Concrete is the most widely used man-made material, commonly used in buildings, roads, bridges and industrial plants. But producing the Portland cement needed to make concrete accounts for 5-8% of all global greenhouse emissions. There is a more environmentally friendly cement known as MOC (magnesium oxychloride cement), but its poor water resistance has limited its use – until now. We have developed a water-resistant MOC, a “green” cement that could go a long way to cutting the construction industry’s emissions and making it more sustainable.
Producing a tonne of conventional cement in Australia emits about 0.82 tonnes of carbon dioxide (CO₂). Because most of the CO₂ is released as a result of the chemical reaction that produces cement, emissions aren’t easily reduced. In contrast, MOC is a different form of cement that is carbon-neutral.
Many countries, including China and Australia, have plenty of magnesite resources, as well as seawater, from which both MgO and MgCl₂ could be obtained.
Furthermore, MgO can absorb CO₂ from the atmosphere. This makes MOC a truly green, carbon-neutral cement.
MOC also has many superior material properties compared to conventional cement.
Compressive strength (capacity to resist compression) is the most important material property for cementitious construction materials such as cement. MOC has a much higher compressive strength than conventional cement and this impressive strength can be achieved very fast. The fast setting of MOC and early strength gain are very advantageous for construction.
Although MOC has plenty of merits, it has until now had poor water resistance. Prolonged contact with water or moisture severely degrades its strength. This critical weakness has restricted its use to indoor applications such as floor tiles, decoration panels, sound and thermal insulation boards.
How was water-resistance developed?
A team of researchers, led by Yixia (Sarah) Zhang, has been working to develop a water-resistant MOC since 2017 (when she was at UNSW Canberra).
To improve water resistance, the team added industrial byproducts such as fly ash and silica fume to the MOC, as well as chemical additives.
Fly ash is a byproduct from the coal industry – there’s plenty of it in Australia. Adding fly ash significantly improved the water resistance of MOC. Flexural strength (capacity to resist bending) was fully retained after soaking in water for 28 days.
To further retain the compressive strength under water attack, the team added silica fume. Silica fume is a byproduct from producing silicon metal or ferrosilicon alloys. When fly ash and silica fume were combined with MOC paste (15% of each additive), full compressive strength was retained in water for 28 days.