Leading construction materials supplier Aggregate Industries has launched ECOPlanet, a range of green cement that delivers at least 30% lower carbon compared to standard CEM I. Launching in the UK for the first time, ECOPlanet uses a broad range of low emission raw materials, such as fly ash, creating a
Scientists and industry unite to decarbonise construction supply chain and tackle global climate emergency Cement 2 Zero (C2Z), a UK-based demonstrator project to trial the world’s first zero-emissions cement on an industrial scale, was officially launched this week having successfully conducted the first in a series of pilot-scale melts. The
Longcliffe Quarries are now supplying LONGFLOOR, a groundbreaking dry powder bulk binder for the manufacture of liquid cement screeds. The LONGFLOOR liquid cement screed system has major advantages over both traditional screeds and anhydrite/gypsum flowing screeds. LONGFLOOR can be laid at ten times the speed of traditional screeds, manual handling
Lafarge Cement, part of the Aggregate Industries business, is calling on housebuilders to insist on tighter controls around the use of mortar, following claims that the use of substandard product is causing damage to hundreds of new homes. The report by the BBC focused on the use of weak mortar
January saw the lowest temperatures in the UK since February 2016, and with the potential for more cold snaps on the way, it’s a good time to review the procedures for placing concrete in cold weather. If young concrete is allowed to cool to below freezing temperature, it is very
Although in the process of being purchased by Breedon Aggregates, Hope Construction Materials has made the move to continue growing and solidifying its market brand, attempting to secure the future of the company, and potentially lay the foundations for the takeover by Breedon Aggregates. The takeover, which still requites approval
BDC 319 : Aug 2024
Leading construction materials supplier Aggregate Industries has launched ECOPlanet, a range of green cement that delivers at least 30% lower carbon compared to standard CEM I. Launching in the UK for the first time, ECOPlanet uses a broad range of low emission raw materials, such as fly ash, creating a low carbon product that doesn’t compromise on performance. Its low carbon footprint is further enhanced by the decarbonising its production process through the use of alternative fuels. ECOPlanet is the latest product range in Aggregate Industries’ suite of green building solutions and is the lowest CO2 footprint fly ash cement available in the UK. Other key benefits of ECOPlanet include its resistance to both sulphate attack and chloride ingress, and prevention against alkali-silica reaction. It also improves pumpability, placing and finishing – making it the ideal solution for high durability requirements. Dragan Maksimovic, CEO at Aggregate Industries, said: “The launch of ECOPlanet expands on our existing low carbon products including ECOPact, the world’s broadest range of green concrete or Super-Low Carbon, the first asphalt using biogenic material within the bitumen. The product is driven by innovation and by our ambitions to build a net zero future, and we’re delighted once again to be pushing the boundaries of low carbon construction solutions.” Steve Curley, Managing Director Cement at Aggregate Industries, said: “The launch of ECOPlanet represents yet another step forward in the transition towards a more sustainable construction industry. Its innovative formula and unique production process delivers at least 30% lower CO2, making it the first low carbon cement for the precast segment available in the UK. We look forward to working with our customers to provide yet another option to support our collective goal of achieving net zero emissions.” The launch of ECOPlanet is part of Aggregate Industries’ ambitious 2030 sustainability strategy, Building Progress for a Sustainable Future. For more information, visit the ECOPlanet webpage. For more information on Aggregate Industries, visit aggregate.com. Building, Design & Construction Magazine | The Choice of Industry Professionals
Scientists and industry unite to decarbonise construction supply chain and tackle global climate emergency Cement 2 Zero (C2Z), a UK-based demonstrator project to trial the world’s first zero-emissions cement on an industrial scale, was officially launched this week having successfully conducted the first in a series of pilot-scale melts. The innovative project, which secured £6.5million of Government funding from UKRI as part of the Transforming Foundation Industries Challenge, aims to further advance the construction, cement and steel sectors’ decarbonisation journey to net zero industries of the future, to help meet the UK Government’s commitment of achieving Net Zero by 2050. Led by the Materials Processing Institute, supported by the University of Cambridge (UoC), and in collaboration with key players in the supply chain, Cement 2 Zero is the first collaborative trial of its kind, to address the global construction industry’s biggest challenge of decarbonisation, in response to the climate emergency. Concrete is the most widely used material on earth, after water, and it is fundamental to our