Bangkok Meeting 21-22 October 2011

Environmental Industries Sector Unit

Run of Station Fly Ash (Unprocessed)

50 COMPRESSIVE STRENGTH, N/mm FA FINENESS, 45m Sieve: % ret. 45 40

35 30 25

20 15 10 5

!! Strength ! !! !! ! ! ! ! !! ! ! ! ! !!Fineness
1 2 3 4 5 6 7 8

0 9
10 11 12 WEEKLY SAMPLES

Pozzocrete: Use in Concrete

Pozzocrete Products

As Sand
Pozz 1

As Filler and Precast

Pozz 2, 3, 4

As Cement Component

Normal Concrete
Pozz 5, 6

High Performance Concrete

Pozz 7, 8 Environmental Industries Sector Unit

Pozzocrete: Water Requirement

P10 P20

Pozzocrete

P30 OPC

P40
P60 P63 P83 P100

85

90

95

100

105

110

Water Requirement, %
Environmental Industries Sector Unit

Pozzocrete: Fineness
P40

Pozzocrete

P63 P83

BS EN 450 (S)

P100
0

<1% retn. 25m sieve

10

20

30

40

Fineness 45m Sieve Retention, %

Environmental Industries Sector Unit

BS EN 450 (N)

P60

IS 3812

Pozzocrete P100:Development of HPC

Cement Combinations 3 days Strength, MPa 7 days 28 days 90 days a.) for OPC Concrete, Water/Cement Ratio = 0.30 100% PC 90% PC+ 10% P100 90% PC+ 10%SF 51.0 53.0 55.0 63.5 77.0 68.5 83.5 96.5 91.5 97.5 112.0 113.0

b.) for OPC Concrete, Water/Cement Ratio = 0.34

100% PC
90% PC+ 10% P100 90% PC+ 10%SF

31.0
36.0 32.5

45.0
55.5 49.5

57.0
62.5 64.5

67.0
78.0 83.0

c.) for OPC Concrete, Water/Cement Ratio = 0.38 100% PC 90% PC+ 10% P100 90% PC+ 10%SF 20.5 29.0 23.0 35.5 38.0 35.5 47.5 57.0 53.0 62.0 76.0 74.0

Environmental Industries Sector Unit

Pozzocrete 100: Development of HPC

4000

Durability- Chloride Resistance

High

RCPT, Coulumb

3000

100% PC
2000

1000

90% PC+ 10% SF 90% PC+ 10% P100

Environmental Industries Sector Unit

Negligible

V. Low

Low

Moderate

Pozzocrete P100:Development of HPC 50

Durability-Permeation Properties
100% PC

Water Permeability, mm

40

30 90% PC+ 10% SF 20 90% PC+ 10% P100

10

Environmental Industries Sector Unit

Potential for Developing Pozzocretes for Marine Exposures

2/s10 2 D /sec Coefficient Diffusion ) cm 10 99 Coefficient, Diffusion D ,(cm

100

For equal chloride diffusion coefficient: PC Concrete: 70 MPa (w/c=0.30, PC=550kg/m3, PFA=0kg/m3)
25 MPa concrete 25 MPa concrete

10

PC55/FA45 Concrete: 40 MPa (w/c=0.45, PC=205kg/m3, FA=165kg/m3)

35 MPa concrete 35 MPa concrete PC 1

Saving: 345 kg/m3

50 MPa concrete Marine bridge concrete exposed to potential 50 MPa concrete 3 70 MPa 70 MPa concrete concrete 0 10

0.1

20 30 %% Fly Fly Ash Ash Content Content

chloride attack, say = 80,000m . Potential for PC saving = 27,600 tonnes. 60 MPa concrete 60 MPa concrete Potential for cement cost saving = Rs 16.56 cr 40 50 60 Potential for CO emission reduction = 27,600t 2

Environmental Industries Sector Unit Bandra Worli Sea Link- Mumbai

Potential for Developing Pozzocrete for Hot Climate Construction

Cement: 400kg/m3, Formwork: Steel, Section thickness1m
Cement Type PC FA, 20% GGBS FA, 30% GGBS FA, 40% GGBS FA, 50% GGBS FA, 60% GGBS FA, 70% GGBS Exposure Temperatures, C 20 30 40 50 48.8 53.9 57.8 n/a 37.2 41.9 45.6 48.6 31.2 35.7 39.4 42.5 42.0 49.8 55.2 n/a 25.8 29.7 33.0 35.8 38.9 47.3 52.9 n/a 20.6 23.9 26.8 29.3 35.4 43.9 49.6 n/a 30.4 38.9 44.8 48.8 25.2 32.8 38.2 41.8