Connections- December 2021

Vol 23 | Issue 2 | December 2021

| www.asa-inc.org.au

Just like that, another year comes to a close!

2021 was a challenge to say the least! Most of us thought the worst was over in 2020, as COVID seemingly dissipated and us Australians got a taste of post-COVID living. This bliss didn’t last long as suddenly, we found ourselves working from home again, trying to navigate life with the Delta strain. Whether you are now back at work trying to remember your desktop password or continuing to WFH, we congratulate you for making it through this difficult time.

This edition of Connections marks our second and final publication for this disjointed year, with a selection of industry stories to help you forget all about COVID. Firstly, we discuss the global rebrand of Holcim and what this means for their separately owned entities. Included in this story is comments by Holcim’s CEO, Mr Jan Jenisch, and an insight into how exactly, Holcim plans to move toward a sustainable business model.

SmartCrete CRC’s new decarbonisation pathways is featured afterward.

In light of the COP26 conference in Glasgow, SmartCrete CRC has demonstrated its belief in the need for change by outlining 8 pathways to ensure the successful transition to a cleaner industry. Find out all you need to know in the next few pages!

Next up, ASA member Australian Steel Mill Services (ASMS) supplied a substantial amount of their RBM800 slag to be used in the Nowra bridge upgrade that is part of the ongoing Princes Highway Project. This story is certainly a must-read this edition.

TH I S I SS U E

Following this, is another member story- how InfraBuild is improving the Sydney Metro network. Anyone who lives in NSW and has been to the big city knows how ridiculous travelling in Sydney can be due to the amount of people who reside there (not to mention tourists when they are able to be here). Without the Sydney metro network, it’s quite possible that getting from A to B quickly would be impossible. Hence, why this is such an important project. This story will touch on how InfraBuild is involved and how they plan to improve mobility in the city’s future.

Speaking of futures, the next story features Boral’s decarbonisation plan.

This story was constructed following the release of their Sustainability Report 2021, and features developments with their low-carbon concrete ranges and how they plan to reduce emissions in the coming years.

Bringing our focus back to a local lens, we report on The University of Wollongong’s project to advance research in steelmaking. Announced only recently, UOW has committed to building the ‘ARC Research Hub’ that will provide multiple opportunities for PHD students. PHD recipients will be able to work in the new hub, alongside industry professionals to develop more advanced products. What an amazing opportunity for Wollongong!

In one of our long-term Independent Cement & Lime, Alan Dow provides an insight into Melbourne Cement Facility’s new multi-cell concrete silo (MCS). The MCS is believed to be the largest of its kind in the world and with $90 Million to its name- It’s an update you won’t want to miss reading up on!

Our second last story this year is how the Snowy Hydro 2.0 project is using slag! If you haven’t already read up on this- I strongly encourage you do.

Find out where the slag is being used, how much is being used and how it’s helping to contribute to a lower-carbon project and future!

Finally for this edition, we have a feature article conducted from an interview we had with Living Seawalls. A project aiming to make a positive impact on marine biodiversity with concrete… yes, concrete and a mix that features slag! This article is our second exclusive article to Connections, so make sure you give it a read.

To conclude, the Australasian (iron & steel) Slag Association would like to wish you all a very happy Christmas and New Year holiday period. We look forward to commencing a new chapter in our story next year and thank our members for the ongoing support through it all.

1. Editorial 2. Holcim Accelerates the Transition to a Low-Carbon Future and Circular Economy with New Branding 3. SmartCrete’s New Decarbonisation Pathways 4. Slag Delivers Again in Regional Roads 5. InfraBuild and the Development of Sydney Metro 6. Boral's Decarbonisation Road Map 7. UOW and Australian Steel Innovation 8. Melbourne Cement Facilities New Multi-Cell Concrete Silo 9. How The $5.1 Billion Snowy Hydro 2.0 Project is Using Slag 10. Living Seawalls: How They’re Bringing Sea Life Back into Busy Urban Areas with the Help of Some Slag 12. Three Teams in the US Join Forces and Give New Life to Stored Ash 13. Carbon Concrete Mix Takes Out Two Prestigious Awards at the 2021 Sustainability Awards 13. Write for ASA Connections

CONNECTIONS EDITORIAL TEAM | December 2021 Edition

CONTENTS

Editorial

21

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: May Anderson Design: 101 Design Contributors: May Anderson, Dan Webb, Craig Heidrich A bi-annual publication with an online circulation of 1500 copies

@asa_info

@australasian-iron-steel-slag-association

connections December 21 | 01

HOLCIM ACCELERATES THE TRANSITION TO A

LOW-CARBON FUTURE AND CIRCULAR ECONOMY WITH

WITH NEW BRANDING

Holcim’s CEO, Mr Jan Jenisch said, “We are launching our new Holcim group identity as a symbol of our vision to become the global leader in innovative and sustainable building solutions."

