ductal materials
DESCRIPTION
civilTRANSCRIPT
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The Lafarge Group
• Over €12.2 billion in sales worldwide
• Over 83,000 people in 75 countries
Products• Cement
• Aggregate and Concrete
• Roofing
• Gypsum
• Specialty Products
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Lafarge North America Inc.
• Over 1000 operations throughout the U.S. and Canada
• More than 15,000 employees• 2003 sales of USD
$3.3 billion
North American Corporate headquarters, Herndon, VALafarge Canada Inc. headquarters, Montreal, Quebec
• 4 main business segments:– Cement and Cement-related
products– Construction Materials– Gypsum– Roofing
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Research and Development
h Lafarge is built on innovation and a focus on its customers
h Lafarge North America is part of an R&D network that consists of:
- technical centers on 5 continents- 500 people- global R&D budget of $100
million
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Agilia®The superior flow of our proprietary concrete Agilia® allows architects to achieve a new level of detail.
AggregatesLafarge was able to match the original stone for the restoration of the Washington Monument
Ductal®A proprietary material that offers a unique combination of strength, ductility, durability and aesthetics
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A Revolutionary New Material for New Solutions
Compressive Strength:130 to 240 MPa
Flexural Strength:25 to 50 MPa
Ductility:Greater capacity to deform and
support flexural and tensile loads, even after initial cracking
Abrasion Resistance:Similar to natural rock
Impermeability:Almost no carbonation and
penetration of chlorides
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Key points of the Ductal® mix design:
• Ductility
• Synergy of two sizes of fibers
• Grading optimization (modified Compactness Theory)
• An efficient Cement-Superplasticizer couple
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Synergy of two sizes of fibres:
Activation of bond microcracking micro-reinforcement
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Shear/ no place for fibres! Modified compact grading
Optimum Mix Modified Mix:Compactness:
®
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MASS (WEIGHT) OF BEAMS
kg/lineal meter 140 112 467 530
Equal Load Carrying Capacity
Steel
Pre-stressed ReinforcedConcrete
STRENGTH
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0
5
10
15
20
25
30
35
40
45
50
0.0 0.5 1.0 1.5 2.0Deflection (mm)
Equi
vale
nt S
tres
s (M
Pa) Ductal
HPC 80
Flexural Strength
DuctalHPC
2,000 lb car on sheet of Ductal
7000 psi
0.5 1.0 1.5 2.0
0.04”
DUCTILITY
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Typical Values for Ductal® FM
195235MPa
Compressive Strength
(75 mm dia. X 150 mm length)
4045MPa
Flexural Strength(40 mm X 40 mm X 160 mm
bending test)
5760GPaE-Modulus
28 days(wet room curing)
3 days(incl. thermal treatment at
90oC for 48 hr)
Ductal FM(2% volume Steel Fibres)
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Typical Values for Ductal® FO
140150MPa
Compressive Strength
(75 mm dia. X 150 mm length)
3035MPa
Flexural Strength(40 mm X 40 mm X 160 mm
bending test)
5050GPaE-Modulus
28 days(wet room curing)
4 days(incl. thermal treatment at
60oC for 72 hr)
Ductal FO(4% volume PVA Fibres)
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DURABILITY
02 mmCarbonation
(depth of penetration)
0.020.5X10-12 m2/sChloride ion diffusion030010-6Post-curing shrinkage
1.22.75Index IAbrasion
(relative volume loss)
100%90%%Freeze-thaw
(residual E-mod after 300 cycles)
Ductal(2% Steel Fibers
90oC Thermal Treatment)
HPC(60 MPa)
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Capillary Porosity
X 1000
X100 000
DUCTAL
Silica Fume
CSH
Porosity(ml/100g)
Diameter of pores (nanometres)DUCTAL does not havecapillary pores
Ordinary Concrete has20 to 25% capillary poresinter-connected(source of permeablity)
High PerformanceConcrete (HPC)has 12 to 20% of capillary pores
X 1000
X100 000
DUCTAL
Silica Fume
CSH
Porosité(ml/100g)
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Impermeability :
X 1000
X100 000
DUCTAL
Silica Fume
CSH
DUCTAL doe not havecapillary pores
Coefficient of Permeability ( x 10-18 m2 )measured after drying at 105°C until constant mass :_______________________________________________________DUCTAL FM 0.01Granite 0.1High Performance Concrete 6Ordinary Concrete 35
Origin of the impermeability is foundthrough the absence of connectedpores, at the nanometric scale
DUCTAL x 100 000
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Ductal®
Productscan be
produced in a range of colors
and textures
Aesthetics
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SustainabilityLafarge is: • committed to continuous improvement in its
environmental performance. • a World Wildlife Fund (WWF) Conservation Partner,
working together to preserve biodiversity and restore the ecobalance of quarries and forests.
• a Wildlife Habitat Council Partner; helping to conserve wildlife habitats and preserve the environment for future generations
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Ductal:• Is partially manufactured from recycled
industrial by-products.• Reduces CO2 emission (compared to
conventional solutions) up to 75% over the life-cycle.
Environmental Advantages
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DUCTAL® PROJECTS
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Architectural Cladding
2.3 m x 1.9 m x 20 mm thickDuctal® FO Acoustical Panels2.3 m x 1.9 m x 20 mm thickPanels cast with rectangular holes.(15mm thickness; holes 15mm x 15mm.)
120 m2 of Ductal® FO Cladding Panels2.5 m x 1.6 m x 25mm thick
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Urban Furniture
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Industrial Applications
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Bridges
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Showcase Project:Shawnessy LRT Station
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Shawnessy LRT StationPrecaster: Lafarge (Calgary)Owner: City of CalgaryArchitect: Culham, Pedersen & Valentine (CPV)Ductal Volume: 80 m3
Description: Architectural roof over a pedestrianunloading area.
