Breakthrough Concrete Mix Designs For Industrial Liners And Pavement Overlays.

Breakthrough Concrete Mix Designs For Industrial Liners And Pavement Overlays.


Dr.Vilas Deshmukh
SMC Infra Structure Pvt.Ltd,Thane, India

Preamble: The Road and Society( Science and Faith)
I was the ardent student of science write from the beginning but in my thirty years of experience in scientific world I have experience that science and faith not work separately but they go hand in hand. Our purpose of doing work is to get degree and acquire position in the scientific community. Once we achieve that we forget research and do administrative work. Almost all research organizations have similar attitude, knowing and conscious of this I had joined ACC LTD in seventies at the research station in Thane.
I was working in research and development group of ACC LTD where with the cooperation of my research heads, I got the opportunity to develop new methodology and various kinds of products to lay roads which are cheaper, fast and durable. I will mention the names of people who are responsible directly or indirectly for this work. While I was busy in the development, I was introduced to various technologies from different people on different occasions, whose mention I am making in the following contributions of the scientists. Mr. Sondur then working for MBT introduced fifth generation admix carboxyl ether which has helped me to make the concrete mix workable in less, water to cement ratio. Dr A.K.Chatterjee concrete technologist ex-director ACC LTD author of many books in nineties in collaboration with Materials Research Laboratory (MRL USA ) started working on new generation cementitious material namely on chemically bonded ceramic(CBC). I had the opportunity to work with Dr Rustom Roy, Dr. Dela Roy, Prof Barry Smith from whom I have learnt the concept of packing density, which I am using in my work. And to our surprise because of the admix and improvements in material packing, I could make the concrete whose compressive strength is of the order of 1500kg/cm2 to 2000kg/cm2 the formulation of mix to achieve properties like ceramic metal became possible Then Mr. A.K.Pathak, President ACC LTD though typical production person transfer to research and consultancy directorate as if sent by some power to lead research team. He saw the commercial potential in work on CBC and because of corrosion, erosion, abrasion resistant properties used in liners in pipes and bents as liners we named it DRC-densified reinforce composite. The product has replaced conventional cast basalt used as liners. We have developed about ten products based on these applications and today the company manufactures it and supplies such cement to thermal power and chemical plants. Mr. Mittal ex-ACC employee, working with Benani cement, wanted to put slag dryer for their Benani cement plant in Dubai. We used our resistant DRC material which is it not different from conventional thinking of using the new material which has been used in market. I have completed that job with help of Pakistani people, which is an example of professionalism. We have used modified concrete of 25mm layer on damaged bituminous road. While we were working on this DRC material, Mr. A.K.Pathak president saw the commercial potential of it and we started making roads for Bombay Municipal Corporation The product called ACC MARG was launched and at many sites we successfully used this product. With our limited manpower, we undertook projects in Surat and made the city pothole-free. Further, we developed concrete with high early strength which has helped us opening the traffic on the road within merely three days. Then came Mr. K.D.Lala chief engineer Thane Municipal Corporation, unaware of the potential of ACC MRAG, in spite of the risk of failure, allowed me to experiment the product which has today become successful and the road is in service for last three years in Thane city. Then under the leadership of Mr.Suhas Mehta of SMC Infrastructure Pvt. Ltd, he has made possible alternative to concrete road. The product was placed first time in Ghantali lane, Thane city. with the initiative of the Thane municipal corporator. It was the first concrete road which was ready the next day for traffic The traffic and pedestrians started believing in the potential of the product when they used the road very next day.

Then came the another chapter, Mr. Bongirwar retired secretary of PWD and advisor to many concrete roads dams and bridges of India, pushed the product UTWT to Prime Minister Gram Sadak Yogana (PMGSY) and promised them to give the concrete road in bituminous cost. The mix is developed by author at marginally higher cost than conventional bituminous road and ready to apply village road of India
The then minister of gram sadak yojana (PMGSY) sent me to the chief engineer of this project in Maharashtra and what a surprise he took the major lead to implement this technology. Today we have received the permission to start on an experimental basis the concrete road from central government. The villagers who were deprived of roads will get opportunity to progress. The dream of common man has come to some extent near to reality.

Few common man reactions
First pedestrian:How is it possible concrete road of 100mm thickness and that to with out removing the old bituminous road ?
Second pedestrian: reflecting on a road in their locality, made their mind full with positive thoughts and responded that the road is so good even if I think of spitting on the road one, will think twice, finally not do it.
Third pedestrian: The old man was happy because of fast work He could walk next day with no trouble.
Fourth one : The people from Rabodi locality, Thane were reluctant to have the road in their area. Their negative thinking turned into positive and started appreciating the development work. Thanks to local leader of locality to convince the product to Rabodi people.
Each person whom I have mentioned above was an expert in their respective fields of working. But all has helped me to develop above mentioned product.
Is it not strange to meet all scientists at required time to go at higher step? I have given you the link of the videos of the concrete road which are cheaper and faster
• MVI_3807.AVI- http://www.youtube.com/watch?v=RFbZYfSaPl8
• mvi_4522.avi- http://www.youtube.com/watch?v=b9uyYNGF3Dg
• http://www.youtube.com/user/vilasdes#p/a/u/0/b9uyYNGF3Dg
• UTWTThane- http://www.youtube.com/watch?v=QQqFk2Zwjdc
Ten years back, the first thing I have made a mould of lord Ganesh out of my new material. And last year I have successfully laid UTWT when at that time also elephant was present at the site

Introduction :

