Decreasing the Clinker Component in Cementing Materials: Performance - - PowerPoint PPT Presentation

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Decreasing the Clinker Component in Cementing Materials: Performance - - PowerPoint PPT Presentation

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Decreasing the Clinker Component in Cementing Materials: Performance of C ti M t i l P f f Portland-Limestone Cements in Concrete in Combination with Supplementary in Combination with Supplementary Cementing Materials Doug Hooton, Amir

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2010 International Concrete Sustainability Conference, Dubai, UAE 1

Decreasing the Clinker Component in C ti M t i l P f f Cementing Materials: Performance of Portland-Limestone Cements in Concrete in Combination with Supplementary in Combination with Supplementary Cementing Materials

Doug Hooton, Amir Ramezanianpour

UNIVERSITY OF TORONTO DEPARTMENT OF CIVIL ENGINEERING DEPARTMENT OF CIVIL ENGINEERING

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2010 International Concrete Sustainability Conference, Dubai, UAE 2

Why Portland-Limestone Cements (PLC)? Cements (PLC)?

  • Portland Cement manufacturing

g produces CO2

– Limestone decomposition – Fuel consumption

  • Governments are preparing cap

p p g p and trade limits on point source CO2 emissions

  • Not new since PLC (CEM IIA-L)

Not new since PLC (CEM IIA L) has been in use in Europe for > 20 years and is now the most widely used cement type

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PLC in Canadian Standards

  • In 2008, a new class of Portland-Limestone cements was

added to the cement standard CSA A3001 with up to added to the cement standard, CSA A3001, with up to 15% blended or interground limestone replacing cement clinker.

  • The CO2 emissions from PLC are ~10% less relative to

CSA Type GU (~ASTM Type I) Portland cement.

  • In addition, fewer raw materials and less energy are

used to produce PLC used to produce PLC.

  • When properly optimized, the limestone is not inert and

contributes to the properties of the cement. p p

  • PLC have to meet the same set time and strength

development performance as portland cement of the same type (eg. GU ---same as ASTM Type I)

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Portland-Limestone Cements in Canadian Standards in Canadian Standards

  • Changes to the CSA

Changes to the CSA A3000 Cementitious Materials standard in 2008 and to the A23.1 Concrete standard in 2009 allow use of PLC

  • The National Building

The National Building Code of Canada was updated in 2010 to include these changes g

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More Sustainable Cementing Materials Cementing Materials

SCMs (and blended cements)

Portland cement Blended hydraulic Portland- limestone type cement type cement type

GU GUb GUL PLC (GULb)

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CSA A23.1 Types of Hydraulic Cements

Portland Blended hydraulic Portland limestone Name Portland cement Blended hydraulic cement Portland-limestone cement *** Name

GU GUb GUL

General use cement

MS MSb

  • Moderate

sulphate-resistant cement

MH MHb MHL

Moderate heat of hydration cement

HE HEb HEL

High early- strength cement strength cement

LH LHb LHL

Low heat of hydration cement

HS HSb

  • High sulphate-

HS HSb

resistant cement

*** Portland-limestone cements shall not be used in sulphate exposures as

defined in Table 3 of CAN/CSA-A23.1 (even when mixed with SCMs)

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PLC in Sulfate Exposures p

  • Currently PLC is not allowed in sulfate exposures

b th CSA A23 1 t t d d d t by the CSA A23.1 concrete standard due to concern with potential for thaumasite sulfate attack (TSA) at cool temperatures (5-10 oC).

  • However, in 2010, the CSA A3001 cement

standard was revised to allow PLC blended cements in sulfate exposures cements in sulfate exposures

  • Research is ongoing to develop sufficient data to

revise the A23.1 concrete standard to allow PLC + SCM (or blended cements) in sulfate exposures.

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2010 International Concrete Sustainability Conference, Dubai, UAE 8

Thaumasite Thaumasite Form Form

  • f
  • f Sulfate

Sulfate Attack Attack

30-year-old bridge column exposed to wet oxidized sulfide clay in to wet oxidized sulfide clay in England Thaumasite is not so common, but when it occurs it attacks the whole when it occurs, it attacks the whole matrix.

Photos from UK Expert Panel

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New Test for Evaluating Mitigation f Th it S lf t Att k

  • f Thaumasite Sulfate Attack
  • A new test method, based on ASTM C1012, but

with mortar bars stored in sulfate solution at 5 oC with mortar bars stored in sulfate solution at 5 C, was standardized by CSA in 2010

  • In this new test, PLCs were found to show

t ti l t f th it if d th l potential to form thaumasite, if used as the sole binder.