With a deep desire to ‘play their part’ to accelerate the transition to a low-carbon future and circular economy, Mr Jenisch says the new group identity is necessary to accommodate for population growth, urbanisation, and climate change. Mr Jenisch describes Holcim as the “home to some of the world’s most trusted brands in the building sector" which includes ACC, Aggregate Industries, Ambuja Cements, Firestone Building Products, Geocycle, Holcim and Lafarge. For Holcim to work towards their goal to build progress for people and the planet, the decision to unite all these unique companies was made. “Our new Group identity sends a signal to the world that we are fully committed to transforming ourselves to be part of the solution,” Mr Jenisch said.

Holcim have been a long-term user and innovator in the development of SCM’s use in cement and concrete manufacture toward low carbon concretes. Holcim’s new branding aligns well with the Australian cement and concrete industry recent declaration and ambition to deliver net zero carbon cement and concrete by 2050, as reported in the SmartCrete CRC report.

Holcim stated goals and how they’ll be achieved: • Using energy-efficient and low-carbon solutions to make cities greener from the inside-out.

• Developing smarter infrastructure that will enable green mobility and renewable energy all the way to essential sanitation.

• Improving living standards for all with affordable solutions.

• Building more with less, driving principles of the circular economy.

• Working to become a net-zero company with sustainability at the focus point of their business strategy.

The Australasian (iron & steel) Slag Association's member, Holcim Australia & New Zealand communicated via LinkedIn that they are "thrilled to join our global company in announcing their new group identity" explaining that "Our world is changing in many ways, with population growth, urbanisation and the climate challenge, so too must we. [This] announcement reinforces our determination to play our part to accelerate low-carbon and circular construction so that we build a net-zero and more inclusive future,” and demonstrates the level of commitment amongst this diverse company.

www.asa-inc.org.au

connections December 21 | 02

SMARTCRETE’S NEW

DECARBONISATION PATHWAYS

SmartCrete CRC has announced in a recent press release, it’s “proud to have been a major contributor to the new independent report “Decarbonisation Pathways for the Australian Cement and Concrete Sector” that was launched on the 19th October 2021, and strongly believes that this document charts a practical way forward to lowering sector emissions by 2050,” they said.

The new report identifies 8 detailed decarbonisation pathways with actions that are essential to implementing this plan successfully. These are: • • • • • • • •

Zero emission electricity and transport Innovation through design and construction Further innovation in concrete Increased use of supplementary cementitious materials in concrete New CO2 efficient cements Alternative fuels and green hydrogen Accounting for concrete to uptake CO2 (re-carbonation) Capture remaining CO2 (CCUS)

In light of COP26, it is vital to outline pathways to achieve climate targets. SmartCrete CRC is paving the way to success and providing an example for us all to follow. The Australasian (iron & steel) Slag Association looks forward to supporting SmartCrete in its endeavour.

Key Pathways to Net Zero For Australian Cement And Concrete Identified Report can be downloaded from website @ (https:// smartcretecrc.com.au/key-pathways-to-net-zero-for-australiancement-and-concrete-identified/)

SmartCrete says they will “continue to facilitate the creation of networks between the concrete industry and research providers to address the research requirements that have been identified,” to ensure the long-term viability of vital concrete infrastructure, they said. SmartCrete CRC has also said it is ready to consider relevant projects that support key innovation areas. In addition, the organisation has funding available to realise these projects.

Sustainability is one of the three focal research streams for SmartCrete CRC and its partners. The goals of the current COP26 summit in Glasgow further validates the need for collaboration between government, industry, and research providers to uncover solutions in the fields of technology, application, and regulation. SmartCrete CRC provides a unique opportunity for the industry and stakeholders to address these goals and generate a lasting legacy.

“Our challenge to all participants in the concrete supply chain is to examine the topic of climate change and discuss what SmartCrete CRC can do to assist in addressing the issues raised at COP26,” they said.

