Real Green Concrete

Sharing a vision for a more sustainable construction industry is behind Oscrete’s latest sustainability-focussed venture with partners Real Green Concrete (RGC) and Denis May & Sons.

During an “overwhelmingly positive” trial undertaken at concrete block supplier Denis May & Sons’ Cornwall site, Oscrete’s admixtures were blended into RGCs eco-friendly cement-free binder to test the viability of RGC as a high-performance, low-carbon replacement for traditional cement in concrete block production.

The trial successfully produced standard concrete blocks using RGC, with a strength class of 7.3N and an average strength of 8.87N recorded after just three days. The block weight remained consistent with industry norms at approximately 17.6kg, proving RGC viability as a practical and high performing alternative.

RGC can significantly lower carbon emissions by replacing Ordinary Portland Cement (OPC) thereby improving its properties. It is produced by using waste material by-products and this process reduces RGC carbon dioxide output by at least 68% making it an environmentally responsibly choice.

Dr Aissa Bouaissi, Real Green Concrete’s Chief Technology Officer, said: “We extend our sincere gratitude to Oscrete and to Denis May & Sons for their collaboration on this trial. Their dedication to sustainability and openness to exploring innovative materials like RGC demonstrate the power of collective action in driving meaningful industry change.

“We have been working towards using RGC in block making for construction by replacing 100% OPC and improving the properties of the binder using different admixtures from Oscrete. The Oscrete team’s product knowledge led to a series of different mix designs and admixtures for us to trial with their guidance.”
 
He added: “In concrete production, our Denis May & Sons trial demonstrated that RGC improves mixability and flow characteristics while allowing for more flexible setting times. It also confirmed that blocks made with RGC exhibited no shrinkage, ensuring long-term integrity and demonstrating that RGC not only meets but surpasses the performance of traditional OPC, while significantly reducing the carbon footprint of the manufacturing process.”

Oscrete’s Product Development and Sustainability Manager Matthew Gabriel said that with around 8% of the CO2 in the world coming from cement manufacture globally, action is needed to ensure businesses can align with leading sustainability certifications such as LEED and BREEAM which encourage the adoption of low-impact materials.

Matt added: “We want to support our partners in meeting these targets for 2030 and 2050 and producing a binder that’s chemically activated from waste products is the ideal solution. Our work with RGC involved repeated testing to ensure we came up with a solution which significantly improved the edges of the blocks and improved the strength across the various testing ages.”

RGC is produced using industrial by-products and waste materials, offering a more resource-efficient and cost-effective alternative to OPC. Unlike traditional cement production, which relies on high-temperature kilns, RGC is manufactured through a lower energy process, reducing natural resource consumption and production costs.

David Bradd, Production Manager at Denis May & Sons, added: “The binder reacted very well to our machines and it seems to have no different properties than when using regular cement – and handling it seems just as good as well. It certainly is a promising material for a sustainable construction future and it’s been great to be part of such a forward-thinking partnership that’s making huge strides in the industry.”