Sectioned processing of compaction self-assembly of an ultralow-binder-content particulate composite

Abstract “Green cement” has been extensively studied to reduce the carbon emission and the energy consumption associated with the construction materials production. In this research, we developed a sectioned compaction system to produce bricks of ultralow-binder-content (UBC) composite, which consisted of ∼96 wt.% sand and ∼4 wt.% epoxy binder. After premixing, the material was compressed in nine sections and two steps. Upon compaction, the small amount of binder self-assembled into polymer micro-agglomerations (PMA), which efficiently bonded the sand grains into a structurally integral solid. The so-produced material was uniform and quite strong. The modulus of rupture was ∼23.5 MPa, two times higher than the typical flexural strength of steel-reinforced concrete.