“SmartCrete CRC is facilitating change for the industry, and we require industry contribution and commitment to allow us to leverage practical research and pave the way forward to lower carbon future,” they said.

www.asa-inc.org.au

connections December 21 | 03

SLAG DELIVERS AGAIN IN REGIONAL ROADS AUSTRALIAN STEEL MILL SERVICES Pty Limited

Iron and Steel Slags (ISS) are co-products at the heart of the Australasian (iron & steel) Slag Association members value added activities – and again are being used in a local road infrastructure project to improve traffic congestion in NSW’s Shoalhaven region.

The Nowra Bridge project in NSW that’s been underway since 2020 is one step closer to the finish line after completing another developmental stage. Association member, Australian Steel Mill Services (ASMS) is playing a pivotal role in the next stage of development, after substantial amount of ASMS' RBM800 slag to be used in the bridge approaches in coming months.

FACTS AND PROGRESS POINTS:

Due to be completed in 2024, this $342 million project aims to amend the renowned traffic jams associated with this area. This will be achieved by transforming the old two-lane bridge into a cycle path/walkway and creating a new multilane bridge that will allow more traffic to flow over the magnificent Shoalhaven River. The new bridge will have four lanes going into Bomaderry and three lanes into Nowra with an additional walkway on the opposite side to the old bridge.

•

The completion of the latest stage in the development process means motorists will soon be able to drive on the new section of Illaroo Road and allow for the widening of nearby roads.

State Member for South Coast Shelley Hancock said that the project uses many engineering tactics to ensure the project is completed in due course.

• •

• • • •

The construction of this project is supporting over 200 local jobs.

Each double-T bridge deck segment of the new bridge requires 360 cubic metres of reinforced concrete and up to 60 concrete trucks.

Piles were built by vibrating and hammering steel casings through the riverbed and into the rock layer deep below the river.

Excavating and removing river sediment inside the top segment of the pile casings and replacing this with reinforced concrete is continuing.

RBM800 slag is intended to be supplied and used in the bridge approaches by ASA Member ASMS. Ground Granulated Blast Furnace Slag GGBFS could also be provided by ASMS however, this can't be confirmed at this stage.

Additional work, including the construction of a new road, building the northern end of the bridge, and the finishing details will begin in the coming months.

The use of slag in this project is a fantastic achievement for industry, the environment, and Circular Economy. Utilising this highly valuable resource will reduce energy usage, greenhouse gas emissions and the number of raw materials used while delivering the same quality result.

www.asa-inc.org.au

connections December 21 | 04

INFRABUILD AND THE

DEVELOPMENT OF SYDNEY METRO Amongst the hustle and bustle of pre-COVID Sydney, a new project to update the Sydney Metro network began. Beginning in 2019, Sydney Metro became known as ‘Australia's biggest public transport project [that is] revolutionising the way Australia’s biggest city travels'. By 2024, Sydney will have 31 metro railway stations and a 66 km standalone metro railway system thanks to this development.

In efforts to keep ‘on track’ with the tight construction schedule, ASA member InfraBuild was approached to assist with meeting project demands through innovative reinforcing.

How InfraBuild Contributed • • •

•

InfraBuild delivered over 48,000 tonnes of reinforcing steel across 7 sites to Sydney Metro City & Southwest stations InfraBuild’s 3D Modelling was essential for delivering the Martin Place, Victoria Cross, and Barangaroo stations with accuracy and assurance of constructability.

Additionally, InfraBuild supplied up to 1700 tonnes of prefabrication cages that allowed uninterrupted access to the tunnel’s main traffic area for associated trades, which in turn allowed more than 50 tradespeople to have uninterrupted access and continuity of on-site works. Additionally, the cages incorporated structural support through load-bearing internal girders fabricated from reinforcing bars that enabled simple attachment to surrounding cages.

Eliminated material wastage by replacing traditional lapped joints (that would’ve required a great deal more material- up to 1800 tonnes approx.) with Couplers as the best solution to address bar congestion and eliminate potential material wastage from lapping.

As outlined in the project report, the primary contractor (JHCPBG joint venture) was able to hand over Victoria Cross Stations ahead of schedule. In total, InfraBuild saved up to 30 + days on the demanding construction schedules across 3 sites.