Recent years have seen the development of many new advances in cementitious materials as ceramic like materials formed as the result of chemical reactions occurring at or near ambient temperatures. These new advances have occurred as a result of manipulating the microstructure and controlling the chemistry or both, of cements. These advances have led to the development of new families of high performance cementitious materials including very high strength materials. Some of these materials cross the boundaries of what have been defined as traditional cementitious materials, and the term chemically bonded ceramics has been used to classify these new materials. CBCs are defined at or near ambient temperatures. These new novel cements or CBCs follow the general rules of behavior of cementitious materials in certain respect. The strength of hardened paste increases as the ratio of water to cement is reduced. Because the residual porosity, its distribution and the excess uncombined molecular water are responsible for most of the limitations on the properties of conventional hardened cement paste. Many attempts have been made to reduce the amount of water used in processing. The situation has changed beginning in about 1970 as new approaches have led to the development of more advanced cement matrix composites.
1) Densification by pressure and heat
The bonds limiting the strength of cement paste are normally thought to be weak van der waals forces Before 1970,the potential strength of cement paste at theoretical density had never been approached because considerable porosity (20 to 30% or more total porosity) always remain after complete hydration of cement. Following this research resulted in achieving very high strengths by warm pressing. Compressive strengths up to 650 Mpa (compared to more typical 30 Mpa) tensile strength up to 68 Mpa and values of youngs modulus up to 40 Gpa were attained. Enormous increases in strength resulted from the removal of most of the porosity and the generation of very homogenous fine microstructure with porosity's as low as 2%.
2) Micro defect free cement.
The warm pressed cements discussed in the previous section were successful but not easy to produce in large amounts due to the high pressure used. The next step was to develop more easily processed materials. .Another innovation was the engineering of a new class of high strength materials, the MDF cement. MDF refers to the absence of relatively large voids or defects which are usually present in conventionally mixed cement paste because of entrapped air and inadequate dispersion. In the MDF process 4 to 7% of one of several water soluble polymer is added as a rheological aid to permit cement to be mixed with very small amount of water., subsequent high shear mixing produces a plastic cohesive mixture which can be shaped by extrusion or other forming technique and which sets in times ranging from minutes to hours. The highest strength materials have been prepared with calcium aluminate cement. Control of the particle size distribution for optimum particle packing was also considered important for generating strength. A final processing stage in which entrapped air is removed by applying modest pressure or heating at 80 0C resulted in a paste that is free of large defects. with excellent mechanical properties. Very low porosity's were achieved <1% as well as flexural strength of 150 Mpa. compressive strength of 300 Mpa and a young’s modulus of 50 Gpa. When MDF material is exposed to moisture, the polymer phase which MDF cement where constitute 30% on a volume basis, swells and softens. This property of MDF cement has restricted the use of its in application where water is used.
3) DSP and other densely packed systems
An important class of new materials termed DSP (Densified systems containing homogeneously arranged ultrafine particles) was first elucidated in detail by Bache The new class of materials is defined as materials with matrix comprising of 1) Densely packed particles of a size ranging from 0.5 to 100micron usually cement 2) Homogeneously arranged ultra-fine particles ranging in size from 50 A0 to 0.5 microns usually silica fume, arranged in the spaces between the larger particles. The combination of densely packed silicafume and cement was found to benefit for a combination of reasons
1) The silica particles are smaller than even the finest cement produced by grinding and therefore pack more easily into the spaces between the cement particles.
2) The silica particles are spherical in shape
3) The particles are chemically less reactive than cement, which eliminates the problem
of too rapid hardening encountered with very fine cement
4) Finally with added dispersing agents a low water requirement may be achieved.
Numerous investigations have contributed to the understanding of the effects of fine particles in densely packed cementitious materials. With 15% silica fume replacement of cement thwere are 2000000 particles of silica fume for each grain of portland cement in a concrete mixture. Concrete containing 5 to 15% silica fume have high compressive strengths up to 100 Mpa flexural strength up to 12 Mpa and young’s moduli (up to 34 Gpa)and have very low permeability to water (10-9 um).The microstructure of the critical interfacial zone between cement paste and the aggregates in concrete is more dense and uniform than when conventional pastes are used and the bond between paste and other embedded materials such as aggregates and fibers appears to be improved. The most striking results have been found with silica fume substituted pastes and DSP systems. Compressive strengths of up to 270 Mpa or higher with young’s moduli up to 80 Gpa were achieved in preparations with up to 20 to 25% silicafume at a water to solid ratio of 0.12 to 0.22 through mechanical compaction. Such materials are used to resist mechanical erosion in impeller screws for moving coal and fly ash and in flooring to industrial area. This material retains a compressive strengths of 300 Mpa up to about 500 0c and 200 Mpa at about 700 0C
Silica fume hydration reactions.
Properly dispersed silica fume particles when used in propertions to replace up to 10 % of cement significantly reduces the bleeding and segregation of the mixtures and may be used in higher proportions. Silica fume contains particles as fine as 0.1 microns or less which partially dissolve in saturated Ca(OH)2 solution in a time as early as 5 to 15 minutes, and a SiO2 rich hydrates is deposited in layers or films on the silica fume particles. Despite the early rapid reaction much silica fume is remained for later slow reaction. The fume particles play an important role in various composites when they surround each cement grain, densifying the matrix, filling the voids with the strong hydration products and improve the bonding with aggregates, and reinforcing materials such as fibers. Silica fume by reacting with alkali also affords a protection against the alkali aggregate type reaction occurring between a cement pore solution and glass fiber.
Particle packing in concrete.
The Toufar/Aim model of dry particle has been verified as adequately modeling the dry packing of mixers of powder, each with a different size distribution. Typically in the model ,materials with three different size distributions may be mixed .Furthermore, the characterization of the size distribution can be modeled by a commonly used procedure describe by Rosin-Rammler. Input to this PC-based algorithm consists of the experimentally determined tap density of each component and the characteristic diameter of the distribution as described by D in Rosin-Rammler fitting equation. The results of applying this algorithm to concrete systems have provided the mathematical basis for formulating concrete mixtures which were developed through field experience in the concrete placement. Its applications should prove useful in monitoring the quality of concrete in the design stages and to maximize performance.
Discussion and summary
The particle packing and hydration reactions in DSP cement pastes are responsible for the fine micro structural development. These complex reactions involve phase solubility, accelerating and retarding effects of a multiphase, multiparticle size distribution material, and surface effects at the solid-liquid interface. This particle packing combined with chemical reaction is extremely important for developing strength. The initial degree of dispersion of cement and fume in the paste strongly influences the development of the final hardened paste microstructure. The ultra fine particles can fill the intergranular interstices and produce a dense paste structure reflected in a high strength. Super plasticizers should be used to minimize the water demand and adequately disperse the fine particles, resulting in dense products with fine pore size, very low permeability and low ionic diffusivity. Despite the rapid early hydration, much silica fume remains unreacted until a later stage. Physical and chemical characteristics together influence the hydration kinetics. Silica fume ordinarily accelerates the early Portland cement hydration, largely because of its very high surface area, increasing the heat development and resembling high early strength cement. Fume also disperses the hydration product, provides for deposition of C- S-H and thereby fills the pore interstices with fine hydration products. The mechanical properties of some high strength DRC -type materials have been summarized in table given below

