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ABSTRACT. Three High rise residential towers are under construction near Hebbal in Bangalore. The developer was keen on application of Value Engineering for the Project. As part of the Value Engineering proposal, the first author had proposed substantial saving in cement and an economical concrete mix with cementitious material content limited to the minimum specified in IS 456 -2000. Accordingly a series of trial mixes were conducted by the contractor under the advice of the authors. Use of minimum cementitious material for M40 concrete mix was specified in the tender as 350kg/m3 of concrete. A series of trial mixes were conducted at the project site to determine a choice of mix satisfying workability of concrete strength and conformity to IS 456-2000. Conventionally, M40 mix is being realized by various agencies in India mainly with cement content of about 420kg/cm3 of concrete. Psychologically the concerned execution agencies as well as independent test laboratories in Bangalore (and the rest of India) were not tuned to the idea of reducing cementitious material content. As such a large number of trials had to be conducted to convince all concern about the practicability of using 350kg cementitious material (cement + fly ash/GGBS). About 150 Trials were conducted before choice of the mix. Refinements in trial mixes included calibration of batching plant, temperature control curing tank, moisture probe for sand, laboratory pan mixer etc. These were introduced progressively, accounting for the increased number of trial mixes. The chosen mix was validated by a reputed recognized third party laboratory before implementation in actual concreting. The paper describes in detailed the process of arriving at the most economical mix. The results of work tests using the chosen mix over 28000m3 till November 2012 are also analyzed and found to be in conformity with the requirements of IS 456. Keywords: Durability, Sustainability, Cement, Material selection, lab maintenance
S A Reddi is a consultant at Value Engineering, Bangalore, India. He has been actively involved in the formulation of Codes and Specifications as a member of the committees of Bureau of Indian Standards, Indian Roads Congress, fib, and International Association of Bridge and Structural Engineering, Zurich. Gurumurthy D M is with QA Engineer Karle Group, India
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INTRODUCTION
Concrete mix proportioning is being done using a number of published methods. The author has found trial mix method yielding satisfactory results. In the case of Zenith Towers, the tender document has included requirement of mix proportioning for use of minimum cementitious material content of 350kg/m3 of concrete. As per IS 456, for Bangalore environment, the minimum specified cementitious material content is 320kg/m3 concrete (severe environment). The successful contractor shall proportion the mix accordingly. Based on trial mixes, any variation in cementitious material content in the approved mix is payable in addition. After a number of trial mixes, it was possible to get an approved mix with the specified cementitious material content. The paper details the procedure followed and improvements practiced which enabled a mix with minimum cementitious material content. The approved mix contained 260kg cement plus 90kg fly ash or 175kg cement plus 175kg ground granulated blast furnace slag (GGBS). Due to uncertainty in obtaining regular supply of GGBS, the developer opted for use of fly ash. More than 32000m3 of M-40 concrete has successfully been carried out for raft, beams, columns, retaining walls, slabs etc. till December 2012.
GRADE OF CONCRETE
The design consultant had earlier specified different grades of concrete (M25, 30 and 40) for slabs, beams and columns. They were persuaded to adopt M40 grade for all components to simplify operations, assured that cementitious material content will be minimum specified in the code. The developer was assured that cement consumption will be equivalent to that of the lowest grade of concrete (M20) permitted in IS 456:2000. Thus only one grade of concrete (M40) is being used for the project. This decision confirms to Cl. 10.2 Batching, of IS 456: To avoid confusion and error in batching, consideration should be given to using the smallest practical number of different concrete mixes on any site or in any one plant. Number of advantages arises out of single grade of concrete at a project site: Saving in cost and time of proportioning different mixes Problem of pouring concrete at interface between columns, beams and slabs No confusion in batch plant settings Error-free batch plant operation
The concrete mix design was carried out by trial mix method, within the framework of IS 10262 2009, Indian standard concrete mix proportioning Guidelines ( First revision 2009). Annexure B of the code gives illustrative example of mix proportioning of concrete using fly ash as part replacement of OPC. The example coincidently was for M40.
WORKABILITY OF CONCRETE
As all concrete was proposed to be pumped, target workability was assumed as 75-100mm, as per Cl 7.1 of IS 456 in the mix proportioning trials. Initially, there was resistance from the constructor, but due to continuing efforts, pumping concrete has stabilized at slump of 80100mm at the delivery point. Subsequent trial mixes were successfully realized with 100mm slump. Normal tendency at Indian sites is to have higher slump, with mistaken notion of easy pumpability; actually higher slump leads to segregation, separation of coarse aggregate etc. Field personnel prefer higher slump for ease of placement; in fact, such higher slumps in pumped concrete may have detrimental results including segregation, bleeding, blocking of pipeline etc. Hours are lost to clear blockages; in some cases the concrete sets and the pipe is lost! (Figure 1). Other factors contributing to need for higher slump included truck mixers and pipelines not cleaned after each pour, lack of coordination between batch plant, truck mixer movement and concrete pumping. These were investigated and corrective action taken during quality site visits.
By persistent efforts and training, it was possible to successfully pump concrete with a slump of 80-100mm for subsequent pours.
Fit the sand bin with moisture probe (Most of the batch plants in India do not have one) (Figures 3a and b).