Through their new technological approach to this project and its many sites, InfraBuild successfully reinforced how sustainable steel can make a difference in developing projects for the future.

www.asa-inc.org.au

connections December 21 | 05

DECARBONISATION ROAD MAP Boral has some big changes coming in the 2022 financial year. From expanding its low-carbon concrete range to new grants and projects, Boral will have its 'plate full'. Last week, Boral released its Sustainability Report 2021 outlining the business' renewed path to reaching net-zero emissions by 2050 and detailing its progress in the last year.

One of the highlights of the new report was that the company will be investigating re-carbonation technology at its Berrima Cement Plant in New South Wales. This comes after Boral was awarded "up to $2.4 million as part of the Australian Government’s Carbon Capture, Use and Storage Development Fund towards a pilot-scale carbon capture and storage project for re-carbonation technology known as mineral carbonation,” that was stated in the report.

Boral also stated in the report that the pilot project will develop a carbon storage technology where the carbon captured from the Berrima Cement plant will be stored permanently in recycled concrete, masonry and steel slag aggregates. As a result of this, recycled aggregates will replace the natural aggregates used in concrete products. In doing this, Boral will be supporting a more circular economy through using less virgin material.

Additionally, Boral stated its commitment to developing its lower carbon concrete range and recycling business that includes a new range of low-carbon concrete. Boral CEO and Managing Director, Mr Zlatko Todorcevski, stated that, “In FY2021, Boral expanded its lower carbon concrete offering to include Envirocrete Plus to help drive adoption and use of its lower carbon concrete. It is also increasing its contribution to a more circular economy by growing its recycling business, which processed more than two million tonnes of construction and demolition materials during the year,” Mr Todorcevski said.

A key focus for Boral's decarbonisation pathway is to reduce cementitious intensity through their lower carbon concrete (LCC) strategy. "By shifting our conventional concrete mixes to our Envisia, Envirocrete and Envirocrete Plus range of LCC products, we will reduce our use of cement in the production of concrete,". These LCC products replace cement with supplementary cementitious materials (such as groundgranulated blast furnace slag and fly ash) and use proprietary binder technology to deliver lower embodied carbon concrete while maintaining and/or improving engineering outcomes.

Boral believes the development of this range is crucial to the adoption and use of environmentally beneficial building materials.

www.asa-inc.org.au

Looking further into the future, Boral says they plan to continue their partnership with the University of Technology Sydney, to improve and accelerate research into new binders and developing the next generation of Envisia concrete. The lower carbon concrete range currently incorporates 40%-55% SCMs such as ground-granulated blast-furnace slag and fly ash, replacing cement but Boral has plans to improve this even further. "We want to push lower carbon boundaries even further while maintaining the practical properties of regular concrete," Mr Todorcevski said.

Being a larger and more public leader in sustainability for an ever-changing industry is a big task, but Mr Todorcevski has no plans to back down. “In my first year as Boral's CEO and Managing Director, we have reshaped Boral to be a stronger and more sustainable business, focussed on our core Australian construction materials business... [and] we believe that being a leader in sustainability is the right thing to do and is central to our future success. Building on our strong foundation, we’ve set a bold ambition that is embedded within our business strategy,” Mr Todorcevski said.

Re-carbonation, an emerging technology, is recognised by the Intergovernmental Panel on Climate Change (IPCC) and is the process where materials (such as recycled concrete) are processed with CO2 to accelerate re-carbonation and permanently store the CO2 in a mineralised form known as mineralised carbon products.

connections December 21 | 06

UOW & AUSTRALIAN

STEEL INNOVATION The University of Wollongong in Australia has announced the plans for its ARC Research Hub for Australian Steel Innovation (Steel Research Hub or The Hub). The Hub is a 5-year research program, valued at $28 million, that is designed to "support the transition of Australia’s steel manufacturing industry to a more sustainable, competitive, and resilient position based on the creation of new, higher value-added products and more advanced manufacturing processes".

The Hub is seen as a large asset to Australian nation-building and has lots to give. Led by UOW, The Hub brings together 9 separate universities, (including RMIT, ANU, SUT, UON, Deakin, USYD, UNSW and Monash) and additionally, 9 industry partners (BlueScope, InfraBuild (Manufacturing), InfraBuild (Wire), Liberty Primary Steel, ArcelorMittal, Australian Steel Institute, Bisalloy, Weld Australia and Australian Industry Group). With a team of experts, The Hub is aimed at securing a globally competitive domestic steel manufacturing industry for Australia, whilst contributing to economic growth, employment and research into a necessary technological shift in the steel supply chain.

