Concrete admixtures

• Plasticizers and Superplasticizer

• Retarders
• Accelerators
• Air entraining agents
• Pozzoloanic or Mineral admixtures
• Curing compounds

1
 Plasticizers
• Water reducers • Anionic surfactants such as
• Organic, or combination lignosulphates and their
modifications and derivatives,
of organic and inorganic salts of sulphonates, hydrocarbons.
substances • Nonionic surfactants such as
• Dosage 0.1 to 0.4 % by polyglycol esters, acid of
weight of cement hydroxylated carboxylic acid and
• Entrained air which is not their modification and derivatives.
• Other products such as
more than 1 to 2 % carbohydrates etc.
• Calcium, Sodium, Ammonium
lignosulphonates are mostly used.

2
 Superplasticizers
• High range water reducers • Sulphonated malanie form
• aldehyde
Dose varies from 0.5 to 3 % by weight condensates
of cement
• They do not entrain air (SMF)
• • Sulphonated naphthalene
Reduction of water up to 15 to 30 %
formaldehyde (SNF)
• Modified lignosulphonates
(MLS)
• Other types

3
Suppliers for Plasticizer and Super
plasticizer
• Remicrete PC 10 – MYK SCHOMBURG
• Muraplast FK and MC-powerflow - MC-
Bauchemie (India) Pvt Ltd
• Conplast SP430- FOSROC (Liquid form)
(HRWR)
• Conplast P211M- FOSROC
• SikaPlast1000 ES – Sika India Pvt Ltd
• Hydraproof-SPL- Krishna Concare Private
Limited
• Ceraplast 300- Cera-Chem Private Limited 4
5
 Factors affecting the Site problems
workability of with the use of
concrete in case of use Superplasticizer
of Plasticizer or Super
plasticizer • Slump loss- Initial high slump,
Using Retarders, By repetitive
dose, By dosing at final point,
• Type of Plasticizer or By keeping temperature low,
By using compatible
Super plasticizer Superplasticizer
• Dosage • Problem with crushed sand
• Sequence of addition of
• Mix composition Superplasticizer
• Type of mixer
• Variability in cement • Importance of shape and
composition grading of aggregates
• Casting the cubes
• Mixing procedure • Excessive segregation,
Retardation
• Equipment 6
 Retarders

Applications Material
•
Most commonly used Calcium
1. Hot weather concreting
sulphate (Gypsum)
2. Grouting oil wells • Starches, cellulose material,
3. RMC Plants sugars, acids or salts of acids
4. To exposed the aggregates • Common sugar- 0.2 %
• Lignosulphonic acid and their
5. Concreting for joints salts, hydroxylated carboxylic
acid and their salts,Mucic acid,
calcium acetate.

7
 Suppliers for Retarders
• Conplast P 211, Conplast RP264, Conplast
SR – FOSROC (Liquid form)
• Plastiment® VZ, SikaTard® R - Sika India
Pvt Ltd
• CERAPLAST 300-RS G - Cera-Chem Pvt
Ltd
• DURASPRED R – Dura Build Care Pvt Ltd

8
 Accelerators

Application Material
• Permit early removal of • Calcium chloride- not more
formwork. than 0.4 %
• Reduced the required
• Soluble carbonates, silicates,
period of curing.
• Advanced the time that fluosilicates and some of the
which structure can be organic compounds.
placed in service.
• Cold weather concreting
• In emergency repair work
• Under water concreting

9
 Suppliers for Accelerators
• MasterSet AC 100 – BASF India Ltd
• MasterSet AC 534 - BASF India Ltd
• Conplast W – FOSROC (For un reinforced
concrete)
• FAIRCRETE W – FAIR MATE India (For un
reinforced concrete)
• DURASPRED A - Dura Build Care Pvt Ltd

10
 Air entraining agents
• Natural wood resin.
• Animal and vegetable fat oils such as tallow, olive oil
and their fatty acids such as stearic and oleic acid.
• Various wetting agents such as alkali salts or sulphated
and Sulphonated organic compounds.
• Water soluble soaps of resin acids and animal and
vegetable fatty acids.
• Miscellaneous materials such as sodium salts of
petroleum, sulphonic acids, hydrogen peroxide and
aluminium powder etc.

