baustoffdesign ff, svb, hsc - tu bergakademie...
TRANSCRIPT
Baustoffdesign
Thomas A. BIER
Institut für Keramik, Glas- und Baustofftechnik, Leipziger Straße 28, 09596 Freiberg,
BaustoffdesignFF, SVB, HSC
Baustoffdesign
Material
Chemie
Mineralogie
Feinheit (SO, PSD)
Zemente PZ, TZ, C$
Füllstoffe
Organische StoffeDispergierbare Pulver
Zusatzmittel
Material
Chemie
Mineralogie
Feinheit (SO, PSD)
Zemente PZ, TZ, C$
Füllstoffe
Organische StoffeDispergierbare Pulver
Zusatzmittel
Verfahren
Mischen und Erhärtung
DSP
TemperaturAutoklav
Trocknen
Pressen /ExtrudierenZiegel
KS Stein
Macro Defect Free
Dry Mortar Technology – Special MortarsOptimization of Rapid Hardening Grouts
Rheology of Self Leveling Underlayments
Redispersible Polymer Powders in Self Leveling Underlayments
Refractories - CastablesBehavior at Temperature
Corrosion against Slags
Self Compacting ConcreteRheology and Early Shrinkage
Mix Design and Placing Underground
High Strength ConcreteRapid hardening Mortars, Concrete
Geopolymers
Autoclaved {Calcium Silicate} MaterialsDrying of CS Material
BauteileZiegel
KS Stein
Macro Defect Free
Baustoffdesign
Dry Mortar Technology – Special MortarsOptimization of Rapid Hardening Grouts
Rheology of Self Leveling Underlayments
Redispersible Polymer Powders in Self Leveling Underlayments
Refractories - CastablesHydration behavior
Behavior at Temperature
Corrosion against Slags
Self Compacting ConcreteRheology and Early Shrinkage
Mix Design and Placing Underground
High Strength ConcreteRapid hardening Mortars, Concrete
Geopolymers
Autoclaved Calcium Silicate MaterialsDrying of CS Material
Baustoffdesign
Density <1T°C <1000
Density>1T°C 1000-1500
Density >1,5T°C 1500
Conventional
Hydraulically bonded
Insulating castables
RegularRodding
RegularVibration
Self flow
Rodding
LCC
Vibration Vibration
Self flow
NCC
Hydraulically bonded Chemically bonded
Dense castables
Refractory Castables
Castables discussed
ULCC
Introduction - The family tree for Refractory Castables
Rodding
Vibration Vibration
MCC
VibrationSelf flow
VibrationSelf flow
Conventional Deflocculated
Baustoffdesign
Cement Fillers AdmixturesCAC with Silica fume Dispersants
- 70% Al2O3 Reactive alumina - TPP, HMP- 80% Al2O3 Spinel - Darvan 7S
MgO - Castament FS10Retarders
- Citric acid- Tri sodium citrate- Boric acid
Accelerators- Li2CO3
- Na2CO3
The universe of raw materials
Only one aggregatetabular aluminaOnly one aggregatetabular alumina
Baustoffdesign
Introduction - Conception of conventional and deflocculated castables
Ultra finefiller
Aggregate1-5 microns
4m
Aggregate1-5 microns
Water
Conventional Castable Low Cement Castable
Baustoffdesign
Comparison of the formulations used
Tabular alumina 6 - 10(mesh) 1/4 - 8
8 - 1414 - 2828 - 48
- 48- 100- 325
Spinel (mm) 0,5 - 10,5 - 00,045
Silica FumeReactive AluminaMagnesia70% CAC80% CACWater
The castables studied
SP-1-33166-5--9410-7--105
SP-2-33166-5--9410-11-6-5
SPF-202510-12105---2853-5,5
CC--14131132---------3011,6
22-1019-29-----510-5-5
LCC/SFC22-1019-29-----612-2-5
ULCC
Baustoffdesign
Influence of admixtures 'LCC/SFC '
% Admixtures
% Water
Working Time
Flow value in % at ± minASTM T0