Advantages: Aesthetics, reduced maintenancelight weight system, fewer pilings,speed of installation, economics
5.62 m
5.1 m 6 m
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Ductal Components
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Forming / Casting / Demolding
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Canopy Production
Canopies Struts
Tie BeamsColumns
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Installing the Canopies
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Installed Canopies
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1-Scale Load-Testing at the U of C
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1-Scale Load-Testing at the U of C
- Full Wind Uplift
- full snow load
At full factored loads, maximum strains were60% of cracking strain
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“Ductal provided the ability to achieve the free-flowing form design of the canopies.”
Shawnessy LRT Station ArchitectEnzo Vicenzino
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Architect’sdream…
…to reality!
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“The material has rich poetic weight … it is bound to shatter a part of architects’ beliefs … The style of artistic structures is bound to change.”
Footbridge of Peace ArchitectRudy Ricotti
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Architect’sdream…
…to reality!
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The End
Visit our web site at:www.imagineductal.com
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Bus SheltersLafarge’s Precast team in Winnipeg has produced the world’s first Ductal®
bus shelters.
Eight single-seat bus shelters ordered by the City of Tucsonwere designed to protect waiting passengers from extreme sun and heat.
During the pre-qualification process, the Ductal prototype was compared to six shelters built from other construction materialsand selected as the best solution.
This is the first project in North America to use white Ductal premix with organic fibers.
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Collaborator: Bouygues ConstructionRenovation of cooling towers.Interest: gains in weight; durability from steam & freeze/thaw.
Cooling Towers at Cattenom
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Joppa Clinker Silos - Joppa, IL
24 Precast Ductal Roof Panels- 4300 pounds each - 120 sq.ft./panel
X-Section
Plan
Penthouse
Collaborator: Strudes
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Production at the Precast Plant
Thermal Treatment
Casting
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Installing the Panels
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Steel vs Ductal:- Roof
Construction Schedule
Table I : Comparison of the Roof Installation Schedule.Item Steel Roof (days) Ductal Roof (days)Pre-Erection Survey 2 1Pre-erection set-up (cranes & scaffolding) 5 1Installation of Penthouse Floor( Temporary Compression ring)
1 1
Installation of Ductal® panels - 3Grouting of Ductal® Panels - 5Installation of Steel Roof Framing 12 -Installation of Steel Roof Deck(M embrane) 10 -Grouting Steel Base Plates for beamsat top of Silo walls.
1.5
Installation of Closure Ring & Flashing for SteelRoof Deck(M embrane)
3.5 -
Total (Construction days) 35 11
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ColumnsPrecaster: Lafarge, WinnipegDuctal Volume: 52 yd3
Owner: Lafarge GL Cement DivisionCollaborator: LCM PrecastDescription: 4- 2.5 ft x 2.5 ft x 55 ft long columns to
support a new cement silo in the truck loading bays below the silo.
Advantage: Increased clearance & access for trucksIncreased rental space for officesReduced construction time
Prototyping: First castings of a 10 ft x 2.5 ft x 2.5 ft section cast to confirm
the casting methodology and to determine the thermal gradients.
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SherbrookeSherbrooke Bridge Bridge -- Quebec, CanadaQuebec, Canada
Constructed in 1997
6 Precast Segments of 30 ft
Total 190 ft span
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Construction: Transporting, lifting and positioning of Precast segments
•erection in 1 day!
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BridgeBridge-- Seoul, KoreaSeoul, KoreaA A precastprecast segmental 6 @ 65 ft, presegmental 6 @ 65 ft, pre--stressed double teestressed double tee
14 ft
1.2 inchesDeck
X - Section
400 ft
3.6 ft
Collaborator: Bouygues Construction
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6’’
6’’
6’’
15’’
3’’
7spaces @ 2’’
18’’2’’
2’’
3 spaces@ 2’’
270 KSI Low Relax
De-bond 50% of strand
26 –1/2’’ Diameter
Strands.Pre-Stress to 80%Of Ultimate Load.
At each end for 36’’
6’’
AASHTO TYPE II BEAM80’0’’ in length
Material Specifications :1) Ductal®:
Minimum Compressive Strength at Release = 12000 psiMinimum Compressive strength at the end of thermal treatment = 23000psi
2) Low Relaxation StrandsUltimate Tensile Strength = 270KSI
12’’
U.S. FHWABridge
Program
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Comparison of Allowable Spans
3’-0”
Maximum of 50’-0” Clear Span
Conventional AASHTO Type II Beam:
3’-0”
80’-0” Clear Span
AASHTO Type II Ductal Beam:®390 plf
4’-6”
80’-0” Clear Span
Requires AASHTO Type IV Beam:822 plf
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Preparing the Girders for TestingCASTING:October 2000 - Prestress Services Inc, Lexington, KY
SET-UP:January 2001 –Turner Fairbanks Research Center, FHWA, McLean, VA
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Testing Measurements
Load = 150 KipsDeflection = 12”
Predicted Load-Deflection based on design calculations using the material properties of Ductal Prism Tests.
Actual Load-DeflectionResults @mid-span& quarter-spans
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AASHTO Type II Girder Test - Bending & Shear
Load = 150 KipsDeflection = 12”
Shear Test
Enhanced image of welldispersed micro-cracking
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Load - Deflection Test Results
-20
0
20
40
60
80
100
120
140
160
180
200
0 5 10 15 20 25
Deflection Mid-span (inches)
Load
(Kip
s)
Load Deflection Curve - Shear AASHTO TII Ductal
-100
0
100
200
300
400
500
600
0 0.5 1 1.5
Deflection at Load Point (inches)
Load
(Kip
s)
Bending Test