Nurhan Gürel
CemenTürk Editor-in-Chief
Part 1: Geopolymer Cement – A Sustainable Alternative to Portland Cement
1.Introduction
The cement industry stands at a critical crossroads as it grapples with the pressing need to balance economic growth with environmental responsibility. Cement production, a fundamental pillar of global infrastructure, is also a major contributor to carbon emissions, accounting for approximately 8% of total CO₂ output. This staggering environmental footprint underscores the urgency of exploring and implementing alternative solutions that mitigate emissions while maintaining the structural integrity and durability required in modern construction.
Geopolymer cement is an advanced, inorganic polymer-based binder that serves as an environmentally friendly alternative to conventional Portland cement. It is produced by chemically activating aluminosilicate precursors, such as fly ash, metakaolin, and slag, with alkaline solutions, eliminating the need for limestone calcination—a primary source of CO₂ emissions in traditional cement production. By utilizing industrial by-products and avoiding the high-temperature kilns required for clinker production, geopolymer cement significantly reduces the carbon footprint of construction materials while offering superior performance characteristics.
2. Composition and Geopolymerization Process
Geopolymer cement is primarily composed of two key components:
1. Aluminosilicate precursors: These include industrial byproducts such as fly ash (a residue from coal combustion), ground granulated blast-furnace slag (a by-product of steel manufacturing), and metakaolin (a thermally activated clay mineral). These materials serve as the reactive base for the geopolymerization process.
2. Alkaline activators: Strong alkaline solutions such as sodium hydroxide (NaOH), potassium hydroxide (KOH), and sodium or potassium silicates are used to dissolve the aluminosilicate precursors, triggering a chemical reaction that leads to the formation of a stable, three-dimensional polymeric network of Si-O-Al bonds.
The geopolymerization reaction involves the dissolution of the aluminosilicate precursors in an alkaline medium, followed by polycondensation, which results in the formation of a rigid, interconnected matrix. This unique structure gives geopolymer cement its high strength, chemical resistance, and long-term durability, making it a promising alternative to conventional cement.
2.1. Key Advantages of Geopolymer Cement
1. Drastic reduction in CO₂ emissions
Traditional cement production is responsible for approximately 8% of global CO₂ emissions, largely due to the calcination of limestone and the energy-intensive clinker production process. In contrast, geopolymer cement eliminates limestone calcination, reducing CO₂ emissions by up to 80% compared to ordinary Portland cement (OPC). By utilizing industrial waste materials as raw ingredients, it further contributes to a circular economy, reducing landfill waste and resource depletion.
2. Superior strength and durability
Geopolymer cement demonstrates high compressive strength, often exceeding that of traditional concrete. It achieves strength levels of 40–80 MPa within 28 days, making it suitable for demanding structural applications. Additionally, its three-dimensional polymeric network provides exceptional resistance to aggressive environments, including exposure to sulfate-rich soils, acidic conditions, and extreme weathering.
3. Resistance to chemical attacks and fireproofing capabilities
Due to its low calcium content, geopolymer cement is highly resistant to sulfate attacks, making it ideal for marine environments, wastewater treatment plants, and chemically aggressive industrial sites. Furthermore, it exhibits superior fire resistance, maintaining structural integrity at temperatures exceeding 1,000°C, which makes it an excellent material for fireproof panels, refractory materials, and structures exposed to high heat.
4. Utilization of industrial by-products and waste reduction
By incorporating fly ash, slag, and metakaolin, geopolymer cement significantly reduces reliance on virgin raw materials, promoting sustainability. The repurposing of industrial by-products not only minimizes environmental waste but also provides cost-effective alternatives for cement production.
5. Energy efficiency and lower carbon footprint
Unlike traditional cement, which requires kilns operating at 1,400– 1,500°C, geopolymer cement cures at ambient or moderately elevated temperatures (typically 60–90°C), leading to substantial energy savings. This makes its production process significantly less carbon-intensive, reducing dependence on fossil fuels and decreasing overall environmental impact.