way of life, our economy and shaping our world. However, the chemical and thermal combustion processes involved in the production of cement are a significant source of carbon dioxide (CO2) emissions – with more than four billion tonnes of cement produced each year, accounting for around seven per cent of global CO2 emissions, according to the Global Cement and Concrete Association (GCCA). In the UK, concrete and cement account for 1.5 per cent of UK carbon dioxide emissions* The Cement 2 Zero project will investigate both the technical and commercial aspects of upscaling Cambridge Electric Cement (CEC) production to produce 20 tonnes of the world’s first zero emissions cement. The first phase of trial melts is being carried out by the Materials Processing Institute, initially in a 250kg induction furnace, before being scaled up to 6T in an Electric Arc Furnace (EAF). Once the process has been substantially trialled, developed and de-risked effectively, industrial scale melts will follow in CELSA’s EAF in Cardiff. The two-year industrial trial will test each stage of the production process and brings together the expertise of the Materials Processing Institute, the University of Cambridge and key supply chain partners – Atkins, Balfour Beatty, CELSA, Day Aggregates and Tarmac – before using the innovative product in a live UK construction project. If successful, it could not only further advance the cement, steel and construction industries, but influence how we recycle, construct and maintain our built environment and transport infrastructure, shaping the future of towns and cities, whilst simultaneously boosting economic development, and most importantly, reducing CO2 emissions to help tackle global warming. Chris McDonald, Chief Executive Officer of the Materials Processing Institute, said: “Cement 2 Zero has the potential to make a significant contribution to achieving a zero-carbon society, secure and increase jobs in the UK cement and steel sectors and challenge conventional production processes, creating high-value materials from demolition waste.” Dr Philippa Horton, University of Cambridge, who created the project consortium, said: “If Cambridge Electric Cement lives up to the promise it has shown in early laboratory trials, when combined with other innovative technologies, it could be a pivotal point in the journey to a zero-emissions society. The Cement 2 Zero project is an invaluable opportunity to collaborate across the entire construction supply chain, to expand CEC from the laboratory to its first commercial application.” This major break-through is a result of Dr Cyrille Dunant and his research team at the University of Cambridge. They invented a new process which brings together two critical industries and construction materials – cement and steel – by combining the production processes, transforming a by-product of steel recycling into a valuable material, in one zero emission process. Dr Dunant, said: “We take the built environment around us for granted, new homes, schools, hospitals, workplaces, roads and railways, as well as infrastructure that provides us with clean water, sanitation and energy all require cement which is an essential building material. It’s estimated that annual production equates to more than 500kg of concrete per person on the planet per year, and it is not currently possible to produce the material without creating CO2 emissions. “This breakthrough offers a positive move in cement production and will support the industry response to the UK’s legally binding commitment to bring all greenhouse gas emissions to net zero by 2050. “ The science behind this breakthrough Known as Cambridge Electric Cement (CEC), three researchers at the University of Cambridge, Dr Cyrille Dunant, Professor Julian Allwood and Dr Philippa Horton, invented a process that converts construction and demolition waste to cement over molten steel, using an Electric Arc Furnace (EAF), which is used to recycle scrap steel. The Cement 2 Zero project aims to demonstrate that concrete can be recycled to create a Slag Forming addition which could, when cooled rapidly, replace Portland cement. Dr Dunant discovered that the chemical composition of used cement is virtually identical to that of the lime-flux used in the conventional EAF steel recycling process. Traditional Portland clinker, one of the main ingredients in cement, is produced by firing limestone and other minerals in a kiln at extremely high temperatures (1,450 degrees Celsius), a process which accounts for more than 50 per cent of the cement sectors’ emissions. By contrast, Cement 2 Zero will use recycled cement as the flux in the electric steel recycling process (EAF powered by renewables), the by-product of which, when cooled and ground, produces Portland cement clinker, which is then blended to make ‘zero-emissions’ cement. Therefore, this innovative cement product (CEC) could be made in a virtuous recycling loop, that not only eliminates the significant emissions of cement and steel production, but also saves raw materials, as illustrated in the infographic attached to this press release. Professor Julian Allwood, University of Cambridge and Cambridge Electric Cement, explained: “By combining steel and cement recycling in a single process powered by renewable electricity, we could supplement the global supply of the basic construction materials to support the infrastructure of a
