The comparative study using all possible additives tried for cost optimisation or improvement in properties is given in above table.The metakeoline with proper calsination gives promising results
The activity of flyash 
Dr.Vilas Deshmukh
Monday, July 5, 2010
EFFECT OF ADDITIVES ON COMPRESSIVE STRENGTH OF CEMENTIOUS GROUT
The comparative study using all possible additives tried for cost optimisation or improvement in properties is given in above table.The metakeoline with proper calsination gives promising resultsThe activity of flyash
Mumbai Pune Express Highway
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 bridgedecks .
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 bridgedecks .
Sunday, July 4, 2010
Tuesday, June 29, 2010
UTWT Roads Development
The photograph you have seen is the work of UTWT at thane.We are successful in impleme nting UTWT technology in Thane.Time has come to propogate UTWT in other Municipality This technology is fast and money saving.It is cheap and fast Please call me for presentation
The work procedure is awailable Technology demands trained personel.you can conduct a seminar for your people
available to train people.Please take the decesion fast for better tomorrow
More photos can be seen at
ttp://www.flickr.com/photos/51608222@N04/sets/72157624260250965/
pictures for need of UTWT surfacing of roads
Hi friends
see the pics and relate it to the need for good roads and development of economy.
Sunday, June 27, 2010
Modified Concrete Technology for Pavements
The prime minister Gram Sadak Yogana (PMGSY) ,the government of India project to improve the connectivity in rural India.
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.
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.
Below are snapshots of the development process
Good Roads Happy Citizens :)
Monday, June 14, 2010
THE ROAD AND SOCIETY- science and faith
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 seperately but they go hand in hand. The level of scientific study in our country is very low. Our purpose of doing work is to get degree and acquire position in the scientific community. Once we achieve we forget research and do administrative work. Almost all research organizations have similar attitude, knowing this I have joined ACC LTD in seventies at the research station in Thane.
For the last hundred years, in cement manufacture, the materials that I have manufactured are an excellent case study, which I would like to share with you.
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 Surat 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 , 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 while working I have faced many pedestrian asking me tough question They first concrete road ready to next day for traffic was a dream to them They started believing when they walked next day for traffic.
Then came the another chapter Mr. Bongirwar retired secretary of PWD and advisor to many concrete roads dams and bridge pushed the product 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
In the process Mr. Suhas Dhuri of e-cube consultants, evaluated all the samples and provided valuable suggestios from time to time. Such assoaciation make it easier to convert my research and developement into commercial sucess.
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 road 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, 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
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 seperately but they go hand in hand. The level of scientific study in our country is very low. Our purpose of doing work is to get degree and acquire position in the scientific community. Once we achieve we forget research and do administrative work. Almost all research organizations have similar attitude, knowing this I have joined ACC LTD in seventies at the research station in Thane.
For the last hundred years, in cement manufacture, the materials that I have manufactured are an excellent case study, which I would like to share with you.
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 Surat 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 , 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 while working I have faced many pedestrian asking me tough question They first concrete road ready to next day for traffic was a dream to them They started believing when they walked next day for traffic.
Then came the another chapter Mr. Bongirwar retired secretary of PWD and advisor to many concrete roads dams and bridge pushed the product 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
In the process Mr. Suhas Dhuri of e-cube consultants, evaluated all the samples and provided valuable suggestios from time to time. Such assoaciation make it easier to convert my research and developement into commercial sucess.
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 road 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, 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
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