Concrete Quality Control Initiatives and Trends in the Industry

1. Concrete Quality Control Initiatives and Trends in the Industry James M. Shilstone, Jr., FACI jshilstone@commandalkon.com 205-879-2320 x2320

2. Session Objective The concrete industry has historically changed at a glacial pace. New products and processes have taken decades to find their way into common use and be allowed by standards and specifications. That is now changing. Outside influences are affecting the industry with relative “blitzkrieg” speed and efficiency. Factors such as EPA regulation of fly ash, sustainability and the need for EPDs, nuclear regulation, and long term durability requirements are often initiated by organizations outside the concrete industry. These organizations aren’t prepared to wait 10 years to see their efforts produce results. It is not uncommon to have an expectation of 6-12 months to resolve some of these issues. These factors WILL affect your business. Learn about them while you can still affect these vital issues. Concrete Quality Control Initiatives and Trends in the Industry

3. What’s Hot in Concrete? • Hot Buttons • Sustainability • LEED 4.0 and Environmental Product Declarations • Health Product Declarations • Green plant requirements • BIM – Building Information Modeling • Nuclear • Ongoing issues • Performance specifications • EPA Regulation of Fly Ash • 500 year durability • Demand for submittals Concrete Quality Control Initiatives and Trends in the Industry

4. Sustainability Greenhouse Gases Global Warming Environmental Impact Depletion of Resources Concrete Quality Control Initiatives and Trends in the Industry

5. Sustainability • Concrete is the most widely used material second only to water • There is about 1 cubic yard of concrete in the U.S. for every man, woman and child • For every ton of cement clinker produced, almost a ton of CO2 is released into the air • 50% due to fuel, 50% due to calcining • For China and India to reach the same level of concrete consumption as in the U.S., production will have to remain at current levels for over 16 years Concrete Quality Control Initiatives and Trends in the Industry

6. Sustainability Initiatives • Kyoto Protocol – U.S. refuses, China exempt • Architecture 2030 – Carbon neutral operations by 2030 • LEED – Promoting more environmentally friendly project design and construction • EPA efforts on fly ash • Restrictions on water run-off • Environmental Product Declarations • Health Product Declarations Concrete Quality Control Initiatives and Trends in the Industry

7. Environmental Product Declarations • Based on European CEN 15804- Product Category Rules • Product Category Rules for U.S. developed by Carbon Leadership Forum with industry participation – www.carbonleadershipforum.org • Central Concrete and ClimateEarth develop first Environmental Product Declaration for the U.S. • NRMCA becomes first “Program Operator” and certifies Central Concrete’s EPD • LEED 4.0 to give ½ credit for industry EPDs and full credit for product-specific EPDs • PCR process in constant flux – new initiatives Concrete Quality Control Initiatives and Trends in the Industry

8. EPD Determination • Raw Materials • Tranportation • Manufacturing • Product transportation • Life Cycle Assesment • Cradle-to-gate vs. cradle-to-site • Carbon footprint • Energy consumption • Renewable • Non-renewable • Water use • Ozone depletion • Acidification • Eutrophication • Ozone creation • Toxicity • Particulate emissions Concrete Quality Control Initiatives and Trends in the Industry

9. Health Product Declaration • Identifies materials a human will be exposed to • Identify Red List materials that impact health • Still under development, but coming Concrete Quality Control Initiatives and Trends in the Industry

10. NRMCA Carbon Calculator Developing your Concrete Quality Control Department

11. NRMCA Carbon Calculator • Plant & Fleet • Plant Location & Fleet description • Materials • Type and source distance from RM plant • RM Plant Annual Energy Consumption • Transportation from Plant to Site Developing your Concrete Quality Control Department

12. Additional concrete initiatives • NRMCA Green-Star Plant certification • Reuse of process water • Top-loaded concrete (initiative underway at ASTM to recognize and regulate it) • Use of recycled crushed concrete • Certification of blended cements • Addition of powdered limestone • Development of new binders • MIT Concrete Sustainability Hub – cshub.mit.edu • Environmental and sustainability committees at NRMCA, ACI and almost everywhere else Concrete Quality Control Initiatives and Trends in the Industry

