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The first Recybéton experimental site at Chaponost Rhône, France

Emmanuel Garcia - Lafarge France Patrick DantecConcrete Product Line – Rhône Alpes Auvergne Recybéton

Table of contents

� Introduction

� A local view on recycling of building materials in the Rhone Alpes area

� The Chaponost jobsite project� Jobsite� Raw materials� Mix Design� Pouring� Concrete performances

� Conclusion

2Chaponost Experience – E Garcia 07/07/2014 |The first experimental site at Chaponost – Emmanuel GARCIA 08/07/2014

Partners of the Chaponost job site

� RECYBETONS (Project)

� ELTS (Contractor & end-user)

� LAFARGE BETONS RHONE ALPES (Concrete producer)

� LAFARGE CENTRE DE RECHERCHE (Mix Design)

� LAFARGE AGGREGATES & CONCRETE DEVELOPMENT CENTER

(CELGB, Vitry sur Seine) & LAFARGE GRANULATS LYON (Natural &

recycled aggregates characterisation)

� FILLOT EUROVIA (Recycled aggregates producers)

� SIGMA Bétons (Concrete quality control & characterization)

� CEREMA (Concrete characterization)

3Presentation name or chapter Date |The first experimental site at Chaponost – Emmanuel GARCIA 08/07/2014

Standards and regulations for Concrete in France

Standards and regulations for Concrete in France� EN NF 206-1 border the use of recycled aggregates i nto concrete to:

� aggregates types, with chemical restrictions� small quantities, according to exposition classes and strengths classes


A local view on recycling of building materials in the Rhone Alpes area

7Presentation name or chapter Date |

Some figures concerning recycling of building materials in the Rhone Alpe area.

� The Rhône-Alpes area is the second biggest french r egion in term of

economy. It represents 10% of the total natural agg regates french market.

� Deposit of building wastes in Rhône Alpes : 19 Mill ions tons of inert wastes.

� 5,1 Millions tons are recycled on site and then not considered as wastes

(european definition).

� 78 % of the deposit is recycled

� Concrete wastes are recycled at 90%

� Asphalt wastes are recycled at 86%

� Bricks and tiles are recycled at 79%

The first experimental site at Chaponost – Emmanuel GARCIA 08/07/2014


Some figures concerning recycling of building materials in the Rhone Alpe area.

� The global aggregates needs for Rhône Alpes is 48 M illions tons

� 14,6 millions tons for concrete

� 4,8 millions tons for asphalt

� 28,5 millions tons are used without binder (earth-moving)

Recycled aggregates represent 24% of the needs.

No recycled aggregates is used today in the readymix industry.


� 1 recycling site on 4 is a quarry ;

� 48% of recycled aggregates come from a quarry.

� 1 quarry on 3 has a recycling area.

Recycling platformsmap around Lyon

Presentation name or chapter Date |The first experimental site at Chaponost – Emmanuel GARCIA 08/07/2014

2012

The Chaponost jobsite

The Chaponost jobsite project

� ELTS (owner, end-user and contractor) wants to buil d his future wharehouse and headquarters in Chaponost (Lyon area ).

� Concrete slabs will be used as an outside storage a rea, car park and circulation lanes.


Where is Chaponost ?

The Chaponost Jobsite

� 2100 m2 / 390 m3 of concrete

� 6 mix-designs between 0 % and 100% recycled aggrega tes

12

ELTS

Presentation name or chapter Date |The first experimental site at Chaponost – Emmanuel GARCIA 08/07/2014


LAFARGE BETONSSEREZIN

EUROVIA (Fillot)

DeconstructionLyon areaJobsite

Circle economy aspects

ELTS jobsite

28/02/2014 | 14

FILLOT EUROVIA recycling platform (VINCI GROUP)


28/02/2014 |Recyclage des bétons - LFARAGE BETONS France - Agence Rhône Alpes Auvergne 15

FILLOT EUROVIA recycling platform (VINCI GROUP)


Recycled aggregates production by a mobile crushing & screening plant

Characterization of recycled aggregates

� 2 fractions have been produced� Sand 0/4 mm� Gravel 4/20 mm� Production balance is about 50/50 (depends on the crusher type / parameters)

28/02/2014 | 16The first experimental site at Chaponost – Emmanuel GARCIA 08/07/2014


Recycled aggregates piles


Recycled aggregates characterization

18

Type 1(CRB)

Soluble sulfates in water < 0,2 (SS0,2)


Recycled aggregates characterization


Laboratory

[63 microns-4 mm]

Raw sand with

fines

[63 microns-4 mm]

washed sand with

fines

4mm-10mm 10mm-20mm

IFSTTAR Nantes 8,3 7,3 5,6 5,8

Mines Alès 7,3 6,3 6,2

Cergy-Pontoise pas de valeur à ce stade 6,2 5,8

Valeur à 10 minutes No value No value 6,9 6,1

Valeur Assymptotique (14 jours) No value No value 8,3 7,8

Absorption normalisée

%

Absorption à la pesée

hydrostatique % Cergy

� 2 fractions� Sand 0/4 mm� Gravels 4/20 mm

� This product was splited in two classes 4/10mm and 10/20 mm for characterization.

