The Uses Of Ecocem GGBS In Concrete 2009

December 2009December 2009Ecocem Ireland LtdEcocem Ireland Ltd

1862: Hydraulic potential of GGBS discovered in GermanyEarly 1900’s - Portland Blast Furnace Cements had an established place in the concrete market

2004: More than 5,000,000 tonnes of GGBS produced in Germany2006: Approximately 2,000,000 tonnes of GGBS produced in UK

2008: Over 400,000 tonnes available in Ireland2008: Over 400,000 tonnes available in Ireland

Long term agreement with partner companies for supplying high quality GBSCan supply the Irish market with over 350,000 tonnes from Dublin

Provide technical back up to specifiers and concrete manufactures

Steel Manufacture Water to make GBS

GBSGrind to make GGBS

Store GGBS for distribution

GGBS cement, and OPC

NRA, OPW, Bord Gáis, ESB, Coillte, RPA, Bord Na Mona, Local Authorities, O , o d Gá s, S , Co te, , o d a o a, oca ut o t es

Engineers, Architects, Developers, Precast, House builders, Farmers

EnvironmentalEnvironmentalEnvironmentalEnvironmentalAdvantages of using GGBSAdvantages of using GGBS

Conflict in Darfur isConflict in Darfur is directly linked to Climate Change

A rise of 1 metre in ocean levels will displace 35 Million

l ipeople in Bangladesh.

Cement manufacture: Second largest source of industrial CO2

Releases harmful pollutants

Significant energy user

D l t t lDepletes natural resources

CO2 emissions for Ecocem GGBS and cement production

Typical CO2 Emissions for Portland Cement and Ecocem GGBS Production(Figures in kg per tonne of output)

700800900 Generation of Electricity Used

Fossil Fuel Useutpu

t

400500600700

Process Emissions

Tonn

e of

O

0100200300

kg p

er T

0

Portland Cement Ecocem GGBS

Depletion of natural presourcesFor every tonne of Portland

t d d 1 6 t fcement produced, 1.6 tonnes of limestone/shale are removed from the landscape

GGBS production involves no quarrying of limestone or clay

Environmental savingsEnvironmental savings example

What is the impact of replacing 50% of cement with GGBS in an

average size shopping centreaverage size shopping centre, using 5,000m3 of concrete?

See calculator on:

www.lowcarbonconcrete.ie

Longer service life from GGBS concrete

Time to replacement extendedSpecified by NRA on road bridges and structural concretep y gReduced demand on natural resources for new concrete

Exposure to chloride attack:Exposure to chloride attack:

Solar radiation isSolar radiation is reflected by lighter coloured surfaces

This heat cannot pass out of the earth’searth s atmosphere through the greenhouse gas

Darker coloured surfaces absorb

l di ti

layerA 100-150m2

driveway can offset the CO2 solar radiation

and re emit it as heat

2produced by 2

cars

Reduce heat island effect Reduces air conditioning requirement; cost and environmental benefit –studies have shown reductions of more than 20% in building cooling costs whose albedo has been increased (in the US potential saving of $1 billion per year)Health benefit

Reduces outdoor lighting requirements by enhancing night g g q y g gtime visibilitySaving money, energy and carbon emissionsApprox. 30% less lighting needed to achieve same visibility for concrete as it does for asphalt

EU procurement Rules Directive 2004/18/EC

Recital 5 states that "contracting authorities may contribute to the protection of the environment and the promotion of sustainable development"

Recital 6 states “Nothing in this Directive should prevent the imposition or enforcement of measures necessary to protect public policy, public morality, public security health human and animal life or the preservation of plant life in particularsecurity, health, human and animal life or the preservation of plant life, in particular with a view to sustainable development…”

Article 26 states ….. “The conditions governing the performance of a contract may, in particular, concern social and environmental considerations”particular, concern social and environmental considerations

Article 53 allows the Contracting Authority to weight the various awarding criteria of which “environmental characteristics” may be one

Annex VI 1(a) states that “technical specification [as per article 23] shall includeAnnex VI 1(a) states that technical specification [as per article 23].....shall include levels of environmental performance....”

OPW requirement for environmental cement

Section 2.4 “Sustainability” of tender documentation

“The OPW require the specification and use of more environmentally friendly cements in publicly funded construction projects, in compliance with EU procurement and environmental p j , p ppolicies.This will involve the partial replacement of Portland Cement by existing waste products to yield significant improvement in theexisting waste products to yield significant improvement in the environmental performance of concrete*.”

