Construction materials company Boral Limited says it has completed product development of what it describes as Australia’s first low-carbon concrete incorporating locally sourced calcined clay, following laboratory testing and field trials.
According to Boral, the product development marks a step toward reducing carbon emissions associated with concrete production and infrastructure, with calcined clay used as a supplementary cementitious material.
Boral said the work followed extensive laboratory testing and large-scale field trials to assess the technical viability of the material.
The company began technical feasibility studies in 2024 in partnership with the University of Technology Sydney (UTS), Transport for NSW and Calix, as part of a project supported by the SmartCrete Cooperative Research Centre, whose activities are funded by industry partners and an Australian Commonwealth Government grant. Boral said the development also builds on earlier studies conducted with UTS between 2020 and 2024.
The company said the calcined clay concrete mixes included binary- and triple-blend formulations, which were tested under operational conditions at its cement facility in Maldon.
Boral noted the trials demonstrated workability and performance characteristics comparable to those of conventional low-carbon concrete products.
Customer trials were also carried out, with Boral supplying a concrete mix for a test slab in collaboration with Victoria’s North East Link and the University of Melbourne. Boral emphasised the trial used clay recycled from excavated material sourced from the project site.
Boral CEO and Managing Director Vik Bansal said the development aligned with the company’s stated sustainability goals.
“Boral is committed to leading the transition to a lower-carbon future,” he said. “Our calcined clay concrete is a major step forward in our innovation journey and progress towards Net Zero. This work ensures we can continue to offer sustainable solutions for Australia’s building and infrastructure needs and meet our customers’ needs.”
Dr Ali Nezhad, Boral’s Head of Sustainability and Innovation, noted the trials demonstrated the material’s performance at scale.
“From the lab to successful field trials and product development, our work demonstrates that calcined clay concrete is not just a concept; it works at scale,” he stated. “Our field trials confirmed workability and placement, and the concrete looks and performs like conventional mixes.”
Dr Nezhad said Boral was developing a range of low-carbon concrete products using different blend formulations to support supply resilience and industry decarbonisation efforts, adding that the company had received early interest from industry partners to participate in further trials.
