2012

HIGH STRENGTH HIGH PERFORMANCE CONCRETE USING ALCCOFINE 1203

JAGDISH PRASAD MALAV INDIAN INSTITUTE OF TECHNOLOGY, BHUBANESWAR, ORISSA 7/6/2012

Acknowledgement
I sincerely express my gratitude to Mr.Amish Bisane,Customer Support head Mumbai, Ambuja Cement and Mr.Abinash Mishra,Head of Alccofine, for giving me opportunity to exercise my engineering, technical and interpersonal skills and to get enough industrial and organization experience in a challenging business environment. I am very much thankful to Mr. Shahir Shaikh, Mr. Anupam Choudhury(Regional Sales Head West), Mr. Aniket Waghmare,Ms.Shweta Agrawal, Mr. Vikash Lokhande for giving me valuable guidance throughout my training program. I would also like to thank the whole team of Ambuja Cement for their relentless patience in familiarising me with the basics of construction technology and their constant encouragement that has led the report its present state.

Content
Chapter No. Topic Page 1. 2. 3. 3.1 3.2 3.3 3.4 4. 4.1 4.2 4.3 5. 5.1 5.2 5.3 6. 7. 8. 9. 10. 11. 12. 12.1 12.2 13. 14. 14.1. 14.2. 15. 15.1 15.2 15.3 15.4 16. 16.1 16.2 17. 18. 19. 20. 21. Concrete History High Performance Concrete Raw Material of HPC Cement and Test of Cement Aggregate and Test of Aggregate Water Admixture and test of Admixture Behavior of Fresh Concrete Workability Setting Time Test of Fresh Concrete Behavior of Hardened Concrete Strength of Concrete Durability Test of Hardened Concrete Comparison between Conventional Concrete and HPC Where HPC Required? Advantage of HPC Limitation of HPC Characteristics of HPC Type and Effect of Material in HPC Specification of HPC Permeability Volume Stability Criteria &Structure of HPC Alccofine 1203 Introduction Characteristics and Properties Comparison of Alccofine 1203 with Silica Fume Discussion of Mix design Durability Water Permeability Chloride Permeability Technical Benefits of Alccofine 1203 In Fresh State In Hardened state Application of Alccofine 1203 Properties of different cementitious material Chemical composition of different cementitious material Particle size distribution of different cementitious material Chloride ponding test report of Alccofine 1203 compared with Silica Fume Economy comparison between Alccofine 1203 and Silica Fume 5 5 6 6 6 6 7 7 7 8 8 8 8 9 9 9 9 10 10 10 10-11 11 11 11 12-13 14 14 14-15 15-22 23 23 24 24 25 25 25 25 25-26 26 26 26

22.

27

23. 24. 25. 26. 27. 28.

Summary of Alccofine 1203 Case study of HPC ACI Mix design Method for HPC Lab Trials Conclusion Reference

28 29-32 33-36 36-39 39 40

Concrete History
Concrete is the most widely used construction material in the world and with a 9000-year history it has played a major part in shaping modern civilization. The Romans were particularly adept at using concrete but it was also known to the Egyptians and in a primitive form to Neolithic civilizations. The main difference between the concrete found in these classical civilizations and modern ready mixed concrete is the binding agent. The Egyptians used crushed gypsum, the Romans knew how to make lime by burning crushed limestone and they even discovered that adding volcanic ash or old bricks and tiles improved the setting characteristics of their cement. Modern concrete was developed after the discovery of Portland cement. First patented in 1824 but not developed in its present form until 1845 when higher kiln temperatures were achieved, Portland cement made new forms of construction possible. Despite these advances attempts to supply the building trade with ready mixed concrete on-site foundered until the late 1920s when delivery trucks were fitted with a drum that agitated the concrete while on the move. In the UK, the first Ready mix operation was set up in 1930 and by the 1960s a successful national network of concrete plants was firmly established. Today, Ready mix concrete comprises a mix of aggregates, cement, water and a variety of admixtures. Understanding these individual ingredients in a little more detail provides an insight into ways of obtaining the best results for different types of project.

High Performance Concrete

American Concrete Institute (ACI) defines High Performance Concrete (HPC) as: A concrete which meets special performance and uniformity requirements that cannot always be achieved routinely by using only conventional materials an normal mixing, placing and curing practices. High performance concrete is a concrete mixture, which possess high workability, high durability and high strength when compared to conventional concrete. This concrete contains one or more of cementitious materials such as Alccofine 1203, fly ash, Silica fume or ground granulated blast furnace slag and high range water reducing super plasticizer such as melamine base, naphtha base, poly-carboxylate, lignosulphonates etc. High performance concrete works out to be economical ,even though its initial cost is higher than that of conventional concrete because the use of high performance concrete in construction enhance the service life of the structure and the structure suffer less damage which would reduce overall cost. The high performance concrete does not require special ingredients or special equipments except careful design and production. High performance concrete has several advantages like improved durability characteristics and much lesser micro cracking than normal strength concrete. Any concrete which satisfies certain criteria proposed to overcome limitations of conventional concretes may be called High Performance Concrete. It may include concrete, which provides either substantially improved resistance to environmental influences or substantially increased structural capacity while maintaining adequate durability.

Raw Material of HPC and their Properties 1. Cement

Physical and chemical characteristics of cement play a vital role in developing strength and controlling rheology of fresh concrete. Fineness affects water requirements for consistency. When looking for cement to be used in High Performance Concrete one should choose cements containing as little C3A as possible because the lower amount of C3A, the easier to control the rheology

and lesser the problems of cement-super plasticizer compatibility. Finally from strength point of view, this cement should be finally ground and contain a fair amount of C3S. 2 The compressive strength of cement used in HPC should not be less than 45 N/mm at 28 days.

Test of Cement
1. Fineness test (IS: 4031 Part 1&2 1996) 2. Soundness Test (IS: 4031 Part 3 1988) 3. Standard Consistency Test (IS: 4031 Part 4 1988) 4. Initial and Final setting time of Cement (IS: 4031 Part 5 1988) 5. Compressive Strength Test (IS: 4031 Part 6 1988)

2. Fine Aggregate
Both river sand and crushed stones may be used. Coarser sand may be preferred as finer sand increases the water demand of concrete and very fine sand may not be essential in High Performance Concrete as it usually has larger content of fine particles in the form of cement and mineral admixtures such as fly ash, etc. The sand particles should also pack to give minimum void ratio as the test results show that higher void content leads to requirement of more mixing water. Fine Aggregate should be inert and not reacting with alkali.

3. Coarse Aggregate
Rounded shape and crushed aggregate are used. Coarse aggregate used in HPC has the maximum Nominal Size = 19 mm. Water absorption shall be maximum =2% for crushed Basalt, and 2.5% for Crushed Limestone. Minimum specific Gravity shall be =2.5 Coarse Aggregate should be inert and not reacting with alkali.

Test of Aggregate
Sieve analysis IS: 2386(Part I) 1963 Water Absorption IS: 2386(Part III) 1963 Aggregate Impact Value IS: 2386(Part IV) 1963 Aggregate Abrasion Value IS: 2386(Part IV) 1963 Aggregate Crushing Value IS: 2386(Part IV) - 1963

4. Water
o o Use drinking water. Water shall not contain more than 500 PPM of chloride ions, and not more than 1000PPM of sulfates.

