Design improvements There is a growing interest in reducing carbon emissions related to concrete from both the academic and industrial sectors, especially with the possibility of future
carbon tax implementation. Several approaches to reducing emissions have been suggested.
Cement production and use Carbon emissions from cement manufacture are high because of the high temperatures required to produce
clinker. A major component of clinker is
alite (Ca3SiO5). Alite is produced at 1,500 °C in the clinker-forming process. Some research suggests that alite can be replaced by a different mineral, such as
belite (Ca2SiO4). Belite is also a mineral already used in concrete. It has a roasting temperature of 1,200 °C. Furthermore, belite actually cures to give stronger concrete. However, belite takes on the order of days or months to set completely, which leaves concrete weak for longer. Belite takes more energy to grind, which may make its full life of impact similar to or even higher than alite. Another approach has been the partial replacement of conventional clinker with such alternatives as fly ash,
bottom ash, and slag, all of which are by-products of other industries that would otherwise end up in
landfills. Fly ash and bottom ash come from
thermoelectric power plants, while slag is a waste from
blast furnaces in the ironworks industry. These materials are slowly gaining popularity as additives, especially since they can potentially increase strength, decrease density, and prolong durability of concrete. One obstacle to wider implementation of fly ash and slag may be largely due to the risk of construction with new technology that has not been exposed to long field testing. Until a carbon tax is implemented, companies are unwilling to take the chance with new concrete mix recipes even if this reduces carbon emissions. However, there are some examples of "green" concrete and its implementation. One instance is a concrete company called Ceratech that has started manufacturing concrete with 95% fly ash and 5% liquid additives. Several startup companies are developing and testing alternative cement production methods. Sublime of
Somerville, Massachusetts uses a no-kiln
electrochemical process, and Fortera captures carbon dioxide from conventional plants to make a new kind of cement. Blue Planet of
Los Gatos, California captures emitted carbon dioxide to produce synthetic concrete.
CarbonCure Technologies of
Halifax, Nova Scotia has retrofitted its
carbon mineralization systems at hundreds of concrete plants around the world, injecting and permanently storing carbon dioxide in concrete as it is being mixed. Furthermore, the production of concrete requires large amounts of water, and global production accounts for almost a tenth of worldwide industrial water use. This amounts to 1.7 percent of total global water withdrawal. A study that appeared in
Nature Sustainability in 2018 predicts that concrete production will in the future increase pressure on water resources in regions susceptible to drought conditions, writing, "In 2050, 75% of the water demand for concrete production will likely occur in regions that are expected to experience water stress".
Carbon concrete Carbonatation, sometimes called carbonation, is the formation of
calcium carbonate (CaCO3) by chemical reaction, which, if used in concrete, can sequester carbon dioxide. The speed of carbonation depends primarily on the
porosity of the concrete and its
moisture content. Carbonation in concrete pores happens only at a
relative humidity (RH) of 40-90%—when RH is higher than 90%, carbon dioxide cannot enter the concrete pores, and when RH is lower than 40%, cannot be dissolved in water. Concrete can be carbonated by two main methods: weathering carbonation and early age carbonation. Weathering carbonation occurs in concrete when calcium compounds react with carbon dioxide (CO2) from the atmosphere and water (H2O) in the concrete pores. The reaction is as follows. First, through
chemical weathering, reacts with water in the concrete pores to form
carbonic acid: :
Carbonic acid then reacts with
calcium hydroxide to form
calcium carbonate and water: : Once the
calcium hydroxide (Ca(OH)2) has sufficiently carbonated, the main component of cement,
calcium silicate hydrate gel (C-S-H), can be decalcified, i.e., liberated
calcium oxide (CaO>) can carbonate: : Early age carbonation is when is introduced to the early stages of fresh premix concrete or upon initial curing, which can occur both naturally through exposure or be artificially accelerated by augmenting a direct intake of . : : A Canadian company patented and commercialized a novel technology that uses early age carbonation to sequester . This is achieved by directly injecting recycled
liquid carbon dioxide from third-party industrial emitters into the concrete wet-mix stage during the manufacturing process. is then chemically mineralized, sequestering the greenhouse gas pollutant in concrete infrastructure, buildings, roads, etc. for long periods of time. In a study published in the
Journal of Cleaner Production, the authors created a model showing that sequestered improved the
compressive strength of concrete while reducing emissions, thus allowing for a cement loading reduction while also having a "4.6% reduction in the carbon footprint". Another proposed method of capturing emissions is to absorb CO2 in the
curing process through the use of an
admixturespecifically, a
dicalcium silicate in phaseas the concrete cures. The use of fly ash or another suitable substitute could theoretically bring CO2 emissions below 0 kg/m3, compared to
Portland cement concrete emissions of 400 kg/m3. The most effective method of production of this concrete would use the exhaust gas of a power plant, where an isolated chamber could control temperature and humidity. In August 2019, reduced CO2 cement was announced which "reduces the overall
carbon footprint in
precast concrete by 70%". The base of the cement is primarily
wollastonite (CaSiO3) and
rankinite (3CaO·2SiO2), in contrast to traditional
Portland cement, based on
alite 3CaO·SiO2) and
belite (2CaO·SiO2). The patented process of reduced-emissions concrete manufacture begins with the bonding of particles through liquid phase
sintering, also referred to as reactive hydrothermal liquid-phase densification (rHLPD). A solution of water and penetrates the particles, reacting in ambient conditions to form a bond which creates reduced-
lime, non-hydraulic calcium silicate cement (CSC). The difference between traditional
Portland concrete and these carbonated calcium silicate concrete (CSC-C) lies in the final curing process reaction between a water- solution and a family of calcium-silicate. According to a study of one reduced-emissions cement, called Solidia, "CSC-C curing is a mildly
exothermic reaction in which the low-lime calcium silicates in the CSC react with CO2 in the presence of water to produce
calcite (CaCO3) and
silica () as follows: : However, as early age carbonation methods have gained recognition due to their substantial
carbon sequestration proficiencies, some authors have argued that the effect of early-age carbonation curing may succumb to weathering carbonation later on. For example, a 2020 article writes, "Experimental results suggest that early-age carbonated concretes with high
w/c ratios (>0.65) are more likely to be affected by weathering carbonation". The article cautions that this may weaken its strength abilities in the corrosion stages during life service. Italian company
Italcementi designed a kind of cement that is supposedly alleviating air pollution by breaking down pollutants that come in contact with the concrete, through the use of
titanium dioxide absorbing
ultraviolet light. Some environmental experts nevertheless remain skeptical and wonder if the special material can "eat" enough pollutants to make it financially viable.
