science & techanalysisThe Conversation (Australia)

It’s possible to make great concrete without the huge emissions from cement. Why isn’t this common?

the gist

Concrete is the most used human-made material on Earth and causes 5-8% of global CO2 emissions, almost all of it from cement, the glue that binds sand and gravel. Portland cement, the method used for two centuries, heats limestone to about 1400°C; the rock breaks down and releases carbon dioxide, and coal- or gas-fired kilns add more. A proven alternative is geopolymer concrete, which swaps limestone cement for industrial byproducts such as fly ash and blast-furnace slag, activated with alkaline chemicals like sodium hydroxide. It can cut emissions by up to 80%. Queensland's Wellcamp Airport used about 40,000 cubic metres of it in 2014, yet it has barely spread since.

how it works

Fly ash or slag is mixed with an alkaline activator such as sodium hydroxide. The chemical reaction turns these mineral wastes into a hard, ceramic-like binder that sets around sand and gravel, without ever cooking limestone, so the process-related CO2 from limestone breakdown never arises.

so what

The main brake is trust, not chemistry: ordinary concrete has around 150 years of real-world performance data, geopolymers only date from the 1980s, so builders and insurers can't yet guarantee them. Public infrastructure trials that monitor long-term performance are one way to build that evidence. Fly ash is also a waste problem, so using it turns a disposal cost into a building material.

the bigger pattern

Proven green technologies often stall on risk, not performance: construction is conservative because failures are costly and long-lived. Many innovations only scale once standards, insurers and public buyers accept them.

fun fact

If concrete were a country, its emissions would rival those of Russia or India.

more on this

background

A geopolymer is an inorganic, often ceramic-like material, that forms a stable, covalently bonded, non-crystalline to semi-crystalline network through the reaction of aluminosilicate materials with an alkaline or acidic solution. Many geopolymers may also be classified as alkali-activated cements or acid-activated binders. They are mainly produced by a chemical reaction between a chemically reactive aluminosilicate powder e.g. metakaolin or other clay-derived powders, natural pozzolan, or suitable glasses, and an aqueous solution (alkaline or acidic) that causes this powder to react and re-form into a solid monolith. The most common pathway to produce geopolymers is by the reaction of metakaolin with sodium silicate, which is an alkaline solution, but other processes are also possible.

The term geopolymer was coined by Joseph Davidovits in 1978 due to the rock-forming minerals of geological origin used in the synthesis process. These materials and associated terminology were popularized over the following decades via his work with the Institut Géopolymère (Geopolymer Institute).

From Wikipedia: Geopolymer (CC BY-SA 4.0) ↗ · text CC BY-SA 4.0

The Conversation

Illustrative photo · Eva Santini, Michela E. Pedretti, Giovanna Canu, CNR-ICMATE, CC BY 4.0, via Wikimedia Commons