Circular Thinking Drives Concrete Innovation at Daracon and Daracrete

Daracon Group and Daracrete are celebrating the successful completion of a major research partnership that has demonstrated how industrial by-products can be transformed into high-performing, lower-carbon concrete, reinforcing the Group’s commitment to sustainable construction and circular economy principles.

Working alongside SmartCrete CRC Project Partner the University of Newcastle as their Industry Lead, Daracon and Daracrete participated in the Development of Eco-Friendly Concrete Using Industrial By-Products project, which investigated the use of furnace bottom ash - a by-product of coal-fired electricity generation that has historically been sent to landfill. The project successfully developed and tested concrete mixes incorporating furnace bottom ash as both a fine aggregate and cement replacement.

The research team found that one of the optimal concrete mixes delivered an 11% increase in 28-day compressive strength while achieving approximately 30% lower embodied carbon than conventional concrete. The project also demonstrated the successful construction of a footpath using the new mix and developed practical guidance to support future industry adoption.

The outcomes align strongly with Daracon Group’s sustainability vision, which focuses on leveraging sustainable materials, supporting the development of innovative construction materials and being environmentally responsible across the products and services provided. Through its partnership with SmartCrete CRC, Daracon has been investigating the increased use of recoverable resources, including coal combustion products such as furnace bottom ash, to help reduce production costs, lower carbon emissions and support the long-term decarbonisation of the concrete industry.

Adam Kelly, Director Business Development, said the successful completion of the project demonstrates the value of industry-led collaboration in accelerating sustainable outcomes.

“This project highlights what can be achieved when industry, researchers and asset owners work together to solve complex sustainability challenges. By finding new uses for materials that would otherwise become waste, we have the opportunity to reduce landfill, conserve natural resources and create practical solutions that benefit both industry and the environment.

“For Daracon, including our alliance organisation Daracrete, this research represents another important step towards embedding sustainability into the materials we produce and the projects we deliver.”

The project also builds on Daracon Group’s broader commitment to circular economy initiatives. In June, the Group opened the Buttai Recycling Centre, located at its Buttai Quarry, creating a dedicated facility capable of receiving and processing a range of construction materials including concrete, concrete washout, reclaimed asphalt pavement, bricks, ceramics, coal ash and coal wash rejects.

The facility allows these materials to be recovered and repurposed into recycled aggregates and blended construction products, helping to offset some of the environmental impacts associated with the construction industry’s most widely used materials. The initiative supports Daracon Group’s efforts to reduce waste, maximise resource recovery and increase the use of recycled products across its operations.

With both the SmartCrete research project completion and the opening of the Buttai Recycling Centre, Daracon Group is continuing to invest in practical solutions that support a more sustainable future for the construction industry.

As the demand for lower-carbon infrastructure continues to grow, initiatives such as these position Daracon and Daracrete at the forefront of industry innovation, helping to shape a future where waste becomes a valuable resource and sustainable construction materials become part of everyday project delivery.