5. Mineral Admixture Mineral admixtures are fine powders mainly composed of silicate glasses or noncrystalline silica which in the presence of moisture, calcium and hydroxyl ions, slowly hydrate to form cementing product. Mineral admixtures like Alccofine 1203, fly ash and silica fume etc. act as puzzolonic materials as well as fine fillets, there by the microstructure of the hardened cement matrix becomes denser and stronger. Different types of mineral admixture are: Alccofine 1203 Silica Fume Ground granulated blast-furnace slag(GGBS) Fly ash

6. Chemical Admixture Chemical admixtures are the essential ingredients in the concrete mix, as they
increase the efficiency of cement paste by improving workability of the mix and there by resulting in considerable

decrease of water requirement. Admixtures are added to concrete to improve its properties in different condition as Improving casting and finishing Improving workability Increasing compression strength Improving general appearance Improving pumping operation

Test of Chemical Admixtures

Marsh-cone test Different types of chemical admixtures are: Super plasticizers & Plasticizers Plasticizers and super plasticizers help to disperse the cement particles in the mix and promote mobility of the concrete mix. Retarders Retarders help in reduction of initial rate of hydration of cement, so that fresh concrete retains its workability for a longer time. Air entraining agents Air entraining agents artificially introduce air bubbles that increase workability of the mix and enhance the resistance to deterioration due to freezing and thawing actions. Water reducing admixture Water reducing admixture reduces the water content in the concrete.

Behavior of Fresh Concrete Introduction: The behavior of fresh High Performance Concrete is not substantially different from conventional
concretes. While many High Performance Concretes exhibits rapid stiffening and early strength gain, others may have long set times and low early strengths. Workability is normally better than conventional concretes produced from the same set of raw materials. Curing is not fundamentally different for High Performance Concrete than for conventional concretes although many High Performance Concretes with good early strength characteristics may be less sensitive to curing.

Workability: The workability of High Performance Concrete is normally good, even at low slumps, and High
Performance Concrete typically pumps very well, due to the ample volume cementitious materials and the presence of chemical admixtures. High Performance Concrete has been successfully pumped even up to 80 storeys. While pumping of concrete, one should have a contingency plan for pump breakdown. Super workable concretes have the ability to fill the heavily reinforced sections without internal or external vibration, without segregation and without developing large sized voids. These mixtures are intended to be self-leveling and the rate of flow is an important factor in determining the rate of production and placement schedule. It is also a useful tool in assessing the quality of the mixture. Flowing concrete is, of course, not required in all High Performance Concrete and adequate workability is normally not difficult to attain.

Setting time: Setting time can vary dramatically depending on the application and the presence of set modifying
admixtures and percentage of the paste composed of Portland cement. Concretes for applications with early strength requirements can lead to mixtures with rapid slump loss and reduced working time. This is particularly true in warmer construction periods and when the concrete temperature has been kept high to promote rapid strength gain. The use of large quantities of water reducing admixtures can significantly extend setting time and therefore reduce very early strengths even though strengths at more than 24 hours may be relatively high. Dosage has to be monitored closely with mixtures containing substantial quantities of mineral admixtures so as to not overdose the Portland cement if adding the chemical admixture on the basis of total cementitious material.

Test of Fresh Concrete

Slump Test Workability Test IS: 1199 - 1959 Compacting Factor Workability Test IS: 1199 - 1959 Vee Bee Test Workability Test IS: 1199 - 1959

Behavior of Hardened Concrete Introduction: The behavior of hardened concrete can be characterized in terms of its short term and long term
properties. Short-term properties include strength in compression, tension and bond. The long-term properties include creep, shrinkage, and behavior under fatigue and durability characteristics such as porosity, permeability, freeze-thaw resistance and abrasion resistance.

Strength: The strength of concrete depends on a number of factors including the properties and proportions of
the constituent materials, degree of hydration, rate of loading, method of testing and specimen geometry. The properties of the constituent materials affect the strength are the quality of fine and coarse aggregate, the cement paste and the bond characteristics. Hence, in order to increase the strength steps must be taken to strengthen these three sources. Testing conditions including age, rate of loading, method of testing and specimen geometry significantly influence the measured strength. The strength of saturated specimens can be 15 to 20 percent lower than that of dry specimens. Under impact loading, strength may be as much as 25 to 35 percent higher than under a normal rate of loading. Cube specimens generally exhibit 20 to 25 percent higher strengths than cylindrical specimens. Larger specimens exhibit lower average strengths.

Strength development: The strength development with time is a function of the constituent materials and
curing techniques. An adequate amount of moisture is necessary to ensure that hydration is sufficient to reduce the porosity to a level necessary to attain the desired strength. Although cement paste in practice will never completely hydrate, the aim of curing is to ensure sufficient hydration. In general, a higher rate of strength gain is observed for higher strength concrete at early ages. At later ages the difference is not significant.

Compressive strength: Maximum practically achievable, compressive strengths have increased steadily over
the years. Presently, 28 days strength of up to 80MPa is obtainable. However, it has been reported that concrete with 90-day cylinder strength of 130 MPa has been used in buildings in US. The trend for the future as identified by the ACI committee is to develop concrete with compressive strength in excess of 140 MPa and identify its appropriate applications.

Tensile strength: The tensile strength governs the cracking behavior and affects other properties such as
stiffness; damping action, bond to embedded steel and durability of concrete. It is also of importance with regard to the behavior of concrete under shear loads. The tensile strength is determined either by direct tensile tests or by indirect tensile tests such as split cylinder tests.

Durability Characteristics: The most important property of High Performance Concrete, distinguishing it from
conventional concrete is its far higher superior durability. This is due to the refinement of pore structure of microstructure of the cement concrete to achieve a very compact material with very low permeability to ingress of water, air, oxygen, chlorides, sulphates and other deleterious agents. Thus the steel reinforcement embedded in High Performance Concrete is very effectively protected. As far as the resistance to freezing and thawing is concerned, several aspects of High Performance Concrete should be considered. First, the structure of hydrated cement paste is such that very little freezable water is present. Second, entrained air reduces the strength of high performance concrete because the improvement in workability due to the air bubbles cannot be fully

compensated by a reduction in the water content in the presence of a superplasticizer. In addition, air entrainment at very low water/cement ratio is difficult. It is, therefore, desirable to establish the maximum value of the water/cement ratio below which alternating cycles of freezing and thawing do not cause damage to the concrete. The abrasion resistance of High Performance Concrete is very good, not only because of high strength of the concrete but also because of the good bond between the coarse aggregate and the matrix which prevents differential wear of the surface. On the other hand, High Performance Concrete has a poor resistance to fire because the very low permeability of High Performance Concrete does not allow the egress of steam formed from water in the hydrated cement paste. The absence of open pores in the structure zone of High Performance Concrete prevents growth of bacteria. Because of all the above- reasons, High Performance Concrete is said to have better durability characteristics when compared to conventional concrete.

Test of Hardened Concrete

o o o Compressive Strength Test Rebound Hammer Test IS: 13311 (Part II) - 1992 Ultrasonic Pulse Velocity Test IS: 13311 (Part I) - 1992

Table-1.Comparison between Conventional and High Performance Concrete

Parameter Compressive Strength Durability Workability Setting time Permeability Void content Rate of slump loss Water demand Conventional Concrete Low Low Durable Low Low High High High High High Performance Concrete High High Durable High High Low Low Low Low

Where HPC Required

Very severe environment condition. Tunnels Bridges Tall buildings Offshore piers and platforms Confinement structures for solid and liquid wastes containing toxic chemicals and radioactive elements Superstructures, foundations and piles in aggressive environment HPC is being extensively used now for the fabrication of precast pylon, piers, and girders of many long span bridges in the world It has also been used in shotcrete repair, poles, parking garages, and agricultural application HPC can be used to prevent deterioration of concrete. Deterioration of concrete mostly occurs due to alternate periods of rapid wetting and prolonged drying with a frequently alternating temperature.