Absorption

Mix Designs

� Concrete will be used outdoor : climatic conditions in Chaponost lead to an exposition class of XF2

� Dimensioning calculations show that a C25/30 streng th class corresponds to the needs.

� Characteristics of a C25/30 XF2 D20 S4 following NF EN 206-1

(Totaly out of standard for recycled aggregates)

20The first experimental site at Chaponost – Emmanuel GARCIA Date |

W/C (max) 0,55

Binder (min) 300 kg/m3

Air trapped (min) 4 %

Cement: CEM II/A-LL 42,5 R Val d’Azergues from Lafarge Ciment

Mix designs

Dates Zone Surface (m2) Thickness (m) Theorical volume (m3) Recycled Agg mix

09/12/2013 1 336 0,18 60 0%S - 0%G (Ref)

11/12/2013 2 444 0,18 80 0%S - 30%G

12/12/2013 3 303 0,18 55 30%S - 30%G

16/12/2013 4 327 0,18 59 30%S - 0%G

18/12/2013 5 372 0,18 67 0%S - 100%G

19/12/2013 6 314 0,18 57 100%S - 100%G

2096 377


The reference mix design uses natural river aggregates from La Petite Craz pit (Lafarge Granulats Lyon). Sand and gravel are semi-crushed.


Mix design

� Influence of recycled aggregates on the cost of the mix design� Cement content� Admixtures content

22Date |The first experimental site at Chaponost – Emmanuel GARCIA 08/07/2014


Jobsite : concrete pouring (between december 3rd and 19th of 2013)


Characterization of concrete

28/02/2014 | 24

Compressive

strenght

@28d (Mpa)

Modulus

(Mpa)

Traction

strength

@28d

(Mpa)

Reference 33,2 38917 2,60

0S-30G 32,1 36003 2,50

30S-30G 29,9 33521 2,50

30S-0G 33,2 37321 2,80

0S-100G 36,8 33116 2,95

100S-100G 30,9 25140 2,10

� Slump & slump retention are fine (200 mm over 2h)

� Air trapped is more difficult to manage when the ra tio of recycled aggregates increase. Values are higher (5,5 to 9%).

� Mechanical strengths are fine for a C2,5 whatever t he mix design.

� Modulus decrease while recycled aggregates increase .

� Traction strengths decrease has not been confirmed by Sigma. (Influence not identified by T. Dao, PhD (Multi-) recyclage du béton hydraulique, 2012)


(SIGMA)

(CEREMA)

Characterization of concrete

� Shrinkage� Shrinkage was measured by 4 different methods

� KRAI TEST (ASTM C1579)� Continuous measurement (SIGMA)� Total shrinkage (NF P18-427)� Ring test

� The highest values are for the 100S/100G mix design (658 µm/m vs 320 µm/m at 28d)� 100S/100G is the only mix design to have developped a crack at the ring test

� Slabs are not cracked today on the Chaponost site.

� Shrinkage will be modelized by the LMT.

28/02/2014 | 25The first experimental site at Chaponost – Emmanuel GARCIA 08/07/2014

Conclusions

Conclusion� It is possible !

� Standards have today a very conservative approachThe Chaponost experience pushed away quantity limitations for the use of recycled

aggregates, from a technical point of view.

� Sustainable aspects: do not forget to be smart !� The global environmental balance of a project is the only durable driver.� High transportation distances lead to a strong increase of CO2/t for aggregates.� >> It makes sense locally, at the heart of a local circle economy.

� Are we able to value in eq CO2/t the ressource econ omy ?� To have arguments to make the right decision

� Sustainable and economic aspects� Mix designs based on high volumes of recycled aggregates lead to a global increase of

cement, then an increase of cost and of CO2 content in the mix design.


Conclusion


Pollution as no technical limit ; only a social ac ceptance limit.

Ressources have limits. Recycling is not an option.



THANK YOU

The first Recybéton experimental site at Chaponost Rhône, France


the first recybéton experimental site at chaponost … · the first recybéton experimental site...

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