*Directive 2004/18/EC: Procedures for Award of Public ContractsDirective 2004/18/EC: Procedures for Award of Public Contracts

Sustainable development is "development that meets the needs of thepresent without compromising the ability of future generations to meet theirown needs“

Recycled by-product – No new raw materials usedRecycled by product No new raw materials used

Durability – Longer life span

Significantly Lowered CO2 Emissions

“The most sustainable building material in the world”

Embodied CO2 Embodied CO2 and the Builtand the Built GGBS: The Best Technology for aand the Built and the Built EnvironmentEnvironment

Embodied CO2f 19%

GGBS: The Best Technology for a Substantial Reduction of Embodied CO2.

accounts for 19% of overall CO2emission in the UK*

GGBS can replace 55% of ordinary cement.

• GGBS will reduce the embodied carbon footprint of concrete by 50%UK*

GGBS is the BAT

carbon footprint of concrete by 50%.

• GGBS will reduce the embodied carbon footprint of a typical building by

for reducing embodied CO2.

25%.

GGBS is the Best A ailable Technolog*Potential for Reducing the Environmental Impact of Construction Materials commissioned by the BioRegional Development Group in association with Stockholm Environmental

GGBS is the Best Available Technology (BAT) to reduce the embodied carbon footprint of the built environment.

Institute and the WWF (UK study)

Properties &Properties &Properties &Properties &Advantages of using GGBSAdvantages of using GGBS

Same constituents as OPC

Different proportionsLess CaO

iMore Si02More Al2O3

GGBS cement replaces ordinary Portland cement on a one-for-one basisNo change in any other element of the mix design:

sandaggregates

/ i ( b d d)w/c ratio (can be reduced)Admixtures

C t f tConcrete manufacture

Batch duration is the sameAllowable time to transport is extended – this increases with increasing percentage of GGBS

Engineering benefits start at 30%U i f 30 t 85%Usage varies from 30 up to 85%Most often specified at 50%

Treated same as Portland cement concreteNo adjustment striking timesAs always curing to comply with BS 8110 (as with all concrete proper curing ensures best practice concrete is achieved)Placing, compacting and powerfloatingConcrete admixtures compatible.

Temperature controlpIssue reduces with increasing percentage of GGBS

More CSH gel More CSH gel –– Less CA(OH)Less CA(OH)22 –– Reduced Permeability/Porosity Reduced Permeability/Porosity

Placing, compacting and pumping easier:lower relative densitysmaller particle sizes

Powerfloating as normalSetting times longer by 1 – 2 hrs Sl t f bl diSlower rate of bleedingWater demand 3% to 5% lowerCompatible with admixturesCompatible with admixtures


Vertical formworkMinimum 2 N/mm2

required to prevent mechanical damage

Horizontal formworkMinimum 10 N/mm2 or twice the stress to whichtwice the stress to which the slab is subjected

- At least 10 N/mm2 achieved after 3 days

- Use Temperature Matched Curing to confirm

70.0

80.0

60.0

70.0

40.0

50.0

N/m

m2

20.0

30.0

0.0

10.0

Days0.0

7 28 90

100/0 Sept 50/50 Sept 30/70 Sept

TMC(50 60 C) St d d (20 C)

35

40

TMC(50 - 60 C) v Standard cure(20 C)380 kgs CEM ll A-L 42.5N cement with 70% GGBS

Cured at 20 degrees

25

30Cured at temperature in structure

15

20

Stre

ngth

5

10

S

00 1 2 3 4 5 6 7 8

Days


Chloride PenetrationChloride PenetrationLower chloride ion diffusivityLower porosity/permeabilityp y p y

Applications: roads and bridges, car parks, sea defences, marine structures.


