Name

Position

Organisation

Mailing Address City P/Code

Telephone Facsimile

Email address

I received connections via a third party, please:

■■■■ Add me to your mailing list ■■■■ Send me only electronic copies via email ■■■■ Send me hard copies only

I WISH TO PURCHASE: ■■■■ ASA Video @ $15.00* x _____ Qty ■■■■ ASA Compendium @ $15.00* x _____ Qty

Business Category (please tick ✓)

■■■■ Producer

■■■■ Processor

■■■■ Materials handler

■■■■ Refining/value adding

■■■■ Industry supplier

■■■■ Specifier/Engineer

■■■■ Government agency

■■■■ Other

Subscription Form: Connections

MODERN construction requires materials thatare readily specifiable and have predictableperformance criteria, the essence of qualityassurance. In order to provide reliable materials, agreat deal of research and performance testing isrequired. For slag products in Australia, this workhas spanned more than 50 years. Beginning withsimple road pavements in the 1950’s and 1960’sthrough to sophisticated pavements and cementstoday, slag products have been well researchedand tested by performance. In 1993, theAustralasian Slag Association produced “A Guideto the Use of Slag in Roads”.This guide is currentlybeing revised, capturing all of the research andperformance experience since then.

Launch of the EcoCem plant at Port Kembladuring 2001, makes an important contribution toimproving concrete properties. Results showimprovements in pumpability, workability and

finishability of concretes containing EcoCem.Thereare now more than 20 concrete plants usingEcoCem from Eden to Penrith and Sydneymetropolitan area.

Blended slag pavements have made a significantcontribution to the construction of roads in theHunter region for a number of years. Since 1994,more than 1.1 million tonne of the popular mix 3has been placed, much of it by the RTA. This hasprovided the opportunity to confirm the superiorperformance of this material and determineoptimal placement techniques. This experience isshared in the article “blended Slag Pavements –

Construction techniques” in this issue.Slag is a by-product in the manufacture of iron

and steel.A major new construction project in theIllawarra region brings these materials together,showcasing their performance characteristics.Thenew BHP Australian Historical Aviation Museum.BHP Coated Steel and BHP Flat Products willsupply steel products for the buildings. AustralianSteel Mill Services (ASMS) will provide materialsfor an upgrade of the Albion Park Airstrip.

The research and performance testing overthe past 50 years underpins slag’s reputation asquality construction material. ■

EXPR

ESS

FAX

:422

8 17

77

*Plus postage and handling • Inclusive of GST.

Since the formation of the Australasian SlagAssociation in 1990, significant changeshave occurred in the effective utilisation of

slag materials. For example during the calendaryear of 1990, approximately 4.5Mt of slag wasproduced, effective utilization of the totalarisings were in the order of 30 to 35%. Note: Effective utilisation, means the use of slagmaterials in a productive or economicallybeneficial way and therefore not requiringdisposal as landfill, which in today’s society mustalways be a last resort.

The following simple multi-level pie graph

illustrates slag utilisation for 2000. Starting at thecentre, some 3.1 million tonnes of variousmetallurgical slag’s were produced during theperiod. The second outer circle represents themajor slag by-products types productionvolumes. The last circle or coloured outersegments represents the total effectiveutilization, which has increased to approx 75%.The major contributors being GBFS(Granulated Blast Furnace Slag–Red) at 100%,BFS (Blast Furnace Slag – Blue) at 71%, BOS(Basic Oxygen Slag – Green) at 64%, EAFS(Electric Arc Furnace Slag – Light blue) at 54%and other slags (Purple) at 24%. The grey areasrepresent slag materials which are stored forsome future use.

Compared to the early nineties and givingdue regard for reduce slag production, effectiveutilisation has increased significantly. Theseachievements are a direct result of slag productbenefits being more widely understood andappreciated by material users in the construction,agricultural and civil engineering industries.

For more information regarding thisarticle please contact Craig Heidrich on 024225 8466.

Utilisation has increased significantly

Connections EditorialConnections is published by ASAThe Australasian Slag AssociationWollongong NSW 2500 AustraliaPhone: 02 4225 8466Facsimile: 02 4228 1777Email: info@asa-inc.org.auWeb: www.asa-inc.org.auPublisher-------------------------------------------------ASA inc.Development Manager ---------------------Craig HeidrichArt Director ---------------------------------Martin CostanzoPre-Press/Print--------------------In-House Graphics (nsw)

Contributors:ASMS, Independent Cement and Lime, David E. Jones,CSIRO, SRC, BHP (NZ) and Craig Heidrich.

Quarterly PublicationCirculation: 2,000

Views expressed in Connections newsletter do notnecessarily reflect the opinion of the Australasian SlagAssociation. All contributions are welcomed, though thepublisher reserves the right to decline, to publish or edit forstyle, grammar, length and legal reasons. ©2002

THIS QUARTER:1 Editorial • Ecocem- a concrete success 2 AustralianHistorical Aviation Museum • Smorgon 3 Blended Slagpavement techniques 5 News in brief • Member Profiles6 ASA formation brings significant changes

T H E A U S T R A L A S I A N S L A G A S S O C I A T I O N N E W S L E T T E R

T H E A U S T R A L A S I A N S L A G A S S O C I A T I O N N E W S L E T T E R

desi

gn•p

rint

•web

: In-

Hou

seG

raph

ics

(nsw

) ©

2002

ww

w.ih

gdes

ign.

com

Editorial comment

VOL 2. ISSUE 4 FEBRUARY 2002

Slag – “the ultimaterenewable mineralresource” – video hasproved to be afavourite with manymembers.Aconsiderable amount of

new additional footage has beenincorporated demonstrating the beneficialproperties of slag in various large-scaleprojects completed in recent years.Thevideo (15mins duration) outlines slag’shistorical beginnings through to the varioustypes of slag produced in a modernproduction process today.

