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A case study on performance of self-compacting concrete in highly congested

reinforcement of cast in situ structure

Article  in  Asian Journal of Civil Engineering · June 2021

DOI: 10.1007/s42107-021-00378-9

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A Case study on performance of self-compacting concrete in highly
congested reinforcement of cast in situ structure

Sandip Sonule*, Dr. K.C Tayade, N.V. P Vidhyasagar, A.B.Gupta

Abstract
Self-compacting concrete is highly advanced concrete with much higher fluidity without segregation, bleeding and it is suitable
for placing in structures with congested reinforcement of structure like Vierendeel truss under its self-weight without vibration.
Mix proportion of self-compacting concrete must ensure a good balance between deformability and stability. Behavior of concrete
can be affected by the characteristics of selected ingredients in concrete and the mix proportions. It becomes necessary to evolve
a procedure for mix design of SCC. The paper presents an experimental procedure for the mix design of self-compacting concrete
for grade M60 and implementation of the same mix at cast in situ heavily dense reinforcement structure-Vierendeel truss of
Sitabuldi Metro Station in Nagpur Metro Project. The test results for acceptance characteristics of M60 grade self-compacting
concrete such as slump flow, V-funnel, L-Box, compressive strength at the ages of 7, 28, and 56 days determined, and results are
included here. Successful production of temperature control Self compacting concrete from batching plant, transportation and
placement procedures and proper planning of handling and execution of self-compacting concrete at site are presented in this
article.

Keywords Self-compacting Concrete, Mix Design, Fresh concrete Properties, Hardened Concrete Properties, Implementation at
site
1. INTRODUCTION
Self-compacting concrete (SCC) is an innovative concrete that does not require vibration for placing and compaction. It can
flow under its own weight, completely filling formwork and achieving full compaction, even in the presence of congested
reinforcement [1]. The hardened concrete is dense, homogeneous and has the same engineering properties and durability as
traditional vibrated concrete. Self-compacting concrete (SCC) was first developed in Japan, in the early nineties of the previous
century, under the stimulating leadership of Prof. Okamura [2]. In Europe it was probably first used in civil works for
transportation networks in Sweden in the mid1990’s. The EC funded a multi-national, industry lead project “SCC” 1997-2000
and since then SCC has found increasing use in all European countries [2]. Self-compacting concrete offers a rapid rate of
concrete placement, with faster construction times and ease of flow around congested reinforcement [3]. The fluidity and
segregation resistance of SCC ensures a high level of homogeneity, minimal concrete voids, and uniform concrete strength,
providing the potential for a superior level of finish and durability to the structure. SCC is often produced with low water-
cement ratio providing the potential for high early strength, earlier remolding and faster use of elements and structures. The
elimination of vibrating equipment improves the environment on and near construction and precast sites where concrete is being
placed, reducing the exposure of workers to noise and vibration [3]. The improved construction practice and performance,
combined with the health and safety benefits, make SCC a very attractive solution for both precast concrete and cast in situ civil
engineering construction.

*Sandip Sonule, Section Engineer- Quality, General consultant – Maharashtra Metro Rail Corporation-, Nagpur, Maharashtra, India
sandipsonule47@gmail.com
Dr.K.C Tayade, Joint General Manager-Quality Control, Maharashtra Metro Rail Corporation, Nagpur, Maharashtra, India
keshavtayade@yahoo.com
N.V.P Vidhyasagar, Addl. General Manager-Civil, Maha metro rail corporation , Nagpur, Maharashtra, India
nvpvs2001@gmail.com
A.B.Gupta, Chief Residential Engineer, Reach-1, General consultant – Maharashtra Metro Rail Corporation, Nagpur, Maharashtra, India
abgrites@gmail.com
2. CONCRETE INGREDIENTS
4.1 Cement
Ordinary Portland cement (Grade 53) of M/s Ambuja is used. Physical & Chemical properties are as given in Table 1 & 2.
4.2 Fly ash
Pulverized fuel fly ash obtained from “Reliance Thermal Power Plant, Buttibori, Nagpur,Maharashtra, India. The physical
and chemical properties of fly ash are given in the Table 1 and Table 2, respectively.
Table 1. Physical Properties of Cement & Fly ash

