Replacement of Concrete Aggregates with Coal-Derived Flash Graphene

Each year, the growth of cities across developing economies in Asia, Africa, and Latin America drives demand for concrete to house and serve their burgeoning populations. Since 1950, the number of people living in urban areas has quadrupled to 4.2 billion, with another predicted 2.5 billion expected to join them in the next three decades. The largest component of concrete by volume is aggregates, such as sand and rocks, with sand as the most mined material in the world. However, the extraction rate of sand currently exceeds its natural replenishment rate, meaning that a global concrete-suitable sand shortage is extremely likely. As such, replacements for fine aggregates, such as sand, are in demand. Here, flash Joule heating (FJH) is used to convert coal-derived metallurgical coke (MC) into flash graphene aggregate (FGA), a blend of MC-derived flash graphene (MCFG), which mimics a natural aggregate (NA) in size. While graphene and graphene oxide have previously been used as reinforcing additives to concrete, in this contribution, FGA is used as a total aggregate replacement for NA, resulting in 25% lighter concrete with increases in toughness, peak strain, and specific compressive strength of 32, 33, and 21%, respectively, with a small reduction in specific Young's modulus of 11%. FJH can potentially enable the replacement of fine NA with FGA, resulting in lighter, stronger concrete.