Vol 18 | Issue 2 | December 2018
| www.asa-inc.org.au
18
Jubilee Bridge - Concrete Institute of Australia Excellence in Concrete Awards 2017. See page 10 for full article.
Editorial
Welcome back to another edition of Connections. At the Australasian (iron & steel) Slag Association (ASA), we are committed to providing up-to-date information on industry advancements, events and research. In this edition, we profile Chani Tennakoon, who has recently been appointed as Chair of the ASA Technical Committee. Chani is the Technical Manager at Independent Cement & Lime Pty Ltd (ICL) and a long-standing board member of the ASA. We spoke with her to gain insight into her roles, career highlights and how she got involved in the industry. In line with the ASA’s mission to promote the effective and beneficial use of iron and steel slags, including the collection, research and dissemination of information, the association strives to make our mark in keeping legislation up to date.
Recently, the board have been working to update NSW EPA’s exemption for ladle furnace slag. In this edition, we take a look at the implemented changes. In terms of industry events, Craig Heidrich, Executive Director, and Gavin Tory, ASA Board Chairman, took to the skies to attend the National Slag Association’s 100th anniversary AGM in Maryland, USA in early September. Back at home, two of our ASA team members attended the Construction Materials Industry Conference (CMIC18) in mid-September. Both events provided important networking and member generation opportunities for the ASA. We hope you enjoy this edition of Connections. As the final edition of the year, we wish you all a happy and healthy end to 2018 and we are looking forward to what’s to come in 2019.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 18.
Editorial Member Profile: Chani Tennakoon (ICL) Engineered Construction Materials from By-Products National Slag Association's 100th Anniversary Iron and Steel Slags: Then & Now Changes to the NSW EPA Exemption for Ladle Furnace Slag Cooperative Research Centre for Low Carbon Living: Demonstrating the Practical Use of Geopolymer Concrete CMIC18 Report Concrete 2019 2019 Awards for Excellence in Concrete Jamie North: Drifting to Void Technical Note - Roads Guide Write for Connections
CONTENTS
TH I S I SS U E
CONNECTIONS EDITORIAL TEAM | December 2018 Edition Connections is published by the ASA The Australasian (Iron & Steel) Slag Association Wollongong NSW 2500 Phone: 02 4258 0160 Fax: 02 4258 0169 Email: info@asa-inc.org.au Web: www.asa-inc.org.au Executive Director: Craig Heidrich Editor: Emma Bruce Design: 101 Design Contributors: Ahmed Al-Tikrite, Muhammad N.S. Hadi, Aiden Chilcott, Emma Bruce, Carol Wilson, Craig Heidrich, Gavin Tory, John Hodgkinson Connections is a biannual publication with an online circulation of 1500 copies
connections December 18 | 01
@asa_info
MEMBER PROFILE: CHANI TENNAKOON
The Australasian (iron & steel) Slag Association is honoured to welcome Chani Tennakoon, Technical Manager at Independent Cement & Lime Pty Ltd (ICL), as Chair of the ASA Technical Committee. Chani spoke with the ASA to give Connections readers an insight into her current role and how she got involved in the industry.
What are your current roles and responsibilities at ICL? I am the Technical manager for Independent Cement and Lime (ICL). ICL is a major supplier of General propose and blended cement, fly ash, granulated blast furnace slag, lime and a wide range of building products to the construction and stabilisation industry in Victoria & New South Wales. As the Technical Manager, I ensure that ICL products meet technical requirements of customers, industry and Australian Standards. I also work on development of new products and technologies that improve efficiency of operations and sustainability. Furthermore, I provide specialist advice to ICL customers on various aspects of concrete materials technology. Have you always worked in the Steel and Cement Industry? No, but I have worked on research and development projects related to the cement industry. From 2012 to 2016, as a PhD student at Swinburne University of Technology, I worked on developing new concrete binders, suitable for road infrastructural applications, that have low carbon footprint and embodied energy. The project was funded by Australian Road Research Board (ARRB).
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During the same time, I worked in ARRB as a Material Researcher where I worked on various projects aimed at improving durability and assessing long-term structural integrity of road-related concrete structures. After a short spell, in the pavement technology team at ARRB where I worked on cement treated and foamed bitumen materials I joined ICL in 2016. How did you become interested in the Industry? Just after finishing my bachelor’s degree in Sri Lanka I moved to Australia to pursue my PhD in civil engineering at Swinburne. As my PhD topic was closely related to the cement industry, I gained a lot of exposure to the industry and was lucky to meet and work with industry leaders from the cement and construction industry. I was passionate about my research area and always wanted to apply my knowledge and expertise to real-world problems. What’s your favourite quote or saying? My favourite quote is: “Passion is energy. Feel the power that comes from focusing on what excites you” – Oprah Winfrey. What do you like to do in your free time? In my free time I like to go for a walk or cook a delicious meal.