Cement Flyash
Type Type Pulverized
OPC -53 Grade
fuel ash
W-M-Y Residue on 45micron
30-07-2018 3.6
sieve (in %)
Specific Gravity 3.14 Specific Gravity 2.2
Fineness(m2/kg) 292 Fineness(m2/kg) 488
Normal consistency (%) Lime reactivity
29.0% 6.90
(N/mm2)
Soundness (Autoclave) Soundness (Autoclave)
0.020 0.039
(%) (%)
Setting time (min.) Compressive strength at
165
Initial 28 days (N/mm2)
225
Final i) test Sample 40.3
Strength (N/mm2) ii) Plain cement Mortar 39.5
34.7
3days Cube
44.9
7days iii) Comparative 102
58.4
28days strength in %

Table 2. Chemical Properties of Cement & Fly ash

Cement Fly ash
Loss on ignition, % by Loss on ignition, % by
1.42 0.0
mass mass
Silica (SiO2), % by mass - Silica (SiO2), % by mass 33.5
Magnesium Oxide Magnesium Oxide
2.43 3.03
(MgO) (MgO)
Total Sulphur (SO3), % Total Sulphur (SO3)
1.84 0.26
by mass
Insoluble residue, % by Insoluble residue
1.39 -
mass
Alkali Content, % by Alkali Content, % by
0.49 0.43
mass mass
Total Chloride content, Total Chloride content,
0.011 0.011
% by mass % by mass

OPC 53 grade Cement and Fly ash are conformed to Indian Standard Specifications IS: 269-2015 and IS:3812-2013 [4-5]

4.3 Admixtures and viscosity modified admixture

Polycarboxylic ether based high range water reducing admixture brand name Auramix 400 of M/s Fosroc is used to bring out
the required water reduction and maintain the dispersing effect during time required for transportation and placement at site.
Viscosity modified admixture brand name VMA-AuramixV100 of M/s Fosroc is used in concrete to maintain the effect of
variation in moisture content, fines in the sand, conditions of other ingredients, avoid the bleeding and improve cohesiveness
of the concrete
Table 3. Physical Properties of Admixture and VMA
Physical tests Admixture VMA
Specific gravity 1.123 1.01
pH 6.65 7.19
Dry material 40.44 4.08
content
Concrete admixture and VMA are conformed to Indian Standard Specifications IS: 9103:1999 [7]

4.4 Aggregates
Coarse aggregate with 12.5 mm maximum size aggregate from nearest source i.e. Kanolibara quarry and natural sand of zone
II from Bhandara ghat of Wainganga River are used. Fine aggregate and coarse aggregate are conformed to Indian Standard
Specifications IS: 383-2016 [6]. Table 4 shows the physical properties of the coarse and fine aggregates.

Table 4. Physical Properties of Coarse and Fine Aggregates

Physical tests Coarse aggregate Fine aggregate

Specific gravity 2.85 2.61
Water Absorption (%) 1.81 0.72
Bulk density (kg/m3) 1600 1690
3. CONCRETE MIX COMPOSITIONS
The concrete mix is designed as per EFNARC specifications & guidelines [3] to meet environmental exposure condition of
Nagpur city Maharashtra i.e., moderate as per IS: 456:2003 and Concrete mix compositions are presented in Table 5

Table 5. Mix Proportions of conducted trial mixes for SCC M60 Grade
Sr. Mi Cemen Fly ash Powder W/P C.A F.A C.A /FA Water HRWR VMA W/p
No. x t (Kg/m3) (Kg/m3) Rati (Kg/m3) (Kg/m3) ratio (%) (Kg/m3) A. (Kg/m3) ratio
(Kg/m o (Kg/m3 by
3) ) vol
1 TR 450 130 580 0.31 910 770 52/48 130 4.06 0.0 0.89
1
2 TR 471 202 673 0.30 814 689 52/48 205 5.05 0.0 0.85
2 5
3 TR 471 202 673 0.30 767 731 49/51 205 5.38 0.0 0.85
3 5
4 TR 450 170 620 0.28 825 819 48/52 174 3.72 0.0 0.79
4
5 TR 450 170 620 0.28 830 810 48.4/51. 174 4.03 1.0 0.79
5 6
Five concrete mix design trials were taken of M60 grade self-compacting concrete for cast in situ heavily dense reinforcement
structure-Vierendeel Truss of Sitabuldi Metro Station in Nagpur Metro Project. Coarse aggregate content, fine aggregate content
and cementitious content were optimized, until a slump flow of 500-700 mm is achieved by slump flow test. For each trial, tests
are carried out in order that the trial mix satisfies slump flow test, V-funnel test and L-box passing ability test and Sieve stability
tests.

