ADMIXTURE FORMULATIONS FOR RCC DAMS

Background

Roller Compacted Concrete (RCC) dams constitute a unique methodology of construction. The
concrete is placed in 300 mm layers. The height is achieved by placing layer-by-layer. Rollers
and vibratory rollers are then used to compact one layer over another. This is a critical step.

The concrete mix design is very lean and consists of < 200 kg/m3 of cementitious. The concrete
looks very dry as it comes out of the mixer. The requirement for strength is typically 15 MPa in 6
months. . In Roller Compacted Concrete dam projects, classical ASTM C494 Type B retarding
admixtures are used. Air entraining agents have been used where freeze-thaw durability is an
issue. There are also instances where water-reducing admixtures have been specifically
developed to reduce the compaction time and also improve compaction. This is called Vis-RCC
developed by BASF in China. For example, the estimated time between the placement of
subsequent concrete layers, determine the setting time performance properties needed for
smooth and continuous operations.

Performance Requirement

- Initial setting time at ~20-24 h and final setting time at 30-48 h. This time is determined
by the time it takes to produce concrete and transport it to the placement, plus the time it
takes to compact. A retarding admixture has to be tested to see if it meets these
conditions.
- The concrete mixture should not bleed over time. This then delays the use of rollers and
therefore can be an issue, especially when the ambient temperatures are below 10 C.
- If the next layer is placed after final set, cold joints will develop. This has to be avoided at
ANY COST as it directly impacts durability and can cause leakages in dams. Hence the
final setting time is crucial.
- Temperature variations need to be considered when designing an admixture on its effect
on setting times. Wind conditions can also impact the concrete and therefore
compaction.
- VeBe is a crude measurement of compaction under vibration. A Vebe of 8-15 sec is
generally expected of the mix. However, we have not found this to be a useful
measurement.

How should you formulate ?

- Typically the mix design is provided. If not, one can start with the design provided below
in the table.
- A typical product used is Delvo Stabilizer. This is a good product to start with.
- For inexpensive formulations once can use combinations of sucrose, glucose, gluconate,
Amino tris-methylene phosphonic acid, phosphates, dextrin. Sucrose is the most
effective retarder.
 - Start with a retarder product used in your area. Develop %dosage versus setting time
data. This data should be ideally derived at extreme temperatures expected at the site.
Observe for bleed water.
- If bleed is significant, use lignosulfonate in your formulation. A VMA might also help.

Figure 1 - RCC Dam in India

Formulation used in RCC Dam in India – TLDP IV on Teesta River

Master Pozzolith 425 (IN)

RM %
Water 66.8
Glucose (70%) 25
Sod. Lignosulfonate 3
Sucrose 5
Preventol D7 0.2

Explanation of the Raw Materials used in this Formulation

This formulation was specifically developed for a RCC dam in North-Eastern India on the river
Teesta. The temperatures varied between 5°C - 28°C. Glucose, Sucrose are traditional
retarders. Glucose was chosen being a little less sensitive than sucrose to dosage in concrete,
especially at lower temperatures. Considering that the temperature would swing even during a
day, it was critical to prevent excessive retardation especially at low temperatures. Sodium
lignosulfonate was merely to provide color to the admixture. Preventol D7 is a biocide containing
CIT/MIT.
Impact of Retarder Dosage on Setting times and Compressive strengths

Vee
Cement Flyash Initial Final 3 14 28 180 365
MasterPozzolith bee
Content, Content, w/b set** set** Days days Days Days Days
425IN (% cwt) time
(kg/m3) (kg/m3) (Hrs.) (Hrs.) (MPa) (Mpa) (MPa) (MPa) (MPa)
(sec)
85 135 0% 0.57 12.0 10.7 23.0 4.0 5.7 8.2 17.3 20.2

85 135 0.25% 0.57 13.5 20.7 31.2 3.3 4.9 10.3 16.0 20.1

85 135 0.35% 0.57 8.5 21.2 30.7 5.6 9.3 12.0 15.1 17.7

85 135 0.40% 0.57 9.0 21.2 32.3 5.8 9.4 11.5 15.4 17.4

85 135 0.45% 0.57 9.0 33.0 44.0 3.4 8.1 11.2 15.7 17.1
** Fresh Concrete Temperature 17 ˚ C. Laboratory testing for RCC dam containing Fly ash as a
supplementary cementitious material. 50 MSA, Mixes carried out with 38.6 % OPC and 61.4 % Fly
ash, replacement.

This data is from the Teesta Lower Dam Project in India where MasterPozzolith 425(IN) was used.
MasterPozzolith 425(IN) contains Sucrose(5%) and Glucose(25%).