Daily monitor the weighing tolerances in concrete component by checking the printout. Calculate cumulative monthly standard deviations; any increase triggers warning for corrective action. Every consignment of constituent materials, including cement, is independently tested, compared with BIS requirements. Any change in source of cement, even with same brand, is implemented only after tests Regular Sieve analysis of coarse and fine aggregates. Form removal time based on tests of cubes site cured, not in curing tank.
sand. Trial mixes have been conducted for cube strength as well as slump of concrete for every trial mix. The following mix was finally approved for use, after extensive trials lasting months. Trials were started as the first activity after establishing the site. The approved mix was ready for use by the time the site was ready for the first pour. Table 1 Details of the approved mix used
APPROVEDMIX Cement FlyAsh Water CA20mm 12.5mm NaturalSand CrushedSan Admixture 260kg 90kg 154L 684kg 293kg 448kg 448kg 0.60%*
SITE LABORATORY
The contractor had established a concrete testing laboratory at site with equipment for following tests, as per contract requirement: Sieve analysis of aggregates Flakiness and elongation of coarse aggregates. Bulk density of aggregates Specific gravity of aggregates. Water absorption of aggregates Wet sieve analysis of river sand and M sand Cement test Cube test Pan mixer Temperature control for curing tank Compressive strength testing machine Fly ash sieve analysis
admixture was selected for trial mixes and eventually for works. Tests were conducted at third party laboratory for compatibility between each brand of chosen cement and the chemical admixture before commencement of trial mixes.
sand; the rest is water. You can allow for this by estimating or measuring the moisture of the sand by conventional method and modify the amount that you weigh in proportion. If your sand moisture decreases by 2% without being noticed, however, the batching system will weigh out 2% more sand than you require and will add appreciably less water than needed, making a dry batch. Moisture content varies through the day. Traditional methods of using frying pan to assess moisture once or twice daily is not good enough. Moisture probe is unique; it can continuously adjust the load water as the material flows over the probe, a method that ensures consistent slump predictability in high specification concrete and concrete product manufacturing. Batch plants should be fitted with moisture probes at the sand feed point. Probe is connected to the computer, which will continuously adjust the mix water accordingly. The aggregate moisture sensor ensures that the batch is proportioned according to the dry weight mix design.
STANDARD DEVIATION
Initially standard deviation was assumed as three based on past experience; used for calculation of target mean strength for proportioning the mix for trials. This is based on the authors prior experience; IS 456 Table 8 gives a value of five. The assumption was validated by analyzing cube test results of trial mixes initially and work test results cumulatively at monthly intervals. The last cumulative standard deviation has been reported as 1.9 in December 2012. This is considered indicating excellent quality control at site.
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THIRD PARTY TEST REPORT ON CONCRETE MIX PROPORTIONING BY CIVIL AIDS BANGALORE DATED 4 MAY 2012
Two trial mixes were validated in the third party laboratory as per the employers requirement in Bangalore with cement content of 260kg and 245kg, fly ash of 90kg and 105kg to make a total of 350kg cementitious material, water 154 litre, admixture 0.7% and other components as per approved mix proportions. Their observations:
Table 2 Compressive strength and slump of two trial mixes SLUMP Initial After 30min After 60min 3 day 7 day 28 day 150mm 140mm 140mm 25.9MPa 37.6MPa 51.5MPa 170mm 165mm 110mm 24.4 mPa 34 mPa 53 mPa
COMPRESSIVE STRENGTH
Special Remarks By the third party laboratory: "Trial mix was carried out as per the mix proportions Suggested in letter dated 3.4.2012 and using materials as supplied by CCCL. The concrete making materials such as cement, fly ash, fine & coarse aggregates, admixture and water should conform to relevant Indian Standards. Correction for water absorption in crushed sand aggregates and coarse aggregates to be applied at site. Fine aggregate of natural river sand & crushed stone sand shall be used in the ratio of 50:50. Coarse aggregate of 20mm and 12.5mm shall be used in the ratio of 70:30 repective1y." "Performance of admixture shall be checked and verified periodically at site." "Trial mix proportions considered above shall be modified in the field using the proposed materials and finalized by observing the actual performance of the concrete mix. Suitable modifications may be necessary to suit field conditions in the light of experience as for the particular materials used in each case."
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TRUCK MIXERS
Six cubic meter capacity truck mixers were deployed for the project. Except for some major pours, four m3 units would have been more appropriate from quality assurance point of view, but rarely employed in India. Mixer drivers were prohibited from adding water en route. Truck mixers were made to come under the plant with their drums in discharge mode to ensure that there is no water in the drum prior to loading concrete. Occasionally there was no coordination between the batch plant production, number of truck mixers employed, and the deployment of concrete pump. This has resulted in delay between mixing and placing concrete beyond the permitted gap as per the code. Attempts are made to correct the situation.
WEEKLY QA VISITS
During the first months after commencement of concreting, the authors conducted weekly QA visits to project sites, verified quality of concrete, reinforcement, formwork, false work etc. and enforced compliance until stabilized. Site visits were preceded by review of compliance of the previous weeks observations and followed by preparing minutes of the current visit.
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Credits Developer: In House QA: Design Consultant: Value Engineering Consultant: Karle Group, Bangalore Mr Gurumurthy DM, Quality Manager BURO Singapore & CRN Chennai SA Reddi, Fellow, Indian National Academy of Eng.
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