Advantage
Low shrinkage and high strength Improved durability against chloride attack Improved durability in aggressive environment Increased durability in marine environment Service life more than 100 years Workability and Pumpability High tensile strength

Speed of construction Most economical material in terms of time and money More economical than steel concrete composite columns Reduction in size of the columns Reduced depth of floor system and decrease in overall building height Higher seismic resistance, lower wind sway and drift Wearing resistance, abrasion resistance Reduced maintenance cost

Limitations
High Performance Concrete has to be manufactured and placed much more carefully than conventional concrete. An extended quality control is required Some special constituents are required which may not be available in the ready mix concrete plants.

HPC Characteristics
Ease of placement High strength High early strength High modulus of elasticity High abrasion resistance High durability and long life in severe environments Low permeability and diffusion Resistance to chemical attack High resistance to frost and deicer scaling damage Toughness and impact resistance Volume stability Low drying shrinkage Low creep Low thermal strain Compaction without segregation Inhibition of bacterial and mold growth

Table-2.Type and Effect of Material in HPC

Material Portland cement Blended cement Flyash GGBS Alccofine 1203 Silica fume Metakaolin Super plasticizers HRWR Retarders Accelerators Water reducers Shrinkage reducers Inhibitors Optimally graded aggregate Primary contribution/Desired property Cementing material/durability Cementing material/durability/high strength Cementing material/durability/high strength Cementing material/durability/high strength Cementing material/durability/high strength Cementing material/durability/high strength Cementing material/durability/high strength Flow ability Reduce water to cement ratio Control setting Accelerate setting Reduce cement and water content Reduce shrinkage Control alkali-silica reactivity Improve workability and reduce paste demand

Specification of HPC Impermeability: Chloride-ion permeability test is found to be more practical ASTMC 1202 classifies chloride-ion
penetrability as follow table: Table-3 Permeability data Chloride-ion Penetrability Charge passed(Coulombs)

High 4000

Moderate 2000 to 4000

Low 1000 to 2000

Very low 100 to 1000

Negligible 100

When concrete permeability coefficient is very low, a chloride ion permeability test is the most appropriate. When the concrete mix shows 500C or less current flow in a 6 hours chloride permeability test, it is considered to be virtually impermeability.

Dimension or volume stability: High dimensional or volume stability will depend on the following
characteristics of concrete: o High elastic modulus o Low thermal strain o Low drying shrinkage o Low creep If the above characteristics of concrete are not taken care of, undesirable stress effects can result in volume change under restrained conditions. Conventional material can produce concrete of high compressive strengths (above 60 MPa) but the increase in elastic modulus is not proportional. The improvement in elastic modulus of concrete can only be achieved when suitable material in correct proportions is incorporated in concrete mixes. Creep and drying shrinkage strain in normal concrete can be as high as 0.08%each.With proper materials and mix proportions ,it is possible to reduces the 90 days drying shrinkage strain to less than 0.04%.Creep and drying shrinkage are highly dependent on the aggregate type and content. To achieve high dimensional stability it is desirable to reduce the magnitude of strain by limiting the total volume of the cement paste in concrete and by using coarse aggregate which has high strength high elastic modulus .With availability of good quality chemical and mineral admixtures it is possible to reduce the volume of the cement paste. Drying shrinkage is more influenced by excessive mixing water than due to cement.

Criteria for HPC

Table-4.Selected Properties of High-Performance Concrete are:

Table-5. Typical High-Performance Concretes Used in Structures

AlCCOFINE 1203
Alccofine 1203 performs in superior manner than all other mineral admixtures used in concrete within India. Due to its inbuilt CaO content, Alccofine 1203 triggers two way reactions during hydration Primary reaction of cement hydration. Pozzolanic reaction: Alccofine 1203 also consumes by product calcium hydroxide from the hydration of cement to form additional C-S-H gel, similar to pozzolans.

Introduction: As a result of growth in advance technology in concrete, high performance concrete (HPC) has
gained worldwide popularity in the construction industry since 1990. In practice, high performance concrete, are generally characterized by high cement factors and very low w/cm ratios. Such concrete suffer from two major weaknesses. It is extremely difficult to obtained proper workability, and to retain the workability for sufficiently long period of time with such concrete mixes. High dosage of high range water reducing agents(HRWR) then become a necessity, and resulting cohesive and thixotropic, sticky mixes are equally difficult to place and compact fully and efficiently. These problem indicate that there is probably a critical limit for the water content below which high HRWR dosage become not only essential but also unhelpful and undesirable, and often even harmful from a durability point of view. In high performance concrete applications, Silica Fume is generally proposed as the appropriate cement extender where high strength, low permeability are the prime requirements. Though silica fume is known to improve durability, its addition in concrete is often negated by the increase water and/or admixture dosage required to improve the workability and handling properties of the fresh concrete. ALCCOFINE 1203 is a specially processed product based on slag of high glass content with high reactivity obtained through the process of controlled granulation. The raw materials are composed primary of low calcium silicates. The processing with other select ingredients results in controlled particle size distribution (PSD). The computed 2 blain value based on PSD is around 12000cm /gm and is truly ultra-fine. Due to its unique chemistry and ultra-fine particle size, ALCCOFINE1203 provides reduced water demand for a given workability, even up to 70% replacement level as per requirement of concrete performance. ALCCOFINE 1203 can also be used as a high range water reducer to improve compressive strength or as a super workability aid to improve flow.

Characteristics and Properties: As can be seen in the chemical composition and physical characteristics
listed in below Table-6, ALCCOFINE 1203 has got the unique chemical composition mainly of CaO 32-34% and SiO2 28-32%. Physically the product is unique with regards to its particle size distribution. Below Figure-1, demonstrates the comparative particle size distribution analysis. Table-6 Distinctive chemical composition and physical composition Chemical analysis Mass % Physical analysis CaO 32-34 Bulk density Al2O3 18-20 Surface area Fe2O3 1.8-2 Particle shape SiO2 28-32 Particle size,d10 MgO 8-10 d50 SO3 0.3-0.7 d90

range 3 600-700kg/m 2 12000cm /gm Irregular <2u <5u <9u

Figure-1 Particle Size Distribution

Table-7 .Test certificate for Alccofine 1203 Test d10 PSD d50 d90 3 Bulk Density(kg/m ) Marsh Cone Flow (water to Alccofine 1203 ratio as 1) Chemical Composition (%) SiO2 Al2O3 Fe2O3 CaO SO3 MgO

Result 0.8 < 2 u 3.9 < 5 u 8.2 < 9 u 600 31 sec

31.4 23.4 1.6 32 0.35 8.8

Table-8.Report on durability test Material(Kg) Cement (OPC 53) Fly ash(Dirk P60) Alccofine 1203 Water Admixture(BASF 1125 UT)

Control 280 70 0 166 3.5

With Alccofine 1203 250 72 8 158 3.5

RCPT ASTM 1202(Coulomb) Water penetration as per DIN1048(mm) ISAT,BS 1881-part 122(m1/m2/sec)

