Geopolymer Concrete Ready Mixed: a Challenge Fifth International Slag Valorisation Symposium TU Leuven, 3-5 April 2017 Peter de Vries, FICT ENCI BV – HeidelbergCementGroup Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Why pilot projects in the Netherlands? In the Netherlands, environmental sustainability is of high importance Focus on `green` is major task on cementindustry Geopolymer binders are low in CO2 Leuven, 2017-04-03 Ing. Peter de Vries, FICT

The Cooperation Infrastructure project OV SAAL Leuven, 2017-04-03 Ing. Peter de Vries, FICT

HC 14/04 Field trial on geopolymers in the Netherlands Objectives examine the technical feasibility of producing elements made of wet system geopolymer binder examine the technical feasibility of producing elements made of dry system geopolymer binder examine the durability of elements made of geopolymer binder examine the market potential of elements made of geopolymer binder Leuven, 2017-04-03 Ing. Peter de Vries, FICT

L - Elements to be produced Reference mix Dry binder geopolymer Wet binder geopolymer Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Requirements on concrete strength class C35/45 15 MPa compressive strength @ 2d for unmoulding no air entrained concrete Dmax 32 mm required workability time: 60 minutes (30 minutes of transport and 30 minutes of casting) targeted workability: S3 (100 - 150 mm), F4 (490 - 550 mm) Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Main Challenge: fresh concrete, open time is crucial Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Distance Mebin RMX-plant - OV-SAAL Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Direct comparison of consistency (open time) Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Modifications of the batching plant Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Extended loading time due to slow dosing of dry binder 19:00h - 19:50h Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Protection on site : dry- binder 22-09-2014 Arrival on site: 20:22h Break down: 20:33h 14.04.2016 Ing. Peter de Vries, FICT

Ten minutes later: we had to stop and…… Ten minutes later: we had to stop and……. we succeeded in saving the truckmixer Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Prevention on site: gravel and water and silo Leuven, 2017-04-03 Ing. Peter de Vries, FICT

De-molding of first element Dry-binder Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Adjustments to prevent a second failure Introduction of compressed air on silo`s dry binder Extra check on raw materials and chemicals by verification in laboratory Rotterdam Conclusion: there is no need to change the recipe 2 truckmixers Concrete chute and funnel for placing were improved More pokervibrators on site 14.04.2016 Ing. Peter de Vries, FICT

Second trial Dry Binder 06–10-2014 Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Second trial Dry Binder 06–10-2014 Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Wet binder: Precautions taken are succesfull Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Elements in position near Motorway A10, Amsterdam 14.04.2016 Ing. Peter de Vries, FICT

Analysis on concrete properties: - mechanical - durability Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Strength development L-elements Initial testing   L-elementen sterkteklasse C35/45 Druksterkte voorvoorspannen Na 5 uur Na 24 uur -- Druksterkte voor ontkisten na 48 uur 15 MPa Verwerkbaarheid Vloeimaat F4 (490-550mm) Open tijd 90 minuten Result Field Trial Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Vaseline is better than common release agent as SIKA AR 1 Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Carbonation on cores Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Chloride migration using RCM- method Rapid chloride migration (RCM) Question: Is RCM the right test method ?? or ……… 14.04.2016 Ing. Peter de Vries, FICT

Electrical resistivity (using TEM-method) Fieldtrial 1 Fieldtrial 2a Fieldtrial 2b Fieldtrial 3 (Ω.m) (reference) (dry binder) (wet binder)   15-09-14 22-09-14 06-10-14 20-10-14 age 28d 91d 184d - 182d 183d 172d cube 1 209 442 459 10 29 179 14 58 171 cube 2 204 369 428 8 42 134 13 56 167 cube 3 212 407 444 53 194 15 55 145 cube 4 232 346 509 12 48 108 37 197 cube 5 226 373 449 113 156 cube 6 405 465 186 84 239 avg 216 390 11 47 162 67 st.dev 34 28 2 1 27 Conclusion: Correlation between RCM and TEM also valid for Geopolymer Concrete HC 14/04 - SC meeting - Martina Dietermann 14.04.2016 Ing. Peter de Vries, FICT

Freeze-thaw resistance , with and without de-icing salts Test limit for the scaling on concrete products under freeze-thaw with the de-icing salt is 1000 g/m2 after 56 cycles Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Surface damage Dry binder after 18 month HC 14/04 - SC meeting - Martina Dietermann Leuven, 2017-04-03 Ing. Peter de Vries, FICT

Conclusions Handling of geopolymer concrete in RMC succeeded: geopolymer concrete was transported over 30 minutes and subsequently cast, emergency measures were effective, Health & Safety issues were mastered. Main challenges for development on geopolymer concrete: elimination of stickiness robustness of fresh concrete general durability needs to be intensively examined freeze thaw resistance appears to be a major drawback Lack of regulations makes broad application difficult. Clear figures on LCA of activators are not available (yet) Leuven, 2017-04-03 Ing. Peter de Vries, FICT

CLIFF HANGER: Hollow Core Slab VBI – March 8, 2016 Sensata Building Hengelo, the Netherlands HC 14/04 - SC meeting - Martina Dietermann Leuven, 2017-04-03 Ing. Peter de Vries, FICT