Maga RMX– Ambathale

Complain on high bleeding, segregation and setting time issue

Introduction
• Customer made a complain on high bleeding, segregation and setting time delaying with
concreting in Prime land project. Due to that concrete had been collapsed when demolding
as customer informed.
• This customer is using INSEE Extra and INSEE RF these days heavily.
• Quality team and I&A team involved and met Plant manager and Material Manager in Maga
RMX Ambathale as immediate response.
• Then I&A team started investigation and proceeded trials for understand situation and find a
solution.
• We proceeded lab trials, production in Apartment project in ‘Pipeline lane’ and Address 606
project. I&A team and B2B team involved heavily on those concreting.

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 Summery: Maga RMX Ambathale
Complain
Concrete not hardened
and collapsed when
demolding in Prime
Grand Residencies
project.
High Bleeding and
segregations
Observations and Results
• Previously this design was
proceeded with both Extra and RF.
But due to not availability of RF,
100% Extra used for concreting
and setting delay may effect
comparing OPC mix.
• Vertical shutters demolding time is
24Hrs as they practice in site but
they had been demolding after
20Hrs. Four hours earlier.
• When we proceed existing design,
concrete shown high bleeding and
segregations. They trialed same
mix with Sika team using Ultratech
PPC but shown no excess
bleeding and segregation.
• Then we optimized design in terms
of admixtures to gain required
properties. Shown no excess
bleeding and segregation.
Recommendation
• Proceeding with trialed mix
design is must and changing
cement types and amount
surely affected to concrete
properties.
• 100% Extra definitely lead to
setting delay and they have
demolded earliest than normal
practice which is double
mistakes done by them.
• With optimized design, we
reduced admixture dosage,
which is cost effective for them.
And gain far more good
concrete than previous.
• But we identified that there
should be internal change in
cement and customer have no
idea. Recommend to inform
property changes,
improvements doing to our
cement.

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 Summery: Maga RMX Ambathale

Complain Observations and Results Recommendation

Setting time Delay with
new cement bulk
• For the existing design, initial
setting time was 22Hrs.
• With optimized design initial setting
time was 15Hrs.
• With optimized design setting
time was controlled but
according to experience 15Hrs
also delayed setting time result.
Need to improve that.

Can not do concreting
with current Extra bulk
• I&A team and B2B team executed
concreting of two projects without
any defect under our inspections
and quality controlling.
• Concreted Apartment project in
‘Pipeline lane’ from G25 100%
Extra.
• Concreted Address 606 project
from G40 100% Extra

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 Summery: Maga RMX Ambathale
Complain Observations and Results Recommendation
• INSEE has done • According to the results and • With cement report which is
some what observations can identify major providing with bulk Maga RMX could
changes in variations in concrete identify setting delay and proceed
cements but not properties for on going precautions.
informed to designs. • As a practice we should inform all
Customers and • And cement report which is customers and Admixture teams in
Admixture teams as providing with bulk also shown terms of our cement property
usual. property changes. changes then they can adopt and we
can avoid this kind of complains.
• Recommend to send our cement
samples to Admixture teams once a
month or two weeks period to adjust
their products.
• In Address 606 concreting we used
complained cement bulk and new
unloaded bulk. Here shown two
colours with two cement bulks and
customer concern is INSEE have
change cement again without
informing and now again some
failure will happen with optimized
designs.

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Concreting in ‘Address 606’ project

New cement Complained cement

bulk/Light colour bulk/Dark colour
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Concreting Prime Grand Residencies
• MAGA RMX complain handling on 10/05/2019
• Problem status :
• 1.G70 Strength not achieved from last two months
• 2.G40 SCC is segregation.
• Handling the issue:
 Batching 1m^3 and observe the performance of initial and after half an hour. Shown high
bleeding.
 Finding out the root cause and optimize the admixture dosage. Reduced dosage from
0.2% dosage.
 Then Batched all required 50 m^3 without any performance issue.
 Some error was in G70 design and it was corrected.
• Concerns of customer :
• If there is any quality change it has to be informed in advance

