NEWS
Producing ultra-low carbon concrete with Grange Quarry
Material Evolution’s goal is to decarbonise the construction industry by producing ultra-low carbon cement. We are currently on track to save one gigaton of carbon by 2040, and it is through partnerships with those in the ready-mix concrete sector that will help us get there.
One such example is our recent work with Grange Quarry, one of the largest suppliers of high quality aggregates and ready-mix concrete in Southwest Scotland and North Cumbria. In a recent trial, Grange Quarry and Material Evolution collaborated to cast a large concrete slab, intended for external paving.
Watch the video below to learn more about the trial:
What is low-carbon cement?
Low-carbon or ultra-low carbon cement is produced with a lower carbon footprint in both production and use than traditional cement, such as Ordinary Portland cement (OPC). OPC is typically produced by burning limestone at 1,400 degrees Celsius, using coal or gas to fuel the energy-intensive kilns, which produce a large amount of carbon dioxide as a result. In addition, the chemical reaction itself produces carbon emissions. According to the Mineral Products Association, one tonne of OPC produces a staggering 840kg of CO2 emissions – equivalent to driving a gas-powered vehicle more than 2,500 miles.
However, at Material Evolution, we have developed an ultra-low carbon alternative, MevoCem, an ultra-low carbon binder material made from industrial by-product feedstocks using alkali fusion technology.
The process involves no heat or kilns and therefore produces ~85% less carbon than OPC, slashing emissions to just 144-196kg of CO2e per tonne. Following the launch of our Mevo A1 facility in Wrexham, we are able to produce our flagship product at scale.
What is alkali fusion?
Alkali fusion is a mechano-chemical reaction that occurs when using a very high energy mechanical treatment to increase the reactivity of materials, allowing them to fuse to the structure of another compound. In the case of alkali fusion cement, this process occurs when supplementary cementitious materials are combined with an alkali, which triggers their activation upon addition of water.
As we source our ingredients from industrial byproducts and waste feedstocks, we also use artificial intelligence and machine learning technology to predict how these waste materials will react when the alkali fusion process takes place. The result is a high-performance replacement for cement that is used to make concrete, with positive impacts on durability and strength of the final product.
Dr. Andrew Longstaff, senior scientist at Mevo, said: “The polymerisation that happens in the production of MevoCem results in higher chloride, sulfate and acid resistance and therefore gives better durability to products.”
Producing ultra-low carbon concrete with Grange Quarry
With Grange Quarry, our trial intended to demonstrate the manufacture of ready-mix concrete without the use of OPC, while still satisfying PAV2 classification in accordance with BS8500.
BS8500 is the main UK standard that dictates what can and can’t be classified as concrete, though it currently dictates that some amount of OPC must be used. However, a key update from September 2024, called Flex350, will allow the industry to measure concrete on a performance basis. The code of practice provides stringent cement and concrete testing procedures that must be carried out to ensure that new low-carbon concrete specification can be more readily considered.
The recent plant trial included producing a concrete slab using ~9 m3 of MevoCem concrete at Grange Quarry’s site.
Don’t just take our word for it…
Douglas Stewart, quality and technical manager at Grange Quarry Limited, said: “This was a really unique project and we could see some genuine structures being built without the use of OPC. Prior to having worked with Mevo, I probably wouldn’t have said that. We are making concrete without cement, and I didn’t think we would see that.”
Stuart Dodd, managing director of Grange Quarry Limited, said: “Our relationship with Material Evolution started around 12 months ago, we were excited by the product and that there was no OPC in it whatsoever. Here we are today, having successfully produced concrete, so hopefully this is the start of something new for Grange and for the wider industry. I think as an industry as a whole, we all need to look at it this way – from small scale projects to the thousand cubic base pours in wind turbines, the potential is there. OPC is such a carbon intensive product, as we know, these low carbon binders are the way forward.”
What can low carbon cement be used for in construction?
Material Evolution’s trials with Grange Quarry have shown that ultra-low carbon cement can be used for large slab pours, commonly used by Grange Quarry for the production of wind turbine bases.
As a framework provider for Scottish Water in the supply of civil materials in Scotland, worth an estimated £80 million, the implications for the application of MevoCem in Grange Quarry’s projects are enormous – and that’s just for the North of England.
Other applications of large slab pours include:
- Flooring
- Marine structures
- Walls
Driving real, sustainable impact
When we consider that 8% of global carbon emissions are produced by the cement industry, the successful application of concrete made without OPC is a huge step forward in proving that ultra-low carbon cement is not just a concept, but a practical, scalable solution for the construction industry.
Ultimately, the future of construction has to be low-carbon if we are to combat climate change and reach the UK’s goal of achieving net zero by 2050. As concrete is the second most-used commodity on the surface of the earth, we have a very real opportunity to make an impact – one large slab pour at a time.
Get in touch with our team to find out more about how we can support your ready-mix application and accelerate the adoption of low-carbon concrete together.