Boral Pioneers Low-Carbon Concrete with Carbon Capture Breakthrough

Australian construction materials giant Boral has successfully created a new type of concrete using recycled materials treated with carbon capture technology, marking a national first.

The trial combined recycled concrete from Boral’s Widemere facility with carbon dioxide emissions captured at its Berrima Cement Works. Using a pilot carbon capture and storage (CCS) plant, flue gases were diverted and used to “recarbonate” the recycled concrete aggregates. These treated aggregates were then used to replace half of the natural stone in Boral’s low-carbon Envisia® concrete.

The innovation builds on a natural process where concrete absorbs carbon dioxide over time, especially once demolished and crushed into recycled aggregates. At Boral’s CCS pilot plant, this process is accelerated under controlled conditions, allowing carbon to be permanently stored while producing a viable construction material.

The field trial took place at Boral’s Maldon cement facility, with funding support from the Federal Government’s Carbon Capture, Use and Storage Development Fund. Results show that recarbonated aggregates can both store carbon and reduce the need for virgin raw materials, lowering the overall carbon footprint of concrete.

Dr Ali Nezhad, Boral’s Head of Sustainability and Innovation, said the breakthrough demonstrates a practical pathway for carbon capture in the cement and concrete industry. “Successful use of these aggregates not only validates our pilot plant but also helps cut the embodied carbon in concrete,” he said.

Boral CEO Vik Bansal added that the company is investing in both short-term and long-term decarbonization strategies. “Alongside alternative fuels and materials, technologies like carbon capture are critical to achieving our net zero ambition by 2050,” he said.

This achievement positions Boral as a leader in developing practical, low-cost solutions for one of the world’s most carbon-intensive industries.

Source: boral.com.au