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Sustainable Concrete and You
How to Survive and Thrive in the
Concrete Green Revolution
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AIA Credits
This program is registered with the AIA/CES for continuing professional education. As such, it doesnot include content that may be deemed or construedto be an approval or endorsement by the AIA of anymaterial of construction or any method or manner of
handling, using, distributing or dealing in any materialor product.Questions related to specific materials, methods and
services will be addressed at the conclusion of thispresentation.
Hanley Wood is a Registered Provider with The AmericanInstitute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported toCES Records for AIA members. Electronic Certificates of Completion for all attendees available 6-7 weeks post show.
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Copyright Materials
This presentation is protected by US and Internationalcopyright laws. Reproduction, distribution, display anduse of the presentation without permission of the
speaker is prohibited.
Kevin A. MacDonald 2010
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Learning Objectives
Upon completing this program, the participant shouldbe able to:
1.Critically review concrete mixture proportions withrespect to the nature of the hydraulic binder present.
2.Explain the role of reduction of cement content inreducing the emissions of Carbon Dioxideassociated with concrete construction.
3.Make knowledgeable recommendations wherepozzolan contents can or should be raised or lowered.
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Where Are We Today?
Portland cement is (relatively) cheap andplentiful
Made from common materials Desirable properties are readily achieved
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So why disturb this situation?
The production of CO 2 occurssimultaneously with the production of cement
Estimates vary, but there is a generalagreement that about 5 to 10 percent of the worldwide emissions of due to CO 2
are from cement plants
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Cements which will setup and be resistantto the action of water
Pozzolans ACI definition Functional Definition Geographic Definition
Hydraulic Materials
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For our purposes, Silica Fume, Flyash andSlag are Po zzolans
Even Though Class C ash and Sla g areHydraulic Ce ments themselves
Pozzolans
http://d/CD%20Directory/1%20Concrete%20Tech/b%20SCM/MK1_016.jpghttp://d/CD%20Directory/1%20Concrete%20Tech/b%20SCM/MK1_016.jpghttp://d/CD%20Directory/1%20Concrete%20Tech/b%20SCM/MK1_016.jpghttp://d/CD%20Directory/1%20Concrete%20Tech/b%20SCM/MK2_006.jpghttp://d/CD%20Directory/1%20Concrete%20Tech/b%20SCM/MK1_016.jpghttp://d/CD%20Directory/1%20Concrete%20Tech/a%20Cement/MK2_072.jpg8/14/2019 WOC 2010 Final Handouts
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Natural Pozzolans
Industrial ByProducts Flyash GGBFS Silica Fume
Rice Hull Ash
Pozzolanic Materials
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SiO 2
Al 2O3CaO
Silica Fume
Metakaolin
Portland Cement
Glass
Class CFlyashGGBFS
Type F Flyash
NaturalPozzalans
Clay
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Concretes containing pozzolans havedifferent properties due to the chemicaland physical interaction
Initial use of these materials waseconomic
The best argument for their use is the
technical aspects of the concrete
Pozzolanic Materials
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ASTM C618 Class C High Calcium Class F - Low Calcium
Need new ( and better ) ways tocharacterize cement and flyash reactivity
Fly Ash
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FlyashParticles
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ASTM C 618 - Fly Ash & Natural
PozzolansClass N Natural PozzolanCalcined or uncalcined
Class F Fly AshFrom burning bituminous
or anthracite coalHas pozzolanic properties15% - 20% cement
replacementClass C Fly Ash
From burning sub-
bituminous or lignitecoalPozzolanic & cementitious
properties20% - 30% cement
replacement
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Premarc 1/18/07
Benefits of Fly AshBenefits of Fly Ash
Lower permeabilityLower permeabilityReduced shrinkageReduced shrinkageLower heat of hydrationLower heat of hydrationHigher ultimate strengthHigher ultimate strengthIncreased durabilityIncreased durabilityActs like ball bearings to improve flowability andActs like ball bearings to improve flowability and
workabilityworkabilityCost effectivenessCost effectivenessImprove sulfate resistance and ASRImprove sulfate resistance and ASRNot all fly ashes are the same !Not all fly ashes are the same !