Product Name : ACCresist
Technology used : CBC/DSP
Raw materials used : 1) Cement OPC-53G /Calundum/Cal-Al-75
2) Sand
3) Calcined bauxite
4) Brown fused alumina
5) Silicon carbide
6) Fine quartz
7) Micro silica
8) Fibers
9) Plasticizer
10) Fly ash
11) Basalt

Chemical Analysis of raw materials
Basalt Slag CB Flyash Microsilica Microsilica*
SiO2 50.6 34.9 3 58.4 85.3 95.1
Al2O3 13.4 15.2 86.6 31.1 2.1 1
Fe2O3 12.4 1.6 4 5.2 3.5 0.2
CaO 10.2 35.7 1.5 0.3 0.8 0.1
MgO 6.3 6.9 0.1 0.7 3.7
LOI 1.7 1.6 0.6 1.5 3.8 1
Na2O 2.21 0.25 0.9 0.08 0.25 0.1
K2O 0.68 0.39 0.02 1.05 0.09 0.1
TiO2 2.18 0.18 4.25 1.4
SO3 0.2 0.2
Mn2O3 0.15 0.6 0.03

BFA Meta-K OPC Calundum HAC Fine quartz
SiO2 1.1 51.1 20.8 4.7 0.4 99
Al2O3 94.9 45.7 4.7 50.5 75.76 0.4
Fe2O3 1.2 0.6 3.7 4.4 0.2 0.1
CaO 0.2 0.1 63.3 32.9 23.25 0.1
MgO 0.1 0.1 0.1
LOI 0.14 1.2 1.8 1.3 0.1
Na2O 0.07 0.09 0.4
K2O 0.02 0.02 0.03
TiO2 2.47 1 0.8
SO3 2.9
Mn2O3
f-CaO 1.7 0.11
Raw material specks
OPC
IS 12269,1987
1) C3S (45-50%)
2) C3A ( 5-8%)
3) Blains Surface 3000-3500 cm2/g
4) PSD D50 25-40 microns,
90microns=3%Max
5) OPC-53 is used
CB
1) Al2O3 >85%
2) TiO2 < 7%
3) SiO2 <5%
4) CaO <2%
5) Apperent porosity 12% max

Microsilica Source Elkem-920U Low temperature application<300oc
SiO2 >85%
LOI <5%



Microsilica High temp application Source Pooja enterprise
SiO2 >90%
LOI < 2%



Fine quartz
SiO2 >90%
PSD D50 < 5-8 microns
90 microns=3%max Calundum
BS915 Part 2,1972
Compressive strength in water
1-day 300kg/cm2
3-day 400kg/cm2
Setting time 30 minutes

High alumia cement
IS 4031
Setting time 30 minutes
Compressive strength
1-Day Air curing 350 kg/cm2
at 110 0c 600kg/cm2 Brown fused alumia
Al2O3 >95%
TiO2 < 3%
CaO = 1% max
Fe2O3=1.5 % max





Fly ash
As per IS 3812,part I
Sp.Surface .>3200cm2/g
LR =40 kg/cm2
CR =80% of control
Blast furnace slag
As per IS 12089
Glass content >85%
MgO<17%

SIC
Purity =85%,Fe2O3=1%max
Purity =95%,Fe2O3=0.7%max

Plasticizers
1) Sodium salt of sulphonated napthalene formaldehyde condensate
B.D. =0.6
2) Polycarboxylic ether
Relative density =1.1

The procedure of manufacturing of DRC powder.
The above raw materials with following proportions are used to make different grades of ACCResist
Material wt%
Aggregates 30-50
Cement (OPC,HAC,SAC) 5.0-40
Quartz fine 10.0-15.0
Silica fume 5.0-10.0
Fly ash 10.0-50.0
Metakeolin 5.0-10.0
Plasticizer 0.5-3.0
Water 5.0-10.0


Preperation of ACCResist powder
1) The raw materials are weighed accurately and blended in a ball mill for 35 minutes.
2) The batch size is 1 MT
3) 5 kg representative sample is removed and sent for analysis.
4) Parameters like density,compressive strength,flexural strength are measured.
5) The finished powder with proper identification is stored in HDP bag with plastic liner
6) The powder is sent to the place where insitu application of casting is carried out.The casting
is carried out under the supervision of RCD personnel.

Mixing of powder
1) The panmixer ( 40 rpm minimumrotor speed ) of 300 litre capacity is used for mixing powder.
2) The dry powder is mixed in the above mixer for two minutes
3) 3/4 quantity of measured water (potable) is added and mixed for further five minutes.The exact
quantity of water to be added during mixing is told to the client during supply of the material.
4) The measured quantity of additive is added and the material is mixed for further five minutes.
5) The measured quantity of desired fibers is added during mixing.
6) The mix is used for insitu casting or preshaped articles.