T15T30T45T60
Darvan 7S : 0,05%CT : 0,015%Na2CO3 : 0,005%
5
80
1301241149970
Sodium Hexameta-phosphate(HMP) : 0,025%
5
88
13012211311095
System 1 System 2
Baustoffdesign
Influence of cement type
0 15 3045
60Time (min) Secar 80HMP only
HMP 0,05 + AB 0,01D7S 0,05 + AB 0,020
50
100
150
200
250
Flow (mm)
Baustoffdesign
Results - Influence of fillers
Characteristics of reactive aluminas
015
3045 60
050
100150200250
Flow value(mm)
System 2 : Al-3System 2 : Al-2
System 2 : Al-1System 1
Reactive alumina andflow value in spinelcastables
Al-1 Al-2 Al-3
BET m2/g 2,6 - 3,1 7,0 3,3
Primary crystal size micron 0,5 - 3,0 - 0,5 - 3,0
D50 micron 2,0 - 2,5 0,6 1,5
Alumina % >99,8 >99,7 >99,8
Na2O % 0,06 0,08 0,03
Baustoffdesign
Results - Influence of fillers
015
3045
60
HMP + OX500
50100150200250300
Flow value(mm)
HMP + 971UTPP + OX50
TPP + 971U
Baustoffdesign
Corrosion Behavior in a Steel Ladle
Baustoffdesign
Failure of Castables
Baustoffdesign
Different Stages in Castable Life
Baustoffdesign
Different Stages in Castable Life
Baustoffdesign
• reaktive Tonerde
• Wassergehalt
• MgO-Körnung
• hydratisierbare Tonerde
Spinellbeton mit einem 80%igen Tonerdezement (System 1)
Spinellbeton mit einem 70%igen Tonerdezement (System 2)
Spinellbildender Beton mit 70%igen Tonerdezement (System 3)
Spinellbeton mit hydratisierbarer Tonerde (System 4)
Einlußfaktoren
Baustoffdesign
System 1 System 2 System 3 System 4Rohstoffe in Gew.-% in Gew.-% in Gew.-% in Gew.-%
Tabulartonerde (mm) 2,36 - 6,7 33 33 20 33 1,18 - 2,36 16 16 25 16
0,6-1,18 6 6 10 6 -0,3 5 5 12 5
-0,15 - - 10 - -0,045 - - 5 -
Spinell (mm) 0,5 - 1 9 9 - 9 0 - 0,5 4 4 - 4
-0,045 10 10 - 10 RW-Füller - - 2 - Magnesia - - 5 - reakt. Tonerde 7 11 8 11 70%CAC - 6 3 - 80%CAC 10 - - - Alphabond 300 - - - 6 Wasser 6 5 5,5 6
H4
Folie 17
H4 - Isolatoren werden abgenommen wenn nötig nachbearbeitet, ansonsten Bomsen abgetrennt
- nun kommen wir zum Problem der Arbeit
- Bomsenabfall zeigen
- warum kann nich wiederverwendet werden??? SIC-Mist beschreiben und ring zum Massekonzept herstelenHolze; 12.06.2004
Baustoffdesign
reaktive Tonerde
Einfluss der Tonerdemenge im System 1
0
20
40
60
80
100
120
140
160
180
200
7,00% 9,00% 11,00% 13,00%
Tonerdeanteil
Flie
smaß
in m
m,
Kal
tdru
ckfe
stig
keit
in M
pa
0
5
10
15
20
25
30
Rohdichte in g/cm
^3, K
altbiegefestigkeit in Mpa,
offene Porosität in %
Druckfestigkeit (RT) Fliesmaß in mm Biegefestigkeit (RT)offene Porosität % Rohdichte in g/cm3
System 1
- Tonerdegehalt- Feinheit der Tonerde - Additive
Verschiedene Tonerden
0
20
40
60
80
100
120
140
160
180
CT3000SG CTC40 CL370C CT9FG
eingesetzte Tonerde (geordnet nach abnehmender spezif. Oberfläche)
Flie
smaß
in m
m,
Kal
tdru
ckfe
stig
keit
in M
pa0
5
10
15
20
25
Rohdichte in g/cm
^3, K
altbiegefestigkeit in Mpa,
offene Porosität in %
Druckfestigkeit (RT) Fliesmaß in mm Biegefestigkeit (RT)
offene Porosität % Rohdichte in g/cm3
Baustoffdesign
Wirkung der verwendeten Additive im System 2
0
50
100
150
200
250
0,3%
Cas
tamen
t
0,08%
Cast+0
,01%
Zitrs
.+0,00
5%NaC
O3
0,3%
Cast+0
,002L
iCO3
0,05%
D7S+0
,02%
Bors.+0
,001
%NaC
O3
0,1HMP
0,06%
HMP+0,01
%Bors.
