mixed type binding systems. a sustainable alternative for rcc pavements
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V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow. Mixed type binding systems. A sustainable alternative for RCC Pavements. I. Papayianni , E. Anastasiou , M. Papachristoforou Laboratory of Building Materials - PowerPoint PPT PresentationTRANSCRIPT
Mixed type binding systems. A sustainable alternative for RCC
PavementsLaboratory of Building Materials
Aristotle University of Thessaloniki
Mixed type binding systems. A sustainable alternative for RCC Pavements
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Background
Binders are the most precious materials in building construction, since they transform a volume of grains into a compact, load-bearing material of adequate volume stability
Portland cement is an excellent high-strength binder which predominates in construction, but is also an energy consuming, high-cost material of low ecological profile
Under the pressure of reality:
Climatic changes and catastrophes
Need of longer service life for constructions
There is an urgency to develop alternative smart mixed type binding systems
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Background
A first simple step for sustainability integration in construction is to make local industrial by-products (fly ashes, slags) beneficial for the structural sector
How do we work to exploit industrial by-products to the maximum:
Test the suitability of the by-products as cementitious materials for a specified use
Development of a mixed type binding system and assessment of its quality
Design and proportioning of a proper concrete mixture for a specified strength
Test the compliance of the concrete with a control mixture
Proceed to a pilot application of the designed concrete
Measure the concrete performance and the long term characteristics on site
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
The construction of a RCC road pavement with a fly ash-based binding system
Stakeholders:
National Technical University of Athens
TITAN Cement Industry
EGNATIA ODOS S.A.
TERNA Construction Company
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
In Greece, only asphaltic concrete has been used for road pavements
There is no tradition in bedding concrete road pavement
The RCC pavement alternative seems to be the most feasible solution
The main advantages for such a solution are:
Longer service life and lower cost of maintenance
Reduced environmental footprint
Laboratory of Building Materials - Aristotle University of Thessaloniki
The construction of a RCC road pavement with a fly ash-based binding system
Construction Asphalt pavement Concrete pavement 232700 361200 Maintenance Asphalt pavement Concrete pavement 276500 40800 Recycling & disposal Asphalt pavement Concrete pavement 28000 18200
Global Warming Potential over 100 years
kg CO2-eq
Stronger and resistant to heavy truck circulation
(RCC pavements are recommended for interchange ramps and heavy truck traffic in hot climates)
Reduction of thermal emissions
Laboratory of Building Materials - Aristotle University of Thessaloniki
The construction of a RCC road pavement with a fly ash-based binding system
Infrared photgraphy of the Atlanta Hatfield Airport (property of NASA) where asphalt parking lots develop higher temperature compared to concrete parking lots
The initial construction cost of a concrete road is slightly higher than that of asphaltic concrete
By using fly ash-based hydraulic binders the cost is significantly reduced
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
The construction of a RCC road pavement with a fly ash-based binding system
Initial construction cost (€/m2)
Cost(€/m2)
Development of the mixed type binder and quality assessment
Aim: 28-d compressive strength of 40 MPa, so as to have on site at least 30 MPa
Materials (% by mass)
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Blended mixed type binder
Laboratory of Building Materials - Aristotle University of Thessaloniki
Content/ Property
Cement clinker
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Physical properties
Blaine (cm2/g)
0.4
Required strength: fck C25/30
Maximum Vebe density (according to ACI 325.10R-95) with Vebe time: 20-40s
Available aggregates: Crushed limestone of maximum size 31.5 mm or 16 mm
“Tefrocement” quantity: ≤ 300 kg/m3
Laboratory of Building Materials - Aristotle University of Thessaloniki