2.2. Applications of Geopolymer Cement
Due to its exceptional mechanical properties and sustainability advantages, geopolymer cement is gaining traction in various construction sectors:
• Infrastructure projects: Bridges, roads, railway sleepers, and airport runways benefit from geopolymer concrete’s high strength and durability.
• Marine and coastal structures: Its sulfate resistance makes it ideal for seawalls, piers, offshore platforms, and port facilities exposed to harsh marine environments.
• Underground and tunnel construction: Geopolymer cement’s superior chemical resistance enhances the longevity of subway tunnels, mining structures, and underground water reservoirs.
• Fireproof and refractory applications: Given its ability to withstand extreme temperatures, it is used in fireproof building panels, furnace linings, and refractory bricks.
• Precast concrete elements: It is suitable for precast concrete applications, including building facades, pavers, and structural elements.
• Retrofitting and rehabilitation: Geopolymer-based coatings and overlays extend the service life of aging concrete structures, reducing maintenance costs and increasing sustainability
3. Case Studies for Geopolymer Cement Production
Several companies are actively advancing geopolymer cement solutions: This section provides a technical overview of such innovations: Ecocem’s ACT, Partanna’s carbon-negative binder, Hoffmann Green Cement’s clinker-free binders, Cemvision’s Rement, and Betolar’s Geoprime® and Materrup.
Figure 1: Ecocem’s ACT Binder Process Flow Diagram
3.1. Ecocem’s ACT: Advanced Cement Technology
Ecocem’s ACT is a next-generation low-carbon cement technology designed to deliver up to a 70% reduction in CO₂ emissions compared to conventional cements. This is achieved by significantly reducing the clinker content—responsible for approximately 94% of cement’s carbon footprint—and substituting it with abundantly available fillers and locally sourced supplementary cementitious materials (SCMs). The technology utilizes raw materials already approved by cement and concrete standards, incorporating specific chemical additions for rheology and activation. Notably, ACT is designed for concrete with a low water-to-cement ratio, enhancing its performance characteristics.
Ecocem’s Advanced Cement Technology (ACT) represents a significant breakthrough in sustainable cement production, achieving up to a 70% reduction in CO₂ emissions compared to conventional cements. This remarkable reduction is primarily due to the minimization of clinker content, which is the main source of CO₂ emissions in cement production. Instead, ACT incorporates abundant, low-carbon materials, significantly lowering its environmental footprint while maintaining high performance. In terms of strength and durability, ACT meets the rigorous requirements of a 42.5 strength class cement, ensuring robust structural integrity.
Additionally, it enhances durability characteristics, contributing to the longevity and resilience of concrete structures. Beyond emissions reduction and strength performance, ACT also promotes resource efficiency by reducing water consumption in cement production by up to 50%, making it a more sustainable choice. Moreover, ACT is designed for seamless integration into existing cement production processes with minimal modifications, leveraging raw materials that are already approved under established cement and concrete standards. This ensures that ACT can be widely adopted without significant additional investment, providing the construction industry with a practical, scalable solution to reduce carbon emissions while maintaining high-performance standards.
Figure 2: Patanna’s Carbon Negative Binder Process Flow Diagram
3.2. Partanna’s Carbon-Negative Binder
Partanna has developed an innovative alternative binder formulated from natural and recycled materials, including brine—a byproduct of desalination processes. The production involves blending these components at ambient temperatures, eliminating the need for energy-intensive heating. During curing, the binder absorbs CO2 from the atmosphere, effectively removing carbon and contributing to its carbon-negative profile.
Partanna’s binder meets international building codes and complies with ASTM C1157 standards for Type GU (general use) cement. It is compatible with standard construction practices and equipment, facilitating its adoption in various structural applications.
