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ECO-Serve Cluster 2: Production and application of blended cements

E UROPEAN CO NSTRUCTION IN SERV IC E OF SOCIETY. ECO-Serve Cluster 2: Production and application of blended cements. Overview and results Christoph Müller and Eberhard Siebel, Düsseldorf ECO-Serve-Network; Status quo 01/2005. Network Steering Committee. Communication & Dissemination.

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ECO-Serve Cluster 2: Production and application of blended cements

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  1. EUROPEAN CONSTRUCTION IN SERVICE OF SOCIETY ECO-Serve Cluster 2:Production and application of blended cements Overview and results Christoph Müller and Eberhard Siebel, Düsseldorf ECO-Serve-Network; Status quo 01/2005

  2. Network Steering Committee Communication &Dissemination Environmentalbaseline &indicators Management and co-ordination The ECO-SERVE Network Cluster 1 Cluster 3 Cluster 4 Cluster 2 Blendedcements Aggregate &concreteproduction Pavements Alternativefuels andraw materials Structure of the network Researchactivities

  3. Objectives of the network „The main objective of the ECO-SERVE Network is to identify the needs of the European Construction Industry in its endeavour towards sustainability of the industries' products and production processes.“ • Improve the working environment • Reduce the environmental impact • Ensure European growth and wealth by increasing the productivity, competitiveness and quality

  4. Definition: Blended cements Cements with a reduced clinker content( 94 m.-% referring to the sum of the main andminor additional constituents)

  5. CO2-Emissions Replacing cement clinker by other main constitutents is a very effective way of lowering specific fuel energy consumption and specific CO2 emissions.

  6. CO2 reduction from the production of blended cements Clinker substitution Clinker substitution -0.093 CO2 from fuelconsumption Finer grinding Slag drying 0.022 -0.009 CO2 fromelectricityconsumption 0.011 CO2 from lime-stone decarbonation -0.151 Clinker substitution Total -0.219 Reduction of CO2 emissions in t CO2/t cement Substitution of clinker by granulated slag for a CEM II/B-S 32.5 with 35 % granulated slag Source: VDZ

  7. CO2-emissions from the production of blended cements 1,0 CEM I CEM II/A CEM II/B CEM III/A CEM III/B 0,8 CO2 conditional on electrical energy 0,6 t CO2/t cement CO2 conditional on thermal energy 0,4 CO2 conditional raw materials 0,2 0 0 20 40 60 80 100 Amount in % Source: VDZ

  8. Cement standard EN 197-1 CEM I Portland cement CEM II Portland-composite cement CEM III Blastfurnace cement CEM IV Pozzolanic cement CEM V Composite cement

  9. Cement standard EN 197-1 Main constituents of cement according to EN 197-1 Portland cement clinker (K) Granulated blast furnace slag (S) Burnt shale (T) • Pozzolana • natural (P) • natural calcined (Q) • Limestone • low TOC content  0.20 m.-% (LL) • high TOC content  0.50 m.-% (L) • Fly ash • silicious (V) • calcareous (W) Silica fume (D)

  10. Cement standard EN 197-1 Main constituents of cement according to EN 197-1 Portland cement clinker (K) Granulated blast furnace slag (S) Burnt shale (T) • Pozzolana • natural (P) • natural calcined (Q) • Limestone • low TOC content  0.20 m.-% (LL) • high TOC content  0.50 m.-% (L) • Fly ash • silicious (V) • calcareous (W) Silica fume (D)

  11. Main constituents of blended cements Portland cement clinker Granulated blast furnace slag Limestone Fly ash

  12. Main constituents of blended cements (SEM) Portland cement clinker (K) Granulated blast furnace slag (S) • Limestone • low TOC content  0.20 m.-% (LL) • high TOC content  0.50 m.-% (L) • Fly ash • silicious (V) • calcareous (W) Silica fume (D)

  13. Main constituents of blended cements (SEM) Portland cement clinker

  14. Main constituents of blended cements (SEM) Granulated blast furnace slag

  15. Main constituents of blended cements (SEM) Limestone

  16. Main constituents of blended cements (SEM) Fly ash

  17. Main constituents of blended cements (SEM) Silica fume

  18. Production of blended cements Multi-chamber mixing tower

  19. Portlandcement CEM I Portland-compositecement CEM II A B Blastfurnacecement CEM III A B C Pozzolaniccement CEM IV A A B B Compositecement CEM V Cement standard EN 197-1 ( -D, -S, -P, -Q, -V, -W, -T, -L, -LL, -M) ( -D, -S, -P, -Q, -V, -W, -T, -L, -LL, -M) ( -D, -P, -Q, -V, -W) ( -S, -P, -Q, -V) 0 10 20 30 40 50 60 70 80 90 100 Amount of main constituents besides clinker in % by mass