3305 48 0.21

1999 41 0.19

COMPARISON OF ALCCOFINE 1203 WITH SILICA FUME

EXPERIMENTAL PROGRAM Concrete quality and mix design: The quality and impermeability of high performance concrete are,
determined by the amount of water utilized in mix design i.e. the water/binder ratio. High range water reducers (HRWR) are extensively used to ensure placement with low water contents. The presence of extremely fine particles decreases the permeability and improves durability. In order to measure the effect of ALCCOFINE1203 on the workability, water requirement and HRWR dosages, three sequences of concrete mixes were prepared, based on the following mix design methodology: A. Workability: Maintaining the water/binder ratio, admixture dosage constant and measuring the slump and compressive strength. B. Water Demand: Maintaining the admixture quantity constant and varying the water/binder ratio and measuring the slump and compressive strength. C. Admixture Requirement: Maintaining the water/binder ratio constant and varying the admixture content and measuring slump and compressive strength. In all three methodologies binders are OPC 430 kg, Fly Ash 80kg and alternately using ALCCOFINE1203 40kg and Silica Fume 40kg as total binder content. The total binder content was maintained constant at 550kg/m3. Crushed Basalt rock was used as coarse aggregate and local river sand was used as fine aggregate. These materials used were dried completely before using. The HRWR used was Polycarboxylate ether. Methodology A: Assessment of Workability From table-9 and figure-2 it is clear that replacement of part of binder by Alccofine 1203 improves the compressive strength as well as slump of the concrete subsequently , even by maintaining water to binder ratio and admixture dosage constant, in comparison with Silica Fume .Due to its unique particle size distribution and inbuilt CaO, Alccofine 1203 results in to formation of dense pore structure, with results in improved workability, workability retention and compressive strength at all age. Table-9.Workability data for concrete specimens of equal water to binder ratio and containing same amount of HRWR Concrete mix design Material Silica Fume Mix Alccofine 1203 Mix Cement 430 430 Fly ash 80 80 Silica fume 40 0 Alccofine 1203 0 40 Water 160 60 Admixture 4 4 Table-10. The effect of Alccofine 1203 addition on Compressive strength and workability of concrete specimen with equal water to binder ratio

Time Initial 30 min 60 min 90 min 120 min 1 Day 3 Day 7 Day 28 Day

Slump(mm) Silica Fume 180 150 110 90 60 Compressive Strength(MPa) 20.4 38.29 49.83 64.17

Alccofine 1203 210 180 150 120 95 20.58 45.11 55.72 67.44

Figure-2 Assessment of workability 250 200

Slump (mm)

150 100 50 0 Initial 30 min 60 min 90 min 120 min Silica Fume Alccofine 1203

Slump time (min)

The rates of strength development for 1, 3, 7 and 28 days and workability of concrete with Alccofine 1203 in comparison with Silica Fume is stated in table-10.Which indicate Alccofine 1203 is better than Silica Fume as per the tests carried out. Figure-3 Assessment of compressive strength

80

Cmpressive Strength (MPa)

70 60 50 40 Silica Fume 30 20 10 0 1 Day 3 Day 7 Day 28 Day Alccofine 1203

Time of Cube Test (Day)

Methodology B: Assessment of Water demand The quality feature of Alccofine 1203 is the optimized particle size distribution and unique chemical composition, which reduces the water demand to achieve a specific slump value. In this methodology, the binder content and admixture content were kept constant and the outcome on water requirement, workability and compressive strength were measured. Table-11. The effect of Alccofine 1203 on the water required to maintain a constant slump Concrete mix design Material Silica Fume Mix Alccofine 1203 Mix Cement 430 430 Fly ash 80 80 Silica fume 40 0 Alccofine 1203 0 40 Water 160 152 Admixture 4 4

Figure-4 Assessment of water required

W a t e r

Alccofine 1203 Silica Fume

148

150

152

154

156

158

160

Water demand in liters

Table-12. Compressive strength and workability of concrete specimen with constant binder and HRWR content Slump(mm) Time Silica Fume Alccofine 1203 Initial 190 200 30 min 155 160 60 min 120 130 90 min 95 110 120 min 65 80 Compressive Strength(MPa) 1 Day 21.3 23.54 3 Day 38.75 47.2 7 Day 50.02 60.42 28 Day 64.50 70.47

Figure-5 Assessment of workability

250

200

Slump (mm)

150 Silica Fume Alccofine 1203

100

50

0 Initial 30 min 60 min 90 min 120 min

Slump time (min)

It is clear from table-12. and figure-6. that decrease in water content increase the compressive strength. Coming to workability, though the water is decreased in sample mix of Alccofine 1203, the retention of slump is better as compared to Silica Fume. The decrease in water demand is because of high glass content which has water repelling property. Figure-6 Assessment of compressive strength 80

Cmpressive Strength (MPa)

70 60 50 40 Silica Fume 30 20 10 0 1 Day 3 Day 7 Day 28 Day Alccofine 1203

Time of Cube Test (Day)

As a constant binder content, the compressive strength of concrete increased along with a reduction in water. As a result the assimilation of Alccofine 1203 in concrete facilitates lower water to binder ratio, which in turn achieves improved compressive strength at all ages and durability as well.

Methodology C: Assessment of HRWR requirement Finer particle size results in rendering more surface area for Pozzolanic reaction, allowing concrete achieving higher strength very easily. Due to optimized particle size of Alccofine 1203 workable concrete can be made using less admixture content. For this methodology water to binder ratio was kept constant and HRWR on case of Alccofine 1203 was reduced, to check the workability and compressive strength. Table- 13. Assessment of HRWR required for a concrete specimen at constant water to binder ratio Concrete mix design Material Silica Fume Mix Alccofine 1203 Mix Cement 430 430 Fly ash 80 80 Silica fume 40 0 Alccofine 1203 0 40 Water 160 160 Admixture 4 3 Figure- 7. Assessment of HRWR required

A d m i x t u r e
0 1 2 3 4 5

Alccofine 1203 Silica Fume

Admixture dosage in kg

Table-14. Workability and compressive strength of concrete specimen at constant water to binder ratio Slump(mm) Time Silica Fume Alccofine 1203 Initial 185 195 30 min 150 165 60 min 125 130 90 min 100 115 120 min 60 75

1 Day 3 Day 7 Day 28 Day

Compressive Strength(MPa) 20 38.95 49.23 63.57

22.58 46.12 54.72 68.64

Figure-8 Assessment of workability 250

200

Slump (mm)

150 Silica Fume Alccofine 1203

100

50

0 Initial 30 min 60 min 90 min 120 min

Slump time (min)

It is clear from table- and figures that even by reducing the content of HRWR Alccofine 1203 shows better workability and compressive strength, as compared to Silica Fume. Using Alccofine 1203 in concrete specimen reduces the amount of HRWR as compared to Silica Fume which in turn reduces the mix cost. Alccofine 1203 provides a lower HRWR dosage to obtain a desired workability. Figure-9 Assessment of compressive strength

80

Cmpressive Strength (MPa)

70 60 50 40 Silica Fume 30 20 10 0 1 Day 3 Day 7 Day 28 Day Alccofine 1203

Time of Cube Test (Day)

Concrete containing Alccofine 1203 display superior results of compressive strength as compared to Silica Fume.

Discussion of Mix design criteria and their test results: The mix deigns containing ALCCOFINE 1203 are
prepared to give optimum advantages in terms of technical as well as economical benefits. The obtained comparative results clearly confirm the superior performance of ALCCOFINE 1203 over Silica Fume. As per the methodologies carried out, in first case with equal amount of water/binder ratio and HRWR in concrete specimen the comparative results of ALCCOFINE 1203 is better than the silica fume. The results are similar even in other two methodologies. Increase in strength & workability and decreased HRWR ratio is mainly due to the optimized Particle Size Distribution and proper chemical composition of ALCCOFINE 1203. ALCCOFINE 1203 facilitate to reduce water content and/or HRWR dosage to provide superior performance of concrete in terms of workability and compressive strength over Silica Fume. long term Pozzolanic activity of ALCCOFINE 1203 can be observed as a function of its particle size distribution and chemical composition. ALCCOFINE 1203 results in to formation of dense pore structure and inbuilt CaO provides increased secondary hydrated products because of which improved strength gain at early as well as later ages are observed. Secondary hydrated products formed due to Pozzolanic and cementitious hydration reaction fills the pores. This reduces the permeability of hydrated products to great extent and protects concrete from chemical attack.

