The Lafarge Group

• Over €12.2 billion in sales worldwide

• Over 83,000 people in 75 countries

Products• Cement

• Aggregate and Concrete

• Roofing

• Gypsum

• Specialty Products

Lafarge North America Inc.

• Over 1000 operations throughout the U.S. and Canada

• More than 15,000 employees• 2003 sales of USD

$3.3 billion

North American Corporate headquarters, Herndon, VALafarge Canada Inc. headquarters, Montreal, Quebec

• 4 main business segments:– Cement and Cement-related

products– Construction Materials– Gypsum– Roofing

Research and Development

h Lafarge is built on innovation and a focus on its customers

h Lafarge North America is part of an R&D network that consists of:

- technical centers on 5 continents- 500 people- global R&D budget of $100

million

Agilia®The superior flow of our proprietary concrete Agilia® allows architects to achieve a new level of detail.

AggregatesLafarge was able to match the original stone for the restoration of the Washington Monument

Ductal®A proprietary material that offers a unique combination of strength, ductility, durability and aesthetics

A Revolutionary New Material for New Solutions

Compressive Strength:130 to 240 MPa

Flexural Strength:25 to 50 MPa

Ductility:Greater capacity to deform and

support flexural and tensile loads, even after initial cracking

Abrasion Resistance:Similar to natural rock

Impermeability:Almost no carbonation and

penetration of chlorides

Key points of the Ductal® mix design:

• Ductility

• Synergy of two sizes of fibers

• Grading optimization (modified Compactness Theory)

• An efficient Cement-Superplasticizer couple

Synergy of two sizes of fibres:

Activation of bond microcracking micro-reinforcement

Shear/ no place for fibres! Modified compact grading

Optimum Mix Modified Mix:Compactness:

®

MASS (WEIGHT) OF BEAMS

kg/lineal meter 140 112 467 530

Equal Load Carrying Capacity

Steel

Pre-stressed ReinforcedConcrete

STRENGTH

0

5

10

15

20

25

30

35

40

45

50

0.0 0.5 1.0 1.5 2.0Deflection (mm)

Equi

vale

nt S

tres

s (M

Pa) Ductal

HPC 80

Flexural Strength

DuctalHPC

2,000 lb car on sheet of Ductal

7000 psi

0.5 1.0 1.5 2.0

0.04”

DUCTILITY

Typical Values for Ductal® FM

195235MPa

Compressive Strength

(75 mm dia. X 150 mm length)

4045MPa

Flexural Strength(40 mm X 40 mm X 160 mm

bending test)

5760GPaE-Modulus

28 days(wet room curing)

3 days(incl. thermal treatment at

90oC for 48 hr)

Ductal FM(2% volume Steel Fibres)

Typical Values for Ductal® FO

140150MPa

Compressive Strength

(75 mm dia. X 150 mm length)

3035MPa

Flexural Strength(40 mm X 40 mm X 160 mm

bending test)

5050GPaE-Modulus

28 days(wet room curing)

4 days(incl. thermal treatment at

60oC for 72 hr)

Ductal FO(4% volume PVA Fibres)

DURABILITY

02 mmCarbonation

(depth of penetration)

0.020.5X10-12 m2/sChloride ion diffusion030010-6Post-curing shrinkage

1.22.75Index IAbrasion

(relative volume loss)

100%90%%Freeze-thaw

(residual E-mod after 300 cycles)

Ductal(2% Steel Fibers

90oC Thermal Treatment)

HPC(60 MPa)

Capillary Porosity

X 1000

X100 000

DUCTAL

Silica Fume

CSH

Porosity(ml/100g)

Diameter of pores (nanometres)DUCTAL does not havecapillary pores

Ordinary Concrete has20 to 25% capillary poresinter-connected(source of permeablity)

High PerformanceConcrete (HPC)has 12 to 20% of capillary pores

X 1000

X100 000

DUCTAL

Silica Fume

CSH

Porosité(ml/100g)

Impermeability :

X 1000

X100 000

DUCTAL

Silica Fume

CSH

DUCTAL doe not havecapillary pores

Coefficient of Permeability ( x 10-18 m2 )measured after drying at 105°C until constant mass :_______________________________________________________DUCTAL FM 0.01Granite 0.1High Performance Concrete 6Ordinary Concrete 35

Origin of the impermeability is foundthrough the absence of connectedpores, at the nanometric scale

DUCTAL x 100 000

Ductal®

Productscan be

produced in a range of colors

and textures

Aesthetics

SustainabilityLafarge is: • committed to continuous improvement in its

environmental performance. • a World Wildlife Fund (WWF) Conservation Partner,

working together to preserve biodiversity and restore the ecobalance of quarries and forests.

• a Wildlife Habitat Council Partner; helping to conserve wildlife habitats and preserve the environment for future generations

Ductal:• Is partially manufactured from recycled

industrial by-products.• Reduces CO2 emission (compared to

conventional solutions) up to 75% over the life-cycle.

Environmental Advantages

DUCTAL® PROJECTS

Architectural Cladding

2.3 m x 1.9 m x 20 mm thickDuctal® FO Acoustical Panels2.3 m x 1.9 m x 20 mm thickPanels cast with rectangular holes.(15mm thickness; holes 15mm x 15mm.)

120 m2 of Ductal® FO Cladding Panels2.5 m x 1.6 m x 25mm thick

Urban Furniture

Industrial Applications

Bridges

Showcase Project:Shawnessy LRT Station

Shawnessy LRT StationPrecaster: Lafarge (Calgary)Owner: City of CalgaryArchitect: Culham, Pedersen & Valentine (CPV)Ductal Volume: 80 m3

Description: Architectural roof over a pedestrianunloading area.

