Boral Limited has successfully produced concrete using recycled concrete aggregates that were recarbonated via carbon capture technology at its Berrima integrated cement plant—marking an Australian-first breakthrough in low-carbon construction materials.
The trial used recycled concrete aggregates from Boral’s Widemere Recycling Facility as feedstock to capture and permanently store CO₂ from flue gas at the Berrima Cement Works. The CO₂ was directed through Boral’s newly commissioned recarbonation-based Carbon Capture and Storage (CCS) pilot plant, where the aggregates absorbed the captured carbon. These recarbonated aggregates were then used to replace 50% of the natural coarse aggregates in Boral’s low-carbon Envisia® concrete.
A Major Step in Low-Carbon Cement and Concrete
The milestone demonstrates a scalable and cost-effective pathway for using recarbonated aggregates, showcasing the potential of recarbonation-based carbon capture as a viable solution for the cement and concrete industry.
Concrete naturally absorbs carbon dioxide over its lifetime—a process known as cement recarbonation. At end-of-life, crushed concrete recarbonates faster due to increased surface area. At Boral’s CCS pilot plant, this natural process is accelerated under controlled conditions, enabling faster and permanent CO₂ storage.
The field trial was conducted at Boral’s Maldon cement facility and jointly funded by the Federal Government’s CCUS Development Fund and Boral.
Industry Statements
Dr Ali Nezhad, Head of Sustainability and Innovation at Boral, said:
“We are proud to lead the development of recarbonated concrete aggregates. Their successful use strengthens the viability of recarbonation-based carbon capture technology while reducing the embodied carbon of concrete by replacing natural aggregates.”
Vik Bansal, CEO and Managing Director of Boral, stated:
“Recarbonation will play a key role in decarbonising the cement and concrete industry. Our successful accelerated recarbonation trial reinforces the potential of this technology and supports our long-term net zero ambition by 2050.”
Supporting the Path to Net Zero
Carbon capture, utilisation and storage (CCUS) is critical for reducing process emissions, which account for around 65% of CO₂ emissions in cement production. Research cited by the Intergovernmental Panel on Climate Change (IPCC) indicates that 20% to 55% of cement process emissions can be reabsorbed by concrete through recarbonation across its lifecycle.
Boral continues to invest in alternative fuels, alternative raw materials, and long-term carbon capture technologies to drive down emissions and support Australia’s transition to a low-carbon future.
