Abstract
New eco-friendly thermal-casting ductile CPNC-concrete and CPNC-mortar materials have been developed without Portland-cement or water-use. It needs three hours for thermal synthesis. It contains 5%, 10% or 15% green natural nanoclay-polymer nanocomposite CPNC as a bonding-agent instead of Portland-cement for mixing with sand and crushed-stones by heating at 250 °C in electric ovens. CPNC is a dry powder consisting of 5% montmorillonite (MMT) nanoclay and 95% high-density polyethylene (HDPE). The study includes mixing, thermal synthesis, mechanical, fracture, and ductility property testing, and characterizations of the chemical composition, microstructure morphology and homogeneity using EDAX, SEM and XRD. It has new properties, such as a homogenous-microstructure with bonding, self-compaction abilities, no-cracks, ductility, good compressive and tensile strengths, and good fracture properties. It does not exhibit steel corrosion; it has rapid processing, no-water curing, low-density, no-shrinkage cracks, no-sudden failure, no-pollution utilizing a new manufacturing technique. CPNC-concrete is developed to stop the Portland-cement industry problems, to produce a clean and green environment without Portland-cement damage for human beings and to conserve drinking water. It has potential for different applications in construction, and it is suitable for 3D techniques with fast construction. Furthermore, this material requires new special codes for design and construction.