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INNOVATION AND TRENDS IN RMC
INOVAÇÃO E TENDÊNCIAS NO
BETÃO PRONTO
24 May 2018
APEB – Concrete Day - Lisbon
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PAST AND PRESENT: materials
Innovation, since the birth of readymix concrete industry, mainly involvedcomponents in concrete:
• Cement: the range has broadened to suit different needs + CO2 and environmental constraints
• Admixtures: a giant leap!• Other components: fibers, fly ash, silica fume and slag, lightweight aggregates• Aggregates & water: no changes
The trend continues but no revolutions are foreseen.
Main topics for components:• Circular economy• CO2 reduction
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PAST AND PRESENT: production
Truckmixers: bigger and faster, but mainly the same. We follow the truck industry: hybrid or electric in the future?
Plants: «standard» performances. Dry or wet, improvements in sensors but no revolution.
Plant automation: follows the average trend of the heavy industry.
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FUTURE
In a rapidly changing world, RMC industry is still mostly conservative.
The concept of concrete itself will not change: a building material prepared mixing aggregates, other components and binders to be poured and hardened in the final shape.
We will have possible innovations in the whole process:
• New performances: requirements, control and assessment• Tailor made design• Specification, order and delivery
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FUTURE
WHY INNOVATE?
High tech materials have higher appeal higher margins!
Industrial process: designed, controlled, measured and traced risk control!
Innovation in products new markets!
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MAIN FIELDS
SUSTAINABILITY
DIGITALIZATION
WASTE
LOGISTICS
QUALITY
PRODUCTS
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Innovation and trends in RMC
SUSTAINABILITY
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SUSTAINABILITY
3 pillars of sustainability:
• Social: concrete is STRONG
• Economic: concrete is STRONG
• Environmental: concrete is (mostly perceived as ) WEAK
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SUSTAINABILITY: environmental
PRODUCT CARBON FOOTPRINT
LOW CO2 CEMENT, WASTE AS FUEL
EPD – PEF – LEVEL(S)
Mostly cement related
RECARBONATION
RECYCLED AGGREGATES
WASTE/SECONDARY MATERIALS
Onlymaterial
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SUSTAINABILITY: environmental
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SUSTAINABILITY: environmental and safety
POLLUTION AT JOB SITES – NO FOSSIL FUEL TRUCKS AND PUMPS
NOISE REDUCTION AT JOB SITES
WASHING - DRUM AND PUMP CLEANING AT JOBSITES
SAFETY ISSUES FOR TRUCKMIXERS AND PUMPSChutes handlingLadderBooms
Truckmixer and pumps cleaning: build up concrete demolition
EXTERNAL
INTERNAL
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WASTE no waste industry
CEMENTITIOUS WATER AND WASTE CONCRETE ARE POLLUTANT
Leftover concrete: some uncertainity in legal definition
Possible actions: rework, separate, harden and crush, pour blocks…
Hardened concrete: landfill or reuse? Truckmixer washing water: leave it in or discharge?
Recycled aggregates (C&D and leftover): national provisions
Sludge water: density measurement, full recycling in production qualitycontrol
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SUSTAINABILITY: RSS
RESPONSIBLE SOURCING SCHEME
The certificate of responsible sourcing shows the level to which a company/plant/product operates in an environmentally, socially and economically acceptable way to stakeholders and that they produce products with a low impact (relative to similar products) on the environment subject to them meeting the other demands, e.g. strength and durability, placed on the product.
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Innovation and trends in RMC
QUALITY
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QUALITY
Parameters that can influence quality
RAW MATERIALS CONTROL IN PRODUCTION = INCREASE RELIABILITY
AGGREGATES:- Moisture probes: improve reliability and range- Cleanliness: to be invented- Superficial texture – absorption: to be invented- Temperature: feasible
CEMENT- Temperature: feasible- Strength development: to be improved?- Performances in fresh concrete: standard to be improved?
SLUDGE WATER- Density: feasible
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QUALITY
ACCELERATED TEST
- To predict performances in hardened concrete.
- Durability for better prescription and acceptance test
- To test new components (e.g. for secondary materials from circular economy)
STANDARDS AND TESTS NEEDED FOR FAIR MARKET
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QUALITY
ADD PRODUCT INFORMATION TO CUSTOMER = INCREASE VALUE
Recognized standard for slump measurement on the truck: feasible
Recognized standard for quantity measurement on the truck: to be invented
Recognized standard for temperature measurement on the truck: feasible
Detection of abnormal operations: water addition, incorrect mixing: feasible
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Innovation and trends in RMC
PRODUCTS
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PRODUCTS: New performances and applications
Concrete roads
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PRODUCTS: New performances and applications
Thermal mass
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PRODUCTS: New performances and applications
Pervious concrete
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PRODUCTS: New performances and applications
Self healing:cracks reduction, water permeability reduction
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PRODUCTS
SCC
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PRODUCTS: what can we do?
Additional concrete performances for designers: tools for right concrete definition, correct pouring operations…
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Innovation and trends in RMC
DIGITALIZATION
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DIGITALIZATION
«the AMAZON concept»
Complete information integration: contract – order – delivery information - delivery notes –invoices – payment – test samples
Informations: all available on the same platform to be shared betweenproducer and customer.
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DIGITALIZATION: LOGISTICS
Plant remote control to allow small volume plants to be runeconomically.
GPS controlled fleet and computerized dispatching programs.
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Fleet efficiencyReduction of misunderstandingsProduction planningTraceabilityInformations shared with customer
DIGITALIZATION: LOGISTICS
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DIGITALIZATION: LOGISTICS
DIGITAL TRUCKMIXER
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DIGITALIZATION: PLANTS
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DIGITALIZATION
“Clever samples”: microchip or RFID to identify specimens for total traceabilityCan we think of a National archive of Control Data?
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DIGITALIZATION: BIM
If cars were designed and builtlike buildings…
You’ll get this…
And this…
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DIGITALIZATION: BIM
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DIGITALIZATION: BIM
Risk or opportunity?
Pros- Evaluate the global effect of concrete performances (strength increase and additional
features: water permeability, thermal mass, durability…..)- Competition on performances at design stage- Integration with customer’s accountability
Cons- «blocked» materials: once concrete type is defined at design stage it may become very
difficult to be changed at jobsite- Competition only on price
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3D PRINTING
Tomorrow, later or never?
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Innovation and trends in RMC
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VISION
TO MAKE CONCRETE BECOME (MORE) AN INDUSTRIAL PRODUCT, CONTROLLED AND CERTIFIED
TO ADD PERFORMANCES AND VALUE TO CONCRETE
TO HELP OWNERS AND DESIGNERS TAKE BENEFIT OF ADDITIONAL PERFORMANCES
TO MAKE CONCRETE (AGAIN) THE BEST BUILDING MATERIAL
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THANK YOU
OBRIGADO PELA VOSSA ATENÇÃO