A presentation outlining the benefits of using GGBS cement in concrete from an environmental, technical and architectural perspective

1. December 2009
Ecocem Ireland Ltd

2. 1862: Hydraulic potential of GGBS discovered in Germany
Early 1900’s - Portland Blast Furnace Cements had an established
place in the concrete market
2004: More than 5,000,000 tonnes of GGBS produced in Germany
2006: Approximately 2,000,000 tonnes of GGBS produced in UK
2008: Over 400,000 tonnes available in Ireland

3. Long term agreement
with partner
companies for
supplying high
quality GBS
Can supply the Irish
market with over
350,000 tonnes from
Dublin
Provide technical
back up to specifiers
and concrete
manufactures

4. Steel Manufacture Water to make GBS
Grind to make GGBS GBS
Store GGBS for
distribution

5. GGBS cement, and OPC

6. NRA, OPW, Bord Gáis, ESB, Coillte, RPA, Bord Na Mona, Local Authorities
,O , o d Gá s, S , Co te, , o d a o a, oca ut o t es
Engineers, Architects, Developers, Precast, House builders, Farmers

7. Environmental
Advantages of using GGBS

8. Conflict in Darfur is
directly linked to
Climate Change
A rise of 1 metre in
ocean levels will
displace 35 Million
people in
l i
Bangladesh.

9. Cement manufacture:
Second largest source of
industrial CO2
Releases harmful pollutants
Significant energy user
Depletes t l
D l t natural resources

10. CO2 emissions for Ecocem GGBS and cement production
Typical CO2 Emissions for Portland Cement and Ecocem GGBS Production
(Figures in kg per tonne of output)
900 Generation of Electricity Used
kg per Tonne of Output
800
Fossil Fuel Use
700
Process Emissions
600
500
400
T
300
200
100
0
Portland Cement Ecocem GGBS

11. p
Depletion of natural
resources
For every tonne of Portland
cement produced, 1 6 t
t d d 1.6 tonnes off
limestone/shale are removed
from the landscape
GGBS production involves no
quarrying of limestone or clay

12. Environmental savings
example
What is the impact of replacing 50%
of cement with GGBS in an
average size shopping centre
centre,
using 5,000m3 of concrete?
See calculator on:
www.lowcarbonconcrete.ie

13. Longer service life from GGBS concrete
Time to replacement extended
Specified by NRA on road bridges and structural concrete
p y g
Reduced demand on natural resources for new concrete
Exposure to chloride attack:

14. Solar radiation is
reflected by
lighter coloured This heat cannot
surfaces pass out of the
earth s
earth’s
atmosphere
through the
greenhouse gas
layer
A 100-150m2
Darker coloured
driveway can
surfaces absorb
offset the CO2
solar radiation
l di ti
produced by 2
and re emit it as
cars
heat

15. Reduce heat island effect
Reduces air conditioning requirement; cost and environmental benefit –
studies have shown reductions of more than 20% in building cooling
costs whose albedo has been increased (in the US potential saving of $1
billion per year)
Health benefit

16. g g q y g g
Reduces outdoor lighting requirements by enhancing night
time visibility
Saving money, energy and carbon emissions
Approx. 30% less lighting needed to achieve same visibility
for concrete as it does for asphalt

17. EU procurement Rules Directive 2004/18/EC
Recital 5 states that "contracting authorities may contribute to the protection of the
environment and the promotion of sustainable development"
Recital 6 states “Nothing in this Directive should prevent the imposition or
enforcement of measures necessary to protect public policy, public morality, public
security, health
security health, human and animal life or the preservation of plant life in particular
life,
with a view to sustainable development…”
Article 26 states ….. “The conditions governing the performance of a contract may, in
particular, concern social and environmental considerations
considerations”
Article 53 allows the Contracting Authority to weight the various awarding criteria of
which “environmental characteristics” may be one
Annex VI 1(a) states that “technical specification [as per article 23].....shall include
technical 23] shall
levels of environmental performance....”

