1. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
L Carbon Concretes (L
ow
CC)
using novel mineral binders as cement substitutes
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3
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2. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
LCC - what does it mean?
Advanced normal concrete, specifically engineered with reduction of greenhouse
gas emissions – mainly CO2 - in mind with respect to
• Choice of concrete materials
• Design and manufacturing of concrete
• Materials and concrete transport
Build up concrete constructions with higher functionality, longer lifetime and
reduced effort for maintenance and repairs
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3. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Why LCC?
Concrete is the world‘s most
consumed man-made material.
Portland cement is the essential
constituent of nearly all concretes.
The demand and consumption of
concretes and cements are constantly
increasing.
CO2-emissions derived from concrete
Cement manufacturing leads to release
of 2,9 billion tons of greenhouse gases
per year (2011), mainly CO2.
In 2050 cement production will
cause >10% of total CO2-release.
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3
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4. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Evaluation of concrete products: An integrated approach
Standards & Directives, Market
Sustainability
New additional assessing criterias for products
Applicability
durable
resource-efficient
reusable
non-polluting
Product
Efficiency
Feasibility
Costs, Prices, Revenues
Engineering, Materials,
Know-how, Staff skills
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3
New materials and advanced technologies
in concrete productions
Lowest carbon footprint product
(Concept of LCC)
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5. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Development strategy for Low Carbon Concretes
Partial substitution of
conventional materials
•
•
•
Unchanged product
Unchanged technology
Innovative potential within
material only
Complete substitution of
conventional materials
•
•
•
Competitive product
Unchanged or modified technology
Innovative potential within material
and technology
New products with new
materials
•
•
•
Novel product
Modified or new technology
Innovative potential within
material, technology and
final product properties
Development efforts (time, cost, staff)
Degree of innovation
Sustainability (low carbon footprint)
Potential of profit
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3
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6. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Low Carbon Concrete for sustainable building
Traditional approach
Consume less concrete
New approach
Use novel binders to
replace cement
Innovative architecture and structural design (HPC)
Consume less cement
bifam
ent
Concrete mix design and modified technical requirements
Consume less clinker
Advanced cement technology (blended cements)
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3
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7. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Blended Cements to reduce carbon footprint
German cement market (2002-2012)
Development
Overall market share
Pure OPC (CEM I)
-43%
56%
29%
Blended OPC with single SCMs
up to 35% (CEM II)
+62%
30%
48%
Blended OPC with several SCMs
up to 35% (CEM II) or
with single SCM up to 95% (CEM III)
+112%
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11%
22%
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8. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
bifam - a novel binder with zero carbon footprint
ent
EW
N
specially developed and processed mineral binder, which
• consists of industrial by-products only (100% cement-free!),
• contains up to 100% of pretreated, hydraulic lignite fly ash,
• has binding properties like cement
is added to concrete as reactive mineral powder replacing
• conventional fillers to 100%,
• conventional cements from 30 up to 100%
with no restrictions on properties of concrete products
stand alone mineral binder for concretes in competition to conventional cements
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3
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9. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Emission of CO2 during production process
CO2-release (kg/t)
Quelle (Zementdaten): Staatl. Forschungsstelle für Energiewirtschaft München – Ganzheitliche Bilanzierung von Grundstoffen und Halbzeugen (1999)
bifam
ent
will be manufactured with
no release of CO2
in contrast to cements!
0 kg/t CO2 !
bifam
ent
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10. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
bifam lowers the carbon footprint of concrete products
ent
Quelle (Zementdaten): Staatl. Forschungsstelle für Energiewirtschaft München – Ganzheitliche Bilanzierung von Grundstoffen und Halbzeugen (1999)
CO2-release (kg/t)
up to 94% less CO2-release
if substituting cements by bifam
ent
Example: Concrete paving blocks
Cement
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3
bifam
ent
bifam
ent
bifam
ent
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11. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Specific characteristics of bifam
ent
Contains typical components of cements, slags and fly ashes initially by origin
 composition and materials behavior are similar to a supersulfated cement
Self-hardening
 need no activators (alkalis, cement, lime ...)
Free of shrinkage
 no particular precautions for preventing cracks (joints, fibres)
Properties can be customized by selected composition and degree of processing
 different qualities designed to individual application or product
Material behavior in concrete production is similar to cements
 requires no technical changes within production process
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12. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
The bifam -project
ent
Basic scientific research
and development
since 1998
Applied research
and suitability tests
since 2000
• Foundation of production
and sales company in 2011
• Installation of production
facility in 2013/14
Application tests
and optimization
since 2005
Long term experiences in
fly ash processing and
material behavior in practice
since 1994
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From 2014:
• Product implementation on
customers site
• Quality assurance in production
• Continual product development
• Product approvals
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13. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Industrial application example 1: Manufacturing of paving blocks
- High-volume cement substitution by bifam ent
Strength development
Increase in product quality
at lower production costs
up to
36 %
or
Maximum potential reduction
in cement consumption and
mixture costs
at equal product quality
more than
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3
50 %
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14. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Industrial application example 1: Manufacturing of paving blocks
- Improvement of frost resistance -
Traditional mix without bifam
ent
Lo w Ca rbo n Co nc re te s – De lft, 3 1 . 1 0 . 2 0 1 3
Advanced mix with partial substitution
of cement by bifam
ent
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15. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Industrial application example 2: Manufacturing of masonry blocks
- Complete cement replacement by bifam ent
Strength development
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16. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
Outlook
Commissioning of production plant in 2014
 Availability of bifam up to 150.000 tons per year
ent
Few custom projects have already been started in Germany
 Concrete goods, civil engineering products, ground and road construction
Several pilot projects for German market are being prepared
 Concrete repair, flood protection, immobilization
Looking for additional projects abroad
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17. Ze ro Ca rbo n Ce m e nt Subs titute s fo r Co nc re te
The University of Queensland‘s Global Change Institute (GCI) Australia
World‘s first building made from cement-free concrete for structural construction
Photography by Angus Martin
Thank you for your attention!
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