Durability: Though the growing strength is an important criterion for concrete performance, it sometimes fails to
give a desired durability. Under durability water permeability and chloride penetration were measured most commonly. Permeability of concrete often dictates the performance with respect to durability. Chloride ion penetration is the most frequently specified durability criterion for a long term service life of concrete structures. RCPT ASTM C1202 is an Standard Test Method for Electrical Indication of Concretes Ability to Resist Chloride Ion Penetration.(Title of ASTM C1202-05) ASTM C1202 says that this test method is applicable to types of concrete where correlations have been established between this test procedure and long term chloride penetration by ponding method. (ASTM C1202 -05, clause1). Most importantly ALCCOFINE 1203 has ability to increase the service life of concrete by its Packing Effect. Packing effect retards ingression of aggressive agents in concrete even by diffusion and thus enhances durability of concrete. The concrete sample for durability test used was having same proportion as in sample Methodology A. To test ALCCOFINE 1203 for Chloride penetration we have used ASTM C 1543.

Water Permeability: The test used to measure the impermeability of concrete was DIN 1048. According to this
test the cubes were initially water-cured for 28 days, and then exposed to water pressure of 5 bars for 72 hours after which the cube was divided and the depth of water penetration measured. Penetration of less than 25 mm is generally considered to be impermeable concrete. Table-15. Water Permeability (DIN 1048) Assessment of water permeability Materials Silica Fume Water Permeability 18 mm

Alccofine 1203 13 mm

As per the results described above we can see that the water permeability in case of ALCCOFINE 1203 is less than that of Silica Fume. Presence of ultra-fine Cementitious / Pozzolanic materials allows denser packing between cement particles and reduces the wall effect in transition zone between the paste and the aggregate. This refines the concrete microstructure and enhances the degree of impermeability and the strength characteristics of concrete. Chloride Permeability: The chloride penetration test was compared between ALCCOFINE 1203 and OPC. The ASTM C 1543 test measures the penetration of chloride iron into concrete. Three slabs of concrete measuring 90mm + 15mm thick and 300mm square surface area. The slabs used were water cured for 28 days. After the conditioning period 3% NaCl solution was ponded on a top surface for 90 days, while the bottom face was left exposed to drying environment. At the end of this time powdered samples by rotary impact hammer are obtained at various depths (10-20, 25-35, 40-50, and 55-65mm). Chloride content of the sample from each depth were determined and reported. Table-16.Concrete Mix Design for chloride permeability test Concrete Mix Design Materials Reference Mix Cement 400 Alccofine 1203 0 Water 160 Admixture 2 Table-17.The ASTM 1543 test /salt ponding test Results(% by mass) Depth of sample extraction(mm) Chloride content for OPC concrete controlled material Top surface 0.4 5 0.31 10 0.29 15 0.2 20 0.18 25 0.15 30 0.15 35 0.11

Mix with Alccofine 1203 360 40 160 2

Chloride content with Alccofine 1203 0.39 0.045 0.0056 0.0051 0.0051 0.0048 0.0048 0.0048

Because of its finer pore structure and chemical stability, ALCCOFINE 1203 in concrete is substantially more resistant to chloride diffusion. Thus, it reduces the penetration of chlorides in concrete and protects embedded steel from corrosion. CaO available in ALCCOFINE 1203 Contribute to maintain CaOH as buffer in pore Solution, which helps to maintain pH of pore solution. Denser pore matrix restricts chloride penetration and alkalinity forms passive layer on steel and protect it from corrosion.

Technical Benefits: Technical benefits of Alccofine 1203 are: Fresh State

Improves workability retention Improves flow ability Improves rheology Reduces segregation Reduces heat of hydration Improves durability Improves resistance to ASR Improves strength at all ages Improves resistance to chemical attack / corrosion Imparts light color Lowers permeability

Hardened State

Improved workability: The thixotropic nature of cement/slag pastes, better particle dispersion and lubrication of the mix by the finer slag grains, surface characteristics creates smooth slip planes in the paste, reduced water demand as slag adsorbs less water. Reduced rate of slump loss: The initial rate of reaction between slag and water is slower than that of cement and water, the rate of heat of hydration is low, Alccofine 1203 hydrates are generally more gel like and add denseness to the cement paste. Reduce Bleeding and Segregation: The principal factor influencing bleeding is the water/binder ratio, proper particle size distribution fills the pores and provide refined pore structure with reduced water demand, and finer particles hold water in the mix leads to more cohesive paste reducing segregation. Increased compressive strength at all age: The unique PSD fills the micro voids in matrix, reduced water demand, In build CaO content provide buffer Ca (OH)2 for secondary hydration. Reduced permeability making concrete more durable: Decreased pore volume due to properly graded fine grains, CaO available in Alccofine 1203 contribute to maintain CaOH as buffer in pore solution and thereby maintaining alkalinity .Finer pore solution restricts sulfer and chloride ingress, alkalinity forms passive layer on steel to protect it from corrosion.

Application of Alccofine 1203: The applications of ALCCOFINE 1203 in various cementitious materials are
gives below: High rise structure Bridges Marine structure Ports Roads Table-18.Different properties of different cementitious materials Property Silica Fume Metakaoline Dispersion in concrete Critical Critical Replacement of cement 10% max Up to 20% Water demand High High Workability Reduced Reduced Super plasticizer dosage Increased Increased Rate of slump loss Fast Fast Initial heat of hydration Increased Increased Alkalinity of pore Reduced Reduced

Alccofine 1203 Proper Up to 70% Low Improved Reduced Slow Lower Maintained

solution Codal specifications

BIS 15338 ASTM 1240

Separate BIS code under process

Base material

Fume generated in Ferro Silicon Alloys Industry

Kaoline is mined and crushed. Further calcined by heating at 600 to 800 degree C and ground to required fineness India Gujarat,chennai

Sources

China,Bhutan,Norvey etc.

BIS 12089-Raw slag for PSC manufacture ASTM C989-ground slag for use in concrete BIS456Recommends usage in concrete Waste from steel industry quenched with water to form granules. Further ground required fineness with selective ingredients India -Goa

Table-19. Chemical Composition of different cementitious materials Chemical analysis Alccofine 1203(%) Silica Fume (%) CaO 32-34 0.2-0.4 Al2O3 18-20 0.04-0.06 Fe2O3 1.8-2 0.4-0.6 SiO2 28-32 92-94 Others Balance balance Table- 20.Particle Size Distribution (PSD) of different cementitious materials Particle Size Distribution Silica Fume Metakaoline Band Width 0.1-1 u 0.1-50 u d10 <1u <2u d50 <1u <6u d90 <1u < 20 u 3 Bulk Density(kg/m ) Marsh Cone Flow (water to Alccofine 1203 ratio as 1)

Metakaolin (%) 0.4-0.8 41-45 0.5-1 50-54 balance

Alccofine 1203 0.1-17 u <2u <5u <9u 600 31 sec

Table-21.Chloride ponding test report of Alccofine 1203 compared with Silica Fume Depth of sample (mm) Chloride content(% by mass) With OPC Concrete With 10% of Micro With Alccofine 1203 controlled material Silica Ultrafine slge Top surface 0.46 0.043 0.41 5 0.30 0.22 0.13 10 0.19 0.040 0.031 15 0.14 0.017 0.0090 20 0.096 0.011 0.0074 25 0.074 0.010 0.0058 30 0.058 0.0094 0.0046 35 0.051 0.0090 0.0040 40 0.051 0.0082 0.0040 60 0.050 0.0082 0.0038

