sustainability with ultra high performance and geopolymer ... · cost of building (ringgit...

Sustainability with

Ultra High Performance and

Geopolymer Concrete Construction

Workshop: Innovative Materials & Techniques in Concrete Construction, Corfu (GR), Oct. 2010

Professor Stephen Foster

Mr. Tian Sing Ng

Centre for Infrastructure Engineering and Safety

The University of New South Wales, Australia

Dr. Yen Lei VooDura Technology, Malaysia

Presentation OutlinePresentation Outline

�Introduction

�Sustainability design concepts

�Examples

�Concluding remarks

IntroductionIntroduction

“Design criteria are given with relation

to reliability, functionality, durability and

sustainability, where the last category is sustainability, where the last category is

in the state of development.”

Preface Model Code Draft, Walraven, Convener fib SAG5

UltraUltra--High Performance ConcreteHigh Performance Concrete

� Highly homogeneous

cementitious based

composite without coarse

aggregates.

� Strong, durable and

Immediate Cost

Saving

Longer Service

Life

Reduce Global Reduce

Minimal or Negligible

Maintenance

� Strong, durable and

ductile

� Suitable for use in the

production of precast

elements Towards sustainable Towards sustainable Towards sustainable Towards sustainable Towards sustainable Towards sustainable Towards sustainable Towards sustainable construction with RPCconstruction with RPCconstruction with RPCconstruction with RPCconstruction with RPCconstruction with RPCconstruction with RPCconstruction with RPC

Global Warming Potential

Reduce Use of

Material

Sustainable Construction

Remarkable Life-Cycle

Cost Saving

Reduce Construction Time & Risk

Geopolymer ConcreteGeopolymer Concrete

� Contains No Portland cement

� Alkali activation of industrial

aluminosilicate waste materials

such as fly ash and slag

� Low shrinkage and creep,

Sustainable Construction

Longer Service

Life

Reduce Global

Warming Potential

Low Carbon Emission

Minimal or Negligible

Maintenance

� Low shrinkage and creep,

superior chemical resistances

� Moderate to low elastic modulus

for its strength

� Suitable for use in the production

of precast elements for civil and

structural engineering.

Towards sustainable Towards sustainable Towards sustainable Towards sustainable Towards sustainable Towards sustainable Towards sustainable Towards sustainable construction with Geopolymer construction with Geopolymer construction with Geopolymer construction with Geopolymer construction with Geopolymer construction with Geopolymer construction with Geopolymer construction with Geopolymer

ConcreteConcreteConcreteConcreteConcreteConcreteConcreteConcrete

Potential

Reduce Use of Virgin Material

Recycle Industrial

Waste

Remarkable Life-Cycle

Cost Saving

Sustainability Design ApproachSustainability Design Approach

Environmental

Impact Calculation

Environmental

Impact Calculation

DurabilityDesign

DurabilityDesign

Three criteria for assessment of a sustainable design:

� Environmental impact calculation

• Embodied energy; and

• 100 year Global Warming Potential

Limit States

Design

Limit States

Design

SLS

ULS

Stability

� Design for longevity (i.e. durable structures), and

� Limit states design.

• Serviceability limit state;

• Stability limit state; and

• Ultimate limit state

Measure of optimisation of the materials used with respect to

the embodied energy (EE), CO2 emissions & global warming

potential (GWP) benchmarked against existing practice.

Environmental Impact Calculation (EIC)Environmental Impact Calculation (EIC)

20 year Global Warming Potential:


20-year GWP = CO2 + 289 NOx + 72 CH4



100-year GWP = CO2 + 298 NOx + 25 CH4

Ref: 2007 International Panel on Climate Change Fourth Assessment Report (AR4)

50-year GWP = CO2 + 294 NOx + 42 CH4

* Hydrofluorocarbon and sulphur hexafluoride gases are excluded from the above

equations as there are not emitted in concrete industry.

100-years is the most commonly used time horizon for

GWP assessment:

Environmental Impact Calculation (EIC)Environmental Impact Calculation (EIC)

Environmental Impact Calculation Data SheetEnvironmental Impact Calculation Data Sheet

100-year GWP = CO2 + 298 NOx + 25 CH4

Example 1 : Example 1 : Single Span 40m Concrete Road BridgeSingle Span 40m Concrete Road Bridge

Bridge width: 15 m

Imposed live load: Load models 1 - 4 with special vehicle 1800/150 (EC1-Part 2)

Design life: 120 years at EC2 exposure class XS1 (exposure to airborne salt).