4.1 Test Methods

Self- Compacting Concrete is able to flow under its own weight without segregation, bleeding and these behavior of concrete
can be ensured by tests like Slump flow, V-funnel, L-box shape, and Sieve stability tests of concrete to determine the flow
ability, passing ability and segregation resistance of SCC mixtures according to EN 12350 Part 8, 9, 10, 11, and 12 [8]. .
Fig.1 Slump flow test Fig.2 V Funnel test

Fig 3. L-Box test Fig 4. Sieve Segregation resistance Test Fig 5. U Box Test

Table 7. Flowing ability, passing ability and segregation resistance are checked after 3 hrs and results are as below

Sr.No Mi Slump T50c V- V- L-box U-box Segrega Remarks

x flow m funnel funnel Blocking Differen tion
(mm) (sec) Tf (sec) T5min ratio(H2/H1) ce Resista
(sec) (mm) nce
1 TR 490 25.0 46 51 - - Not achieved
1
2 TR 550 17 21 22 - Not achieved
2
3 TR 580 6 12 13 0.77 38 - Not achieved
3
4 TR 590 5 11 12 0.78 26 8 Satisfactory
4
5 TR 610 4 9 10 0.82 15 6 More
5 Satisfactory

Trial mix no TR 4 has achieved all the requirements of filling ability and passing ability, but initial bleeding and minor
segregation were observed up to 1 hour then all these are disappeared. Batching plant trials of the same mix was also conducted
and found more variation in bleeding and segregation as compare to lab trials. Hence for better performance of concrete and
avoid the chances of segregation VMA Auramix V100 of M/s Fosroc was used then achieved more satisfactory results in trial
mix no TR5 as mentioned above table.
4.2 Final mix proportion of self compacting concrete, test results for fresh and hardened concrete
Details of final selected self-compacting concrete mix design trial mix no- TR5 is as below
TABLE 8: Table showing the mix proportion for the Self Compacting Concrete Grade M-60(12.5 MSA)

Coarse
Water Rever Sand aggregate
Cementitious (Kg) HWRA (Kg) VMA (Kg)
(Kg) (kg) (12.5
MSA) (Kg)

Cement OPC 53 Fly ash

grade (Ambuja) (RTPP) 174 811 830 4.03 1

450 170
Table 9.Test Results of SCC of M60 grade in Laboratory
Observation Characteristics Acceptance Limits Initial 1hr 2hrs 3 hrs.
Slump-flow class Flowability/Filling ≥ 520mm, ≤
700 680 670 610
SF1 Ability 700mm
T500 Viscosity Flowability between 3-7 Sec 2 3 3 4
V5min viscosity Flowability --- 5 6 6.5 9
V Funnel Tv Viscosity Flowability ≤ 10s 5 6 6 10
L Box 200 mm Passing Ability --- 2 2 2 2
L Box 400 mm Passing Ability --- 3 3 3 3
L Box (H2/H1) Passing Ratio ≥ 0,75 0.9 0.87 0.86 0.82
U Box Deference Height difference 30 mm Max 0 5 7 15
Sieve Segregation Segregation Resistance < 23 % 5 5.5 6 6
Ambient
27.5 28.5 29 29.7
Temperature

Mix proportion of selected mix design TR5 implemented at site for Vierendeel truss and total 1250 cum concrete quantity is
executed from 25th Aug 2018 to 30th june’2019.The flowing ability and passing ability of concrete mix are checked at site and
observed results are as below

Table 10. The Average Test Results of Site executed self–compacting concrete mix during concreting for Vierendeel truss

Before pouring Remarks

Results of
at site (around 1 (Comparison
Observation Characteristics Limits Batching
to 2 hrs after with 2 hrs
Plant
batching time) results of TR5)
Slump-flow class Flowability/ Filling -90 mm than
≥ 520mm, ≤ 700mm 690 580
SF1 Ability TR 5
+ 2 sec than
T500 Viscosity/Flowability between 3-7 Sec 3 5
TR5
V5min Viscosity/Flowability --- --- --- ---
+2 sec than
V Funnel Tv Viscosity/Flowability ≤ 10s 6 8
TR5
L Box 200 mm Passing Ability --- --- --- ---
L Box 400 mm Passing Ability --- --- --- ---
- 0.03 than TR
L Box (H2/H1) Passing Ratio ≥ 0,75 0.87 0.83
5
+3 mm than
U Box Deference Height difference 30 mm Max 5 10
TR5

Sieve Segregation Segregation Resistance < 23 % - - Not taken

Ambient + 0.5 deg
26.5 30.2
Temperature Celsius
V-funnel, L-box and U-box tests are conducted 2 times only in concrete pours because equipment handling could not practically
possible during concreting at site but Slump flow and T500 tests are carried out for 210 Transit Mixers and their average values
are mentioned in above table.

