1.

HARI BANGUNAN INDONESIA

Good Practices for Quality, Durability,

Sustainability & Environmental Friendly
Construction
Dr Arvind Suryavanshi, FICT
PhD (University of Manchester, UK), M. Tech, B. Eng, ACTA

General Manager-Technical, PT Pionirbeton Industri

4th November 2020

Slide 1
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 Long-Term Durability of Concrete (50 -100 years)
Long-term Durability
Durability is the ability of concrete to resist weathering action, chemical attack (Chloride,
Sulfate), Abrasion, or any other process of deterioration (Leakage, Cracks, Permeable Cover)
Causes that affect long-term durability of concrete
- Corrosion of rebar steel due to Chlorides from Sea Salt
- Corrosion of rebar steel due to Atmospheric Carbonation (Low pH)
- Sulfate attack by Soil and Ground Water (Brownfield)
Durability tests
- Resistance to Chloride Penetration (RCPT): ASTM C1202 (6 hrs)
- Resistance to Water Penetration: DIN 1048 (5 bar, 72 hrs, 30 mm)
Salt attacks rebar steel by rust
- Resistance to Sulfate Attack: ASTM C 1012 (Expansion, S1, S2 and S3) formation, Cracks & Spalling
Charge passed Chloride permeability Typical concrete
(Coulombs)
˃4,000 High W/C ˃0.60, conventional PCC, lean concrete

2,000-4,000 Moderate W/C 0.4-0.5

1,000-2,000 Low W/C < 0.4
100-1,000 Very low Latex-modified concrete / waterproofed
concrete / concrete with Silica Fume (7-8%)
Sulfate attacks concrete surface <100 Negligible Polymer concrete
Slide 2
Name of Presentation I dd.mm.yyyy Ref: ASTM C 1202
 Supplementary Cementitious Materials (SCM)
Purpose of SCMs
1. Long-term DURABILITY. Service Life of 50 to 100 years
with minimum maintenance
2. Long-term strength gain. Strength gain after 28 days
3. Provide good Filler Effect due to different sizes (Binary &
Tertiary blends)
Method of Application of SCMs Fly Ash concrete: Low initial strength;
gains after 28 days (Ref: PCA)
Pre-Blended Cements: PCC, PPC, Hydraulic Cement (SNI 8912) & Slag Cement
Slag Cement, Low Heat: For Mass Pours (Example: Raft Slab)
Slag Cement, General Purpose (Example: RCC Structures exposed to Marine
atmosphere, Bore Piles, Pre-Cast Piles)
Slag Cement by Inter-
Types of SCMs in Indonesia Grinding of OPC & GBFS
1. Fly Ash, ASTM Class C (CaO> 8%) & F (CaO < 8%) 1. Homogenous Mix
2. It is a Final Product-
2. Silica Fume Easy to handle at
3. Trass (Natural Pozzolan, Volcanic product) RMC plant
Slide 3
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 Hydration Process (Supplementary Cementitious Material)
 Primary CSH Gel

OPC + H2O + CaSO4.2H2O C-S-H + Ca(OH)2 + C3A.3CaSO4.32H2O + HEAT

Primary Gel
POROUS Portlandite Calcium Sulphoaluminate
Hydrate (Ettringite)

 Secondary C-S-H Gel Due to Pozzolanic Reaction

NetSCMs + Ca(OH)
effect of SCMs 2 + H2O
in Concrete: C-S-H
Secondary CSH Gel
DENSER
1. Grain-size refinement Capillary pores
Defective & oriented
Ca(OH)2 is replaced Water / Gas / Chlorides /
Sulfates
with smaller & less
oriented Ca(OH)2

2. Pore-size refinement Impermeable

Denser secondary CSH Concrete
Gel fills the porous
primary CSH gel
Unsegmented & Segmented of Capillary Pores
Slide 4 Net effect of SCMs in concrete in concrete
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 Long-Term Durability - Water to Cement Ratio

1 x 1 x 0.150 m RCC slabs (350 kg / m3)

were ponded with salt solution with
alternate wetting and drying for 5 years
Effect of water to cement ratio of concrete on Chloride
Penetration. Ref: R.N Swamy; A.K. Suryavanshi, S. Tanikawa, Basics for Durability
ACI Materials Journal (USA), Vol 95, No 2, March- April 1998, 1. Use of SCMs (Binary / Tertiary)
PP 101-112. 2. Lower Water / Cement Ratio
Sustainable concrete construction:3 Rs 3. Wet Curing
 Reduce: 4. Proper Consolidation at Site
- Reduce OPC (Limestone & Clay) & add SCMs 5. Impermeable concrete cover
- Reduce CO2 Emission: GREEN Concrete Design for Durability & Derive Strength Through
- Use High Strength Concrete with SCMs Durability Design & Not Vice Versa (Late Prof Swamy)
Green Concrete: Green
Slide 5 Use of Waterproofing compounds: ICING ON THE CAKE
in colour?
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 Environmental Friendly: CO2 Emission (Green House Gas)
I. CO2 Emission for Binary blend of Type I OPC + Fly Ash & Portland Composite Cement (PCC)
S.No. Embodied CO2 Emission for Cementitious CO2 Emission % Savings in CO2
Material (kg/Tonne) Compared to OPC
Type I
1 OPC Type 1 1010 ---
2 15% Fly Ash* + 85% OPC 876.3 13.2
3 Portland Composite Cement (PCC) - Normal 656.5# 29.35
* 4 kg CO2 per tonne of FA., # Emission by SCMs not included

