process-design principle, but they do not allow differences between routes to be attributed exclusively to particle size or yet demonstrate an overall environmental advantage. The study should be interpreted as a proof of concept that identifies critical variables, experimental limitations, and subsequent validation pathways.
12 November 2026








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