Table-22.Economy comparison between Alccofine 1203 and Silica Fume (M50 Grade of concrete) Material Quantity per cu.m Rate/kg Cost Alccofine Cost Micro Silica 1203 Cement ( OPC 53) 385 5 1925 1925 Fly ash(Dirk P60) 125 1.5 188 188 Alccofine 1203/ Silica 25 22/28 550 700 fume 20 mm 560 0.23 112 112 10 mm 440 0.16 70 70 Natural sand 623 0.42 262 262 Crushed sand 212 0.21 42 42 Water 140 50 Rs lumsum 50 50 Admixture 5.7 30 171 171 3 Density (kg/m ) 2516 Cost of 3370 3520 concrete(Rs) 3 Note: Saving of 150 Rs/m is achieved by using Alccofine 1203

Comparison between Alccofine 1203 and Silica Fume for Mix design of M60 grade of concrete (IS 10262:2009 guidelines)
Trial-1 Concrete mix design of M60 (IS 10262:2009 guidelines) Material Silica Fume Mix(Kg) Alccofine 1203 Mix(Kg) Cement (OPC 53 Grade) 511.5 511.5 Fly ash(Dirk P60) 0 0 Silica fume 38.5 0 Alccofine 1203 0 38.5 Water 170.5 170.5 Crushed Sand 568.60 571.97 CA1 395.26 397.60 CA2 734.06 738.41 W/CM Ratio 0.31 0.31 Admixture(Glenium-141) 3.85 3.85 Total 2422.27 2432.33 Slump(mm) Silica Fume 160 155 150 135 Compressive Strength(MPa) 39.9 50.1 68.3 Rate/kg 5 Qty/m 511.5
3

Time Initial 15 min 30 min 60 min 3 Day 7 Day 28 Day Material Cement (OPC 53)

Alccofine 1203 180 180 170 160 41.6 53.5 72.4

3

Cost/m

Qty/m 511.5

Cost/m

Fly ash Silica fume Alccofine 1203 Admixture(PCE based) Total Trial-2

1.6 28 22 30

0 38.5 0 3.85

0 0 38.5 3.85

Material Cement (OPC 53 Grade) Fly ash Silica fume Alccofine 1203 Water Aggregate Admixture(PCE based) Time Initial 60 min 7 Day 28 Day

Concrete mix design of M60 Silica Fume Mix(Kg) 430 80 40 0 155 6.6 Slump(mm) Silica Fume 180 80 Compressive Strength(MPa) 51.68 67.5 Qty/m 430 80 40 0 6.6
3

Alccofine 1203 Mix(Kg) 420 90 0 40 150 5.5 Alccofine 1203 190 120 53.35 70.39
3

Material Rate/kg Cement (OPC 5 53) Fly ash 1.6 Silica fume 28 Alccofine 1203 22 Admixture(PCE 30 based) Total 3 Note: Net Saving of 307 Rs/m

Cost/m 2150 128 1120 0 198 3596

Qty/m 420 90 0 40 5.5

Cost/m 2100 144 0 880 165 3289

Summary: ALCCOFINE 1203 can be used as practical substitute for Silica Fume as per the results obtained. If the
advantages of ALCCOFINE 1203 are observed in the concrete mix design, the initial rate of strength development was found to be increased or similar as that of Silica Fume. Durability test measuring the water permeability showed better results than the Silica Fume. But in case of chloride permeability we have compared ALCCOFINE 1203 with OPC and the results shows less permeability in case of ALCCOFINE 1203 than that of OPC. The use of ALCCOFINE 1203, as an alternative to Silica Fume can be effective in enhancing the properties of concrete, both in its fresh and hardened state. Due to the lower water demand, ALCCOFINE 1203 can be ideally used to: o Lower the water/binder ratio o Use of more cost-effective admixture dosages o A combination of above ALCCOFINE 1203 is a new generation supplementary cementitious material (SCM) with a built-in high tech content. In spite of its high fineness it does not increase water demand at the dosage range of 5 to 15 percent of normal OPC in general. In fact concrete slump is seen to be improved, due to the dense packing of cementitious material, producing low void content. The use of ALCCOFINE 1203 results in hydrated cement matrix to comprise of very

small pores. Strength development increases drastically at early ages and the later on strengths are higher compared to traditional supplementary cementitious material due to its unique PSD. Concretes of over 100 MPa (HPC / UHPC) are possible to be made using ALCCOFINE 1203. Judicious use of ALCCOFINE 1203 can produce concrete of superior properties and performance in every way.

CASE STUDY OF HPC

South wacker tower, USA Features o Year of completion 1990 o Total height 293m,70 stories st o 1 14 stories including the underground basement constructed using 80 MPa concrete. o Concrete pumped using only one pump upto full height. Criteria o High strength o Reduction in column size o Pumpability (workability and cohesiveness) o Saving due to reduction of construction time, formwork and materials to the tune of 3000t of 3 reinforcement steel and 7650 m of concrete. Concrete mix used Concrete grade : 80MPa 3 Portland cement : 390Kg/m 3 Silica fume : 50Kg/m Water /binder ratio : 0.30 Slump : Over 200mm Compressive strength : 88Mpa (28days) Modulus of elasticity : 4.28Mpa (56days)

Euro Tunnel, UK/France Features o Year of completion 1994 o Important link between UK and other European countries o Design life 120 years o Total length 51Km (14Km below land and 37 Km below sea) o 40m below sea bed o 50-250m below sea level Criteria o Extremely low permeability o Low thermal expansion o Cracking control o Workability retention-long transportation distance 20Km and 6 hrs. duration for insitu lining concrete o Cohesiveness & Pumpability-long distance pumping (1Km)for sea wall construction.

Concrete mix used Cementitious material content Portland cement: flyash Water /binder ratio Concrete grade Chemical admixture Compressive strength Permeability co-efficient

: : : : : : :

440Kg/m 70:30 0.35 55MPa HWRA 70 to 80Mpa (28days) 10-13m/s

AKASHI KAIKYO, JAPAN Features o Year of completion 1998 o Longest suspension bridge in the world o Link kobe city with AwaijishimaIsland o Main span 1991m o Total length 3911m. Criteria o Minimum thermal cracking o Low heat generation o High strength and workability o Low segregation o Aggressive environment Concrete mix used (3 parts) Part I Composition of 40:40:20 cementitious mix(PC:slag:flyash) in % Water binder ratio 0.33 Compressive 51.9MPa(28days) strength(with crushed sand) Compressive 50.5 MPa(28days) strength(without crushed sand)

II 50:50:00 44:56:00

III

0.33 64 MPa(28days)

0.33 54.5 MPa(28days)

52.7 MPa(28days)

48.4 MPa(28days)

KAIGA ATOMIC POWER PROJECT UNIT-2, INDIA Feature o Year of completion 1998 st o Use of HPC 1 time in the primary structure in India o The main function of this structure is to mitigate the effects of radioactive rays on operating staff, public and environment. o Prestressed concrete vertical walls of about 43m high used as primary containment wall with small and large openings and capped with prestressed concrete segmented hemispherical dome having diameter 42.56 with four large openings.Thicknesss of the wall 0.61m. Criteria o Radioactive protection o High impact resistant, low permeability, low shrinkage, low heat of hydration, low creep and high durability. o Good workability and cohesiveness for pumping.

