The Production Process of Circular Carbstone Building Blocks
In this article, we explore the innovative production process of Carbstone building blocks, a circular and CO2-negative alternative to traditional concrete blocks. Discover how these sustainable building solutions contribute to a greener future.
Introduction to CO2 Neutral Construction
CO2-neutral construction is an essential component of the modern building sector. It focuses on reducing CO2 emissions during the construction process. This is achieved by using sustainable materials and techniques that minimize the ecological footprint.
With increasing pressure on the building sector to become more sustainable, innovations like Carbstone building blocks are crucial. These solutions not only help reduce environmental impact but also decrease reliance on traditional building materials.
Benefits of CO2-Neutral Construction
- Reducing carbon footprint: Using carbon-neutral materials significantly reduces overall emissions during construction.
- Increased energy efficiency: Sustainable construction methods often lead to improved insulation and energy performance of buildings.
- Contribution to circular economy: The use of recycled materials promotes a circular approach to construction.
What Are Carbstone Building Blocks?
Carbstone building blocks are innovative construction materials designed to be circular and CO2-negative. This means that over their life cycle, they absorb more CO2 than they emit. The blocks are produced using recycled materials, such as steel slags, and require no traditional cement. This makes them not only more environmentally friendly but also cost-effective.
Features of Carbstone Building Blocks
- Duurzaamheid: Deze blokken zijn ontworpen om lang mee te gaan en zijn bestand tegen verschillende weersomstandigheden.
- Insulation: Carbstone blocks offer excellent thermal insulation, contributing to energy efficiency in buildings.
- Recycled materials: The blocks are made from recycled steel slag, which reduces the demand for new raw materials.
The Concrete Ban and Circular Construction
De Betonstop en Circulair Bouwen
The concrete ban is a response to growing concerns about the environmental impact of the construction sector. This policy encourages the industry to transition towards circular construction practices.
Circular construction involves reusing and recycling materials, extending the life cycle of building materials and reducing waste.
Impact of the Concrete Summit
- Limiting new concrete production: This forces the industry to seek alternatives, such as Carbstone building blocks.
- Increased focus on sustainability: Construction companies are encouraged to incorporate sustainable and circular solutions into their projects.
- Innovation in building materials: The pressure to comply with the concrete ban encourages the development of new, environmentally friendly building materials.
The Importance of Natural Granules
Natural aggregates are an essential part of traditional concrete production. However, with the announcement of the concrete freeze, there is growing concern about the availability of these raw materials.
Reducing the use of natural aggregates is crucial to reducing the ecological impact of the construction industry. This can be achieved by using innovative materials such as Carbinox.
Alternatives to Natural Granules
- Recycled materials: The use of recycled materials reduces the demand for new granules. Such as Carbinox and Stynox.
- Upcycling: Reusing waste materials, such as steel slag, increases resource efficiency.
- Innovative mixtures: developing new mixtures that replace natural granules with sustainable alternatives.
Recycling and circular economy
Recycling is a foundation of the circular economy. It promotes the reuse of materials and reduces waste. In the construction industry, recycling is essential for creating sustainable structures.
By recycling materials, such as concrete and steel slag, we can reduce the demand for new raw materials and lower the ecological impact of the construction industry.
Benefits of recycling in construction
- Cost savings: Reusing materials can save costs in construction projects.
- Reducing waste: Recycling materials reduces the amount of construction waste that ends up in landfills.
- Promoting sustainable practices: Recycle encourages companies to operate more sustainably and contribute to a circular economy.
Upcycling of steel slag
Upcycling steel slag is an innovative solution that helps the construction industry become more sustainable. Steel slag, a byproduct of steel production, is transformed into valuable building materials.
This process not only reduces waste, but also reduces reliance on traditional building materials such as cement and natural aggregates. This reduces the need to operate environmentally damaging quarries.
Benefits of upcycling
- Waste reduction: Upcycling steel slag reduces the amount of waste produced in the steel industry and reduces it to zero.
- Reduced CO2 emissions: The use of recycled materials reduces the CO2 emissions normally associated with the production of new materials.
- Economic benefits: Creating new products from steel slag can provide economic opportunities and open up new markets.
The innovation behind CO2-negative blocks
The development of CO2 negative blocks, such as Carbstone, is an example of how innovation can transform the construction industry. These blocks are designed to absorb more CO2 than they emit during their production, contributing to the fight against climate change.