  • But when sufficient levels of slag fly ash

But when sufficient levels of slag, fly ash, metakaolin, and silica fume (ternary) binders were used, no thaumasite formed. Thi th b i f CSA A3001 b i i d

  • This was the basis for CSA A3001 being revised

in 2010, allowing blended cements with limestone

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ASTM and PLC

  • At least 2 producers in the USA are making

p g 10% limestone cements under ASTM C1157 and have used them in both structures and pavements.

  • ASTM C595 may be amended in 2011 to allow

for PLC blended cements.

  • In support of ASTM activities, Thomas &

H t d t PCA R&D SN3142 Hooton prepared a report: PCA R&D SN3142, The Durability of Concrete Produced with Portland-Limestone Cement: Canadian Studies Studies.

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A3001 PLC Performance Requirements Requirements

  • In CSA A3000, the setting times and strength

, g g development limits are the same for PLC as for portland cements.

  • Heat of hydration limits are also the same for

y MH and LH cements.

  • In concrete, PLC also performs well with slag
  • r fly ash at normal replacement levels.
  • Mechanisms: Carbo-aluminate hydrates form

and also fine carbonates provide nucleation sites that accelerate hydration

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Cement types sold in Europe 1999 - 2004 (according to Cembureau data)

5 6 4.0 3.2 6.1 5.5 5.0 3.4 1.7 6.5 5 1.5 2.1 4 8 9.5 1.9 1.8 5.1 5.4 2.9 2.1 5.6 5.7 1.8 2.2 90 100

Others CEM V - Composite Cement CEM IV - Pozzolanic

( g )

16.8 5.6 16.8 14.5 24 0 9.6 4.8 14.3 12.5 70 80 pe (%)

CEM III - Blast furnace slag CEM II - Portland-composite CEM II - Portland-limestone CEM II - Portland-fly ash CEM II - Portland-pozzolana

4 8 3.7 5.4 15.0 5 4 2.9 6.2 18.9 2.1 5.7 24.6 2.7 7.0 24.0 1.2 6.9 24.5 7 4 31.4 40 50 60 nt Types in Europ

CEM II - Portland-slag CEM I - Portland

PLC had the

35.4 4.8 34.2 5.4 33.7 4.2 32.1 6.8 31.6 5.9 1.2 27 5 4.5 1.4 7.4 20 30 Cemen

largest use in 2004

Most portland-

27.5 10 1999 2000 2001 2002 2003 2004

p composite cements contain limestone too

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Why PLC works: (Herfort, 2008) Limestone and cement aluminates form Carboaluminates, which fill in porosity and increase strength + if get more aluminates from SCM optimum will shift to higher % limestone

10 15 nd ] compressive strength measured

aluminates from SCM, optimum will shift to higher % limestone

5 10

  • f porosity a

strength [%] increase 10

  • 5

ive change o compressive decrease

  • 15
  • 10

2 4 6 8 10 12 14 16 18 20 22 relati c total porosity calculated amount of CaCO3 added [wt.-%]

Equal strength at 0 and 13% PLC

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PLC + Slag, Fly Ash, or Metakaolin

10 15 nd compressive strength measured 5 10 f porosity an strength [%] increase

  • 5

ve change of

  • mpressive s

decrease

  • 15
  • 10

2 4 6 8 10 12 14 16 18 20 22 relativ co total porosity calculated amount of CaCO3 added [wt.-%]

Research is currently underway at U of Toronto to confirm

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Limestone Fineness

100% D50 (Limestone): 7 to 10 μm 50% D50 (clinker): 15 μm 1μm 10μm 100μm

Limestone fineness in the interground product is significantly finer than the clinker fraction

  • L. Barcelo, Lafarge
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Lab Concrete Data

  • Before balloted by CSA A23 1 all of
  • Before balloted by CSA A23.1, all of

the Cement companies and several universities performed extensive p testing for fresh, hardened, and durability properties on PLC and t th ith SCM ll d together with SCMs normally used.

