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Sustainable Concrete and You

How to Survive and Thrive in the


Concrete Green Revolution
AIA Credits
Hanley Wood is a Registered Provider with The American
Institute of Architects Continuing Education Systems.
Credit earned on completion of this program will be reported to
CES Records for AIA members. Electronic Certificates of
Completion for all attendees available 6-7 weeks post show.

This program is registered with the AIA/CES for


continuing professional education. As such, it does
not include content that may be deemed or construed
to be an approval or endorsement by the AIA of any
material of construction or any method or manner of
handling, using, distributing or dealing in any material
or product.
Questions related to specific materials, methods and

services will be addressed at the conclusion of this


presentation.
Copyright Materials
This presentation is protected by US and International
copyright laws. Reproduction, distribution, display and
use of the presentation without permission of the
speaker is prohibited.

© Kevin A. MacDonald 2010


Learning Objectives
Upon completing this program, the participant should
be able to:

1.Critically review concrete mixture proportions with


respect to the nature of the hydraulic binder

present.
2.Explain the role of reduction of cement content in
reducing the emissions of Carbon Dioxide
associated with concrete construction.
3.Make knowledgeable recommendations where
pozzolan contents can or should be raised or
lowered.
Learning Objectives

4.Know the difference between water:cement ratio


and water content, and the impact of these
items on performance of concrete.
5.Understand the role of admixtures in high volume
 pozzolan concrete, and be able to critically assess
the chemistry and their impact on performance of
concrete.
6.To explain the role of durable concrete in the life-
cycle environmental aspect of the concrete.
7.
Where Are We Today?
• Portland cement is (relatively) cheap and
plentiful
• Made from common materials
• Desirable properties are readily achieved
So why disturb this situation?
• The production of CO2 occurs
simultaneously with the production of
cement
• Estimates vary, but there is a general
agreement that about 5 to 10 percent of
the worldwide emissions of due to CO2
are from cement plants
Forces Beyond Our Control
• Environmental and political forces require
us to reduce these emissions.
• The LEED system rewards the reduction
in cement usage.
Hydraulic Materials
• Cements which will setup and be resistant
to the action of water
• Pozzolans
– ACI definition
– Functional Definition
– Geographic Definition
Pozzolans
• For our purposes, Silica Fume, Flyash and
Slag are Pozzolans

• Even Though Class C ash and Slag are
Hydraulic Cements themselves

Pozzolanic Materials
• Natural Pozzolans

• Industrial ByProducts
– Flyash
– GGBFS
– Silica Fume
– Rice Hull Ash
SiO2

Silica Fume
Glass
Natural
Pozzalans

Type F Flyash

Clay
Metakaoli
n
Portland
Cement Class C
Flyash
GGBFS

CaO Al2O3
Pozzolanic Materials
• Concretes containing pozzolans have
different properties due to the chemical
and physical interaction
• Initial use of these materials was
economic
• The best argument for their use is the
technical aspects of the concrete
Fly Ash
• ASTM C618
– Class C – High Calcium
– Class F - Low Calcium

• Need new ( and better ) ways to


characterize cement and flyash reactivity

Flyash
Particles
ASTM C 618 - Fly Ash & Natural
Pozzolans
 Class N Natural Pozzolan
 Calcined or uncalcined
 Class F Fly Ash
 From burning bituminous
or anthracite coal
 Has pozzolanic properties
 15% - 20% cement
replacement
 Class C Fly Ash
 From burning sub-
bituminous or lignite
coal
 Pozzolanic & cementitious
properties
 20% - 30% cement
replacement
Benefits of Fly Ash
Lower permeability
Reduced shrinkage
Lower heat of hydration
Higher ultimate strength
Increased durability
Acts like ball bearings to improve flowability and
workability
Cost effectiveness
Improve sulfate resistance and ASR
Not all fly ashes are the same !

Premarc 1/18/07
Class C Flyash
• Class C ashes contain C2S and

• Will have some hydraulic action
• Can contribute Alkali (K+, Na+)
Class F Ash
• Pozzolanic action alone
• Longer term strength gain over Class C
• Retards more than class C
Setting
Effect Set Time of LMN Cement & ICF Ash
Replacements
Updated Data of New Lehigh Cement (8/1/03)
Laboratory Condition
LMN & 0% ash (3:45 / 5:40)
5000