Since our last issue we have had toproduce another 100 copies to meetfurther demand. Copies are available tomembers at a cost of $15.00 each, non-members $20.00 plus postage andhandling. Just complete and fax back thesubscription/order form indicating yourrequirements.

Given the number of high quality guidesthe ASA hasp r o d u c e d , a n dcontinues to produce(“Guide to the Useof Steel Furnace Slagin Asphalt and ThinBituminousSurfacings”)together withbulletins,newsletters and

general correspondence, the Educationand Promotion Committee havedeveloped a Technical Compendium forthe purposes of storing these importantdocuments and more.

The Compendiums are an invaluablereference tool for engineers, specifiers,consultants, government authorities, andvarious slag users. Copies are available tomembers at a cost of $15.00 each, nonmembers $20.00 plus postage andhandling. Please note that as amendmentsare made to the contents of thecompendiums, registered holders willreceive updates. Just complete and faxback the subscription/order formindicating your requirements.

www.asa–inc.org.au

Q U A R T E R L Y

2002

conn

ectio

ns

Following the opening of the EcoCem GrindingFacility at Port Kembla by the Premier of NSW, Mr.Bob Carr, sales of EcoCem have been steadilyincreasing. Currently more than twenty concreteplants from Eden in the south to Penrith in theSydney metropolitan area are utilising Ecocem inconcrete.

In most concrete applications Ecocem is replacingup to 50% of the Portland Cement content.Concrete placement contractors reportimprovements in pumpability, workability andfinishability of concretes containing Ecocem. Settingtimes, although slightly extended at the 50%

substitution level, are generally offset with the lowerwater demand and bleed tendency resulting inacceptable finishing times. Even in the southernreaches of NSW where winter temperatures are stillexperienced, setting times are not an issue.

Early concrete compressive strengths areacceptable even in mixes containing fly ash.Compressive strength gain is excellent and later agestrengths are greater than those without Ecocem byup to 20% at 28 days.

Replacement of 50 percent of Type SL withEcocem produces significantly greater resistance tosulfate attack.This is demonstrated when Ecocem is

tested to AS 2350.14–1996 “Length change ofportland and blended cement mortars exposed to asulfate solution”.Typical data are shown in the figureand expansion at sixteen weeks is significantly lowerthan the specification maximum of 900 microstrain.

For more information please contact IhorHinczak, Technical Sales Manager – EcoCem on02 4225 7191. ■

Ecocema concrete success

“There are now more than 20 concreteplants using EcoCem from Eden to Penrith

and Sydney metropolitan area.”

connectionsconnectionsA S S O C I A T I O N

CONTINUED PAGE TWO

Company MembersA primary role of our Association is to bring

together Slag Producers, Processors,

Customers and Suppliers to the Slag

industry. Our activities cover Technical

Developments, Plant Operations and

Processes, Education and Promotion. If you

would like more information on the

Association and how you can become

involved, just complete the information

section at the end of this newsletter.

Current membership is as listed below.

› Australian Cement Ltd› Australian Steel Mill Services Pty› BHP Flat Products - Pt. Kembla› Blue Circle Southern Cement Ltd› Boral Concrete & Quarries› Brambles Equipment› Brambles Industrial Services (Whyalla)› Cleary Bros (Bombo) P/L› Comsteel – Newcastle› CSIRO DBC&E› CSR Readymix Group› University of Wollongong –

Dr Denis Montgomery › Gough & Gilmour› Heckett Multiserv (UK)› HBL (Heggies Bulkhaul Ltd)› Hunter Bulk Materials Pty Ltd› Hunter Mill Services Pty Ltd› Kress Corporation Ltd› Lincom Pacific Equipment Pty Ltd› Mahaffey Associates Pty Ltd› Metserv Australasia Pty Ltd› Milburn New Zealand Ltd› University of Newcastle –

Mr Stephen Fityus› Nichimen Australia Limited› NS Komatsu Ltd› Pioneer Construction Materials› Port Kembla Copper P/L› Premium Tyre Service P/L› Queensland Cement Ltd› Roads & Traffic Authority of NSW› Slag Cement Sdn Bhd, Malaysia› Smorgon Steel› South Coast Equipment› Steel Cement Ltd› SteelServ Ltd (NZ)› Steelstone Services (Aust)› Sulphide Corporation P/L› Sunstate Cement Pty Ltd› Wormald Fire Systems

Personal Members› Anderson L› Dobson G› Heaton, B (Hon.)› Jones D E (Hon.)› Maric M› Prosser S D (Hon.)› Venour M (Hon.)

Related Associations› National Slag Association (US)› Nippon Slag Association (Japan)› European Slag Association (EU)

2 | CONNECTIONS 2002 CONNECTIONS 2002 | 5

South Coast Equipment Pty Ltd. is a longstanding,family-owned company involved in thehandling/processing of bulk materials, industrial wasteand mining. The business is based in Wollongong,New South Wales - 75 kilometres south of Sydney.

The company has been long involved in slaghandling, processing, and product marketing withinthe region. The company operates concrete plants,quarrying operations within NSW.

