Adding Value to Concrete

BASF - The Chemical Company BASF - The Chemical Company

BASF is the global leader in the chemicals industry. Our portfolio ranges from chemicals, plastics, performance products, agricultural products and fine chemicals to oil and natural gas. Our high-value products and intelligent system solutions assist customers in virtually all industry segments to be more successful. BASF has 95 000 employees on five continents, business partners in over 200 countries and more than 150 production sites. Continuous innovation is a guiding philosophy. More than 8000 BASF employees work in research and development worldwide and the company expects to earn 4 billion in sales from product innovations by 2010. BASF carefully combines economic success with environmental protection and social responsibility, ensuring our technology contributes to a better future for us and for coming generations.

BASF Construction Chemicals Admixture Systems

Leading the way A division of BASF, the world's largest chemical company, BASF Construction Chemicals is the market leader in admixtures. Our chemical systems and formulations for the construction industry include ready-mix, precast and manufactured concrete products. Continuous innovation is key to our success. Our objectives are clear: to engineer materials to match the needs of the enduser and to drive the concrete industry forward. From the molecular level to the finished admixture, enhancing the performance of concrete for our customers is at the heart of whatever we do.

South Africa
New innovations include admixtures for high performance concretes, durable structures and fast track construction processes, concrete waste management systems, all these and more have been tailored to suit local conditions and construction practices. BASF offers you the broadest range of technologically advanced chemical admixtures, the best technical support and the proximity of a regional company with the backing of a global group. BASF Construction Chemicals South Africa is an ISO 9001:2000 accreditated company assuring the quality of our products, the integrity of our systems and infrastructure, and the high standards we apply to all our processes and interactions.

Tatara Bridge, Japan. Cable-stayed bridge with a span of 890m.

Adding Value to Concrete

Admixture Systems
The Romans used organic material in there concreting since 476 BC. Since then admixture technology has become a scientific discipline in concrete technology. Chemical admixtures are water based solutions, which are added to the ingredients in concrete (cementitious material and aggregate) during mixing. Admixtures modify and improve the plastic and hardened properties of cementitious systems. Applying the science of nanotechnology, BASF Construction Chemicals has engineered organic and morganic molecules to design functionality into materials at nanoscale. These now fulfil local requirements and conditions better than before.

Ready-mix Achieve high-quality concrete with extended workability Precast Eliminate vibration, enhance durability and shorten the precast production cycle

Manufactured Concrete Products Optimise processes and enhance final product performances 8 Concrete Waste Management System Turning ecological constraints into economic benefits Smart Dynamic Concrete A quantum leap in concrete robustness Supplementary Systems Adding Value to Concrete Value Added Services

10

12

13 14

Contents

Ready-mix
The TOTAL PERFORMANCE CONTROL concept ensures that the needs of the entire ready-mix industry are fulfilled. Principles of the Glenium SKY technology. Innovative superplasticisers based on second generation polycarboxylate ether (PCE) polymers, engineered to provide high water reduction and slump retention for ready-mix concrete simultaneously. ! Ensuring a constant high-quality concrete at low water/ cement ratio ! Providing a concrete with extended workability at high temperature, without delayed strength development. ! Guaranteeing a concrete that meets the original specification from the fresh to the hardened stage. ! Offering a single, versatile admixture for many types of applications and conditions. Evolution of admixtures performances This combination of technologies delivers a high quality concrete mix with exceptional placing characteristics, accelerated cement hydration for early strength development and extended workability. Superplasticers adsorb onto the cement particles, and through ionic charges cause electrostatic repulsion and steric hindrance. The resultant dispersion reduces water requirement of the mix and increases workability of the concrete.
State of the art GLENIUM molecule

The hydration product, ettringite soon covers the adsorbed superplasticer molecule, rendering it ineffective. Glenium SKY is configured to delay adsorbtion onto the cement particle. This ensures that optimum dispersion over a longer period of time. Unlike conventional PCE molecules, which cover the entire cement grain, the Glenium SKY molecules progressive adsorbtion leaves sufficient room on the cement surface to allow a rapid hydration to produce high early strength development.

Bridge over the Great Belt, Denmark. Intelligent concrete cuts a catching figure.