  • A couple of examples follow.
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Initial concrete test results – straight cement (and limestone)

[MPa]

40 10 20 30 1d 3d 7d 28d 56d GU P LC 10 P LC 15 20 40 60

w/c 0.70

1d 3d 7d 28d 56d 91d GU P LC 10 P LC 15 40 60 20 40 1d 3d 7d 28d 56d 91d

w/c 0.40 GU PLC10 w/c 0.37

GU P LC 10 P LC 15

PLC15

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Initial concrete test results – with 30% Slag

[MPa]

40 10 20 30 40 10 1d 3d 7d 28d 56d GU P LC 10 P LC 15 40 60

w/cm 0.70

20 1d 3d 7d 28d 56d 91d GU P LC10 P LC15 40 60

w/cm 0.40

GU P LC 10 P LC 15 20 40 1d 3d 7d 28d 56d 91d

GU PLC10 w/cm 0.37

GU P LC 10 P LC 15

PLC15

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56-day ASTM C1202 Results (w/cm = 0 40) (w/cm = 0.40)

56 Day RCPT Results 56 Day RCPT Results

3000 3500 2000 2500

lombs

GU PLC10

CSA C-1 Exposure Limit

1000 1500

Coul

PLC10 PLC15

p

500

Cement-100% Cement-70%+Slag-30%

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85-day ASTM C1202 Results y

85 Day RCPT Results

2500 3000

GU

1500 2000

ulombs

GU PLC10

500 1000

Co

PLC15

500

Cement-100% Cement-70%+Slag-30%

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Lafarge PLC Trials from 2008 (Concrete International ( Jan.2010)

  • 8 concrete slabs were cast

8 concrete slabs were cast in Oct 2008 at Lafarge, Gatineau QC

  • 80-100mm (3-4 in ) slump

80 100mm (3 4 in.) slump, air-entrained, 30MPa, C-2 exposure(355kg/m3, 592 pcy) pcy)

  • GU and PLC with 0, 25, 40

& 50% mixed SCM (2 slag: 1 fly ash) 1 fly ash)

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RCP Coulomb Values for Site Cast Cylinders & Cores y

Equal performance

  • f GU and PLC

mixes at same age and SCM content

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3, 7, 28, 35-day Cylinder & 35-day Core Strengths g

(12% limestone PLC mixes in Green)

0 25 40 50 % SCMs

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Air Void, Freeze/Thaw and Chloride Diffusion Data Chloride Diffusion Data

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  • Nov. 2009 Barrier Wall
  • Dufferin Construction Barrier Wall Test
  • Dufferin Construction Barrier Wall Test

sections 23m3 of PLC+Slag vs GU+Slag

  • Queen Elizabeth Expressway in

Burlington

  • First MTO trial of PLC
  • Testing performed by Dufferin Concrete

(Holcim) and University of Toronto.

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2010 International Concrete Sustainability Conference, Dubai, UAE 26

PLC Barrier Walls on QEW Nov 4 2009

  • Nov. 4, 2009

GU Cement + GUL Cement 25% Slag + 25% Slag 23 m3 of each mix was placed, 30 MPa, 60-100 mm (2.5-4 in.) slump

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2010 International Concrete Sustainability Conference, Dubai, UAE 27

  • Nov. 2009 QEW Barrier Wall

QEW Barrier Wall PC +25% SLAG PLC + 25% SLAG Shrinkage (28d) 0.038% 0.038% Strength (MPa) 1 9 5 10 3 1 9.5 10.3 3 19.3 19.4 7 25.6 26.8 28 36.9 37.9 56 91 38.9 40.7 38.0 40.2 9 Freeze/Thaw Durability 94% 94% MTO LS-412 Scaling 0.24 kg/m2 0.24 kg/m2 RCP (Coulombs) 28 days 2070 1490 56 days 1930 1340

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PLC Paving Trial Sept 27, 2010

Cooperation between MTO, Dufferin Construction, H l i d U i it f T t Holcim and University of Toronto

  • New Highway 401 East bound exit to #10

New Highway 401 East bound exit to #10 from collector lanes.

  • 100 m of paving was done with

PLC 25% Sl bi d th i PLC+25% Slag as binder, otherwise identical to GU+25% Slag control mixture. mixture.