ASA MEMBERS AND THEIR INVOLVEMENT

The University of Wollongong says that to accomplish this goal, a team of dedicated professionals are needed to 'make it happen'; and they'll do whatever it takes. The Hub will create a multi-disciplinary team of 20 Post-Doctoral Research Fellows and 31 PhDs, across 4 integrated research programs, that will create a skilful and diverse workforce, which is critical in achieving a transformation across the industry.

Another one of the ASA's dedicated members is contributing to The Hub as a testament to their new Net-zero carbon emissions by 2030. As a big supporter of the Circular Economy and waste reduction technologies, InfraBuild is committed to Australia's greener future in this industry and collaborations with other likeminded organisations.

Areas of research focus: • Integrating advanced enabling technologies in large and small businesses • Developing step-change performance in anti-corrosion treatments and coating lines • Generating more functional and durable products and increasing resource intensities.

BLUESCOPE

BlueScope, one of the ASA's dedicated members has contributed $4,533,000 cash, and $4,863,660 in-kind to the research program as a sign of their commitment to supporting steel manufacturing and product research and development.

With The Hub, BlueScope and its researchers will actively participate in research activities across all 4 programs.

INFRABUILD

SWINBURNE UNIVERSITY OF TECHNOLOGY

Swinburne University of Technology (SUT), ASA dedicated member is a world-class university creating social and economic impact through science technology and innovation. SUT will be contributing to The Hub via research avenues and is committed to assisting Australia in developing a greener industry future.

OPPORTUNITIES FOR PHD STUDENTS If this isn't good enough, The Hub is also offering additional support to prospective Ph.D. students who are successful in securing an AGRTP* at the University of Wollongong and wish to conduct a PHD in steel-related disciplines.

Those interested in securing a PHD with The Hub are encouraged to apply on UOW’s website. *Australian Government Research Training Program Scholarship Additional Support.

www.asa-inc.org.au

connections December 2021 | 07

MELBOURNE CEMENT FACILITIES NEW

MULTI-CELL CONCRETE SILO In efforts to meet Victoria’s demand for cementitious materials, the Melbourne Cement Facility (MCF) has embarked on the construction of an additional 45,000-tonne Multi-Cell Silo (MCS). The MCS is believed to be the largest of its kind in the world is under construction at South Wharf in Port Melbourne.

Designed to store multiple cementitious products such as Portland cement, ground granulated blast furnace slag (GGBFS) and fly ash the MCS is configured to receive a wide variety of pneumatic self-discharge vessels, accordingly the facility has been a design challenge for the team at MCF. This $90 million investment is a key piece of infrastructure that will supply Victoria’s “Big Build projects” into the future, with expectations for total completion in late 2022.

Design challenges the project needs to overcome Located on some of the most difficult soil conditions, the foundation design has gone through significant rigour to ensure all conditions of silo loading can be safely accommodated, including earthquake loads. A significant number of 1m diameter Continuous Flight Auger concrete piles have been constructed 40m through the Coode Island Silts into the Moray Street Gravels.

The concrete mix designs contain various SCM’s to obtain various desired durability properties, (such as CI resistance, ASR conditions and durability whilst reducing the heat of hydration) demanded of the piles. Once these piles had been installed, a pile cap was required to connect all the piles, resulting in a sharing of the silo loads across all piles. The pile cap used was 1100 cubic metres, 1.3 metres deep that used cement and slag mix. 35% Cement/65% Slag mix was incorporated in the mix design to achieve both these specifications. This was of significant mass and thickness, demanding not only durability for its location but reduced heat of hydration to meet the design specification.

www.asa-inc.org.au

Temperature monitoring was undertaken to ensure maximum differentials could be measured. Slag [Eco blend] was supplied from the nearby Steel Cement grinding facility. Steel Cement has been supplying the Victorian market for over 30 years, so it was great to share this local and relevant application with operators at the Yarraville plant, “all too often operators at the facility see tankers come and go without regard to the project destination,” said Alan Dow (Independents Cements Group Operations Manager) “observing the silo construction to its 80m finished height will now have some relevance for the operators,” Mr Dow continued.