Achieve high-quality concrete

Benefits of Total Performance Control

Ready-mix producer The challenge for ready-mix producers is to maintain profitability in spite of escalating input costs, and material availability. Optimising production and logistic costs is thus crucial. The Total Performance Control concept enables mix design optimisation for different cement and aggregate types. Concrete with both extended workability and low water/cement ratio are now possible. Glenium SKY is tailored to the ready-mix producers material, and project requirements. Cost effective, high-quality concrete can now be produced efficiently. Contractor The placing teams can now place concrete with greater ease, requiring less energy and labour. Optimum concrete densities and finishes are easily achieved. Early strength facilitates faster formwork and prop removal. This positively reduces the production cycle. Significant reduction in project time and cost. The Total Performance Control concept ensures the placement of the same concrete as specified and ordered from the ready-mix plant. Engineer Specifications for consistent high-quality concrete, with improved durability are easily achieved. The Total Performance Control concept provides longer service life, less maintenance work and, therefore, optimised economy.

Sunshine Skyway

with extended workability

Precast
The precast industry consistently pursues a single goal: the manufacture, with continually increasing productivity, of highquality concrete components that satisfy industrial and economical requirements The ZERO ENERGY SYSTEM takes into consideration all the aspects of the manufacturing process of precast elements. Apart from eliminating vibrations, reducing energy consumption and labour, the durability of the concrete itself is also enhanced. The Zero Energy System is suitable for a diverse range of markets, including components for buildings, civil engineering, drains, artstone, agriculture, roads and highways, railways and telecommunications. It can also be used in the casting of girders, prestressed floor support slabs, floor slabs, panels, segments, pipes, blocks, vaults, cross-beams, faade units, paving and copings. The key elements of the ZERO ENERGY SYSTEM are; Rheodynamic Concrete an optimised self compacting concrete, provides a concrete mix with exceptional placing characteristics, accelerated cement hydration for early strength development and high-quality concrete. Glenium ACE molecules are rapidly adsorbed on the surface of the cement grains and act through electrostatic and steric repulsion to powerfully disperse the individual particles of cement. The molecular structure of polycarboxylate ether polymers is essential for early development of strength. With conventional PCE superplasticisers, the molecules cover the entire surface of the cement grain and build a barrier against contact with water. Therefore, the hydration process takes place slowly. The unique, proprietary molecular structure of Glenium ACE exposes increased surface of the cement grains to react with water. As a result of this effect, it is possible to obtain earlier development of the heat of hydration, faster development of the hydration products and, as a consequence, higher strengths at very early age. This advantage can even be utilized at low temperatures. Glenium ACE - an advanced superplasticiser that is engineered to optimise dispersion, and stimulate a rapid rate of hydration.
Molecule of GLENIUM ACE

The Zero Energy System has revolutionised the manufacture of precast concrete elements ecologically, economically and ergonomically.

Eliminate vibration, enhance durability and

Benefits of the Zero Energy System

Increased Productivity Productivity in the precast industry depends directly on the speed at which concrete cures, regardless of which manufacturing process is used. Glenium ACE acts on the cement molecules, significantly increasing hydration kinetics without disturbing hydrate morphology. The natural exothermic heat produced in the first few hours is capable of speeding up the crystallization processes, developing faster material strength.
Early Strength Development
(fluid concrete 350 kg CEM I 52.5 20 C)

Elimination This feature of the Zero Energy System not only has economic benefits; it also impacts on the durability of concrete by limiting any micro cracks that may result from heat curing (thermal shock, temperature gradient, desiccation, etc). The vibration energy required to place concrete is a further key factor in calculating the costs of precast elements. The flow and water reduction action of Glenium ACE, combined with a viscosity-modifying agent such as Glenium Stream, enables the robust and direct formulation of selfcompacting concretes, which can be placed without vibrations when combined with a compatible manufacturing process. The Zero Energy System therefore reduces the related costs while improving working conditions in the precast concrete plant. The ZERO ENERGY SYSTEM is an innovative concept for the precast industry typical of the BASF Construction Chemicals's drive for innovation and developing technologies in partnership with the precast industry.

