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Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

L Carbon Concretes (L
ow
CC)
using novel mineral binders as cement substitutes

Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

1
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

LCC - what does it mean?

Advanced normal concrete, specifically engineered with reduction of greenhouse
gas emissions – mainly CO2 - in mind with respect to
• Choice of concrete materials
• Design and manufacturing of concrete
• Materials and concrete transport
Build up concrete constructions with higher functionality, longer lifetime and
reduced effort for maintenance and repairs

Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

2
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Why LCC?
Concrete is the world‘s most
consumed man-made material.
Portland cement is the essential
constituent of nearly all concretes.
The demand and consumption of
concretes and cements are constantly
increasing.
CO2-emissions derived from concrete

Cement manufacturing leads to release
of 2,9 billion tons of greenhouse gases
per year (2011), mainly CO2.
In 2050 cement production will
cause >10% of total CO2-release.

Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

3
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Evaluation of concrete products: An integrated approach
Standards & Directives, Market

Sustainability
New additional assessing criterias for products

Applicability

durable
resource-efficient
reusable
non-polluting

Product
Efficiency

Feasibility

Costs, Prices, Revenues

Engineering, Materials,
Know-how, Staff skills

Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

New materials and advanced technologies
in concrete productions

Lowest carbon footprint product
(Concept of LCC)
4
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Development strategy for Low Carbon Concretes
Partial substitution of
conventional materials

•
•
•

Unchanged product
Unchanged technology
Innovative potential within
material only

Complete substitution of
conventional materials

•
•
•

Competitive product
Unchanged or modified technology
Innovative potential within material
and technology

New products with new
materials

•
•
•

Novel product
Modified or new technology
Innovative potential within
material, technology and
final product properties

Development efforts (time, cost, staff)
Degree of innovation
Sustainability (low carbon footprint)
Potential of profit
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

5
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Low Carbon Concrete for sustainable building
Traditional approach
Consume less concrete

New approach
Use novel binders to
replace cement

Innovative architecture and structural design (HPC)

Consume less cement

bifam
ent
Concrete mix design and modified technical requirements

Consume less clinker
Advanced cement technology (blended cements)
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

6
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Blended Cements to reduce carbon footprint
German cement market (2002-2012)
Development

Overall market share

Pure OPC (CEM I)

-43%

56%

29%

Blended OPC with single SCMs
up to 35% (CEM II)

+62%

30%

48%

Blended OPC with several SCMs
up to 35% (CEM II) or
with single SCM up to 95% (CEM III)

+112%

Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

11%

22%

7
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

bifam - a novel binder with zero carbon footprint
ent

EW
N

specially developed and processed mineral binder, which
• consists of industrial by-products only (100% cement-free!),
• contains up to 100% of pretreated, hydraulic lignite fly ash,
• has binding properties like cement
is added to concrete as reactive mineral powder replacing
• conventional fillers to 100%,
• conventional cements from 30 up to 100%
with no restrictions on properties of concrete products
stand alone mineral binder for concretes in competition to conventional cements

Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

8
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Emission of CO2 during production process

CO2-release (kg/t)

Quelle (Zementdaten): Staatl. Forschungsstelle für Energiewirtschaft München – Ganzheitliche Bilanzierung von Grundstoffen und Halbzeugen (1999)

bifam
ent
will be manufactured with
no release of CO2
in contrast to cements!

0 kg/t CO2 !
bifam
ent
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

9
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

bifam lowers the carbon footprint of concrete products
ent
Quelle (Zementdaten): Staatl. Forschungsstelle für Energiewirtschaft München – Ganzheitliche Bilanzierung von Grundstoffen und Halbzeugen (1999)

CO2-release (kg/t)

up to 94% less CO2-release
if substituting cements by bifam
ent

Example: Concrete paving blocks

Cement
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

bifam
ent

bifam
ent

bifam
ent
10
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Specific characteristics of bifam
ent
Contains typical components of cements, slags and fly ashes initially by origin
 composition and materials behavior are similar to a supersulfated cement
Self-hardening
 need no activators (alkalis, cement, lime ...)
Free of shrinkage
 no particular precautions for preventing cracks (joints, fibres)
Properties can be customized by selected composition and degree of processing
 different qualities designed to individual application or product
Material behavior in concrete production is similar to cements
 requires no technical changes within production process

Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

11
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

The bifam -project
ent
Basic scientific research
and development
since 1998

Applied research
and suitability tests
since 2000

• Foundation of production
and sales company in 2011
• Installation of production
facility in 2013/14

Application tests
and optimization
since 2005

Long term experiences in
fly ash processing and
material behavior in practice
since 1994
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

From 2014:
• Product implementation on
customers site
• Quality assurance in production
• Continual product development
• Product approvals
12
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Industrial application example 1: Manufacturing of paving blocks
- High-volume cement substitution by bifam ent

Strength development

Increase in product quality
at lower production costs
up to

36 %

or
Maximum potential reduction
in cement consumption and
mixture costs
at equal product quality
more than
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

50 %
13
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Industrial application example 1: Manufacturing of paving blocks
- Improvement of frost resistance -

Traditional mix without bifam
ent

Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

Advanced mix with partial substitution
of cement by bifam
ent

14
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Industrial application example 2: Manufacturing of masonry blocks
- Complete cement replacement by bifam ent
Strength development

Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

15
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

Outlook
Commissioning of production plant in 2014
 Availability of bifam up to 150.000 tons per year
ent
Few custom projects have already been started in Germany
 Concrete goods, civil engineering products, ground and road construction
Several pilot projects for German market are being prepared
 Concrete repair, flood protection, immobilization
Looking for additional projects abroad

Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

16
Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te

The University of Queensland‘s Global Change Institute (GCI) Australia
World‘s first building made from cement-free concrete for structural construction