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Class C ashes contain C 2S and
Will have some hydraulic action Can contribute Alkali (K+, Na+)
Class C Flyash
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Pozzolanic action alone Longer term strength gain over Class C Retards more than class C
Class F Ash
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SettingEffect Set Time of LMN Cement & ICF AshReplacements
Updated Data of New Lehigh Cement (8/1/03)Laboratory Condition
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
3:00 3:30 4:00 4:30 5:00 5:30 6:00 6:30 7:00
Age, hr:min
P e n e
t r a
t i o n
R e s
i s t a n c e ,
p s
i
LMN & 0% ash (3:45 / 5:40)
LMN & 10% ash (3:50 / 5:50)+0:05/+0:10
LMN & 20% ash(4:05 / 6:10)+0:20/+0:30
LMN & 30% ash (4:30 / 6:25)+0:45/+0:45
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Fly Ash ManufacturingFly Ash Manufacturing
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Flyash is not a constant
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
2:00 3:00 4:00 5:00 6:00 7:00 8:00 9:00 10:00 11:00 12:00 13:00 14:00 15:00
P e n e t r a t i o n R e s i s t a n c e , p s i
A e hr:m in
Mortar Fraction, 6 1/4 Bag, 0.45 W/C, 1490 lb SSDLLFA per C.YLM1 standard & 20% , 40% Replacement
2 0% ICF(4 :0 0 / 6:1 0) 4 0% ICF(5 :15 / 7:3 0)
20% MPC (6:40 / 9:45) 40% MPC(8:50 / 12:20)
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Extracted from the non-ferrous product of a Bessemer furnace
Material is cooled rapidly to trap slag inthe glass state
Consists mainly of aluminates andsilicates of Calcium
GGBFS
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Slag CementSlSl ag Cementag Cement
manufactured under manufactured under ASTM C 989ASTM C 989HydraulicHydraulic cementcementCo-productCo-pr oduct of a highlyof a highly
controlled metallurgicalcontrolled metallurgicalprocessprocessEnhances concreteEnhances concrete
propertiesproperties
Environmentally positiveEnvironmentally positivematerialmaterial
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Slag CementSlag CementDefinition: Finely ground
granulated materialoriginating from an iron blastfurnace and consisting of primarily calcium (CaO) andaluminum (AL 2O3) silicates(SiO 2) , used as a partialreplacement for portlandcement in concrete
Also known as:
Ground Granulated Blast-Furnace SlagGGBFSSlag
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Slag Cement HistorySlag Cement History
AspdinAspdinpatentspatentsportlandportlandcementcement
SlagSlagcementcement
producedproducedas aas aseparateseparatematerialmaterial
...18241824 1950s1950s 2000s2000s
SparrowsSparrowsPoint startsPoint startswidespreadwidespread
use inuse inEasternEastern
U.S.U.S.
LoriotLoriotmakesmakesslag-slag-limelime
mortar mortar
17741774 1890s1890s
First slagFirst slagportlandportlandblendedblendedcementscements
19821982
RapidRapid
expansionexpansionthroughoutthroughoutU.S.U.S.
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How Is Slag Produced?How Is Slag Produced?
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Premarc 1/18/07
Granulation Process
hot slag
High pressure water 6 - 10 tons water/ton slag
Slag is changed to glassy sand likesubstance known as granulated blastfurnace slag - GBFS
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Premarc 1/18/07
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Condensed molten siliceous material amorphous in nature
Product of the silicon and ferrosilicon smelting
industries Mean Diameter of 0.15m Specific Surface Area of 15000 20000 m 2/kg At 10 percent, there are 50000 to 100000
particles present for each grain of cement
Silica Fume
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350 kg of Cement 3000 m 2/kg 105000 m 2
8 percent silica fume 28 lb 560000m 2
Large Surface Forces result in verycohesive mixture
Large Surface area and high proportion of reactive material makes it extremelyreactive
Silica Fume
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Properties of Materials
Property SilicaFume
Slag Fly Ash
SpecificGravity 2.2 2.85 2.6-2.75
SpecificSurface
Very Fine Varies Finer thancement
Reactivity Very RapidVaries withsize andChemistry
Varies withsize andChemistry
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Chemically active Major and Minor Constituents Sulfate Form can be very important Solids must either dissolve in solution or a
surface reaction takes place
Cement Chemistry
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C3S
C2S
C3A C4AF
CaSO 4
Major Components
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Chemical reaction between individualclinker minerals, calcium sulfate andwater
Proceed at different rates in series andin parallel and influence one another
Hydration
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Cement + Water Glue and Ca(OH)2
Ca(OH)2 + Pozzolans More Glue
Pozzolanic Reaction
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High Volume Flyash Concrete
Significant increases in ASR, sulphate andthermal cracking resistance are possibleat 25 percent or higher flyash
replacement Problems with setting time and early age
strength gain
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High Volume Flyash Concrete
Minimum of 50 percent flyash by mass of cementitious materials
Low water content 130 kg/m3 Low cement content 200 kg/m3 Air entrained for freeze thaw 4500 psi, 6 inch or higher w/cm ~0.3 Below 4500 psi , w/cm ~ 0.4
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Comparisons to OPC Concrete
High Volume FlyAsh Concrete
Less energyintensivemanufacture
Higher ultimatestrength
More durableUses a waste by-
productLess global warminggases created
ConventionalConcrete
Energy intensivemanufacture
Weaker ultimatestrength
Less durableUses virgin materials
onlyMore global warming
gases created
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Plastic Properties
Low water content dictates use of Superplasticizer So slump is availableas required
Concrete is readily air entrained usingconventional admixtures
Workability is high, and fines content
promotes cohesion
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Plastic Properties
Bleeding - Negligible to very small Time of set may be significantly
increased depends on flyash beingused
Autogenous temperature rise peaktemperature is lower
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Hardened Concrete Properties
Strength Early age and later age strength
