R2Crete: A Circular Solution to Concrete Waste
Concrete is the most widely used man-made material on the planet, forming the foundation of cities, infrastructure, and industry. But it comes at a massive cost: around 35 billion tonnes of concrete are produced each year, generating more than 2 billion tonnes of waste and contributing to roughly 8% of global CO2 emissions. R2Crete is on a mission to change that, with a modular solution that transforms concrete waste into low-carbon, high-value materials.
A massive industry, a massive waste problem
Concrete is the world’s most widely used building material, strong, affordable and versatile. But because we use so much of it the sector has a significant environmental footprint. Most people don’t realise it, but by mass, concrete makes up almost half of everything humans have ever created. With over 35 billion tonnes used annually, the sector is both resource and emissions intensive.
"The industry also heavily relies on extraction of natural materials like limestone, sand and aggregate, putting strain on finite natural resources," explains Tuan Nguyen, co-founder of R2Crete.
Waste concrete tends to be downcycled, crushed and used as low-grade road base or backfill. As cities grow and construction accelerates, this linear model of extraction, use and downcycling is both unsustainable and costly for the concrete sector.
R2Crete sees a better way: a circular economy approach where waste concrete is turned back into raw materials that can be reused in new concrete production, including high-performance cement replacements, directly reducing emissions.
Regenerating concrete, a circular and low-carbon solution
R2Crete has developed a modular, containerised system that can process concrete waste into recycled cement and aggregates for new concrete production.
“Most recycling facilities can only produce low-quality recycled aggregates from concrete waste. We’re aiming to fix that. Our technology can recover 75% of the cement in waste concrete and use this recycled cement as supplementary cementitious material (SCM),” says Warren Overton, Managing Director of R2Crete. Cement is the most emissions-intensive component of concrete, so every tonne replaced by the SCM directly reduces carbon impact.
“By regeneration of concrete, we literally develop the same material with the same characteristics that the sector is familiar and comfortable to adopt. But it uses 50% recycled components and produce 50% less CO2,” Tuan adds the importancemeeting the requirements of workability, finishability and technical performance for industry adoption while achieving sustainability benefits.
“Our system is efficient, scalable, and easily deployed. It’s literally a plug-and-play model: drop the container on-site and start processing,” says Overton. “We can slot into existing facilities without needing major construction works or council approvals. It means waste is processed on-site, and the recovered materials can be reused immediately in new concrete.”
Concrete made from R2Crete technology (R2C) above and normal concrete (NC) below. Same material, sample performance, but 50% recycled content and 50% CO2 reduction.
Initial market feedback has been strong, especially in regions where concrete waste disposal is difficult or costly. In Australia alone, R2Crete estimates their target market includes over 7 million tonnes of waste concrete per annum. Globally, that number could exceed 2 billion tonnes.
A team built on experience and impact
The R2Crete team brings together deep technical expertise, commercial know-how, and a strong commitment to impact. Tuan Nguyen has spent the past decade researching concrete materials and recycling technologies at the University of Melbourne, where he developed the foundation for R2Crete’s technology.
While he originally viewed the project through a researcher’s lens, Tuan says his mindset has shifted dramatically. “I used to think: how can my research help industry? Now I ask: what real problems is industry facing?”
Joining him are Warren Overton, a sustainability consultant and executive with decades of experience in recycling and cleantech and Professor Mahdi Disfani, an expert in geotechnical engineering and co-founder of another research commercialisation venture. Together they form a cross-disciplinary team that understands both the technical and business sides of innovation.
Tuan Nguyen, Co-Founder of R2Crete and Warren Overton Managing Direction of R2Crete
Their mix of academic and industry experience is already paying off. R2Crete has secured proof-of-concept funding from the University of Melbourne and is preparing to deploy its first pilot unit in partnership with a local concrete company. They’ve also had strong early conversations with major infrastructure projects and concrete suppliers, who are under increasing pressure to reduce emissions and meet recycled content targets.
Cutting emissions in the concrete supply chain
With their first pilot system expected to be operational in early 2026, R2Crete is focused on validating its performance in real-world conditions and building market confidence in the product. The team estimates that their system can reduce greenhouse emissions by up to 50% and achieve a 50% recycled content, a major improvement over traditional concrete currently used in the industry.
Beyond environmental benefits, R2Crete sees local economic advantages, too. The system enables on-site material reuse, reduces landfill costs and opens new opportunities for job creation and local manufacturing. Long-term, the team hopes to establish Australian-based production of its modular systems, helping rebuild domestic industrial capability.
“Imagine sending a unit to a city after a major earthquake, or anywhere that needs rapid reconstruction,” says Overton. “This isn’t just a recycling solution, it’s a way to democratise access to sustainable construction materials.” Warren Overton Managing Direction of R2Crete
TRAM and the road ahead
R2Crete joined the TRAM Air program in 2025 to sharpen their go-to-market strategy and connect with investors. For Tuan, the journey has been a powerful learning curve.
“TRAM helped me understand what it takes to bring a research idea into the real world,” he says. “It’s not just about the technology, it’s about finding the right deployment model, the right timing and the right partners.”
Warren Overton, Managing Director of R2Crete and Tuan Nguyen, Co-Founder of R2Crete
Looking ahead, R2Crete is seeking pre-seed investment to support their pilot launch and ramp up manufacturing. They’re also applying for non-dilutive grants and exploring partnerships with early adopter customers, government agencies and sustainability-minded construction firms.
If they succeed, the team believes R2Crete could become a global platform technology, delivering circularity, emissions reduction and local resilience wherever concrete is made.
Read more about the 2025 TRAM Air cohort
Get in touch with Masha to learn more about TRAM Air: masha.pelipas@unimelb.edu.au