Geopolymers for Precast Market

This industry comprises establishments primarily engaged in manufacturing concrete pipe, brick and block from a mixture of cement, water and aggregate.

Example Activities:

  1. Architectural block, concrete (e.g., fluted, screen, split, slump, ground face), manufacturing
  2. Blocks, concrete and cinder, manufacturing
  3. Bricks, concrete, manufacturing
  4. Cinder (i.e., clinker) block, concrete, manufacturing
  5. Concrete blocks, bricks and pipe, precast, manufacturing
  6. Culvert pipe, concrete, manufacturing
  7. Patio blocks, concrete, manufacturing
  8. Paving blocks, concrete, manufacturing
  9. Pipe, concrete, manufacturing
  10. Precast concrete blocks and bricks, manufacturing
  11. Precast concrete pipe, manufacturing
  12. Prestressed concrete pipe, manufacturing
  13. Sewer pipe, concrete, manufacturing

In general, the three most important categories for manufacturing costs are:

  1. Cost of materials and supplies;
  2. Cost of energy, water and vehicle fuel; and
  3. Production worker wages.

The costs of materials and supplies (for manufacturing activities) increased from $2.2 billion in 2001 to $3.8 billion in 2010, or at a compound annual growth rate of 6.5%. Between 2009 and 2010 materials and supplies costs increased 5.1%.

 

Testing for Geopolymer precast.

The cost of materials and supplies is 96% of the cost of the final product

Total revenues in the Concrete Pipe, Brick and Block Manufacturing industry have increased from $704.1 million in 2001 to $1.1 billion in 2010 or by 4.7% per year on average. In the latest year total revenues increased by 9.7%.

  

Geopolymer Commercial Products

  1. Construction blocks
  2. Hollow core flooring
  3. Paving and cobblestone bricks
  4. Geopolymer cement
  5. Road and parking lot curbs
  6. Embankments and retaining walls
  7. Form molded products to client requirements
  8. Repair and maintenance to concrete structures
  9. Geopolymer railroad ties(sleepers)

 

Total precast concrete building systems are becoming a popular choice for many construction projects. Architectural and structural precast, prestressed concrete components can be combined to create the entire building.

This design approach can take several forms, including precast columns and beams with panelized cladding or load-bearing precast walls and double tee or hollow core flooring. These advantages benefit every member of the construction team – specially the owner, whose goals are always paramount.

Low Maintenance
Precast structures require less maintenance than buildings built using other materials. Incorporating the architecture into the structure using large panel sizes, minimizes the number of joints.

Effective Pricing
Because of precast concrete’s tightly controlled and shorter production process, costs can be more accurately estimated earlier in the process. Changes during design development can be quickly reassessed by CPCI member engineering departments to verify that estimates remain stable. The contractor, owner and design team are assured that project budgets remain sound.

Interior Design Flexibility
Long-span precast concrete systems help building owners adapt to changing client needs in future years. Hollow core slabs and double tees can span 14 to 16 m (45 to 50 ft) to match typical composite-steel framing and minimize the need for interior columns required with cast-in-place systems. Precast can span as far as 21 m (70 ft) to provide flexibility for challenging interior requirements. Precast also provides high loading capacity at little added cost.

Green Design
Precast concrete offers a number of benefits that make it environmentally friendly a growing need as the Leadership in Energy & Environmental Design (LEED Canada) criteria become more popular. Precast’s energy efficiency, recyclability, reusability along with minimal waste in the precast plant and on the jobsite are keys to meeting environmental standards that are gaining client interest.

Precast offers high thermal mass that has become a feasible element of building design. With precast’s ability to aid in meeting LEED standards, the benefits of thermal mass will become more apparent to designers in the future. The use of fly ash, slag and other waste materials aid its environmental friendliness. Precast’s high durability produces buildings with a total service life that far outpaces other designs.

Construction Speed
Time is money for the entire construction team. Precast concrete’s speed through design, fabrication and erection help meet tight deadlines. This particularly aids contractors when permitting processes slow down or unforeseen delays arise at the site due to soil conditions or other factors. Precast structural systems are ready to be erected when the foundations are prepared.

All-Weather Construction
Contractors can minimize the added “cushion” created in schedules to accommodate bad weather conditions, since precast components can be produced and erected all year round.

Efficient Erection
Because precast concrete pieces are fabricated in precast plants under controlled conditions using high-quality materials, designs more exactly meet specifications. Field adjustments are reduced, creating a smooth erection process with minimal surprises.

PRECAST COMPONENTS MEET ALL NEEDS
A wide range of precast concrete architectural and structural components can be used in commercial buildings. The key pieces used most often in these designs include:

· ARCHITECTURAL PANELS:
Architectural precast wall panels are the solution of choice for the cladding on many office buildings, institutional facilities and mixed-use retail projects of all types. A key reason is that these panels offer beauty and affordable economy without sacrificing design freedom. That economy results from the low initial cost, the ability to enclose the structure quickly, the ability to continue construction through winter weather and the panel’s long-term durability. In some cases, further economies can be achieved by designing load-bearing precast walls or using insulated wall panels to improve energy efficiency. These budget, scheduling and design benefits combine with precast’s mold ability to create dramatic and cost-effective looks for all types of commercial buildings.

· GFRC PANELS AND DECORATIVE ELEMENTS:
Glass-fiber reinforced concrete (GFRC) can expand the options for attractive exteriors by using it for architectural panels and decorative accent elements, such as balusters, medallions and cornices. It consists of a Portland cement-based composite with alkali-resistant glass fibers randomly dispersed throughout. These fibers add flexural, tensile and impact strengths, producing a The use of GFRC can save costs in a variety of ways, including the use of lighter structural framing, faster erection using lighter cranes and creative rehabilitation of older, detailed buildings. GFRC also provides energy savings and will last the lifetime of the building, ensuring an attractive and consistent look through the years.

· BEAMS AND COLUMNS:
A complete precast concrete structural system offers tremendous advantages and value for commercial buildings. The use of precast columns and beams makes an ideal framework for hanging precast panels, creating a design that offers fast construction, structural stability and enhanced fire resistance. A wide range of options is available for creating the perfect system to achieve the size and shape of commercial building required.

· DOUBLE TEES:
These components provide excellent roof and flooring units, spanning considerable distances and providing quick erection to close in a structure faster. In some cases, they also can be used as wall panels on low-rise commercial buildings, creating distinctive designs that require little maintenance and offer fire resistance and durability as with architectural wall panels.

· HOLLOW CORE PLANKS:
Precast hollow core flooring units provide long spans with cross-sections that reduce the height of the building, saving material cost, and their inorganic composition enhances fire protection. Local precasters can help determine which sizes, shapes and styles of components will best suit any individual commercial building project. Bringing the precaster into the planning early in the design process will ensure the precast components maximize their effectiveness in aesthetic appeal, functionality and cost effectiveness.

 

CONCLUSION

Industry Canada rates the precast concrete sales in Canada at $1.3 billion. We do not have total market segments for China however the market appetite for concrete products there is huge.

LEED points will play a larger role in construction material procurement as we move towards a sustainable industry. Post industrial waste material is becoming more important as a cement replacement and LEED currently allows only half the points for these waste materials. Our final design mixes will utilize approximately 70% recycled content making them some of the most sustainable construction products on the market.

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