EARTH FRIENDLY CONCRETE (EFC)

Transcription

1 EARTH FRIENDLY CONCRETE (EFC) Commercial Geopolymer Concrete ASCP, November 2014

2 About Wagners Family Company based in Toowoomba, Australia International base in KL Malaysia Contract Quarrying Contract Concrete Cement Precast Concrete Composite Fibre Technologies (CFT) Steel Reinforcing Bulk haulage & transport 900 People

3 Concrete Supply Contract for Ichthys Project Onshore LNG Facilities, Darwin Wagners scope of works Build and operate Concrete Batch Plants Build and operate ice plant Provide quarry materials and concrete Supply 300,000 m3 concrete

4 CFT - Wagners Innovation in Building products Cross Arms Bridge Beam Replacement Board Walk Floating Structures Road Bridges Pedestrian Bridges

5 Wagners Earth Friendly Concrete EFC

6 Geopolymer Binders Dates back to Russia, 1930 s alkali activated slag cements Renewed focus by Joseph Davidovits work in 1970 s, commercialised in rapid setting cements Australia Research groups in 2000 s Geopolymer concrete recommended practice 2011, Concrete Institute of Australia

7 Wagners Earth Friendly Concrete (EFC) 9 years of development - EFC CEMENT FREE concrete, binder constituents are: Ground Granulated Blast Furnace Slag (GGBS) Fly Ash Unique chemical activators Purpose made admixtures Water Setting and construction characteristics similar to normal concrete ambient temp curing

8 EFC Production BWWA Site EFC Concrete Batch Plant

9 EFC Delivery EFC can be delivered by truck, pump or chute like conventional concrete.

10 EFC Project Examples Structural precast Pavements Precast prestressed bridge beams Water tanks Boat Ramps Road Bridge decks Precast Tunnel Segments

11 Precast EFC Panels Natural off - white colour

12 Global Change Institute Building University of QLD Campus, Brisbane

13 EFC Floor beams Installed 2012

14 In situ pavements

15 BWWA HD aircraft pavements Turning node - 16,000 m2, 435 mm thick. Aprons and taxiways 32,000 m2, 435 mm thick. Hangars - 2,500 m2, 435 mm thick. VIDEO

16 West Brisbane Wellcamp Airport (BWWA) Aircraft pavements

17 Prestressed bridge beams Wagners Precast yard, Brisbane

18 EFC Bridge Decks BWWA Entry Bridge, Toowoomba

19 EFC Tunnel Segments Legacy Way Tunnel segments Fibre EFC low slump mix Wagners Brisbane Precast Factory

20 Overseas applications EFC Tunnel Segments, Malaysia

21 EFC Structural Performance Mechanical Material Property EFC (compared to Portland Cement Concrete) Compressive strength equivalent Flexural tensile strength 30% higher Early age strength good Shrinkage Lower (average 350 ) Youngs Modulus (stiffness) Similar ; 10% higher Poissons Ratio Similar ;

22 GCI Precast Beams - Load Test Elastic Deflection

23 EFC Durability Performance Durability related Property EFC performance (compared to Portland Cement Concrete) Acid resistance higher Sulfate resistance higher Chloride resistance higher Heat of reaction VERY low Fire resistance higher

24 Temperature Rise - 1 m3 Block Temperature Rise (0 C) % SLAG Mix 15 EFC Mix Time after casting (Hours) 36

25 Durability Data on EFC RMIT University, Melbourne, Australia Laboratory standard non-destructive tests (accelerated) Sulfate attack / resistance Acid attack / resistance Chloride ion ingress Carbonation Site specimens at 3 x coastal locations Corrosion rate

26 6 Magnesium Sulfate- Expansion results, plotted against control GP/Flyash mix GP/Flyash Control Mix, 400 kg/m3 binder content 500 Mg EFC Length change (%) Mg EFC Mg EFC Mg PFA 5000 Mg PFA Mg PFA 2 Wagners EFC Mix, 400 kg/m3 binder content Time (Days)

27 Sodium Sulfate- Expansion results, plotted against control GP/Flyash mix Na EFC Length change (%) Na EFC Na EFC 4 GP/Flyash Control Mix, 400 kg/m3 binder content 500 Na PFA 5000 Na PFA Na PFA 2 Wagners EFC Mix, 400 kg/m3 binder content Time (Days)

28 Acid- Mass Loss results, plotted against control GP/Flyash mix Wagners EFC Mix, 400 kg/m3 binder content M EFC Mass Change (%) M EFC M EFC M PFA M PFA M PFA GP/Flyash Control Mix, 400 kg/m3 binder content Time (Days)

29 Standards and Certification Testing / Performance Verification RMIT Durability Studies Bridge Beams Study Water Tanks 2 x independent engineering reports by Dr James Aldred, AECOM

30 Standards - International Assessment and certification by the German construction Institute, DIB(t) Submission and testing by Brameshuber + Uebachs Consultants, Aachen, Germany. Tests include: Fresh concrete properties Sulfate resistance using flat prism method Chloride penetration resistance, similar to NT Build method Chloride diffusion co-efficient ASR Compressive strengt5h Carbonation Full scale segment manufacture, mix suitability

31 Standards - Australia 1st Australian Standard for geopolymer concrete currently being produced by a CRC group led by UNSW, Wagners is a member Interim Standard and commentary will be produced within 3 years Follow performance based provisions of AS 3600 Concrete Structures.

32 EFC Environmental Performance Extremely low CO2 emission and embodied energy EFC binder has % reduction CO2 emissions compared to Portland Cement Recycled materials: slag and flyash CO2 Emissions Reduction 1 m3 EFC 25 MPa saves 154 kg of CO2 1 m3 EFC 32 MPa saves 184 kg of CO2 1 m3 EFC 40 MPa saves 220 kg of CO2

33 Awards for EFC 2011 QLD Premiers ClimateSmart award, overall winner 2012 BCC Innovation Survey Best Practise Case Study 2013 BPN Sustainability Awards, overall winner 2013 The Australian Shell Innovation Awards, category winner Hi-tech Manufacturing and Design

34 EFC Summary Commercial geopolymer concrete Lowest CO2 emission concrete High resistance to chloride ingress High resistance to Acid attack High resistance to Sulfate attack Very little temperature rise Low shrinkage

35 Thank You. Contacts for further information Tom Glasby