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ENGINEERED CONSTRUCTION MATERIALS FROM BY-PRODUCTS Recycling by-products in construction has been a focus of a number of research projects conducted at RMIT, The University of Melbourne, Monash University and the ARC Nanocomm Hub. Most of these are sponsored by industry sectors which generate large amounts of by-products. There are significant benefits that can be realised by translation of the technologies to practice and also the methods developed can be used to convert other by-product materials to useful products. RMIT University hosted an invitation-only workshop in October, focusing on engineered construction materials from recycled by-products. Craig Heidrich, ASA Executive Director, attended and spoke on behalf of the Association. This exclusive workshop offered a great platform for information sharing and industry networking. The event aimed to showcase research outcomes, explore new research and development needs and opportunities, and identify gaps in the translation pathway to realise end user benefits from the completed research.
F
• • • •
Ash development in Australia High volume fly ash & slag concrete Self-healing concrete using high volumes of fly ash By-product concrete from concrete trucks as recycled coarse aggregate • Geopolymer concrete • Other recycled solutions The workshop concluded with a facilitated session with all industry partners on opportunities for the future.
ge
terchan
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- Ca ootpath
Heidrich’s presentation formed part of an abundant program that explored topics including;
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NATIONAL SLAG ASSOCIATION'S
100 ANNIVERSARY th
2018 was a special year for the National Slag Association [www.nationalslag.org] celebrating its Centennial (100th) Anniversary as an association during the September Annual meeting held at the Gaylord National Resort on the outskirts of Washington DC in Oxon Hill MD. Chair, Gavin Tory ASMS and Executive Director, Craig Heidrich, were invited to join the NSA and be a part of this historic milestone event. Gavin and Craig provided a joint presentation titled ‘Six years on, what we have learned about Geopolymer concretes and Steel Furnace Slag aggregates’ which was well received by the 200+ attendees from 9 different countries.
Gaylord National Resort, Oxon Hill MD 4 - 7 September 2018 Themes & Topics for Presentations Included:
Some 29 presentations were delivered across a range of topics such as; regulation, environmental, pavements, cement and concrete and how slag could save the ‘Everglades’. Once the papers have been provided these will be uploaded onto our website.
Regulation
Environmental
Pavements
A key takeaway for the Association was the progressive move towards recognition of iron and steel slags as ‘products’ which are an integral part of the ‘circular economy’ extracting maximum value from resources arising from the manufacture of iron and steel.
Cement
Concrete
Slag
One highlight during the event was a speech by Ed Levy Jr., who was present for the NSA 100th anniversary event. Coincidently, Edw. C. Levy Co. also celebrated its 100th anniversary in 2018. Ed’s parting words were, “Our industry must continue to look forward with enthusiasm and innovate for the next 100 years.”
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IRON & STEEL SLAGS Slag is produced daily as a by-product of iron and steel making. The uses of iron and steel slags throughout history has ranged vastly, including; cast cannon balls in Germany (1589), wharf buildings in England (1652), slag cement in Germany (1852), slag wool in Wales (1840) reinforced concrete in Germany (1892) and slag bricks made from granulated slag and lime in Japan (1901).
65%
REPLACEMENT LEVELS OF UP TO 65%
THEN &NOW
In Australia, slag products have been utilised in applications such as roads, concrete aggregates and lightweight aggregates, through to land applications and granulation for production of slag cements. Today, for every tonne of crude steel created, approximately 350kg of by-products are produced, including iron and steel slags. Efficient and environmentally friendly uses are needed to avoid filling valleys and ponds with the materials. Fortunately, slags have physical and chemical properties which are well suited for use in various value-adding applications such as cement and concrete manufacturing and as aggregates for structural and civil applications. The use of these slags in such applications lower greenhouse gas emissions (GHG) more effectively than other supplementary cementitious materials (SCMs), due to the high replacement levels of up to 65%. The recovery and use of iron and steel slags reduce carbon emissions by almost 1 million tonnes.
London, England (1952)
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CHANGES TO THE NSW EPA EXEMPTION
FOR LADLE FURNACE SLAG The Blast Furnace Slag Exemption 2014
The Steel Furnace Slag Exemption 2017
The Processed Electric Arc Furnace Ladle Slag Exemption 2014
The Electric Arc Furnace Slag Exemption 2014
7.4. In non-cementitious mixes the consumer can only apply blast furnace slag or blended blast furnace slag to land where it:
7.4. In non-cementitious mixes, the consumer can only apply steel furnace slag to land where such application:
7.3. The consumer can only apply processed electric arc furnace ladle slag to land where it complies with:
7.4. In non-cementitious mixes the consumer can only apply electric arc furnace slag or blended electric arc furnace slag to land where it:
7.4.1. complies with the relevant specification or Australian Standard, or
7.3.1. a relevant specification or Australian Standard, or supply agreement,
7.4.1. Complies with the relevant specification or Australian Standard or complies with supply agreement/s, OR 7.4.2. complies with a development consent that specifically considers the use of blast furnace slag and 7.4.3. is not applied in or beneath water, including groundwater.
7.4.2. complies with a supply agreement, OR 7.4.3. complies with a development consent that specifically considers the use of steel furnace slag or blended steel furnace slag, and 7.4.4. is not applied in or beneath water, including groundwater.