II. CO2 Emission for Slag Cement (Binary blend of Type I OPC & GBFS)
S.No. Embodied CO2 Emission for Cementitious CO2 Emission % Savings in CO2
Material (kg/Tonne) Compared to OPC Type I

1 OPC Type 1 1010 ---

2 Slag Cement: Low Heat 413.7* 59.0

3 Slag Cement: General Purpose 427.4* 57.7

Slide 6
* For Slag 17.8 kg CO2 per tonne. GREEN HOUSE GAS EMISSION: SEA LEVEL RISE
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 Curing of Concrete at Site - Affects Quality of Cover
Objective of Curing: To avoid loss of moisture and to supply additional
moisture & maintain a favorable temperature of concrete Ponding, Wet Burlap,
Water Sprinkle, Wet
Initial Curing: Between Sand, Straw / Hay
Placement and Levelling
Fogging, Evaporation
Retarders, Wind Screen, Sun Curing Compounds
Shade Rigid
Plastic Cover – Without
Plastic Shrinkage & Wrinkles (Mottling)
Plastic Shrinkage cracks: Diagonal /
Settlement Cracks
Random & Zig Zag
Re-Trowelling, Re-Vibration Beginnings of
Strength Gain

Limits of Handling
Loss of Slump
  Initial Set Final Set

Cracks cut through the slab & follow

Slide 7
rebar steel
Name of Presentation I dd.mm.yyyy Settlement cracks: Follow rebar steel
 Curing at Site – Affects Durability of Cover
Termination of Curing at Site
Until the Concrete reaches
70% of the Target Strength
(ACI 301)
Vertical members: After the concrete has hardened loosen
the formwork ties and run down the water inside the
formwork and keep the concrete wet. After removing the
formwork wrap the element with water saturated fabric &
keep wet.
Ref: ACI 308R-19 Horizontal & Slopy members: Ponding, wet sand, cover
with water saturated fabric
Type of formwork / props Minimum period before striking
Vertical formwork to columns, walls & 1 day
large beams
Soffit formwork to slabs 3 days (Curing not possible)
Soffit formwork to beams and props to 7 days (Curing not possible)
slabs
Props to beam 9 days (Difflection cracks)

Slide 8 Plan for striking of formwork & props (CP 65: Part 1)
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 Consolidation of Concrete – Affects Durability of Concrete
Vibrator Radius of Vibrator
diameter action
(mm) (mm)
20-40 80-150
30-60 130-250
50-90 180-360 Pour Lines on Retaining
Wall lead to water
80-150 300-510 leakage
Overlapping circles
130-180
Poker 400-610
vibrator: Radius of action Poker vibrator to be vertical.
of influence (~100 mm) Horizontal vibrator promotes
Critical parameters: Head Diameter,
Frequency & Amplitude bleeding
1. Avoid vibrator touching the form face and reinforcement.
2. The layer depth should not be deeper than the vibrator head length.
3. Place vertical formwork on rubber pads to avoid loss of grout / vibration
4. When Vibrator is inserted into the concrete frequency drops,
then increases, finally becomes constant when concrete is free of
Entrapped air.
4. Stop Vibration when a sheen of water appears on the top; or no more air Poker vibrator not for moving
Slide 9
bubbles are emerging to the surface. the concrete (Segregation)
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 Setting Time of Concrete – Critical for finishing
PP: Proctor Penetrometer (A spring reaction probe)
Initial Setting Time: Resistance to Penetration = 3.5 MPa, or 500 psi
Final Setting Time: Resistance to Penetration = 27.6 MPa, or 4000 psi
Compressive Strength of Standard Cylinder at Final Setting Time = 0.7 MPa
Period for Transport, Placing &
Screeding / Bull Floating. Finish
the concrete only after Bleed
Water has disappeared. Transition Period-
Window for Final
Finishing before Bleeding Finishing.
affects Durability.
Power Floating Rigid
1. Results weakened zone Concrete with surface Bleed Water
below the surface. Stiff Concrete to
DELAMINATION support weight of
finisher / Machine Beginnings of
2. Tend to remix the water into
Strength Gain
the surface concrete
increasing the w/b ratio
causing DUSTING/ CRAZING PP
Limits of Handling
PP
Loss of Slump
Initial Set Final Set
  
Delamination of surface concrete as
a result of trapping of water beneath
Slide 10
the surface layer
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 Setting Time of Concrete

Early Demoulding: Lead to Repair of cover concrete.