More CSH gel More CSH gel –– Less CA(OH)Less CA(OH)22 –– No CNo C33A A –– Reduced Permeability/Porosity Reduced Permeability/Porosity

Sulphate ResistanceSulphates react with C3A and Ca(OH)2 to form ettringiteSulphate Resisting cement (SRPC) has reduced C3A, but no reduced Ca(OH)2, and no reduced C3 , but o educed Ca(O )2, a d o educedporositySRPC cannot be used in marine environmentsGGBS much lower price than SRPC

• Note: In BS8500 the only option recommended as suitable for the most severe sulphate exposure (Class DC-sulphate exposure (Class DC4m) is concrete containing at least 66% GGBS

• Use of Sulphate resistant cement is not permittedcement is not permitted

Waste water plants


Aggressors:

SulphatespSodium Sulphate Na2SO4Magnesium Sulphate MgSO4

AcidsSulphuric Acid H2SO4

http://www.ecocem.ie/index.php?p=technical&q=wastewater

0.12

•On going Masters Study in UCD, Dublin

0.1

0.06

0.08

xpan

sion

CEM II 100%

CEM II + 50% GGBS

CEMII 70% GGBS

0.04% E

x CEMII + 70% GGBS

CEMI 100%

CEM I + 70% GGBS

SRPC

0

0.02

0 50 100 150 200 250 300

Days Exposure

Extract from “Civil Engineering Specification for the Water Industry – 6th Edition”

Normal refers to DC classes 1 & 2 and special refers to DC classes 3 & 4 – from “Special Digest 1 – Concrete in Aggressive Ground”. DC1 is the least aggressive with DC 4 being the most aggressive.

0% GGBS

30% GGBS30% GGBS

50% GGBS


GGBS lowers peak and overall heatReduces thermal stressingReduces micro-cracking (particularly useful in water retaining structures, basements, podium slab, bridges, stadiums, secant pile walls etc.)bridges, stadiums, secant pile walls etc.)Optimum substitution level 60 – 85%

0% GGBS 30% GGBS26 degrees 25 degrees

50% GGBS23 degrees

70% GGBS19 degrees

Thermocouple locations and slab insulationThermocouple locations and slab insulation

60

50

60

40

20

30 Highest

Lowest

Difference

10

0

45

50

Min Max Difference

25

30

35

40

10

15

20

25

0

5

08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30

06/09/2007 07/09/2007 08/09/2007 09/09/2007 10/09/2007 11/09/2007 12/09/2007 13/09/2007

70.0 Top

60.0

Core

Bottom

Differential Top to Core

Differential Bottom to Core

40.0

50.0

o C)

20.0

30.0

Tem

pera

ture

(o

10.0

20.0

0.00 21 28 33 46 58 70 77 92 99 118 139 164 189 234

Time after placing (hours)


GGBS is an off-white powderLi ht l d tLighter, more even-coloured concreteSmoother, more defect-free surfaceSuppresses/Eliminates efflorescenceLower pigment requirements – 20% savingGGBS can be used as partial replacement for white cement, up to 70%

GGBS cement, and OPC

Bridge pier and bridge deck, Enfield bypass

Bridge deck 100% OPCBridge deck 100% OPC

Bridge pier 50% GGBS

C k Ci i OffiCork Civic Offices

Cathleen Falls Bridge2006 ICS Design and2006 ICS, Design and Construction Awards

Sleeping Giant2007 ICS2007 ICS,

Design and Construction

Award

S O’C B ildi D bliSean O’Casey Building Dublin2008 ICS,

Design andDesign and Construction

Award

QE II bridge, Dartford M25QE II bridge, Dartford M25

5050--70% GGBS for chloride 70% GGBS for chloride resistance, reduced heat of resistance, reduced heat of hydration and appearancehydration and appearance

Second Severn CrossingSecond Severn CrossingSecond Severn CrossingSecond Severn Crossing

A i St di D bliAviva Stadium, Dublin

Father Collins Park DublinFather Collins Park, Dublin

Standard concrete specification containing GGBSp g

The world’s first Carbon Neutral Building Material launched in 2007 in partnership with the biggest names in the Irish Construction Industry:

T H ldiTreasury HoldingsPierseDurkan GroupMcNamaraJJ Rhatigan

Details on all prestigious projects can be found onwww.carbonneutralconcrete.ie

What is in it for you!

•Best durability (longer life)•Reduce lifetime maintenance costReduce lifetime maintenance cost

•Best sustainable material•Demonstrates your commitment to ya sustainable agenda•Create a lot of positive PR

•Best Architectural•Reduce cost to achieve desired finish

•Best value for money

Should you have any questions in the future:y y q

David O’Flynn, 087 965 4891

[email protected]

The Uses Of Ecocem GGBS In Concrete 2009

Documents

ggbs cement

embodied ggbs

tonnes of ggbs

portland cement ecocem

ggbs concretetime

ecocem ggbs productionfigures

hydraulic potential

tonne of portland cement