AND OR 7.3.2. development consent that specifically considers the use of processed electric arc furnace ladle slag. 7.4. The consumer must ensure that the processed electric arc furnace ladle slag is not applied in or beneath water, including groundwater.
7.4.1. complies with the relevant specification or Australian Standard, or complies with supply agreement/s, OR 7.4.2. complies with a development consent that specifically considers the use of electric arc furnace slag, and 7.4.3. is not applied in or beneath water, including groundwater.
About the EPA The NSW Environment Protection Authority (EPA) manages environmental issues, responds to pollution incidents, enforces environmental regulations and issues environment protection licences. What are Resource Recovery Orders and Exemptions? If you intend to apply by-products to land, reuse it as fuel, or use it in connection with a process of thermal treatment, you may need to hold an environment protection licence or pay the waste levy. However, the EPA has the power to grant exemptions from these requirements in some circumstances, if it can be demonstrated that by-products can be safely and effectively used for another purpose. Resource Recovery Exemption: The Processed Electric Arc Furnace Ladle Slag Exemption The Australasian (iron & steel) Slag Association (ASA) have been working with NSW EPA to amend the published Processed Electric Arc Furnace Ladle Slag Exemption 2014. Following changes to the Protection of the Environment Operations Act (POEA), the Resource Recovery Exemption (RRE) were split into Resource Recovery Orders (RRO) and Resource Recovery Exemptions (RRE). The Association has been made aware of some issues with people using ladle furnace slag (LFS) in applications where developments consents weren’t applicable. This was due to the wording of the exemption, which didn’t reflect the intent of the latest amendments made in 2014. As a result of the Association’s discussions with NSW EPA, the exemption has now been amended. While not a large volume of material, LFS is a unique material. The amended wording avoids issues and essentially removes barriers to the use of LFS. To view current orders and exemptions, visit: www.epa.nsw.gov.au.
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COOPERATIVE RESEARCH CENTRE FOR LOW CARBON LIVING: DEMONSTRATING THE PRACTICAL USE OF GEOPOLYMER CONCRETE In the last edition of Connections, we took a look back at the seven programs the Cooperative Research Centre for Low Carbon Living (CRC-LCL) have undertaken over the past seven years of their initiative. The ASA has been heavily involved in projects contributing to the output of Research Program 1. Research Program 1 - Integrated Building Systems Aimed to develop: (i) Low-carbon-lifecycle building construction components & materials and (ii) Building-integrated multipurpose solar products, to support the next generation construction practice. High Density GPC Project The ASA has been working with CRC-LCL on a high density Geopolymer Concrete (GPC) Project. The collaborative project brings together industry partners (Australasian (iron & steel) Slag Association, Ash Development Association of Australia and AECOM), key industry stakeholders and end-users.
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Project partners supplied the armour unit moulds, the bulk materials for geopolymer, the demonstration site, and the manufacturing and construction. The project demonstrates the use of GPC in a novel application, in this case, the construction of coastal protection (seawalls). Fourteen batches of GPC were cast and finished on site into high density non-ferrous armour units (that do not require steel reinforcing). Initial results of testing were confirmatory of the mix design, progressing the project. All units are in the field with ongoing monitoring, being used in the repair of the Illawarra Port Seawall which was damaged in the June 2016 east coast low. The project has resulted in a new way to use steel furnace slag in concrete matrices that does not have dilatory effects. View a video of the process at the ASA website [http://www. asa-inc.org.au/blog/2018/10/crclcl-geopolymer-concrete]. The design, construction and field trials make up the second last stage of the CRC-LCL’s research program. The final milestone report will be produced and published by the Cooperative Research Centre for Low Carbon Living in June 2019.
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CMIC18 REPORT The Construction Materials Industry Conference was held at the International Convention Centre, Sydney from 19 – 21 September. Alex Heidrich and Aiden Chilcott attended the event on behalf of the Australasian (iron & steel) Slag Association.
Now in its seventh year, CMIC18 continues to widen the scope of information exchange, educate the industry on trends and developments, and provide concrete networking opportunities. Day one was ‘Industry Innovation Day’, focusing on industry innovation and best practice, with members and industry suppliers presenting a series of short TED-style talks. Day two’s program included similar style presentations on topics including the future, innovation, energy markets and the construction materials market. The third and final day was all about the community, environment and diversity. The day began with the IQA awards presentation and wrapped up with the Construction Materials Insurance Australia Business Leaders Lunch.
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EDUCATING THE INDUSTRY ON TRENDS & DEVELOPMENTS The exhibition focused on maximum delegate flow and exposure for exhibitors. Alex and Aiden spent the conference talking to attendees and other exhibitors, showcasing and advocating for the Association’s mission and objectives.
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CONCRETE 2019 The Concrete Institute of Australia’s 29th national conference, Concrete 2019, will be held from 8 – 11 September 2019 at the International Convention Centre, Sydney. Concrete 2019 will bring together global leaders and participants, exploring the theme ‘Concrete in Practice – Progress through Knowledge’.