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Siam City Cement (Lanka) Limited | All Rights Reserved. 09/24/2020 8
• Loss of 1D strength due to delay in setting time of Extra

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CEC RMX– Central Expressway Narammala
Complain on high bleeding and segregation issue
Introduction
• Customer made a complain on high bleeding and segregation with Rapid flow plus. .
• This customer is using INSEE Extra and INSEE RF + these exclusively.
• I&A team involved and met Material Manager in CEC RMX CEW as immediate response.
• Then I&A team started investigation and proceeded trials for understand situation and find a
solution.
• We proceeded lab trials, plant trials for design optimization as solution for complained
cement bulk. I&A team and B2B team involved heavily on those trials and discussions with
CEC Senior Project Manager, Plant Manager and Material Engineer.

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 Summery: CEC RMX Central Express way
Complain Observations and Results
High bleeding and • When we proceed existing design,
segregations concrete shown high bleeding and
segregations.
• Then we optimized design in terms
of admixtures( reduced dosage
from 1.05 to 0.9) to gain required
properties. Shown no excess
bleeding and segregation with
admixture reductions.
Admixture behavior • For the bulk received on
changed bulk to bulk 2019.03.29 optimized admixture
dosage was 0.9%.(Shown good
flow and retention)
• For the bulk received on
2019.04.01, 0.95% admixture
dosage also gave margin results.
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Recommendation
• With optimized design, we
reduced admixture dosage,
which is cost effective for them.
And gain far more good
concrete than previous.
• But we identified that there
should be internal change in
cement and customer have no
idea. Recommend to inform
property changes,
improvements doing to our
cement.
• Explained them variation of
admixture will be huge effect to
concrete with Quarry dust and
need to check admixture time to
time.
09/24/2020 12
 Summery: CEC RMX Central Express way
Complain
Design optimization for
coming cement bulk
Slump is increased
when concreting going
on.
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Observations and Results
• We received samples from Quality
team for improved next cement
bulk.
• According to lab trials on going
admixture dosage 1.05% shown
high bleeding and segregation
after 45min.
• Then according to trials proceeded
0.9% dosage gave good results.
• As shown when concreting first
three or four mixers are good but
after that high initial slump is giving
so tend to bleeding.
Recommendation
• Should proceed plant trial after
receiving new bulk.
• Should change mix design and
get approvals for reduced
admixture dosage from
consultant.
• I&A team proceeded lab trials
simultaneously and shown no
issue with cement, but their
might be error in plant.
• So recommendation given to
customer for proper plant
calibration should done before
move on.
09/24/2020 13
Plant trials with on going design

Initial slump
70mm After 1Hrs:Slump-240mm
High segregation and bleeding
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Plant trials with optimized design

Initial slump After 1Hrs:Slump-200mm

75 mm No segregation and bleeding

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Lab trials for cement samples

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Access RMX– Paliyagoda
Complain on high water demand and strength lost
Introduction
• Customer made a complain on water demand increased with Extra so adding around 10kg to
15kg for on going design.
• This customer is using INSEE Extra these days heavily.
• Customer complaining on property variation with each cement bulk so feel difficult to control
fresh concrete quality and affect to strength.
• As they start to use Extra from 2019 May 3 rd replacing INSEE RF+, strength reduction also
shown and they have lost major three projects as mentioned by Plant manager Mr.Anura.
• I&A team and B2B team started investigation and proceeded lab trials with their samples in
Extra ( Batch date-2019/05/21) with Access lab crew to find best solution for customer.

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 Summery: CEC RMX Central Express way
Complain Observations and Results
Early strength reduction • When we proceed existing design,
optimized to INSEE RF+ but using
INSEE Extra cement. So early
strength reduction was shown to
customer.
Increase in water • Customer seems water demand
demand for cement new increased with new bulks. So we
bulks proceeded flow test.
• Flow test results shown slight
water demand increment than
previous may affect to concrete
highly.
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Recommendation
• We proceeded design
optimization with customer for
INSEE Extra and achieved
good early strength.
• Due to increase of water
demand in Msand and cement
may be adding more water to
concrete which should be
avoids..
• Design optimization done for
water demand by adjusting
admixture, and fine so no need
of more water.
• Need to check cement variation
for water demand in our side.
09/24/2020 19
 Trials/Testing summery