  20. Portlandcement CEM I Portland-compositecement CEM II A B Blastfurnacecement CEM III A B C Pozzolaniccement CEM IV A A B B Compositecement CEM V Cement standard EN 197-1 The letter M indicates CEM II-cements which contain at least two further constituents besides clinker. ( -D, -S, -P, -Q, -V, -W, -T, -L, -LL, -M) ( -D, -S, -P, -Q, -V, -W, -T, -L, -LL, -M) ( -D, -P, -Q, -V, -W) ( -S, -P, -Q, -V) 0 10 20 30 40 50 60 70 80 90 100 Amount of main constituents besides clinker in % by mass

  21. Portlandcement CEM I Portland-compositecement CEM II A B Blastfurnacecement CEM III A B C Pozzolaniccement CEM IV A A B B Compositecement CEM V Cement standard EN 197-1 (18-30) % S(18-30) % (P, Q, V) (31-50) % S(31-50) % (P, Q, V) 0 10 20 30 40 50 60 70 80 90 100 Amount of main constituents besides clinker in % by mass

  22. Performance of blended cements - Example 1 Water demand of the cement Consistency of concrete 2 Erwärmung in Kelvin Druckfestigkeit in N/mm Source: Ludwig 2002

  23. Performance of blended cements - Example 2 d = 0,6 m (Steel formwork), c = 330 kg/m3, w/c = 0.50, Tb,fr = TU = 20 °C 24 25 2 CEM I 32,5 R CEM I 32,5 R 20 20 16 15 Compressive strength in MPa Heat development in Kelvin 12 10 CEM III/A 32,5 8 5 4 CEM III/A 32,5 0 0 Erwärmung in Kelvin 0 12 24 36 48 0 12 24 36 48 Druckfestigkeit in N/mm Concrete age in h Concrete age in h Source: VDZ

  24. SCR VLH III/B + CVLH IV/A + BVLH V/A + B - 22,5 VLH 220 J/g X underpreparation 2004-04 Product Standards in CEN/TC 51 „Cement and building limes“ Examples EN 197-1 Cement-Compositionspecifications and conformity criteria for common cements(27 cements) CEM ICEM IICEM IIICEM IVCEM V 32,5 N/R 42,5 N/R 52,5 N/R X 2000-06 EN 197-1/A1 Low heat common cements LH 270 J/g 2004-04 EN 197-4 Low early strength blast furnace cements(3 cement types) CEM III/ACEM III/BCEM III/C 32,5 L42,5 L52,5 L X 2004-04 EN 14216 Cement – Composition specifications and conformity criteria for very low heatspecial cements (6 cement types) Report Sulphate Resisting Cement

  25. Performance of blended cements - Example 3 2,5 Wittekindt-Test(29800 mg SO4/l)after 56 days 8°C 2 20°C 1,5 Expansion in mm/m 1 0,5 0 CEM I NW/HS CEM III/B NW/HS Source: VDZ

  26. Performance of blended cements - Example 4 Low alkali cements Alkalinity of the pore solution can be reduced by the use of pozzolana or slag, due to - lower available alkali content - uptake of alkalis by the reaction products

  27. Questions to be answered in cluster 2 To what extend are there differences concerning - Composition and used amount of blended cements in Europe, - Existing national application rules for blended cements, - Experience with blended cements - examples for applications. - Kinds and quality of main constituents besides clinker for the production of blended cements in Europe. ... and why ?

  28. Expected outcome - 1 • Europeanwide exchange of knowledge on • the properties, • the capability, • the availability and • the application • of blended cements with the objectiveof a broaderapplicationof blended cements in Europe.

  29. X X X X Bundesanstalt für Wasserbau (BAW), Germany E. Schwenk Zementwerke KG (SCHWENK), Germany Titan Cement CO. S. A. (TITAN), Greece NORCEM A.S (NORCEM), Norway LAFARGE ROMCIM SA (LAFARGE), Romania Verein Deutscher Zementwerke (VDZ), Germany CTG-Italcementi Group (CTG), Italy National Building Res. Inst. (INCERC), Romania Cluster 2: Partners / members Activities Partner / Member Research Network X X X X X X X X

  30. Expected outcome - 2 • Europeanwide exchange of knowledge on • the properties, • the capability, • the availability and • the application • of blended cements with the objectiveof a broaderapplicationof blended cements in Europe.

