HIGH STRENGTH HIGH PERFORMANCE CONCRETE USING ALCCOFINE 1203

AcknowledgementI 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.

ContentChapter Topic Page No.

1. Concrete History 52. High Performance Concrete 53. Raw Material of HPC 63.1 Cement and Test of Cement 63.2 Aggregate and Test of Aggregate 63.3 Water 63.4 Admixture and test of Admixture 74. Behavior of Fresh Concrete 74.1 Workability 74.2 Setting Time 84.3 Test of Fresh Concrete 85. Behavior of Hardened Concrete 85.1 Strength of Concrete 85.2 Durability 95.3 Test of Hardened Concrete 96. Comparison between Conventional Concrete and HPC 97. Where HPC Required? 98. Advantage of HPC 109. Limitation of HPC 1010. Characteristics of HPC 1011. Type and Effect of Material in HPC 10-1112. Specification of HPC 1112.1 Permeability 1112.2 Volume Stability 1113. Criteria &Structure of HPC 12-1314. Alccofine 1203 1414.1. Introduction 1414.2. Characteristics and Properties 14-1515. Comparison of Alccofine 1203 with Silica Fume 15-2215.1 Discussion of Mix design 2315.2 Durability 2315.3 Water Permeability 2415.4 Chloride Permeability 2416. Technical Benefits of Alccofine 1203 2516.1 In Fresh State 2516.2 In Hardened state 2517. Application of Alccofine 1203 2518. Properties of different cementitious material 25-2619. Chemical composition of different cementitious material 2620. Particle size distribution of different cementitious material 2621. Chloride ponding test report of 26

Alccofine 1203 compared with Silica Fume

22. Economy comparison between Alccofine 27 1203 and Silica Fume

23. Summary of Alccofine 1203 2824. Case study of HPC 29-3225. ACI Mix design Method for HPC 33-3626. Lab Trials 36-3927. Conclusion 3928. Reference 40

Concrete HistoryConcrete 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 1920’s 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 1960’s 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, ligno-sulphonates etc.High performance concrete works out to be economical ,even though it’s 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 specialequipment’s 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 Properties1. 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.The compressive strength of cement used in HPC should not be less than 45 N/mm2 at 28 days.

Test of Cement1. 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 AggregateBoth 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 AggregateRounded 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 AggregateSieve analysis IS: 2386(Part I) – 1963Water Absorption IS: 2386(Part III) – 1963Aggregate Impact Value IS: 2386(Part IV) – 1963Aggregate Abrasion Value IS: 2386(Part IV) – 1963Aggregate Crushing Value IS: 2386(Part IV) - 1963

4. Watero Use drinking water.o 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 non-crystalline 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 finishingImproving workabilityIncreasing compression strengthImproving general appearanceImproving pumping operation

Test of Chemical AdmixturesMarsh-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 ConcreteIntroduction: 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, other’s 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 ConcreteIntroduction: 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 Concreteo Compressive Strength Testo Rebound Hammer Test IS: 13311 (Part II) - 1992o Ultrasonic Pulse Velocity Test IS: 13311 (Part I) - 1992

Table-1.Comparison between Conventional and High Performance Concrete Parameter Conventional Concrete High Performance ConcreteCompressive Strength Low HighDurability Low Durable High DurableWorkability Low HighSetting time Low HighPermeability High Low Void content High Low Rate of slump loss High Low Water demand High Low

Where HPC RequiredVery severe environment condition.TunnelsBridgesTall buildingsOffshore piers and platformsConfinement structures for solid and liquid wastes containing toxic chemicals and radioactive elementsSuperstructures, 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 applicationHPC 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.

