RP1020u1: Demonstrating the practical use of geopolymer concrete: high density coastal protection units

_{Peer Reviewed Research Publications}

RP1020u1: Technical Paper: Development of high-density geopolymer concrete for breakwater armour for Port Kembla Harbour

Coastal infrastructure is under constant attack from the marine environment. Under current conditions, breakwaters and seawall armoured by rock or concrete units require regular monitoring and maintenance. But with anticipated changes to the coastal wave climate due to climate change scenarios, costal structures would be exposed to even greater wave energy, and higher rates of damage.

In this project, researchers and industry partners worked together in the development and trial of a unique, sustainable high-density Geopolymer concrete mix for coastal structures. The system developed in the laboratories of UNSW was upscaled and is being tested at the northern breakwater of NSW Ports’ Port Kembla Harbour. The concrete uses steel furnace slag (SFS) aggregate in a blended fly ash-blast furnace slag binder to eliminate delayed hydration and expansion of the aggregate.

The concrete properties were measured and microstructural analysis undertaken. The results show that SFS aggregate offers higher bulk density to the concrete and can reduce armour mass requirements. This important result provides a novel approach to both repair of existing structures, and construction of new structures with reductions to both cost and carbon footprint.

Concrete in Australia, Vol 44, No. 4, pp 34-39

Development of high-density geopolymer concrete for breakwater armour for Port Kembla Harbour (1314075 PDF)

_{CRCLCL Project Reports}

RP1020: Field Performance of Geopolymer Concrete Structures

A major barrier to the adoption of Geopolymer concrete in construction is the lack of long-term performance data. Field testing can determine the behaviour of geopolymers in different service environments and address the gaps in knowledge. The University of New South Wales and Swinburne University of Technology undertook field testing to examine durability aspects including carbonation, chloride ingress, reinforcement corrosion and acid attack. This report describes: in-situ testing and core sampling of Geopolymer concrete at four sites across Australia; long-term performance monitoring of two Geopolymer concrete structures; and in-situ test procedures to investigate the biogenic corrosion of mortar specimens.

crclcl rp1020 final report gpc field testing final 260218 (23378406 PDF)

RP1020 Pilot Study on the Development of Synthetic Lightweight Aggregate

Utilisation of Coal Combustion Product (CCP) from coal-fired power stations is of great interest in Australia. According to ADAA (Ash Development Association of Australia), in 2012, 12.8 Mt (million tonnes) of coal ash was produced from coal fired utilities in Australia [1]. Due to the increase in energy demands, the amount of coal ash continues to increase each year. This increases the pressure on coal and utility industries and associated waste management, to find solutions to the environmental problems that are associated with coal ash production.

One of the good approaches to utilise CCP is to convert fly ash into aggregates as a natural aggregate replacement. The main reasons to consider this approach are: (1) the continuous increasing demands for aggregates and (2) the depletion of the natural aggregate resource. Manufacturing of economical and good quality synthetic fly ash aggregate will reduce the impact of fly ash on the environment and provide a great benefit to economy.

Most fly ashes are physically and chemically suited for production of synthetic aggregates. By using different processing methods, it is possible to produce different qualities of synthetic aggregate in terms of strength, particle shape and density. Therefore, the synthetic aggregate can be more flexible than the natural aggregate as they can be used indifferent applications.

rp1020 synthetic aggregate report (2932627 PDF)

_{Fact sheet}

RP1020u1 FACTSHEET: Turning Waste into Low Carbon Marine Concrete

We have commenced a trial at NSW Ports’ Port Kembla Harbor to validate geopolymer concrete in the marine environment. A small batch of 18-tonne Hanbar units made from high density GPC have been cast and placed on the north breakwater. These units will be monitored for stability and integrity, and will provide a valuable benchmark for future use of geopolymer concrete.

rp1020u1 geopolymer concrete (495388 PDF)