Partanna’s carbon-negative binder presents a groundbreaking alternative to traditional cement, delivering significant environmental and structural benefits. Unlike conventional cement, which emits approximately 800 kg of CO2 per ton during production, Partanna’s binder actively absorbs around 100 kg of CO2 per ton from the atmosphere throughout its curing process, making it a truly carbonnegative solution. This innovative approach addresses one of the largest contributors to global greenhouse gas emissions while maintaining high-performance characteristics. In terms of durability, Partanna’s binder demonstrates superior resistance to saltwater, making it particularly suitable for coastal and marine applications where traditional concrete often deteriorates. With a compressive strength of around 40 MPa, it meets international building standards and is fully compatible with reinforced steel, ensuring the structural integrity of buildings and infrastructure. Another key advantage of Partanna’s binder is its sustainable production process, which utilizes approximately 80% recycled materials, such as brine and slag—by products from desalination and steel manufacturing. By repurposing these materials, Partanna avoids the high CO2 emissions associated with clinker production in conventional cement, further reinforcing its eco-friendly credentials. These combined characteristics position Partanna’s carbon-negative binder as a pioneering solution for sustainable construction, proving that environmentally responsible materials can achieve high performance without compromising on strength, durability, or scalability.
3.3. Hoffmann Green Cement’s
Clinker-Free Binders H-UKR and H-EVA Binders
H-UKR is an alkali-activated slag binder produced by activating blast furnace slag with specific alkaline activators. This process occurs at ambient temperatures, eliminating the need for high-temperature kilns and resulting in a binder with zero clinker content. H-EVA is based on alkaline ettringitic technology, combining flash-calcined clay with gypsum or industrial by-products like desulfogypsum. Activators and superactivators formulated by Hoffmann Green are added to this mixture to produce the binder.
Figure 3: Hoffmann Green Cement’s Clinker-Free Binders: H-UKR Binder Process Flow Diagram
H-UKR is an innovative, low-carbon binder developed by Hoffmann Green Cement Technologies, designed as a sustainable alternative to traditional Portland cement. Unlike conventional cement, which relies on clinker—a major source of CO2 emissions—H-UKR is entirely composed of alkali-activated ground granulated blast furnace slag (GGBFS), containing 0% clinker. This composition results in a significant carbon footprint reduction of approximately 70% compared to standard CEM I cement, making it a highly eco-friendly solution for the construction industry. The elimination of clinker not only cuts CO2 emissions but also promotes a circular economy by utilizing industrial by-products, further reducing environmental impact. Despite its low-carbon nature, H-UKR does not compromise on mechanical properties, achieving a compressive strength of approximately 46.7 MPa after 28 days, comparable to traditional Portland cement-based concrete. This ensures its suitability for a wide range of structural applications. Additionally, H-UKR excels in durability and efficiency, performing reliably across different temperature conditions. One of its key advantages is the ability to allow formwork removal after just 16 hours, significantly improving construction efficiency, even in cold weather, by maintaining steady worksite progress. Moreover, its production is entirely based in France, leveraging industrial by-products like GGBFS to minimize raw material extraction and further enhance sustainability.
Figure 4: Hoffmann Green Cement’s Clinker-Free Binders: H-EVA Binder Process Flow Diagram
These characteristics position H-UKR as a groundbreaking solution for sustainable construction, providing an environmentally responsible alternative that meets high-performance standards without sacrificing strength, durability, or practicality.
H-EVA is an ettringite-based binder developed by Hoffmann Green Cement Technologies, designed as a sustainable and efficient alternative for construction applications. Unlike conventional clinker-based cement, H-EVA is formulated from flashed clay and deconstruction gypsum, utilizing recycled materials to minimize environmental impact. This composition significantly reduces the carbon footprint associated with traditional cement production while maintaining high performance in various construction applications. One of H-EVA’s key advantages is its extended shelf life of approximately 9 months, which is notably longer than the typical 6-month shelf life of conventional cement. This extended usability ensures better storage efficiency and reduced material waste, contributing to more sustainable construction practices.
By leveraging alternative materials such as flashed clay and deconstruction gypsum, H-EVA promotes a circular economy by repurposing waste from other industries. These characteristics position H-EVA as a pioneering binder that balances sustainability and efficiency, making it a viable solution for reducing the cement industry’s reliance on clinker without compromising durability or usability.Environmental Impact By eliminating clinker and utilizing industrial by-products, Hoffmann Green’s binders significantly reduce CO2 emissions associated with cement production. The cold manufacturing process further minimizes energy consumption, contributing to a more sustainable construction industry.
