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

Low Carbon Concretes – Delft, 31.10.2013Low Carbon Concretes – Delft, 31.10.2013 11

Zero Carbon Cement Substitutes for Concrete

Low Carbon Concretes (LCC)Low Carbon Concretes (LCC)

using novel mineral binders as cement substitutesusing novel mineral binders as cement substitutes



LCC - what does it mean?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



Why LCC?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.



Evaluation of concrete products: An integrated approachEvaluation of concrete products: An integrated approach

Applicability

Efficiency

ProductProduct

Feasibility

Standards & Directives, Market

Costs, Prices, Revenues Engineering, Materials,Know-how, Staff skills Lowest carbon footprint product

(Concept of LCC)

New materials and advanced technologiesin concrete productions

Sustainability

New additional assessing criterias for products

durable

reusablenon-polluting

resource-efficient



Partial substitution of Partial substitution of conventional materialsconventional materials

• Unchanged productUnchanged product• Unchanged technologyUnchanged technology• Innovative potential within Innovative potential within

material onlymaterial only

Complete substitution of Complete substitution of conventional materialsconventional materials

• Competitive productCompetitive product• Unchanged or modified technologyUnchanged or modified technology• Innovative potential within material Innovative potential within material

and technologyand technology

New products with new New products with new materialsmaterials

• Novel productNovel product• Modified or new technologyModified or new technology• Innovative potential within Innovative potential within

material, technology and material, technology and final product propertiesfinal product properties

Development efforts (time, cost, staff)Development efforts (time, cost, staff) Degree of innovationDegree of innovation Sustainability (low carbon footprint)Sustainability (low carbon footprint) Potential of profitPotential of profit

Development strategy for Low Carbon ConcretesDevelopment strategy for Low Carbon Concretes



Low Carbon Concrete for sustainable buildingLow Carbon Concrete for sustainable building

Traditional approachTraditional approach

Advanced cement technology (blended cements)

Consume less clinker

Concrete mix design and modified technical requirements

Consume less cement

Innovative architecture and structural design (HPC)

Consume less concrete

New approachNew approach

Use novel binders toreplace cement

bifamentbifament



Pure OPC (CEM I)Pure OPC (CEM I)

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

Blended OPC with several SCMsBlended OPC with several SCMsup to 35% (CEM II) orup to 35% (CEM II) orwith single SCM up to 95% (CEM III)with single SCM up to 95% (CEM III)

Blended Cements to reduce carbon footprintBlended Cements to reduce carbon footprint

Development Development

-43%-43%

+62% +62%

+112%+112%

Overall market share Overall market share

56% 29% 56% 29%

German cement market (2002-2012) German cement market (2002-2012)

30% 48% 30% 48%

11% 22% 11% 22%



bifament bifament - a novel binder with zero carbon footprint- a novel binder with zero carbon footprint

stand alone mineral binder for concretes in competition to conventional cementsstand alone mineral binder for concretes in competition to conventional cements

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

NEW

NEW



Emission of COEmission of CO22 during production process during production process

bifamentwill be manufactured with

no release of CO2

in contrast to cements!

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

bifament

0 kg/t CO2 !

CO

2-re

leas

e (k

g/t

)



bifamentbifament lowers the carbon footprint of concrete products lowers the carbon footprint of concrete products

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

bifament bifament bifament

Example: Concrete paving blocks

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

CO

2-re

leas

e (k

g/t

)

Cement



Specific characteristics of Specific characteristics of bifamentbifament

Self-hardening

need no activators (alkalis, cement, lime ...)

Contains typical components of cements, slags and fly ashes initially by origin

composition and materials behavior are similar to a supersulfated cement

Free of shrinkage

no particular precautions for preventing cracks (joints, fibres)

Material behavior in concrete production is similar to cements

requires no technical changes within production process

Properties can be customized by selected composition and degree of processing

different qualities designed to individual application or product



The The bifamentbifament-project-project

Basic scientific researchand developmentsince 1998

Application testsand optimizationsince 2005

Long term experiences infly ash processing andmaterial behavior in practicesince 1994

• Product implementation on customers site

• Quality assurance in production

Applied researchand suitability testssince 2000

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

• Continual product development

• Product approvals

From 2014:



Industrial application example 1: Manufacturing of paving blocksIndustrial application example 1: Manufacturing of paving blocks- High-volume cement substitution by - High-volume cement substitution by bifament bifament --

Increase in product qualityIncrease in product quality

at lower production costsat lower production costs

up toup to 36 % 36 %

oror

Maximum potential reductionMaximum potential reduction

in cement consumption andin cement consumption and

mixture costsmixture costs

at equal product qualityat equal product quality

more thanmore than 50 % 50 %

Strength development



Industrial application example 1: Manufacturing of paving blocksIndustrial application example 1: Manufacturing of paving blocks

- Improvement of frost resistance -- Improvement of frost resistance -

Traditional mix without bifamentbifament Advanced mix with partial substitutionof cement by bifamentbifament



Industrial application example 2: Manufacturing of masonry blocksIndustrial application example 2: Manufacturing of masonry blocks- Complete cement replacement by - Complete cement replacement by bifamentbifament --

Strength development



OutlookOutlook

Commissioning of production plant in 2014

Availability of bifamentbifament up to 150.000 tons per year

Several pilot projects for German market are being prepared

Concrete repair, flood protection, immobilization

Few custom projects have already been started in Germany

Concrete goods, civil engineering products, ground and road construction

Looking for additional projects abroad



Thank you for your attention!

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

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