Test
Grade Slump/ mm Strength / MPa Remarks
#

Cube Time Requirement Achievement Days Requirement Achievement

01 G30 Initial 175+-25 170 • Added 10 kg of

Extra
4 23.7 MPa extra water to get
1.1% required initial
dosage 1Hrs 175+-25 180 7 slump
of Sika • Flow was slow
208 2Hrs 175+-25 195

3Hrs 175+-25 125

02 G30 Initial 175+-25 165 • Added 11.5 kg of

3 extra water to get
Extra
1.2% required initial
dosage 1Hrs 175+-25 180 7 slump
of Sika • Flow was slow
208 2Hrs 175+-25 110 • Slump dropped
in 2hrs.
3Hrs 175+-25

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 Trials/Testing summery

Test
Grade Slump/ mm Strength / MPa Remarks
#

Cube Time Requirement Achievement Days Requirement Achievement

03 G30 Initial 175+-25 185 • Moisture of MS

Extra 4 22.2 MPa increased 5.8%
1.1% to 9.4% and
dosage proceed same
of Sika 1Hrs 175+-25 200 design in T#01.
208 7 • Added 6 kg of
extra water to get
2Hrs 175+-25 200 required initial
slump
• Concrete and
Flow was very
3Hrs 175+-25 195 good.

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 Trials/Testing summery

Test
Grade Slump/ mm Strength / MPa Remarks
#

Cube Time Requirement Achievement Days Requirement Achievement

04 G35 Initial 175+-25 • This concrete

Extra 3 was concreted to
1.1% site and we
dosage proceed lab trial
of
1Hrs 175+-25 to get
Hyperc 7 understand.
rete • Proceed with
+M moisture of MS
2Hrs 175+-25 5.8% .
• Added 16 kg of
extra water but
required slump
was not their.
3Hrs 175+-25 • Removed as
failed

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 Remarks…
• In #T01 and #T02 trials proceeded with same design and same material condition but
different admixture dosage. Dosage was increased as #T01 dropped in 3Hrs but #T02
also behave as #T01 and dropped in 2hrs.
• Then #T03 trial was proceeded with same material and #T01 dosage but Msand moisture
was increased from 5.8% to 9.4%. Then concrete was so good in fresh stage and gave
good retention. So there is a issue with Msand absorption which is clearly shown
comparing #T01 and #T03 lab trials and successful concrete production and #T04 lab trial.
• After discussion with Mr.Anura and Lab crew we proceeded Grading and Clay test for
Msand sample, although fine % is slightly high (12.6%) and clay content 3.68%, results
can be accepted for those parameters.
• May be due to wrong absorption, admixture will absorb to Msand with water initially then
they will add more water to get required initial slump and will effect to water cement ratio
ultimately strength of concrete. As Ultratech crew also their and as heard strength issue is
with them also. 7day strength of Ultretech less around 2MPa than our PPC Extra.
• We achieved acceptable 4 day strengths and customer was satisfied with those results.
• We need to focuses on consistent cement properties and inform customer on any variation
as requested by customer Access RMX Paliyagoda.

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Port city project RMX
Complain on cement variation
Introduction
• Customer made a complain on cement variation with new cement bulks.
• They have noticed that fresh concrete properties couldn’t achieved with proceeding design
and materials.
• So I&A team with B2B team involved to find solution to customer supporting with admixture
supplier CashTech.

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 Summery: CEC RMX Central Express way
Complain
Customer complaining
on cement variation in
Extra bulk to bulk.
Observations and Results
• We proceeded trials with new
cement samples provided by
Quality team.
• As customer concern they refuse
to go with design optimization so
we had to go with trials for existing
design.
Recommendation
• In fresh stage we couldn’t
achieve initial slump
requirement.
• We added water 25 kg to one
meter cubes then get some flow
but slump was not their.
• Then discussed with admixture
supplier to upgrade admixture
to achieve requirements of
customer.

