AALBORG EXTREME –Next generation HPC and UHPC

technologies based on AALBORG WHITE

Carmen Maria Batista RuizWhite Cement Applications Specialist

• Cementir Group: the biggest white cement producer in the world.

• Conventional concrete.

• UHPC: concept, history, properties and applications.

• White cement and UHPC.

• AALBORG EXTREME Light 120.

• To keep in mind.

About this presentation

Aalborg Portland, the only cement producer in Denmark

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The Cementir Group

Research and Quality Centre

Research and Quality Centre in AalborgThe Cementir Holding unit for:

• R&D, • Quality • Technical Sales Support

• Geologists• Chemists• Chemical engineers• Civil engineers• Environmental engineer

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International cooperation

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• Growing the market for white cement– New high value product

• Ultra-high performance concrete– Patented mineral addition

• Glass-fibre reinforced concrete– New construction elements

We continue this in white cement

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Evreux

Opus 5 Architects/UHPC

Producer: Guillerm

Producer: OmegaZeta

Producer: OmegaZeta

Producer: HICON

Arkitema A/SHI-CON - CRC® Technology

Producer: HICON

Orestaden

Lundgaard & Tranberg ArkitekterHI-CON - CRC® Technology

• According to the standard EN 206:2013 Concrete – Specification, performance, production and conformity:“Material formed by mixing cement, coarse and fine aggregate and water with or without admixtures , additions of fibres, which develops its properties by hydration”

Cement Aggregates Water

Conventional Concrete

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Fresh concrete:- Workability

Hardened concrete:- Density- Compressive strength- Tensile strength- Durability

Some important properties of concrete

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Strength classes for conventional concrete

EN 206:2013 Concrete – Specification, performance, production and conformity

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The European Standard for concretedoes not include strength classeshigher than C100/115, therefore(U)HPC is not included

What is Ultra High Performance Concrete (UHPC)?

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UHPC are materials with cementitious matrix and characteristic compressive strength after 28 days in excess of 150 Mpa, possibly attaining 250 MPa; containing steel fibers in order to achieve ductile behavior under tension

French Interim Recommendations (AFGC Recommendations - 2013)

NF P 18-470 Standard (2016)

UHPFRC with a characteristic compressive strength equal to or greater than 150 MPa and comprising metallic fibers

UHPFRC materials where the non-brittleness is achieved through the use of other types of fibers (designated “type A UHPFRC”) as well as UHPFRC mixes with a lower characteristic strength, yet above 130 MPa, whatever the type of fibers contributing to non-brittleness

Structural applications Non structural or architectonic structures

Note: all compressive strength values showed are measured on cylinders 150x300mm at 28d

(U)HPC IS A LOT MORE THAN ONLY A STRONG MATERIALAnother definition

“Ultra-High Performance Fibre-Reinforced Concrete (UHPFRC) is defined as anhydraulic cement-based composite material, which combines threetechnologies in concrete:1. High characteristic compressive strength.2. Ductile behavior under tension due to the presence of fibres.3. A special selection of fine and ultrafine aggregates that provides dense

particle packing, high durability and certain degree of flowability.”

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Ultra High Performance ConcreteBasic Principles

Ultra High Performance Concrete – UHPC

• Very low W/B ratio: 0,15 – 0,25• Addition of silica fume: 17-20% BWOC.• High packing density.• Use of homogeneous, high strength and reduced diameter aggregates.• Use of last generation admixtures, in order to provide to the material selfcompactability with

low W/B ratio.• High flexural and compressive strength, high ductility, durability, toughness, stiffness and

thermal resistance.

• Megastructures.• Load bearing elements.• Traffic elements.• Safety (cash machines).• Offshore and onshore foundations.• Others (growing market).

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Performance is the key• UHPC/UHPFRC is a versatile structural material with properties between steel and concrete.• It makes viable to design lighter structures, save raw materials, increase the live span and

obtain more aesthetic surfaces with shapes that until now were unthinkable with conventionalconcrete.

• There is not an “unique” way of designing UHPC, the design can be adjusted to the application“VERSATILITY”

• High ductility, durability, toughness, stiffness and thermal resistance.

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Producer: mbx

Basic components of traditional UHPC

Binder• Binder contents in UHPC are a lot

higher than those for conventional concrete.

• Binder can easily represent more than 50% in weight of the product.

• Superplasticizers, water reducing admixtures, are included in the binder.

Aggregates•Normally two sands are combined to obtain an adequate granulometry.•Commonly, maximum diameter is between 0,5 and 2mm.

FibresFibres are necessary to increase the ductility and the post-peak behaviour, avoiding brittle failures.Fibres can be made of steel, glass, PP, PVA, others.

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Basic components of traditional UHPCBinder

Cem

ent • Cement as the

hydraulic binder. It hardens due to its hydration reaction

Sili

ca fu

me • Amorphous

silicon dioxide, silica. It is an ultrafine powder collected as a by-product of the silicon and ferrosilicon alloy production and consists of spherical particles with an average particle diameter of 150 nm.