Concrete Road BridgeConcrete Road Bridge

FULL WIDTH 15000

WALKWAY

2500

WALKWAY

2500

CARRIAGEWAY

10000

200mm THK. RC DECK

50mm THK ASPHALT (1 kPa) RC PARAPET

(9.22kN/m)

WALKWAY

9 kN/m

I – Girder section for Portland

cement and geopolymer concreteU – Girder section for RPCvs

100 100 100 100

92.1100

Co

nve

nti

on

al M

eth

od

(O

PC

co

ncre

te)

as 1

00

OPC Concrete RPC Geopolymer Concrete

- 7 Nos. girders, each weighs 21.5kN/m

- Prestressed & steel reo to carry shear

force and transverse moment

- 3 Nos. girders, each weighs 22kN/m

- Prestressed & steel fibres to carry shear


5000 5000

FULL WIDTH 15000

2500 2500

WALKWAY

2500

WALKWAY

2500

CARRIAGEWAY

10000

200mm THK. RC DECK

50mm THK ASPHALT (1 kPa)

UHPdC U-GIRDER

(G = 22 kN/m)

RC PARAPET(9.22kN/m)

1950

200mm THK. RC DECK

CONVENTIONALSUPER-TEE GIRDER

(G = 21.5 kN/m) 2325

2250 2250 2250 2250 2250 2250

CONVETIONAL METHOD (VIEW A-A)

UHPdC METHOD (VIEW B-B)

WALKWAY

9 kN/m

62.5

80.377.1

79.7

92.1

80.082.6

59.6

0

20

40

60

80

Mass of Material(excluded Waste

Product)

Embodied energy CO2 Emission 100 yr GWP

Co

nve

nti

on

al M

eth

od

(O

PC

co

ncre

te)

as 1

00

B

ase

lin

e In

de

x

Environmental Impact CalculationEnvironmental Impact Calculation

Concrete Road BridgeConcrete Road Bridge

Australian Super – T Girder section

for Portland cement and

geopolymer concrete

U – Girder section for RPCvs


- Prestressed & steel reo to carry shear



- Prestressed & steel fibres to carry shear


WALKWAY 2500

CARRIAGEWAY 10000

WALKWAY 2500

FULL WIDTH 15000

50mm THK ASPHALT (1 kPa) RC PARAPET(9.22kN/m)

WALKWAY9 kN/m 100 100 100 100


Environmental Impact CalculationEnvironmental Impact Calculation5000 5000

FULL WIDTH 15000

2500 2500

WALKWAY 2500

CARRIAGEWAY 10000

RPC U-GIRDER

(G = 22 kN/m)1950

CONVENTIONALSUPER-TEE GIRDER

(G = 17 kN/m)

CONVENTIONAL METHOD (VIEW A-A)

RPC METHOD (VIEW A-A)

2500 2500 2500 2500 2500

2000

WALKWAY 2500

200mm THK. RC DECK

(9.22kN/m)9 kN/m

200mm THK. RC DECK

50mm THK ASPHALT (1 kPa) RC PARAPET

(9.22kN/m)WALKWAY9 kN/m

100 100 100 100

79.2

86.5 88.090.692.0

84.3 86.0

65.3

0

20

40

60

80

100


Product)


Co

nve

nti

on

al M

eth

od

(O

PC

co

ncre

te)

as 1

00

B

ase

lin

e In

de

x

Example 2 : Example 2 : 1.5m high Retaining Wall1.5m high Retaining Wall

Design Load: 10 kPa (service); 15 kPa (ultimate)

WallWall

CROSS SECTION

750

100MM CHAMBER

30

30

1000

100

100

50

50

1500

25 25 kPakPa Surcharge LoadingSurcharge Loading

100 100 100 100

24.3

52.7

60.164.8

90.8

75.3

81.0

42.7

0

20

40

60

80

100


Product)


Co

nven

tio

nal M

eth

od

(O

PC

co

ncre

te)

as 1

00

Baseli

ne In

dex


Conventional RPC – DURA®


Benefits of High Performance MaterialsBenefits of High Performance Materials

� Reduction in overall consumption of non-renewable

raw materials;

� Encourage the use of recycled materials;

� Higher quality and finishes of finishing products;� Higher quality and finishes of finishing products;

� Longer service life with a minimum of maintenance

� Final products that have reduced total CO2

emissions, reduced EE, and reduced GWP providing

a better utilisation of materials

RPC Portal Frame SystemRPC Portal Frame System(Dura Technology, Malaysia)(Dura Technology, Malaysia)

RPC Portal Frame SystemRPC Portal Frame System

84.1 87.1

76.381.4 83.8

0

20

40

60

80

100

120

Cost Material (ton) Embodied

Energy

CO2 Emission 100 yr GWP

Ba

se 1

00

% f

or

Ste

el P

ort

al

Fra

me

Steel Portal Frame Dura Portal Frame

Energy


Table 1 – Material quantities and EIC for Example 2.