The company can be contacted via[www.sce-aust.com]

Owned by Australian Steel Mill Services (ASMS),Ecocem Pty Ltd, specialises in processing andmarketing blast furnace slag from BHP Port Kembla.Australian Steel Mill Services was established 12years ago to focus on marketing 1.8 million tonnesper year of iron and steel slag from BHP PortKembla. Slag is the by-product from iron and steelproduction and for many years had been dumped orused as landfill. Slag generally looks like natural stonesuch as basalt, gravel and sand. Granulated slag whenused in cement manufacture, provides significantlyimproved performance and durability.

The company can be contacted via[www.ecocem.com.au]

An essential Guide for all material usersThe association has been over the last severalmonths, carrying out a review of the first of the userguides published by the Association “A guide to theUse of Slag in Roads”.

The original version of this guide was producedin 1993 after much consultation and reviewing. Infact at the time I remember seeing Draft 15 at least.Anyone who has seen the document, could seefrom the list of acknowledgments that there was agreat amount of assistance given from throughoutthe construction and materials supply industry.

Geoff Youdale who was, at the time with theRoads and Traffic Authority, along with other RTAcolleagues, gave valuable input in this original guide.It is with great respect for Geoff ’s ability andknowledge the Association again asked Geoff toassist with this review. In fact, Geoff is the maindriving force in the review. This time we are helpinghim, rather than he, us.

Why review?Firstly, the need for review came from the change

in the Slag industry, or should I say, the Steel Industry.Availability of slag types and tonnages changedfollowing the closure of the Newcastle Steelworks.Since the first guide, there has been a greater

emphasis on insitu stabilisation.There was also the task of producing a Guide for

Stabilisation. The Technical Committee came to theconclusion that the original guide was in need of anupdate and that the issues of Stabilisation could beintegrated into that review rather than anotherdocument at this time. Partly because AustStab hadrecently issued guides on stabilisation and it was notthe Association’s intent to detract from these but toenhance them.

Where is the review up to?The final draft which includes an enhanced

section on stabilisation, has been circulated to a widerange of interested parties for comment and is inthe final stages of completion. It is expectedpublishing will be carried out in February 2002.

The Association is excited about the chance toput into the arena of materials and construction afurther document that will enhance the knowledgeof people and the positive attributes of a productthat is technically some of the best available. We arealso looking forward to its launch early next year.

For more information please contact WayneJames, Chairperson - ASA Technical Committee one: technical@asa-inc.org.au” ■

FROM COVER PAGE

NEWS in BRIEF…

“A recent feasibility study showed there was already significant development

interest in the airport to create up to 223 full-time equivalent positions and

contribute more than $17 million annually to the regional economy.”

www.asa–inc.org.au www.asa–inc.org.au

Australian Historical Aviation Museum gets off the ground

Member Profile

The research for the project was carried out byCSIRO Sustainable Materials Engineering andfunded by Smorgon Steel Group Ltd. Theobjective was to improve the overallenvironmental and financial performance of thesteel making process.

The work of the CSIRO SME team hasrecently been recognised by winning the MohanMalhotra Award for Supplementary CementingMaterials, awarded by the Canada Centre forMinerals & Energy Technology and the AmericaConcrete Institute.

The Australian construction industry currentlyuses over 4Mt/pa of fly ash and iron/steel slag,These materials are used in road constructionand blended cements, and can improve the lifeexpectancy of concrete structures.

”In Victoria there has been little interest in theuse of this valuable resource which has been

either stockpiled, land filled or used to stabiliseboggy private roads in rural areas in the vicinity ofour plant,” said Smorgon’s Joe ltaliano.

60,000t of reprocessed slag is produced everyyear from the electric arc furnaces operated bySmorgon at its North Laverton plant inMelbourne.

“We have conducted trials on slag fromSmorgon’s electric arc furnaces and found anumber of technically viable and commerciallyuseful applications for this by-product” saidRobert Baker, CSIRO SME’s BusinessDevelopment Manager.These include:

> base course and top course for asphalt roads,> antiskid surfacing for roads on accident-prone intersections and curves,> low-strength concrete for footpaths, bicyclepaths, edge strips and behind kerbs and

gutters,> controlled low-strength fill for backfill fortrench stabilisation concrete subbase for rigidpavements.VicRoads tested the slag from the Smorgon

steel mill in polished stone value testing, whichconfirmed that the material provides a good skidresistance surface material for roads.

“Smorgon is now progressing the commercialdevelopment of viable applications arising fromCSIRO’s research. With commercial viability willcome the environmental benefits of replacingvirgin quarried raw materials with an industrial by-product,” said Mr ltaliano.

Thousands of tonnes of slag from steel millscould be effectively utilised into a range of usefulproducts for building roads and pavements.

For further information, please contact SandroCostabile on (03) 9360 2489.

Smorgon commercial development of slag resource

Premier Bob Carr opens facility.

Business based in the Illawarra, BHP Coated,BHP Flat Products and Australian Steel MillServices (ASMS) will provide materials for

an upgrade of the Albion Park Airstrip and theconstruction of a facility to house the AustralianHistorical Aviation Museum to be built at AlbionPark Airport.The facility will be known as the BHPSteel Australian Historical Aviation Museum.