Compressive Strength (N/mm 2)

Glenium ACE 30 Traditional PCE 60

40

20

12

16

20

24

28 Time (h)

Minimised Heat Curing The energy required for heat curing is one of the key parameters when calculating the cost of precast concrete elements. The action of the Glenium ACE polymer, combined with the control of manufacturing and placing parameters, allows optimum use of natural energy for hydration -- making it happen sooner. External energy supplies can therefore be reduced or eliminated, removing the need for heat curing.
Curing Cycle

Temperature (C)

Standard concrete Zero Energy System (ZES) Value options: 1 2 1 2 Shorter curing cycle with ZES Lower curing temperatu re with ZES

Conditioning

Curing Time

Cooling Down

Time (h)

and shorten the precast production cycle

Manufactured Concrete Products

The Manufactured Concrete Products (MCP) industry produces everything from paving stones and blocks to roof tiles, pipes and hollow-core slabs. Appealing designs and surfaces, reduced construction times and low cost make these products highly desirable and a wide variety of shapes, textures and colours are available at competitive prices. The MCP industry is further characterised by the highest degree of automation among all concrete producers. From batching to form filling, compacting, curing and subsequent surface treatment, every process step is optimised. This automation requires consistent mix properties independent of varying water contents and grading of the utilised raw materials. Green and early strength are critical parameters for the production process, as are aesthetics and the economical manufacture of long-lasting MCP products. RheoFIT The FIT 4 VALUE concept addresses all the process steps leading to high-quality products. FIT 4 VALUE considers the pour elements essential for MCP manufacturers: ! ! ! ! FIT for ECONOMICS FIT for PERFORMANCE FIT for AESTHETICS FIT for DURABILITY

The FIT 4 VALUE concept optimises on all the process goals to provide superior performance of the final product. The FIT 4 VALUE concept is suitable for all manufactured concrete products made of earth-dry concrete such as pavers, blocks, pipes (instantly demoulded), roof tiles and hollow core slabs. RheoFIT technology RheoFIT products are especially engineered to meet the specific needs of MCP manufacturers. RheoFIT products take into consideration the different chemical and physical reactions in earth-dry concrete mixes and the complex interaction in a machine intensive environment. ! Optimal dispersion of cement/pigment particles due to electrostatic and steric repulsion. ! Effective tribological, lubricating action resulting from minimised friction between concrete elements. ! Chemical stabilisation of hydration products to prevent capillary raise.

Optimise processes and enhance

Benefits of FIT 4 VALUE

FIT for ECONOMICS An economical production considers concrete mix design, production process, labour and material safety, as well as logistics.
Faster Strength Development
Strength (MPa) RheoFIT Traditional admixtures 1 Value Option 1 Shorter curing with RheoFIT Value Option 2 Mix optimisation due to RheoFIT

FIT for AESTHETICS Outstanding aesthetics go beyond design, they are the main differentiation criteria for MCP manufacturers. Properties such as water and dirt repellence, uniform colours, closed and efflorescence-free surfaces are increasingly demanded by the end user of MCP products. RheoFIT provides ! Efflorescence control ! Closed surfaces ! Sharp edges ! Appealing surface appearance ! Enhanced colour uniformity/vibrancy ! Dirt repellence FIT for DURABILITY A key benefit of MCP products besides their appealing aesthetics is their durability. The wide range of RheoFIT products assists manufacturers to produce economical, long lasting products. RheoFIT provides ! Improved strengths (green, early & final) ! Reduced water absorption ! Increased water tightness ! Improved freeze-thaw resistance ! Increased abrasion resistance

2 Required strength

Time (h) 1

RheoFIT provides ! Optimised mix design (cement reduction/replacemet) ! Reduced curing time ! Higher tolerance to change in moisture content ! Less maintenance ! Less product rejections

FIT for PERFORMANCE The performance of MCP manufacturing equipment can be measured by its cycle time (form filling, compaction and stripping.) The shorter the cycle time, the higher the production output.
Shorter Cycle Time
Density (kg/m3) RheoFIT Traditional admixtures 1 Value Option 1 Shorter cycle time with RheoFIT Value Option 2 Higher density with RheoFIT

