A Review on Fraction-Wise Utilization of Wire-Cut Cable Insulation Waste for Construction and Composite Applications

Abstract

Wire-cut insulation waste generated during cable processing and e-waste recycling is often discarded due to its mixed composition, irregular particle size, and limited direct reuse options. However, this waste contains valuable polymeric materials and mineral fillers that can be effectively repurposed when properly understood. This review focuses on the characterization and utilization potential of wire-cut cable insulation waste, with special emphasis on size-based fractionation and construction-related applications. Existing studies highlight that cable insulation waste mainly consists of plasticized polyvinyl chloride (PVC), polyethylene-based polymers, and a significant amount of calcium carbonate (CaCO₃) filler, along with trace amounts of residual copper. Characterization techniques such as sieve analysis, Fourier Transform Infrared Spectroscopy (FTIR), and X-ray Diffraction (XRD) are commonly used to identify particle size distribution, polymer composition, and crystalline mineral phases. These techniques provide critical insight into how different fractions of the waste behave in composite and construction materials. This review discusses how sieve-based separation enables fraction-wise utilization of insulation waste, where coarse fractions act as lightweight aggregates or cushioning fillers, medium fractions contribute to acoustic and insulation performance, and fine fractions behave as mineral-rich fillers suitable for cementitious and resin-based composites. Applications in lightweight concrete, cement mortar, quarry dust blends, and resin-bonded panels are highlighted from recent literature. By adopting a fraction-wise approach rather than treating insulation waste as a single bulk material, improved material performance, better resource efficiency, and reduced environmental impact can be achieved. The review also identifies current research gaps and future opportunities for optimizing mix design and performance evaluation, supporting the sustainable integration of wire-cut insulation waste into construction and composite materials.