The proposed BHP Steel Australian HistoricalAviation Museum will provide a wonderfulpermanent asset to the Illawarra generally and toShellharbour region. The project will showcasepremium BHP Steel Building Products, featuringcladding made from Colorbond® prepaintedsteel and purlins made from Galvaspan®galvanised steel for building structures. Theairstrip upgrade will utilise some 100,000 tonnesof premium roadbase materials supplied byASMS. This premium product was also used inthe construction of the Third Runway project atMascot Airport, Sydney.

The Museum can’t proceed without anupgrade of the airstrip, and the museum providesan excellent motivation for upgrading theairstrip, so the projects are joined at the hip.The

upgrade of the airstrip might eventually lead tothe recommencement of regular passengerservices in and out of Albion Park.

In particular, once upgrades to the airstrip havebeen completed, larger aircraft similar to “Dash 8”will be able to utilise this Airport.This has obviousdirect benefits to the region, affording greatereconomies of scale to prospective commercialairline operators.

The Museum will be a first class collection ofhistoric aircraft, many of them operational,together with a relevant collection of artefacts, alibrary and conference and training facilities. It willgenerate both permanent and part-time jobs,training opportunities, provide an undercoverfacility for the housing of AVIEX, a major biennialexposition of aviation business and technologyscheduled to be held at Albion Park Novembernext year.

Shellharbour City Mayor, Cec Glenholmeswelcomed the announcement saying the BHPSteel Australian Historical Aviation Museum woulddeliver substantial tourist and economic benefitsto Shellharbour and the entire Illawarra region.

”To be able to attract a respected, national

organisation like HARS to our airport is a majorcoup and to have it backed by companies likeBHP Steel and ASMS is a ringing endorsement ofthis project and Shellharbour City.

“A recent feasibility study showed there wasalready significant development interest in theairport to create up to 223 full-time equivalentpositions and contribute more than $17 millionannually to the regional economy. We aredelighted that our adjoining Councils,Wollongong and Kiama, are also contributing tothe runway upgrade,” he said.

Cr Glenholmes also recognised theconsiderable commitment from Australian SteelMill Services who will assist with the provisionand transport of road base material forupgrading the runway.

THE use of blended slag pavements has become common place inthe construction industry, especially in areas where steel makingslags are readily available. Initially, slag road construction was carried

out predominantly by the NSW Roads and Traffic Authority (RTA) and localcouncils. However due to the superior performance and consequentlygreater acceptance of these products, more and more civil contractors areusing blended slag pavements.

Experience has shown that certain construction techniques will ensurethat optimum performance of slag pavements is achieved. In the past,standard construction practices for conventional road bases have beenused on slag blended pavements. The following report explains severalissues that have arisen when placing Steelstone’s Mix 3 slag road base in theNewcastle region with conventional construction techniques. Mix 3 is a20mm minus blended slag pavement consisting of steel slag, granulated slagand fly ash.

Since 1994 Steelstone has supplied approximately 1.1 million tonnes ofMix 3, and in this time the RTA and local councils have provided valuablefeedback on its performance. Due to the self-cementing properties of Mix3 the slag pavement is heavily bound, and therefore the same constructionprinciples as semi-rigid construction are required. RTA specification RN73Ais a local Newcastle specification that has addressed the issues ofconstruction, and the important points are outlined below.

Construction JointingFresh Joints

Fresh jointing techniques are used when the joints are constructedwithin the allowable working time of the older material. When freshlongitudinal joints are required the outer 300-400mm of the older materialis left uncompacted until the adjoining material is placed ready forcompaction.

Cold Joints Where the older material has passed the allowable working time cold

jointing techniques are required.Transverse jointing is always at right angles to the road centre-line.

Before fresh slag material is placed, a clean vertical surface is cut at aminimum depth of 150mm thickness. If a sub-base bound layer has beenplaced, the base layer transverse joints shall be offset at a minimum of 2mfrom the sub-base joints.

Longitudinal jointing should be constructed in a similar fashion. If a sub-base bound layer has been placed, the base layer longitudinal joints shall beoffset at a minimum of 150mm from the sub-base joints.

Instances have occurred where ramping of the pavement has occurredduring construction, and these ramps have remained in the pavement at theend of the day as cold joints.This has resulted in a wedge effect at the jointsfrom day to day construction.

Movement due to thermal expansion at this wedge has caused elevationdifferences at the joint, resulting in deformation of the wearing surfacesimilar to the effect of tree roots.This is normally evident at regular intervalsalong the pavement coinciding with the end of each day’s construction.Thedeformation to the asphalt can be seen in the pictures following:

CONNECTIONS 2002 | 3www.asa–inc.org.au

A S A D A T A S H E E T

CONTINUED PAGE FOUR

Blended SlagPavementsConstruction Techniques By Adam Kelly – Steelstone Services (Aust)

Old Material Fresh Material

Vertical Joint (Min 150mm deep)

BASE

SUB-BASE

Base and Sub Base Joints Offset

Old Material Fresh Material

BASE

SUB-BASE

Construction Ramp Becomes Cold Joint

(Deformation to the asphalt – close-up) (Deformation to the asphalt – across pavement)

Confirmation of the wedging effect can be seenin the following picture of a core sampleillustrating the distinct movement of Mix 3 intothe asphalt layer, with the asphalt surrounding theresulting slag wedge.

This movement effects both the rideability andnoise level of the pavement. The problem hasbeen addressed by milling away either side of thewedged joint at least 150mm deep and replacingthe material with a vertically jointed slagpavement.

Alternatively only the deformation in the wearingsurface has been removed and asphalt onlyreplaced in these areas.There is no evidence at thistime to suggest that more movement is evident atthe joint when using this second method.