  • Pavement was 4.25 m (13 ft) wide x 280

mm (11.5 in.) thick with pre-placed dowel b k t baskets

  • ~8 m (25 ft) was wet-cured and rest used

normal curing compound

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2010 International Concrete Sustainability Conference, Dubai, UAE 29

Testing

  • fresh concrete tests and strength
  • fresh concrete tests and strength

development

  • Flexural and tensile strengths

Flexural and tensile strengths

  • Shrinkage
  • Freeze/Thaw and De-icer scaling tests

Freeze/Thaw and De icer scaling tests

  • Chloride Permeability and Bulk

Diffusion us o

  • Temperature monitoring
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Concrete Plant

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PLC (GUL) Test Section

Floating and Tyning

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GUL on Left and GU on Right

(after tyning but before curing ( y g g compound)

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GUL Mix on left and GU Mix on right in Paver (note segregation in GU Mix) Paver (note segregation in GU Mix)

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Burlap & Plastic vs Curing Compound Compound

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PLC pavement at 2 months, prior to opening to traffic prior to opening to traffic

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7 & 28-Day Data (random samples from trucks) (random samples from trucks)

GU Control PLC Slump (mm) 35 20 Air (%) 5 4 4 6 Air (%) 5.4 4.6

  • Temp. (oC)

18 19 Strength (MPa) 7 day 35.0 31.9 28 day 50.4 48.9 Split Tensile (MPa) 7 day 3.3 3.0 28 day 4.3 4.0 Flexural (MPa) 7 day 5.8 5.2 28 day 7.4 6.8

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Holcim US PLC Pavements

  • Holcim makes ASTM C1157 cements
  • Holcim makes ASTM C1157 cements

with 10% limestone for use in Colorado and Utah.

  • These have been used on at least 5

State paving contracts.

  • In several cases the PLC was used

together with Class F fly ash

Data courtesy of Al Innis, Brooke Williams, & Tom Van Dam

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2010 International Concrete Sustainability Conference, Dubai, UAE 38

Colorado 2008-2009 US HW 287 Near Lamar US HW 287 Near Lamar

  • 6.5 Miles PCCP with 10% Limestone cement meeting ASTM C1157

and 20% Class F fly ash (CM = 540 pcy, 322 kg/m3) w/cm = 0.34 and 20% Class F fly ash (CM 540 pcy, 322 kg/m3) w/cm 0.34

  • 28-day flexural strength average = 695 psi (4.8 MPa)
  • Contractor received quality incentive per CDOT specifications
  • Concrete was placed in 100 F (38C) weather without problems
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Lehigh Cement Terminal 20 000 Ton Silo 2010 20,000 Ton Silo, 2010

  • In Leeds Alabama
  • In Leeds, Alabama
  • Slip-formed silo made with PLC (10%)

and 40% slag and 40% slag

  • Three concentric silos all slip-formed
  • Mix used 10% limestone blended

Mix used 10% limestone blended cement meeting ASTM C1157 HE (clinker was Type II low-alkali).

Data from Gary Knight and Colleagues

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80 foot (24 m) diameter x 240 feet (72 m) high feet (72 m) high

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Three concentric silos

Outer wall 33 in (0 84 m) thick at bottom Outer wall 33 in. (0.84 m) thick at bottom

Concrete Mixture for slip Form PCY kg/m3 C1157-HE PLC 420 250 Slag 280 167 Sand 1202 716 Stone 1856 1106 Water 275 164 w/cm 0 39 0 39 w/cm 0.39 0.39

Water-reducer and HRWR used

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Early-age and 7-Day Strengths

Leeds D-Silo Concrete Phase I 60% Lehigh C1157 HE & 40% Slag Cement 7000

SILO 6041

Average 7 day Strengths SILO 6041 5507 psi. (38.0MPa) STD 311 psi (23 tests) SILO 6040 5647 i ( ) STD 384 i (13 t t )

Mix ID

5000 6000

SILO 6040 SILO 6039

SILO 6040 5647 psi. (38.9 MPa) STD 384 psi (13 tests) SILO 6039 6223 psi. (42.9 MPa) STD 908 psi (10 tests)

3000 4000 PSI (4x8)

20MPa

1000 2000

Lehigh C1157HE (10% Interground Limestone Cement)

20MPa

20 40 60 80 100 120 140 160 180

Time (hours)

7day

Interground Limestone Cement)

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Summary

  • Portland-Limestone cements have been used

successfully in numerous pavements, in a barrier wall and in a large slip-formed silo.

  • PLC works well with slag and fly ash at typical

g y yp cement replacement levels.

  • PLC, as defined in CSA, provides a 10%

reduction in CO2 emissions from cement plants d d th b f t i t f t b and reduce the carbon footprint of concrete by an additional 10% without affecting performance.

  • Use of PLC should not affect concrete properties
  • r construction practices
  • r construction practices.
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Portland-Limestone Cement makes “Greener” Concrete Concrete