The Concrete Institute of Australia are now calling for abstract submissions. Confirmed themes for this year’s abstracts include: • Alkali-activated concretes • Precast & prefabricated concrete • Alternative cementitious materials
• Reinforcing & Prestressing Materials
• Case studies & major projects
• Resilience
• Bridge structures
• Concrete materials for Design & Construction – What’s New? • Construction (infrastructure, development, innovations) & major projects
• Durability (and modelling for durability) • History of concrete & education • Modelling & design
• New concrete component materials
• Repair & rehabilitation • Seismic
• Shear & Torsion • Shotcrete
• Shrinkage & Creep
• Standards, specifications & codes • Structural Strengthening
• Underground and Foundation Structures
Submissions close 14th December 2018 • Visit www.concrete2019.com.au/program for submission guidelines & templates
Program Update: Concrete 2019 have announced the following Keynote Speakers, with key dates listed below. Anne Ellis
Prior to founding her own company, Ellis Global, Anne Ellis was Vice President, Innovation and Knowledge Share Director at AECOM.
Christoph Gehlen
Prof. Gehlen is the director of the Center for Building Materials of Technical University of Munich. He is also an active researcher in civil engineering materials. Michelle L. Wilson
Michelle L. Wilson, FACI, is Director of Concrete Technology at the Portland Cement Association (PCA), Skakie, IL USA. Wilson is an expert in concrete materials and specifications.
Abstract Submissions Open
Now Open!
Abstract Submissions Close
14th December 2018
Abstract Author Notification & Full Paper Submissions Open
31st January 2019
Full Paper Author Notifications
30th May 2019
Registration Open
7th October 2018
Conference Dates
8th - 11th September 2019
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2019 AWARDS
FOR EXCELLENCE IN CONCRETE
The Concrete Institute of Australia’s Awards for Excellence in Concrete has recognised and publicised significant contributions to excellence in concrete design, construction and materials since 1971. The Concrete Institute of Australia’s Awards for Excellence in Concrete has recognised and publicised significant contributions to excellence in concrete design, construction and materials since 1971. Entries are now open for the 2019 Awards for Excellence in Concrete program. With over 50 submissions in the 2017 Awards program, the Concrete Institute of Australia are looking forward to another exciting year of entries! Concrete related projects, technologies and innovations are all eligible to enter, with projects and organisations of all sizes catered for in five distinct categories; residential buildings, commercial buildings, infrastructure projects, repairs & rehabilitation, and technology & innovation. Awards are granted at state and national levels. Award winners from each state will be judged for an overall category winner. These national winners will receive a Medallion for Excellence in Concrete. All entries must be finalised by 1 March 2019. For more information, please visit www.concreteinstitute.com.au/Awards-for-Excellence.
Adelaide Convention Centre - Aurecon, awarded Medallion for Excellence - Repair and Rehabilitation, 2017.
The Song School - J Woodside Consulting and SA Precast, winner of the Kevin Cavanagh Trophy, 2017.
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Jubilee Bridge - ARUP, awarded Medallion for Excellence - Infrastructure Projects, 2017.
Manly House - Partridge Engineers, Popov Bass Architects and Horizon Build, awarded Medallion for Excellence - Residential Projects, 2017.
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JAMIE NORTH: DRIFTING TO VOID
Drifting to Void (2016) presents as an eroded brick column inhabited by a community of plant species native to the Illawarra. The form of the column has as its reference points various columns of antiquity, in addition to more modern industrial stacks. This industrial reference is reinforced by the use of blast furnace slag along the eroded edges of the column. Each brick within the column was moulded and cast individually to fit exactly within its prescribed place. Rather than using mortar to set the bricks in place, the bricks fit together in mutual dependency and are secured by being thread onto a steel armature. The column was made as a homage to my father, who was both a bricklayer and coal miner. Jamie’s sculptures are made from a combination of cement, blast-furnace slag, coal ash, marble waste, steel and living Australian plants. One of his creations features as a centrepiece in the ASA’s office.