AdvantageLow shrinkage and high strengthImproved durability against chloride attackImproved durability in aggressive environment Increased durability in marine environmentService life more than 100 yearsWorkability and Pumpability High tensile strengthSpeed of construction

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

LimitationsHigh Performance Concrete has to be manufactured and placed much more carefully than conventional concrete.An extended quality control is requiredSome 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 Primary contribution/Desired propertyPortland cement Cementing material/durabilityBlended cement Cementing material/durability/high strengthFlyash Cementing material/durability/high strengthGGBS Cementing material/durability/high strengthAlccofine 1203 Cementing material/durability/high strengthSilica fume Cementing material/durability/high strengthMetakaolin Cementing material/durability/high strengthSuper plasticizers Flow ability HRWR Reduce water to cement ratioRetarders Control settingAccelerators Accelerate settingWater reducers Reduce cement and water contentShrinkage reducers Reduce shrinkageInhibitors Control alkali-silica reactivityOptimally graded aggregate Improve workability and reduce paste demand

Specification of HPCImpermeability: Chloride-ion permeability test is found to be more practical ASTMC 1202 classifies chloride-ion penetrability as follow table:

Table-3 Permeability dataChloride-ion Penetrability High Moderate Low Very low NegligibleCharge passed(Coulombs) ˃4000 2000 to 4000 1000 to 2000 100 to 1000 ˂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 moduluso Low thermal straino Low drying shrinkageo 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 HPCTable-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 blain value based on PSD is around 12000cm2/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 compositionChemical analysis Mass % Physical analysis rangeCaO 32-34 Bulk density 600-700kg/m3

Al2O3 18-20 Surface area 12000cm2/gmFe2O3 1.8-2 Particle shape IrregularSiO2 28-32 Particle size,d10 <2uMgO 8-10 d50 <5uSO3 0.3-0.7 d90 <9u

Figure-1 Particle Size Distribution

Table-7 .Test certificate for Alccofine 1203Test Resultd10 PSD 0.8 < 2 ud50 3.9 < 5 ud90 8.2 < 9 uBulk Density(kg/m3) 600Marsh Cone Flow (water to Alccofine 1203 ratio as 1)

31 sec

Chemical Composition (%)SiO2 31.4Al2O3 23.4Fe2O3 1.6CaO 32SO3 0.35MgO 8.8

Table-8.Report on durability testMaterial(Kg) Control With Alccofine 1203Cement (OPC 53) 280 250Fly ash(Dirk P60) 70 72Alccofine 1203 0 8Water 166 158Admixture(BASF 1125 UT) 3.5 3.5

RCPT ASTM 1202(Coulomb) 3305 1999Water penetration as per DIN-1048(mm)

48 41

ISAT,BS 1881-part 122(m1/m2/sec)

0.21 0.19

COMPARISON OF ALCCOFINE 1203 WITH SILICA FUME

EXPERIMENTAL PROGRAMConcrete 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 WorkabilityFrom 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 designMaterial Silica Fume Mix Alccofine 1203 MixCement 430 430Fly ash 80 80Silica fume 40 0Alccofine 1203 0 40Water 160 60Admixture 4 4

Table-10. The effect of Alccofine 1203 addition on Compressive strength and workability of concrete specimen with equal water to binder ratio

Slump(mm)Time Silica Fume Alccofine 1203Initial 180 21030 min 150 18060 min 110 15090 min 90 120120 min 60 95 Compressive Strength(MPa)1 Day 20.4 20.583 Day 38.29 45.117 Day 49.83 55.7228 Day 64.17 67.44

Figure-2 Assessment of workability

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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

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Methodology –B: Assessment of Water demandThe 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 designMaterial Silica Fume Mix Alccofine 1203 MixCement 430 430Fly ash 80 80Silica fume 40 0Alccofine 1203 0 40Water 160 152Admixture 4 4

Figure-4 Assessment of water required

148 150 152 154 156 158 160

Alccofine 1203Silica Fume

Water demand in liters

Water

Table-12. Compressive strength and workability of concrete specimen with constant binder and HRWR content Slump(mm)Time Silica Fume Alccofine 1203Initial 190 20030 min 155 16060 min 120 13090 min 95 110120 min 65 80 Compressive Strength(MPa)1 Day 21.3 23.543 Day 38.75 47.27 Day 50.02 60.4228 Day 64.50 70.47

Figure-5 Assessment of workability

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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

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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 designMaterial Silica Fume Mix Alccofine 1203 MixCement 430 430Fly ash 80 80Silica fume 40 0Alccofine 1203 0 40Water 160 160Admixture 4 3