The continuous slip walls will also contain supplementary cementitious products in the mix design to meet the demands of the continuous slip process, requiring 100 operators around the clock to feed reinforcement and concrete as the form continually moves upwards. Elements of the inverted cone are formed as precast elements and lifted into place and stitched jointed into place. Specialist supervisors have joined the project team to ensure the elements that will make up the final structure, are constructed per the designer’s intent. As part of the project team, Alan Dow has described the project as demanding and unique in both its design and construction, a showcase of concrete applications and construction techniques, combining continuous slip, traditional in-situ form, precast elements, and concrete piles to build a silo superstructure entirely of reinforced concrete, including the roof.

Steel Cement is a founding member of the Australasian (iron & steel) Slag Association (ASA), instrumental in the original formation of the Industry Association in 1990. Alan Dow was a member of the inaugural Executive Committee for the Association and has seen significant changes in those 30 plus years, with its acceptance as an important supplementary cementitious material. Steel Cement congratulates the work undertaken by various ASA working committees to promote the application of iron and steel slags into such significant projects.

connections December 21 | 08

HOW THE

$5.1 BILLION SNOWY HYDRO 2.0 PROJECT IS USING SLAG

The 5.1 billion dollar Snowy 2.0 project is one of the largest renewable energy projects in Australia that supports the transition to a low-carbon future.

Located in the beautiful Snowy region of NSW, the project aims to link two existing dams, Tantangara and Talbingo, through approximately 27km of tunnels and a new underground power station.

Once linked, water will be pumped to the upper dam when there is a surplus of renewable energy production, and the energy demand is low. The water will then be released back to the lower dam to generate energy when electricity demand is high. In doing this, the 2.0 project will offer flexible, and readily available power. This process also allows for the ‘recycling’ of water in a loop to maximise the efficiency of renewables, “by using excess solar and wind energy to pump water to the higher dam, to be stored for later use” (Snowy Hydro 2.0 2021).

RECENT UPDATES

In October, Snowy Hydro launched their precast factory in nearby-town, Cooma. In this factory, about 130,000 concrete segments are being produced to line the lengthy tunnels, connecting the two dams. To keep up with the demanding nature of this task, approximately 220 locals have been employed to work within the factory.

Not only does this make for local job opportunities, but also a larger opportunity for the use of local materials and SCM’s to manufacture these concrete segments. Raw, local materials are said to be mixed into the concrete mixture within the batching plant that is then transferred to the precast factory. Here, the special concrete mixture is poured into specialised moulds every 10 minutes, making it possible to produce and install 72 concrete segments (8 rings) a day on average.

Snowy Hydro has also said that up to 70,000 tonnes of ground granulated blast furnace slag (GGBFS) will be used to produce the segments. With the use of GGBFS, the amount of cement required for the project is reduced by up to 40%. Using GGBFS for the segments is a notable low carbon initiative by the Snowy Hydro team to affirm their commitment to supporting the transition to a lowcarbon future.

MOVING FORWARD INTO THE FUTURE The segments provided by the new factory will be supplied to the three Snowy 2.0 tunnel boring machines (TBM) as “they excavate and line more than 27 kilometres of tunnels between Tantangara and Talbingo reservoirs” (Snowy Hydro 2.0 2021).

Snowy Hydro reports that The Lady Eileen Hudson TBM is well underway excavating the main access tunnel (currently more than 600 metres in), and the second machine, TBM Kirsten, is being assembled ready for commissioning and launch.

www.asa-inc.org.au

connections December 21 | 09

LIVING SEWALLS HOW THEY’RE BRINGING SEA LIFE BACK INTO BUSY URBAN AREAS WITH THE HELP OF SOME SLAG. It's not every day you stumble across a project that uses concrete panels to encourage sea life back into urbanised harbours... Yes, that's right, concrete.

It seems that in recent years, concrete has been given a spotlight in the media that not been very positive whatsoever.

As the world's most used material second to water, the manufacture of concrete, in particular cement, results in large amounts of carbon dioxide being emitted. Many ENGO’s across the world label concrete as ‘climate’ a problem. But what if it's the solution?

The Australasian (iron & steel) Slag Association mission is to expand the effective and beneficial use of iron and steel slags.

Various forms of Slag can be used to manufacture concrete to reduce the amount of cement and natural aggregates in the mixture (which is better for the environment). Technically, its’ common knowledge that including slag in concretes increases workability, durability, and water tightness, providing benefits to all those who choose to utilise this SCM.

