Dr.Vilas Deshmukh

Dr.Vilas Deshmukh

Thursday, April 25, 2013


DEMO TRIAL USING TATA POWER FLYASH IN UTWT FOR RURAL ROADS–A Case study
The Prime Minister Gram Sadak Yogna, an India govt scheme is doing good progress in all the Indian states. The scheme gives preference to new roads where there is no access to particular village to the main roads. The bituminous macadam roads are preferred over concrete roads because of higher initial laying cost and more time required for concrete roads although the extreme climatic condition in our country, bituminous macadam roads do not last.
 Dr Vilas Deshmukh, Material Scientist under the guidance of Mr. P. Bongirwar retired secretary PWD Maharashtra state developed a concrete mix design which is marginally higher in cost than cost of the bituminous road. The PWD of Thane under the scheme of PMGSY laid UTWT of 150mm thick on GSB. The road was laid in the year 2010. Though the white topping cost was reduced significantly it was still costly than DSR rates of Thane PWD  for bituminous roads
TATA Power produces around 350 tons per day flyash in the Mumbai and Mundra plants. Huge production creates waste material causing disposal problem .TATA Power flyash has unique problem since they are using Indonesian coal for burning, the flyash colour is red which is not acceptable to Indian concrete industry. Mean while Mr. Rajendra Bhonsale of CTTL subsidiary of Tata power approached Dr. Deshmukh who has further reduced the cost of concrete by judicially using more Tata flyash and cheaper admixture polyheed of BASF.
PMGSY units of Nasik and Amrawati are currently using this technology.
The demo trial of 100 mm thick white topping is carried at CTTL on 12th April 2013.

The highlights are
·        Use of fly ash 45%+in the mix
·        Thickness of topping is 100mm
·        The SCC with slump flow 500 mm is used
·        The cost of UTWT  100mm thick is same 50mmBM+20mmAC
·        Admixture  polyheed of BASF is used
The strength data of various compositions is studied and the results are given below:

cost/RS
3-DAYS
7DAY
28DAYS
56DAYS
w/b
exp.conducted
original mix
2665.8
16.96
20.47
37.63
46.91
0.38
BASF
260+100pfa
2546.75
12.99
18.79
29.96
42.28
0.38
BASF
250opc+100pfa
2511.65
13.28
17.81
32.38
38.78
0.38
BASF
250opc+90pfa
2519.2
12.9
38.19
33.06
36.97
0.38
BASF
240opc+90pfa
2501.1
12.77
18.76
38.19
39.01
0.38
BASF
240opc+100pfa+20alcofine
2809.75
12.79
20.3
33.63
43.01
0.38
BASF
230opc+100pfa+20alcofine
2711.65
11.24
16
29.26
41.44
0.38
BASF
210opc+90pfa+30alcofine
2842.2
14
19.53
35.18
39.13
0.38
BASF
290opc+200pfa
2445
18
25
38

0.34
PUNE ENGINEERING COLLEGE
290opc+200pfa from tata power
3265
25
35
51

0.35
BASF








Chemical analysis of typical Indian coal flyash and tata power Indonesian coal flyash is given below
Element
INDONESIA
INDIA
·                    SiO2
·                    33.9
·                    57.5
·                    Al2O3
·                    20.4
·                    29.8
·                    Fe2O3
·                    19.8
·                    5.8
·                    CaO
·                    14.9
·                    0.4
·                    MgO
·                    5.8
·                    1.0
·                    Na2O
·                    0.54
·                    0.07
·                    K2O
·                    0.93
·                    1.55
·                    TiO2
·                    0.70
·                    1.3
·                    SO3
·                    0.8
·                    0.08
·                    Carbon
·                    1.6
·                    2.2
·                    LOI
·                    2.2
·                    2.4
·                    IR
·                    40.8
·                    92.9

·        Benefits of using TATA POWER Fly ash.
·        More replacement of cement by flyash
·        The early day strength is not reduced
·        Production of green concrete.


Cost comparison:
Ball park comparison between both the technologies – bituminous macadam roads are 1-2% expensive compared to concrete and  the benefits are already given in this document

Few photographs of the trail conducted at CTTL is given below

.

Conclusion:
TATA Power in collaboration with  any reputed cement manufacturer produce green concrete which can be used in pavement of Indian rural roads

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