Development of Fly Ash for Application in Thailand

Transcription

1 Development of Fly Ash for Application in Thailand Somnuk Tangtermsirikul Professor Sirindhorn International Institute of Technology Thammasat University, THAILAND

2 Interesting Statistics about Concrete in Thailand

3 World Cement Consumption Consumption (million tons) Year Others Americas Europe Asia

4 Cement Consumption in Asia Top 5 Countries Year 2000 Unit : Million tons China India Japan Korea Thailand

5 Cement Production in Asia Top 5 Countries Year 2000 Unit : Million tons China India Japan Korea Thailand

6 World Cement Export Top 5 Countries 6.3 Year 2000 Unit : Million tons Thailand Indonesia Japan Turkey Greece

7 Per capita cement and concrete consumption in Thailand (2003) Annual cement consumption 500 kg/person (about the same as Japan) Annual concrete consumption 1 m 3 /person

8 Some World Records in Thailand Klong Tha Dan Dam Fly Ash Highest amount of RCC utilization 5.5 million m 3 Highest amount of RCC placing in 1 day 15,000 m 3 Highest percentage of utilization in concrete more than 80%

9 Fly Ash A type of pozzolan derived from burning pulverized coal.

10 Starting BC Volcanic Ash

11 Sources of Coal in Thailand Lampoon 1) Banpu 2) Ban Pa Ka Lampang 1) Maemoh 2) Maetueb, Amphur Ngaw Krabi 1) Ban Pu Dam

12 Mae Moh Generating Plants in Lampang

13 Mae Moh Generating Plants Coal stocking area Fly ash dumping area

14 Fly Ash Silo Bottom Ash

15 The first study on fly ash in Thailand was in 1980 not successful due to bad quality of fly ash (too high SO 3 content) cracking due to early ettringite formation

16 Start research again in 1992

17 Find local cement replacing materials for conducting research on Self-Compacting Concrete

18 Only one problem

19 No systematic and useful studied results except for a consecutively 10-year results of chemical composition and physical properties of fly ash

20 Raw Data

21 Mae Moh Generating Plants Coal stocking area Fly ash dumping area

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24 Problem No systematic and useful studied results except for a consecutively 10-year results of chemical composition and physical properties of fly ash Confidence

25 Typical Properties of Thai Fly Ashes

26 Particle Size Diameter from 1 to 150 Micron (about the same size as cement) Cement Fly Ash

27 Particle Shape Spherical solid Porous Irregular Cenosphere, Plerosphere

28 Cement Mae Moh Rayong Samutsakorn Rachaburi Abroad

29 Typical Properties of Fly Ash in Thailand Chemical component SiO 2 CaO Al 2 O 3 Fe 2 O 3 SO 3 MgO (Na 2 O+0.658K 2 O) Range (%) Blaine Fineness 1,800 to 4,000 cm 2 /g Specific Gravity 1.8 to 2.5 LOI 0.1 to 5 majority < 1.0

30 Researches on Effect of Fly Ash on Concrete Properties Improved Workability, Pumpability, Heat Generation, Longterm Strength, Autogenous and Drying Shrinkage, Steel Corrosion Resistance, Sulfate and Acid Resistance, AAR Resistance Worse Setting time delay, Early age strength, Bleeding, Carbonation, Freezing and thawing resistance Equivalent Mechanical Properties, Abrasive Resistance Caution Curing

31 Various types of fly ash in Thailand (properties and qualities) Problem Consistency? Design? Benefit Opportunity Systematic QC

32 Problem Toxicity?

33 Heavy Metal Content in Mae Moh Fly Ash,mg/ mg/l Sample Ag nd nd nd nd nd nd nd nd Ba Cr Pb nd nd nd nd nd nd nd nd Cd nd nd nd nd nd nd nd nd As nd nd nd nd Se nd nd nd nd Hg nd nd nd nd nd nd nd nd Spec.

34 Interesting Data of Fly Ash in Thailand

35 Annual Production About 3 Million tons About 95% from Mae Moh (EGAT)

36 Fly Ash Consumption Fly ash consumption (tons) (tons) * '94 '95 '96 '97 '98 '99 '00 '01 '02 '03 '04 * Forecasted value for 2004

37 Consumption Growth (%) '94'95'96'97'98'99'00'01'02'03'04 *

38 Consumption/Production (%) '94 '95 '96 '97 '98 '99 '00 '01 '02 '03 '04 Computed based on annual production of 3 million tons *

39 Note Bad dream for many but opportunity for fly ash Economic Crisis in 1997 stimulated the use of fly ash in concrete industry

40 Interesting Records Among countries with producing capacity > 2 million tons/annum, Thailand is 1. The fastest-growth in term of fly ash consumption in the world in the past decade 2. Now the No.1 user of fly ash in cement and concrete in term of consumption/production (almost 100% in 2004).

