"Green Concrete. A Guide to Sustainable Concrete Production: From Cement & Aggregate Substitutes to Sustainable Production Methods
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1 "Green Concrete A Guide to Sustainable Concrete Production: From Cement & Aggregate Substitutes to Sustainable Production Methods International Concrete Sustainability Conference December Dubai, UAE Courtesy of: Mobil-Baustoffe GmbH Nadja Ortner-Ortner Consulting International Concrete Sustainability Conference, Dubai, UAE 1
2 Sustainable Properties of Concrete fully recyclable good insulating properties (> steel; < wood) good energy storing properties large thermal mass 2010 International Concrete Sustainability Conference, Dubai, UAE 2
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4 PRIMARY ENERGY vs. COMPRESSIVE STRENGTH Material Compressive Strength E-Module Primary Energy Consumption N/mm² N/mm² kwh/to Brick Work 5 5, Concrete 50 30, Aluminum ,000 52,000 Steel ,000 5, International Concrete Sustainability Conference, Dubai, UAE 4
5 CO 2 embodied in traditional concrete Material kg per m 3 of concrete c % per m 3 of concrete c kg of CO 2 emitted per ton produced d kg of CO 2 emitted per m 3 of concrete Cement Coarse aggregate 1, Fine aggregate Admixture Water TOTAL 2, NA > International Concrete Sustainability Conference, Dubai, UAE 5
6 CO 2 Emissions in Concrete Life-cycle Carbon Dioxide Emissions System Boundary Admixtures Production Fine Aggregates Production Diesel Fuel LPG Fuel Unexploite d Resources Cement Production Fly Ash Processing Transport of Raw Materials to Concrete Batching Plants Concrete Production Transport of Concrete to Constructio n Site Placement (Pumping) of Concrete on Site One Cubic Meter of Concrete in Structure GGBFS Processing Electricity Coarse Aggregates Production Explosives 2010 International Concrete Sustainability Conference, Dubai, UAE 6
7 Supplementary Ingredient Materials Cork Wood Crushed Glass Recycled Concrete A1 Electric Arc Furnace Slag Rice Husk Ash Scrapped Tyre Rubber Micro Silica (Silica Fume) Ground Granulated Blast Furnace Slag 2010 International Concrete Sustainability Conference, Dubai, UAE 7
8 Supplementary Cementitious Materials Fly Ash Type C Type F Mixing with type C fly ash results in higher compressive strength Compressive Strength vs. Time - C Ash Mixtures as by (Crouch, Hewitt, & Byard, 2007) 2010 International Concrete Sustainability Conference, Dubai, UAE 8
9 Supplementary Cementitious Materials Rice Fly Husk Ash Ash 20% of rice paddy is rice husk 20% of those are if burnt for a few hours between 600 and 850 C rice husk ash rice husk is burnt in biomass power plants to produce electricity by-product RHA Evolution of compressive strength of concretes against curing time as by (Cordeiro, Filho, & de Moraes Rego Fairbairn, 2008) 2010 International Concrete Sustainability Conference, Dubai, UAE 9
10 Supplementary Cementitious Materials Micro Rice Silica Fly Husk (Silica Ash Ash Fume) byproduct from electric arc furnaces producing alloys highly pozzolanic, such as RHA Relationship between 28 day compressive strength and percentage replacement of silica fume as by (Katkhuda, Hanayneh, & Shatarat, 2009) 2010 International Concrete Sustainability Conference, Dubai, UAE 10
11 Supplementary Cementitious Materials RHA and SF - comparison Concrete mixture proportions of the mixes as by (Sampaio, J., Coutinho, J.S., Sampaio, M.N., 2000) Average strength of the mixes as by (Sampaio, J., Coutinho, J.S., Sampaio, M.N., 2000) 2010 International Concrete Sustainability Conference, Dubai, UAE 11
12 Proposed Cement Replacement Levels (GGBS, Fly Ash) Concrete Application Cement Concrete Paving 25-50% Et Exterior Flt Flatwork not exposed dto di deicer salts 25-50% Exterior Flatwork exposed to deicer salts with w/cm % Interior Flatwork 25-50% Basement floors 25-50% Footings 30-65% Walls & Columns 25-50% Tilt-up panels 25-50% Pre-stressed Concrete 20-50% Pre-cast Concrete 20-50% Concrete blocks 20-50% Concrete pavers 20-50% High Strength 25-50% ASR mitigation 25-70% Sulfate resistance Type II equivalance 25-50% Type V equivalance 50-65% Lower permeability 25-65% Mass concrete 50-80% 2010 International Concrete Sustainability Conference, Dubai, UAE 12