Figure- 7. Assessment of HRWR required

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

Alccofine 1203Silica Fume

Admixture dosage in kg

Admixture

Table-14. Workability and compressive strength of concrete specimen at constant water to binder ratio Slump(mm)Time Silica Fume Alccofine 1203Initial 185 19530 min 150 16560 min 125 13090 min 100 115120 min 60 75

Compressive Strength(MPa)1 Day 20 22.583 Day 38.95 46.127 Day 49.23 54.7228 Day 63.57 68.64

Figure-8 Assessment of workability

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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

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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 Concrete’s 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 permeabilityMaterials Silica Fume Alccofine 1203Water Permeability 18 mm 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 DesignMaterials Reference Mix Mix with Alccofine 1203Cement 400 360Alccofine 1203 0 40Water 160 160Admixture 2 2

Table-17.The ASTM 1543 test /salt ponding test Results(% by mass)Depth of sample extraction(mm) Chloride content for OPC concrete

controlled materialChloride content with Alccofine 1203

Top surface 0.4 0.395 0.31 0.04510 0.29 0.005615 0.2 0.005120 0.18 0.005125 0.15 0.004830 0.15 0.004835 0.11 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

Hardened State Improves durability Improves resistance to ASR Improves strength at all ages Improves resistance to chemical attack / corrosion Imparts light color Lowers permeability

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 materialsProperty Silica Fume Metakaoline Alccofine 1203Dispersion in concrete Critical Critical Proper Replacement of cement 10% max Up to 20% Up to 70%Water demand High High Low Workability Reduced Reduced Improved Super plasticizer dosage Increased Increased Reduced Rate of slump loss Fast Fast SlowInitial heat of hydration Increased Increased Lower Alkalinity of pore solution

Reduced Reduced Maintained

Codal specifications BIS 15338 ASTM 1240 Separate BIS code under process

BIS 12089-Raw slag for PSC manufacture ASTM C989-ground slag for use in concrete BIS456-Recommends usage in concrete

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

Waste from steel industry quenched with water to form granules. Further ground required fineness with selective ingredients

Sources China,Bhutan,Norvey etc. India –Gujarat,chennai India -Goa

Table-19. Chemical Composition of different cementitious materialsChemical analysis Alccofine 1203(%) Silica Fume (%) Metakaolin (%)CaO 32-34 0.2-0.4 0.4-0.8Al2O3 18-20 0.04-0.06 41-45Fe2O3 1.8-2 0.4-0.6 0.5-1SiO2 28-32 92-94 50-54Others Balance balance balance

Table- 20.Particle Size Distribution (PSD) of different cementitious materialsParticle Size Distribution Silica Fume Metakaoline Alccofine 1203Band Width 0.1-1 u 0.1-50 u 0.1-17 ud10 < 1 u < 2 u < 2 ud50 < 1 u < 6 u < 5 ud90 < 1 u < 20 u < 9 uBulk Density(kg/m3) 600Marsh Cone Flow (water to Alccofine 1203 ratio as 1)

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 controlled material

With 10% of Micro Silica

With Alccofine 1203 Ultrafine slge

Top surface 0.46 0.043 0.415 0.30 0.22 0.1310 0.19 0.040 0.03115 0.14 0.017 0.009020 0.096 0.011 0.007425 0.074 0.010 0.005830 0.058 0.0094 0.004635 0.051 0.0090 0.004040 0.051 0.0082 0.004060 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

1203Cost Micro Silica

Cement ( OPC 53) 385 5 1925 1925Fly ash(Dirk P60) 125 1.5 188 188Alccofine 1203/ Silica fume

25 22/28 550 700

20 mm 560 0.23 112 11210 mm 440 0.16 70 70Natural sand 623 0.42 262 262Crushed sand 212 0.21 42 42Water 140 50 Rs lumsum 50 50Admixture 5.7 30 171 171Density (kg/m3) 2516 Cost of

concrete(Rs)3370 3520

Note: Saving of 150 Rs/m3 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) 511.5 511.5Fly ash(Dirk P60) 0 0Silica fume 38.5 0Alccofine 1203 0 38.5Water 170.5 170.5Crushed Sand 568.60 571.97CA1 395.26 397.60CA2 734.06 738.41W/CM Ratio 0.31 0.31Admixture(Glenium-141) 3.85 3.85Total 2422.27 2432.33