Most of the time Repair is not on par with the original

quality of cover due to various reasons (Repair
Product & Workmanship) Ref: Significance of tests & properties of
concrete making materials. STP 169D. ASTM
Check the condition of field cured test specimen cast
using the same batch of concrete and placed next to
the element
SETTING TIME IN EXCESS OF 12 TO 16 HOURS

CONCRETE IS NOT GOOD

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 Bleeding of Concrete - Affect Durability Due to Weak Cover
Porous & weak concrete at the surface (Low Abrasion
Resistance, Crazing & Dusting)

Visible
bleed
water

Internal Concrete surface with foot marks: Do

bleed not walk on the surface. Use pump or
water cloth to push the bleed water

Crusted surface layer

Bleeding Water/ Air (Blister) formed
during finishing

During Power Floating due to trapped water beneath the surface hard layer
causes Blisters. To eliminate flatten the Trowel Blades, or open the surface
Sand Streaks on RCC Wall due to
Slide 12 with wood float.
Name of Presentation I dd.mm.yyyy excess bleeding
 Curing of Test Specimen – For Compliance Test

Various issues with Curing of Test

Specimens (Test cylinder fully soaked in
water with at least 1 inch of water above the
test cylinder).

Test cylinder failure due to improper curing

Slide 13
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lead to unnecessary Core Test.
Improper Capping of test cylinders also lead
to failure of concrete – Grind the ends of the
test cylinders
Relationship between the strength
development and age with different types of
curing. Ref: ACI 308 R-19
 Honeycombing – Lead to Porous Cover
Honeycombing refers to voids in the concrete caused due to mortar not filling
the spaces between the split (Lack of Subsidence). It becomes apparent after
stripping the formwork revealing “Stony” concrete surface with ACI 318
air voids between the split. Max size of split shall not be
Cause for Honeycombing greater than 3/4th the
1. Too large split size compared to Clear Cover. minimum clear spacing
2. Low slump which reduces compacting ability of the concrete. between individual bars
3. Insufficient vibration. Example: For 25 mm max size
Repair Method of Honeycombed Concrete Split the Clear Cover shall be
4. Isolate affected area by removing layer of honeycombed at least 33 mm.
concrete until good quality of concrete is visible.
2. Clean and remove all loose material & wet the cleaned area.
3. Fill the affected area by using non-shrink grout (≥ fc’ of
the parent concrete) after applying Bond Coat.
How to avoid Honeycombing of concrete?
4. Use concrete of workable slump.
Leakage of grout
2. For vertical elements & beams in addition to using internal
vibrator also tap the formwork using light hammer / rubber mallet.
3. If concrete of high slump or flow is used then ensure that there is no
Slide 14
leakage of grout at joints and corners (Tape the joints).
4. of Presentation
Name Use correct
I dd.mm.yyyy size of aggregates to match the Clear Cover and rebar spacing.
 Mass Concreting (Cold Joint, Leakage, Structural Integrity)
125 mm dai pipe.
START END
No plastic pipe Pump 1
3m
Segment I

Mesh Separator
Pump 2
Segment II

Mesh Separator
Pump 3
Segment III

PLACING OF CONCRETE FOR RAFT SLAB

Cold joint
1. Follow correct procedure & plan for placing the concrete to avoid Cold
Joint.
2. During unusual delays the concrete shall be kept alive by re-vibration.
3. Use different dosage of Retarders depending on the time of supply (Day
time, Night time, Peak Traffic hours).
4. Supply of concrete to be continuous with minimum disruption Cold joint on a Shear Wall
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 Mass Concreting
– Proper Casting Sequence to control thermal cracks
1. End-on-end form of construction, at least one free end to accommodate free movement

Segment No : 1 Segment No : 2 Segment No : 3

2. Avoid in-fill pours

In-Fill pours

Segment No : 1 Segment No : 2

3. Avoid in-fill pours between rigid Type of Exposure Allowable Crack

ends End constraint Width (mm)
Dry Air, or Protective Membrane 0.41
Humidity, Moist Air, Soil 0.30
Raft Slab Seawater / Sea Spray, Wetting & 0.25
Drying
4. Base of Raft Slab shall be lean concrete to Water Retaining Structure 0.10
allow easy thermal movement Guideline for crack widths (Ref ACI 224R)

Slide 16
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 Conclusions
1.Long-Term Durability can be achieved by following measures.
• By adopting lower water / binder ratio.
• By using Blended cements (PCC/ PPC / Slag Cement / Hydraulic Cement (SNI 8912)).
• By proper curing until the concrete reached 70% of the Target strength.
• By following correct procedure while compacting the concrete at site.
• By following proper construction practice to avoid defects in the Concrete Cover

2. Sustainability & Environmentally Friendly Construction can be achieved by

the following measures.
• By using Blended cements (PCC / PPC / Slag Cement / Hydraulic Cement (SNI 8912)).

Construction is not only for building

but for Durability, Environment &
Slide 17
Sustainability
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