This is a low cost solution, however it may not becost effective if movement continues to occur atthe joint.

Compaction and TrimmingDue to the ease of compaction of slag blendedproducts, Mix 3 has been able to be compactedup to 300mm in a single layer. This will ensurethat lamination throughout the layer in thepavement does not occur.

Primary trimming should be completed abovethe required levels to ensure that when finaltrimming is done, extra material is not required ina thin layer. If extra material is required, the existingcompacted layer should be ripped up and theextra product added and re-compacted.This willavoid thin laminating layers plating and causingpavement problems when the material hashardened. Plating is normally evident by similarmovement in the asphalt to the above-mentionedjointing issues. However it will appear randomly inthe pavement depending on where the laminationhas occurred. Thin laminations are best fixed byremoving the thin layer of slag and replacing thethin layer with asphaltic concrete.Alternatively, thebase layer must be removed to a depth ofapproximately 150mm (including laminationdepth) and the slag base replaced.

Moisture ContentSlag blended pavements are less sensitive tomoisture than conventional materials. Mix 3 hasbeen placed in wet weather, or placed when themoisture content is above optimum. In theseinstances the material will pass compaction tests

very easily, but will take longer to harden.Moisture content becomes important with Mix

3 when it is used in applications where traffic isplaced directly on newly constructed pavements.Extensive night work on major roadways requiresthe removal of old pavement, placement of Mix 3and an asphalt layer within approximately 10hours. Due to the lower temperatures at night,and immediate trafficking, moisture contentsoften are 2-3% below optimum laboratorymoisture content to meet all the requirements.

Density testing should be carried out as soonas possible after compaction has occurred.This willensure that if extra compaction is required theplacement moisture content is still available beforehydration occurs.The decision should be made asto whether the material can be close to laboratoryoptimum moisture content and allowed to dryover time, or whether trafficking immediately isrequired. The compaction ratio required shouldreflect the application of Mix 3.

Finished Surfaces It is common to bring a slurry to the surface ofMix 3 when finishing.This will aid in the curing ofthe pavement by assisting to contain moisture forhydration. If this practice is used, it is imperativethe slurry is removed before adding prime sealsto the pavement. In several instances the slurryhas been left on the slag base surface and therehas been no bond between the base and asphaltinterface.This has induced shoving of the asphaltwearing surface, and caused concern over thesuitability of Mix 3 for asphalt surfacing. Contraryto this concern, the basic nature of Mix 3 assuresan affinity to bituminous surfacing. Standardpreparation of the base course includingremoving of slurry will ensure a successfulpavement. If the slurry exists on the sub basecourse it is necessary to scarify the surface with agrader to ensure that a good bond is achievedbetween the base and sub base layers.

The uses of slag blended pavements andespecially the placement of Mix 3, have assuredthat correct placement techniques have beenformulated and are outlined in this report. Manythanks go to Newcastle and Lake MacquarieCouncils for their input and advice. This allowssuppliers such as Steelstone to ensure that allissues regarding our products are available to allinvolved in using slag blended materials.

For further information regarding this articleplease contact Adam Kelly on 02 4961 2393.

4 | CONNECTIONS 2002 www.asa–inc.org.au

Construction TechniquesFROM PAGE THREE

”Density testing should be carried out as soon as possible after compaction hasoccurred. This will ensure that if extra compaction is required the placementmoisture content is still available before hydration occurs.”

Core Sample

Required Level

Company MembersA primary role of our Association is to bring

together Slag Producers, Processors,

Customers and Suppliers to the Slag

industry. Our activities cover Technical

Developments, Plant Operations and

Processes, Education and Promotion. If you

would like more information on the

Association and how you can become

involved, just complete the information

section at the end of this newsletter.

Current membership is as listed below.

› Australian Cement Ltd› Australian Steel Mill Services Pty› BHP Flat Products - Pt. Kembla› Blue Circle Southern Cement Ltd› Boral Concrete & Quarries› Brambles Equipment› Brambles Industrial Services (Whyalla)› Cleary Bros (Bombo) P/L› Comsteel – Newcastle› CSIRO DBC&E› CSR Readymix Group› University of Wollongong –

Dr Denis Montgomery › Gough & Gilmour› Heckett Multiserv (UK)› HBL (Heggies Bulkhaul Ltd)› Hunter Bulk Materials Pty Ltd› Hunter Mill Services Pty Ltd› Kress Corporation Ltd› Lincom Pacific Equipment Pty Ltd› Mahaffey Associates Pty Ltd› Metserv Australasia Pty Ltd› Milburn New Zealand Ltd› University of Newcastle –

Mr Stephen Fityus› Nichimen Australia Limited› NS Komatsu Ltd› Pioneer Construction Materials› Port Kembla Copper P/L› Premium Tyre Service P/L› Queensland Cement Ltd› Roads & Traffic Authority of NSW› Slag Cement Sdn Bhd, Malaysia› Smorgon Steel› South Coast Equipment› Steel Cement Ltd› SteelServ Ltd (NZ)› Steelstone Services (Aust)› Sulphide Corporation P/L› Sunstate Cement Pty Ltd› Wormald Fire Systems

Personal Members› Anderson L› Dobson G› Heaton, B (Hon.)› Jones D E (Hon.)› Maric M› Prosser S D (Hon.)› Venour M (Hon.)