Special design requirement for prestressed concrete-minimum compressive strengths 60MPa and tensile strength 3.87 MPa.
3

Concrete mix used composition Portland cement Silica fume Water and ice flakes Coarse aggregate (MSA 20mm) Fine aggregate (natural and crushed) Modified polycarboxylic based superplasticiser Water binder ratio Slump Air content Compressive strength Tensile strength

: : : : : : : : : : :

400Kg/m 3 25Kg/m 3 136Kg/m 3 1096Kg/m 3 827Kg/m 5.82Liters 0.32 175+25mm 2% 75.9MPa (28days) 4.36 MPa (28days)

URBAN VIADUCT, MUMBAI, INDIA Feature o Year of completion 2002 o HPC M75 grade concrete used o Length of 1.932Km,Width of 16.2m o 56 spans 3 o Concrete quantity 20000m Criteria o High strength o Durability o Good surface finish o Slump retention in warm to hot climate Concrete mix used composition Cement Silica fume Coarse aggregate (MSA 20mm) Coarse aggregate (MSA 10mm) Fine aggregate (river sand) Chemical admixture (38.5%solids) Water Water /binder ratio Slump at plant Slump at placement point Air content Compressive strength Draying shrinkage Chloride ion permeability (ASTM C1202-97)

: : : : : : : : : : : : : :

500Kg/m 3 50Kg/m 3 762Kg/m 3 384Kg/m 3 682Kg/m 8.25lit. 148lit. 0.269 130 to 180 mm 80 to 120 mm 1.5% 79.6 to 81.3MPa (28days) 0.00142 core 100C (very low) test sample 240C

PETRONAS towers, Malaysia Features o Year of completion 1999 o Tallest building in the world at that time (451.9m) 2 o 88 stories,216901m floor area o Design life of 100 years Criteria

o High strength o Durability high performance to meet the design life o Slump retention Concrete mix used for 2.4 m RCC columns and ring beams upto 22 floor level 3 Cement : 260Kg/m 3 Mascrete (cement-flyash compound in ratio 20:80) : 260Kg/m 3 Micro silica : 35Kg/m 3 Coarse aggregate (MSA 20mm) : 1000Kg/m 3 Sand : 700Kg/m Water /binder ratio : 0.25 to 0.27 Slump : 180 to 220 mm Grade : 80MPa (28 days)

The port de Normandie cable- stay Bridge Features o Year of completion 1993 o Tallest building in the world at that time 3 o 2141m overall length and a center span of 856m,35,000m of M-60 grade concrete are used Concrete mix used for 2.4 m RCC columns and ring beams upto 22 floor level 3 Blended Portland cement : 425Kg/m 3 Water : 153Kg/m Silica fume : 8% 3 Coarse aggregate (MSA 20mm) : 1065Kg/m 3 Fine aggregate : 770Kg/m Water /binder ratio : 0.36 3 Melamine type superplasticiser : 11L/m
st

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

M-75 grade of HPC 1 time used in India for construction of J.J.Hospital flyover in Mumbai. High performance concrete was used on a bridge on S.R.516 near Auburn, Wash.The use of concrete with strength of 69 MPa. In Colorado, an HPC bridge was used to replace a previous structure that carried Interstate 25 over Yale Avenue in Denver. M-70 to 80 grade of HPC used in the construction of Structural engineering research center at madras. M-50 to 80 grade of HPC used in the construction of IIT Madras. M-75 grade of HPC are used in construction of Bandra-worli sea link. nd M-60 grade of HPC are used in the construction of 2 Narmada Bridge in Bharuch at Gujarat. HPC was used on the East Bridge of the Great Belt Link in Denmark 1994. HPC was used on the Confederation Bridge in Canada 1997. HPC was used on the Joigny (France), Greatbelt (Denmark), Akkegawa (Japan), Willows (Canada) Bridge HPC was used on the High rise buildings tower plaza (US), Nova Scotia (Canada) HPC was used on the Tunnels La Bauma and Villejust (France), Manche (UK) HPC was used on the Nuclear structures Civeaux (France)

Mix Proportioning as per ACI

Concrete mix proportioning of Concrete by American Concrete Institute (ACI) method is described below: 1. Select the slump required for the condition of placing, from table-23. 2. Select the maximum size of aggregate to be used. 3. Estimate the amount of entrapped air, from table-27.

4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Estimate the mixing water for the slump and for the selected maximum size of aggregate, from table-27 Select the target strength for the grade of concrete to be proportioned, from table-4. Select the water-cement ratio for the desired strength and for the grade of cement proposed, from figure11. Calculate cement content. Check cement content and water-cement ratio for durability of concrete, from tables -29&30. Estimate the coarse aggregate content, from tables-26&28. Estimate the fine aggregate content. Adjust the moisture in aggregate and water absorption by aggregate. Adjust weight of aggregate to compensate for moisture content in them. Make trial mixes. Cast the cube specimen (15x15x15cm) and check the 3, 7, and 28 days compressive strength of the specimen.

Table-23.Range of workability of concrete Placing condition Workability Concreting of mass pours, shallow Stiff sections, lightly reinforced sections. Concreting of screeds, precast Stiff plastic section, beam, columns, slabs, prestressed sections. Concreting of wall sections, Plastic Concrete for vacuum dewatering,slipforming and pumping Concreting of piles, diaphragm Flowing walls using tremie.

Slump(mm) 0 to 30

30 to 80

80 to 130

130 to 180

Table-24.Target strength for different grades of concrete 2 Grade of concrete Characteristics Target strength for degree of control(N/mm ) 2 strength(N/mm ) Very good Good Fair M15 15 19 21 22 M20 20 26 28 29 M25 25 32 34 35 M30 30 38 40 42 M35 35 44 45 47 M40 40 49 51 53 M45 45 55 57 58 Table26. Bulk volume of Coarse aggregate per unit volume of Concrete MSA Bulk volume of dry rodded Coarse aggregate. Cu.m. per unit volume of Concrete for different fineness modulus of sand 2.4 2.6 2.8 3 3.2 10 0.50 0.48 0.46 0.44 0.42 12 0.59 0.57 0.55 0.53 0.51 20 0.66 0.64 0.62 0.60 0.58 25 0.71 0.69 0.67 0.65 0.63 40 0.76 0.74 0.72 0.70 0.68

Table-27. Estimation of mixing water and air content as per ACI-211 Description Water content(kg/m^3) of workability Slump(mm) MSA(mm) 10 12 20 Extremely 180 170 160 dry Very stiff 185 185 170 Stiff 0-30 200 195 180 Stiff plastic 30-80 205 200 185 Plastic 80-130 225 215 200 Flowing 130-180 240 230 210 Entrapped air 3 2.5 2 (%)

25 150 160 170 180 195 205 1.5

40 140 150 155 160 175 185 1

Table28. Correction factor for coarse aggregate Description Slump(mm) Correction factor to bulk volume for maximum size of aggregate(mm) of workability 10 12 20 25 40 Extremely 1.90 1.70 1.45 1.40 1.30 dry Very stiff 1.60 1.45 1.30 1.25 1.25 Stiff 0-30 1.35 1.30 1.15 1.15 1.20 Stiff plastic 30-80 1.08 1.06 1.04 1.06 1.09 Plastic 80-130 1.00 1.00 1.00 1.00 1.00 Flowing 130-180 0.97 0.98 1.00 1.00 1.00 Table-29.Durability of Concrete under Specified condition of Exposure Exposure Plain concrete Reinforced concrete Minimum Cement Maximum Free Minimum Cement Maximum Free content(Kg/m^3) Water-Cement Ratio content(Kg/m^3) Water-Cement Ratio Mild 220 0.70 250 0.65 Moderate 250 0.60 290 0.55 Severe 310 0.50 360 0.45 Note: 1.when maximum w/c ratio is strictly controlled,the cement content can be reduced by 10%. 2. Minimum cement content given is for 20 mm aggregate. For 40 mm aggregate it should be reduced by 10%, for 12 mm aggregate it should be increased by 10%.

Table30.Requirements for concrete exposed to sulphates attack Dense, fully compacted concrete made with 20mm nominal maximum size aggregate

Concentration of sulphates expressed as SO 3

Clas s SO3 in 2:1 water: soil extract g/L In ground water g/L Type of cement

In soil total SO3 %

1.

0.2

0.3

2.

0.2 to 0.5

1 to 1.9

0.3 to 1.2

3.

0.5 to 1

1.9 to 3.1

1.2 to 2.5

4.

