Commercial Geopolymer Concrete ASCP , November 2014 - Wagners EFC.pdf · EARTH FRIENDLY CONCRETE...
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EARTH FRIENDLY CONCRETE (EFC) Commercial Geopolymer Concrete ASCP , November 2014
Transcript of Commercial Geopolymer Concrete ASCP , November 2014 - Wagners EFC.pdf · EARTH FRIENDLY CONCRETE...
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
