Leeds D Silo Building a cement silo using Sustainable cements.

Transcription

1 Leeds D Silo Building a cement silo using Sustainable cements Concrete Sustainability Conference Tempe, AZ April Gary Knight Heidelberg Technology Center Manager of Concrete Research & Support Atlanta, Georgia Co-Author: Robert Bachmann 2010 Concrete Sustainability Conference 1 National Ready Mixed Concrete Association

2 Lehigh Leeds C1157 / C150 Type I, II Cements Performance / Prescriptive ASTM C150 Type III 1 day, 1740 psi ASTM C1157 GU 1 day n/a, 3d-1890, 7d-2900, 28d ASTM C1157 HE 1 day-1740, 3d Concrete Sustainability Conference 2 National Ready Mixed Concrete Association

3 Three (3) chamber silo with total of 20,000 MT capacity 80 feet diameter, 240 feet tall Fully automated truck loading facility Construction cost $20.5 million 18 months construction ti time Concrete Sustainability Conference 3 National Ready Mixed Concrete Association

4 Situation 1157HE cement (10% limestone) Slag as SCM Admixture to control setting time Contractor experience only with Type I/II 28d strength 6000psi Concrete Sustainability Conference 4 National Ready Mixed Concrete Association

5 Challenge Slip forms require specific properties Shortage of time for mix design development Contractor concerned about experimental mix design Lack of acceptance for ASTM C1157 specification Lab Data vs. field test ( real world ) -> field test t box Major concern: setting time control -> 1157HE perceived spike Admixture -> Retarder? Concrete Sustainability Conference 5 National Ready Mixed Concrete Association

6 Lab Data I) Time of Set Concrete Sustainability Conference 6 National Ready Mixed Concrete Association

7 Lab Data II) Calorimeter 0%, 30%, 40%, 50% slag Concrete Sustainability Conference 7 National Ready Mixed Concrete Association

8 Lab Data II) Calorimeter 30% Slag, changing WR dose Concrete Sustainability Conference 8 National Ready Mixed Concrete Association

9 Lab Data II) Calorimeter Concrete Sustainability Conference 9 National Ready Mixed Concrete Association

10 Lab Data III) Consistometer Concrete Sustainability Conference 10 National Ready Mixed Concrete Association

11 Lab Data III) Consistometer Concrete Sustainability Conference 11 National Ready Mixed Concrete Association

12 Field Trial Box test 3 layer of concrete 16 each layer 30min between each filling with new load of concrete Rebar test as measurement Shawn Concrete Sustainability Conference 12 National Ready Mixed Concrete Association

13 Gaining & Loosing Bottom Gaining Bottom Loosing Bottom Placement Rate 90 min min 30 min Concrete Sustainability Conference 13 National Ready Mixed Concrete Association

14 Field Trial Box test Concrete Sustainability Conference 14 National Ready Mixed Concrete Association

15 Field Trial Box test rebar test 45 inch crust, 3 Mixes for 1 Box 4000 Inc ches ToS only for #1 load 1:13 1:28 1:43 1:58 2:13 2:28 2:58 3:28 3:58 4:28 4:48 4:58 1:45 PM 2:00 PM 2:15 PM 2:30 PM 2:45 PM 3:00 PM 3:30 PM 4:00 PM 4:30 PM 5:00 PM 5:20 PM 5:30 PM Time Concrete Sustainability Conference 15 National Ready Mixed Concrete Association

16 Field Trial Box test Concrete Sustainability Conference 16 National Ready Mixed Concrete Association

17 Field Trial Box test BASF Admixtures: P1025, Delvo, 322N Water Reducer / Hydration stabilizer Concrete Sustainability Conference 17 National Ready Mixed Concrete Association

18 Variable set time mix design Concrete Sustainability Conference 18 National Ready Mixed Concrete Association

19 Day 1 Tuesday: 0 20ft, 10.8in/h Concrete Sustainability Conference 19 National Ready Mixed Concrete Association

20 Day 2 Wednesday: 20 40ft, 10.3in/h Concrete Sustainability Conference 20 National Ready Mixed Concrete Association

21 Day 3 Thursday: 40 57ft, 9.8in/h Concrete Sustainability Conference 21 National Ready Mixed Concrete Association

22 Day 4 Friday: 57 84ft, 10.8in/h Concrete Sustainability Conference 22 National Ready Mixed Concrete Association

23 Interior Ring Silo Slip Concrete Sustainability Conference 23 National Ready Mixed Concrete Association

24 Other Concerns Concrete Sustainability Conference 24 National Ready Mixed Concrete Association

25 Other Concerns sink holes Concrete Sustainability Conference 25 National Ready Mixed Concrete Association

26 1938c Building of the original Leeds Silos Concrete Sustainability Conference 26 National Ready Mixed Concrete Association

27 1938c Building of the original Leeds Silos Concrete Sustainability Conference 27 National Ready Mixed Concrete Association

28 Concrete Sustainability Conference 28 National Ready Mixed Concrete Association

29 1938c Building of the original Leeds Silos Concrete Sustainability Conference 29 National Ready Mixed Concrete Association

30 Questions? Working together for success with performance materials C % Limestone Cement C595 Ground Granulated Slag 244 Breaks -60hrs Concrete Sustainability Conference 30 National Ready Mixed Concrete Association