Slump(mm)Time Silica Fume Alccofine 1203Initial 160 18015 min 155 18030 min 150 17060 min 135 160 Compressive Strength(MPa)3 Day 39.9 41.67 Day 50.1 53.528 Day 68.3 72.4

Material Rate/kg Qty/m3 Cost/m3 Qty/m3 Cost/m3

Cement (OPC 53)

5 511.5 511.5

Fly ash 1.6 0 0

Silica fume 28 38.5 0Alccofine 1203 22 0 38.5Admixture(PCE based)

30 3.85 3.85

Total

Trial-2 Concrete mix design of M60Material Silica Fume Mix(Kg) Alccofine 1203 Mix(Kg)Cement (OPC 53 Grade) 430 420Fly ash 80 90Silica fume 40 0Alccofine 1203 0 40Water 155 150Aggregate - -Admixture(PCE based) 6.6 5.5 Slump(mm)Time Silica Fume Alccofine 1203Initial 180 19060 min 80 120 Compressive Strength(MPa)7 Day 51.68 53.3528 Day 67.5 70.39

Material Rate/kg Qty/m3 Cost/m3 Qty/m3 Cost/m3

Cement (OPC 53)

5 430 2150 420 2100

Fly ash 1.6 80 128 90 144Silica fume 28 40 1120 0 0Alccofine 1203 22 0 0 40 880Admixture(PCE based)

30 6.6 198 5.5 165

Total 3596 3289Note: Net Saving of 307 Rs/m3

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, USAFeatures

o Year of completion 1990o Total height 293m,70 storieso 1st 14 stories including the underground basement constructed using 80 MPa concrete.o Concrete pumped using only one pump upto full height.

Criteriao High strength o Reduction in column sizeo Pumpability (workability and cohesiveness)o Saving due to reduction of construction time, formwork and materials to the tune of 3000t of

reinforcement steel and 7650 m3 of concrete. Concrete mix usedConcrete grade : 80MPaPortland cement : 390Kg/m3

Silica fume : 50Kg/m3

Water /binder ratio : 0.30Slump : Over 200mmCompressive strength : 88Mpa (28days)Modulus of elasticity : 4.28Mpa (56days)

Euro Tunnel, UK/FranceFeatures

o Year of completion 1994o Important link between UK and other European countrieso Design life 120 yearso Total length 51Km (14Km below land and 37 Km below sea)o 40m below sea bedo 50-250m below sea level

Criteria o Extremely low permeabilityo Low thermal expansion o Cracking controlo Workability retention-long transportation distance 20Km and 6 hrs. duration for insitu lining concreteo Cohesiveness & Pumpability-long distance pumping (1Km)for sea wall construction.

Concrete mix usedCementitious material content : 440Kg/m3

Portland cement: flyash : 70:30

Water /binder ratio : 0.35Concrete grade : 55MPaChemical admixture : HWRACompressive strength : 70 to 80Mpa (28days)Permeability co-efficient : 10-13m/s

AKASHI KAIKYO, JAPANFeatures

o Year of completion 1998o Longest suspension bridge in the world o Link kobe city with AwaijishimaIslando Main span 1991mo Total length 3911m.

Criteriao Minimum thermal cracking o Low heat generation o High strength and workabilityo Low segregationo Aggressive environment

Concrete mix used (3 parts)Part I II IIIComposition of cementitious mix(PC:slag:flyash) in %

40:40:20 50:50:00 44:56:00

Water binder ratio 0.33 0.33 0.33Compressive strength(with crushed sand)

51.9MPa(28days) 64 MPa(28days) 54.5 MPa(28days)

Compressive strength(without crushed sand)

50.5 MPa(28days) 52.7 MPa(28days) 48.4 MPa(28days)

KAIGA ATOMIC POWER PROJECT UNIT-2, INDIAFeature

o Year of completion 1998o Use of HPC 1st 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.o Special design requirement for prestressed concrete-minimum compressive strengths 60MPa and tensile

strength 3.87 MPa.

