10061093Graphene enhanced concrete sleeper for lower embodied carbonClosedCollaborative R&DInnovate UKIn the UK, ageing infrastructure and population growth are increasing demand for concrete, not least in the rail sector; where 20,000 miles of new track are needed. The production of cement (concrete's binding agent) releases CO2 as a direct by-product of CaCO3 calcination. These direct emissions, in combination with indirect process-emissions (transport, process energy etc), represent a staggering 8-10% of global emissions. The concrete sector has undertaken substantial efforts towards decarbonisation already; however, a second-phase of more ambitious decarbonisation is urgently needed in order to meet UK climate targets. This project vision directly addresses this urgent decarbonisation need through the development of novel graphene-enhanced concrete (GEC) materials for load-bearing sleeper applications. Our method of graphene dosing delivers a 50% improvement in mechanical strength. In addition, a combination of reduced concrete volume, reduced cement content and reduction in amount of steel reinforcement needed (thanks to the superior mechanical performance) will reduce total carbon-footprint by up to 50%. Key Objectives: 1. To review our current admixture formulations with high graphene loading for compatibility with sleeper concrete mix designs, prescribed to Network Rail standards. 2. To define optimum admixture dosing into concrete sleepers (with graphene content of concrete remaining <0.1wt%). 3. Prove the science in sleeper trials at Phase 2 stage to demonstrate the benefits for sleeper applications. Whilst other GECs are in development, most emerging technologies are not suitable for structural applications. Those GEC products that aim to target structural applications are struggling to overcome the challenge of dispersing graphene nano-platelets (GNPs) within cement. Existing approaches result in the incorporation of excess air into concrete's microstructure, severely limiting structural performance. We have overcome the dispersion challenge, enabling 5x greater graphene-loading than the state-of-the-art, with uniform dispersion, and no excess air entrainment. Network-Rail, infrastructure manager of the UK rail-network, are not included in the grant consortium, but will be early technology adopters, providing a clear route to market. In addition, we are on the steering group for the development of the forthcoming new sleeper standard, which will be re-written to encourage low embodied carbon products to be used in sleepers.