Cement-free concrete: a little history, varieties and features

An inventive material that has gained popularity recently is cement-free concrete. This type of concrete uses different materials to achieve similar, if not better, results than traditional concrete, which primarily uses cement as its binder. This change addresses environmental issues and creates new opportunities in the building industry.

The story of cement-free concrete’s development and experimentation is one of experimentation. Researchers and engineers have been looking for ways to lessen the impact that the production of concrete has on the environment for decades. Cement-free concrete, whose origins can be traced to early experiments with industrial and natural by-products, became a promising solution.

Cement-free concrete comes in a variety of forms these days, each with special qualities and advantages. These substitutes, which range from lime-based mixtures to geopolymers, offer various benefits and uses. Comprehending these variations facilitates the selection of the appropriate type for particular construction requirements, rendering cement-free concrete a flexible option for contemporary construction endeavors.

Innovative cement-free concrete is a useful and environmentally friendly substitute for conventional cement-based mixes. This article examines its history, varieties, and special qualities, emphasizing how it minimizes carbon footprints and offers a wide range of uses while retaining strength and durability.

About the term

The word "concrete" comes from the name of the natural bitumen deposit in Trinidad, known as Peach Lake.

The word "concrete" generally refers to a combination of binders and fillers. Since the type of binder is not stated, many concretes are made without cement. Take a look at the street; the road is probably covered in asphalt, which is a type of concrete with bitumen—an organic substance—serving as the binder. By the way, asphalt concrete is the proper term for asphalt.

Interesting fact. The French word for "concrete" is beton, which is derived from the Latin bitumen, which means "mountain oil." This is how natural asphalt or bitumen was referred to in Latin (the words are even highly consonant with Russian). Thus, it stands to reason that asphalt concrete, rather than a Portland cement-based mixture, is the most accurate type of concrete.

A little history

In actuality, cementless concrete is among the oldest materials, right up there with clay (even unfired) brick. The pyramids in Ancient Egypt were built using cementless concrete technology.

The structures from that era are still standing and are just as strong as those from today. They used a lime-based solution, which developed strength and water resistance over time, to secure the blocks.

Prior to the development of clinker firing technology and the manufacture of Portland cement in the early 19th century, this technology was in use for thousands of years.

Interesting. The ancient Romans were able to produce goods that were extremely similar to contemporary concrete in quality thanks to the discovery of pozzolanic additives.

Today, Portland cement is the "lifeblood" of the construction industry, used extensively in the construction of the majority of buildings. But there are substitutes for it, and plenty of them. Now let’s look at the substances that are frequently referred to as cementless concrete.

Types of cementless concrete

We will describe the types of concrete that are currently available that don’t contain cement. Simultaneously, because history is where we began, we will make an effort to follow the timeline of the materials’ discovery in the description that can substitute regular Portland cement.

As mentioned earlier, pozzolan, a finely ground natural material that is well-known in Rome, should be the first. However, since it is currently only utilized as a cement additive, we will leave it out. We are discussing mixtures that have not a single gram of burnt clinker in them.

Gypsum concrete

In this case, the binder is gypsum, or alabaster. Gypsum concrete and lime-based solutions have been around for nearly the same amount of time. Although it is easier to form, its strength is marginally less than that of other concretes.

Furthermore, this concrete slightly expands in volume rather than contracting as it hardens. This enables you to pour out the most intricately shaped products from it. Its ivory surface is as smooth as marble—that is, if you use pure quartz sand as filler.

Among the drawbacks are its lack of moisture resistance and inability to be utilized for products and structures that will be exposed to the elements when it rains.

Asphalt concrete

It was covered in our article’s opening paragraph. It is prepared using bitumen, which is obtained during the distillation of oil. Natural asphalt is rarely usable in close proximity to deposits. The melted binder is supplemented with fillers.

The material is moisture-resistant and reasonably priced. The primary application for it is in road surfaces due to its ease of laying.

The great majority of highways built worldwide are built with it. There are roofs made of asphalt concrete as well. One of the drawbacks is that it becomes softer and loses strength in response to temperature changes.

Silicate concrete

The age of this material is comparable to that of regular concrete. The technology came into existence between 40 and 50 years after Portland cement. Simultaneously, the first brick buildings constructed using this technique emerged.

The image below shows one of the older silicate-brick homes. However, it wasn’t until much later that silicate houses started to appear in our rural areas around the middle of the previous century.

We will focus on this material a little more because it is very common, and we will include a more thorough list of its benefits and drawbacks.

The material is created by autoclaving pressed products made from a sand and lime mixture in small amounts. It gains strength and water resistance there while being affected by steam at high pressure.

Large-sized blocks with a porous structure can also be made from silicate, which is becoming increasingly popular as a material that combines structural and thermal insulation qualities, in addition to bricks.

Advantages of silicate concrete

1. Low price of products due to cheap raw materials.
2. Possibility to set up production almost anywhere in the world. There are deposits of sand and limestone almost everywhere.
3. When making bricks and blocks from this material, they do not shrink or dry out, maintaining their shape and size. It is easy to lay out from them.
4. Products made of silicate are almost pure white.

Disadvantages of silicate concrete

1. Due to the need to use autoclaves, large-sized monolithic structures cannot be formed from the material.
2. Less heat resistance than ordinary concrete.
3. Also, the material does not like moisture, although its frost resistance is not inferior to other materials. However, technologies have been developed to eliminate this drawback.