Concrete mix used compositionPortland cement : 400Kg/m3

Silica fume : 25Kg/m3

Water and ice flakes : 136Kg/m3

Coarse aggregate (MSA 20mm) : 1096Kg/m3

Fine aggregate (natural and crushed) : 827Kg/m3

Modified polycarboxylic based superplasticiser : 5.82LitersWater binder ratio : 0.32 Slump : 175+25mmAir content : 2%Compressive strength : 75.9MPa (28days)Tensile strength : 4.36 MPa (28days)

URBAN VIADUCT, MUMBAI, INDIAFeature

o Year of completion 2002o HPC M75 grade concrete usedo Length of 1.932Km,Width of 16.2mo 56 spanso Concrete quantity 20000m3

Criteriao High strengtho Durabilityo Good surface finisho Slump retention in warm to hot climate

Concrete mix used composition Cement : 500Kg/m3

Silica fume : 50Kg/m3

Coarse aggregate (MSA 20mm) : 762Kg/m3

Coarse aggregate (MSA 10mm) : 384Kg/m3

Fine aggregate (river sand) : 682Kg/m3

Chemical admixture (38.5%solids) : 8.25lit. Water : 148lit. Water /binder ratio : 0.269 Slump at plant : 130 to 180 mmSlump at placement point : 80 to 120 mmAir content : 1.5%Compressive strength : 79.6 to 81.3MPa (28days)Draying shrinkage : 0.00142Chloride ion permeability (ASTM C1202-97) : core 100C (very low) test sample 240C

PETRONAS towers, MalaysiaFeatures

o Year of completion 1999o Tallest building in the world at that time (451.9m)o 88 stories,216901m2 floor areao Design life of 100 years

Criteriao High strengtho Durability high performance to meet the design life

o Slump retentionConcrete mix used for 2.4 m RCC columns and ring beams upto 22 floor levelCement : 260Kg/m3

Mascrete (cement-flyash compound in ratio 20:80) : 260Kg/m3 Micro silica : 35Kg/m3

Coarse aggregate (MSA 20mm) : 1000Kg/m3

Sand : 700Kg/m3

Water /binder ratio : 0.25 to 0.27 Slump : 180 to 220 mmGrade : 80MPa (28 days)

The port de Normandie cable- stay BridgeFeatures

o Year of completion 1993o Tallest building in the world at that time o 2141m overall length and a center span of 856m,35,000m3 of M-60 grade concrete are used

Concrete mix used for 2.4 m RCC columns and ring beams upto 22 floor levelBlended Portland cement : 425Kg/m3

Water : 153Kg/m3 Silica fume : 8%Coarse aggregate (MSA 20mm) : 1065Kg/m3

Fine aggregate : 770Kg/m3

Water /binder ratio : 0.36 Melamine –type superplasticiser : 11L/m3

1. M-75 grade of HPC 1st time used in India for construction of J.J.Hospital flyover in Mumbai.2. High –performance concrete was used on a bridge on S.R.516 near Auburn, Wash.The use of concrete with

strength of 69 MPa.3. In Colorado, an HPC bridge was used to replace a previous structure that carried Interstate 25 over Yale

Avenue in Denver.4. M-70 to 80 grade of HPC used in the construction of Structural engineering research center at madras.5. M-50 to 80 grade of HPC used in the construction of IIT Madras.6. M-75 grade of HPC are used in construction of Bandra-worli sea link.7. M-60 grade of HPC are used in the construction of 2nd Narmada Bridge in Bharuch at Gujarat.8. HPC was used on the East Bridge of the Great Belt Link in Denmark 1994.9. HPC was used on the Confederation Bridge in Canada 1997.10. HPC was used on the Joigny (France), Greatbelt (Denmark), Akkegawa (Japan), Willows (Canada) Bridge11. HPC was used on the High rise buildings tower plaza (US), Nova Scotia (Canada)12. HPC was used on the Tunnels La Bauma and Villejust (France), Manche (UK)13. 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. Estimate the mixing water for the slump and for the selected maximum size of aggregate, from table-275. Select the target strength for the grade of concrete to be proportioned, from table-4.