All the required tests could not be conducted at site laboratory due to non-availability of enough testing equipment’s. Hence
samples of specimens were sent to Maha-Metro authorized laboratory M/s BVIL for conducting tests are as below.

Table 11. Hardened Concrete Test results

Sl. NO. Test Description Acceptance Requirement Actual Results obtained

1 RCPT 1000-2000 Coulombs 1252 coulombs

2 Permeability 25 mm 8 mm
3 Flexural strength > 0.7 √fck 6.03 n/mm 2
= 5.42 N/mm2
4 Split tensile strength > 0.5 √fck 6.41 n/mm 2
= 3.87 N/mm2
5 Drying Shrinkage 0.05 % (Max) 0.033 %
6 Moisture Moment 0.03 % (Max) 0.018 %
7 Chloride content 0.5 % (Max) 0.20 %
8 Sulphate content 3.7 % (Max) 0.48 %

Table 12. The Cube Compressive Strength for Successful Trial Mix no TR-5 for M60 grade Self Compacting Concrete in
N/mm2

Strength of Sample Avg. Strength of Samples

Sr.No Age of Cubes No. Sample
in N/mm2 in N/mm2
1 52.33
2 7 days 3 55.18 54.65
3 56.44
5 69.52
6 70.33
7 72.45
28 days 6 71.34
8 71.63
9 71.66
10 72.45
11 80.46
12 78.69 78.88
13 56 3 77.49

After achieving all the parameters for self-compacting concrete for grade M60 then same mix is implemented for the Vierendeel
Truss at Sitabuldi Interchange Station and compressive strength results of site casted cubes for 7 days,28 days and 56 days are
represented in table and graph as below.

Table 13. The Compressive Strength of site casted cubes for M60 grade Self Compacting Concrete ( in N/mm2)

Standard
No. Avg. Strength of % of Strength Coefficient of
Sr.No Age of Cube Deviation
Sample Samples (N/mm2) Gaining Variation (%)
(N/mm2)
1 7 days 9 54.09 90.15
2 28 Days 34 70.22 117.03 1.8 2.6
3 56 days 9 78.04 130.07
 Strength in Mpa
100 7 days strength 28 days strength 56 days strength
Compressive

90
80
70
60
50
40
30

6
1

9
Sample Number
Fig 6. Graphical representation for Compressive Strength of site casted cubes for 7 days, 28 days and 56 days
Consistency of site casted cube compressive strength of individual working structures is also found satisfactory. Cube strength
of individual working structures cube samples, average compressive strength, standard deviation, and coefficient of variation
are represented in graph as below.

Average Compressive Strength - 70.22 N/mm2

Compressive Strength ( Min- max) - 67.74 - 75.58 N/mm2 Compressive Strength in N/mm2
Standar Deviation -1.8
78 Avearage Comressive Strength in N/mm2
Coefficient of Variation-2.6
Cube Compressive Strength in

76
74 Acceptance Compressive Strength in N/mm2
72
70
N/mm2

68
66
64
62
60
0 5 10 15 Sample No 20 25 30

Fig 7. Graphical Representation of site casted Cube Compressive Strength for Vierendeel Truss SCC M60 grade

4. EXECUTION OF THE CONCRETE POURING IN VIERENDEEL TRUSS

There were 3 layers of Vierendeel truss, and each layer contains approximately 550 cum concrete quantity along with
1100 MT of reinforcement. The size of major Vierendeel beam was 38.3 x 1.1 m x 2.8 m, highly dense reinforcement
i.e. 210 kg/cum was proposed in small section size of beams with high grade M60 concrete.

Fig 8. Heavily congested reinforcement steel in the structure

4.1 Sequence of concrete pouring

Periphery length of longitudinal and transverse beams is (2 x 38.3 + 2 x 21.5) = 119.6meter, total quantity of 119.6 x
1.1 x 2.4 = 316 cum
Depth of concrete pouring layer kept 300 mm. Hence concrete quantity in one layer calculated = 119.6 x 1.1 x 0.3 =
39.5 cum.
Two concrete pumping boom placers were deployed for proper pouring as shown in figure below.
 Fig 9. Plan for concrete pouring
Rate of Concrete pumping of boom placer kept 15 cum/ hour during concreting. It was assumed 15 cum /hour capacity
of the two boom placer on more safer side. self-compacting concrete was designed t for 3 hours retention time. Hence
one layer of concrete for complete periphery quantity i.e., 39.5 cum could be easily placed and overlapped within
designed time.
After completely covering the entire periphery area with 300 mm layer thickness, next layer was started from same
point and same manner again.
4.2 Details of machineries and equipmentst
1) Batching Plant 2nos – Capacity 30 cum/hrs (CP-60) One batching plant was working and one was standby
2) Boom Placer 2 nos – Capacity 30 cum/hrs
3) Stationery Pump 1 no. Standby – Capacity- 20 cum/hrs
4) Transit Mixers – 13 no’s working and 3 were standby