0,1TPP
Zusätze
Flie
smaß
in m
m,
Kal
tdru
ckfe
stig
keit
in M
pa
0
5
10
15
20
25
30
35
40
Rohdichte in g/cm
3̂, K
altbiegefestigkeit in Mpa,
offene Porosität in %
Druckfestigkeit (RT) Fliesmaß in mm Biegefestigoffene Porosität % Rohdichte in g/cm3
Wassergehalt System 2
- Wassergehalt- Additive
Verschiedene Castamentgehalte
0
20
40
60
80
100
120
140
160
180
200
0% 0,20% 0,30% 0,40%
Castamentgehalt
Flie
smaß
in m
m,
Kal
tdru
ckfe
stig
keit
in M
pa0
5
10
15
20
25
30
35
40
Rohdichte in g/cm
^3, K
altbiegefestigkeit in Mpa,
offene Porosität in %
Druckfestigkeit (RT) Fliesmaß in mm Biegefestigkeit (RT)
offene Porosität % Rohdichte in g/cm3
Baustoffdesign
MgO-Körnung System 3
- verschiedene MgO-Körnungen - Additive
Einfluss verschiedener MgO-Körnungen
0
50
100
150
200
250
MgO 1 MgO 2 MgO 3 MgO 4
eingesetzte MgO-Körnungen
Flie
smaß
in m
m,
Kal
tdru
ckfe
stig
keit
in M
pa
0
5
10
15
20
25
30
35
40
Rohdichte in g/cm
3̂, K
altbiegefestigkeit in Mpa,
offene Porosität in %
Druckfestigkeit (RT) Fliesmaß in mm Biegefestigkeit (RT)
offene Porosität % Rohdichte in g/cm3
Baustoffdesign
Wirkung verschiedener Alphabondgehalten mit 1%ADW
0
20
40
60
80
100
120
140
160
180
4 6 8
Alphabondgehalt in %
Flie
smaß
in m
m,
Kal
tdru
ckfe
stig
keit
in M
pa
0
5
10
15
20
25
Rohdichte in g/cm
^3, K
altbiegefestigkeit in Mpa,
offene Porosität in %
Druckfestigkeit (RT) Fliesmaß in mm Biegefestigkeit (RT)
offene Porosität % Rohdichte in g/cm3
hydratisierbare Tonerde System 4
- Tonerdegehalt- Additive
System 4 mit verschiedenen Additiven
0
20
40
60
80
100
120
140
160
180
200
1%ADW1 0,2% ZS 0,05%ZS+0,5%BL05
Zusätze
Flie
smaß
in m
m,
Kal
tdru
ckfe
stig
keit
in M
pa
0
5
10
15
20
25
30
Rohdichte in g/cm
^3, K
altbiegefestigkeit in Mpa,
offene Porosität in %
Druckfestigkeit (RT) Fliesmaß in mm Biegefestigkeit (RT)
offene Porosität % Rohdichte in g/cm3
Baustoffdesign
H3-1 H3-2 H3-3Korund 6978 11368 10156Spinell 2192 2333 2759Nephelin 128 374 445C3A5 134 - - CA6 2068 - 177
Baustoffdesign
Formation of Phases as a Function of Temperature
Korund
Spinellbeta-Tonerde
Periklas
Quarz Nephelin
80°C 1200°C 1600°C
Baustoffdesign
SEM Investigations
Baustoffdesign
SVB
SVB for a tunnel shell in the research mine of TU Bergakademie Freiberg
Excavation
Baustoffdesign
SVB for a tunnel shell in the research mine of TU Bergakademie Freiberg
Lining
SVB
Baustoffdesign
SVB for a tunnel shell in the research mine of TU Bergakademie Freiberg
Reinforcement
SVB
Baustoffdesign
SVB for a tunnel shell in the research mine of TU Bergakademie Freiberg
Framework
SVB
Baustoffdesign
SVB for a tunnel shell in the research mine of TU Bergakademie Freiberg
Concreting
SVB
Baustoffdesign
SVB for a tunnel shell in the research mine of TU Bergakademie Freiberg
Finished shell
SVB
Baustoffdesign
SVB for a tunnel shell in the research mine of TU Bergakademie Freiberg
Finished shell
Baustoffdesign
Entrained Air
Sedimentation
Self Compaction
Flow Value [mm]
Stagnation Fu
nnel
Tim
e [s
]
Workability Evaluation according to DAfStB
DAfStb-Richtlinie Selbstverdichtender Beton (Ausgabe Nov, 2003) ANHANG Q; Q.1 Seite 32
Baustoffdesign
5
10
15
20
25
30
35
30 31 32 33 34 35
Flow Value [cm]
Funn
el T
ime
[s]
Lime Stone Powder
Fly Ash
Fly Ash + RHA
Fly Ash + SF
LSP
FA + RHA
FA
FA + SF
Cem I Cem I
Cem I
Cem I Cem II
Cem II
Cem II Cem II
Cem III
Cem III
Cem III
Cem III
Example: Workability for different Powder Additions
Ranking CEM II and III:LSP » FA+SF » FA+RHA » FA
Thomas A. Bier, Syed A. Rizwan:” EARLY SHRINKAGE IN SELF-COMPACTING MORTARS USING SECONDARY RAW MATERIALS” 9th Symposium on High Performance Concrete Rotorua, NZ, (2011)