13 Aggregate substitutes Wood Scrap Tire Rubber Woodwaste produced by manufacturers of furniture Mainly used in asphalt concrete Substantial decrease in compressive strength Also used as lightweight aggregate in flowable fill 2010 International Concrete Sustainability Conference, Dubai, UAE 13
14 Aggregate substitutes Cork Unique cell structure allows for additional CO₂ absorption Excellent insulation material (thermal and acoustic) Usage in cladding (consider loss in compressive strength) th) Geographic distribution of cork forests as by (Cork Information Bureau, 2009, p.4) 2010 International Concrete Sustainability Conference, Dubai, UAE 14
15 Aggregate substitutes Recycled and Cork Crushed Concrete Compressive cube strength test results as by (Limbachiya, Koulouris, Roberts, & Fried, 2004) 30% of coarse aggregates can usually be replaced without little or no effect on compressive strength 2010 International Concrete Sustainability Conference, Dubai, UAE 15
16 Waste Concrete Reuse and Recycling Methods crushing concrete into recycled aggregates washing out the waste concrete before the hardening begins- eco-friendly version, if wash-out water is recycled and reused recycled concrete use in non structural elements such as backfills, blinding slabs, core filling, embankments and road construction 2010 International Concrete Sustainability Conference, Dubai, UAE 16
17 Coarse Aggregate Replacement Electric Arc Furnace Slag 1.6 ncretes/cc propertie es Ratio, harde ened properties of co C-QFS C-GFS C-EAFS25 C-EAFS50 C-EAFS100 CC Compressive strength Splitting tensile strength Modulus of elasticity Type of concrete Ratio Hardened Properties / Conventional Concrete as by (Etxeberria, et al., 2010) 2010 International Concrete Sustainability Conference, Dubai, UAE 17
18 Electric Arc Furnace Slag ngth (MPa) Compressive Stre CC C-QFS C-GFS C-EAFS25 C-EAFS50 C-EAFS Age (days) Compressive Strength as by (Etxeberria, et al., 2010) 2010 International Concrete Sustainability Conference, Dubai, UAE 18
19 Concrete without Cooling short time workability due to a faster setting process extreme high concrete temperatures caused by heat of hydration at the setting process uncontrollable cracking high costs for intensive curing extension of construction periods due to a production stop caused by high temperatures Courtesy of: Mobil-Baustoffe 2010 International Concrete Sustainability Conference, Dubai, UAE 19
20 Threats due to High Fresh Concrete Temperature Problems with mixing, correct placing and curing Thermal / differential thermal cracking of concrete Decreased 28-days and later strengths 2010 International Concrete Sustainability Conference, Dubai, UAE 20
21 Threats due to High Fresh Concrete Temperature Delayed Ettringite Formation (DEF) in concrete when exceeding a temperature of about 65 C during hydration, which can cause cracking even years after installation 2010 International Concrete Sustainability Conference, Dubai, UAE 21
22 Flake-Ice Cooling At high temperatures further activities are needed; such as shading the aggregates or the production of concrete during the cooler night time period Lower production capacity due to a limited ice production and a long mixing process. Courtesy of: Mobil-Baustoffe 2010 International Concrete Sustainability Conference, Dubai, UAE 22
23 SAMPLE MIX (8% moisture content in fine aggregates) Cement 400kg w/c ratio < humidity in sand 8% =58l maximum water content= 160l concrete temperature without cooling= 47 C cooling 1 C = 7.5kg of ice SAMPLE MIX (2% moisture content in fine aggregates) Cement 400kg w/c ratio < humidity in sand 2% =14.5l maximum water content= 160l concrete temperature without cooling= 47 C cooling 1 C = 7.5kg of ice 2010 International Concrete Sustainability Conference, Dubai, UAE 23