Preparation of ACCResist

ACCResist is used as a corrosion,erosion,abrasion resistant material.There are seven grades of
ACCResist depending on the abrasion resistance reqired to be used for particular application.
The grades are as follows
E-05 : Sand as aggregate and OPC
E-10 : Calcined bauxite as aggregate and OPC
E-20 : Brown fused alumina as aggregate and OPC
E-30 : Silicon carbide as aggregate and OPC
E-10T : Calcined bauxite as aggregate and HAC
E-20T : BFA as aggregate and HAC
E-30T : SiC as aggregate and HAC

Curing of ACCResist

1) The ACCResist is cured in waterbath at 80 0c for 24 hrs.
2) ACCResist is also cured by spraying water

Properties of ACCResist

Grades E-05 E-10 E-20 E-30

Compressive strength,Mpa
BIS4032,1985
1 day 40 65 60 50-60
3 days 70 80-100 90 90
7 days 90 110 100 100-110
28 days 100 130 120 120

Flexural strength,Mpa
BIS4032,1985
1 day 9 11 9 9
3 days 12 15 13 13
7 days 13 19 18 19
28 days 15 22 20 20.0+

Hardness of aggregate,Modified 8 12-Nov 12 13
Moh's scale
Casting shrinkage %,ASTM 806-82 0.2 0.2 0.2 0.2
Particle size,mm 0.0001-4.0 0.0001-4.0 0.0001-4.0 0.0001-4.0
Density (when cast)gm/cc 2.5 2.6 2.7 2.8
Max.temp.of application(0c) 300 300 300 300
Wear resistance BS 1902 part-1A 15-20 13-15 10 6.0-9.0
Water absorption %IS 1237 0.5 0.5 0.5 0.5
Grades E-10T E-30T
Compressive strength,Mpa 140 95
Flexural strength,Mpa 17 15
Hardness of aggregate,Moh's scale 11.0-12.0 13
Casting shrinkage %,ASTM806-82 0.2 0.2
Particle size,mm 0.0001-4.0 0.0001-4.0
Density(when cast)gm/cc 2.7 2.8
Max.temp.of application (0c) 1200 1200
Wear resistance BS 1902 part-1A 10 6
Water absorption %IS 1237 0.5 0.5

The ACCResist is used for following application

1) Transportation of fine coal at Wadi
2) Slag dryer at Binani cement,Dubai
3) VRM duct at Gagal
4) Bends for fine coal transportation at Chanda
5) Fly ash slurry handling pipeline at TNEB
6) Fly ash slurry handling pipeline at ABB
7) Fly ash slurry handling pipeline at MELCO
8) Flue gas duct at chandrapur electricity board





































Fast track compositions


cement 450 550 150 275
calundum 400 275
fly ash 115 15
sand 850 850 1000 1000
metal-2 400 400
metal-1 350 350 850 850
sky 2.7 2.7
pozolith 3 3
suparex 70 70
gypsum 200 130
water 200 180 120 120

strength
six hrs 10Mpa 9Mpa
comp.12hrs 11Mpa 14Mpa
comp.24hrs 24Mpa 31Mpa 23Mpa 15Mpa

Flexural
six hrs 2.8mpa 2mpa
12hrs 2.2mpa 3mpa
24hrs 3.2mpa 4mpa 3.1mpa 2.5mpa




ACCMarg: Methodology for application as flexible wearing course

Introduction

ACCMarg technology is described as a flexible composite consisting of an open-graded bitumen coated aggregates filled with a special cement grout. The joint-less surface is approximately 25 to 100 mm thick, applied to an existing asphalt or concrete pavement. The primary use of ACCMarg on road surfaces is to provide strengthening and resurfacing, for higher durability against fuel spillage, resistance to abrasion and rutting. ACCMarg has been applied to various types of pavements in India over the past few years. These include bridge decks, road junctions, roads sections etc. Based on the experience to date ACCMarg pavement can withstand abrasive action from heavy vehicles, heavy point loads, and pavement deterioration from fuel spills.

Materials and construction

The coated aggregates mixture is a porous bituminous course and is placed using standard paving techniques. Mix design procedure is used to determine the optimum binder content. The aggregate gradation is part of the ACCMarg technology. Rolling the surface with a predetermined number of passes produces a surface with 25-30 percent voids. The air voids content is critical since the grout cannot penetrate the mix if sufficient voids are not present.
After laying the porous mix, grout is introduced into the voids. The grout is composed of a proprietary material of ACC, which is wet mixed and poured into coated aggregates surface. The excess grout is squeezed over the surface and removed to improve skid resistant.
Procedure for Construction

The construction procedure is developed based on extensive research and data of field experience of ACC team.

SPECIFICATIONS

WEARING COURSE FOR PAVEMENTS

Scope of Work

The work shall consist of the general requirements for mixing and placing of coated aggregate filled with a grout. It includes the requirements for aggregate, binder, mixing at asphalt plant/ mixer, surface preparation, spreading and compacting of mix, mixing and pouring of grout
The composite shall consist entirely of aggregate coated with hot bitumen.. The voids in the finished mixture must comprise between 25 and 30 % of the total volume. The wearing course shall be laid in a thickness of 25 mm constructed of porous coated aggregates and filled with grout .

Coated Aggregate mixture: The mixture shall be as given in Table 1.