Required density

Time (s) 1

RheoFIT provides ! Reduced cycle time/faster production ! Better fillability ! Enhanced compactibility ! Improved extrudability ! Less wear & tear of production equipment ! Smooth, easy instant demoulding ! Increased resistance to deformation

final product performances

Concrete Waste Management

In South Africa, on a daily basis, the ready-mix concrete industry uses considerable volumes of water in the production process. A higher proportion of this water is used in washing the mixer trucks. Managing the disposal of this wash water is costly and time consuming. Another disposal problem is returned concrete, which cannot be rerouted. DELVO ECO Concrete Waste Management System Delvo Eco Waste Management System represents a breakthrough that will revolutionise the management of concrete waste in South Africa. The DELVO Waste Management System is specifically designed for South African conditions and cement types, it resolves both problems of wash water and returned concrete disposal. An essential component of the DELVO ECO system is the application of the TOTAL HYDRATION CONTROL TOTAL HYDRATION CONTROL is a unique molecule that envelops the surface of the cement particles and forms a closed protective coating which significantly slows the rate of hydration. Depending on dosage the hydration can be stalled for a period up to 48 hours. During this period no further water uptake occurs and no heat of hydration is liberated. The concrete goes into a dormant state. The hydration is reinitiated when the concrete is reactivated, using different approaches. The hydration continues unabated, and the typical setting times and strength performance is maintained.

Turning ecological constraints

Benefits of Delvo Eco Waste Management System

Wash Water Recycling Using the Delvo Eco technology all wash water that is traditionally disposed off into settlement pits, can now be recycled back into the concrete. Methodology: 1. When a truck mixer returns empty from site, Delvo ECO is added along with only 20% of the water normally used into the drum 2. The solution is mixed thoroughly in the drum, and breaks down adhering concrete from the inside and on the mixer blades. 3. The solution is not discharged, but left inside the drum until the next batch. This can be done overnight or over a weekend. 4. The truck mixer is loaded with concrete as usual. However the fresh loads need to reduce the mix water by 200 litre, which is the Delvo solution. 5. The concrete can be dispatched as usual. The concrete performance in respect of setting times and strength performance will not be compromised in any way. The ready-mix contractor can remove direct and indirect cost associated with; ! Elimination of settlement pits ! Eliminates routine maintenance and cleaning of settlement tanks ! Significant reduction of water consumption ! Eliminates residual solid waste removal ! Keeps truck mixer drum cleaner, and improves on their mixing capability ! Optimum utilization of costly industrial land sites ! Improved utilisation environmental responsibility. Returned Concrete Recycling Delvo Eco effectively deals with the unplanned nature of returned concrete in a very efficient way.

Methodology: 1. When a truck mixer returns with concrete which was not possible to be used on site. When rerouting within the 2-3 hour period is not possible. Establish the quantity and grade of concrete left in the mixer drum. 2. Add the prescribed amount of Delvo to the concrete. On occasion it may require additional plasticiser to increase the workability. This is thoroughly mixed in by revolving the mixer drum. 3. Based on the dosage rate prescribed the concrete can remain in the mixer drum, from 18- 48 hours. The stabilised concrete will retain its workability and will not set. 4. Fresh concrete is batched into the drum mixer along with the stabilised concrete in the usual manner. The concrete performance in respect of setting times and strength performance will not be compromised in any way. The benefits of the Delvo Eco system; ! extends concrete workability for up to 48 hours ! enables 100% recycling of returned concrete load (48hours) ! eliminates maintenance of settlement tanks, recycling/reclamation plants ! eliminates dump pits, dump removal costs ! delivers cleaner plant environments as per ISO 14000 requirements ! assists with compliance to environmental protection requirements

into economic benefits

Smart Dynamic Construction

Most concrete in South Africa is produced using mechanically crushed sands. These materials typically require a fine sand to supplement the fine material necessary to produce concrete with a good quality paste. The quality of the paste influences the workability, place ability and compactibility of the concrete. RheoMATRIX is a unique state of the art viscosity modifying agent, which creates a new generation concrete. Combining the benefits of traditionally vibrated concrete with those of selfcompacting concrete.
BRIDGING

BRIDGING cement

BRIDGING fine sand

Benefits of Smart Dynamic Construction It is now possible to produce an average 25MPa concrete with the characteristics of a SCC concrete, and the cost effectiveness of a lower slump concrete. ! Supplementary filler sand can be eliminated or significantly reduced in mix proportioning. ! High Fluid Concrete can be placed with less skilled labour and within shorter construction times. ! Higher volume of concrete can be placed properly. ! Less remedial work for defects, voids and honeycombing. ! Surface finishing will be easier achieved to architectural specifications. ! The concrete structure will be more durable, as the reinforcement cover concrete zone is homogenous and of improved quality.