4500
LMN & 10% ash (3:50 / 5:50)
+0:05/+0:10
Penetration Resistance, psi

4000
LMN & 20% ash(4:05 / 6:10)
+0:20/+0:30
3500
LMN & 30% ash (4:30 / 6:25)
3000 +0:45/+0:45
2500

2000

1500

1000

500

0
3:00 3:30 4:00 4:30 5:00 5:30 6:00 6:30 7:00

Age, hr:min
Fly Ash Manufacturing
Flyash is not a constant
Mortar Fraction, 6 1/4 Bag, 0.45 W/C, 1490 lb SSDLLFA per C.Y
LM1 standard & 20% , 40% Replacement

20% ICF(4:00 / 6:10) 40% ICF(5:15 / 7:30)

20% MPC (6:40 / 9:45) 40% MPC(8:50 / 12:20)

7000

6500

6000

5500

5000

4500

4000

3500

3000
R
,p
io
c
s P
n
tra
e

2500

2000

1500

1000

500

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

Age, hr:min
GGBFS
• Extracted from the non-ferrous product of
a Bessemer furnace
• Material is cooled rapidly to trap slag in
the glass state
• Consists mainly of aluminates and
silicates of Calcium

Slag Cement
Slag Cement
manufactured under
ASTM C 989
Hydraulic cement
Co-product of a highly
controlled metallurgical
process
Enhances concrete
properties
Environmentally positive
material
Slag Cement
 Definition: Finely ground
granulated material
originating from an iron blast
furnace and consisting of
primarily calcium (CaO) and
aluminum (AL2O3) silicates
(SiO2) , used as a partial
replacement for portland
cement in concrete

Also known as:


“Ground Granulated Blast-Furnace Slag”
“GGBFS”
“Slag”
Aspdin Slag
patents cement Rapid
portland produced expansion
Loriot cement as a throughout
makes separate Sparrow’s U.S.
slag- material Point starts
lime widespread
mortar First slag use in
portland Eastern
blended U.S.
cements
...
1774 1824 1890’s 1950’s 1982 2000’s

Slag Cement History


How Is Slag Produced?
Granulation Process

hot slag
Slag is changed to glassy sand like
substance known as granulated blast
furnace slag - GBFS

High pressure water


6 - 10 tons water/ton slag

Premarc 1/18/07
Premarc 1/18/07
Silica Fume
• Condensed molten siliceous material –
amorphous in nature
• Product of the silicon and ferrosilicon smelting
industries
• Mean Diameter of 0.15μm
• Specific Surface Area of 15000 – 20000 m2/kg
• At 10 percent, there are 50000 to 100000
particles present for each grain of cement
Silica Fume
• 350 kg of Cement 3000 m2/kg 105000 m2
• 8 percent silica fume 28 lb 560000m2

• Large Surface Forces result in very
cohesive mixture
• Large Surface area and high proportion of
reactive material makes it extremely
reactive
Properties of Materials
Property Silica Slag Fly Ash
Fume
Specific 2.2 2.85 2.6-2.75
Gravity
Specific Very Fine Varies Finer than
Surface cement
Reactivity Very Rapid Varies with Varies with
size and size and
Chemistry Chemistry
Cement Chemistry
• Chemically active
• Major and Minor Constituents
• Sulfate Form can be very important
• Solids must either dissolve in solution or a
surface reaction takes place
Major Components
• C3S
• C2S
• C3A
• C4AF
• CaSO4
Hydration
• Chemical reaction between individual
clinker minerals, calcium sulfate and
water
• Proceed at different rates – in series and
in parallel – and influence one another
Pozzolanic Reaction
• Cement + Water  Glue and Ca(OH)2

• Ca(OH)2 + PozzolansMore Glue


High Volume Flyash Concrete
• Significant increases in ASR, sulphate and
thermal cracking resistance are possible
at 25 percent or higher flyash
replacement
• Problems with setting time and early age
strength gain
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
Comparisons to OPC Concrete
 High Volume Fly  Conventional
Ash Concrete Concrete
 Less energy  Energy intensive
intensive manufacture
manufacture  Weaker ultimate
 Higher ultimate strength
strength  Less durable
 More durable  Uses virgin materials
only
 Uses a waste by-  More global warming
product gases created
 Less global warming
gases created

Plastic Properties
• Low water content dictates use of
Superplasticizer So slump is available
as required
• Concrete is readily air entrained using
conventional admixtures
• Workability is high, and fines content
promotes cohesion
Plastic Properties
• Bleeding - Negligible to very small
• Time of set – may be significantly
increased – depends on flyash being
used
• Autogenous temperature rise – peak
temperature is lower
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 1
day strengths of 2500 psi or more
Hardened Properties
• Tensile strength and flexural strength are
the same as OPC Concrete
• Modulus of Elasticity is high – 35 GPa
(~107psi)
• Caused by infilling of the ITZ – flyash as
microfine aggregate
Hardened Properties
• Creep and Shrinkage
• Drying strains are lower than conventional
concrete
• Creep is lower than conventional concrete
• Likely due to denser microstructure
Durability
• Water Permeability Low
• Freezing and Thawing – Behaves as
conventional air entrained concrete
• Scaling resistance Some sidewalks have
been constructed in Canada with good
reported performance. Others have not
seen the same results. Should be
avoided in deicer exposure
Durability
• Penetration of Chloride Ions
• Rapid Chloride Permeability
– 28 days 2500 coulombs passed
– 90 days 1000 coulombs passed
– 365 days 150 coulombs passed
Durability