Table 1: Coated aggregate mix proportion

Material
Proportion
Bituminous material
3.8-4.0%
Aggregate
96-96.2 %

1. 1. Mix design shall conform with the requirement and the aggregates shall have a maximum size of 15 mm... After laying and rolling the Air Voids shall be in the range of 25-30%



2. Materials

2.1 Aggregate

The aggregates shall be chosen from basalt, granite, grit stone etc. The nominal size of the aggregates shall be as per requirement and in keeping with the thickness of the pavement. The aggregates shall have a maximum size of 15 mm and minimum of 5mm. The property specs is attached

Bituminous Material and Tack Coat

The bitumen shall be bitumen of 60/70 grade as per penetration test.
Modified Bitumen Emulsion as per ACC specifications. The bitumen content in emulsion is measured as per IS 8887-1995.

ACCMarg Grout:

The grout shall be made using ACCMarg dry powder.It is cement based with mineral and chemical additives. The wet mixed grout shall be made at site in a mixer. The grout property specs is attached

3. Equipment

3.1 Mixing Plant

Aggregate coating shall be produced in a Hot Mix Asphalt mixing plant/ Mixer

3.2 Mix Transportation

Mixed bitumen coated aggregates from hot mix plant shall be transported to the site in tipper trucks constructed so as to prevent loss or undue segregation of materials after loading.

3.3 Rollers

Only steel-wheel rollers of 8-10 ton, max without vibration shall be used. Use of pneumatic rollers and vibratory rollers is prohibited.


3.4 Mixing and pouring of grout

The ACCMarg grout shall be mixed in a mixer at brought to the site in wheel barrow/suitable equipments and laid.


4. Surface Preparation

The surface of the existing black top road shall be cleaned of all foreign material and broomed free of dust and all pot holes are repaired.

The tack coat of bitumen emulsion shall be applied at a rate of 0.5 kg/m2 as indicated in the specification.. The Tack Coat shall be evenly applied to the surface. The specs is attached

5. Mixing, Spreading and finishing

Mixing, spreading and finishing shall be a continuos operation. During the tack coating and the paving work only road roller necessary for the execution of the paving work shall be allowed on the coated aggregate course.

6. Installation of ACCMarg grout

No traffic on the laid porous coated aggregate should be allowed before application of the grout. The porous aggregate course shall be free of any loose particles or other contaminants.

Mixing and pouring shall be a continuous operation. Not more than 3 hour shall elapse between water addition and the time of completion of grout laying.

ACCMarg Composite

Property parameter Method of test Value
Compressive Strength(28days),Mpa on 4" core of composite IS-516 4
Abrasion resistance in mm IS-1237 4


ACCMarg Grout

% X
PC 53 G45 50
Suraksha
PSC cement
Fly ash C class
Fly ash F class 55 45
Micro silica
Pozzocrete 83
Pozzocrete 60
GGBS
Metakaolin 5
Glenium- 51
0.5 0.5
W/Cementitious ratio
0.28 0.26
compressive strength(kg/cm2)
1 day 80 200
3 days 250 450
7 days 370 500
28 days 500 620


Property parameter
Method of test Value
Density, kg/m3 IS 1528 -XII 1700-2000
Compressive strength, MPa, (3 days) IS 516
15-20
Compressive strength,MPa, (28 days) IS 516 50


Property parameter
Method of test Value
Density, kg/m3 IS 1528 -XII 1700-2000
Compressive strength, MPa, (3 days) IS 516
15-20
Compressive strength,MPa, (28 days) IS 516 50


The above does not constitute the specification of ACCMarg. Depending on the project requirement, project specific specifications are drawn.

Specification for aggregate, bitumen content for coating and the grade of bitumen are given below:
In case of aggregate, the following is the sieve analysis :

Sr.No. IS sieve designation % weight passing **
1 15-10 mm 80-100
2 10-5mm 0-20
3 0-5 mm 0-5

**The tolerance shall be +/- 5% by weight

Aggregate specification

Property parameter
Method of test Value
Flakiness and elongation index IS 2386 Max 30%
Aggregate Impact value IS 2386(Part-4) Max 30%
Los Angeles Abrasion value IS 2386(Part-4) Max 30%
Water absorption IS 2386(Part-3) Max 2%



Binder specification

Property parameter
Method of test Value
Bitumen content in emulsion IS-8887,1995 65%
Bitumen content in BM IS-8887 1995 3.8-4.0%
Bitumen Grade IS -1203-1978 60-70


This development is reported as research paper in NCCBM international seminar .The paper has received best paper award. The Copy has been attached here with. The product properties are studied by CRRI.The report is attached here with.


Trials with Metakeoline as substitute to Elkem Microsilica in GR-II
Experiments are conducted during mansoon,month of July

Cement 55 55 55 55 55 55
Flyash 40 40 42 42 43 43
Himacem 5 3 2
Microsilica 5 3 2
Glenium 0.5 0.5 0.5 0.5 0.5
Water 28 28 28 28 28 28
W/C 0.28 0.28 0.28 0.28 0.28 0.28
Slury second 30 30 30 30 30 30
Batch size(Kg) 100 100 100 100 100 100
Mixer type Concrete Concrete Concrete Concrete Concrete Concrete

Compressive strenght(kg/cm2)

1-Day 120 110 115 110 110
3-Days 430 385 400 350 300
7-Days 540 460 535 525 510
28-Days 550 510 540 544 570


Concrete with SBR Coated aggregates
% Cost Rs/kg I II III IV VII VIII
Wadi OPC - 53 G 3 9 16 10 17 17 17
Fly ash 1 9 16 10 0 8 8
Metal - I 0.25 28.4 32.25 47 25 25 24
Metal - II 0.25 28.4 0 0 25 25 25
Sand 0.5 17.8 34 33 33 24 24
Glenium - 51 160 0 0.037 0.025 0.1 0.05 0.1
Glenium stream 92 0 0.006 0.003 0 0 0
Conplast SP - 500 90 0.09 0 0 0 0 0
Microsilica 25 0 0.75 0 0 0 0
SBR - Latex 70 0 1 0 0 1 2
Water 7.2 13 12.2 6.8 6.5 4.25
Slump (mm) 5 30 30 35
Slump flow (mm) 600 600
Density(kg/m3) 2200 2300 2490 2630
Cost/100kg 67.2 184.2845 72.526 96 161.5 239.25

