Page 1 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012 Composite...

API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012

Composite Cement Testing Dyckerhoff Germany

Denver, June 2012, Heiko Plack


Test Programme• Combinations tested (varying contents):

Cementitious component:• API Class G

(medium coarse cement, Blaine 3.100 cm2/g)• API Class G + CEM I 42,5 N

(medium fine cement, Blaine 3.900 cm2/g)• API Class H

(coarse cement , Blaine 2.550 cm2/g)

Additive:• Silica flour

• Medium fine

(Blaine 3.200 cm2/g)• Coarse

(Blaine 1.000 cm2/g)• Natural pozzolan

(very fine, Blaine 8.000 cm2/g) Variations include also changing water-to-cement/blend ratio = slurry density

Blends were tested according to physical API Spec 10A requirements


Components Involved (Characterization)

Absolute Density

Fineness

g/cm3 cm2/g

3,17 3 110

3,14 3 860

3,14 2 550

2,65 3 230

2,66 1 000

2,56 8 000

Random Sample taken from DY production

Silica flour, coarse Purchased (foreign source), SiO2 > 97%

Natural pozzolan (volcanic) Purchased (foreign source), SiO2 > 97%

Class H Random Sample taken from BU USA production

Physical parameter

RemarksComponent

Random Sample taken from DY production

Purchased (foreign source), SiO2 > 97%

Class G

Silica flour, medium fine

CEM I 42,5 N


Discussion Of Results• Assumption (Dyckerhoff proposal): Standardization efforts target on

specifying a „basic“ cement, and not a „special cement“, e.g. lightweight cement (covered by Lafarge NA proposal)

• = slurry density for performance testing is > 1.800 g/cm3

• Additives do affect the slurry density by • their own absolute density differing from Portland cement• higher specific surface area increasing the water demand

• = difficult to specify the water-to-cement/blend ratio, like for current basic cements, G and H

• However, most important performance requirements identified as • Free fluid (slurry stability)• Max. consistency 15 – 30‘ („rheology“)• Thickening time Schedule 5 („pumping time“)• Compressive strength 8h@140°F („later“ strength)


Discussion Of Results – Conclusion (I)

• Blends of different cement components (reactivity / fineness) + silica flour of different fineness have been tested (+ a very fine natural pozzolan)

• Apart from the content of used components the water-to-cement/blend ratio has been varied respectively adjusted.

• It is evident that a cement manufacturer has sufficient degree of freedom to adjust physical performance properties of a composite cement by varying

• Cement type (reactivity)

• Additive fineness and content

• Water-to-cement/blend ratio


Discussion Of Results – Conclusion (II)

• Thus • no maximum or mininim share of additive is to be specified,• no water-to-cement ratio is to be specified,

• instead, a slurry density range is to be specified for performance testing


Conclusion / Suggestion (I) - Lafarge NA proposal

Suggestion to specify two new API Spec 10A Composite Cement Classes with the following physical requirements:

• Composite cement #1 (API Class E?)

→ Lafarge NA results / proposal:

• Additives: Pozzolanic (natural + artificial), list of materials to be defined!

• Slurry density for performance testing:

12,0 lb/gal < SG < 16,7 lb/gal

• Free fluid:

< 5,9%

• API Schedule 5 thickening time:

TT > 90‘

• Max. consistency 15 – 30‘:

< 30 Bc

• Compressive strength 24h@100°F:

> 500 psi

No chemical requirements to be specified for both new Classes!


Conclusion / Suggestions (II) – Dyckerhoff proposal

• Composite cement #2 (API Class F?)

→ Dyckerhoff results / proposal

• Considered as a „basic cement“

• Additives: Silica flour + Pozzolans

• Slurry density for performance testing:

15,0 lb/gal < SG < 16,7 lb/gal

• Free fluid:

< 5,9%

• API Schedule 5 thickening time:

90‘ < TT < 120‘ (130‘?)

• Compressive strength 8h@140°F:

> 1.000 psi

No chemical requirements to be specified !

However, classification as HSR grade possible if

- Portland clinker used complies with HSR requirements of Classes G/H


Conclusion / Suggestions (III)• Specifying slurry density requires a reference to API RP 10B for the

test method. Mud balances usually available at all cement manufacturer‘s labs, calculation from absolute densities of components may also be considered.

• Requirement to provide test report along with any order shall state:• Slurry density at which performance tests were conducted• Water-to-cement/blend ratio at which performance tests were conducted• Share of Portland cement respectively of additive• Type of additive (silica flour, fly ash, natural pozzolan)• + results of physical testing as specified (see above)• Chemical specification ???


Test ResultsComments Test # Class G

CEM I24,5 R -

HSRClass H

SF I"med-fine"

SF II"coarse"

Nat. pozz.

Consistencyafter 30 min,

Bc

TT(Bc=100)min

8h @ 38°Cpsi

8h @ 60°Cpsi

A1 100 0 0,44 15,92 2,1 15 106 517 1.990

B2 90 10 0,44 15,79 2,6 2 113 584 2.274

B3-0 74 26 0,44 15,67 1,9 25 106 390 1.284

B3-1 74 26 0,42 15,77 1,8 22 96 420 1.530

B3-2 74 26 0,40 15,92 1,1 20 93 411 1.474

Class G (med. coarse cem.) + coarse SF B3-3 74 26 0,41 15,84 6,6 7 112 1.467

A2 100 0 0,44 15,91 3,2 11 102 690 2.410

C1 69 5 26 0,44 15,57 2,1 15 116 425 1.630

C2 64 10 26 0,44 15,57 1,6 25 88 570 1.780

C3 59,6 14,4 26 0,44 15,57 1,6 22 80 580 1.790

C4 60 10 30 0,44 15,52 1,8 14 108 460 1.550

A3 100 0 0,44 15,92 2,1 17 98 653 2.387

D2 70 30 0,44 15,49 0,4 25 95 400 860

Class G (med. coarse cem.) + nat. pozz, w /c +

D3 60 40 0,67 13,77 1,8 7 110 too low too low

E1 100 0,38 16,70 5,1 13 110 1004 2.528

E2 74 26 0,38 16,33 3,1 29 92 794 1.882

E3 74 26 0,4 16,11 4,6 8 117 596 1.473

E4 74 26 0,44 15,71 4,3 14 141

Min (excl. Test# D3 = lightweight cement) 59,6 5 74 0 26 0 0,38 15,49 0,4 2 80 390 860

Max (excl. Test# D3 = lightweight cement) 100 14,4 100 30 26 40 0,44 15,86 6,6 29 141 1004 2528

Class G (med. coarse cem.)+ medium fine SF +/-

Class G (med. coarse) + medium fine SFw ater-to-cement ratio +/-

Class H (coarse cem.)+ medium fine SF +/-

Class G (med. coarse cem.)+ natural pozzolan (very f ine) +/-

Class G (med. coarse cement)+ CEM I 42,5 N (med. f ine cement) +/-+ med. f ine SF +/-

not enough sample

API Spec 10 A - Results

Component, %Thickening Time Test

API Schedule#5, 356bar, 52°CCompressive strength

Slurry density,

lb/gal

Free Fluid,%

Mixw ater,

% BWOB

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