Conventional Steel

Portal Frame System

DURA®

-UHPdC

Portal Frame System

Raw Material (tonne)↑ 1403 1222

Steel (tonne) 116 80

Cement (tonne) 158 192

Embodied Energy (GJ) 3707 2830

CO2 Emission (tonne) 417 340

100-years GWP (tonne) 946 793

Cost of building (Ringgit Malaysia) 722,728 (year 2007) 608,052 (year 2008)

↑ total mass of material consumption for the portal frame, metal roofing, purlins, lateral and cross bracing,

bolting, stiffeners, wall cladding, reinforced concrete slab and beams and pile caps (but excluded piling).

Material Quantities, EIC & CostMaterial Quantities, EIC & Cost

RPC Wall SystemRPC Wall System(Dura Technology, Malaysia)(Dura Technology, Malaysia)

19

RPC Wall SystemRPC Wall System(Dura Technology, Malaysia)(Dura Technology, Malaysia)

20

Advances in Concrete TechnologyAdvances in Concrete Technology

Lightweight Geopolymer Concrete @ UNSWLightweight Geopolymer Concrete @ UNSW

� Mix design: fly ash, slag, sodium hydroxide, sodium

silicates solution, water, sand &

cenospheres.

Basic Material PropertiesBasic Material Properties

Plain 1% Steel Fibres 2% Steel Fibres

Dry density ρ (kg/m3) 1680 1700 1800

Compressive strength fcm (MPa) 64.6 60.8 72.2

Modulus of Elasticity E (GPa) 13.1 13.5 17.9

Indirect tensile test fct.sp (MPa) 2.4 6.7 8.0

Basic Material PropertiesBasic Material Properties

Testing:Testing: Lightweight Geopolymer Concrete BeamLightweight Geopolymer Concrete Beam

200

50

10

0

120

55

3 x 7.4φAFRP

Technora

Rod

AFRP

StrengthenedCore

CrossCross--Section: Section: AFRP Strengthened Core BeamAFRP Strengthened Core Beam(AFRP Core = Hand Lay(AFRP Core = Hand Lay--up of 3 layers of Kevlarup of 3 layers of Kevlar®®--49 49

Experimental Test SetupExperimental Test Setup2000.0

1600.0

533.5 533.0 533.5

LVDT 1roller support

pin support

Load (P)

spreader beam

beam

specimen

All dimensions are in mm

LVDT 2 LVDT 3

200

50

100

120

55

Polystyrene

Foam as

sacrificial

form

(AFRP Core = Hand Lay(AFRP Core = Hand Lay--up of 3 layers of Kevlarup of 3 layers of Kevlar®®--49 49 300gsm Biaxial sheets with vinyl300gsm Biaxial sheets with vinyl--ester resin) ester resin)

CrossCross--Section: Section: Hollow Core BeamHollow Core Beam

Experimental Test SetupExperimental Test Setup

Lightweight Geopolymer Concrete BeamLightweight Geopolymer Concrete Beam

60

80

100

120

Loa

d,

P (

kN

)

2% vol. Steel 2% vol. Steel FibresFibres & &

AFRP Strengthened Core AFRP Strengthened Core

BeamBeam

Plain & AFRP Plain & AFRP

0

20

40

0 10 20 30 40 50 60 70

Loa

d,

P (

kN

)

Mid Deflection (mm)

Plain & Hollow Plain & Hollow

Core BeamCore Beam

1% vol. Steel 1% vol. Steel FibresFibres & &

AFRP Strengthened Core AFRP Strengthened Core

BeamBeam

Plain & AFRP Plain & AFRP

Strengthened Core Strengthened Core

BeamBeam

Lightweight Geopolymer Concrete BeamLightweight Geopolymer Concrete Beam

Failure Load = 14.3 kN

Plain & Hollow Core BeamPlain & Hollow Core Beam


Plain & AFRP Strengthened Core BeamPlain & AFRP Strengthened Core BeamPlain & AFRP Strengthened Core BeamPlain & AFRP Strengthened Core Beam


1% vol. Steel 1% vol. Steel FibresFibres & AFRP Strengthened Core Beam& AFRP Strengthened Core Beam


2% vol. Steel 2% vol. Steel FibresFibres & AFRP Strengthened Core Beam& AFRP Strengthened Core Beam

� Environmental Impact Assessment calculation show that high

performance materials and “green materials” are able to

provide savings in terms of primary material consumption,

embodied energy, CO2 emissions and global warming potential.

� High performance materials open the door for new, innovative,

design approaches that can lead to more sustainable structures

Concluding Remarks Concluding Remarks

design approaches that can lead to more sustainable structures

that provide for lower life-cycle costs.

� Objective, simple, metric measures such as embodied energy

(EE) and 100-year global warming potential (GWP) enable

designers to evaluate, quantify and compare the environmental

implications of their designs.

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