6. Select the water-cement ratio for the desired strength and for the grade of cement proposed, from figure-11.

7. Calculate cement content.8. Check cement content and water-cement ratio for durability of concrete, from tables -29&30.9. Estimate the coarse aggregate content, from tables-26&28.10. Estimate the fine aggregate content.11. Adjust the moisture in aggregate and water absorption by aggregate.12. Adjust weight of aggregate to compensate for moisture content in them.13. Make trial mixes.14. Cast the cube specimen (15x15x15cm) and check the 3, 7, and 28 days compressive strength of the

specimen.

Table-23.Range of workability of concretePlacing condition Workability Slump(mm)Concreting of mass pours, shallow sections, lightly reinforced sections.

Stiff 0 to 30

Concreting of screeds, precast section, beam, columns, slabs, prestressed sections.

Stiff plastic 30 to 80

Concreting of wall sections, Concrete for vacuum dewatering,slipforming and pumping

Plastic 80 to 130

Concreting of piles, diaphragm walls using tremie.

Flowing 130 to 180

Table-24.Target strength for different grades of concreteGrade of concrete Characteristics

strength(N/mm2) Target strength for degree of control(N/mm2)Very good Good Fair

M15 15 19 21 22M20 20 26 28 29M25 25 32 34 35M30 30 38 40 42M35 35 44 45 47M40 40 49 51 53M45 45 55 57 58

Table26. Bulk volume of Coarse aggregate per unit volume of ConcreteMSA Bulk volume of dry rodded Coarse aggregate. Cu.m. per unit volume of Concrete for different

fineness modulus of sand2.4 2.6 2.8 3 3.2

10 0.50 0.48 0.46 0.44 0.4212 0.59 0.57 0.55 0.53 0.5120 0.66 0.64 0.62 0.60 0.5825 0.71 0.69 0.67 0.65 0.6340 0.76 0.74 0.72 0.70 0.68

Table-27. Estimation of mixing water and air content as per ACI-211

Description of workability

Water content(kg/m^3)Slump(mm) MSA(mm)

10 12 20 25 40Extremely dry

- 180 170 160 150 140

Very stiff - 185 185 170 160 150Stiff 0-30 200 195 180 170 155Stiff plastic 30-80 205 200 185 180 160Plastic 80-130 225 215 200 195 175Flowing 130-180 240 230 210 205 185Entrapped air (%)

3 2.5 2 1.5 1

Table28. Correction factor for coarse aggregateDescription of workability

Slump(mm) Correction factor to bulk volume for maximum size of aggregate(mm)

10 12 20 25 40Extremely dry

- 1.90 1.70 1.45 1.40 1.30

Very stiff - 1.60 1.45 1.30 1.25 1.25Stiff 0-30 1.35 1.30 1.15 1.15 1.20Stiff plastic 30-80 1.08 1.06 1.04 1.06 1.09Plastic 80-130 1.00 1.00 1.00 1.00 1.00Flowing 130-180 0.97 0.98 1.00 1.00 1.00

Table-29.Durability of Concrete under Specified condition of ExposureExposure Plain concrete Reinforced concrete

Minimum Cement content(Kg/m^3)

Maximum Free Water-Cement Ratio

Minimum Cement content(Kg/m^3)

Maximum Free Water-Cement Ratio

Mild 220 0.70 250 0.65Moderate 250 0.60 290 0.55Severe 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

Class

Concentration of sulphates expressed as SO3

Dense, fully compacted concrete made with 20mm nominal maximum size aggregate complying with IS : 383

Type of cementIn soil total SO3 %

SO3 in 2:1 water: soil extract g/L

In ground water g/L

Minimum cement content not less than Kg/m3

Maximum free water cement ratio

1. ˂0.2 ˂1 ˂0.3 Ordinary Portland cement or Portland slag cement or Portland pozzolana cement

280 0.55

2. 0.2 to 0.5 1 to 1.9 0.3 to 1.2 Ordinary Portland cement or Portland slag cement or Portland pozzolana cement

330 0.5

Supersulphated cement or sulphates resisting Portland cement

310 0.5

3. 0.5 to 1 1.9 to 3.1 1.2 to 2.5 Supersulphated cement or sulphates resisting Portland cement