24 SAMPLE MIX (8% moisture content in fine aggregates) Maximum possible addition of water: 102 litres Fresh concrete temperature after adding flake ice: = 34 C SAMPLE MIX (2% moisture content in fine aggregates) Maximum possible addition of water: litres Fresh concrete temperature after adding flake ice: = 28 C 2010 International Concrete Sustainability Conference, Dubai, UAE 24
25 Coarse Aggregate Cooling More time to place and finish concrete works on site Significant energy savings Reduced dust emissions Reduced admixture usage Cement savings (low w/c ratio) Achieving concrete temperatures as low as 25 Degree Celsius. Reduces the risk of rejected concrete due to temperatures out of specification Courtesy of: Mobil-Baustoffe Transportation over longer distances possible 2010 International Concrete Sustainability Conference, Dubai, UAE 25
26 CASE STORY Gotthard Tunnel North- Lot Amsteg and Erstfeld Client: Arbeitsgemeinschaft Amsteg, Switzerland Quantity: 1,000,000m3 Duration: 70 months Maximum Capacity: 2x240m3/h 2010 International Concrete Sustainability Conference, Dubai, UAE 26
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38 Ventilation shafts Cool water pipes Rock-water pipes and pumps Belt conveyor Railway system 2010 International Concrete Sustainability Conference, Dubai, UAE 38
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43 Aggregate & Cement Cooling Cement cooled down by 10 C results in a reduction of the overall concrete temperature of 1 C Methods: Air Nitrogen or carbon dioxide Courtesy of: Mobil-Baustoffe 2010 International Concrete Sustainability Conference, Dubai, UAE 43
44 TEMPERATURE DEVELOPMENT- COOLING METHODS Temperature in Degree D Celsiu us Without cooling Flake-ice cooling 40 Aggregates cooling Aggregates & cement cooling Fresh Concrete Temperature Site Concrete Temperature Cooling Method 2010 International Concrete Sustainability Conference, Dubai, UAE 44
45 Cooling Method Comparison: 1500 m3 of Concrete in 24h (as per mix and air temperatures from previous sample with 8% moisture content in fine aggregates) Conventional flakeice cooling Energy saving flakeice cooling Coarse aggregate cooling system up to 316 kw per unit 135 kw per unit 350kW per unit 407 kw/h* 270 kw/h* 350 kw/h 1kW = 0,32 l Diesel 1 C= 7.5kg of ice/m l/day 2074 l/day 2688 l/day 21lperm 2,1 3 14lperm 1,4 3 18lperm 1,8 3 * Usage of the best case scenario ice plant mix 2010 International Concrete Sustainability Conference, Dubai, UAE 45
46 Cooling Method Comparison: 1500 m3 of Concrete in 24h (as per mix and air temperatures from previous sample 2% moisture content in fine aggregates) Conventional flakeice cooling Energy saving flakeice cooling Coarse aggregate cooling system up to 316 kw per unit 135 kw per unit 350kW per unit 632 kw/h* 405 kw/h* 350 kw/h 1kW = 0,32 l Diesel 1 C= 7.5kg of ice/m l/day 3110 l/day 2688 l/day 32lperm 3,2 3 21lperm 2,1 3 18lperm 1,8 3 * Usage of the best case scenario ice plant mix 2010 International Concrete Sustainability Conference, Dubai, UAE 46
47 Sample project assess embodied CO₂ within the concrete for each of the listed mixes following sources of CO₂ emitters were taken into account for the LCA: winning of raw materials for concrete (e.g. fossil fuel consumption) raw materials extracted and processed for cement all of the transportation t ti necessary (transport t to construction ti site not included!) d!) transportation of raw materials to the batching plant water consumption (incuding energy required for chilling and processing) 2010 International Concrete Sustainability Conference, Dubai, UAE 47
48 Sample project Class of required Mix required amount C16-C20 351m³ C32-C m³ C35-C45 873m³ C40-C m³ C50-C60 C m³ 2010 International Concrete Sustainability Conference, Dubai, UAE 48
49 Green Mixes Fly Ash GGBS by-product in the process of coal combustion (replacement level: up to 40%) produced from blast furnaces used to make iron (replacement level: up to 80%) EAFS by-product in the process of smelting iron in an electric arc furnace (replacement level: up to 100%) 2010 International Concrete Sustainability Conference, Dubai, UAE 49