Related Associations› National Slag Association (US)› Nippon Slag Association (Japan)› European Slag Association (EU)

2 | CONNECTIONS 2002 CONNECTIONS 2002 | 5

South Coast Equipment Pty Ltd. is a longstanding,family-owned company involved in thehandling/processing of bulk materials, industrial wasteand mining. The business is based in Wollongong,New South Wales - 75 kilometres south of Sydney.

The company has been long involved in slaghandling, processing, and product marketing withinthe region. The company operates concrete plants,quarrying operations within NSW.

The company can be contacted via[www.sce-aust.com]

Owned by Australian Steel Mill Services (ASMS),Ecocem Pty Ltd, specialises in processing andmarketing blast furnace slag from BHP Port Kembla.Australian Steel Mill Services was established 12years ago to focus on marketing 1.8 million tonnesper year of iron and steel slag from BHP PortKembla. Slag is the by-product from iron and steelproduction and for many years had been dumped orused as landfill. Slag generally looks like natural stonesuch as basalt, gravel and sand. Granulated slag whenused in cement manufacture, provides significantlyimproved performance and durability.

The company can be contacted via[www.ecocem.com.au]

An essential Guide for all material usersThe association has been over the last severalmonths, carrying out a review of the first of the userguides published by the Association “A guide to theUse of Slag in Roads”.

The original version of this guide was producedin 1993 after much consultation and reviewing. Infact at the time I remember seeing Draft 15 at least.Anyone who has seen the document, could seefrom the list of acknowledgments that there was agreat amount of assistance given from throughoutthe construction and materials supply industry.

Geoff Youdale who was, at the time with theRoads and Traffic Authority, along with other RTAcolleagues, gave valuable input in this original guide.It is with great respect for Geoff ’s ability andknowledge the Association again asked Geoff toassist with this review. In fact, Geoff is the maindriving force in the review. This time we are helpinghim, rather than he, us.

Why review?Firstly, the need for review came from the change

in the Slag industry, or should I say, the Steel Industry.Availability of slag types and tonnages changedfollowing the closure of the Newcastle Steelworks.Since the first guide, there has been a greater

emphasis on insitu stabilisation.There was also the task of producing a Guide for

Stabilisation. The Technical Committee came to theconclusion that the original guide was in need of anupdate and that the issues of Stabilisation could beintegrated into that review rather than anotherdocument at this time. Partly because AustStab hadrecently issued guides on stabilisation and it was notthe Association’s intent to detract from these but toenhance them.

Where is the review up to?The final draft which includes an enhanced

section on stabilisation, has been circulated to a widerange of interested parties for comment and is inthe final stages of completion. It is expectedpublishing will be carried out in February 2002.

The Association is excited about the chance toput into the arena of materials and construction afurther document that will enhance the knowledgeof people and the positive attributes of a productthat is technically some of the best available. We arealso looking forward to its launch early next year.

For more information please contact WayneJames, Chairperson - ASA Technical Committee one: technical@asa-inc.org.au” ■

FROM COVER PAGE

NEWS in BRIEF…

“A recent feasibility study showed there was already significant development

interest in the airport to create up to 223 full-time equivalent positions and

contribute more than $17 million annually to the regional economy.”

www.asa–inc.org.au www.asa–inc.org.au

Australian Historical Aviation Museum gets off the ground

Member Profile

The research for the project was carried out byCSIRO Sustainable Materials Engineering andfunded by Smorgon Steel Group Ltd. Theobjective was to improve the overallenvironmental and financial performance of thesteel making process.

The work of the CSIRO SME team hasrecently been recognised by winning the MohanMalhotra Award for Supplementary CementingMaterials, awarded by the Canada Centre forMinerals & Energy Technology and the AmericaConcrete Institute.

The Australian construction industry currentlyuses over 4Mt/pa of fly ash and iron/steel slag,These materials are used in road constructionand blended cements, and can improve the lifeexpectancy of concrete structures.

”In Victoria there has been little interest in theuse of this valuable resource which has been

either stockpiled, land filled or used to stabiliseboggy private roads in rural areas in the vicinity ofour plant,” said Smorgon’s Joe ltaliano.

60,000t of reprocessed slag is produced everyyear from the electric arc furnaces operated bySmorgon at its North Laverton plant inMelbourne.

“We have conducted trials on slag fromSmorgon’s electric arc furnaces and found anumber of technically viable and commerciallyuseful applications for this by-product” saidRobert Baker, CSIRO SME’s BusinessDevelopment Manager.These include:

> base course and top course for asphalt roads,> antiskid surfacing for roads on accident-prone intersections and curves,> low-strength concrete for footpaths, bicyclepaths, edge strips and behind kerbs and

gutters,> controlled low-strength fill for backfill fortrench stabilisation concrete subbase for rigidpavements.VicRoads tested the slag from the Smorgon

steel mill in polished stone value testing, whichconfirmed that the material provides a good skidresistance surface material for roads.

“Smorgon is now progressing the commercialdevelopment of viable applications arising fromCSIRO’s research. With commercial viability willcome the environmental benefits of replacingvirgin quarried raw materials with an industrial by-product,” said Mr ltaliano.

Thousands of tonnes of slag from steel millscould be effectively utilised into a range of usefulproducts for building roads and pavements.

For further information, please contact SandroCostabile on (03) 9360 2489.

Smorgon commercial development of slag resource

Premier Bob Carr opens facility.