Longcliffe Quarries are now supplying LONGFLOOR, a groundbreaking dry powder bulk binder for the manufacture of liquid cement screeds. The LONGFLOOR liquid cement screed system has major advantages over both traditional screeds and anhydrite/gypsum flowing screeds. LONGFLOOR can be laid at ten times the speed of traditional screeds, manual handling is avoided and a denser, more even surface and creamy smooth finish achieved. LONGFLOOR dries at three times the speed of anhydrite/gypsum based flowing screeds. There is no laitance to sand off. Contamination and blistering issues with wet concrete or cement based floor adhesives are totally avoided. This innovative product is not susceptible to cracking, crazing or curling and can be laid in wet areas. Applications include both domestic and commercial and provide good thermal conductivity over underfloor heating. It can be applied down to 25mm thickness in bays of up to 150m2. A single crew can lay 1000m2 in a day. The binder consists of superfine high purity limestone powder plus a suite of dry chemical reagents and admixtures manufactured to BSEN 13813:2002. It is made in a new state of the art factory at the Longcliffe quarry near Matlock then delivered by Longcliffe tanker to a stockist’s silo where sand, cement, water and a liquid admixture are added. Stockists are typically ready mixed concrete plants, mixer or dry leg. Delivery to customer can be from drum mix or volumetric trucks. LONGFLOOR liquid cement screed is discharged or more usually pumped in to the building, then simply dappled before applying LONGCURE, a sprayed proprietary curing agent. Longcliffe Quarries are the UK’s largest independent producer of calcium carbonate, (limestone), powders, a company with a 90 year history of quarrying and grinding high purity Derbyshire limestone. As a result of a unique manufacturing process LONGFLOOR has a certified 95% recycled content. Andy Littler, LONGFLOOR Director said: “We are very excited about this pioneering easy to use screed product. For many years the concrete industry has tried to develop a cement based liquid screed which flows well, dries quickly and is not prone to cracking. We have now achieved this. The screed industry is witnessing a sea change in favour of cement based liquid screeds and we intend to make LONGFLOOR the market leader and top performing benchmark standard”. LONGFLOOR screed is currently available to screed contractors in the North West, Midlands, South East, London, South West, Humberside and Scotland. LONGFLOOR screed is being supplied on a daily basis in these areas with contracts up to 600m3 secured. We would welcome enquiries from additional stockists who would receive full technical and commercial support from the highly experienced Longfloor team. For further information please go to www.longfloor.co.uk or phone the LONGFLOOR sales office on 01629 540284.
Lafarge Cement, part of the Aggregate Industries business, is calling on housebuilders to insist on tighter controls around the use of mortar, following claims that the use of substandard product is causing damage to hundreds of new homes. The report by the BBC focused on the use of weak mortar – not meeting required industry standards – leading to crumbling found in properties across 13 estates in the UK[1]. The news has caused widespread concern amongst residents and across the construction industry. Jeremy Lee, Commercial Director at Lafarge Cement, comments: “This latest report is concerning, especially as it has been identified as a potential industry-wide problem affecting hundreds of homes. As acknowledged by the BBC, mortar performance is a complex issue, with a myriad of factors including weather and correct specification and application having a potential detrimental impact. “However, this is why it’s critical that all building products, including mortar, meet required industry standards – which according to the NHBC should be one part cement to 5.5 parts sand for most of the UK but for areas that experience extreme weather conditions such as Scotland, it’s recommended that a higher proportion of cement is used to increase durability. “Building standards are in place for a reason and tighter controls are needed to ensure that the correct products are specified, as well as being mixed and applied properly on-site. From housebuilders to the wider industry, it is everyone’s responsibility to ensure that adequate and suitable products are used, through a robust specification process and due diligence during all stages of the construction process.” As part of Aggregate Industries, Lafarge Cement offers a solutions-based packed cement portfolio, underpinned by robust technical knowledge and the latest product innovation. Through continual research and development with builders and builders’ merchants deployed by a highly skilled team, Lafarge Cement has an unrivalled track record for customer-focused innovation in cement products. The range includes the premixed and ready to use Mortar Mixed product, which is made up of a selected blend of cement, lime and aggregates and is suitable for laying all types of brick and block. For further information, please call 01285 646900, email packedcement@aggregate.com or visit www.aggregate.com [1] https://www.bbc.co.uk/news/business-46454844
