Several studies have explored the use of graphene to
improve the
properties of cement-based materials. However, most commercially available
graphenes are expensive, not amenable to mass production, and have
high embodied energy and emissions, making their use in concrete less
attractive, despite the beneficial mechanical property attributes.
This paper discusses the use of two novel graphene types, fractal
graphene (FG) and reactive graphene (RG), obtained through a cost-effective
and scalable detonation synthesis, in cement-based materials. FG and
RG are sheets containing 6–10 layers, with lateral dimensions
of 20–50 nm and a z-axis thickness of <5
nm. RG is functionalized with carboxylic groups. An ultrasonication
process is employed to ensure dispersion of graphene particles in
aqueous solutions. Both FG and RG, when added at very small dosages
(≤0.04% by mass of cement), enhance the compressive strength
of cement mortars by >70% at early ages and up to 20% at later
ages.
The beneficial effect of functionalization results in better performance
for RG-modified mixtures, even at dosages as low as 0.02%. Concomitant
enhancements in heat of hydration, hydrate formation, and rheological
response are observed. A significant reduction in porosity and critical
pore size (by 50% or more) promises significantly improved concrete
durability, and thus reduced life-cycle costs. A comparative life
cycle analysis (LCA) is used to show that FG- and RG-modified mortars
have normalized (by the 28 d strength) energy demand and global warming
potential (GWP) that is up to 15% lower than those of conventional
mortars. Overall, this study shows that FG and RG, manufactured through
a scalable, cost-, energy-, and CO2-efficient detonation
synthesis, can beneficially impact the engineering and environmental
performance of concretes.