2014)
Principal Consultant, Ready-Mixed Concrete Manufacturers Association (RMCMA) Former President, Indian Concrete Institute (ICI) Former Editor, The Indian Concrete Journal (ICJ)
* Views expressed are not necessarily those of RMCMA or ICI
Broad Outline
Concrete Industry Scenario Role of Production Control System influencing durability Recent up-gradation of Production Control Criteria Properties of ingredients affecting durability Some Live examples of customer-specified mixes Use of SCMs: Code-specified Limitations Recent changes in IRST and IRC Standard specifications Laboratory Data on RCPT & Strength Conclusion Future
Delhi
2012-13 2017-18
7.5% 10%
Assumptions Production figures include concrete produced from all sources using modern batching and mixing plants (commercial and captive plants) Concrete production figure is calculated by assuming that the average cement consumption is 300 kg/m3
Source: ERMCO * Not authentic; contains organized concrete industry data collected from private sources.
RMC: A Mockery?
Intermixing of Aggregates
Calibration
Accuracy and sensitivity of weighing devices
Tolerances specified in IS 4926
Cement & SCMs:
2 percent of the quantity of constituents being measured
U.K.
Canada
Turkey
1. 2.
1. 2.
10
15
20
25
30
0
18 25 28 15 9 3 4 2 1 12 2 1 19 1 4 4
(March 2012)
3 8 2 3 1 3 1
Efforts in Enhancing Production Control Criteria Multi-stakeholder Ownership Auditing: Completely Independent character RMCMA signs MoU with QCI on Dec. 11, 2011 to develop a New Quality Scheme
What is QCI ?
Established under Cabinet decision in 1996, formed in January 1997 Registered as a non-profit autonomous society Joint initiative of the Government of India, and the Indian Industry, represented by :
Associated Chambers of Commerce and Industry of India (ASSOCHAM) Confederation of Indian Industry (CII) Federation of Indian Chambers of Commerce & Industry (FICCI)
QCI: Objectives
Establish and maintain an accreditation structure in the country Provide right and unbiased information on quality related standards Facilitate upgradation of equipments and techniques related to quality Spread quality movement in the country through National Quality Campaign Represent Indias Interest in International forums Help establish brand equity of Indian products and service
Technical Committee
Two Schemes Ready-Mixed Concrete Plant Certification Scheme (RMCPCS) RMC Capability Certification: A Must
Who are Qualified to Certify RMC Plants? Bureau Veritas Certification (I) Pvt Ltd (BVCI) ICMQ India Tata Projects Ltd.
Control on quality of incoming materials Concrete design Production and delivery Control on process control equipments and maintenance Complaints Feedback Section B Check List (182 Item ) Tables Table No 1 to 11
Resource Management
Resource Management
Laboratory
Key Personnel
Operational Skills
Batching Equipment
Central Mixer
Specific Knowledge
Test on Concrete
IS 2386- Part III one each for C.A. and F.A. one no. one no.
Fly ash
GGBS
Silica fume
IS 15388
Water
All code-specified tests before finalization of source BIS conformity tests once in six month or when source changed Non-mains water: Initially every week for first 6 weeks and then at 3-monthly internal Mains water: Annual basis once all tests for source are satisfactory All IS-specified tests during selection of source or change of source Minimum tests in plant lab Other tests at NABL-accredited lab at IS-specified frequencies
b) IS 1199
c) IS 1199 d) IS 1199
Hardened concrete
a) Compressive strength * a) At least one sample for every 50 m3 of production or every 50 batches whichever is of greater frequency * IS 516
# optional test (if specified) * One sample involves casting of 3 specimens of 150x150x150mm size, to be tested at 28 days.
Key Personnel
Key personnel to be competent, adequately qualified and trained Basic knowledge in concrete technology essential QC in-charge to have degree/diploma in civil engineering with min. 3 years of experience Lab Technicians to have knowledge and skills in sampling and testing Identification of gaps in knowledge and efforts in training personnel
U. K.
18 years 16 years
India
6 years 5 years
Dredging restrictions on sand from natural sources Industry constrained to use Crushed Stone Sand (CSS) What constitutes CSS?
IS 383 definition of CSS
IS 383 draft revision (2014) introduced one more term - Blended sand
Fine aggregate produced by blending natural sand and crushed stone sand or crushed gravel sand in suitable proportions
100 80 60
Paradeep, Orrisa
Min.
40 20
Min.
0.15
Max.
0.15
Max.
R. SAND R. SAND
120 100 80 60 40 20 0 10 4.75
Min. Min.
Max. Max.
CSS CSS
120 100
R. SAND
Min.
Max.
CSS
Hospet, Karnataka
Max. Min.
Min.
0.15
Max.
2.36
1.18
0.6
0.3
0.15
R. SAND
Min.
Max.
CSS
(1) (2) i) Coal and Lignite ii) iii) iv) v) vi) Clay lumps Materials finer than 75- IS Sieve Soft fragments Shale Total of percentages of all deleterious materials (Except mica) including Sl. No. (i) to (v) for Col 4,6,7 and Sl. No. (i) and (ii) for Col 5 only.