January saw the lowest temperatures in the UK since February 2016, and with the potential for more cold snaps on the way, it’s a good time to review the procedures for placing concrete in cold weather. If young concrete is allowed to cool to below freezing temperature, it is very likely that it will be damaged to the point of being entirely unfit for use. Should freshly-placed concrete be allowed to reach temperatures lower than 0°C, the water in the mix will freeze and expand; maintaining a temperature above zero degrees will help to ensure the intended strength of your concrete is reached- even if it is at a slower rate than was anticipated. However, if the concrete is able to reach a strength of approximately 2N/mm2 it is likely to be able to resist the expansion and damage. It is important to note that even if temperatures don’t reach freezing point, low temperatures will cause the concrete’s strength to develop significantly slower than in warmer ambient temperatures. This strength is typically reached within 48 hours for most mixes, should the concrete be kept above 5°C. So how, during cold weather, should you keep concrete sufficiently warm for the first 48 hours to ensure that this strength is able to develop? Concrete should never be poured onto frozen ground, snow or ice. You can use heaters to thaw the ground prior to pouring concrete. If you plan to use heated enclosures, make certain they are both windproof and weatherproof. Your concrete should include a maximum water to cement ratio, to limit bleeding. Additionally, you should not begin your final finishing operations whenever bleed water is still present. It is important that formwork is not removed early, or else there is a risk that concrete in suspended slabs or beams could be too weak to carry its own weight due to the slower rate of strengthening the slow rate of strength development needs to be taken into account when calculating times for formwork removal. Strength gain can be increased by minimising the amount of cement replacements or using admixtures- always seek the advice of your suppliers If temperatures are low enough that frost is expected, useful protection measures include insulated or heated frost blankets and insulated formwork. Timber formwork often offers sufficient insulation by itself. Steel formwork is a poor insulator, and exposed surfaces should be covered with insulating material or temporary covers heated with space heaters. For severe frost, it is best to heat the concrete (10°C) for delivery. If heated concrete is not available, it is better to delay your concreting until the ambient temperature rises to above 2°C. When planning your concreting, you can obtain information on the likely temperatures from the Met Office, and should use this to plan your approach so you are never caught short or forced to delay your work. Armed with this information, you will be able to place your concrete perfectly, first time, whatever the weather.
Although in the process of being purchased by Breedon Aggregates, Hope Construction Materials has made the move to continue growing and solidifying its market brand, attempting to secure the future of the company, and potentially lay the foundations for the takeover by Breedon Aggregates. The takeover, which still requites approval from the competition authorities, is predicted to come to fruition over the course of the year, yet, whether through uncertainty of approval or a determination to prove the strength of the brand to Breedon Aggregates, the company is displaying a degree of normality in operation as if planning for the future of the organisation, much like any other. Additionally, Hope Construction Materials is also set to launch a brand new brand of bagged cement, to be transported from the production plant in Derbyshire by rail, through to distribution at the new plant in Dagenham. The products, once distributed, are expected to be available to customers throughout the South of England. The move represent the company’s first time both producing and branding its own cement products for mass distribution – previously the supply of its cement products had been undertaken by third party suppliers. It’s of no real surprise that Hope Construction Materials expects to go ahead with the product launch, despite the takeover talks, due to the stage of the project which has been some around a year and a half in the making. Additionally, a great deal of research has been undertaken so as best to ensure that the product is targeted towards the increasingly-specific requirements of the modern building industry – this undertaken through communication with leading builders and merchants to understand their needs. Hope Construction Materials’ Commercial Director, Gary Brennand explained: “Using this insight we have developed a full package which we believe will redefine the sector.” As such, the new, professional grade cement is expected to be received with much anticipation with the greater construction industry.