Compressive strength(kg/cm2)

1 day 60 70 30 147 200 282
3 day 140 95 75 249 337 446
7 day 206 130 85 357 440 597
28 day 340 215 110 479 460 703

Flexural strength(kg/cm2)
1 day
3 day 35
7 day 50 30 9 39 58 76
28 day 70 50 20 60 86 83

ACCMarg with SBR coated aggregates
Experiment
Grout II (OPC : 55, FA: 40, Microsilica : 5) was poured into it.
Slurry second: 15 sec
Compressive strength (3 day)
Grout : 141 kg/cm2
Composite : 75 kg/cm2

Trial at BANDRA KURLA COMPLEX
Experiment :

used for the trial at BANDRA KURLA COMPLEX on 10/11/04
Age kg/cm2
1day 150













































1) Lavalling course (LC) THICKNESS 10MM AREA 10728 sq.metrs

Material Quantity
K-Sand 3mm 110.92 MT
Cement OPC 53 G 59.0 MT
Flyash 59.0 MT
Silicafume 7.0 MT
Suparex 1.18 MT

2) ACCFlor : Thickness 8mm area 10728 sq.metrs
Material Quantity
K-Sand -25 meah 107.5 MT
Cement white 64.5 MT
Fine quartz 32.25 MT
Silicafume 10.75 MT
Glenium 2.15 MT
Fibers 0.4mm dia *10mm length 10.75MT
Baige colour 1.61 MT

Remarks

1) We are using dahanu flyash in all our composition.Hence if there is not much difference in price of fly ash at site than the flyash from AHAMADABAD ELCTRICITY , DAHANU flyash is recommended.
2) M/S S.S.Associates is ready to set a fiber cutting unit at bridgestone site.Cutting fiber is time consuming process hence order to be placed immediately.
.
FLOOR IN BRIDGESTONE TYRE FACTORY IN PRITHUMPUR AT MADHYA PRADESH



PROPERTY COMPARISION OF ACCFlor toppings with M25 CONCRETE


PROPERTIES ACCFlor M25 Concrete REMARKS

COMPRESSIVE STRENGTH (Kg/cm2) 1000 250 More load bearing capacity
FLEXURAL STRENGHT(Kg/cm2) 150 30 More bending /stress bearing capacity
HARDNESS (Moh's) 7-8 5-6
ABRADIBILITY INDEX(Marshal Morgen Test (

10-13 25-30 Life expectancy four times for trollys and tract vehicle movement
CHLORIDE PENETRATION (coulombs),ASTM 1202,Rapid chloride penetration test 12,00,000 3000-4000 Four hundred times higher , Excellent corrosion resistance
ELECTRICAL RESISTIVITY(ohm-cm) 7,50,000 3000 250 times higher
WATER ABSORPTION(%) 0.5 10
PERMEABILITY COEFFICIENT(m/sec) 0.5*10-12
100*10-12



Salient features

1) Abrasion resistant
2) Corrosion resistant
3) Impervious to oil
4) Dust free , hygienic and easy to clean
5) Available in different colours
6) Ready to use floor in two days
7) Chemical resistant

















Repair of Bridge decks of Bumbai-Pune express highway using ACCMARG Technology of ACC-LTD.

The Mumbai-Pune Express highway is the first modern expressway in the country. The ministry of surface transport during the seven five year plan identified this corridor as amongst the three most congested national highway corridors and proposed it to be developed as part of national expressway system.

The 100 kilometer long stretch that winds up the hill and literally flies over the twin hill station resorts of Lonavala and khandala 600 m up in the western ghats. It continues its impressive routes into the inland plateau towards Pune The views while travelling up the western ghats looking towards mumbai are quite spectacular. The number of civil engineering structures on this express way are

 Underpass 26
 Overpass 20
 Major bridges/viaducts :6
 Minor bridges :21
 Box/slab culverts :81
 Cart tracks/pedestrian crossing :33
 Railway bridges :2
 Interchanges :4

It is indeed a pleasure ride to reach Pune in two hours from Mumbai using the express way. Such a marvel piece of work in the history of Indian road was not with out few blemices.
The 75 mm thick reinforced concrete wearing course over bridge decks was cracking. The cracking was may be due to many reasons. There were many articles in news paper stating the reasons of cracking. The problem of cracking was more severe at bridge decks at Khandala,kune and kusgaon.These threee bridge decks of roughly 60,000 square meter were cracking and there were potholes on the decks even before one year of opening the traffic.

The MSRDC the main body responsible for building the Mumbai-Pune express highway approached ACC to give solution to this severe problem. The ACC at that time has developed ACCMARG technology which can exclusively used for resurfacing of damaged concrete and bituminous roads.The same was used to solve the problem.

ACCMARG TECHNOLOGY

ACCMARG technology can be described as a semi flexible surfacing process consisting of open graded asphalt concrete filled with a special cement grout. The joint less wearing surface is approximately 30 to 100 mm thick applied to an existing asphalt or concrete pavement. The primary use of ACCMARG on road surfaces to provide protection against fuel spillage and resistant to abrasion and rutting. ACCMARG has been applied to various types of pavements in India. These includes bridge decks, road intersections. roads sections etc. The material has been tested in and around Mumbai on several high trafficed roads. Based on the experience to date ACCMARG pavement can withstand abrasive action from heavy vehicles, heavy point loads and pavement deterioration from fuel spills.

