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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. Mixed type binding systems. A sustainable alternative for RCC Pavements. I. Papayianni , E. Anastasiou , M. Papachristoforou Laboratory of Building Materials

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Mixed type binding systems. A sustainable alternative for RCC Pavements

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  1. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Mixed type binding systems. A sustainable alternative for RCC Pavements I. Papayianni, E. Anastasiou, M. Papachristoforou Laboratory of Building Materials Aristotle University of Thessaloniki Greece

  2. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 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 • Global economic depression • Need of longer service life for constructions • There is an urgency to develop alternative smart mixed type binding systems Laboratory of Building Materials - Aristotle University of Thessaloniki

  3. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow 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 Laboratory of Building Materials - Aristotle University of Thessaloniki

  4. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow The construction of a RCC road pavement with a fly ash-based binding system Stakeholders: • Aristotle University of Thessaloniki (responsible for research and consultancy) • National Technical University of Athens • TITAN Cement Industry • EGNATIA ODOS S.A. • TERNA Construction Company Project: • TEFRODOS 2011-2014 Funds: • General Secretary of Research and Technology, Greece Laboratory of Building Materials - Aristotle University of Thessaloniki

  5. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow The construction of a RCC road pavement with a fly ash-based binding system • 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

  6. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow The construction of a RCC road pavement with a fly ash-based binding system • 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 • Light reflectivity • Infrared photgraphy of the Atlanta Hatfield Airport (property of NASA) where asphalt parking lots develop higher temperature compared to concrete parking lots Laboratory of Building Materials - Aristotle University of Thessaloniki

  7. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow The construction of a RCC road pavement with a fly ash-based binding system • 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 Laboratory of Building Materials - Aristotle University of Thessaloniki

  8. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow 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) • Calcareous fly ash 50% • Clinker 25% • Natural pozzolan 12.5% • Limestone filler 12.5% • Test measurements: • Fineness • Grinding time • Water demand • Setting time • Le Chatelier volume stability • Compressive strength at 2, 7 and 28 days • Blended mixed type binder • Testing according to EN 13282 for Hydraulic Road Binders Laboratory of Building Materials - Aristotle University of Thessaloniki

  9. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Characteristics of the constituents of the hydraulic binder developed Laboratory of Building Materials - Aristotle University of Thessaloniki

  10. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Properties of the produced mixed type hydraulic binder Laboratory of Building Materials - Aristotle University of Thessaloniki

  11. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Proportioning RCC with fly ash-based hydraulic binder “Tefrocement” • 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 • Water/cementitious ratio: ≤ 0.50 Laboratory of Building Materials - Aristotle University of Thessaloniki

  12. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow The proposed aggregate gradations Laboratory of Building Materials - Aristotle University of Thessaloniki

  13. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Trial mixes series A and B • Decision to use 280 kg/m3 “Tefrocement” Laboratory of Building Materials - Aristotle University of Thessaloniki

  14. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow New series of laboratory test mixtures series A and B, accounting for transport time Laboratory of Building Materials - Aristotle University of Thessaloniki

  15. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Pilot construction • Ground layer with CBR ≥ 18 • Concrete plant at 30 minutes driving distance • Continuous feeding of the paver • Compaction achieved by rollers • Measurement of compaction with Humboldt nuclear gauge Laboratory of Building Materials - Aristotle University of Thessaloniki

  16. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Truck loading Laboratory of Building Materials - Aristotle University of Thessaloniki

  17. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Truck unloading onto paver Laboratory of Building Materials - Aristotle University of Thessaloniki

  18. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Difficulty unloading truck due to delay in transportation Laboratory of Building Materials - Aristotle University of Thessaloniki

  19. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Laying RCC Laboratory of Building Materials - Aristotle University of Thessaloniki

  20. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Laying RCC Laboratory of Building Materials - Aristotle University of Thessaloniki

  21. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Roller compaction of pavement Laboratory of Building Materials - Aristotle University of Thessaloniki

  22. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Fresh concrete density measured with nuclear gauge Laboratory of Building Materials - Aristotle University of Thessaloniki

  23. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Achieved compaction • Only with the paver, the compaction achieved was 80% Laboratory of Building Materials - Aristotle University of Thessaloniki

  24. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Effective compaction scenarios • 3 non vibrating passes with a 4 ton roller • 2 vibrating passes with a 10 ton roller • Maximum single layer thickness achieved: 20 cm Laboratory of Building Materials - Aristotle University of Thessaloniki

  25. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow 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 Laboratory of Building Materials - Aristotle University of Thessaloniki

  26. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Joints • Thermal dilation joints Source: Cement and Concrete Association of New Zealand, "Concrete ground floors and pavements", Part 1 Laboratory of Building Materials - Aristotle University of Thessaloniki

  27. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Survey of concrete pavement 2 months after construction • Core drilling and testing • Mechanical properties • Freeze-thaw resistance (-25°C to +20°C) Laboratory of Building Materials - Aristotle University of Thessaloniki

  28. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow Survey of concrete pavement 2 months after construction • Mechanical properties of drilled cores • Continuous monitoring of the test road Laboratory of Building Materials - Aristotle University of Thessaloniki

  29. V International Conference ASHES FROM TPPS – Removal, Transport, Processing, StorageApril 23-25, 2014, Moscow 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. Laboratory of Building Materials - Aristotle University of Thessaloniki

  30. Thank you for your attention! Laboratory of Building Materials - Aristotle University of Thessaloniki

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