13. BIM – Building Information Modeling www.bim.construction.com Concrete Quality Control Initiatives and Trends in the Industry

14. BIM – Building Information Modeling A/E Design Contractor Suppliers Concrete Quality Control Initiatives and Trends in the Industry

15. Nuclear plant construction • USA produces more than 30% of world’s nuclear power • Currently have 104 nuclear reactors producing 19% of our total electricity • Almost no nuclear construction in 30 years • Plans to build 24 more, with 4-6 coming online by 2020 • Nuclear construction may be slowing due to low natural gas prices Concrete Quality Control Initiatives and Trends in the Industry

16. Nuclear plants and concrete • Current specifications are totally out of date • Level V Nuclear Inspector certification no longer exists • New products and materials are available • Seismic codes and standards have changed • ACI certifications • Field and Lab Technician • Construction Inspector • Concrete Quality Technical Manager (in development) • NRMCA certifications • Concrete technologist Level II, III, IV • Quality Certificaton Concrete Quality Control Initiatives and Trends in the Industry

17. Performance Specifications Concrete Quality Control Initiatives and Trends in the Industry

18. Performance Specifications • ACI initiatives have resulted in ACI 318 adopting “Exposure Classes” and in 2014 dropping strength overdesign. • New - ACI Performance Concrete Committee • ASTM – Changes in water & blended cements and ASTM C-94, Specifications • NRMCA Specification Review program & Model Spec program • NRMCA Quality Initiatives • Quality Award • Model Quality Management System • Increased emphasis on internal QC training Concrete Quality Control Initiatives and Trends in the Industry

19. EPA Regulation of Fly Ash • 2008 impoundment failure at TVA Kingston Power Plant – inundated homes on Emory River • EPA asked to regulate fly ash, but would require that fly ash receive a “hazardous” rating • Concrete producers reluctant (or unable) to use a material with a hazardous rating, even though we successfully encapsulate fly ash • Ruling by EPA postponed several times (election) • U.S. House passes legislation to prohibit declaring fly ash hazardous, but stalled in Senate • Federal court to issue a statement by the end of October regarding lawsuits to force EPA response Concrete Quality Control Initiatives and Trends in the Industry

20. 500 Year Durability • Increase in the number of projects requiring concrete to meet long term durability demands • Premature deterioration of highways & bridges • Short-lived buildings in the Middle East • Deterioration in infrastructure • New tests have been developed • Permeability • Chloride difusivity • Abrasion resistance (Micro-Deval) • ASR Concrete Quality Control Initiatives and Trends in the Industry

21. Durability Models Complex models requiring lots of testing - Stadium Concrete Quality Control Initiatives and Trends in the Industry

22. Durability Models Simple models – Texas Concrete Works, Life-365, Hiperpav Concrete Quality Control Initiatives and Trends in the Industry

23. Submittals • Sharp rise in requests for submittals and background documentation • Qualification testing • Chloride penetration • Shrinkage • ASR (validity of test results in question) • According to NRMCA Quality Study, over 50% of submittals contain historical statistical data • Certification of materials is required • Increase in ACI 318 limit on age of tests to 18 months Concrete Quality Control Initiatives and Trends in the Industry

24. Submittals Concrete Quality Control Initiatives and Trends in the Industry

25. What’s Hot in Concrete? • Hot Buttons • Sustainability • LEED 4.0 and Environmental Product Declarations • Health Product Declarations • Green plant requirements • BIM – Building Information Modeling • Nuclear • Ongoing issues • Performance specifications • EPA Regulation of Fly Ash • 500 year durability • Demand for submittals ? Concrete Quality Control Initiatives and Trends in the Industry

26. Please Complete Your Evaluation • Be sure to circle the session you are evaluating on the back of your card • QC (Track Name) • QC-002 (session code) • Concrete Quality Control Initiatives and Trends in the Industry • All breakout session materials can be accessed at:www.commandalkon.com/cc2013/update/index.htm • Thank You! Concrete Quality Control Initiatives and Trends in the Industry