Interesting fact. Many structures were constructed in the Krasnoyarsk Territory in the 1990s using silicate as the primary building material instead of Portland cement for all components, including the foundations. This was extensively covered in construction-related publications. Despite the harsh conditions in this region and the passage of nearly three decades, they remain intact. Furthermore, upon inspection, the foundations revealed that not a single percent of their strength had been lost.

The following materials were all published later, by the early 20th century.

Glass concrete

Based on magnesium, potassium, or silicate glass. The substance can be nearly transparent and has a great texture. Of course, in terms of strength, it is not as strong as regular concrete. Its ability to keep water out is exceptional.

Its tendency to melt at relatively low temperatures is one of its drawbacks. Products made of it will, of course, not burn in the heat, but they will undoubtedly lose their shape in a flame.

Slag-alkali concrete

Crushed slag is exposed to alkali, such as liquid potassium silicate or sodium silicate, to produce the material. Its resistance to frost is surpassed only by a few polymers.

As such, it finds widespread application in the production of curbstones and paving slabs.

• Just like traditional concrete based on Portland cement, it gains strength over time. But this happens more intensively.
• For example, after ordinary cement has gained brand strength, the increase in this characteristic slows down sharply to literally several percent per year. Slag-alkaline concrete can increase its resistance to compressive forces by one and a half to two times in a year.
• The advantages of this material include the fact that waste is used for its production – slag. Thus, the problem of its disposal is solved. Although, of course, some types of slag can also be used as raw material for the production of slag Portland cement.
• By the way, the material was of great interest in the Soviet Union. The video in this article at the link is one of the issues of the newsreel "Architecture and Construction" for 1988. One of the essays in it tells about the development of porous slag-alkaline concrete technology by Kirovohrad scientists.

Note: The creators were even awarded a state prize for the material’s exceptional qualities and extensive application of industrial waste.

Sulfur concrete

Since the first attempts to use natural sulfur as a binder were made in North America at the end of the 18th century, it could be argued to be older. This kind of concrete didn’t become well-known until the 1950s and 1960s, mainly in the USA and Canada.

Regarding slag-bore concrete, it is made from industrial waste, specifically a chemical. Together with aggregates that are unfit for additional processing, modifiers are added when the sulfur is melted. Although the production process of server concrete is very similar to that of asphalt concrete, it is more robust and long-lasting.

The acid resistance of server concrete is a huge benefit.

Studies show that the resultant substance does not lose its properties when left in sulfuric acid for several decades.

• Another plus – it is a bactericide. That is, products and structures from it are almost sterile. It is not clear why it is not used for sewage and other structures associated with sewage?
• Used for underground structures and parts of structures that come into contact with the soil. Like asphalt, it can be used in road construction. In addition to resistance to chemicals, it is also resistant to low temperatures.
• The disadvantages include the fact that it begins to melt at temperatures above 150 degrees. It is afraid of open fire and is fire hazardous. It also cannot be used in contact with other building materials – it causes corrosion.

Pay heed. It poses a threat to both people and animals, as repeated contact can result in poisoning. With the exception of cesspools and septic tanks, which were already discussed, this material is therefore inappropriate for use in homes.

Polymer concretes

There are numerous concretes in this group, all with different qualities. They are created using industrial waste and polymers that have been specifically synthesized for the material.

The polymer that is used to make the material has a significant impact on its attributes. As a result, polyvinyl chloride-based concretes crack at low temperatures, but polyurethane-based compositions do not. The majority of polymer concretes have a high level of moisture resistance.

The binder used to make concrete affects the production technology as well.

1. For most resins (epoxy, etc.). P.) and some other polymers, as a rule, a mixture of binder with hardener and fillers is mixed. The composition is then molded (poured into a mold or formwork) where polymerization occurs.
2. For most thermoplastic materials, the technology is similar to the production of asphalt concrete. The binder is heated to a liquid state, then fillers are added to it. Hardening occurs during cooling.

Polymer concretes have the benefit of not only withstanding moisture but also not being afraid of corrosion. They can be used to create a wide range of products with different looks. Many materials can be easily mimicked, including priceless varieties of real stone. They have many times more tensile and bending strength than other varieties of concrete.

There are drawbacks as well. These materials tend to be heat-sensitive and may ignite a fire. Additionally, dangerous substances may release when polymer concrete is heated. Prolonged exposure to ultraviolet radiation (sunlight) can destroy some types.

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Topic	Details
History	Cement-free concrete has been explored since the early 20th century. Researchers sought alternatives to traditional cement due to environmental concerns and the need for more sustainable materials.
Varieties	There are several types of cement-free concrete, including geopolymer concrete, which uses industrial by-products, and lime-based concrete, which relies on natural lime as a binding agent.
Features	Cement-free concrete often offers improved sustainability, reduced carbon footprint, and in some cases, enhanced durability. It can also have unique aesthetic qualities depending on the materials used.

An intriguing substitute for conventional cement-based mixtures is cement-free concrete. We can observe how this novel material satisfies contemporary building requirements while having a minimal environmental impact by investigating its history, variations, and features.

Cement-free concrete has come a long way from its early experiments with non-cementitious binders to its sophisticated formulations today. Its various varieties—like geopolymer and magnesium-based concretes—each offer special benefits, like increased durability and reduced carbon footprints.

Making educated decisions is aided by knowledge of these materials for architects and builders. Cement-free concrete is a useful addition to the construction industry because it solves environmental issues and offers a variety of applications.

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