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Dave Flax – Euclid Chemical

Business Development Group

Manager Southwest Region

[email protected]

858-405-0356

MINING APPLICATIONS SEAoA June 18, 2015

Make Better Concrete

• Reduce Shrinkage and Cracking

• Corrosion Inhibitors to protect rebars

• Synthetic Macro Fibers to get rid of steel in SOG, shotcrete, CMD, & toppings

Withstand Heavy-Duty Mine Abuse

• Iron Aggregate Products for high abrasion & impact resistance

• Grouts for dynamic loading

• Coatings and Linings for chemical protection

Dave Flax

Civil Engineering Degree from RPI

Over 35 years experience with concrete

Years as a Field Engineer

Years with a contractor

Years with the Corps of Engineers

doing research

Published dozens of articles

Specialized in concrete

Earned CDT and CCPR from CSI

Spent 10 years calling on the copper mines

CONCRETE WITH

REDUCED SHRINKING,

CRACKING, AND CURLING

COARSE AGGREGATE

Provide largest topsize coarse aggregate available that

meets the following constraints:

• 1/5 of narrowest dimension between sides of forms.

• 1/3 of depth of slab.

• 3/4 of minimum clear distance between reinforcing

bars or between bars and forms, whichever is least.

Coarse Aggregate

MORE & LARGER COARSE AGGREGATE

MEANS LESS SURFACE AREA

AND LESS SPACE TO FILL

WHICH MEANS LESS PASTE

WHICH MEANS LESS CEMENT

WHICH MEANS LESS WATER

WHICH MEANS LESS EXCESS WATER

WHICH MEANS LESS SHRINKAGE

WHICH MEANS LESS CRACKING & CURLING

SHRINKAGE REDUCING ADMIXTURES

Capillary Pore Stress

Stress = Cracks

Shrinkage Reduction

-0.035

-0.03

-0.025

-0.02

-0.015

-0.01

-0.005

0

0 7 14 21 28 35 42 49 56

Time (days)

Le

ng

th c

ha

ng

e (

%)

Reference

SRA 1

SRA 2

Cement 517 lb/yd3

Water 255 lb/yd3

Fine aggregate 1450 lb/yd3

Coarse aggregate 1700 lb/yd3

WR 3 oz/cwt

AEA 1.65 oz/cwt

SRA 2% by

cementitious

Example

SHRINKAGE-COMPENSATING

CONCRETE

FINAL LENGTH

Potential

Expansion

Actual

Expansion

CONCRETE REBAR, MACRO FIBERS, or CABLE

ORIGINAL LENGTH

TYPICAL SLABS 200’ by 250’ 50,000ft2

Shrinkage-Compensating

1,550 lf of joints

SAVED 6,000 LF OF JOINTS

Portland Concrete

7,550 lf of joints

Joints 12.5’ x 12.5’ Joints 50’ x 50’

WELL OVER

A MILE

Abrasion

Resistance

Increased

30-40% per ACI 223R-10

TYPICAL APPLICATIONS

Parking Garage

Secondary Containment

Water Treatment Tank

Repair Topping

Loading Dock Retail

Metal Deck

TYPICAL COPPER MINE USES:

• Where cracks will allow chemical infiltration

• Tanks

• Secondary containment

• Where cracks and joints will chip and spall

from physical abuse

• Where flat floors without curling are desired

• Pretty much all concrete

CORROSION INHIBITING

ADMIXTURE

Phelps Dodge

El Paso, TX

Asarco Copper

Hayden, AZ

• Corrosion expands 400 - 800%

• Lose bond

• Delamination

• Lose cross sectional area

• Lose load bearing capacity

Consequences of Corrosion

I should’ve

listened to

Dave !!!

Corrosion Inhibiting Admixtures:

• Calcium Nitrite reacts

• Creates a passivity layer

• Delays the onset of corrosion

• Decreases the rate of corrosion

• Increases the service life of the structure


• Where water and chemicals can cause

corrosion of rebars

• Just about everywhere in the mine

SYNTHETIC MACRO FIBERS

We should have used Synthetic Macro Fibers

Fiber Development

After

Mixing

Before

Mixing

Fiber ends fray during mixing

to improve bond with concrete

10 mil

crack

FEDEX in North Phoenix

5 pcy Synthetic Macro Fibers

Slab Design Software

Slab Design Software

Dosage

Recommendation

This is the process

that is mandated in

the Slab Design

Document TR34

which is where the

ACI 360 derives its

calculations.