  31. Properties and capability - 1 Establish a comprehensive overview on relevant organisationsworking in the field of the production and applicationof blended cements (Mapping of activities and stakeholders)  Tools: Questionnaire, Inquiry of existing data bases, Internet

  32. Mapping of activities and stakeholders - examples

  33. Properties and capability - 2 Establish a comprehensive overview on relevant organisationsworking in the field of the production and applicationof blended cements (Mapping of activities and stakeholders)  Tools: Questionnaire, Inquiry of existing data bases, Internet Establish a reference list on the properties of blended cements  Tools: Literature review, Questionnaire, Inquiry of existing data bases, Internet

  34. Reference list – Examples (1)

  35. Reference list – Examples (2)

  36. Expected outcome - 3 • Europeanwide exchange of knowledge on • the properties, • the capability, • the availabilityand • the application • of blended cements with the objectiveof a broaderapplicationof blended cements in Europe.

  37. Cement Types in CEMBUREAU Countries (1999 - 2002) Source: CEMBUREAU 2002: without UK

  38. Cement Types in CEMBUREAU Countries (1992 / 1999 - 2002) Source: CEMBUREAU 2002: without UK

  39. Cement Types in CEMBUREAU Countries (2002) Source: CEMBUREAU without UK

  40. CEM II in CEMBUREAU Countries (2002) Source: CEMBUREAU

  41. D D F F I I Development of CEM I production / use Source: VDZ/CEMBUREAU Values refer to all cements per strength class

  42. Cement CEM I in CEMBUREAU Countries (2001) 1) 2) 1) estimated2) 2000 Source: CEMBUREAU Values refer to all cements per country

  43. Availability of constituent materials for concrete • Besides the availablity per country the regional availability of blended cements is different. • Due to the availability of main constituents besides clinker, not every cement plant is able to produce any kind of blended cement in a cost-effective and ecologically way (transport etc.). • The same aspects have to be considered concerning the combination of cements and concrete additions.

  44. Expected outcome - 4 • Europeanwide exchange of knowledge on • the properties, • the capability, • the availability and • the application • of blended cements with the objectiveof a broaderapplicationof blended cements in Europe.

  45. Application of blended cements Compilation and comparison of national application rules (NARs)to EN 206-1 - Concrete composition acc. to exposure classes(min. cement content,max. water cement ratio etc.) - Application rules for blended cements Co-operation with cluster 3

  46. EN 206-1: Requirements related to Durability (exposure classes) Exposure class Explanation X0 Zero Risk No risk of corrosion or attack XF Frost Exposure classes forrisk ofconcrete corrosion Freeze/thaw attack with andwithout de-icing salts XA Chemical Attack Chemical attack Mechanical abrasion XM Mechanicalabrasion XC Carbonation Exposure classes forrisk ofsteel corrosion Carbonation XD De-icing salt Chlorides other thanfrom sea water XS Seawater Chlorides from sea water

  47. EN 206-1: Requirements related to exposure classes (Durability) - 1 • Due to the lack of experience on how the classification of the environmentalactionson concrete reflect local differencesin the same nominalexposure class, the specific values of these requirements for the applicableexposure classesaregiven inthe provisions valid in the place of use. • The requirements for each exposureclass shall be specified in terms of:– permitted types and classes of constituent materials;– maximum water/cement ratio;– minimum cement content;– minimum concrete compressive strength class (optional);and if relevant– minimum air-content of the concrete. EN 206-1, Chapter 5.3.2

  48. Environmental actions Steel Corrosion Carbonation Chlorides Others than sea watere. g. de-icing salts Sea water CO2 Carbonation Controlling influencing variable Cl- Penetration of Cl- Quality of the concrete cover H2O / O2 Corrosion Thickness Penetration resistance w/c Cement type Curing

  49. Depth of carbonation – Range for different cements 1 d in the mould, 6 d under water,  7 d 20 °C / 65 % r. H. Source: VDZ

  50. Depth of carbonation – Range for different cements 1 d in the mould, 6 d under water,  7 d 20 °C / 65 % r. H. Source: VDZ

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