MATERIALS AND CONSTRUCTION

The open graded bituminous macadam mixture is similar to a porous bituminous course and is placed using standard paving techniques. The mix design procedure is used to determine the optimum bitumine content. The aggregate gradation is part of the ACCMARG technology. With a bitumine content of about 4% and rolling the surface with a predetermined number of passes produces a surface with 25-30% voids. The air voids content is critical since the grout canot penetrate the mix if sufficient voids are not present.
After laying the porous bituminous mix it is allowed to cool only then is the grout introduced into the voids.The grout is composed of a proprietary material of ACC which is wet mixed and poured onto the open graded bituminous surface.The excess grout is squeezed out by brooming the surface.

PROCEDURE OF CONSTRUCTION.

The ACC’S expert team visited L&T site at Lonawalla on 25 th December 2002.The three bridge decks at Khandala, Kune and Kusgaon were damaged and around 60000 sq meter area covering all the three bridge decks were to be repaired using ACCMARG technology

The badly cracked concrete panels were removed and fresh concrete panels were laid. The rest of the panels with surface cracks and before damaging further were used as such for ACCMARG placement.

.M/S Lonawalla construction limited which is local party who has supplied the aggregates to L&T for their concrete making has been finalized for bituminous macadam placement. The general requirement of mixing and placing the open graded macadam includes requirements of aggregates, bituminous binder, hot mix asphalt plant, surface preparation, spreading and compacting of porous bitumen macadam. The asphalt mixture is of two component mixture as given in Table-1
Table-1:Asphalt mix proportion.

Material Proportion
Bituminous material 3.7-4.3%
Aggregate 95.8-96.2%

M/S Lonawalla construction has used bituminous of 60/70 grade as per penetration test from BPCL. The aggregates used were from Chakan area 30km away from Lonawalla .The aggregates used are of following specifications.


Test VALUE
Water absorption 1.6%
Aggregate impact value 24.75%
Aggregate abrasion value 29.8%

There was a challenge to ACC team to execute ACCMARG laying job in two months time without stopping the vehicular traffic. The job started from the right carriage way of Kune bridge which is 430 meters long and 11 meters wide. Out of two lanes of right carriage way one lane was kept open for traffic and the other was used for ACCMARG laying. Fourty eight hours were required for ACCMARG placement with curing period of 36hrs.

The concrete surface is cleaned and emulsified bitumen Hincol is used as tack coat and 30 mm hot bituminous macadam is placed using paver.The mixing,spreading and finishing should be a continuous operation.Not more that two hours should be elapse between porous asphalt is mixed and the time of completion of rolling.During tack coating and the paving work only traffic necessary for the execution of the paving work was allowed on asphalt base course pavement. The paved bituminous macadam is rolled with 10 ton steel wheel roller to obtained 25-30% voids. The thickness of bituminous macadam and necessary camber is monitored at regular interval.

Mixing and pouring of grout.

The M-60 grout was made using ACCMARG dry powder and water at ready mix concrete plant of L&T situated at Kusgaon few kilometers away from the site. The grout was brought to the site in transit mixers. Grout mixing, pouring and spreading was a continuous operation. Not more than three hour should elapse between water is added to the mix and the time of completion..The ACCMARG pavement is cured for further 32 hrs and open to traffic. After completion of write carriage way left carriage way was completed by similar fashion.

ACCMARG laying at Khandala which is 670 meter long and 11 meter wide amd Kusgaon which is 1090 meter long and 15 meter wide were completed. The entire job is copleted by second week of march.In case of Kune and khandala decks the ACCMARG 30mm thick is laid expansion joint to expansion joint with taper near the joints.In case of kusgaon deck the expansion joints were raised by 30 mm by welding the circular metal bar to the existing expansion joints and then 30 mm ACCMARG is laid throughout.

The job was completed in time and handed over to client L&T. This experience has proved ACCMARG as unique wearing course material for PAVEMENT OVERLAYS
REFERANCE
Ultra Thin White Topping to re-strengthen infrastructural structures and
pavements


P. Buitelaar
Contec ApS, Højbjerg, Denmark

C.R. Braam
Delft University of Technology, Delft, The Netherlands


METHODOLOGY FOR PAVEMENT APPLICATION AS WEARING COURSE
Procedure for construction: The construction procedure is development based on the field experience of ACC team.
Scope of work: The wearing course shall be laid in a thickness of 30mm constructed as 20mm thick M-15 grade concrete and 10 mm concrete modified polymer with ACC-RCD specifications. The work shall consist of the general requirements for mixing and placing concrete. It includes requirements for aggregate, binder, surface preparation ,spreading and compacting the concrete.

