Incorporating waste materials into low-carbon concrete production: from laboratory to commercial scale

The Mevocrete project is pioneering the use of next-generation low-carbon feedstocks, derived from mineral and industrial by-products to develop alternative supplementary cementitious materials that offer significantly lower embodied carbon without relying on legacy materials like ground granulated blast furnace slag and fly ash.

Challenge

The construction industry is a significant contributor to global CO2 emissions, accounting for approximately 11% of the global total. The Mevocrete project is pioneering the use of next-generation low-carbon feedstocks, derived from mineral and industrial by-products to develop alternative supplementary cementitious materials that offer significantly lower embodied carbon without relying on legacy materials like ground granulated blast furnace slag and fly ash.

The high production of concrete and its contribution to emissions create an opportunity for innovative and greener solutions. The UK government has set a target of achieving net zero emissions by 2050, and geopolymer technology can be used as a tool to help achieve this goal through concrete manufacturing.

Solution

Incorporating steel slag waste materials into concrete production, this process involved testing to optimise conditions for enhancing CO2 capture within the waste materials prior to their integration into the concrete mix. This innovative approach has provided crucial insights into the initial capacity of waste materials for CO2 sequestration.

A geopolymer concrete was developed, using carefully selected waste materials and subjected it to curing under CO2-enriched conditions. The findings showed success in achieving a CO2 capture capacity of approximately 150-200 kg per tonne of geopolymer concrete.

A comprehensive Life Cycle Assessment was conducted in accordance with ISO 14040/14044 standards, comparing the impacts of geopolymer concrete with those of traditional concrete materials. This assessment covered various impact categories, including both midpoint factors like global warming potential and resource depletion, as well as endpoint factors such as human health and ecosystem quality, for the waste derived geopolymer concrete products.

This ground-breaking innovation has facilitated a full evaluation of how integrating waste materials into concrete production can offer an effective means to reduce greenhouse gas emissions across diverse industries and move closer to achieving net-zero targets by 2050.

Impact

Considering the rapid increase in the construction industry and its need for cement and concrete materials around the world, this project considered as one of the highest priority projects for the UK government to significantly reduce CO2 emissions in the construction sector. The results of this unique research have resonated to have a big impact in several key areas:

Environmental benefits: Mevocrete significantly reduced greenhouse gas emissions, contributing to the goal of achieving net-zero strategies.

Economic benefits and job creation: By introducing new methods to the concrete industry, this project has created several jobs for the current and future timelines. Additionally, by supporting businesses that focus on eco-friendly building materials, it has helped to improve the economy.

Improved waste management: Mevocrete offers a chance to reuse million tons of waste materials in the UK, keeping them away from landfills.

Innovative green concrete: Mevocrete creates advanced green concrete that is stronger, more durable, and a sustainable material compared to traditional concrete in the construction sector and other industries.