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An environmental and business game changer

A concrete without portland cement? That’s right. No portland cement and its related CO2 emissions.

Sustainacrete™ is a sustainable alternative to portland cement concrete. It uses locally-sourced fly ash that energy utilities dispose of in landfills. Fly ash is a byproduct of burning coal in power plants.

This innovative geopolymer product is ideal for use in precast concrete products. It sets rapidly, costs less, and is more reliably priced and consistently available than portland cement. It is produced using the same equipment you use now. And it looks like, smells like, and cleans up like concrete.

The production of portland cement concrete (PCC) requires large kilns burning fossil fuels; this process is responsible for around five to 10 percent of the world’s global carbon dioxide (CO2) emissions. That’s equal to the emissions from every car in the U.S. and half of the cars in Europe!

Portland cement currently is used in the production of almost all concrete, the second most-consumed substance on earth after water.

Sustainacrete™ fly ash is a byproduct so it does not go through a manufacturing process.

 Portland Cement
Concrete
Sustainacrete™ geopolymer cement concrete
Compressive strengthas requiredas required
Set Timeusually 90 minutesas needed
Curingwater/chemicalsheat
Permeabilitylowlower
Thermalsamesame
Moisture Reactionhydrationcondensation
Fire resistancehighhigher
Aggregate usedsamesame
Portland Cementpartial to allnone
Fly Ash Class Cnone to partialpartial
Recycled Materialsnone to partialall
Colorgraylight gray
Sourcecement companiescoal-fired power plants
   

When we say Sustainacrete™ is a game-changer, we’re not just blowing smoke. We’ve got the science to back it up.

Portland cement concrete is produced by a mixture of aggregates and paste formed from cement and water. The paste coats the aggregates and through a chemical reaction called hydration, hardens and gains strength to form what we know as concrete. Once poured, this concrete is cured to ensure the continued hydration of the cement so the concrete gains strength.

Sustainacrete™ geopolymer concrete is produced by a mixture of aggregates and paste formed from fly ash and an alkaline solution, but the chemical reaction uses condensation to harden the mixture into concrete. Sustainacrete™ is heat cured.

PCC vs GCC chemistry

Portland cement concrete hardens through hydration of calcium silicate into calcium silicate hydrate (C-S-H) and portlandite, Ca(OH)2. Geopolymer cement concrete hardens through poly-condensation of potassium oligo-(sialate-siloxo) into potassium poly(sialate-siloxo) cross linked network (Source: Wikipedia).

Preliminary test results showing geopolymerization

Batch #1 Preliminary results
showing geopolymerization
Slump, inches 2-3/4
Air content, % 1.5
Unit weight, pcf 146.4
Temperature, °F 70
Compressive strength, psi (avg of two tests) Precast plant cure
24 hours 2000
3 days 2,820
6 days 2,970
7 days 3,260
28 days 3,680

A proof of concept test was performed to show geopolymerization. The strength gain characteristics showed early strength gain. Microscope images and x-ray diffraction showed calcium aluminates and other typical geopolymer condensates.

Photos tell the story

Conventional calcium silicate hydrate structure from hydration.
Condensate structure of Geopolymer
Condensate structure of geopolymer.
Energy dispersive assay showing atomic distribution.
Energy dispersive assay showing atomic distribution.

Sustainacrete™ is a custom-blended material that is proportional to meet your requirements for setting, strength gain and durability.