The proposed aggregate gradations
Laboratory of Building Materials - Aristotle University of Thessaloniki
Trial mixes series A and B
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Mixture
A1
A2
A3
A4
B1
B2
B3
B4
Decision to use 280 kg/m3 “Tefrocement”
New series of laboratory test mixtures series A and B, accounting for transport time
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Mixture
A5
A6
B5
B6
60
40
12
50
100
80
30
80
2385
2313
2430
2447
2420
2410
2415
2400
2474
2505
2466
2490
Concrete plant at 30 minutes driving distance
Continuous feeding of the paver
Compaction achieved by rollers
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Truck loading
Laboratory of Building Materials - Aristotle University of Thessaloniki
Truck unloading onto paver
Laboratory of Building Materials - Aristotle University of Thessaloniki
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Difficulty unloading truck due to delay in transportation
Laying RCC
Laboratory of Building Materials - Aristotle University of Thessaloniki
Laying RCC
Laboratory of Building Materials - Aristotle University of Thessaloniki
Roller compaction of pavement
Laboratory of Building Materials - Aristotle University of Thessaloniki
Fresh concrete density measured with nuclear gauge
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Achieved compaction
Laboratory of Building Materials - Aristotle University of Thessaloniki
depth
-
2 vibrating passes with a 10 ton roller
Maximum single layer thickness achieved: 20 cm
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Joints
Shrinkage joints: cut every 5.5-6.0 m after hardening, to a depth corresponding to 1/4 - 1/3 of the road thickness
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Joints
Laboratory of Building Materials - Aristotle University of Thessaloniki
Source: Cement and Concrete Association of New Zealand, "Concrete ground floors and pavements", Part 1
Survey of concrete pavement 2 months after construction
Core drilling and testing
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Survey of concrete pavement 2 months after construction
Mechanical properties of drilled cores
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Construction area (average of 6)
1
2
3
Conclusions
The construction of a RCC road with this mixed type binder is feasible
The technical problems that appeared were properly confronted
The long term strength and resistance were adequate in order to guarantee a long service life
The incorporation of a low cost industrial by-product into a hydraulic binder contributes essentially towards lowering the initial cost of a concrete road, rendering this sustainable alternative also cost-effective.
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Thank you for your attention!
Laboratory of Building Materials - Aristotle University of Thessaloniki
Aristotle University of Thessaloniki
Mixed type binding systems. A sustainable alternative for RCC Pavements
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Background
Binders are the most precious materials in building construction, since they transform a volume of grains into a compact, load-bearing material of adequate volume stability
Portland cement is an excellent high-strength binder which predominates in construction, but is also an energy consuming, high-cost material of low ecological profile
Under the pressure of reality:
Climatic changes and catastrophes
Need of longer service life for constructions
There is an urgency to develop alternative smart mixed type binding systems
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Background
A first simple step for sustainability integration in construction is to make local industrial by-products (fly ashes, slags) beneficial for the structural sector
How do we work to exploit industrial by-products to the maximum:
Test the suitability of the by-products as cementitious materials for a specified use
Development of a mixed type binding system and assessment of its quality
Design and proportioning of a proper concrete mixture for a specified strength
Test the compliance of the concrete with a control mixture
Proceed to a pilot application of the designed concrete
Measure the concrete performance and the long term characteristics on site
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
The construction of a RCC road pavement with a fly ash-based binding system
Stakeholders:
National Technical University of Athens
TITAN Cement Industry
EGNATIA ODOS S.A.