18. OPW requirement for environmental cement
Section 2.4 “Sustainability” of tender documentation
“The OPW require the specification and use of more
environmentally friendly cements in publicly funded construction
p j
projects, in compliance with EU p
, p procurement and environmental
policies.
This will involve the partial replacement of Portland Cement by
existing waste products to yield significant improvement in the
environmental performance of concrete*.”
*Directive 2004/18/EC: Procedures for Award of Public Contracts
Directive

19. Sustainable development is "development that meets the needs of the
present without compromising the ability of future generations to meet their
own needs“
Recycled by-product – No new raw materials used
by product
Durability – Longer life span
Significantly Lowered CO2 Emissions
“The most sustainable building material in the world”

20. Embodied CO2
and the Built GGBS: The Best Technology for a
Environment Substantial Reduction of Embodied CO2.
Embodied CO2
accounts f 19%
for GGBS can replace 55% of ordinary cement.
of overall CO2
emission in the • GGBS will reduce the embodied
UK* carbon footprint of concrete by 50%
50%.
• GGBS will reduce the embodied
GGBS is the BAT carbon footprint of a typical building by
for reducing 25%.
embodied CO2.
*Potential for Reducing the GGBS is the Best Available Technolog
A ailable Technology
Environmental Impact of
Construction Materials
commissioned by the BioRegional
(BAT) to reduce the embodied carbon
Development Group in association
with Stockholm Environmental
footprint of the built environment.
Institute and the WWF (UK study)

21. Properties &
Advantages of using GGBS

22. Same constituents as OPC
Different proportions
Less CaO
More Si02
i
More Al2O3

23. GGBS cement replaces ordinary Portland cement on a one-
for-one basis
No change in any other element of the mix design:
sand
aggregates
w/c ratio (can be reduced)
/ i ( b d d)
Admixtures
Concrete manufacture
C t f t
Batch duration is the same
Allowable time to transport is extended – this
increases with increasing percentage of GGBS

24. Engineering benefits start at 30%
Usage varies from 30 up to 85%
U i f t
Most often specified at 50%
Treated same as Portland cement concrete
No adjustment striking times
As always curing to comply with BS 8110 (as with all concrete
proper curing ensures best practice concrete is achieved)
Placing, compacting and powerfloating
Concrete admixtures compatible.
Temperature control
p
Issue reduces with increasing percentage of GGBS

25. More CSH gel – Less CA(OH)2 – Reduced Permeability/Porosity
Placing, compacting and pumping easier:
lower relative density
smaller particle sizes
Powerfloating as normal
Setting times longer by 1 – 2 hrs
Slower rate of bl di
Sl t f bleeding
Water demand 3% to 5% lower
Compatible with admixtures

26. More CSH gel – Less CA(OH)2 – Reduced Permeability/Porosity
Vertical formwork
Minimum 2 N/mm2
required to prevent
mechanical damage
Horizontal formwork
Minimum 10 N/mm2 or
twice the stress to which
the slab is subjected
- At least 10 N/mm2 achieved after 3 days
- Use Temperature Matched Curing to confirm

27. 80.0
70.0
60.0
50.0
N/mm2
40.0
30.0
20.0
10.0
Days
0.0
7 28 90
100/0 Sept 50/50 Sept 30/70 Sept

28. TMC(50 - 60 C) v Standard cure(20 C)
St d d (20
380 kgs CEM ll A-L 42.5N cement with 70% GGBS
40
Cured at 20 degrees
35
Cured at temperature in
30 structure
25
Strength
20
15
S
10
5
0
0 1 2 3 4 5 6 7 8
Days

30. More CSH gel – Less CA(OH)2 – Reduced Permeability/Porosity
Chloride Penetration
Lower chloride ion diffusivity
Lower porosity/permeability
p yp y
Applications: roads and bridges, car parks, sea defences,
marine structures.

31. More CSH gel – Less CA(OH)2 – Reduced Permeability/Porosity

32. More CSH gel – Less CA(OH)2 – No C3A – Reduced Permeability/Porosity
Sulphate Resistance
Sulphates react with C3A and Ca(OH)2 to form
ettringite
Sulphate Resisting cement (SRPC) has reduced
C3A, but no reduced Ca(OH)2, a d no reduced
, o educed Ca(O ) and o educed
porosity
SRPC cannot be used in marine environments
GGBS much lower price than SRPC
• Note: In BS8500 the only
option recommended as
suitable for the most severe
sulphate exposure (Class DC-
DC
4m) is concrete containing at
least 66% GGBS
• Use of Sulphate resistant
cement is not permitted

