EARTH FRIENDLY CONCRETE(EFC)

Commercial Geopolymer Concrete

ASCP , November 2014

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

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

Concrete Supply Contract for Ichthys ProjectOnshore LNG Facilities, Darwin

CFT - Wagners Innovation in Building products

Cross Arms Bridge Beam Replacement

Road Bridges Pedestrian Bridges

Board Walk

Floating Structures

Wagners Earth Friendly ConcreteEFC

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 recommendedpractice” 2011, Concrete Institute ofAustralia

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 tonormal concrete – ambient temp curing

EFC Production

BWWA SiteEFC Concrete Batch Plant

EFC Delivery

EFC can be delivered by truck, pumpor chute like conventional concrete.

EFC Project Examples

• Structural precast• Pavements• Precast prestressed bridge beams• Water tanks• Boat Ramps• Road Bridge decks• Precast Tunnel Segments

Precast EFC Panels

Natural off - whitecolour

University of QLD Campus,Brisbane

Global Change Institute Building

EFC Floor beams Installed 2012

In situ pavements

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 , 435mm thick.

VIDEO

West Brisbane Wellcamp Airport (BWWA) – Aircraft pavements

Prestressed bridge beams

Wagners Precast yard, Brisbane

BWWA Entry Bridge , Toowoomba

EFC Bridge Decks

EFC Tunnel Segments• Legacy Way Tunnel segments• Fibre EFC low slump mix

Wagners Brisbane Precast Factory

EFC Tunnel Segments, Malaysia

Overseas applications

Mechanical MaterialProperty

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 ; 0.20 – 0.24

EFC Structural Performance

GCI Precast Beams - Load TestElastic Deflection

Durability relatedProperty

EFC performance(compared to Portland Cement Concrete)

Acid resistance higher

Sulfate resistance higher

Chloride resistance higher

Heat of reaction VERY low

Fire resistance higher

EFC Durability Performance

0

5

10

15

20

25

30

35

40

0 6 12 18 24 30 36

Tem

pera

ture

Rise

(0C)

Time after casting (Hours)

Temperature Rise - 1 m3 Block

65% SLAG MixEFC Mix

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

-1

0

1

2

3

4

5

6

0 50 100 150 200 250 300 350

Leng

th c

hang

e (%

)

Time (Days)

500 Mg EFC

5000 Mg EFC

50000 Mg EFC

500 Mg PFA

5000 Mg PFA

50000 Mg PFA

Magnesium Sulfate- Expansion results, plottedagainst control GP/Flyash mix

GP/Flyash Control Mix,400 kg/m3 binder content

Wagners EFC Mix,400 kg/m3 binder content

-1

0

1

2

3

4

5

6

0 50 100 150 200 250 300 350

Leng

thch

ange

(%)

Time (Days)

500 Na EFC

5000 Na EFC

50000 Na EFC

500 Na PFA

5000 Na PFA

50000 Na PFA

Sodium Sulfate- Expansion results, plottedagainst control GP/Flyash mix

GP/Flyash Control Mix,400 kg/m3 binder content

Wagners EFC Mix,400 kg/m3 binder content

-7

-6

-5

-4

-3

-2

-1

0

1

0 50 100 150 200 250 300 350

Mas

s C

hang

e (%

)

Time (Days)

0.5 M EFC

0.05 M EFC

0.005 M EFC

0.5 M PFA

0.05 M PFA

0.005 M PFA

Acid- Mass Loss results, plotted against controlGP/Flyash mix

Wagners EFC Mix,400 kg/m3 binder content

GP/Flyash Control Mix,400 kg/m3 binder content

Standards and Certification

• Testing / PerformanceVerification• RMIT Durability Studies• Bridge Beams Study• Water Tanks

• 2 x independentengineering reports by DrJames Aldred, AECOM

Standards - International

• Assessment and certification by the German constructionInstitute , DIB(t)

• Submission and testing by Brameshuber + UebachsConsultants, 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

Standards - Australia

• 1st Australian Standard forgeopolymer concretecurrently being produced bya CRC group led by UNSW,Wagners is a member

• Interim Standard andcommentary will beproduced within 3 years

• Follow performance basedprovisions of AS 3600“Concrete Structures” .

EFC Environmental Performance

• Extremely low CO2 emission and embodied energy• EFC binder has 80-90 % 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

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”

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

Thank You.Contacts for further information

• Tom Glasbytom.glasby@wagner.com.au+61 402 087710