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QUICK REFERENCE GUIDE 1 - 2013
Roads Guide Supplement on Roads Supplement on GeneralGuide Applications General Applications QUICK REFERENCE GUIDE 1 - 2013
1. INTRODUCTION 1. INTRODUCTION
The continuing need to preserve diminishing natural resources and sustainable practices is a fundamental in Theincrease continuing need to preserve diminishing natural tenet resources business today. This has predominantly occurred through the and increase sustainable practices is a fundamental tenet in promotion of increased reuse, recycling and reprocessing. business today. This has predominantly occurred through the Here, disposal has become therecycling last resort and is an issue of promotion of increased reuse, and reprocessing. great in become our society. Here,importance disposal has the last resort and is an issue of great importance in our society. This focus on the importance of preservation and resource This focus on the importance of preservation resource recovery is supported by international, federal,and state and local recovery is supported by international, stateempowered and local Governments with respective regulatingfederal, authorities respective regulating empowered toGovernments ensure thesewith sustainable goals are metauthorities through effective to ensure these sustainable goals are met through effective policy implementation. policy implementation. The use of iron and steel slags (ISS), being a co-product of iron Thesteel use of iron and steel slags (ISS), being a co-product of iron and production, are predominant in road construction andmaintenance steel production, are predominant in road construction and applications. These large-scale applications and maintenance applications. These applications provide for the large-scale recovery of large-scale an abundant product provide for the large-scale recovery of an abundant product which demonstrates the goals of sustainability. which demonstrates the goals of sustainability. With the formation of the Australasian (iron & steel) Slag With the formation the Australasian (iron & steel) Slag Association in 1990,ofthere has been a number of significant Association in 1990, there has been a number of significant changes and advances in the effective utilisation of slag changes and advances in theiseffective of slag in materials. Effective utilisation the useutilisation of slag materials materials. Effective utilisation is the use of slag materials in a productive or economically beneficial way which does not a productive or economically beneficial way which does not require disposal as landfill. The vast majority of ISS produced require disposal as landfill. The vast majority of ISS produced in Australia is sold for use in today’s market.11 For example, in Australia is sold for use in today’s market. For example, in 2010, 88% percent of the 2.67 million tonnes (Mt) of ISS in 2010, 88% percent of the 2.67 million tonnes (Mt) of ISS produced was effectively utilised within various value added produced was effectively utilised within various value added civil and construction material applications throughout civil and construction material applications throughout Australasia. The key results include: Australasia. The key results include:
• 33% consumed in high value add cementitious applications • 33% consumed in high value add cementitious • 50% delivered into road construction and civil works applications • 50% delivered into road construction and civil works During the 1990s, effective utilisation of ISS remained at 30-40%. current utilisation utilization of rests around 85%, During theHowever, 1990s, effective ISS at remained at 30-40%. However, current utilization rests at around 85%, illustrating changing paradigms in the active reuse of these illustrating products. changing paradigms in the active reuse of these products. Collaborating through the Association in ‘doing together what Collaborating thewe Association in ‘doing together what we could not through do alone’, have broadened both stakeholder we not do understanding. alone’, we have This broadened both stakeholder andcould community now extends to material and community understanding. now extends to material users, specifically those in roadThis construction which has led to users, those in road construction which has led to furtherspecifically increases in effective utilisation. further increases in effective utilisation.
Slag co-products are the result of highly controlled steel-making Slag co-products are the result of highlycarry controlled steel-making processes. Therefore, these materials the same level of processes. Therefore, the same of the quality as the result ofthese thesematerials process carry controls, whichlevel ensure quality as theof result these process controls, which ensure the consistency slag of chemistry and quality. consistency of slag chemistry and quality. The types of slag covered in this guide are: The types of slag covered in this guide are: 1) Blast Furnace Slag (BFS) 1) Blast Furnace Slag i. Granulated Blast(BFS) Furnace Slag (GBFS) i.ii.Granulated Blast Furnace (GBFS) Ground Granulated BlastSlag Furnace Slag (GGBFS) ii. Ground Granulated Blast Furnace Slag (GGBFS) 2) Steel Furnace Slag (SFS) 2) Steel Furnace Slag (SFS) 3) Electric Arc Furnace Slag (EAFS) 3) Electric Arc Furnace Slag (EAFS) 4) Ladle Furnace Slag (LFS) 4) Ladle Furnace Slag (LFS)
Table 1 - Typical values for the physical properties of iron and steelmaking slags.22 Table 1 - Typical values for the physical properties of iron and steelmaking slags. Physical Property - Aggregate Physical Property - Aggregate
Blast Furnace BlastSlag Furnace Slag Rock Slag Rock Slag 1.2 1.2
Steel Slag Steel Slag
Test Method Test Method
BOS Slag BOS Slag 1.7 1.7
EAF Slag EAF Slag 1.7 1.7
100 100
250 250
250 250
(AS1141.22) 1141.22) (AS
Wet WetStrength Strength(kN) (kN)
90 90
220 220
220 220
(AS1141.22) 1141.22) (AS
Wet/Dry Wet/DryVariation Variation(%) (%)
10 10
Water WaterAbsorption Absorption(%) (%)
5 5
LA LAAbrasion Abrasion Polished PolishedAggregate AggregateFriction Friction Value Value (PAFV) (PAFV)
40 40
Bulk BulkDensity Density(t/m (t/m) )(loose) (loose) 3 3
Dry DryStrength Strength(kN) (kN)
12 12 12 12 fine -- 3.0 3.0 fine--3.0 3.0 fine fine coarse -- 2.0 2.0 coarse coarse--2.0 2.0 coarse 15 16 15 16
(AS1141.4) 1141.4) (AS
(AS1141.22) 1141.22) (AS (AS1141.5/6) 1141.5/6) (AS (AS1141.23) 1141.23) (AS
50 50
55 55
60 60
(AS1141.41/42) 1141.41/42) (AS
<1.0 <1.0
<1.0 <1.0
<4 <4
(AS1141.24) 1141.24) (AS
2,200
2,200 2,200
2,250 2,250
(AS1289.5.1.1) 1289.5.1.1) (AS
10
11.0 11.0
10 10
(AS1189.5.1.1 1189.5.1.1&&AS AS1289.2.1.1) 1289.2.1.1) (AS
Sodium SodiumSulfate SulfateSoundness Soundness (%) (%) Physical PhysicalPropertyProperty-20mm 20mm Road Road base base Maximum MaximumDry DryDensity Density(kg/m³) (kg/m³) Optimum OptimumMoisture MoistureContent Content (%) (%)
Note:- -¹OMC ¹OMCdepends dependsonon the components the mix. Note: the components ofof the mix.