Photography by Angus Martin

Thank you for your attention!
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3

17

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B&i2013 donderdag 15.45_zaal_b_low-carbon concretes using novel mineral binders as cemetn substitutes

  • 1. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te L Carbon Concretes (L ow CC) using novel mineral binders as cement substitutes Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 1
  • 2. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te LCC - what does it mean? Advanced normal concrete, specifically engineered with reduction of greenhouse gas emissions – mainly CO2 - in mind with respect to • Choice of concrete materials • Design and manufacturing of concrete • Materials and concrete transport Build up concrete constructions with higher functionality, longer lifetime and reduced effort for maintenance and repairs Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 2
  • 3. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Why LCC? Concrete is the world‘s most consumed man-made material. Portland cement is the essential constituent of nearly all concretes. The demand and consumption of concretes and cements are constantly increasing. CO2-emissions derived from concrete Cement manufacturing leads to release of 2,9 billion tons of greenhouse gases per year (2011), mainly CO2. In 2050 cement production will cause >10% of total CO2-release. Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 3
  • 4. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Evaluation of concrete products: An integrated approach Standards & Directives, Market Sustainability New additional assessing criterias for products Applicability durable resource-efficient reusable non-polluting Product Efficiency Feasibility Costs, Prices, Revenues Engineering, Materials, Know-how, Staff skills Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 New materials and advanced technologies in concrete productions Lowest carbon footprint product (Concept of LCC) 4
  • 5. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Development strategy for Low Carbon Concretes Partial substitution of conventional materials • • • Unchanged product Unchanged technology Innovative potential within material only Complete substitution of conventional materials • • • Competitive product Unchanged or modified technology Innovative potential within material and technology New products with new materials • • • Novel product Modified or new technology Innovative potential within material, technology and final product properties Development efforts (time, cost, staff) Degree of innovation Sustainability (low carbon footprint) Potential of profit Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 5
  • 6. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Low Carbon Concrete for sustainable building Traditional approach Consume less concrete New approach Use novel binders to replace cement Innovative architecture and structural design (HPC) Consume less cement bifam ent Concrete mix design and modified technical requirements Consume less clinker Advanced cement technology (blended cements) Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 6
  • 7. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Blended Cements to reduce carbon footprint German cement market (2002-2012) Development Overall market share Pure OPC (CEM I) -43% 56% 29% Blended OPC with single SCMs up to 35% (CEM II) +62% 30% 48% Blended OPC with several SCMs up to 35% (CEM II) or with single SCM up to 95% (CEM III) +112% Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 11% 22% 7
  • 8. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te bifam - a novel binder with zero carbon footprint ent EW N specially developed and processed mineral binder, which • consists of industrial by-products only (100% cement-free!), • contains up to 100% of pretreated, hydraulic lignite fly ash, • has binding properties like cement is added to concrete as reactive mineral powder replacing • conventional fillers to 100%, • conventional cements from 30 up to 100% with no restrictions on properties of concrete products stand alone mineral binder for concretes in competition to conventional cements Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 8
  • 9. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Emission of CO2 during production process CO2-release (kg/t) Quelle (Zementdaten): Staatl. Forschungsstelle für Energiewirtschaft München – Ganzheitliche Bilanzierung von Grundstoffen und Halbzeugen (1999) bifam ent will be manufactured with no release of CO2 in contrast to cements! 0 kg/t CO2 ! bifam ent Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 9
  • 10. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te bifam lowers the carbon footprint of concrete products ent Quelle (Zementdaten): Staatl. Forschungsstelle für Energiewirtschaft München – Ganzheitliche Bilanzierung von Grundstoffen und Halbzeugen (1999) CO2-release (kg/t) up to 94% less CO2-release if substituting cements by bifam ent Example: Concrete paving blocks Cement Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 bifam ent bifam ent bifam ent 10
  • 11. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Specific characteristics of bifam ent Contains typical components of cements, slags and fly ashes initially by origin  composition and materials behavior are similar to a supersulfated cement Self-hardening  need no activators (alkalis, cement, lime ...) Free of shrinkage  no particular precautions for preventing cracks (joints, fibres) Properties can be customized by selected composition and degree of processing  different qualities designed to individual application or product Material behavior in concrete production is similar to cements  requires no technical changes within production process Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 11
  • 12. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te The bifam -project ent Basic scientific research and development since 1998 Applied research and suitability tests since 2000 • Foundation of production and sales company in 2011 • Installation of production facility in 2013/14 Application tests and optimization since 2005 Long term experiences in fly ash processing and material behavior in practice since 1994 Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 From 2014: • Product implementation on customers site • Quality assurance in production • Continual product development • Product approvals 12
  • 13. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Industrial application example 1: Manufacturing of paving blocks - High-volume cement substitution by bifam ent Strength development Increase in product quality at lower production costs up to 36 % or Maximum potential reduction in cement consumption and mixture costs at equal product quality more than Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 50 % 13
  • 14. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Industrial application example 1: Manufacturing of paving blocks - Improvement of frost resistance - Traditional mix without bifam ent Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 Advanced mix with partial substitution of cement by bifam ent 14
  • 15. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Industrial application example 2: Manufacturing of masonry blocks - Complete cement replacement by bifam ent Strength development Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 15
  • 16. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te Outlook Commissioning of production plant in 2014  Availability of bifam up to 150.000 tons per year ent Few custom projects have already been started in Germany  Concrete goods, civil engineering products, ground and road construction Several pilot projects for German market are being prepared  Concrete repair, flood protection, immobilization Looking for additional projects abroad Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 16
  • 17. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te The University of Queensland‘s Global Change Institute (GCI) Australia World‘s first building made from cement-free concrete for structural construction Photography by Angus Martin Thank you for your attention! Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3 17