1) Materials
1.1) Aggregates: The aggregates shall be chosen from basalt, granite, grit stone etc.The size of the aggregates shall be as per requirement and in keeping with the thickness of the pavement for 20mm thick M-15 grade concrete layer the aggregates shall have maximum size of 12mm and minimum size of 5mm.and for 10mm top layer of cement modified polymer the aggregates shall be grit stone of size between 5mm and 1mm.The aggregates shall be tested for aggregate crush strength, aggregate impact value, moisture content and deleterious constituents as per IS-2386-1963.
1.1.1)Storage and handling of aggragates.Sufficient quantity of aggregates should be crushed in advance so that tere is adquate supply of matching aggregates available in the site.The aggregates that have become mixed with earth or foreign material shall not be used.The aggregates contaminated with fine dust are screened before use.
1.2) Cement: The cement shall be used of ordinary portland cement(OPC-43&53) ,Portland slag cement(PSC) and portland pozzolana cement (ppc).It is to be tested for physical and chemical properties as per IS-269-1967,445-1964 and 1489-1967.
1.2.1) Storage and handling of cement: Supply of cement shall be co-ordinated with its consumption so that it is not stored right through the rainy season. Cement having lumps which have been caused due to improper storage or by pressure due to over loading of bags shall not be considered for use unless these lumps can be easily powered with pressure between fingers. Before such cement is used the sample containing lumps shall be tested to fulfill minimum requirement. The cement should not be stored longer than three months.
1.3) Flyash : The flyash of any field from thermal power plant is used. The ash shall be dry and tested as per IS-3812 dated 1989.
1.4) Sand : The fine sand shall be free from soft particles,clay,shale,loam,cemented particles,mica and other foreign matter.The sand shall not contain substances more than the following
Clay lumps 4.0%
Coal and lignite 1>)%
Material passing IS sieve no 75 micron 4.0%
1.5) Microsilica:It is a biporduct of silicon industry.There are many grades of microsilica available in market.We use Elkem's 920u undensified microsilica.The party should rovide the test certificate.
1.6) SBR Latex:It is copolymer of styrene and butadine.It is anionic in nature and stabilised with nonnoninionic stabillisers.The solid content in SBR LATEX SHOULD BE 45%+1%.and the butadiene content should be 30-35%.
1.7) Plasticizer :Fourth generation polycaboxyl ethers are used.The MBT 's Glenium-51 is used
1.8) Viscosity modifier.: MBT's glenium stream -II is used as viscosity modifier.
1.9) Water : Water used shall be potable and chemically tested as per IS -456-1964.
2.0) Mixing : The concrete mixer/the mini batching plant is used for making self compacted concrete(SCC).The aggregate sand ,binder as specified in ACC COMPOSITION I &II is added in mixer .The dry material is mixed for minute and 3/4 quantity of total water is added .The mixing is continued for a minute.The Measured quantity of additive I &II are added seperately along with the remaining quantity of water.The mixing is continued for further one minute and the mix is tested for a mix property called slump flow.The mix is filled in slump cone and the mix is spread on the ground by lifting the slump cone from the ground.The diameter of the concrete spread on the ground is measured.The measured diameter should be between 600mm to 700mm.The SCC is ready for use,.
3.0) Surface preperation: The old bituminous surface on which the fresh concrete is laid shall be cleaned.The potholes if any shall be filled with bituminous macadam and rolled for compaction.Any loose material shall be removed.The clean surface shall be made wet by sprikalling water.
4) ing of 20mm SCC concrete. The concrete shall be placed on the prepared base between the form work.The concrete shall not be droped from a height greater than 90 cm and shall be deposited with in 20 minutes from thr time of discharge from the mixer.The metal angle of 30mm height is used for form work.The first 20 mm thick layer is adjusted by sliding a rod with 10mm metal sheet is welded across the lenth of the rod over the 30mm angle.
3.1) The strength of the concrete shall be ascertain from cube specimens as specified.During the progress of the work cube samples shall be casted for testing at 3,7 and 28 days.The sampling and testing shall be in accordance with IS 1199 &516 RESPECTIVELY.
4)Laying of 10mm cement modified polymer over 20 mm laid concrete.
Mixing and making concrete is similar as described earliar.The difference is specified amount of SBR lattex is added in order to coat the aggrgate.The sequence of addition is first aggregate to be added in mixer and coated with SBR Latex.After coating of aggragate with sbr latex binder,addtives and the water to be added similar way described earliar.The top 10 mm layer is added on earliar 20 mm layer after two hoursand not after six hours of placement of first layer.The horizontal rod is used for levalling and final final finish is done with roller.The strength of the concrete is measured as per IS516.
The fresh concrete shall have the slump flow between 600mm to 700mm.
5) Curing:The surface is to be kept moist for first 12 hrs.The conventional curing method of ponding is strictly avoided.The road is to be opened for traffic after 3 days.
6) Joints : Joints are cut after every 3.5 meters. The cut width of 2-5mm is fille with bitumen.In case of total 30 mm thickness 20 mm from the top is cut.
7) Properties:
8)
9) MODIFIED CONCRETE TECHNOLOGY FOR PAVEMENTS
10)
11)
12) The prime minister Gram Sadak Yogana (PMGSY) ,the government of India project to improve the connectivity in rural India.
13)
14) The scheme is getting positive response from the people The flexible pavement is recommended for cheaper in cost and fast in laying though the life of the road is short and maintenance of the road starts with in a year. More over the quality of the bitumen and its content is questionable.
15)
16) The author visit at different rural location under stood that the black topping is rejected by the people .The solution is concrete road with comparable cost with flexible solution.The PMGSY Maharashtra unit successfully found the solution by modifying the concrete technology. which is durable ,cost effective and easy to lay .The concrete which has been used in both the application relaying of damaged bituminous road and on new roads. The self compacted concrete is made by using more amount of powdery material which contain cement ,flyash and slag etc.The M40 concrete is prepared with half the quantity of cement and adding flyash which is a by product of thermal power plant.
17) The following table will give you the details of the concrete used .The study is carried in Contech group
18) Table no 1: To show the details of Mix Design of Concrete to be used as substitute to flexible pavement in PMGSY scheme
Trial No.& Trial Date Cement Flyash Micro Silica Water Sand 10 mm 20 mm Density, Kg/Cum Admixture
NS CS Qty Brand
Kg/Cum
354 22/6/09 248 269 nil 150 469 314 447 516 4.5 Glenium
356 22/6/09 266 218 nil 150 nil 591 617 632 3.4 Glenium
19)
Trial No.& Trial Date Workability, Slump, mm Compressive Strength, Mpa
0 mts 30 mts 60 mts 90 mts 120 mts 1D 3D 7D 28D 56D 90D

354 22/6/09 610 610 520 28.75 54.5 74
356 22/6/09 360 75 26 50 63
20)
21) The concrete is developed by PMGSY Maharashtra division under the supervision of Dr.V.V.Deshmukh material scientist and Mr.P.Bongirwar retired secretary of PWD.. The concrete is designed in such a way that the cost is marginally higher than the flexible road .
22) The concrete is used by TMC thane municipality for internal roads and is with out maintenance working for last three years. The photograph of the road is given below.
23)
24)
25)
26)