SC

M a

nd fi

llers • Supplementary

Cementitious Materials:- Fly ash- Calcined clay

• Fillers:• - Quartz flour.• - Limestone.

Sup

erpl

astic

izer • Polycarboxylate

based polymer (PCE), capable of reducing the water content up to 40%

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UHPC: The history

• Advances in admixture technologies, specifically indispersants allowed the use of particles smaller than cement,filling the wholes and reaching then a more compact matrix.

DSP = Densified Systems containing homogeneously arranged, ultra-fine Particles

• Ultra fine cement.• Silica fume.• Strength: 128MPa at 24h.

Hans Henrik Bache

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UHPC: The history

CRC = Compact Reinforced Concrete• Based in a very high strength fibre reinforced matrix and

conventional steel reinforcement in high percentage.• It belongs to the category of Heavy Reinforced Ultra High

Performance Concrete (HRUHPC).

SIFCON = Slurry Infiltrated Fibre Concrete

• Very fluid cementitious slurry with small sizeaggregates pouring over steel fibres.

• Patented product, same concept but with maximum sizeaggregate of 0,6 mm to reduce microcracks.

• In the 90’s, several commercial binders based on DSP andRPC technologies were launch to the market.

RPC = Reactive Powder Concrete

• The concept of UHPC is introduced for the first time in a research journal.

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UHPC: The historyAnd now…• UHPC technology is continuing growing and getting into new markets and

applications.

• More and more structural and architectural projects, especially in Europe and China.

• Pre-cast elements for architectural and structural applications: façades, balconies,load bearing elements for massive structures.

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To keep in mind

Properties of (U)HPC material:

1. Self compacting: flowable2. High compressive strength3. Ductile behavior4. Dense particle packing

Durability

5. Light weight: possibility of achieving more performance than conventional concrete with less material

6. Good surface finish

Applications:

Precast:- Housing elements: façades,

balconies, columns.- Girders, bridge elements.

In situ cast:- Megastructures:Wind turbines (grouted structural connections)

Oil platforms (foundations and structural connections)

Others:- High impact resistant structures

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White cement in (U)HPC

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WHY TO CHOOSE WHITE CEMENT FOR USING IN UHPC MATERIALS?

§ Due to its low C3A and alkali content, Aalborg Portland White chemical reaction with superplasticizers is more effective.

§ Colour must be stable and monitored for white cement, which means that all the production parameters must be incomplete control to avoid contamination, specially the sources of raw materials and fuels.

§ White cement has a high degree of purity and low alkali content.

§ Performance of white cement is higher than grey (higher potential strength and lower porosity)

§ In general, due to a larger control of raw materials and production process, the quality of white cement is more stable

EASY TO FORMULATE WITHHIGHER STRENGTHHIGH AESTHETICGOOD COMPATIBILITY WITH ADDITIVES

TOTAL CONTROL DURING PRODUCTIONSTABLE QUALITYBETTER AND PREDICTABLE PERFORMANCE

HIGH QUALITY FINAL PRODUCTUHPC

White Cement Composition

Raw materials for AALBORG WHITE CEM I

CaO source

(chalk, limestone, etc.)

SiO2 source

(quartz sand, etc.)

Al2O3 source

(Kaolin, alusilicate, etc.)

+

Clinker

(~1400 oC)CaSO4 source (gypsum, anhydrite, etc.)

AALBORG WHITE

cement

=

Grey Portland CEM I

As White cement + Fe2O3 source (iron oxide, etc.)

Fe2O3 is used for lowering the melting point in the cement klin

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White Cement CompositionWhite Clinker Grey Clinker

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White Cement Performance CEM I 52,5 Grey CEM I 52,5

0.60-0.80%

8-14%>8%

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Why to develop an (U)HPC solution?5 Main Pains identified (DK example)

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Inefficient logistics

on the site

Very stressed

construction site

Inefficient logistics to

the site

Limited possibilities for on-site corrections

Limited quality of finished surface

Due to the high weight of concrete elements, it becomes very difficult to move them around – they have to be loaded directly and on-time to final location. As it is not possible to move the elements on site, it is

not possible to create temporary storage areas

The available area on building sites is very limited, especially in the cities. The contractors would therefore prefer to move as many activities as possible out of the building site – like e.g. finishing,

installations, etc.

In many cases it is only possible to transport one façade precast element per truck – timing on site becomes critical. For modules in

wood special convoys are often needed due to the size of the elements

The construction of modern buildings is very complex and errors often occur, needing onsite correction. With traditional precast elements, the

possibilities for onsite corrections become limited

Elements often become damaged on site, requiring extended finishing operations. This is largely due to the stressed environment on the

building site. Less important

Paramount importance

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Why to develop an (U)HPC solution?

