A Roadmap for Production of Cement and Concrete with Low-CO2 Emissions

Abstract

This review will show that low-CO2 cements can be produced to give superior durability, based on a sound understanding of their microstructure and how it impacts macro-engineering properties. For example, it is essential that aluminium is available in calcium-rich alkali-activated systems to offset the depolymerisation effect of alkali cations on C-(N-)A-S-H gel. The upper limit on alkali cation incorporation into a gel greatly affects mix design and source material selection. A high substitution of cement clinker in low-CO2 cements may result in a reduction of pH buffering capacity, hence susceptibility to carbonation and corrosion of steel reinforcement. With careful mix design, a more refined pore structure and associated lower permeability can still give a highly durable concrete. It is essential to expand thermodynamic databases for current and prospective cementitious materials so that concrete performance and durability can be predicted when using low-CO2 binders. Cationic copolymer and amphoteric plasticisers, when available commercially, will enhance the development of alkali-activated materials. The development of supersonic shockwave reactors will enable the conversion of a wide range of virgin and secondary source materials into cementitious materials, replacing blast furnace slag and coal fly ash that have dwindling supply. A major obstacle to the commercial adoption of low-CO2 concrete is the prescriptive nature of existing standards and design codes, so there is an urgent need to shift towards performance-based standards. The roadmap presented here is not an extension of current cement practice, but a new way of integrating fundamental research, equipment innovation, and commercial opportunity.

Graphic Abstract

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Abbreviations

AAFA:

Alkali-activated fly ash

AAGBS:

Alkali-activated ground granulated blast furnace slag

AAM:

Alkali-activated materials

AAMK:

Alkali-activated metakaolin

AFm:

Aluminate ferrite monosulphate

AFt:

Aluminate ferrite tri-sulphate

ASR:

Alkali silica reaction

BFRP:

Basalt fibre reinforced polymer

CAC:

Calcium aluminate cement

C-(N,K-)(A-)S-H:

Calcium (alkali) (alumino)silicate hydrate

C-A-S-H:

Calcium aluminosilicate hydrate

C-S-H:

Calcium silicate hydrate

C2S:

Dicalcium silicate

DFT:

Density functional theory

EESS:

Electrically-enhanced supersonic shockwave reactor

FA:

Coal fly ash

GBS:

Ground granulated blast furnace slag

GDP:

Gross domestic product

LC3 :

Calcined clay limestone cements

LDH:

Layered double hydroxide

MCL:

Mean chain length

N-A-S(-H):

Alkali aluminosilicate hydrate

NMR:

Nuclear magnetic resonance

OPI:

Oxygen Permeability Index

PC:

Portland cement

PCE:

Polycarboxylate ethers

PDF:

Pair distribution function

SCM:

Supplementary cementitious material

TEM:

Transmission electron microscopy

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Acknowledgements

RJM acknowledges funding provided by the Engineering and Physical Sciences Research Council of the U.K. (EP/S006079/1). The research leading to this publication benefitted from EPSRC funding under Grant No. EP/R010161/1 and from support from the UKCRIC Coordination Node, EPSRC grant number EP/R017727/1, which funds UKCRIC’s ongoing coordination. CEW acknowledges financial support from Grant Nos. 1362039 and 1553607 and the MRSEC Center (Grant No. DMR-1420541) from the National Science Foundation, USA. Access to the Princeton Institute for Computational Science and Engineering (PICSciE) and the Office of Information Technology’s High Performance Computing Center and Visualization Laboratory at Princeton University is acknowledged. Unpublished pore structure and permeability data were obtained and analysed by Kengran Yang, Anna Blyth and Bridget Zakrzewski (Princeton University).

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Jannie S.J. van Deventer declares a conflict of interest through the commercial application of electrically-enhanced supersonic shockwave reactors for the processing of minerals, secondary sources and cementitious materials. RJM and CEW declare no conflict of interest.

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van Deventer, J.S.J., White, C.E. & Myers, R.J. A Roadmap for Production of Cement and Concrete with Low-CO2 Emissions. Waste Biomass Valor (2020). https://doi.org/10.1007/s12649-020-01180-5

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Keyword

  • Alkali-activated material
  • Cementitious materials
  • Commercialisation
  • Durability
  • Standards
  • Thermodynamic modelling