Jubilee Church in
Rome is built from this kind of concrete. Another aspect to consider in carbon concrete is surface scaling due to cold climatic conditions and exposure to de-icing salt and freeze-thaw cycles (
frost weathering). Concrete produced by carbonation curing also shows superior performance when subject to physical degradations, e.g., freeze-thaw damage, particularly due to a pore densification effect enabled by the precipitation of carbonation products The vast majority of CO2 emissions from concrete come from cement manufacturing. Therefore, methods to reduce cement materials in each concrete mix are the only known methods to reduce the emissions.
Photocatalysis to reduce smog Titanium dioxide (TiO2), a
semiconductor material shown to exhibit
photocatalytic behavior, has been incorporated into an experimental concrete. The resulting material mitigates NOx pollution.
Embedded solar cells Dye-sensitized solar cells embedded in concrete has been proposed as a method of reducing the carbon and energy footprints of buildings. The usage of embedded solar cells allows for on-site energy generation, which when coupled with batteries, would provide constant power throughout the day. The top layer of the concrete would be a thin layer of dye-sensitized solar cells. Dye-sensitized solar cells are particularly attractive due to its ease of mass production, either via roll-printing or painting, and a reasonably high efficiency of 10%. One example of the commercialization of this concept is the German company Discrete, which produces a dye-sensitized solar cell embedded concrete product. Their process uses a spray-coating method to apply organic dyes that generate electricity onto concrete.
Energy storage Energy storage has become an important consideration for many renewable energy generation methods, especially for popular methods such as solar or wind energy, both of which are intermittent energy producers that require storage for constant use. Currently, 96% of the world’s energy storage comes from
pumped hydro, which uses excess generated electricity to pump water up a dam and then allowed to fall and turn turbines that produce electricity when the demand exceeds generation. The problem with pumped hydro, however, is that the setup requires specific geographies that can be difficult to find. A similar concept that uses cement instead of water has been realized by Energy Vault, a Swiss startup. They created a setup that uses an electric crane surrounded by stacks of 35-ton concrete blocks, which can be produced using waste products, to store energy by using excess energy generation to power the crane to lift and stack the concrete blocks. When energy is needed, the blocks are allowed to fall and the rotated motor would send energy back to the grid. The setup would have a storage capacity of 25-80 MWh.
Other improvements "Smart" concretes use electrical and mechanical signals to respond to changes in loading conditions. One variety uses carbon fiber reinforcement which provides an electrical response that can be used to measure strain. This allows for monitoring the structural integrity of the concrete without installing sensors. The
road construction and maintenance industry consumes tons of
carbon-intensive concrete every day to secure road-side and urban infrastructure. As populations grow this infrastructure is becoming increasingly vulnerable to impact from vehicles, creating an ever increasing cycle of damage and waste and ever increasing consumption of concrete for repairs (roadworks are now seen around our cities on almost a daily basis). A major development in the infrastructure industry involves the use of recycled petroleum waste to protect the concrete from damage and enable infrastructure to become dynamic, able to be easily maintained and updated without disturbance to the existing foundations. This simple innovation preserves the foundations for the entire lifespan of a development. Another area of concrete research involves the creation of certain
“waterless” concretes for use in extraplanetary colonization. Most commonly, these concretes use sulfur to act as a non-reactive binder, allowing for construction of concrete structures in environments with no or very little water. These concretes are in many ways indistinguishable from normal hydraulic concrete: they have similar densities, can be used with currently existing metal reinforcement, and they actually gain strength faster than normal concrete This application has yet to be explored on Earth, but with concrete production representing as much as two-thirds of the total energy usage of some developing countries,
Clay Mixtures of
clay are an alternative construction material to concrete that have a lower environmental footprint. In 2021, the first
prototype 3D printed house,
Tecla, printed from locally sourced soil and water as well as fibers from
rice husks and a binder was completed.
Such buildings could be very inexpensive, well-insulated, stable and weatherproof, climate-adaptable, customizable, get produced rapidly,
require only very little easily-learnable manual labor, require less energy, produce very little waste and reduce carbon emissions from concrete. ==Surface runoff==