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QuickReference ReferenceGuide Guide112013 2013| |Roads RoadsGuide GuideSupplement Supplement on on General General Applications Quick
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1 1
2. METHOD OF MANUFACTURE Slag is a co-product of all common steel production methods. Here it forms either through the addition of fluxes such as lime or as the oxide portion of iron ore. There are a number of different slag types produced which is dependent on the steel-making process used. Table 1 outlines typical physical properties of ferrous slag produced in Australia.
2.3 GROUND GRANULATED BLAST FURNACE SLAG (GGBFS)
2.1 BLAST FURNACE SLAG (BFS)
Figure 2.3 - GGBFS Manufacturing Process. GGBFS is produced when GBFS is ground to cement powder fineness in a ball or vertical roller mill and has an off-white colouration.
2.4 STEEL FURNACE SLAG (SFS) Figure 2.1 - BFS Manufacturing Process. BFS is produced when iron ore is reduced to iron in a blast furnace. Molten slag from the furnace is poured into pits and allowed to cool in air. Rock like minerals are formed which are then crushed and screened to separate them into aggregates and sands. Air cooled blast furnace slag materials are grey, vesicular rocks slightly lighter in weight than natural materials like basalt.
2.2 GRANULATED BLAST FURNACE SLAG (GBFS)
Figure 2.4 - SFS Manufacturing Process. SFS is a co-product of the conversion process of molten iron to steel in a basic oxygen steelmaking shop within an integrated steelworks. Where the violent reaction occurs within the vessel after the oxygen lance is lowered, a protective slag layer forms with the addition of lime. When the reaction has been completed, the steel and slag are separated and molten slag is poured into pits where the slag is cooled with waters sprays after initial solidification. Figure 2.2 - GBFS Manufacturing Process. GBFS is produced when molten BFS is rapidly quenched by a series of high pressure/high volume water sprays. These conditions cause the slag to solidify before crystallisation is able to occur, creating a glassy material.
SFS has a dark grey colour, with a particle density that is 20% greater than basalt and is definitively harder than BFS. This product crushes into a cubical shape and has the potential for expansion if not adequately weathered. Weathering is typically achieved by periodic watering, monitoring and internal stockpile management procedures.
GBFS is similar in appearance to river sand with a density of 60-70% that of natural sand.
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2
2.5 ELECTRIC ARC FURNACE SLAG (EAFS)
Table 2 - Quality Assurance Principles.3, 4, 5, 6, 7 Application
Road Base
Fill
Principle Heavily Bound: NSW RMS R73 and various Council specifications Unbound: RMS 3051 Austroads, ARRB SR41 and various Council Specifications Select Fill: NSW RMS 3071 and various Council specifications General Fill: RMS R44 and various Council specifications
3. TYPICAL CHEMICAL
Figure 2.5 - EAFS Manufacturing Process. As the molten slag is produced, it is tapped directly into adjacent pits and begins to solidify in air. This product then undergoes a further refinement process to remove the residual metallics and remaining slag, which is then separated into various product streams. As a co-product of the steel making process, EAFS is produced in an electric arc furnace. In terms of its physical appearance, the slag is dark grey in colour and harder than BFS with a particle density of 20-25% greater than basalt. This product crushes into a cubical shape and has the potential for expansion if not adequately weathered. Weathering is typically achieved by periodic watering, monitoring and internal stockpile management procedures.
2.6 LADLE FURNACE SLAG (LFS) Refer to Figure 2.5 for the diagram of the manufacturing process. LFS is a co-product of the Ladle Metallurgy Furnace (LMF) process which is the refining process of liquid steel sourced from the EAF, but prior to casting. After the EAFS process has occurred (see Figure 2.5) and most of the EAFS removed, the liquid steel is tapped from the EAF into a ladle. The ladle of liquid steel is then alloyed at the LMF to achieve the required chemical specifications. After specification is achieved, the liquid steel is poured out during casting and the remaining LFS is retained to be poured out separately, cooled, and then reprocessed to recover metallics. The composition of LFS varies depending on the EAF, ladle furnace processing conditions and the type of steel grade being produced.
2.7 CURRENT STANDARDS Quality assurance principles, as seen in Table 2, are in place to ensure the supply of high quality, safe, reliable and uniform ISS products to the market place. Under these standards, slag products are used to substitute or supplement naturally won materials to maximize natural resource sustainability, minimise waste to landfill and improve construction and manufacturing processes.
