STADIUM® Modeling reactive transport in concrete...

STADIUM® Modeling reactive transport in concrete Application to CBP

Eric Samson SIMCO Technologies Inc. September 2012 www.simcotechnologies.com

© SIMCO Technologies 2012

SIMCO Overview

Internal/External use of STADIUM®

Graphical User interface/User

experience

Model development/

Testing procedures

R&D Software

Sales & Marketing

Consulting activities

45+ employees 25+ engineers/scientists Fully operational lab/technical staff


What is STADIUM®?

Reactive transport model

• Tailored for cementitious materials • Can deal with different aggressive exposure cases • Access to all model features through input text file

Software

• Tool for engineers • Graphical interface • Material database • Exposure condition database • Focuses on chloride ingress, corrosion initiation • Time-dependent boundary conditions


STADIUM®-Lab Modules

Permeability Moisture isotherm

Tortuosity Diffusion coefficients

STADIUM®

Migration test

analysis

Drying test

analysis


Test methods part of Unified Facilities Guide Specifications (UFGS) 03 31 29 (February 2010) test protocol

• US Navy (NAVFAC ESC) • USACE • USAF • NASA

Performance specification protocol




The UFGS certification process

1. Review of existing facilities equipment

2. Acquisition of missing equipment (if necessary) and subscription

3. Training session: Sample preparation, laboratory testing and STADIUM® Lab analysis

4. Final certification


Thin-client interface Calculations performed on SIMCO’s server Data stored on SIMCO’s server

STADIUM® overview


STADIUM® overview

• Coupled species diffusion • Moisture/Temperature coupling • Transport of main species • Feedback effect • Time-dependent B.C.


STADIUM® overview

• Local Equilibrium Assumption • Dissolution/precipitation • Solid solutions • Chemical/Pitzer database in

separate text file


STADIUM® modeling results

Concrete exposed to sodium chloride in saturated and unsaturated condition conditions



Leaching – calcium profiles in thin paste samples immersed in pH 7 water

2 days

7 days

4 days



Leaching – silicon profiles in thin paste samples immersed in pH 7 water

2 days

7 days

4 days



Sulfate exposure – sulfur profiles in paste samples immersed one-year in sodium sulfate solution

Three months

Twelve months



Sulfate exposure – calcium profiles in paste samples immersed one-year in sodium sulfate solution

Three months

Twelve months



CBP test case

Concrete

barrier

Waste material

(saltstone)

Soil

x = L

x = 0

20 c

mConcrete

barrier

Waste material

(saltstone)

Soil

x = L

x = 0

20 c

m

C G Soil

A

B

C

C

D

Soil



CBP test case

Concrete

barrier

Waste material

(saltstone)

Soil

x = L

x = 0

20 c

mConcrete

barrier

Waste material

(saltstone)

Soil

x = L

x = 0

20 c

m

0

20

40

60

80

100

120

0 5 10 15 20 25 30

Position (cm)

So

lid

ph

ase c

on

ten

t (g

/kg

)

Portlandite

CaH2SiO4

Ettringite

Monosulfate

C4AH13

Calcite

Monocarboal

Concrete Saltstone

Minerals after 5000 years



CBP test case

Concrete

barrier

Waste material

(saltstone)

Soil

x = L

x = 0

20 c

mConcrete

barrier

Waste material

(saltstone)

Soil

x = L

x = 0

20 c

m

Species (liquid phase) after 5000 years



CBP test case

Concrete

barrier

Waste material

(saltstone)

Soil

x = L

x = 0

20 c

mConcrete

barrier

Waste material

(saltstone)

Soil

x = L

x = 0

20 c

m



CBP test case

pCO2: 10-3.5 atm

200 ppm NaCl

Saturated soil

Vault 2 Concrete

Stee

l lin

er

20 cm

Analysis: estimation of the risk of corrosion due to chloride and drop of pH at the concrete/liner interface

Risk of corrosion initiation


STADIUM® field applications

Panama Canal –

Third Set of Locks Case

Studies



Panama Canal –

Third Set of Locks Case

Studies

High Water Mark

Two Coring-Drill Diameter

0.5 - 1 m



STADIUM® Specified Kilo Wharf Extension

Case Studies

Kilo Wharf Extension US NAVY, GUAM

CBP ongoing activities

www.simcotechnologies.com


Material preparation

Concretes (Vault 1/4 & Vault 2) October 2011.

Raw materials

Source

Vault 1/4 w/b = 0.38

(kg/m3)

Vault 2 w/b = 0.38

(kg/m3)

Type I/II cement Lafarge 255 - Type V cement Lehigh - 121

GGBFS Holcim 169 162 Force 10000 SF Grace - 27 Class F Fly Ash SEFA - 95

Sand Foster 691 548 N° 67 Stone Rinker 1096 1111

Water - 162 152

(ml/100kg binder)

(ml/100kg binder)

MicroAir BASF 1.2 3.1 Polyheed N BASF 390 205

Glenium 3030 NS BASF 936 232 Fresh concrete Properties @15min

Air content(%) - 6.6 6.6 Unit weight(kg/m3) - 2283 2240

Slump(mm) - 150 155 Concrete properties @28days

Porosity(%) - 11.6 13.1 OH Diff. (e-11 m2/s) - 4.6 3.3

Concrete properties @97days Porosity(%) - 11.6 14.3

OH Diff. (e-11 m2/s) - 4.0 1.6



Four Hardened cement pastes (w/b =0.40) mixes have been prepared in December 2011. Pastes compositions are based on concrete Vault 1/4 & Vault 2 mixtures.



Limewater curing tanks


Experimental study – contact solutions

Contact solutions - Concentrations (mmol/L)

Salts Im.1 Im.2 Im.3 Im.4 Im.5

Na2SO4 150 150 150 150 150

NaOH 0 500 0 500 0

NaNO3 0 0 3000 3000 0

Na2CO3 0 0 0 0 150

Sulfate immersions

Sealed surface

Exposed surfaces 25mm

Pastes are immersed in different solutions Planned durations:

1) 3 months (June 2012) 2) 12months (March 2013)

Contact Solution


Experimental study – contact solutions

Metallic case

(filled up with water)

Concrete specimens

(Ø100×55mm)

T t

DOH (10-11 m2/s)

Mixtures Damage level

d0 (0%) d1 (2-4%) d2 (6-8%)

B1 13.13 19.51 -

B2 21.20 29.31 -

B3 21.91 29.23 36.53

Damage vs. paste alteration


Experimental study – saltstone/concrete

Wasteform mixture

Vault concrete

0

10 000

20 000

30 000

40 000

50 000

60 000

-25 -20 -15 -10 -5 0 5 10 15To

tal S

od

ium

co

nc

en

tra

tio

n, (P

PM

)

Depth (mm)

Vault 1/4

Saltstone

Model

Saltstone Concrete

Interface

180-day exposure Sulfur profile



180-day exposure Sulfur profile



Raw materials Density Wasteform (kg/m3)

Type I/II cement 3.18 94 GGBFS 2.92 423

Class F Fly Ash 2.43 423 DI Water 1.00 564

Salt - 232 Salt solution 1.22 796

Seal (silicone)

Salt solution

Saltstone

Concrete (cV1/4 or cV2)

Seal

Waterproof membrane

80

-90

6

0

20

Dimensions in millimeters


Corrosion in CO2 environment

Na2CO3 solution (0.1M)

Na2CO3 (0.1M)

Mortar (W/C=0.65)

Steel rebar



Potential measurements

RE (calomel)



CO2 ingress – Carbonate profile @ 120 days

STADIUM® Modeling reactive transport in concrete...

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