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Pictures for the latest project finished outside Drumquin, the supply of aggregates, which allowed access for 4 kilometres of roads and fill materials. Also the supply of over 3000 metres of high strength GGBS concrete as well as 5000 metres of general application concrete for this project. All completed on time and with no breakdowns. Above is pictures showing the erection of the two of the eight 80 metre high turbines.

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Thanks

https://www.surveymonkey.com/s/58CVDPD

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Concrete blocks where also supplied with combination of GGBS/Cement to help lower the carbon foot print of the build.

A number of specialist mixes where supplied including a high strength floor screed for under floor heating, and also porous concrete.

Asphalt material was also supplied to the surfacing squads that where re-surfacing the main street and foot paths in the village of Pettigo.

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Due to expansion within the company a new refitting shed was designed and constructed to meet the needs of the company starting on January 2013. As well as supplying foundation materials to the build, the contract was won to supply over 500 cubic metres of concrete for the floor slab inside the new industrial unit. There was specialist floor finish applied to the concrete which was designed to endure the extreme conditions which the floor will be exposed to.

Below is pictures taken during the pour and of the finished floor.

Picture location – During pour

Finished floor

Video of the pour

Click here to see video

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Ecocem GGBS Cement

“Ground granulated blastfurnace slag (GGBS) cement is a by-product of the manufacture of iron. Because GGBS cement originates from burnt limestone, as does OPC its chemistry is similar to OPC. These similarities permit GGBS cement to replace up to 70% of OPC in concrete, on an equal-part basis. But the minor differences between GGBS and OPC also give enhanced durability to concrete made with GGBS. For most farm applications the most durable concrete will be obtained using a 50:50 blend of GGBS and OPC. In the most aggressive environments the use of 60–70% GGBS might be required.”

Protective Characteristics of Ecocem GGBS

Increased Resistance to Acids

Concrete made with GGBS cement has a lower porosity and permeability than concrete made with Ordinary Portland Cement (OPC) only. Pore sizes are smaller and less numerous. This reduces the rate of penetration of acids into the concrete, giving enhanced protection from acids, erosion and abrasion damage.

Greater Long Term Strength

Concrete made with GGBS has greater long-term strength than concrete made with OPC, due to the denser cement matrix of GGBS concrete. The same 28-day strength will be achieved in concrete with 50% GGBS as concrete made with 100% OPC. However beyond 28 days, GGBS concrete continues to hydrate and gain in strength more than concrete made only with OPC.

Increased Resistance to Sulphates

Sulphates can be present in slurry, manure and wastewater. Sulphates react with C₃A and Ca(OH)₂ present in OPC concrete, causing the concrete to expand and crack. GGBS is a sulphate-resisting cement. Specifying GGBS at 50%–70% content gives optimum protection against sulphate attack.

Increased Resistance to De-icing Salt

De-icing salts and seawater can cause corrosion of reinforcement in concrete leading to cracking of concrete. The presence of GGBS reduces the rate and degree to which chlorides penetrate through concrete, enhancing the service life of concrete exposed to these salts.

Environmental Benefits of GGBS

Ecocem GGBS cement is a recycled product. It is much more environmentally friendly and has a much lower CO₂ footprint than CEM II or CEM I cements. The CO₂ footprint of Ecocem is just 29kg/tonne (audited by NSAI), whereas that of CEM II cement is in the order of 700kg/tonne.Using a 50% blend of GGBS in concrete saves 1 tonne of CO₂ per truck load of concrete delivered.On an average farm slab of 500 m², with two silage pits, this will result in a saving in the order of 100 tonnes of CO₂—equivalent to the annual greenhouse gas emissions of a herd of 40 dairy cows.

Working with GGBS Concrete

Placing and Compacting

The requirements for placing concrete with GGBS are the same as that of ordinary concrete. It is essential that all concrete should be fully compacted to ensure long-term durability. The concrete should be mechanically vibrated using a vibrating poker or vibrating screed. Compaction by hand tamping will not lead to the same quality results and may reduce the life of the concrete. It is not permitted to add water to concrete on site—doing so will significantly damage the integrity of the concrete.It is important to permit bleed water to evaporate from the concrete surface before the final finishing. Finishing the concrete whilst there is bleed water lying on the surface remixes the bleed water into the top surface of the concrete, leading to the formation of a weak layer on the top of the concrete.

Curing

Proper curing is particularly important in farm concrete. The purpose of curing is to ensure that sufficient moisture is available for hydration of the concrete in the first 7 days. Great care must be taken to ensure concrete does not dry out during this period. This can be achieved by covering the concrete with a fabric that is kept moist; covering the concrete with plastic sheeting; using a curing compound; or regular spraying with water. Failure to cure properly will result in a lower strength and more porous surface layer of concrete. This will make the concrete more susceptible to abrasion, acid attack and frost damage, and will shorten the life of the concrete. It is also important to protect fresh concrete from heavy rainfall, and from frost.

B. McCaffrey’s Experience with GGBS

Having over three years experience in production and delivery of GGBS concrete, it is also incorporated in our block production due to its beneficial properties (reduced efflorescence). Individual mix designs can be devised to the customers needs on request. Have extensively used this cement type with large wind turbine bases, pavement grade concrete and starting to expand into the shuttering market, it is a versatile product with many beneficial properties.                       

Wind Turbine Base.

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This was a twenty two wind turbine farm that was split between two sites outside Killeter. The main contractor for the project was Adman’s Civil Projects Ltd, and after successfully tendering for the contract B. McCaffrey’s started to supply materials from November 2011 with the first trial concrete bases being poured in April 2012.

Each Turbine consisted of approximately 360 cubic meters of high strength GGBS (Slag) concrete. This was successfully delivered within a restricted time frame as imposed by planning regulations.

Aggregates where also supplied to the site to provide roadways, crane pads and various other functions including drainage and washout bays.

Materials for the associated substation at Magherakeel were also supplied with a number of specialist concretes produced including water proof concrete (admixtures supplied by Grace Construction Products) and high strength frost resistant concrete for roadways around the substation.

The total tonnage of aggregate was X tonnes. There was X cubic meters of concrete supplied to the entire project. All of which was delivered efficiently and on time.

First pour of many!

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