The ability of the RheoMATRIX molecule to develop continuity develops a molecular network within the paste. This highly structured paste, now has the optimised characteristics. The RheoMATRIX molecule imparts a level of viscosity within a mix enabling the right balance between fluidity, passing ability and resistance to segregation apparently opposing properties to be achieved.

A quantum leap in

Supplementary Systems
BASF Construction Chemicals have a broad range of speciality products that enhance concrete specifications and performance. RETARDERS and ACCELERATORS A range of retarder and retarding plasticisers, are available to extend the period of workability retention. Set and strength accelerating admixture required for high early strength, are available in chloride and non-chloride derivatives. CONCRETE ADDITIVES Additives for powdered system; plasticing, accelerating, pump and expansive aids.

CORROSION INHIBITORS Corrosion Inhibitors are admixtures that are incorporated into the fresh concrete. They give the steel reinforcement a longterm increase in passivation, even if the concrete quality allows the ingress of deleterious salts and carbonates. These admixtures significantly reduce maintenance costs of reinforced concrete, and they extend the service life of concrete structures.

CONCRETE FIBRES Secondary reinforcing material as short length polypropylene fibres, used to reduce plastic shrinkage cracking, improve concretes flexural and tensile strength are available.

CURING Various types of liquid curing compounds are available for effective curing of exposed concrete surfaces. Curing compounds are the most practical and effective method of ensuring optimum curing of large areas of exposed concrete, like surface beds, suspended slabs and columns.

INTEGRAL WATERPROOFERS Intregral waterproofers are admixtures that are added to fresh concrete, to improve the water resistance of the concrete. They reduce the permeability of the concrete, by reducing size, number and continuity of pores structure. The capacillary pores are lined with a 'hydrophobic' material to resist water absorbtion or capillary suction. They are very effective in waterproofing water retaining structural concrete under a constant pressure head.

concrete robustness

Project References

Maguga Dam, All high performance admixtures supplied by BASF to Magugu Dam, Swaziland, one of the highest dams in South Africa with a capacity of 332 million litres and a wall height of 115 metres.

Nandoni Water Treatment Works, Venda. The walls and columns were poured in a single lift.

Burj Dubai, earmarked to be the highest built concrete structure, used Glenium technology in its concrete.

Nagoya Dome, Japan. Fully covered sports arena with 40,500 seats and concrete foundations.

Deliverables of the

Adding Value to Concrete

Deliverables of the Global Leader As part of the world's largets chemical company, BASF Construction Chemicals is the market leader in the admixtures business. We are committed to engineering quality solutions to drive the concrete industry forward. Through constant research and development into new products, systems, application methods and equipment, we add value to concrete. Our market-segment oriented structure means that you can rely on the proximity of a regional company with the backing of a global group. Innovative products Comprehensive range of admixtures specially engineered for the needs of the ready-mix producers, precast operators, contractors and manufactured concrete producers

Single source Complete range of latest technology for concrete and mortar as well as auxiliary products such as form release agents, curing compounds, surface retarders, concrete fibres and specialised additives. Superior logistics Easy communication and proficient means of transportation ensured by local organisation.

Knowledge and experience Superior expertise in concrete and mortar technology, it's application and design with full local coverage Value-added service ! Specification development ! Mix design and production process optimisation ! Concrete Support laboratory ! On-site consultation and troubleshooting. Expert training Specific in-service training and orientation programmes for producers and contractors.

global leader

BASF Construction Chemicals South Africa (Pty) Ltd Admixture Systems Customer Care Line: 011 203 2405 www.basf-cc.co.za info : rashid.jaffer@basf.com Midrand 852 Sixteenth Road Midrand 1682 Westonaria 11 Pullinger Street Westonaria 1780 Western Cape 2nd Floor, Centre Point Loxton Road Milnerton Cape Town 8001 Tel: +27 21 555 9800 Fax: +27 21 551 2293 Eastern Cape Struanway Struandale Port Elizabeth 6001 Tel: +27 41 401 1066 Fax: +27 41 401 1067

Tel: +27 11 203 2405 Fax: +27 11 203 2379

Tel: +27 11 754 1343 Fax: +27 11 754 1105