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Quick Reference Guide 1 2013 | Roads Guide Supplement on General Applications
The typical chemistry of BFS, SFS, EAFS and LFS after appropriate conditioning and weathering is shown in Table 3 below. All ISS comply with the necessary guidelines for their chemical composition. Table 3 - Typical Chemical Characteristics.8 Constituents as Oxides
Symbol
BFS (%)
Calcium Oxide
(CaO)
41
40
35
0
2
1
% Free Lime
SFS (%) EAFS (%)
Silicon Oxide
(SiO2)
35
12
14
Iron Oxide
(Fe2O3)
0.7
20
29
Magnesium Oxide
(MgO)
6.5
9
9
Magnesium Oxide
(MnO)
0.5
5
6
Aluminum Oxide
(Al2O3)
14
3
6
Titanium Oxide
(TiO2)
1
1
0.5
Potassium Oxide
(K2O)
0.3
<0.5
0.1
Chromium Oxide
(Cr2O3)
<0.005
0.1
1
Vanadium Oxide
(V2O5)
<0.05
1.4
0.3
Sulphur
(S)
O.6
<0.1
0.1
4. ENVIRONMENTAL Australia’s adopted environmental policy holds closely to the precautionary principle without regard or recognition of the considerable scientific evidence gathered over the past 30 years.8 National environmental legislators and regulators have been hesitant in adopting more progressive and modern international approaches that incorporate sustainability objectives. Despite definitions and traditional categorisations which have kept slag labeled as a ‘waste’ material,9 our members have explored and developed innovative, value-adding options for ISS to rebut these restrictions. In recent years, National and State Environmental Departments and Agencies, as part of an overall review of the classifications of ‘wastes’ have progressively implemented changes to simplify and streamline the current waste classification systems.
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Through these systems, the Association has been instrumental in negotiating and securing various exemptions or approval pathways for ISS materials including: • Blast Furnace Slag including, Granulated Blast Furnace Slag • Steel Furnace Slag • Electric Arc Furnace Slag • Ladle Furnace Slag
5. CASE STUDIES There are numerous case studies, which demonstrate the effective utilisation of slag. The following case studies are a selection of recent projects where ISS provided solutions for the project contractor, proponent or client. Table 4 - Case Studies in NSW. Application
Amount of Slag Used (kt) 165
These exemptions represent a significant and important step towards creating greater investment certainty for our industry members.
North Kiama By-Pass Lake Macquarie City Council various projects
80
Exemptions may be used by anyone, without seeking approval from the EPA, provided the generators, processors and consumers fully comply with the conditions of the exemption. However, these exemptions do not excuse those using them from complying with relevant planning consent requirements and it is their responsibility to seek any necessary development consents from the appropriate regulatory authority.
Princes Highway Realignment Oak Flats
70
Hunter Expressway NSW
68
Wollongong Northern Distributor Extension
40
RTA/RMS various projects Greater Newcastle NSW
31
Gosford City Council various projects
22
New England Highway, Harpers Hill NSW
16
General exemptions are developed and published by NSW EPA with input from industry groups for materials which can be recovered, reprocessed or reused. These exemptions can be used without notifying the granting authority provided that the conditions of the Exemption are met. For example, conditions that are prescribed in the General Exemption give guidance for end use applications ‘such as’ concrete. This is not to mean only concrete but applications that result in bound matrices, for example, bound pavement products like slag road base. General exemptions are gazetted as they become available or when the exemption is amended or revoked. Resource Recovery Exemptions can be amended from time to time and generators, processors or consumers of waste derived materials should reference the website for the latest versions. Copies of NSW EPA exemptions gazzetted for iron and steel slags can be downloaded from: http://www.epa.nsw.gov.au/ waste/generalrre.htm In recent years, increasing awareness of environmental issues in our society has improved utilisation of slag. For example, carbon reduction opportunities through the use of slag have been tried and tested as a sustainable alternative which gives preference to this material in comparison to the use of traditional cement and quarried resources.10, 11 When coupled with member companies identifying new opportunities for slag products, investment will continue to ensure these markets are further developed.
5.1 CASE STUDY 1: NORTHERN DISTRIBUTOR EXTENSION, BULLI NSW In 2009, construction commenced on the Princes Highway Northern Distributor Extension linking Wollongong to the northern Bulli area. The main slag product used was an 80:20 ratio of air-cooled BFS:GBFS with 2% binder. In addition, 300 mm of BFS select fill and a 600 mm fines layer of air cooled BFS was used in the sub base. BFS road base was the preferred material proposed under tender. This material was preferred over natural equivalents because of its reduced compactive effort and increased life expectancy as a result of strength gain over time. Over the period of March 2009 until November 2009, 40 kt of BFS material supplied to the project. This material complied with RMS specifications R73 and 3051.
Figure 5.1 - Northern Distributor heading north.
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5.2 CASE STUDY 2: NORTH KIAMA BY-PASS, SOUTH COAST NSW The Kiama by-pass commenced construction in 2005 with a significant amount of slag used over a large area.
Once delivered to the manufacturing facility, the SFS and EAFS is blended with other constituent materials in a computer controlled process to produce a heavily bound pavement material. The stabilised road base material is placed and compacted using a combination of proven civil construction methodologies and ongoing best practice in the use of slag based materials for civil construction purposes. This material has been used in a number of applications including: •
Heavily Bound Pavement: Construction of new heavily bound traffic pavements meeting RMS specification RN73 Ed6.