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Image property of: TAKTL®

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AALBORG EXTREME Light 120

White colored High Performance Concrete dry mix

New binder technology

All-in solution / ready to use: just add water

Self-compacting

Shrinkage reduced mortar

High aesthetic, durability and mechanical performance

Possibility of tailorization by the end producer: fibres, pigments, coatings

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AALBORG EXTREME Light 120

1,95 to 2,1 Kg

• White. • Self-compacting.• Minimum 120 MPa

compressive strength after 28 days.

• Durable.

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Some applications of AALBORG EXTREME Light 120

• AALBORG EXTREME Light 120, can be use for several applications, as:

ü Light weight high strength panels: façades, cladding, sun-screens, ornamentalelements.

ü Artistic and ornamental elements made in concrete.

üWet cast tiles.

ü Gardening / street architectural elements.

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AALBORG EXTREME Light 120Properties

§ Fresh state properties:

Initial flow: 900mm – self compactingFlow retention: 45minAir content: 1%Dmax: 3mm

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AALBORG EXTREME Light 120

Casting of elements at a precast factory with 0,8% v/v glassfibres

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AALBORG EXTREME Light 120Properties

§ Hardened state properties:

Shrinkage: ˂ 600µm/m (90days)Setting time: 6.5 to 7 hours

Compressive strength: 1d (40x40x160mm): ˃75MPa1d (Ø150/300 cyl): ˃75MPa

28d (40x40x160mm): ˃130MPa28d (Ø150/300 cyl): ˃120MPa

E-modulus: 50GPa

§ Durability:

Chloride content: ˂0,09% to cementAlkali content: ˂3,4Kg/m3

Chloride migration: 0,35 x 10-12 m2/sWater absorption: WC2 (˂ 0,02 Kg/m2)

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AALBORG EXTREME Light 120Property and Test Method

Units Value Fresh State � Flow ASTM C 230/ C 1437-151) (initial/30 min/45min)

cm 29±2 / 29±2 / 29±2

EN-206 (Initial) mm >900 � Air content, EN 1015-7 Vol% < 2 � Fresh mortar density, EN 1015-7 kg/m3 2,425 � Aggregate size mm < 3 Hardening State � Hydraulic shrinkage, EN 12617-(40x40x160mm)

– 90 days µm/m < 600

� Setting Time (Proctor, time to achieve 3.5 MPa) hours 6.5-7.5 Mechanical Properties � Compressive Strength, EN 196-1, 40x40x160mm

1 day 28 days

MPa

>75

>130 � Compressive Strength, diam. 150/300 cylinder

1 day 28 days

MPa

>75

>120 � E-modulus, EN 12390-13

28 days

GPa

50 � Flexural strength MPa

EN 12390-5, 100x100x500 mm 28 days

MPa

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Durability Properties � Chloride content, excl. chloride from mixing

water Wt.% to cement

<0.09%

� Water soluble equivalent alkali content (Na2O+0.658xK2O), excluding contribution from mixing water

kg/m3 < 3.4 (NO alkali silica

reactive aggregate is used)

� Chloride Migration, NT Build 492, 28 days 56 days

x 10-12 m2/s

0.35 0.27

� Water absorption, EN 1015-18 kg/(m2 ˑ min0.5)

<0.02 (WC2)

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AALBORG EXTREME Light 120

“In our effort to limit the use of scarce materials, AALBORG EXTREME Light 120 is manufactured with raw

materials from sources vastly available in nature. Therefore, it is not constrained by the availability and

quality of waste materials from other industries”

SUSTAINABILITY:

AALBORG EXTREME Light 120SUSTAINABILITY

Cem

ent • Cement as the

hydraulic binder. It hardens due to its hydration reaction

Sili

ca fu

me • Amorphous

silicon dioxide, silica. It is an ultrafine powder collected as a by-product of the silicon and ferrosilicon alloy production and consists of spherical particles with an average particle diameter of 150 nm.

Pat

ente

d bi

nder

tech

nolo

gy • Our product is based on our FUTURECEM patent.

• No silica fume, fly ash, slag are used in the formulation

Sup

erpl

astic

izer • Powder

superplasticizer.

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To keep in mind• (U)HPC is a growing technology, due to its workability (easy to cast), strength, ductility and

versatility.

• Going for (U)HPC allows to reduce the thickness of the elements keeping the bestmechanical and aesthetical performance and saving transportation costs.

• Using a pre-mixed (U)HPC material will save R&D costs, time, and also will guarantee thequality of the final products.

• AALBORG EXTREME Light 120 is a new HPC technology, which has the advantages ofHPC products in terms of mechanical performance plus a high level of whiteness andopportunity for customer tailorization.

• Due to its self compacting nature and long opening time (45min), AALBORG EXTREMELight 120 is perfectly suitable for an industrialized/automatized pre-cast productionprocess.

Unlimited Possibilities of White Cement

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THANK YOU