Baustoffdesign
Workability Boxes according to Wallevik
O.H. Wallevik, J.E. Wallevik, Rheology as a tool in concrete science: The use of rheographs and workability boxes,Cem. Concr. Res. (2011)
Baustoffdesign
Workability Boxes for SCC
O.H. Wallevik, J.E. Wallevik, Rheology as a tool in concrete science: The use of rheographs and workability boxes,Cem. Concr. Res. (2011)
Baustoffdesign
Workability Boxes for different Applications
O.H. Wallevik, J.E. Wallevik, Rheology as a tool in concrete science: The use of rheographs and workability boxes,Cem. Concr. Res. (2011)
Baustoffdesign
Plasticizers and Stabilizers
Baustoffdesign
Entrained Air
Sedimentation
Self Compaction
Flow Value [mm]
Stagnation Fu
nnel
Tim
e [s
]
DAfStb-Richtlinie Selbstverdichtender Beton (Ausgabe Nov, 2003) ANHANG Q; Q.1 Seite 32
Plasticizers and Stabilizers
Baustoffdesign
Classical View into Workability
Baustoffdesign
Classical View into Workability
Baustoffdesign
500
750
1000
1250
1500
1750
2000
0 1 2 3 4 5 6 7
Yield Stress [Pa]
Vis
cosi
ty [m
Pas]
W/C = 0.4 W/C = 0.45 W/C = 0.5
Apparent Viscosity and Yield Stress in Pastes
Baustoffdesign
Funnel Time vs. Mini Slump in Pastes
5
15
25
35
10,00 15,00 20,00 25,00 30,00 35,00Mini Slump [cm]
Funn
el T
ime
[s]
W/C = 0.40 W/C = 0.45 W/C = 0.50
Baustoffdesign
Funnel Time vs. Flow Value
0
5
10
15
20
25
30
35
30,5 31 31,5 32 32,5 33 33,5 34
Mini Slump (cm)
Funn
el T
ime
(s)
Lime Stone PowderFly AshFly Ash + Rice Husk AshFly Ash + Silica Fume
Baustoffdesign
Self Compacting Mortars with Mineral Additives
Mortars with Fly Ash at two exposures
-600
-500
-400
-300
-200
-100
0
100
200
300
0 8 16 24
Time (Hours)Sh
rinka
ge/E
xpan
sion
(µm
/m)
C1-FA-Uncovered C1-FA-covered C2-FA-UncoveredC2-FA-Covered C3-FA-Uncovered C3-FA-covered
[Syed Ali Rizwan, Thomas. A Bier and Muhammad Sharif Nizami:” HIGH PERFORMANCE SELF-COMPACTING MORTARS CONTAINING POZZOLANIC POWDERS” BMC8, Poland(2006)]
Mortars with Lime Stone Powder at two exposures
-3000
-2500
-2000
-1500
-1000
-500
0
500
0 8 16 24
Time(Hours)
Shrin
kage
(µm
/m)
C1-LSP-Uncovered C1-LSP-Covered C2-LSP-UncoveredC2-LSP-Covered C3-LSP-Uncovered C3-LSP-Covered
Limestone Fly Ash
Baustoffdesign
Pedestrian Bridge in Sakata, Japan (Ductal)
Conception of conventional and deflocculated, dense concrete
Ultra finefiller
Cement grain1-5 microns
Ultra finefiller
Cement grain1-5 microns
4m
Cement Grain1-5 microns
Water
Conventional Concrete Low W/C Concrete
Design and ConstructionUltra High Strength Concrete
Baustoffdesign
Ultra High Strength ConcreteRunway D – Haneda Airport
Photo courtesy Prof. Kawakami
Baustoffdesign
Ultra High Strength ConcreteRunway D – Haneda Airport
Photo courtesy Prof. Kawakami
Baustoffdesign
Reactive-Powder Concrete (RPC)
Properties:High strength — 200 MPa
(can be produced to 810 MPa)
Very low porosity
Properties are achieved by:Max. particle size 300 mOptimized particle packing
Low water content
Steel fibers
Heat-treatment
Baustoffdesign
Mechanical Properties of RPC
Property Unit 80 MPa RPCCompressive strength MPa (psi) 80 (11,600) 200 (29,000)
Flexural strength MPa (psi) 7 (1000) 40 (5800)
Tensile strength MPa (psi) 8 (1160)
Modulus of Elasticity GPa (psi) 40 (5.8 x 106) 60 (8.7 x 106)
Fracture Toughness 103 J/m2 <1 30
Freeze-thaw RDF 90 100
Carbonation mm 2 0
Abrasion 10-12 m2/s 275 1.2
Baustoffdesign
What is the typical Ductal® mix ?
230 kg/m3
710 kg/m3
210 kg/m3
40 - 160 kg/m3
13 kg/m3
140 kg/m3
1020 kg/m3
Cement
Silica fume
Crushed Quartz
Sand
Fibres
Superplasticizer
Total water
No aggregates !
uctal
Baustoffdesign
Ultra High Strength ConcretePerformance