1 to 2

3.1 to 5

2.5 to 5

5.

Ordinary Portland cement or Portland slag cement or Portland pozzolana cement Ordinary Portland cement or Portland slag cement or Portland pozzolana cement Supersulphated cement or sulphates resisting Portland cement Supersulphated cement or sulphates resisting Portland cement Ordinary Portland cement or Portland slag cement or Portland pozzolana cement Supersulphated cement or sulphates resisting Portland cement Supersulphated cement with protective coatings or sulphates resisting Portland cement

complying with IS : 383 Mini Maximum mum free water cem cement ratio ent cont ent not less than Kg/ 3 m 280 0.55

330

0.5

310

0.5

330

0.5

350

0.45

370

0.45

400

0.4

Figure-10..Relation between Free Water Cement Ratio and Concrete Strength at 28 days for different cement strengths(IS:10262-1982)

Mix Proportioning: ACI

Concrete mix proportioning of High Performance Concrete by American Concrete Institute (ACI) method is described below: 1. 2. 3. 4. 5. 6. Select the slump required for the condition of placing Select the characteristics strength in MPa Select the maximum size of aggregate to be used in mm Find out the volume multiply factor for coarse aggregate, From table-31 Estimate the coarse aggregate content in kg Estimate the mixing water for the slump and for the selected maximum size of aggregate, from table-32 7. Estimate the amount of entrapped air, From table-32 8. Select the water-binder ratio for the desired strength, From table-33 9. Calculate cement content 10. Estimate the flyash content in kg 11. Estimate the Alccofine 1203 content in kg 12. Estimate the fine aggregate content 13. Adjust the moisture in aggregate and water absorption by aggregate

14. Adjust weight of aggregate to compensate for moisture content in them 15. Make trial mixes 16. Cast the cube specimen (15x15x15cm) and check the 3, 7, and 28 days compressive strength of the specimen Table-31 Selection of coarse aggregate content MSA(mm) Volume Multiply factor 10 0.65 Volume of coarse aggregate 12 20 0.68 0.72 25 0.75

Table-32 Estimation of mixing water and air content Slump(mm) 25-50 50-75 75-100 Entrapped air (%) 10 183 189 195 2.5 Water content(kg/m^3) MSA(mm) 12 174 183 189 2

20 168 174 180 1.5

25 165 171 177 1

Table-33 Selection of water to binder ratio Characteristics strength(MPa) Age(days) Water to binder ratio MSA(mm) 28 56 58 56 28 56 28 56 10 0.42 0.46 0.35 0.38 0.30 0.33 0.26 0.29 12 0.41 0.45 0.34 0.37 0.29 0.32 0.26 0.28 20 0.40 0.44 0.33 0.36 0.29 0.31 0.25 0.27 25 0.39 0.43 0.33 0.35 0.28 0.30 0.25 0.26

48 55 62 69

Lab trials
Trial-1 Date:19/6/2012 Material Type Cement Fly ash Alccofine 1203 Water Sand CA1 CA2 W/CM Ratio Admixture Total Time(minutes) Initial 30 60 90 120 180 Days 3 Weight(kg) 8.380 8.154 8.400 8.430 8.295 8.440 8.365 8.402 8.390 Load(KN) 802.2 850 1067 1196 1122 1145 1495 1500 1490 Slump(mm) Collapse Collapse Collapse Collapse Collapse 180 Strength(MPa) 35.67 37.78 47.43 53.16 49.87 50.89 66.44 66.67 66.22 Avg. Strength(MPa) 40.3 OPC 53 Dirk P60 Grade:M100 Qty in Corrected SSD(kg) (kg) 400 400 120 120 63 63 150 656 492 492 0.26 11.66(2%) Batch(kg) 14.890 4.466 2.345 6.864 24.410 18.310 18.310 Time:11:10 AM WA % MC % Cost(Rs)

Crushed Crushed Crushed

656 492 492

3% 1.5 % 1.5 %

Rheobuild 918 BASF

0.437

51.31

28

66.44

Remarks: In this trial admixture dosage is very high. Trial-2 Date:20/6/2012 Material Type Cement Fly ash Silica fume Alccofine 1203 Water Sand CA<20mm W/CM Ratio Admixture Total Time(minutes) Initial 30 60 90 120 180 Days 3 Weight(kg) 8.480 8.385 8.518 8.320 8.530 8.355 8.530 8.410 8.476 Load(KN) 1117 1074 1291 1597 1631 1497 1730 1831 1597 Slump(mm) Collapse Collapse Collapse Collapse Collapse 180 Strength(MPa) 49.64 47.73 57.38 70.98 72.49 66.53 76.89 81.38 70.98 Avg. Strength(MPa) 51.58 OPC 53 Dirk P60

Grade:M100 Qty in Corrected(kg) SSD(kg) 333.334 333.334 166.667 166.667 66.667 66.667 100 100 140 630 900 0.21 5.33(0.8 %)

Batch(kg) 12.592 6.296 2.518 3.777 6.5 23.8 34

Time:12:00 PM WA % MC %

Cost(Rs)

Crushed Crushed

630 900

3% 1.5 %

Glenium ACE30

0.204

70

28

76.42

Remarks: In this trial admixture dosage is very high. Trial-3 Date:22/6/2012 Material Type Cement Fly ash Alccofine 1203 OPC 53 Dirk P60

Grade:M120 Qty in Corrected(kg) SSD(kg) 500 500 120 120 40 40

Batch(kg) 18.800 4.520 1.500

Time:11:35 AM WA % MC %

Cost(Rs)

Water Sand CA1<10mm CA2<20mm W/CM Ratio Admixture Total Time(minutes) Initial 30 Days 3

Natural Crushed Crushed Glenium ACE30

130 650 460 460 0.2 2.64(0.4 %)

650 460 460

5.896 24.440 17.290 17.290 0.100

2% 1.5 % 1.5 %

Slump(mm) Collapse 140 Weight(kg) 8.339 8.368 8.270 8.450 8.395 8.507 8.406 8.360 8.4 Load(KN) 1076 1220 1160 1226 1380 1316 1480 1483 1579 Strength(MPa) 47.82 54.22 51.56 54.49 61.33 58.49 65.78 65.9 70.18 Avg. Strength(MPa) 51.2

58.1

28

67.29

Remarks: This trial has the very good workability. And strength is also good. Trial-4 Date:26/6/2012 Material Type Cement Fly ash Alccofine 1203 Water Sand CA1 CA2 W/CM Ratio Admixture Total OPC 53 Dirk P60

Qty in SSD(kg) 450 140 60 140 700 500 500 0.23

Grade:M100 Corrected(kg) 450 140 60 140+29 700 500 500

Batch(kg) 16.014 4.982 2.135 6.014 24.911 17.794 17.794

Time:2:30 PM WA % MC %

Cost(Rs)

Natural Crushed Crushed

2% 1.5 % 1.5 %

2.6(0.4 %) 2528.6

0.0925

Time(minutes) Initial 30 60
Days Weight(kg) Load(KN)

Slump(mm) Collapse 180 120

Strength(MPa) Avg. Strength(MPa)

28

8.380 8.409 8.483 8.350 8.590 8.580 8.428 8.492 8.390

849 804 992 1110 1060 1158 1433 1364 1423

37.73 35.73 44.1 49.33 47.11 51.47 63.69 60.62 63.24

39.2

49.30

62.52

Remarks: In this trial workability is good.

Conclusion: We do trial of High Grade of concrete.Trial-2 has the good workability for three hours and has the three day strength is 51.58 MPa and seven days average strength is 70 MPa but this trial is not economical .after that we done the trial-3.This trial has the good flow ability and three days average strength is 51.2MPa and seven days average strength is 58.1 MPa.

Reference
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