Advantages: Aesthetics, reduced maintenancelight weight system, fewer pilings,speed of installation, economics

5.62 m

5.1 m 6 m

Ductal Components

Forming / Casting / Demolding

Canopy Production

Canopies Struts

Tie BeamsColumns

Installing the Canopies

Installed Canopies

1-Scale Load-Testing at the U of C

1-Scale Load-Testing at the U of C

- Full Wind Uplift

- full snow load

At full factored loads, maximum strains were60% of cracking strain

“Ductal provided the ability to achieve the free-flowing form design of the canopies.”

Shawnessy LRT Station ArchitectEnzo Vicenzino

Architect’sdream…

…to reality!

“The material has rich poetic weight … it is bound to shatter a part of architects’ beliefs … The style of artistic structures is bound to change.”

Footbridge of Peace ArchitectRudy Ricotti

Architect’sdream…

…to reality!

The End

Visit our web site at:www.imagineductal.com

Bus SheltersLafarge’s Precast team in Winnipeg has produced the world’s first Ductal®

bus shelters.

Eight single-seat bus shelters ordered by the City of Tucsonwere designed to protect waiting passengers from extreme sun and heat.

During the pre-qualification process, the Ductal prototype was compared to six shelters built from other construction materialsand selected as the best solution.

This is the first project in North America to use white Ductal premix with organic fibers.

Collaborator: Bouygues ConstructionRenovation of cooling towers.Interest: gains in weight; durability from steam & freeze/thaw.

Cooling Towers at Cattenom

Joppa Clinker Silos - Joppa, IL

24 Precast Ductal Roof Panels- 4300 pounds each - 120 sq.ft./panel

X-Section

Plan

Penthouse

Collaborator: Strudes

Production at the Precast Plant

Thermal Treatment

Casting

Installing the Panels

Steel vs Ductal:- Roof

Construction Schedule

Table I : Comparison of the Roof Installation Schedule.Item Steel Roof (days) Ductal Roof (days)Pre-Erection Survey 2 1Pre-erection set-up (cranes & scaffolding) 5 1Installation of Penthouse Floor( Temporary Compression ring)

1 1

Installation of Ductal® panels - 3Grouting of Ductal® Panels - 5Installation of Steel Roof Framing 12 -Installation of Steel Roof Deck(M embrane) 10 -Grouting Steel Base Plates for beamsat top of Silo walls.

1.5

Installation of Closure Ring & Flashing for SteelRoof Deck(M embrane)

3.5 -

Total (Construction days) 35 11

ColumnsPrecaster: Lafarge, WinnipegDuctal Volume: 52 yd3

Owner: Lafarge GL Cement DivisionCollaborator: LCM PrecastDescription: 4- 2.5 ft x 2.5 ft x 55 ft long columns to

support a new cement silo in the truck loading bays below the silo.

Advantage: Increased clearance & access for trucksIncreased rental space for officesReduced construction time

Prototyping: First castings of a 10 ft x 2.5 ft x 2.5 ft section cast to confirm

the casting methodology and to determine the thermal gradients.

SherbrookeSherbrooke Bridge Bridge -- Quebec, CanadaQuebec, Canada

Constructed in 1997

6 Precast Segments of 30 ft

Total 190 ft span

Construction: Transporting, lifting and positioning of Precast segments

•erection in 1 day!

BridgeBridge-- Seoul, KoreaSeoul, KoreaA A precastprecast segmental 6 @ 65 ft, presegmental 6 @ 65 ft, pre--stressed double teestressed double tee

14 ft

1.2 inchesDeck

X - Section

400 ft

3.6 ft

Collaborator: Bouygues Construction

6’’

6’’

6’’

15’’

3’’

7spaces @ 2’’

18’’2’’

2’’

3 spaces@ 2’’

270 KSI Low Relax

De-bond 50% of strand

26 –1/2’’ Diameter

Strands.Pre-Stress to 80%Of Ultimate Load.

At each end for 36’’

6’’

AASHTO TYPE II BEAM80’0’’ in length

Material Specifications :1) Ductal®:

Minimum Compressive Strength at Release = 12000 psiMinimum Compressive strength at the end of thermal treatment = 23000psi

2) Low Relaxation StrandsUltimate Tensile Strength = 270KSI

12’’

U.S. FHWABridge

Program

Comparison of Allowable Spans

3’-0”

Maximum of 50’-0” Clear Span

Conventional AASHTO Type II Beam:

3’-0”

80’-0” Clear Span

AASHTO Type II Ductal Beam:®390 plf

4’-6”

80’-0” Clear Span

Requires AASHTO Type IV Beam:822 plf

Preparing the Girders for TestingCASTING:October 2000 - Prestress Services Inc, Lexington, KY

SET-UP:January 2001 –Turner Fairbanks Research Center, FHWA, McLean, VA

Testing Measurements

Load = 150 KipsDeflection = 12”

Predicted Load-Deflection based on design calculations using the material properties of Ductal Prism Tests.

Actual Load-DeflectionResults @mid-span& quarter-spans

AASHTO Type II Girder Test - Bending & Shear

Load = 150 KipsDeflection = 12”

Shear Test

Enhanced image of welldispersed micro-cracking

Load - Deflection Test Results

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40

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80

100

120

140

160

180

200

0 5 10 15 20 25

Deflection Mid-span (inches)

Load

(Kip

s)

Load Deflection Curve - Shear AASHTO TII Ductal

-100

0

100

200

300

400

500

600

0 0.5 1 1.5

Deflection at Load Point (inches)

Load

(Kip

s)

Bending Test