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Transcript of Page 1 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012 Composite...
Page 1 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012
Composite Cement Testing Dyckerhoff Germany
Denver, June 2012, Heiko Plack
Page 2 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012
Test Programme• Combinations tested (varying contents):
Cementitious component:• API Class G
(medium coarse cement, Blaine 3.100 cm2/g)• API Class G + CEM I 42,5 N
(medium fine cement, Blaine 3.900 cm2/g)• API Class H
(coarse cement , Blaine 2.550 cm2/g)
Additive:• Silica flour
• Medium fine
(Blaine 3.200 cm2/g)• Coarse
(Blaine 1.000 cm2/g)• Natural pozzolan
(very fine, Blaine 8.000 cm2/g) Variations include also changing water-to-cement/blend ratio = slurry density
Blends were tested according to physical API Spec 10A requirements
Page 3 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012
Components Involved (Characterization)
Absolute Density
Fineness
g/cm3 cm2/g
3,17 3 110
3,14 3 860
3,14 2 550
2,65 3 230
2,66 1 000
2,56 8 000
Random Sample taken from DY production
Silica flour, coarse Purchased (foreign source), SiO2 > 97%
Natural pozzolan (volcanic) Purchased (foreign source), SiO2 > 97%
Class H Random Sample taken from BU USA production
Physical parameter
RemarksComponent
Random Sample taken from DY production
Purchased (foreign source), SiO2 > 97%
Class G
Silica flour, medium fine
CEM I 42,5 N
Page 4 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012
Discussion Of Results• Assumption (Dyckerhoff proposal): Standardization efforts target on
specifying a „basic“ cement, and not a „special cement“, e.g. lightweight cement (covered by Lafarge NA proposal)
• = slurry density for performance testing is > 1.800 g/cm3
• Additives do affect the slurry density by • their own absolute density differing from Portland cement• higher specific surface area increasing the water demand
• = difficult to specify the water-to-cement/blend ratio, like for current basic cements, G and H
• However, most important performance requirements identified as • Free fluid (slurry stability)• Max. consistency 15 – 30‘ („rheology“)• Thickening time Schedule 5 („pumping time“)• Compressive strength 8h@140°F („later“ strength)
Page 5 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012
Discussion Of Results – Conclusion (I)
• Blends of different cement components (reactivity / fineness) + silica flour of different fineness have been tested (+ a very fine natural pozzolan)
• Apart from the content of used components the water-to-cement/blend ratio has been varied respectively adjusted.
• It is evident that a cement manufacturer has sufficient degree of freedom to adjust physical performance properties of a composite cement by varying
• Cement type (reactivity)
• Additive fineness and content
• Water-to-cement/blend ratio
Page 6 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012
Discussion Of Results – Conclusion (II)
• Thus • no maximum or mininim share of additive is to be specified,• no water-to-cement ratio is to be specified,
• instead, a slurry density range is to be specified for performance testing
Page 7 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012
Conclusion / Suggestion (I) - Lafarge NA proposal
Suggestion to specify two new API Spec 10A Composite Cement Classes with the following physical requirements:
• Composite cement #1 (API Class E?)
→ Lafarge NA results / proposal:
• Additives: Pozzolanic (natural + artificial), list of materials to be defined!
• Slurry density for performance testing:
12,0 lb/gal < SG < 16,7 lb/gal
• Free fluid:
< 5,9%
• API Schedule 5 thickening time:
TT > 90‘
• Max. consistency 15 – 30‘:
< 30 Bc
• Compressive strength 24h@100°F:
> 500 psi
No chemical requirements to be specified for both new Classes!
Page 8 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012
Conclusion / Suggestions (II) – Dyckerhoff proposal
• Composite cement #2 (API Class F?)
→ Dyckerhoff results / proposal
• Considered as a „basic cement“
• Additives: Silica flour + Pozzolans
• Slurry density for performance testing:
15,0 lb/gal < SG < 16,7 lb/gal
• Free fluid:
< 5,9%
• API Schedule 5 thickening time:
90‘ < TT < 120‘ (130‘?)
• Compressive strength 8h@140°F:
> 1.000 psi
No chemical requirements to be specified !
However, classification as HSR grade possible if
- Portland clinker used complies with HSR requirements of Classes G/H
Page 9 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012
Conclusion / Suggestions (III)• Specifying slurry density requires a reference to API RP 10B for the
test method. Mud balances usually available at all cement manufacturer‘s labs, calculation from absolute densities of components may also be considered.
• Requirement to provide test report along with any order shall state:• Slurry density at which performance tests were conducted• Water-to-cement/blend ratio at which performance tests were conducted• Share of Portland cement respectively of additive• Type of additive (silica flour, fly ash, natural pozzolan)• + results of physical testing as specified (see above)• Chemical specification ???
Page 10 API SC 10 Denver, June 2012 – Composite Cement Testing | H. Plack | May 2012
Test ResultsComments Test # Class G
CEM I24,5 R -
HSRClass H
SF I"med-fine"
SF II"coarse"
Nat. pozz.
Consistencyafter 30 min,
Bc
TT(Bc=100)min
8h @ 38°Cpsi
8h @ 60°Cpsi
A1 100 0 0,44 15,92 2,1 15 106 517 1.990
B2 90 10 0,44 15,79 2,6 2 113 584 2.274
B3-0 74 26 0,44 15,67 1,9 25 106 390 1.284
B3-1 74 26 0,42 15,77 1,8 22 96 420 1.530
B3-2 74 26 0,40 15,92 1,1 20 93 411 1.474
Class G (med. coarse cem.) + coarse SF B3-3 74 26 0,41 15,84 6,6 7 112 1.467
A2 100 0 0,44 15,91 3,2 11 102 690 2.410
C1 69 5 26 0,44 15,57 2,1 15 116 425 1.630
C2 64 10 26 0,44 15,57 1,6 25 88 570 1.780
C3 59,6 14,4 26 0,44 15,57 1,6 22 80 580 1.790
C4 60 10 30 0,44 15,52 1,8 14 108 460 1.550
A3 100 0 0,44 15,92 2,1 17 98 653 2.387
D2 70 30 0,44 15,49 0,4 25 95 400 860
Class G (med. coarse cem.) + nat. pozz, w /c +
D3 60 40 0,67 13,77 1,8 7 110 too low too low
E1 100 0,38 16,70 5,1 13 110 1004 2.528
E2 74 26 0,38 16,33 3,1 29 92 794 1.882
E3 74 26 0,4 16,11 4,6 8 117 596 1.473
E4 74 26 0,44 15,71 4,3 14 141
Min (excl. Test# D3 = lightweight cement) 59,6 5 74 0 26 0 0,38 15,49 0,4 2 80 390 860
Max (excl. Test# D3 = lightweight cement) 100 14,4 100 30 26 40 0,44 15,86 6,6 29 141 1004 2528
Class G (med. coarse cem.)+ medium fine SF +/-
Class G (med. coarse) + medium fine SFw ater-to-cement ratio +/-
Class H (coarse cem.)+ medium fine SF +/-
Class G (med. coarse cem.)+ natural pozzolan (very f ine) +/-
Class G (med. coarse cement)+ CEM I 42,5 N (med. f ine cement) +/-+ med. f ine SF +/-
not enough sample
API Spec 10 A - Results
Component, %Thickening Time Test
API Schedule#5, 356bar, 52°CCompressive strength
Slurry density,
lb/gal
Free Fluid,%
Mixw ater,
% BWOB