Resolution Copper Mining, Superior, Arizona

One of the largest copper resources in North America

Copper is more than a mile below the surface

Two 7,000 foot deep shafts to start

10 pcy


• Where water and chemicals can cause

corrosion of rebars

• Slabs on grade

• Toppings

• Tunnels

• Shotcrete

• Composite metal decks

DRY SHAKE HARDENERS

Moscone Convention Center in San Francisco

Phelps Dodge Warehouse – Morenci, AZ

Relative Abrasion Resistance ASTM C-779

Liquid

Densifier

Mineral

Aggregate

Shake

Nonoxidizing

Metallic

Aggregate

Shake

Metallic

Aggregate

Shake

800

100

200

600 Percent

of

Reference Plain

Concrete

Boeing – South Carolina


• Warehouses

• Shops

• Labs

• Where abrasion resistance is required

• Where light reflectivity is required

IMPACT RESISTANT FLOORS

Relative Abrasion Resistance

ASTM C-779

Liquid

Densifier

Mineral

Aggregate

Shake

Nonoxidizing

Metallic

Aggregate

Shake

Metallic

Shake or

Iron

Aggregate

Topping

800

100 200

600 Percent

of

Reference Plain

Concrete

2” cube

4,000 psi

concrete

10,000 psi

concrete

with emery

12,000 psi

cementitious

topping

with iron

aggregate

18,000 psi

cementitious

topping

with iron and

natural

aggregate

2” cube

4,000 psi

concrete

10,000 psi

concrete

with emery

12,000 psi

cementitious

topping

with iron

aggregate

18,000 psi

cementitious

topping

with iron and

natural

aggregate

2” cube

4,000 psi

concrete

10,000 psi

concrete

with emery

12,000 psi

cementitious

topping

with iron

aggregate

18,000 psi

cementitious

topping

with iron and

natural

aggregate

2” cube

4,000 psi

concrete

10,000 psi

concrete

with emery

12,000 psi

cementitious

topping

with iron

aggregate

18,000 psi

cementitious

topping

with iron and

natural

aggregate

2” cube

4,000 psi

concrete

10,000 psi

concrete

with emery

12,000 psi

cementitious

topping

with iron

aggregate

18,000 psi

cementitious

topping

with iron and

natural

aggregate

LA Rattler: 2” cubes of material, 2” steel balls, rotate slowly for 2,000 cycles

Cyprus Copper

San Manuel, AZ

Asarco Copper

Hayden, AZ

Magma Copper

Miami, AZ

Asarco Copper

Ray, AZ


• Anode storage areas

• Tracked vehicle maintenance shop floors

• Moly crushing areas

• Loading docks

• Scales

• Copper recycling areas

• Smelter floors

• Launderers

• Sluiceways

• Wooden flumes

• Setting panels in ball and rod mills

• Mills floors

• Anything and everything that takes a beating

CEMENTITIOUS GROUT

Cementitious

grout - the

way it

should be!

Cyprus Copper - Bagdad, AZ

Asarco Copper

Ray to Hayden

EPOXY GROUT

Magma Copper

San Manuel, AZ

DIFFERENCES BETWEEN

CEMENTITIOUS AND EPOXY GROUTS

Consistency:

• Cementitious Flows while Epoxy Oozes

Sticks to Base Plate:

• Cementitious Doesn’t while Epoxy Does

Compressive Strength:

• Epoxy has Higher Early and Ultimate

Creep:

• Epoxy Creeps More at High Temperatures

Dynamic Loading:

• Cementitious with Natural Aggregate is Good

• Cementitious with Iron Aggregate is Better

• Epoxy is Best


• Ball mills

• Rod mills

• Generators

• Tanks

• Equipment

• Rail chocks

• Radial ore stackers

• Cone crushers

• Etc.

COATINGS AND LININGS

Flake Filled Epoxy Novolac

Coating, Broadcast, or Trowel-Down

for Severe Chemical Attack like Tankhouses

FMI Copper

Morenci, AZ

Hycroft Mine

Winnemucca, NV


• Tank lining

• Columns under tank houses

• Floors under tank houses

• Floors subject to chemicals

• Grout shoulders

• Secondary containment

• Locker rooms

• Water treatment

• SX-EWs

• Etc.

When it comes to

construction its:

• The contractor’s

job to build it

• Your job to tell

them how in

the spec or GSN

• My job to help you

with product

selection and

the spec & GSN

Dave Flax – Euclid Chemical

Business Development Group

Manager Southwest Region

[email protected]

858-405-0356

Make Better Concrete

• Reduce Shrinkage and Cracking

• Corrosion Inhibitors to protect rebars

• Synthetic Macro Fibers to get rid of steel in SOG, shotcrete, CMD, & toppings

Withstand Heavy-Duty Mine Abuse

• Iron Aggregate Products for high abrasion & impact resistance

• Grouts for dynamic loading

• Coatings and Linings for chemical protection

MINING APPLICATIONS SEAoA June 18, 2015

mining applications seaoa june 18, 2015 - … · mining applications seaoa june 18, 2015 make...

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