41 Distribution of Fly Ash used in Various Types of Concrete (from 1994 to 1997) SRC 4% LHC 82% SCC 5% NC 8% Others 1% LHC SRC SCC NC Others

42 Distribution of Fly Ash used in Various Types of Concrete (1999) Others 12% LHC NC 46% SRC SCC SCC 2% SRC 5% LHC 35% NC Others

43 Way of Thinking and Concept of Application Before 1997 Thinking : Application : From 1997 Thinking : Application : Fly ash is a waste. How to get rid of Use in low strength materials. No adverse effect Fly ash is an asset How to manage/control quality Use for the benefit on durability and special concrete

44 Efforts ( ) 2001) 1. Test and Collect Basic Properties of Fly Ash and Concrete with Fly Ash (more than 20 reports) 2. Education : 8 Seminars since 1992 (BKK, Chiang Mai, KhonKaen, BKK, Songkhla, Nakhorn Srithammarat, Rayong, BKK) and more than 10 special lectures 3. Construction Tests (many pilot projects) 4. QC and Supply System (Business) 5. Standards for Fly Ash EIT and TIS(2001) 6. A Book on Mix Design for Fly Ash Concrete EIT(1999) 6. A Book on Use of Fly Ash in Concrete (2001) 7. A Software for Mix Design (FACOMP T1.0) (2001 : EGAT & SIIT) : Training 2 times 8. Research Groups on Fly Ash Concrete (7 Universities) sponsored by EGAT, NSTDA, TRF 9. Learn On-line Project

45 Research On properties of fly ash and concrete with fly ash More than 30 research reports More than 100 technical papers (more than 30 only for myself) Research Group on Fly Ash Concrete (7 Universities) sponsored by EGAT, NSTDA, TRF

46 Education and Training 8 Seminars since 1992 (BKK, Cheingmai, KhonKaen, BKK, Songkhla, Nakhorn Srithammarat, Rayong, BKK) A Book on Durability of Concrete A Book on Mix Design for Fly Ash Concrete EIT(1999) A Book on Use of Fly Ash in Concrete (2001) Learn On-line Project

47 1993

48 1997 to 2001

49 2000

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52 1999

53 2001

54 Online Learning Homepage (in Thai Language) NSTDA, EGAT, SIIT, etc. Joint Project June 2001 Open Together with One Seminar

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56 2001 (NSTDA)

57 Support for Real Practice Many Construction demonstrations at Mae Moh during 1993 to 1996 Set up Business and QC Unit for Fly Ash in Mae Moh Standards for Fly Ash EIT and TIS(2001) A Book on Use of Fly Ash in Concrete (2001) A Software for Mix Design (FACOMP T1.0) (2001 : EGAT & SIIT) : Training 2 times with about 120 copies sold till now

58 1997 revised 2003

59 2002

60 มอก.) Thai Industrial Standards (มอก 2001 Quality Class 1 : Processed Fly Ash Quality Class 2 : Original (non-processed) Fly Ash 2.1 Class 2a : Low Calcium 2.2 Class 2b : High Calcium Quality Class 3 : For mass concrete, low strength concrete, block, lean concrete, etc. Remarks : JIS A : 4 Classes (based on quality) ASTM : 2 Classes (C and F based on chemical composition)

61 1999

62 Low Heat Concrete

63 Application of Low Heat Fly Ash Concrete in Mae Moh

64 4.75m thick Mat Foundation of BTS project using Low Heat Fly Ash Concrete Foundation of BTS Morchit station

65 Use of Low Heat Fly Ash Concrete at Rachaburi Power Plant

66 Mat foundation of ABAC 2 Bangna Campus

67 Use of Low Heat Fly Ash Concrete at Bangkok Subway Station

68 Self-Compacting Concrete 40

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70 First Time for Self- Compacting Concrete in Thailand in 1994 (at EGAT Mae Moh)

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72 Application of Self-Compacting Fly Ash Concrete in Mae Moh

73 Application of Self-Compacting Fly Ash Concrete in Mae Moh

74 Self - Compacting Concrete at the Pakred-Bang Pa in interchange behind Thammasat Rangsit Campus (very dense reinforcement)

75 Rama 8 Bridge project used Low Heat and Self-Compacting Fly Ash Concretes

76 การซ อมโครงสร างโรงงานระยองโอร ฟ นใช Self - Compacting Concrete

77 Roller-Compacted Concrete

78 Pak Mool Dam in Ubol Rachathani with 52,000 m 3 of RCC

79 Roller-Compacted Concrete Pavement in Mae Moh

80 Khlong Ta Dan Dam Project with 5.5 million m 3 of RCC

81 Sulfate Resisting Concrete 10

82 Sulfate Attack

83 บ อบำบ ดน ำเส ยหนองแขมใช Sulfate Resisting Concrete

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85 Chloride Resisting Concrete

86 Steel Corrosion Chloride induced Carbonation

87 Channel Tunnel อ โมงรถไฟใต น ำท ยา วท ส ดในโลก เช อมเกาะอ งกฤษแล ะฝร งเศษ ท าเท ยบเร อน ำล ก Jetty (จ.ระยอง) ใช คอนกร ตผสมเถ าล อยจากถ านห น

88 Fly Ash Many Types of Special Concrete in Thailand Low-Heat Concrete Self-Compacting Concrete Sulfate-Resisting Concrete Marine Concrete (Sulfate and Chloride Resisting Concrete) Roller-Compacted Concrete

89 Khlong Ta Dan Dam Project with 5.5 million m 3 of RCC

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91 Aggregate Crushing Plant

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93 Aggregate Storage

94 Mixing plant of RCC (capacity 10,000 m 3 /day)

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99 Transportation and placement of RCC by trucks

100 RCC leveling by bulldozers

101 RCC compaction

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103 RCC curing after compaction

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107 Development of fly Ash in Thailand Resulted in 20 Billion baht/year in economic value but took more than 100 man years of effort

108 The Success of Fly Ash Development in Thailand An Example of Self-Reliance Development Project An Example of Good Team Playing

109 The End Thank you for your kind attention