The team at Living Seawalls recognise the opportunity to utilise these resources to make an environmental impact. Back in November, the Australasian (iron & steel) Slag Association had the chance to sit down with Aria Lee (Research Assistant) and Alex Goad (Director and Industrial Designer) from Living Seawalls to learn more about this project.

At Living Seawalls, it is clear the team is trying to change the way we think about building in the ocean. Specifically, instead of building structures that are damaging sea life- what if we could give back to life under the sea?

Living Seawalls has been operating for the past three years though is a product of over 20 years’ worth of scientific research.

As a result of this research, the organisation identified a large problem and worked to find a solution.

Continued over..

www.asa-inc.org.au

connections December 21 | 10

THE PROBLEM:

Seawalls are a dominant feature in urbanised areas around the world. All you must do is go to Sydney Harbour to witness where the property meets the sea. To ensure the structural integrity of these great edifices, seawalls are common.

The problem is that seawalls pose a threat to marine life, which are vital in providing a range of ecosystemic functions. The habitat that seawalls provide is vastly different from natural foreshores. Natural shores typically consist of several microhabitats, such as crevices, cavities, pools, boulders, and overhangs that support the recruitment of marine life (such as barnacles, seaweed, oysters and more).

Seawalls are typically the opposite- smooth surfaces that deflect anything that comes upon it. Not only this, but the material type, roughness, porosity, and chemical composition of the substrate also differ between seawalls and natural shores. This would only naturally affect the habitation in this area.

THE SOLUTION:

Having been based on over 20 years of research, Living Seawalls set out with a mission to conjure a solution that benefits all parties.

It became evident almost immediately that there's no stopping the construction of seawalls or in fact, the construction boom. The global extent of these marine built structures is significant, cumulatively covering 32,000 km2 Living Seawalls in conjunction with a precaster have formed what Alex Goad describes as an "Eco blend" concrete mixture featuring slag, fly ash and other SCMs (such as ground shells) to curate a concrete panel that mimics natural rock formations. In total, there are 10 different 'Habitat panel' designs aiming to attract different species per panel. The panels are formed by precasting in a 3D printed mould designed by project partner, Reef Design Lab (directed by Alex). Following a series of tests, these panels are then sent out to fulfil their purpose. Successful test completion saw the seawall panels able to withstand up to 2 tonnes of pressure while still maintaining structural integrity.

In future, Alex told the ASA that he's open to experimenting with more recycled materials, providing it is safe to do so. Some PhD students are also experimenting with coloured concrete to see if colours impact the habitation on certain panels, leaving room for further development.

WHY WE SHOULD CARE? Research Assistant Aria Lee says that the support of the construction and building industries can make all the difference. Implementing simple strategies like Living Seawalls allows for a sustainable solution for marine life that has been impacted.

In an interview with the Australasian (iron & steel) Slag Association, Ms Lee said, "I'd just like to stress this is the sector that can push forward change... Building multifunctional structures makes sure we give back to the environment," she said.

Living Seawalls is changing the face of marine construction and conservation one panel at a time. Being an Earthshot Prize Finalist in 2021, this organisation still has so much to give.

The Australasian (iron & steel) Slag Association would like to thank both Alex and Aria for their insight and contribution to this article.

www.asa-inc.org.au

connections December 21 | 11

THREE TEAMS IN THE US JOIN FORCES

AND GIVE NEW LIFE TO STORED ASH

LafargeHolcim (US) has announced a new "multi-year project" that will give new life to ash lying in existing repositories.

In the second week of November, Holcim, and its subsidiary, Geocycle and CenterPoint Energy Inc. announced a 'major milestone' in their multi-year initiative with the first shipment of coal ash. This shipment is part of a project that Holcim estimates will result in the "recovery and recycling of more than six million tons of coal ash for beneficial reuse in producing cement," they said in a recent press release.

Amongst the three companies, US$80 million in infrastructure was purchased to extract, process, transport, store and recycle the coal ash produced at CenterPoint Energy’s A.B. Brown generating station in Evansville, Indiana. This ash is then transported for use in concrete at LafargeHolcim’s flagship cement plant in Ste. Genevieve, Missouri, reducing the number of natural materials whilst recycling piled ash.