dependent on choosing the right cement
and flyash 1 day strength 900 to 1200 psi 28 day strength 4000 to 8000 psi routinely
available
Accelerators or type III Cement will give 1day strengths of 2500 psi or more
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Hardened Properties
Tensile strength and flexural strength arethe same as OPC Concrete
Modulus of Elasticity is high 35 GPa(~10 7psi)
Caused by infilling of the ITZ flyash asmicrofine aggregate
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Hardened Properties
Creep and Shrinkage Drying strains are lower than conventional
concrete Creep is lower than conventional concrete Likely due to denser microstructure
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Durability
Water Permeability Low Freezing and Thawing Behaves as
conventional air entrained concrete
Scaling resistance Some sidewalks havebeen constructed in Canada with goodreported performance. Others have notseen the same results. Should beavoided in deicer exposure
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Durability
Penetration of Chloride Ions Rapid Chloride Permeability
28 days 2500 coulombs passed 90 days 1000 coulombs passed 365 days 150 coulombs passed
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Durability
og Time
,
Charge
Passed
Coulombs
HVFA
i l ica Fume
1000
2000
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0
.0002
.0004
.0006
.0008
.001
.0012
.0014
.0016
C h e m i c a l S h r i n k a g e , m l / m l
Time, minut e
Mixture No .5
Mixture No .2
Mixture No .3
Mixture No .1
Mixture No .1
Mixture 5 100% OPCMixture 2 Slag: OPCMixture 3 Flyash:OPCMixture 1,10 FA:Slag:OPC
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Drying Shrinkage, 7 day cure
0.0005.001
.0015.002
.0025.003
.0035.004
.0045
0 5 10 15
Mix 1
Mix 2Mix 3
Mix 5
Log. (M ix2
Log. (M ix1
Log. (M ix5
Log. (M ix3
Time, Days
Shrinkage%
IncreasingPozzolanContent
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Chemical reaction between individualclinker minerals, calcium sulfate andwater
Proceed at different rates in series andin parallel and influence one another
Hydration
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Hydration Curve
Time
HeatEvolved,dH/dt
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Progress dependent on Rate of dissolution Rate of Nucleation and Crystal growth Rate of Diffusion of reagents through
hydration products
Hydration
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Water/Cement Ratio Curing Conditions and Humidity Hydration Temperature Presence of Admixtures
Hydration
Mi t P ti i d
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Mixture Proportioning andAdjustment
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Water Content
Water can be expressed in many ways:
Lb per cubic yard Gallons per cubic yard
Water cement ratio is not one of them
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550 lb cement and 220 lb water
660 lb cement and 264 lb water
Both have the same water : cement ratio
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Water Content will dictate the slump andworkability
Water:cement ratio will dictate the strengthand durability
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Water Cement Ratio
HighLow
The fluidity of a water-cement system is afunction of attractive and repulsiveforces between cement particles
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Workability Ease of Finishing
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Slump and Viscosity
Shear Stress
Shear Rate
Viscosity is slope of line
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Viscosity Models
.
0 +=
BinghamPlastic
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Bingham Model
Shear Stress
Shear Rate
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Viscosity Behavior
Shear Stress
Shear Rate
Viscosity is slope of line
WRDA
HRWRDA
SCC
Water
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Mixture Design - Rheology
0
Viscosity
2
10
20
Water
SuperPlasticizer
Air VMA
Flyash Slag*
Silica Fume
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Dispersion the water
reduction trickCapillaryPores
Gel
Pores
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Water:Cement Ratio
Controls the pore space
Lower w/c = fewer pores=less water
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Life-Cycle Costing
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Case Studies
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Great River Energy
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Freeze-Thaw Resistance
Freeze thaw resistance is imbued by air entrainment
Pozzolans do not change this low permeability ASTM C666 testing Very high class C may be detrimental
secondary crystallization
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Drying Period
Water in concrete can fill pores that oncedried cannot be refilled
So concrete may be more saturatedbefore drying than after immersionfollowing drying
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Scaling Resistance
Making the skin of concrete becauseconcrete beauty is skin deep
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f
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Modified Pore Structure
Gel pores Capillary Pores
0.001 0.01 0.1 110 Pore diameter, m
In
truded Volume
OPC
OPC +GGBFS
60 %Hydration
d f d
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Modified Pore Structure
Gel pores Capillary Pores
0.001 0.01 0.1 110 Pore diameter, m
In
truded Volume
OPC 3Days
OPC +GGBFS
28 days
60 %Hydration
Platinum LEED 45 percent
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Platinum LEED 45 percentreduction in cement content
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Flyash replacement of 60 percent Total cementitious content increased Net reduction 45 percent
I 35 W S A h F ll B id
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I 35 W St. Anthony Falls Bridge
All concrete in foundation andsubstructure is High Pozzolan Content
Conventional cementitious contents
less than 625 lb per cubic yard
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756
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319
783
756
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Thank You!
This concludes the American Institute of ArchitectsContinuing Education Systems Program.
Any Questions?Kevin A. MacDonald
1-800-CEMSTONE
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