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
.
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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