330 0.5

Ordinary Portland cement or Portland slag cement or Portland pozzolana cement

350 0.45

4. 1 to 2 3.1 to 5 2.5 to 5 Supersulphated cement or sulphates resisting Portland cement

370 0.45

5. ˃2 ˃5 ˃5 Supersulphated cement with protective coatings or sulphates resisting Portland cement

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. Select the slump required for the condition of placing 2. Select the characteristics strength in MPa3. Select the maximum size of aggregate to be used in mm4. Find out the volume multiply factor for coarse aggregate, From table-315. Estimate the coarse aggregate content in kg6. Estimate the mixing water for the slump and for the selected maximum size of

aggregate, from table-327. Estimate the amount of entrapped air, From table-328. Select the water-binder ratio for the desired strength, From table-339. Calculate cement content10. Estimate the flyash content in kg11. Estimate the Alccofine 1203 content in kg12. Estimate the fine aggregate content13. Adjust the moisture in aggregate and water absorption by aggregate14. Adjust weight of aggregate to compensate for moisture content in them

15. Make trial mixes16. 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

Volume of coarse aggregateMSA(mm) 10 12 20 25Volume Multiply factor

0.65 0.68 0.72 0.75

Table-32 Estimation of mixing water and air content

Water content(kg/m^3)Slump(mm) MSA(mm)

10 12 20 2525-50 183 174 168 16550-75 189 183 174 17175-100 195 189 180 177Entrapped air (%)

2.5 2 1.5 1

Table-33 Selection of water to binder ratio

Characteristics strength(MPa)

Age(days) Water to binder ratio

MSA(mm)

10 12 20 2548 28 0.42 0.41 0.40 0.39

56 0.46 0.45 0.44 0.4355 58 0.35 0.34 0.33 0.33

56 0.38 0.37 0.36 0.3562 28 0.30 0.29 0.29 0.28

56 0.33 0.32 0.31 0.3069 28 0.26 0.26 0.25 0.25

56 0.29 0.28 0.27 0.26

Lab trialsTrial-1

Date:19/6/2012 Grade:M100 Time:11:10 AM Material Type Qty in

SSD(kg)Corrected (kg)

Batch(kg) WA % MC % Cost(Rs)

Cement OPC 53 400 400 14.890Fly ash Dirk P60 120 120 4.466Alccofine 1203

63 63 2.345

Water 150 6.864Sand Crushed 656 656 24.410 3 % -CA1 Crushed 492 492 18.310 1.5 % -CA2 Crushed 492 492 18.310 1.5 % -W/CM Ratio

0.26

Admixture Rheobuild 918 BASF

11.66(2%) 0.437

Total

Time(minutes) Slump(mm)Initial Collapse30 Collapse60 Collapse90 Collapse120 Collapse180 180

Days Weight(kg) Load(KN) Strength(MPa) Avg. Strength(MPa)3 8.380 802.2 35.67 40.3

8.154 850 37.788.400 1067 47.43

7 8.430 1196 53.16 51.318.295 1122 49.878.440 1145 50.89

28 8.365 1495 66.44 66.448.402 1500 66.678.390 1490 66.22

Remarks: In this trial admixture dosage is very high.

Trial-2Date:20/6/2012 Grade:M100 Time:12:00 PM Material Type Qty in

SSD(kg)Corrected(kg) Batch(kg) WA % MC % Cost(Rs)

Cement OPC 53 333.334 333.334 12.592Fly ash Dirk P60 166.667 166.667 6.296Silica fume 66.667 66.667 2.518Alccofine 1203

100 100 3.777

Water 140 6.5Sand Crushed 630 630 23.8 3 % -CA<20mm Crushed 900 900 34 1.5 % -W/CM Ratio

0.21

Admixture Glenium ACE30

5.33(0.8 %)

0.204

Total

Time(minutes) Slump(mm)Initial Collapse30 Collapse60 Collapse90 Collapse120 Collapse180 180

Days Weight(kg) Load(KN) Strength(MPa) Avg. Strength(MPa)3 8.480 1117 49.64 51.58

8.385 1074 47.738.518 1291 57.38

7 8.320 1597 70.98 708.530 1631 72.498.355 1497 66.53

28 8.530 1730 76.89 76.428.410 1831 81.388.476 1597 70.98

Remarks: In this trial admixture dosage is very high.