3.4. Cemvision’s Re-ment
Cemvision has developed an alternative binder named Re-ment, produced using industrial by-products primarily sourced from the mining and steel industries. This approach eliminates the need for virgin limestone, thereby reducing CO2 emissions associated with traditional cement manufacturing. The production process operates at lower temperatures and is powered by green energy, further minimizing environmental impact.
Figure 5: Cemvision’s Re-ment Binder Process Flow Diagram
Cemvision’s Re-ment is an innovative low-carbon cement designed as a sustainable alternative to traditional Portland cement, offering substantial environmental benefits while maintaining highperformance standards. One of its most remarkable features is its ability to reduce CO2 emissions by up to 95% compared to conventional cement. This significant reduction is achieved by replacing clinker— the primary source of CO2 emissions in standard cement—with calcium oxide-rich materials derived from industrial by-products. By eliminating clinker from its composition, Re-ment significantly lowers the carbon footprint of cement production while promoting circularity in the construction industry. Despite its environmentally friendly formulation, Re-ment does not compromise on strength, achieving a 28-day compressive strength of up to 60 MPa (C50/60 classification), making it suitable for demanding structural applications. Furthermore, the binder is designed for seamless compatibility with traditional aggregates and admixtures, ensuring ease of use and efficient batching in standard construction practices. Re-ment consistently achieves the required consistency and specified characteristic strength, facilitating widespread adoption without requiring significant process modifications. Additionally, its production process focuses on sustainability by utilizing 100% industrial by-products, further reducing the environmental impact associated with raw material extraction. These performance characteristics position Cemvision’s Re-ment as a pioneering solution for sustainable construction, offering near-zero carbon emissions, exceptional mechanical properties, and superior compatibility—all without compromising workability or efficiency.
3.5. Betolar’s Geoprime®
Betolar’s Geoprime® binder is formulated by activating industrial byproducts such as fly ash, blast-furnace slag, and mining tailings. These materials undergo a chemical activation process that enables them to function as effective binders in concrete, eliminating the need for cement. This approach not only diverts waste from landfills but also reduces the reliance on virgin natural resources.
Figure 6: Betolar’s Geoprime® Binder Process Flow Diagram
Betolar’s Geoprime® binder is an innovative, cement-free binder that provides a sustainable alternative to traditional Portland cement while maintaining comparable performance characteristics. One of its most significant advantages is its ability to reduce CO2 emissions by up to 80%, a remarkable improvement over conventional cement production. This drastic reduction is achieved by replacing clinker— the primary source of CO2 emissions in standard cement—with industrial side streams such as slag from the steel industry and fly ash from energy production. By utilizing 100% recycled industrial by-products, Geoprime® not only lowers carbon emissions but also promotes circularity within the construction sector. Despite its sustainable composition, Geoprime® does not compromise on strength, offering compressive strengths ranging from 40 MPa to 75 MPa after 28 days, making it suitable for various structural applications, from general construction to high-performance infrastructure. Additionally, Geoprime® excels in durability, demonstrating excellent chemical resistance, including sulfate resistance, which enhances its long-term performance in harsh environmental conditions. It meets rigorous European durability standards such as EN 1338, EN 1339, and EN 1340, ensuring its suitability for diverse construction projects. Furthermore, Geoprime® is designed to seamlessly integrate with traditional aggregates and reinforcement methods, providing a workability level comparable to conventional cement-based concrete. This allows construction professionals to adopt Geoprime® without requiring major changes in production processes, making it a practical and scalable solution. By leveraging sustainable production techniques that prioritize circularity and resource efficiency, Betolar’s Geoprime® significantly reduces environmental impact while delivering high-performance concrete. These attributes position Geoprime® as a groundbreaking material in the quest for low-carbon, high-performance cement alternatives, ensuring a more sustainable future for the construction industry.