HVFA
2000
Charge Passed ,
Coulombs

1000

Silica Fume

Log Time
Mixture 5 100% OPC
Mixture 2 Slag: OPC
Mixture 3 Flyash:OPC
00
. 16 Mixture 1,10 FA:Slag:OPC
00
. 14
Mixtu re No5
.
00
. 12

00
. 1 Mixtu re No.2

00
. 08 Mixtu re No.3

00
. 06

00
. 04
Mixture No1
.
em

00
. 02
kg
,/ icalS
rn C
h

Mixtu re No1
. 0
0

T ime, min u tes


Drying Shrinkage, 7 day cure

00
. 45
00
. 4 M ix 1
00
. 35 M ix 2
00
. 3 M ix 3
Shrinkage %

00
. 25 M ix 5
Increasing
00
. 2 Pozzolan Log. (M ix2 )
Content Log. (M ix1 )
00
. 15
00
. 1 Log. (M ix5 )
00
. 05 Log. (M ix3 )
0
0 5 10 15
Time, Days
Hydration
• Chemical reaction between individual
clinker minerals, calcium sulfate and
water
• Proceed at different rates – in series and
in parallel – and influence one another
Hydration Curve

Heat
Evolv
ed,
dH/dt

Time
Hydration
• Progress dependent on
• Rate of dissolution
• Rate of Nucleation and Crystal growth
• Rate of Diffusion of reagents through
hydration products
Hydration
• Water/Cement Ratio
• Curing Conditions and Humidity
• Hydration Temperature
• Presence of Admixtures

Mixture Proportioning and
Adjustment
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

• 550 lb cement and 220 lb water

• 660 lb cement and 264 lb water

• Both have the same water : cement ratio


• Water Content will dictate the slump and
workability
• Water:cement ratio will dictate the strength
and durability

Water Cement Ratio
Low High

The fluidity of a water-cement system is a


function of attractive and repulsive
forces between cement particles
Workability Ease of Finishing
Slump and Viscosity

Viscosity is slope of
line
Shear
Stress

Shear Rate
Viscosity Models

Bingham
Plastic

.
τ =τ0 + µ γ
Bingham Model

Shear
Stress

Shear Rate
Viscosity Behavior

SCC
Viscosity is slope of
line
Shear
Stress

WRDA

HRWRDA
Water
Shear Rate
Mixture Design - Rheology

20 Silica Fume

Air
τ0

1
VMA
0
2

Flyash Slag* Water


SuperPlasticizer

Viscosity
Dispersion – the water
reduction trick
Capillary
Pores

Gel
Pores
Water:Cement Ratio
• Controls the pore space –

• Lower w/c = fewer pores=less water
How to Change Viscosity
• Alter the properties of the particles, the
fluid or their interaction

• Admixtures

• Geometry (particle packing)
Life-Cycle Costing
Case Studies
Great River Energy
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
Drying Period
• Water in concrete can fill pores that once
dried cannot be refilled

• So concrete may be more saturated
before drying than after immersion
following drying
Scaling Resistance
• Making the skin of concrete – because
concrete beauty is skin deep


Modified Pore Structure

OPC
Gel pores Capillary Pores
Intruded Volume

OPC +
GGBFS

60 %
Hydration
0.001 0.01 0.1 1
10
Pore diameter, μm
Modified Pore Structure

Gel pores Capillary Pores OPC3


Days
Intruded Volume

OPC +
GGBFS
28
days
60 %
Hydration
0.001 0.01 0.1 1
10
Pore diameter, μm
Platinum LEED 45 percent
reduction in cement content
• Flyash replacement of 60 percent
• Total cementitious content increased
• Net reduction 45 percent

I 35 W St. Anthony Falls Bridge
• All concrete in foundation and
substructure is High Pozzolan Content
• Conventional cementitious contents –
less than 625 lb per cubic yard

756

783

319
Thank You!
This concludes the American Institute of Architects
Continuing Education Systems Program.

 Any Questions?
Kevin A. MacDonald

1-800-CEMSTONE

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