50 Green Mixes Average Reduction of CO2 Emissions for Standard Mixes: Average Reduction of PM₁₀ Emissions for Standard Mixes: OPC + GGBS 7% PM₁₀ 6,5g/m³ OPC + GGBS + EAFS 49% PM₁₀ 42,1g/m³ 2010 International Concrete Sustainability Conference, Dubai, UAE 50
51 Green Mixes Average Reduction of CO2 Emissions for Standard Mixes: OPC + GGBS 48% CO2 219kg/m³ OPC + GGBS + EAFS 49% CO2 222,1kg/m³ 2010 International Concrete Sustainability Conference, Dubai, UAE 51
52 CO₂ emissions for the project Batching Prod. Process CO 2 Emissions in Metric tons for entire Proje ect % OPC 70% OPC + 30% Fly Ash 40% OPC + 60% GGBS Tranport emissions (BP - > Site) Mix C50-C60 Mix C40-C50 Mix C35-C45 Mix C32-C40 Mix C16-C20C International Concrete Sustainability Conference, Dubai, UAE 52
53 Reducing CO₂ emissions by substituting coarse aggregates with EAFS f CO 2 Emissions Tons of % 0.900% 0.800% 0.700% 0.600% 0.500% 0.400% 0.300% 0.200% 0.100% Reduction of en ntire CO 2 emissions in % 520 Replacment lvl 0% Replacment lvl 25% Replacment lvl 50% Replacment lvl 75% Replacment lvl 100% 0.000% 100% OPC 70% OPC + 30% Fly Ash 40% OPC + 60% GGBS 100% OPC 70% OPC + 30% Fly Ash 40% OPC + 60% GGBS 2010 International Concrete Sustainability Conference, Dubai, UAE 53
54 Reducing PM₁₀ emissions by replacing natural coarse aggregates with EAFS kg of PM 10 emission fo or project (primary produ uction figures) % Aggregates 75% Aggregates 25% EAFS 50% Aggregates 50% EAFS 25% Aggregates 75% EAFS 0% Aggregates 100% EAFS Replacement level 2010 International Concrete Sustainability Conference, Dubai, UAE 54
55 Power consumption compared with Ice production Power consumption compared with ice production (100% OPC) Ice which can be ad dded (kg/m3) tion for cooling (kw) Average power consumpt Moisture Content (%) OPC Common Energy eff. Coarse Aggregate Linear (OPC Ice (kg)/m3 Flake Ice Flake Ice Cooling Ice (kg)/m3) 2010 International Concrete Sustainability Conference, Dubai, UAE 55
56 Power consumption compared with Ice production Ice which can be ad dded (kg/m3) Power consumption compared with Ice Production (40% OPC + 60% GGBS) Moisture Content (%) OPC Common Energy eff. Coarse Aggregate Linear (OPC Ice (kg)/m3 Flake Ice Flake Ice Cooling Ice (kg)/m3) ion for cooling (kw) Average Powerconsumpti 2010 International Concrete Sustainability Conference, Dubai, UAE 56
57 Power consumption compared with Ice production Ice which can be ad dded (kg/m3) Power consumption compared with Ice Production (70% OPC + 30% Fly Ash) Moisture Content (%) OPC Common Energy eff. Coarse Aggregate Linear (OPC Ice (kg)/m3 Flake Ice Flake Ice Cooling Ice (kg)/m3) ion for cooling (kw) Average Powerconsumpti 2010 International Concrete Sustainability Conference, Dubai, UAE 57
58 Green Concrete Mix compared to common OPC Mix 20% 10% 11% 2% 0% -10% GGBS -7% GGBS+EAFS -20% -30% -40% -50% -48% -49% -48% -60% CO2 Emissions total PM10 Emissions total Costs total 2010 International Concrete Sustainability Conference, Dubai, UAE 58
59 GGBS GGBS+EAFS 2010 International Concrete Sustainability Conference, Dubai, UAE 59
60 GGBS GGBS+EAFS 2010 International Concrete Sustainability Conference, Dubai, UAE 60
61 GGBS GGBS+EAFS 2010 International Concrete Sustainability Conference, Dubai, UAE 61
62 CASE STORY Ras Laffan Port Expansion Project, Doha Qatar Client: Jan De Nul Dredging Ltd. Boskalis Westminster Middle East Ltd Quantity: m3 Duration: 24 months Maximum Capacity: 150m3/h 2010 International Concrete Sustainability Conference, Dubai, UAE 62
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CHAPTER 3 MATERIAL PROPERTIES AND MIX PROPORTIONS
45 CHAPTER 3 MATERIAL PROPERTIES AND MIX PROPORTIONS 3.1 GENERAL In the present investigation, it was planned to cast M40 & M50 grade concrete with and without supplementary cementitious material such
IS : Dr. S. RAVIRAJ
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