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• Flow test done in portcity

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ICC RMX Bokundara
Complain on slump drop
ICC RMX Bokundara
Complain on slump drop
 Summery
Place Contacted Task No. of Materials Final Result
person attempts
Complain on Bleeding and • Extra Done
segregation. So proceed and do • RF+
CEC CEW; design optimization • Qdust
CEC CEW RMX • Mr.Neel • 5-20mm
Narammala • Mr.Nishshanka #Trial: G30:flow 550(+/- 50): 4 • Hy+M
Retention 3Hrs
#Trial: G50:slump 200(+/- 25):
Retention 3Hrs

Consultant lab trials G40 for new • Extra Done

plant in port city project. • M-Sand
CashTech- CashTech; • LRPS3000
Seeduwa • Mr.Aruna 2
Lab Trial: G40:slump 200(+/- s
25): Retention 3Hrs

Complain on flow reduction • Extra Trials shown

• M-Sand less flow. After
Portcity; Lab Trial: G40:slump 200(+/- • Sea sand discussion with
Portcity trials • Mr.Amila 25): Retention 3Hrs 2 • LRPS3000 CasTech
s adjustment done
to achieve
requirements

Complain on strength drop and • Extra Done

high water demand in Extra new • M-Sand Strength
Access RMX- Access; bulk • Sika 208 satisfied with lab
4
Paliyagoda • Mr.Wijesunghe Lab Trial: G30:slump 200(+/- • Hy+M trials
25): Retention 3Hrs

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 Summery of last two week
Place Contacted Task No. of Materials Final Result
person attempts
Bleeding and segregation with Had a deep
Extra and strength loss discussion and
Thudawe;
Thudawe RMX attended to plant
CEW-Wilgoda
• Mr. 1 concrete. Results
were accepted. Only
one time issue
Complain on cracks and Done
Mechanical Sanken; customer request on strength Hammer test result
plant project • Mr.Chamila check as site complaining on were accepted and
Digampathana cement 3 CECB was
-Sanken RMX CECB; convinced on
Kandy • Mr.Thusitha cement. Design
failure
Complain on 1D strength Done
reduction Cube was crushed
Maga RM- Maga;
for 1D and 2D.
Ambathale • Mrs. Muditha
Results accepted by
ME
Issue with strength gain 7D to • RF Done
28D • Rsand
Nuwani
Nuwani; #Trial: G30:slump 150(+/- 25): • Sika 208
Construction-
• Mr.Thilina Retention 2Hrs
2 • MP 300R
Matara
#Trial: G25:slump 150(+/- 25):
Retention 2Hrs

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 Summery
Place Contacted Task No. of Materials Final Result
person attempts
#Trial: G25:slump 125(+/- 25): Done
Retention 2Hrs • RF
• RF+ (slag)
Sam Dam Sam Dam; • Rsand
Engineering- • Mr.Sudam 4 • Qdust
Balangoda • 5-20mm
• CashTech

Consultant lab trials G40 for new • Extra Done

plant in port city project. • M-Sand
CashTech- CashTech; • LRPS3000
Seeduwa • Mr.Aruna 2
Lab Trial: G40:slump 200(+/- s
25): Retention 3Hrs

Complain on flow reduction • Extra Trials shown

• M-Sand less flow. After
Portcity; Lab Trial: G40:slump 200(+/- • Sea sand discussion with
Portcity trials • Mr.Amila 25): Retention 3Hrs 2 • LRPS3000 CasTech
s adjustment done
to achieve
requirements

Complain on strength drop and • Extra Done

high water demand in Extra new • M-Sand Strength
Access RMX- Access; bulk • Sika 208 satisfied with lab
4
Paliyagoda • Mr.Wijesunghe Lab Trial: G30:slump 200(+/- • Hy+M trials
25): Retention 3Hrs

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Next Two Weeks Key Priorities…

ELS Precast yard Sooriyawewa slag cement Trials

SSP RMX Rathnapura slag cement trials

Nuwani construction Matara trials with Extra

ICC RMX Bokundara reactivation with MM

Senarath RMX Pannala Lab trials

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