April 15, 2013 ACI Minneapolis MN

Gary Knight

Lehigh Hanson

Atlanta, Georgia

Using Limestone Cement to build the future for a 100 year old cement

plant using Sustainable Cements

Before we get started, a review of cement standards

2100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

3

Type I, Type II, Type III, Type

IV, Type V

Type IP Type IS, Type IT, Type

IL (Total 26 Types)

Types: GU, HS, MS, HE LH

Prescriptive

Prescriptive

Performance

4100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

Leeds Cement Plant (Leeds Alabama)

1906-1919 Standard Portland Cement Plant

1919-1930 Atlas Portland Cement

1930-1980 Universal Atlas Cement Company� United States Steel Corporation

1980-2002 Lehigh Portland Cement Company� Heidelberg Cement

2002-2007 Lehigh Cement Company

2007-present Lehigh Hanson

1977, Lehigh was acquired by Heidelberger Zement AG

Updating a 100 year old cement plant using Sustainable cements

In the beginning&

5100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

In the beginning&

6100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

7100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

1914 - 2000 barrels of cement /day

1916 - 3000 barrels of cement /day

1938 Expansion… Most modern in the world

8Name of presentationPresenter, Date

2008

9Name of presentationPresenter, Date

2008 Plan to update the 1976 Lehigh Leeds

10Name of presentationPresenter, Date

� Extend Quarry by relocating local creek

� Install Truck Self Loading

� Three (3) chamber silo with total of 20,000 MT capacity

Updated in 1976 to

current layout

The Proposal

11Name of presentationPresenter, Date

Use Limestone cement to construct the Creek and Silo Projects

C595 IL / C1157 HE… Design concrete for durability

The Proposal

12Name of presentationPresenter, Date

Use Limestone cement to construct the Creek and Silo Projects

C595 IL / C1157 HE… Design concrete for durability26,781 Yards … Creek Shell and Ground Stabilization5,153 Yards … Silo and Foundation

The Creek relocation project

13100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

The SILO

14100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

15

� Three (3) chamber silo with total of 20,000 MT capacity

� 80 feet diameter, 240 feet tall

� Fully automated truck loading facility

� Construction cost $20.5 million

� 18 months construction time

16

Situation contractor push back

� Shortage of time for mix design development

� Slip forms require specific properties

� Contractor concerned about “experimental mix design”

� Lack of acceptance for Limestone Cement specification (before C595IL)

� Lab Data vs. field test (“real world”)

-> field test “box”

� Major concern: “setting time” control

-> 1157HE “perceived spike” (C595 IL fine grind)

Admixture -> Retarder?

17

Situation� ASTM C595 IL / ASTM C1157HE cement (12% limestone)

� Slag as SCM

� Admixture to control “setting time”

� Contractor experience only with Type I/II and none with Slag cement

� 28d strength 6000psi

Proving our case& in the lab

18100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

19

Lab Data – I) Time of Set

20

Lab Data – II) Calorimeter – 0%, 30%, 40%, 50% slag

21

Lab Data – II) Calorimeter 30% Slag, changing WR dose

22

Lab Data – II) CalorimeterAdmixture dosage rate controlling set time (3.5 / 6.0 / 8.0 oz/cwt

23

Lab Data – III) Consistometer

1938

24

Lab Data – III) Consistometer

The contractor would not except any of

our testing&.

25100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

Convince “Shawne”

What could we do to persuade the contractor?

26

Field Trial – “Box” test� 3 layer of concrete

� 16” each layer

� 30min between each filling with new load of concrete

� Rebar test as measurement

�Shawne

27

Gaining & Loosing Bottom

16”

30 min

90 min

60 min

Gaining

Bottom

Loosing

Bottom

Placement Rate

Each tier represents

a new load of

concrete

28

Field Trial – “Box” test

29

Field Trial – “Box” test

rebar test

0

5

10

15

20

25

30

35

40

45

1:13 1:28 1:43 1:58 2:13 2:28 2:58 3:28 3:58 4:28 4:48 4:58

1:45 PM 2:00 PM 2:15 PM 2:30 PM 2:45 PM 3:00 PM 3:30 PM 4:00 PM 4:30 PM 5:00 PM 5:20 PM 5:30 PM

Time

Inches

0

500

1000

1500

2000

2500

3000

3500

4000inch crust, 3 Mixes for 1 Box

ToS only for #1 load

30

Field Trial – “Box” test

31

Field Trial – “Box” test

BASF Admixtures: P1025, Delvo, 322N

Hydration stabilizerWater Reducer /

Slope / Time

32

Variable set time mix design

Faster Set Slower Set

33

Day 1 – Tuesday: 0–20ft, 10.8in/h

34

Day 2

35

Day 3

36

Day 4

37

Interior Ring Silo Slip

Testing and Specifications

38100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

39Name of presentationPresenter, Date

40100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

C1202 RCP Testing for Creek Project

41100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

C595 IL Material Certificate Fine Grind High Early (HE) ~Type III Alternative

Used in Silo /

Creek project

42100 Year Old Cement Plant with Sustainable cementsGary Knight 4/15/13

ASTM C595 IL (Normal Grind) ~Type I Alternative

Conclusions� C595 IL (Limestone Cements)

� Can be substituted for Portland Type I cements

� Works very well with C618 Fly Ash and C989 Slag Cements

� Works very well with current commercial admixtures

� Works very well in complex concrete Applications

� Can produce durable concrete

43Name of presentationPresenter, Date 52% reduction in clinker factor

44

Other Concerns

45

Other Concerns& sink holes

46

1938c Building of the original Leeds Silos

47

1938c Building of the original Leeds Silos

48

1938

49

1938c Building of the original Leeds Silos

50

Questions? &&&&&&..the end

Working together for success with performance material

12% Limestone Cement

C989 Ground Granulated Slag

244 Breaks -

60hrs