Lafarge Holcim's CEO for US cement, Toufic Tabbara said, “This milestone is an example of how industry participants together can develop creative and efficient solutions that contribute to the circular economy. Together, LafargeHolcim, Geocycle and CenterPoint Energy will avoid landfilling for power plants and reduce the consumption of non-renewable raw materials. This is a clear win-win for people and our planet,” she said.

The first shipment that was received, contained approximately 2,000 tonnes of bottom, and fly ash from CenterPoint Energy’s A.B. Brown plant.

Since 2009, Geocycle has managed the supply of approximately 1.5 million tonnes of dry fly-ash waste from CenterPoint Energy’s A.B. Brown, F.B. Culley and Warrick generating stations for reuse at the Ste. Genevieve cement plant. This first shipment represents the next phase in operations amongst the companies.

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Steve Greenly, the Senior Vice President of Indiana Electric Operations for CenterPoint Energy said the decision to recycle the ash has reduced the impact on the environment and allowed for a choice with less financial impact than other compliance options. He told Holcim, “Our multi-year initiative with LafargeHolcim and Geocycle has been the ideal solution as it has allowed for the material to be removed from the environment and used for beneficial purposes,” he said.

According to the American Coal Ash Association, only 52% of the 78.6 million tonnes of coal ash produced in electricity generation in 2019 was reused in the US. The balance (37.6 million tonnes) was disposed of in landfills or ponds. There are more than 2 billion tonnes of stored ash in the US. To manage the amount of ash stored unnecessarily, federal regulations are attempting to mandate the closure of ash ponds and encouraging the recycling of the materials in products like cement to achieve environmental and economic benefits.

With careful material sourcing and testing, this initiative advances the treatment of stored ash material for beneficial reuse in the fabrication of more environmentally friendly concrete mixes.

Holcim says this beneficiation technology, which included trials on CenterPoint Energy’s ponded coal ash, is being deployed in select markets that are experiencing fly-ash shortages due to the ongoing retirement of coal-fired power plants in the US. Sophie Wu, Head of Geocycle North America said, “This significant circular-economy relationship with CenterPoint Energy is a powerful example of how our Geocycle recycling management business seeks out innovative solutions to turn our nation’s ecosystem challenges into opportunities that contribute value to our operations and advance our leadership commitment to a Net Zero future,” she said.

connections December 21 | 12

CARBON CONCRETE MIX TAKES OUT

TWO PRESTIGIOUS AWARDS

AT THE 2021 SUSTAINABILITY AWARDS The Architecture & Design Sustainability Awards recognise all-around excellence in sustainable construction, including the overall design and delivery of buildings, public infrastructure, and civil engineering projects in Australia.

The awards are given to projects that display a high level of sustainable architecture or design. This includes those projects that provide long-term sustainable solutions and have a positive effect on the surrounding community.

This year, Holcim Australia's ECOPact and ECOPact Zero carbon concrete has been fortunate enough to win not one, but two awards.

GREEN BUILDING MATERIAL AWARD

Partnered with Big Ass Fans, this award is given to a building product that is renewable, environmentally responsible and where the impact of the product is considered over the entire lifetime of the product.

WINNER: ECOPact and ECOPact Zero (Holcim)

About the Products ECOPact is a lower carbon concrete developed by Holcim Australia. With this product, Holcim states that carbon intensity in concrete can be reduced by up to 30-60% by replacing the standard cement with alternative, recycled materials.

These materials include fly ash, blast furnace slag or silica fume that reduce the number of virgin materials in the mix. ECOPact provides designers and contractors with easy solutions to achieve lower embodied carbon outcomes in their projects.

ECOPact is produced with significantly less cement making production more sustainable than standard concrete. ECOPact concrete can be used in conjunction with ECOPact ZERO, which offsets and compensates unavoidable process-related CO2 emissions to reach "100% less carbon emissions".

The second award is considered the most prestigious award amongst all the awards.

BEST OF THE BEST AWARD

Partnered with Alspec, this award is selected from among all the category winners based on both sustainable outcomes and aesthetics and/or innovative design principles.

WINNER: ECOPact and ECOPact Zero (Holcim)

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connections December 21 | 13

WE NEED YOUR CONTENT

Connections is produced twice a year for the benefit of ASA members and before each publication is drafted, an email is sent to all members urging them to contribute their stories.

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. So if you have an idea or content that you think might make an interesting article, get in contact with the Association 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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connections December 21 | 14