Business based in the Illawarra, BHP Coated,BHP Flat Products and Australian Steel MillServices (ASMS) will provide materials for

an upgrade of the Albion Park Airstrip and theconstruction of a facility to house the AustralianHistorical Aviation Museum to be built at AlbionPark Airport.The facility will be known as the BHPSteel Australian Historical Aviation Museum.

The proposed BHP Steel Australian HistoricalAviation Museum will provide a wonderfulpermanent asset to the Illawarra generally and toShellharbour region. The project will showcasepremium BHP Steel Building Products, featuringcladding made from Colorbond® prepaintedsteel and purlins made from Galvaspan®galvanised steel for building structures. Theairstrip upgrade will utilise some 100,000 tonnesof premium roadbase materials supplied byASMS. This premium product was also used inthe construction of the Third Runway project atMascot Airport, Sydney.

The Museum can’t proceed without anupgrade of the airstrip, and the museum providesan excellent motivation for upgrading theairstrip, so the projects are joined at the hip.The

upgrade of the airstrip might eventually lead tothe recommencement of regular passengerservices in and out of Albion Park.

In particular, once upgrades to the airstrip havebeen completed, larger aircraft similar to “Dash 8”will be able to utilise this Airport.This has obviousdirect benefits to the region, affording greatereconomies of scale to prospective commercialairline operators.

The Museum will be a first class collection ofhistoric aircraft, many of them operational,together with a relevant collection of artefacts, alibrary and conference and training facilities. It willgenerate both permanent and part-time jobs,training opportunities, provide an undercoverfacility for the housing of AVIEX, a major biennialexposition of aviation business and technologyscheduled to be held at Albion Park Novembernext year.

Shellharbour City Mayor, Cec Glenholmeswelcomed the announcement saying the BHPSteel Australian Historical Aviation Museum woulddeliver substantial tourist and economic benefitsto Shellharbour and the entire Illawarra region.

”To be able to attract a respected, national

organisation like HARS to our airport is a majorcoup and to have it backed by companies likeBHP Steel and ASMS is a ringing endorsement ofthis project and Shellharbour City.

“A recent feasibility study showed there wasalready significant development interest in theairport to create up to 223 full-time equivalentpositions and contribute more than $17 millionannually to the regional economy. We aredelighted that our adjoining Councils,Wollongong and Kiama, are also contributing tothe runway upgrade,” he said.

Cr Glenholmes also recognised theconsiderable commitment from Australian SteelMill Services who will assist with the provisionand transport of road base material forupgrading the runway.

Name

Position

Organisation

Mailing Address City P/Code

Telephone Facsimile

Email address

I received connections via a third party, please:

■■■■ Add me to your mailing list ■■■■ Send me only electronic copies via email ■■■■ Send me hard copies only

I WISH TO PURCHASE: ■■■■ ASA Video @ $15.00* x _____ Qty ■■■■ ASA Compendium @ $15.00* x _____ Qty

Business Category (please tick ✓)

■■■■ Producer

■■■■ Processor

■■■■ Materials handler

■■■■ Refining/value adding

■■■■ Industry supplier

■■■■ Specifier/Engineer

■■■■ Government agency

■■■■ Other

Subscription Form: Connections

MODERN construction requires materials thatare readily specifiable and have predictableperformance criteria, the essence of qualityassurance. In order to provide reliable materials, agreat deal of research and performance testing isrequired. For slag products in Australia, this workhas spanned more than 50 years. Beginning withsimple road pavements in the 1950’s and 1960’sthrough to sophisticated pavements and cementstoday, slag products have been well researchedand tested by performance. In 1993, theAustralasian Slag Association produced “A Guideto the Use of Slag in Roads”.This guide is currentlybeing revised, capturing all of the research andperformance experience since then.

Launch of the EcoCem plant at Port Kembladuring 2001, makes an important contribution toimproving concrete properties. Results showimprovements in pumpability, workability and

finishability of concretes containing EcoCem.Thereare now more than 20 concrete plants usingEcoCem from Eden to Penrith and Sydneymetropolitan area.

Blended slag pavements have made a significantcontribution to the construction of roads in theHunter region for a number of years. Since 1994,more than 1.1 million tonne of the popular mix 3has been placed, much of it by the RTA. This hasprovided the opportunity to confirm the superiorperformance of this material and determineoptimal placement techniques. This experience isshared in the article “blended Slag Pavements –

Construction techniques” in this issue.Slag is a by-product in the manufacture of iron

and steel.A major new construction project in theIllawarra region brings these materials together,showcasing their performance characteristics.Thenew BHP Australian Historical Aviation Museum.BHP Coated Steel and BHP Flat Products willsupply steel products for the buildings. AustralianSteel Mill Services (ASMS) will provide materialsfor an upgrade of the Albion Park Airstrip.

The research and performance testing overthe past 50 years underpins slag’s reputation asquality construction material. ■

EXPR

ESS

FAX

:422

8 17

77

*Plus postage and handling • Inclusive of GST.

Since the formation of the Australasian SlagAssociation in 1990, significant changeshave occurred in the effective utilisation of

slag materials. For example during the calendaryear of 1990, approximately 4.5Mt of slag wasproduced, effective utilization of the totalarisings were in the order of 30 to 35%. Note: Effective utilisation, means the use of slagmaterials in a productive or economicallybeneficial way and therefore not requiringdisposal as landfill, which in today’s society mustalways be a last resort.