Trial-3Date:22/6/2012 Grade:M120 Time:11:35 AM Material Type Qty in

SSD(kg)Corrected(kg) Batch(kg) WA % MC % Cost(Rs)

Cement OPC 53 500 500 18.800Fly ash Dirk P60 120 120 4.520Alccofine 1203

40 40 1.500

Water 130 5.896Sand Natural 650 650 24.440 2 % -CA1<10mm Crushed 460 460 17.290 1.5 % -CA2<20mm Crushed 460 460 17.290 1.5 % -W/CM Ratio 0.2Admixture Glenium

ACE302.64(0.4 %)

0.100

Total

Time(minutes) Slump(mm)Initial Collapse30 140

Days Weight(kg) Load(KN) Strength(MPa) Avg. Strength(MPa)3 8.339 1076 47.82 51.2

8.368 1220 54.228.270 1160 51.56

7 8.450 1226 54.49 58.18.395 1380 61.338.507 1316 58.49

28 8.406 1480 65.78 67.298.360 1483 65.98.4 1579 70.18

Remarks: This trial has the very good workability. And strength is also good.

Trial-4Date:26/6/2012 Grade:M100 Time:2:30 PM Material Type Qty in

SSD(kg)Corrected(kg) Batch(kg) WA % MC % Cost(Rs)

Cement OPC 53 450 450 16.014Fly ash Dirk P60 140 140 4.982Alccofine 1203

60 60 2.135

Water 140 140+29 6.014Sand Natural 700 700 24.911 2 %CA1 Crushed 500 500 17.794 1.5 %CA2 Crushed 500 500 17.794 1.5 %W/CM Ratio

0.23

Admixture 2.6(0.4 %) 0.0925Total 2528.6

Time(minutes) Slump(mm)Initial Collapse30 18060 120

Days Weight(kg) Load(KN) Strength(MPa) Avg. Strength(MPa)

3 8.380 849 37.73 39.28.409 804 35.738.483 992 44.1

7 8.350 1110 49.33 49.308.590 1060 47.118.580 1158 51.47

28 8.428 1433 63.69 62.528.492 1364 60.628.390 1423 63.24

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

1. http://theconstructor.org/2010/01/durability-of-concrete/2. http://www.ce.berkeley.edu/~paulmont/CE60New/durability.pdf3. http://www.ceat.uiuc.edu/PUBLICATIONS/brownbag/presentations/Oct%2005%20Leslie%20Struble.pdf4. http://www.crusherinindia.net/aggregate-plant-in-inida.php5. http://www.cement.org/bridges/br_case_confederation.asp6. http://www.engineeringcivil.com/various-lab-test-on-aggregates.html7. http://www.sciencedirect.com/science/article/pii/S00088846980016538. http://www.kunal-umbarkar.limewebs.com/projects.html9. http://civil-resources.blogspot.in/2010/06/high-performance-concrete.html10. http://cordis.europa.eu/search/index.cfm?fuseaction=proj.document&PJ_RCN=493978311. http://www.engineeringcivil.com/various-lab-test-on-aggregates.html12. http://www.sciencedirect.com/science/article/pii/S000888469800165313. http://www.icevirtuallibrary.com/docserver/fulltext/cien163-2-066.pdf?

expires=1338128242&id=id&accname=guest&checksum=F2D084C70457517A8BE6F30317322DF0

14. http://fire.nist.gov/bfrlpubs/build99/PDF/b99060.pdf15. http://www.bhrc.ac.ir/Portal/LinkClick.aspx?fileticket=kSFe9D9bqYA%3D&tabid=58416. http://www.sefindia.org/forum/files/concrete_901.pdf17. http://www.concrete.elkem.com/eway/default.aspx?

pid=245&trg=Main_7244&Main_7244=7270:0:4,4564:1:0:0:::0:0&MainLeft_7246=6271:31255:18. http://l2build.com/concrete%20articles/high%20strength%20concrete%281%29.html19. http://www.theconcreteportal.com/frc.html20. Ambuja Literature Series21. Concrete Technology by M.S.Shetty