Development of Fly Ash for Application in Thailand Somnuk Tangtermsirikul Professor Sirindhorn International Institute of Technology Thammasat University, THAILAND
Interesting Statistics about Concrete in Thailand
World Cement Consumption Consumption (million tons) 1200 1000 800 600 400 200 0 1994 1995 1996 1997 1998 1999 2000 Year Others Americas Europe Asia
Cement Consumption in Asia Top 5 Countries 72.3 48.0 21.0 Year 2000 Unit : Million tons 99.6 581.0 China India Japan Korea Thailand
Cement Production in Asia Top 5 Countries 83.3 52.2 33.7 Year 2000 Unit : Million tons 101.6 586.2 China India Japan Korea Thailand
World Cement Export Top 5 Countries 6.3 Year 2000 Unit : Million tons 14.0 6.4 7.6 8.5 Thailand Indonesia Japan Turkey Greece
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
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%
Fly Ash A type of pozzolan derived from burning pulverized coal.
Starting BC. 2300 Volcanic Ash
Sources of Coal in Thailand Lampoon 1) Banpu 2) Ban Pa Ka Lampang 1) Maemoh 2) Maetueb, Amphur Ngaw Krabi 1) Ban Pu Dam
Mae Moh Generating Plants in Lampang
Mae Moh Generating Plants Coal stocking area Fly ash dumping area
Fly Ash Silo Bottom Ash
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
Start research again in 1992
Find local cement replacing materials for conducting research on Self-Compacting Concrete
Only one problem
No systematic and useful studied results except for a consecutively 10-year results of chemical composition and physical properties of fly ash
Raw Data
Mae Moh Generating Plants Coal stocking area Fly ash dumping area
Problem No systematic and useful studied results except for a consecutively 10-year results of chemical composition and physical properties of fly ash Confidence
Typical Properties of Thai Fly Ashes
Particle Size Diameter from 1 to 150 Micron (about the same size as cement) Cement Fly Ash
Particle Shape Spherical solid Porous Irregular Cenosphere, Plerosphere
Cement Mae Moh Rayong Samutsakorn Rachaburi Abroad
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 (%) 20 55 1 35 5 40 1 15 0 + - 10 0 + - 5 0.5 2.5 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
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
Various types of fly ash in Thailand (properties and qualities) Problem Consistency? Design? Benefit Opportunity Systematic QC
Problem Toxicity?
Heavy Metal Content in Mae Moh Fly Ash,mg/ mg/l Sample 1 2 3 4 5 6 7 8 Ag nd nd nd nd nd nd nd nd Ba 0.18 0.18 0.16 0.12 0.20 0.17 0.13 0.11 Cr 0.05 0.06 0.09 0.11 0.05 0.10 0.13 0.15 Pb nd nd nd nd nd nd nd nd Cd nd nd nd nd nd nd nd nd As nd nd 0.04 0.07 nd nd 0.04 0.05 Se nd nd 0.04 0.05 nd nd 0.05 0.06 Hg nd nd nd nd nd nd nd nd Spec.
Interesting Data of Fly Ash in Thailand
Annual Production About 3 Million tons About 95% from Mae Moh (EGAT)
Fly Ash Consumption 2500000 2000000 1500000 1000000 500000 Fly ash consumption (tons) (tons) 2100000 1800000 1400000 800000 1000000 400000 2500000 * 0 400 1000 2200 15460 '94 '95 '96 '97 '98 '99 '00 '01 '02 '03 '04 * Forecasted value for 2004
Consumption Growth (%) 2500 2487 2000 1500 1000 500 0 780 603 100 250 100 25 40 29 17 19 '94'95'96'97'98'99'00'01'02'03'04 *
90 80 70 60 50 40 30 20 10 0 Consumption/Production (%) 0.0130.0330.0730.52 13.33 26.67 33.33 46.67 60 70 84 '94 '95 '96 '97 '98 '99 '00 '01 '02 '03 '04 Computed based on annual production of 3 million tons *
Note Bad dream for many but opportunity for fly ash Economic Crisis in 1997 stimulated the use of fly ash in concrete industry
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).
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
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
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
Efforts (1992-2001) 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 EIT1014-97 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
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
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
1993
1997 to 2001
2000
1999
2001
Online Learning Homepage (in Thai Language) NSTDA, EGAT, SIIT, etc. Joint Project http://flyash.learn.in.th June 2001 Open Together with One Seminar
2001 (NSTDA)
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 EIT1014-97 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
1997 revised 2003
2002
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 A6201-99 : 4 Classes (based on quality) ASTM : 2 Classes (C and F based on chemical composition)
1999
Low Heat Concrete
Application of Low Heat Fly Ash Concrete in Mae Moh
4.75m thick Mat Foundation of BTS project using Low Heat Fly Ash Concrete Foundation of BTS Morchit station
Use of Low Heat Fly Ash Concrete at Rachaburi Power Plant
Mat foundation of ABAC 2 Bangna Campus
Use of Low Heat Fly Ash Concrete at Bangkok Subway Station
Self-Compacting Concrete 40
First Time for Self- Compacting Concrete in Thailand in 1994 (at EGAT Mae Moh)
Application of Self-Compacting Fly Ash Concrete in Mae Moh
Application of Self-Compacting Fly Ash Concrete in Mae Moh
Self - Compacting Concrete at the Pakred-Bang Pa in interchange behind Thammasat Rangsit Campus (very dense reinforcement)
Rama 8 Bridge project used Low Heat and Self-Compacting Fly Ash Concretes
การซ อมโครงสร างโรงงานระยองโอร ฟ นใช Self - Compacting Concrete
Roller-Compacted Concrete
Pak Mool Dam in Ubol Rachathani with 52,000 m 3 of RCC
Roller-Compacted Concrete Pavement in Mae Moh
Khlong Ta Dan Dam Project with 5.5 million m 3 of RCC
Sulfate Resisting Concrete 10
Sulfate Attack
บ อบำบ ดน ำเส ยหนองแขมใช Sulfate Resisting Concrete
Chloride Resisting Concrete
Steel Corrosion Chloride induced Carbonation
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
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
Khlong Ta Dan Dam Project with 5.5 million m 3 of RCC
Aggregate Crushing Plant
Aggregate Storage
Mixing plant of RCC (capacity 10,000 m 3 /day)
Transportation and placement of RCC by trucks
RCC leveling by bulldozers
RCC compaction
RCC curing after compaction
Development of fly Ash in Thailand Resulted in 20 Billion baht/year in economic value but took more than 100 man years of effort
The Success of Fly Ash Development in Thailand An Example of Self-Reliance Development Project An Example of Good Team Playing
The End Thank you for your kind attention