TERNA Construction Company
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
In Greece, only asphaltic concrete has been used for road pavements
There is no tradition in bedding concrete road pavement
The RCC pavement alternative seems to be the most feasible solution
The main advantages for such a solution are:
Longer service life and lower cost of maintenance
Reduced environmental footprint
Laboratory of Building Materials - Aristotle University of Thessaloniki
The construction of a RCC road pavement with a fly ash-based binding system
Construction Asphalt pavement Concrete pavement 232700 361200 Maintenance Asphalt pavement Concrete pavement 276500 40800 Recycling & disposal Asphalt pavement Concrete pavement 28000 18200
Global Warming Potential over 100 years
kg CO2-eq
Stronger and resistant to heavy truck circulation
(RCC pavements are recommended for interchange ramps and heavy truck traffic in hot climates)
Reduction of thermal emissions
Laboratory of Building Materials - Aristotle University of Thessaloniki
The construction of a RCC road pavement with a fly ash-based binding system
Infrared photgraphy of the Atlanta Hatfield Airport (property of NASA) where asphalt parking lots develop higher temperature compared to concrete parking lots
The initial construction cost of a concrete road is slightly higher than that of asphaltic concrete
By using fly ash-based hydraulic binders the cost is significantly reduced
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
The construction of a RCC road pavement with a fly ash-based binding system
Initial construction cost (€/m2)
Cost(€/m2)
Development of the mixed type binder and quality assessment
Aim: 28-d compressive strength of 40 MPa, so as to have on site at least 30 MPa
Materials (% by mass)
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Blended mixed type binder
Laboratory of Building Materials - Aristotle University of Thessaloniki
Content/ Property
Cement clinker
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Physical properties
Blaine (cm2/g)
0.4
Required strength: fck C25/30
Maximum Vebe density (according to ACI 325.10R-95) with Vebe time: 20-40s
Available aggregates: Crushed limestone of maximum size 31.5 mm or 16 mm
“Tefrocement” quantity: ≤ 300 kg/m3
Laboratory of Building Materials - Aristotle University of Thessaloniki
The proposed aggregate gradations
Laboratory of Building Materials - Aristotle University of Thessaloniki
Trial mixes series A and B
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Mixture
A1
A2
A3
A4
B1
B2
B3
B4
Decision to use 280 kg/m3 “Tefrocement”
New series of laboratory test mixtures series A and B, accounting for transport time
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Mixture
A5
A6
B5
B6
60
40
12
50
100
80
30
80
2385
2313
2430
2447
2420
2410
2415
2400
2474
2505
2466
2490
Concrete plant at 30 minutes driving distance
Continuous feeding of the paver
Compaction achieved by rollers
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Truck loading
Laboratory of Building Materials - Aristotle University of Thessaloniki
Truck unloading onto paver
Laboratory of Building Materials - Aristotle University of Thessaloniki
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Difficulty unloading truck due to delay in transportation
Laying RCC
Laboratory of Building Materials - Aristotle University of Thessaloniki
Laying RCC
Laboratory of Building Materials - Aristotle University of Thessaloniki
Roller compaction of pavement
Laboratory of Building Materials - Aristotle University of Thessaloniki
Fresh concrete density measured with nuclear gauge
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Achieved compaction
Laboratory of Building Materials - Aristotle University of Thessaloniki
depth
-
2 vibrating passes with a 10 ton roller
Maximum single layer thickness achieved: 20 cm
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Joints
Shrinkage joints: cut every 5.5-6.0 m after hardening, to a depth corresponding to 1/4 - 1/3 of the road thickness
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Joints
Laboratory of Building Materials - Aristotle University of Thessaloniki
Source: Cement and Concrete Association of New Zealand, "Concrete ground floors and pavements", Part 1
Survey of concrete pavement 2 months after construction
Core drilling and testing
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Survey of concrete pavement 2 months after construction
Mechanical properties of drilled cores
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Construction area (average of 6)
1
2
3
Conclusions
The construction of a RCC road with this mixed type binder is feasible
The technical problems that appeared were properly confronted
The long term strength and resistance were adequate in order to guarantee a long service life
The incorporation of a low cost industrial by-product into a hydraulic binder contributes essentially towards lowering the initial cost of a concrete road, rendering this sustainable alternative also cost-effective.
V International Conference ASHES FROM TPPS – Removal, Transport, Processing, Storage April 23-25, 2014, Moscow
Laboratory of Building Materials - Aristotle University of Thessaloniki
Thank you for your attention!
Laboratory of Building Materials - Aristotle University of Thessaloniki