By using recycled materials, such as steel slag, and avoiding traditional cement, these blocks can have a significant impact on the environmental performance of construction projects.
Technological Innovations
- Advanced manufacturing techniques: Carbstone’s manufacturing process uses innovative techniques that increase efficiency and reduce its carbon footprint.
- Use of CO2 cycling: CO2 curing makes this possible and ensures limestone formation.
- Research and Development: Ongoing research into the properties of materials ensures improvements in product quality and performance. In collaboration with Orbix, VITO and the Universities of Hasselt and Leuven.
Production process of Carbstone
Carbstone’s manufacturing process involves several steps that are essential to creating durable and strong building materials. This process begins with the selection of high-quality recycled raw materials.
Steel slag is upcycled into a fine mineral used in the composition of the blocks called Carbinox. By avoiding cement, CO2 emissions during production are significantly reduced.
Steps in the Production Process
- Raw material selection: Recycled steel slag is selected and prepared for processing.
- Processing: The steel slag is upcycled into a fine mineral that serves as the basis for the blocks.
- Composition: A concrete-like composition is made without cement, further reducing the ecological impact.
- Shaping: The composition is molded into the desired shapes to create the blocks.
Drying chamber and curing
After shaping, the Carbstone blocks are placed in a drying chamber. This is a crucial step in the manufacturing process, where the blocks undergo CO2 curing that is essential for their strength and durability.
The cycle takes 24 hours, after which the blocks are ready for transport and use. This process ensures that the blocks are not only strong, but also remain CO2-negative. The injected CO2 is used integrally for curing the bricks.
Importance of Curing
- Strengthening the blocks: curing ensures that the blocks maintain their structural integrity.
- CO2 absorption: During curing, the blocks are allowed to absorb CO2 from the air.
- Accelerating the process: Advanced drying chambers allow the curing process to be carried out efficiently. In a span of 24 hours where concrete needs 28 days and bricks need high temperatures.
Applications of cicular CO2 negative blocks
CO2-negative blocks can be used in a variety of construction projects. Their versatility makes them suitable for both public and private construction projects.
From housing to civil works, the possibilities are endless. These blocks can play an important role in promoting sustainable building practices.
Carbstone is the sustainable alternative to sand-lime brick, ceramic quick build bricks and concrete blocks
Examples of applications
- Public buildings: Carbstone blocks can be used in the construction of schools, residential care centers and community centers.
- Private homes: Homeowners can choose these blocks as an environmentally friendly alternative to traditional building materials.
- Civil infrastructure: The blocks are also suitable for roads and other civil projects, where sustainability is a priority.
Conclusion
The development of Carbstone building blocks marks an important step toward a more sustainable future in the construction industry. By using innovative techniques and recycled materials, these blocks contribute to the reduction of CO2 emissions.
It is essential that the construction industry continues to invest in circular solutions such as Carbstone to minimize ecological impact and contribute to a greener world.
Frequently Asked Questions
Nothing but in a classic concrete stone. The composition will not expand as a result of drilling. So the CO2 remains trapped.
Absolutely, the stone stores CO2 and will continue to do so. However, this does not mean that he releases them into the home, rather that he binds more and more and thus becomes harder.
Yes, they meet all the same specifications (see technical sheet). In addition, Carbstones – when placed outdoors – will continue to absorb CO2, further hardening them and, consequently, making them stronger.
Carbstone blocks are priced similar to conventional bricks on the market, have the same price as concrete blocks, and are cheaper than quick construction and sand-lime blocks.
The minimum curing time of the blocks is 24h, unlike traditional masonry blocks that require 3 weeks. Production time always varies according to order size. Contact us for more information.
Carbstone blocks offer numerous benefits, including a negative carbon footprint, excellent acoustic insulation properties and the use of recycled materials.
Carbstone blocks are the sustainable alternative to all existing building blocks on the market, including ceramic, concrete and sand-lime blocks. Carbstone is used to significantly reduce the carbon footprint in public and civil construction projects, automatically making the walls circular.
On average, each Carbstone block captures about 2 Kilo CO2 and saves another 2 Kilo CO2 by eliminating the need for cement production or firing process. Since an average family home uses about 12,000 blocks, this results in significant CO2 savings of up to 48000 Kilo CO2.