33. Waste water plants

34. More CSH gel – Less CA(OH)2 – No C3A – Reduced Permeability/Porosity
Aggressors:
Sulphates
p
Sodium Sulphate Na2SO4
Magnesium Sulphate MgSO4
Acids
Sulphuric Acid H2SO4
http://www.ecocem.ie/index.php?p
=technical&q=wastewater

35. •On going Masters Study in UCD, Dublin
0.12
0.1
0.08
xpansion
CEM II 100%
0.06 CEM II + 50% GGBS
% Ex
CEMII + 70% GGBS
CEMI 100%
0.04 CEM I + 70% GGBS
SRPC
0.02
0
0 50 100 150 200 250 300
Days Exposure

36. Extract from “Civil Engineering Specification for the Water Industry – 6th Edition”
Normal refers to DC classes 1 & 2 and special refers to DC classes 3 & 4 – from
“Special Digest 1 – Concrete in Aggressive Ground”. DC1 is the least
aggressive with DC 4 being the most aggressive.

37. 0% GGBS
30% GGBS
50% GGBS

38. More CSH gel – Less CA(OH)2 – No C3A – Reduced Permeability/Porosity
GGBS lowers peak and overall heat
Reduces thermal stressing
Reduces micro-cracking (particularly useful in
water retaining structures, basements, podium slab,
bridges, stadiums, secant pile walls etc.)
Optimum substitution level 60 – 85%

39. 0% GGBS 30% GGBS
26 degrees 25 degrees
50% GGBS 70% GGBS
23 degrees 19 degrees

40. Thermocouple locations and slab insulation

41. 60
50
40
30 Highest
Lowest
Difference
20
10
0

42. Min Max Difference
50
45
40
35
30
25
20
15
10
5
0
08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30 08:15 13:00 17:30
06/09/2007 07/09/2007 08/09/2007 09/09/2007 10/09/2007 11/09/2007 12/09/2007 13/09/2007

43. 70.0 Top
Core
Bottom
60.0 Differential Top to Core
Differential Bottom to Core
50.0
40.0
Temperature (oC)
30.0
20.0
10.0
0.0
0 21 28 33 46 58 70 77 92 99 118 139 164 189 234
Time after placing (hours)

45. More CSH gel – Less CA(OH)2 – No C3A – Reduced Permeability/Porosity

46. GGBS is an off-white powder
Lighter, more even-coloured concrete
Li ht l d t
Smoother, more defect-free surface
Suppresses/Eliminates efflorescence
GGBS cement, and OPC Lower pigment requirements – 20% saving
GGBS can be used as partial replacement for
white cement, up to 70%

47. Bridge pier and bridge deck, Enfield bypass
Bridge deck 100% OPC
Bridge pier 50% GGBS

48. Cork Civic Offi
C k Ci i Offices

49. Cathleen Falls Bridge
2006 ICS Design and
ICS,
Construction Awards

50. Sleeping Giant
2007 ICS
ICS,
Design and
Construction
Award

51. Sean O’Casey Building Dublin
S O’C B ildi D bli
2008 ICS,
Design and
Construction
Award

52. QE II bridge, Dartford M25
50-
50-70% GGBS for chloride
resistance, reduced heat of
hydration and appearance
Second Severn Crossing

53. Aviva Stadium, Dublin
A i St di D bli

54. Father Collins Park, Dublin
Park

55. Standard concrete specification containing GGBS
p g

57. The world’s first Carbon Neutral Building Material
launched in 2007 in partnership with the biggest
names in the Irish Construction Industry:
Treasury Holdings
T H ldi
Pierse
Durkan Group
McNamara
JJ Rhatigan
Details on all prestigious projects can be found on
www.carbonneutralconcrete.ie

58. What is in it for you!
•Best durability (longer life)
•Reduce lifetime maintenance cost
Reduce
•Best sustainable material
•Demonstrates your commitment to
y
a sustainable agenda
•Create a lot of positive PR
•Best Architectural
•Reduce cost to achieve desired
finish
•Best value for money

59. Should y
you have any q
y questions in the future:
David O’Flynn, 087 965 4891
doflynn@ecocem.ie