3.6. Materrup’s Clay Cement MCC1®
Materrup has developed an innovative alternative binder that utilizes industrial by-products and supplementary cementitious materials (SCMs) to replace traditional clinker-based cement. The formulation primarily incorporates pozzolanic materials, calcined clays, and recycled mineral components, eliminating the need for high-temperature clinker production. The manufacturing process operates at significantly lower temperatures and is optimized for energy efficiency, further reducing its environmental footprint.
Figure 7: Materrup Binder Process Flow Diagram
Materrup has introduced an innovative low-carbon cement, known as Clay Cement MCC1®, which provides a sustainable alternative to traditional Portland cement while maintaining high performance. This cement is produced using uncalcined local clay, which eliminates the need for high-temperature calcination, significantly reducing both CO2 emissions and energy consumption. As a result, Materrup’s cement achieves a 50% reduction in CO2 emissions compared to conventional cement, making it a highly eco-friendly solution for the construction industry. Additionally, its production process requires 50% less energy than traditional cement manufacturing, further decreasing its environmental impact and promoting energy efficiency. Despite its sustainable composition, the mechanical performance of Materrup’s concrete remains comparable to conventional concrete, ensuring its suitability for a wide range of structural applications. In terms of durability, Materrup’s cement provides a lifespan of approximately 100 years, aligning with the durability standards of traditional concrete. Furthermore, the binder is developed using 100% local waste materials, promoting a circular economy by repurposing industrial by-products and reducing the environmental burden associated with raw material extraction and transportation. These attributes position Materrup’s Clay Cement MCC1® as a groundbreaking material in sustainable construction, offering substantial reductions in carbon emissions and energy use while maintaining the strength, durability, and versatility required for modern infrastructure.
4. Conclusion
The emergence of Ecocem ACT, Partanna’s binder, Hoffmann Green Cement’s H-UKR and H-EVA, Cemvision’s Re-ment, Betolar’s Geoprime®, and Materrup’s Clay-Based Cement represents a transformative shift in cement and concrete production. These technologies provide low-carbon, high-performance alternatives that align with global net-zero goals. While challenges such as scalability, regulatory hurdles, and industry conservatism remain, continued innovation, policy support, and investment will drive adoption forward. With a collective effort from governments, industry leaders, and researchers, alternative binders have the potential to revolutionize the construction sector and pave the way for a more sustainable built environment.
The development of alternative binders such as Ecocem ACT, Partanna’s Carbon-Negative Binder, Hoffmann Green Cement’s H-UKR and H-EVA, Cemvision’s Re-ment, Betolar’s Geoprime®, and Materrup’s Clay-Based Cement marks a significant step forward in addressing the environmental impact of traditional cement production. These innovations offer promising solutions by significantly reducing CO2 emissions, optimizing resource efficiency, and integrating industrial by-products into their production processes. However, while these technologies present numerous benefits, they also face key challenges and industry bottlenecks that must be overcome to ensure widespread adoption.
4.1. Advantages of Geopolymer Binders
1. Drastic CO2 emission reductions
One of the most significant advantages of these alternative binders is their potential to reduce greenhouse gas emissions. For example, Cemvision’s Re-ment reduces CO2 emissions by up to 95%, while Partanna’s binder is carbon-negative, actively removing CO2 from the atmosphere during curing. Similarly, Geoprime® achieves up to an 80% reduction in emissions, and Materrup’s Clay Cement MCC1® cuts emissions by 50% by eliminating high-temperature calcination. By minimizing reliance on clinker—the primary contributor to cement-related emissions—these alternatives play a vital role in decarbonizing the construction sector.
2. Sustainability and circular economy ıntegration
Many of these binders promote a circular economy by repurposing industrial waste materials. Hoffmann Green Cement’s H-UKR and H-EVA binders utilize industrial by-products such as blast furnace slag and desulfogypsum, reducing the demand for virgin raw materials. Betolar’s Geoprime® transforms fly ash, blast-furnace slag, and mining tailings into viable binding agents, preventing these materials from being discarded in landfills. Similarly, Materrup’s clay-based cement leverages locally sourced quarry waste and construction site soil, preserving natural resources while reducing waste.