Figure 5.2 - Truck unloading slag material at site. The types of slag used depended on the specific area on which the road traversed. In one section, 75 mm of air cooled BFS was used as a drainage layer. The area closest to Bombo beach required 300 mm of modified road base with an 80:20 ratio of air cooled BFS:GBFS with 2% binder.
Figure 5.3 - Aerial view of completed project.
Figure 5.4 - Heavily Bound Pavement. •
Mine Void Platforms: Existing mining voids underneath the Hunter Expressway alignment required filling to minimize the risk of mine subsidence. Slag material is a preferred material to the emplacement of unbound road base due to the increased production capacity, a safer working environment for personnel on the ground due to a stable ground covering and a decreased program due to weather tolerance.
•
Access Tracks and Platforms for Bridge Works: Most of the 23 bridges used a 200-300 mm thick layer of BFS and SFS stabilised road base as a piling platform. The advantages of using this material include decreased run off and erosion and minimal costly piling delays.
Once again, BFS was the preferred material and from January 2005 until October 2007, 165 kt of BFS stabilized road base was supplied which complied with RMS specifications R73 and 3051.
5.3 CASE STUDY 3: HUNTER EXPRESSWAY HEA, NEWCASTLE NSW In 2011, 67 kt of slag material was supplied to the Hunter Expressway in the form of heavily bound pavement and heavily bound, high load bearing hardstand material. During this process, the Specific RMS specification RN73 “Ed 6 Bound Pavement Course (Slag or Ash based)” and the relevant EPA waste regulation specific exemptions have been conformed to. The SFS and EAF slags are sourced from the Port Kembla, Rooty Hill and Newcastle steel-making operations.
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Figure 5.5 - Hunter Express way piling works at bridge BW13 on a layer of stabilized road base. In summary, the slag materials used added to the overall efficiency of the Hunter Valley Expressway project.
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6. CONCLUSIONS In terms of its competitive advantages in relation to other materials, ISS products have been proven for use in various types of applications including: cement and concrete manufacture, civil works, road construction, rehabilitation and stabilisation of existing roads, car parks and pavements. Economically, ISS are comparative to other traditional resources, but should be assessed on a case by case basis given the other performance and environmental advantages. The Australasian (iron & steel) Slag Association will continue to advocate for the current and potential uses of slag products as well as improving regulatory understanding of the benefits arising from slag use.
REFERENCES 1. http://www.asa-inc.org.au/annual-membership-reports.php (2012) 2. Australasian (iron & steel) Slag Association (2002), A Guide to the Use of Iron and Steel Slag in Roads: 2nd Revision, Wollongong, IHG Design (with amendments) 3. NSW RMS, R73, http://www.rms.nsw.gov.au/doingbusinesswithus/ specifications/roadworks.html 4. NSW RMS, 3051, http://www.rms.nsw.gov.au/doingbusinesswithus/ specifications/materials.html 5. ARRB, SR41, http://www.arrb.com.au/Information-services/Publications.aspx 6. NSW RMS, 3071, http://www.rms.nsw.gov.au/doingbusinesswithus/ specifications/materials.html 7. NSW RMS, R44, http://www.rms.nsw.gov.au/doingbusinesswithus/ specifications/roadworks.html2. Heidrich, C. (2010). A move towards legal certainty - changing the waste paradigm 6th Global Slag Conference and Exhibition, Sydney, Pro Publications. 8. Australasian (iron & steel) Slag Association (2002), A Guide to the Use of Iron and Steel Slag in Roads: 2nd Revision, Wollongong, IHG Design, p. 6 (with amendments) 9. Heidrich, C. (2010). A move towards legal certainty - changing the waste paradigm 6th Global Slag Conference and Exhibition, Sydney, Pro Publications. 10. Heidrich, C., I. Hinczak, et al. (2006). GGBFS lowering Australiaâ&#x20AC;&#x2122;s greenhouse gas emissions profile. Global Slag Conference, Bankok, Thailand, GBC. 11. Woodhead, A., C. Heidrich, et al. (2010). A sustainable supply chain approach to creating new EAFS product opportunities. 6th Global Slag Conference and Exhibition, Sydney, Pro Publications.
AUSTRALASIAN (IRON & STEEL) SLAG ASSOCIATION Suite 2, Level 1, 336 Keira Street, Wollongong NSW 2500 Australia PO Box 1194 Wollongong NSW 2500 Australia Telephone: +61 2 4225 8466 Fax: +61 2 4228 1777 Email: info@asa-inc.org.au
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WE NEED YOUR CONTENT Connections is produced twice a year for the benefit of ASA members. If you have an article you’d like to contribute that may be of interest, please contact us! The types of content we are looking for include: • New developments or technologies • New projects • New employees We also have a Member Profile section, which is open to all member companies for contributions on behalf of the business in general, or a specific employee. If you have an idea or even some content that you think might make an interesting article for our readers, get in contact with the Editor, Emma Bruce, today: publications@asa-inc.org.au
SUBSCRIBE TO www.asa-inc.org.au Views expressed in Connections newsletter do not necessarily reflect the opinion of the Australasian Slag Association. All contributions are welcomed, though the publisher reserves the right to decline or edit for style grammar, length and legal reasons.
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