(3) IS: 2386 (Part II) IS: 2386 (Part II) IS: 2386 (Part I) IS: 2386 (Part II) IS: 2386 (Part II) ----
FINE AGGREGATE PERCENTAGE BY WEIGHT, Max Uncrushed Crushed (4) (5) 1.00 1.00 1.00 3.00 ---1.00 5.00 1.00 15.00 ------2.00
COARSE AGGREGATE PERCENTAGE BY WEIGHT, Max Uncrushed Crushed (6) (7) 1.00 1.00 1.00 3.00 3.00 ---5.00 1.00 3.00 ------5.00
NOTE 1 -The presence of mica in the fine aggregate has been found to reduce considerably the durability and compressive strength of concrete and further investigations are underway to determine the extent of the deleterious effect of mica. It is advisable, therefore, to investigate the mica content of fine aggregate and make suitable allowances for the possible reduction in the strength of concrete or mortar. NOTE 2- The aggregate shall not contain harmful organic impurities [tested in accordance with IS:2386 ( Part II )- I963 ] in sufficient quantities to affect adversely the strength or durability of concrete. A fine aggregate which fails in the test organic impurities may be used, provided that, when tested for the effect of organic impurities on the strength of mortar, the relative strength at 7 and 28 days, reported accordance with 7 of IS : 2386 (Part VI )-1963 is not less than 95 percent.
Microfine Content
Research Report ICAR 102-1F Good quality concrete can be made with
amounts of microfines (particles passing 75 sieve) as high as 15%. In fact, most of the concrete made with MFA in both projects surpassed the concrete made with natural sand in terms of strength, resistance to chloride ion penetration, and abrasion*
Limits of Deviations
Sieve size, mm 9.5 4.75 2.36 1.18 0.6 0.3 0.15 0.075 Maximum deviation, % 5 10 15 15 10 5 3
IS 3812 requirement
% retained on 45 micron sieve
50 40 30 20 10 0
30 25 20 15 10 5 0
20 20
25
25
25
25
w/b ratio
OPC, kg
380 300 380 290 380 400 315
Fly ash, kg
100 (25%) 90 (24%) 65 (17%)
Total cementitious, kg
380* 400* 380* 380* 380* 400* 380*
Mumbai
Not specified Not specified Not specified Not specified Not specified 0.48 Not specified
w/b ratio
OPC, kg
Fly ash, kg
40 (9%) 95 (23%) 50 (11%)
Total cementitious, kg
350* 400* 400* 390* 400* 420* 430*
Mumbai
Not specified Not specified Not specified Not specified Not specified 0.44 Not specified
w/b ratio
OPC, kg
Fly ash, kg
90 (19%) 95 (19%) 73 (17%) 90 (19%) -
Total cementitious, kg
450* 480* 490* 438* 420* 480* -
Mumbai
Not specified Not specified Not specified Not specified Not specified Not specified Not specified
Mix Optimization Currently, little freedom given to RMC players to optimize mixes even for strength - leave apart durability Result: Uneconomical mixes devoid of durability and sustainability Shrinkage cracking owing to higher cement and water contents Usual blame goes to RMC producer
Customer
RMC Producer
Improving Durability through Enhanced utilization of SCMs Code-specified Upper Limit on SCMs
Pozzolanic materials like fly ash (conforming to IS 3812) 35%
Slump, mm 160
170
170
32.31
340
140 120 100 80 60 40 20 0
0.44
57 7 day
100
112
136
28 day
56 day
90 day
Compressive strength
44.64 42.26
200 160 120 80 40 0 7 day 28 day 56 day 90 day 72 61 100 100 115 143 169 122
90-day
Permeability test shall be mandatory for all RCC/PSC bridges under severe, very severe and extreme environment The depth of penetration shall not exceed 25mm
RCPT value shall be less than 800 coulombs. Additional durability tests, such as, Water Permeability test as per DIN: 1048 Part 5-1991 or Initial Surface Absorption test as per BS:1881 Part 5 can also be specified. The permissible values in such tests shall be decided taking into account the severity of the exposure conditions.
40 45 50 75
Acceptance criteria
To be arrived at prior to testing
In spite of other developments, it is likely that this test (RCPT) will remain as an index test for permeability for many years to come*
* Hearn, N, Hooton, R. J, and Nokken, M. Pore structure, permeability and penetration resistance characteristics of concrete.. Significance of tests and properties of concrete and concrete making materials, ASTM STP 169D, ASTM International, 2006, pp. 237-252.
4000
28-day RCPT Values and Compressive strength for different replacement levels of OPC by Fly Ash
50
40
2275
20
1500 1000
10
500 0 0 35 40 45 50 60 70
28-day RCPT Values and Compressive strength for different replacement levels of OPC by Fly Ash
Conclusion
When ordering concrete, it will be appropriate to specify:
Third-party production control criteria and certification Exposure conditions Higher % utilization of SCMs Allow freedom to RMC supplier to optimize concrete mixes to achieve desired strengths and durability Provide incentives for producers optimizing mixes for strength and durability Specify durability tests and permissible limits
Future
Evolve Guidelines Document for specifying durability (on lines of ISO 22965 Part I and II*)
New definition of exposure classes Properties of concrete constituents including their uniformity requirements Encourage increased utilization of SCMs for enhancing durability and sustainability Upgraded production control criteria Durability requirements including conformity criteria for different tests Encourage service life design and specify service life requirements
* ISO 22965-1, Concrete Part 1: Methods of specifying and guidance for the specifier * ISO 22965-2, Concrete Part 2: Specification of constituent materials, production of concrete and conformity of concrete
Thank You!
RCPT Shortcomings
Current passed is related to all ions Measurement made before any steady state migration is achieved High voltage may increase temperature Presence of fibers, calcium nitrite increases the value of coulombs