The following simple multi-level pie graph

illustrates slag utilisation for 2000. Starting at thecentre, some 3.1 million tonnes of variousmetallurgical slag’s were produced during theperiod. The second outer circle represents themajor slag by-products types productionvolumes. The last circle or coloured outersegments represents the total effectiveutilization, which has increased to approx 75%.The major contributors being GBFS(Granulated Blast Furnace Slag–Red) at 100%,BFS (Blast Furnace Slag – Blue) at 71%, BOS(Basic Oxygen Slag – Green) at 64%, EAFS(Electric Arc Furnace Slag – Light blue) at 54%and other slags (Purple) at 24%. The grey areasrepresent slag materials which are stored forsome future use.

Compared to the early nineties and givingdue regard for reduce slag production, effectiveutilisation has increased significantly. Theseachievements are a direct result of slag productbenefits being more widely understood andappreciated by material users in the construction,agricultural and civil engineering industries.

For more information regarding thisarticle please contact Craig Heidrich on 024225 8466.

Utilisation has increased significantly

Connections EditorialConnections is published by ASAThe Australasian Slag AssociationWollongong NSW 2500 AustraliaPhone: 02 4225 8466Facsimile: 02 4228 1777Email: info@asa-inc.org.auWeb: www.asa-inc.org.auPublisher-------------------------------------------------ASA inc.Development Manager ---------------------Craig HeidrichArt Director ---------------------------------Martin CostanzoPre-Press/Print--------------------In-House Graphics (nsw)

Contributors:ASMS, Independent Cement and Lime, David E. Jones,CSIRO, SRC, BHP (NZ) and Craig Heidrich.

Quarterly PublicationCirculation: 2,000

Views expressed in Connections newsletter do notnecessarily reflect the opinion of the Australasian SlagAssociation. All contributions are welcomed, though thepublisher reserves the right to decline, to publish or edit forstyle, grammar, length and legal reasons. ©2002

THIS QUARTER:1 Editorial • Ecocem- a concrete success 2 AustralianHistorical Aviation Museum • Smorgon 3 Blended Slagpavement techniques 5 News in brief • Member Profiles6 ASA formation brings significant changes

T H E A U S T R A L A S I A N S L A G A S S O C I A T I O N N E W S L E T T E R

T H E A U S T R A L A S I A N S L A G A S S O C I A T I O N N E W S L E T T E R

desi

gn•p

rint

•web

: In-

Hou

seG

raph

ics

(nsw

) ©

2002

ww

w.ih

gdes

ign.

com

Editorial comment

VOL 2. ISSUE 4 FEBRUARY 2002

Slag – “the ultimaterenewable mineralresource” – video hasproved to be afavourite with manymembers.Aconsiderable amount of

new additional footage has beenincorporated demonstrating the beneficialproperties of slag in various large-scaleprojects completed in recent years.Thevideo (15mins duration) outlines slag’shistorical beginnings through to the varioustypes of slag produced in a modernproduction process today.

Since our last issue we have had toproduce another 100 copies to meetfurther demand. Copies are available tomembers at a cost of $15.00 each, non-members $20.00 plus postage andhandling. Just complete and fax back thesubscription/order form indicating yourrequirements.

Given the number of high quality guidesthe ASA hasp r o d u c e d , a n dcontinues to produce(“Guide to the Useof Steel Furnace Slagin Asphalt and ThinBituminousSurfacings”)together withbulletins,newsletters and

general correspondence, the Educationand Promotion Committee havedeveloped a Technical Compendium forthe purposes of storing these importantdocuments and more.

The Compendiums are an invaluablereference tool for engineers, specifiers,consultants, government authorities, andvarious slag users. Copies are available tomembers at a cost of $15.00 each, nonmembers $20.00 plus postage andhandling. Please note that as amendmentsare made to the contents of thecompendiums, registered holders willreceive updates. Just complete and faxback the subscription/order formindicating your requirements.

www.asa–inc.org.au

Q U A R T E R L Y

2002

conn

ectio

ns

Following the opening of the EcoCem GrindingFacility at Port Kembla by the Premier of NSW, Mr.Bob Carr, sales of EcoCem have been steadilyincreasing. Currently more than twenty concreteplants from Eden in the south to Penrith in theSydney metropolitan area are utilising Ecocem inconcrete.

In most concrete applications Ecocem is replacingup to 50% of the Portland Cement content.Concrete placement contractors reportimprovements in pumpability, workability andfinishability of concretes containing Ecocem. Settingtimes, although slightly extended at the 50%

substitution level, are generally offset with the lowerwater demand and bleed tendency resulting inacceptable finishing times. Even in the southernreaches of NSW where winter temperatures are stillexperienced, setting times are not an issue.

Early concrete compressive strengths areacceptable even in mixes containing fly ash.Compressive strength gain is excellent and later agestrengths are greater than those without Ecocem byup to 20% at 28 days.

Replacement of 50 percent of Type SL withEcocem produces significantly greater resistance tosulfate attack.This is demonstrated when Ecocem is

tested to AS 2350.14–1996 “Length change ofportland and blended cement mortars exposed to asulfate solution”.Typical data are shown in the figureand expansion at sixteen weeks is significantly lowerthan the specification maximum of 900 microstrain.

For more information please contact IhorHinczak, Technical Sales Manager – EcoCem on02 4225 7191. ■

Ecocema concrete success

“There are now more than 20 concreteplants using EcoCem from Eden to Penrith

and Sydney metropolitan area.”

connectionsconnectionsA S S O C I A T I O N

CONTINUED PAGE TWO