Fig 10. Actual site photographs during concrete placing

4.3 Contigency Plan

Contingency plan also prepared in advance for all the preventive actions to avoid break downs of equipment’s and unpredicted
weather condition.
a) Standby Machineries & Equipment’s were arranged before placing order for concrete production at Batching plant.
1. Batching Plant – 1 no (Cp 30)
2. Transit Mixers - 5 nos
3. Stationery Pump – 1

b) In case any Emergency concrete placing work could be stopped using arrangement as below
1. Wooden battens could be inserted vertically to make barrier for further concrete flowing at one third length of
Beam
 2. Wooden battens could be inserted vertically to make barrier for further concrete flowing at one sixth length of
Beam
c) Concrete layers could be protected from rain using polyethene sheet, it would be available at site with appropriate
quantity.

4.4 Deployment for Staff

Appropriate staff were deployed at Batching plant, TM checking point and placement point.
Self-compacting concrete has been placed successfully in formwork without any break downs and obstacles due to proper
planning and systematic arrangement. After De-shuttering of beams, concrete surfaces found smooth without any defects.

Fig 11. Smooth surfaces of the cast in situ self-compacting Vierendeel truss

5. CONCLUSION
1. Self-compacting concrete is more suitable for fast-track job like Nagpur metro project to reduce the construction time
and for getting enhanced quality and durability of the structure.
2. Self- compacting concrete can be easily placed in heavily dense reinforcement structure without any obstacles.
3. VMA is very necessary for maintaining cohesiveness, avoiding segregation and bleeding in self-compacting concrete.
4. Without VMA self-compacting concrete can be designed but more controlling at the time of production is required
because HWRA is a very sensitive in concrete, minor changes in dosage or moisture correction in aggregates are easily
affected to concrete mix, resulting that bleeding and segregation occurred at the time of batching plant trial for the mix
of Trial Mix No-4.
5. Recommended water/powder ratio is between 0.85 – 1.10 as per European guidelines but based on field trials all the
parameters of passing ability, filling ability and segregation resistance are well within limits at water/ powder ratio
0.79 and no difficulty observed at site during implementation.

Acknowledgment

The authors are thankful to Hon. Managing Director & Director Projects of Maharashtra Metro Rail Corporation Ltd Nagpur
for his motivational inputs and supports.

Compliance with ethical standards

Conflict of interest - On behalf of all authors, the corresponding author states that there is no conflict of interest.

References

[1]. Patrick Paultre, Kamal Khayat, Daniel Cusson, Stephan Tremblay.Structural performance of self-consolidating
concrete used in confined concrete columns.ACI Struct J, 102 (7) (2005), pp. 560-568
[2]. The European Guidelines for Self-Compacting Concrete Specification, Production and Use, May2005.
[3]. Adesina A (2018) Concrete sustainability issues. In: 38th Cement and concrete science conference
[4]. IS: 269-2015, Specifications for ordinary Portland cement, Bureau of Indian Standards, New Delhi, India.
[5]. IS: 3812-2013, Specifications for Pulverized fuel ash, Bureau of Indian Standards, New Delhi, India.

[6]. EFNARC (European Federation of national trade associations representing producers and applicators of specialist
building products), Specification and Guidelines for self-compacting concrete, February 2002, Hampshire, U.K.
[7]. BS EN 206:2013 Concrete Specification, performance, production and conformity
 [8]. IS: 269-2015, Specifications for ordinary Portland cement, Bureau of Indian Standards, New Delhi, India.
[9]. IS: 3812-2013, Specifications for Pulverized fuel ash, Bureau of Indian Standards, New Delhi, India.
[10]. 383-2016, Specifications for Coarse and Fine aggregates from Natural sources for Concrete, Bureau of Indian
Standards, New Delhi, India.
[11]. IS: 9103:1999 Reaffirmed 2004.edition 2.2-(2007-08) Bureau of Indian Standards, New Delhi, India.
[12]. BS EN 12350:2019 Testing of fresh concrete.

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