3. Enhanced performance and durability
Despite their environmentally friendly compositions, these alternative binders demonstrate mechanical performance and durability comparable to conventional cement. Re-ment develops early strength up to five times faster than traditional cement, H-EVA reaches mechanical strengths of up to 60 MPa after 28 days, and Geoprime® achieves a compressive strength range of 40-75 MPa, making it suitable for various structural applications. The increased resistance to chemical attacks, such as sulfate resistance in Geoprime® and enhanced carbonation resistance in Ecocem ACT, further enhances long-term performance and structural reliability.
4. Lower energy consumption and efficient manufacturing
Many of these binders require significantly less energy to produce than traditional clinker-based cement. Materrup’s process eliminates high-temperature calcination, reducing energy consumption by 50%, while H-UKR and H-EVA operate at ambient temperatures, completely bypassing the need for kilns. Additionally, Cemvision’s Re-ment relies on green energy to power its low-temperature production process, ensuring a smaller environmental footprint.
5. Adaptability and compatibility with conventional construction practices
A crucial factor for industry adoption is the compatibility of alternative binders with existing construction practices. Ecocem ACT enhances traditional cement properties while optimizing grinding efficiency, enabling seamless integration into conventional production systems. Geoprime®, Re-ment, and Partanna’s binder work with traditional aggregates and reinforcement methods, making their implementation easier without requiring drastic changes to established infrastructure. These features ensure that transitioning to sustainable binders does not create excessive barriers for construction professionals.
4.2. Challenges and Bottlenecks Hindering Widespread Adoption
Despite these benefits, several challenges must be addressed for these alternative binders to gain widespread industry acceptance:
1. Regulatory and standardization hurdles
One of the biggest obstacles for alternative binders is the lack of well-established industry standards and certifications. Portland cement has been the dominant material in construction for decades, with clearly defined global standards. Many of these alternative binders, such as Partanna’s carbon-negative binder and Betolar’s Geoprime®, must meet stringent building codes (e.g., ASTM C1157, EN standards) before gaining widespread acceptance in construction projects. Regulatory frameworks need to adapt to accommodate these innovative materials and encourage their adoption in large-scale infrastructure.
2. Market acceptance and industry conservatism
The construction industry is historically risk-averse and slow to adopt new materials. Many contractors, developers, and engineers are hesitant to switch to alternative binders due to concerns about long-term durability, workability, and supply chain consistency. Traditional cement has well-documented performance records, whereas alternative materials must prove their reliability over decades of use. Overcoming skepticism through education, pilot projects, and successful case studies will be essential.
3. Production scalability and supply chain limitations
While these alternative binders offer significant environmental benefits, their scalability remains a key challenge. The cement industry operates on a massive scale, producing billions of tons annually. Industrial by-products such as fly ash and blast furnace slag—key components in some alternative binders—may not be available in sufficient quantities to replace all conventional cement. Additionally, some materials, such as Materrup’s local clay, depend on regional availability, limiting large-scale production in some areas. The development of robust supply chains and alternative material sources will be crucial for ensuring consistent production.
4. Economic viability and cost competitiveness
Alternative binders currently face cost-related challenges compared to traditional cement. Portland cement benefits from economies of scale, well-established supply chains, and decades of optimization, making it relatively inexpensive to produce. In contrast, many of these new binders rely on proprietary chemical activation processes, specialized sourcing, and emerging production technologies that may increase costs. However, as demand grows and production scales up, costs are expected to decrease, making these materials more economically competitive.
5. Workability and construction-specific challenges
Although many alternative binders claim to be compatible with existing concrete production techniques, practical implementation can still present issues. Cemvision’s Re-ment, for example, develops strength significantly faster than traditional cement, requiring adjustments in curing time and handling processes. Water demand, setting times, and long-term performance under extreme weather conditions may also vary among different binders, necessitating further research and optimization.
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