11
 Suppliers for Air entraining agents
• MasterAir AE 90- – BASF India Ltd
• KEM PLAST AEA 10 – Chembond
Chemicals Ltd
• DURASPRED AEA - Dura Build Care Pvt
Ltd
• Cebex 120 - FOSROC (Powder form)

12
 Factors affecting amount of air
entrainment
• Type and quantity of air entraining agent
• W/C ratio of the mix
• Type and grading of aggregate
• Mixing time
• Temperature
• Type of cement
• Influence of compaction
• Admixtures other than air entraining agent

13
 Effect of air entrainment on properties of
concrete

• Increased resistance to • Increases resistance to

freezing and thawing
• Improvement in workability
• Reduction in strength
• Reduces segregation and
bleeding.
• Reduces permeability
• Reduces alkali aggregate
reaction
chemical attack
• Reduces sand content, cost
and heat of hydration
• Reduces unit weight of
concrete
• Improves abrasion resistance

14
 Optimum air content in concrete
• Depends upon purpose for • Gravimetric method
which concrete is used, its • Volumetric method
location and climatic
conditions, maximum size of • Pressure method
aggregates, and richness of
mix.
• Usually ranges from 3 to 6 %
• lower air content for floors
• For surfaces exposed to
atmosphere 3 to 4 %
• For mass concrete 3%

15
 Mineral/Pozzoloanic Admixtures/Cement
Replacement Materials (CRM) or (SCM)

Mineral/Pozzoloanic admixtures

Reactive type Inert materials

Artificial Pozzolana
Natural Pozzolana 1. Fly ash - Up to 50 %
1. Clay and shale 2. GGBS – Up to 70 % 1) Finely grounded marble
2. Opalinc cherts 3. Silica fume – Up to 10 %
4. Rice husk ash
2) Quartz
3. Diatomaceous earth
4. Volcanic tuffs and pumicities 5. Metakaolin – Up to 15 % 3) Granite powder
6. Surkhi

16
 Concrete Mix Design Method for
RCC
• Step 1- Determine all the requirements related to properties of
concrete mix.
– Required strength and age
– Expected exposure time and condition
– Maximum size, source and material
– Admixture requirement
– Cementations material requirement
• Step 2 – Determine the essential properties of materials or
ingredients of concrete.
– Grading of aggregates
– Specific gravity of aggregates and cementitious materials
– Water absorption of aggregates

17
• Step 3 – Select suitable size of aggregates with proper grading.
Optimize coarse aggregate and sand proportion.
• Step 4 – Optimize aggregate proportion to achieve maximum dry
rodded density.
• Step 5 – Select the cementitious content and various % of cement
replacement by fly ash.
• Step 6 – Prepare the mix and cast cubes or cylindrical specimens for
testing strength and durability properties of concrete.
• Step 7 – Select mix proportion that satisfies desired parameters such
as require compressive strength at 3, 7, 28, 56 days, Flexural
strength, durability and imperability.
• Step 8 – Conduct the final mix proportion for suitability to various
fly ash sources, if supply of fly ash from one source becomes
insufficient during the construction.
• Step 9 – Carry out site effective mix design by adjusting aggregates
and water content for workability and admixture dose for retarding
setting, depending upon the time required for conveyance,
placement and compaction.
18
• Pulverized Fuel Ash (PFA) – Ash generated by
burning of ground or pulverized or crushed coal. It
can be fly ash, bottom ash, pond ash or mound ash.
– Fly ash- PFA extracted from flue gases by any suitable process
such as by cyclone separator or electro static precipitator.
– Bottom Ash- PFA collected from the bottom of the boilers by
any suitable process.
– Pond Ash- Fly ash or bottom ash or both mixed in any proportion
and conveyed in the form of water slurry and deposited in pond or
lagoon.
– Mound Ash- Fly ash or bottom ash or both mixed in any
proportion and conveyed or carried in the dry and deposited dry.

19
• Siliceous Pulverized Fuel Ash – PFA with
reactive calcium oxide less than 10 %, by mass.
Such fly ash are normally produced from burning
anthracite or bituminous coal and has pozzolanic
properties.
• Calcareous Pulverized Fuel Ash - PFA with
reactive calcium oxide not less than 10 %, by
mass. Such fly ash are normally produced from
burning lignite or sub-bituminous coal and has
both pozzolanic and hydraulic properties.
• As per ASTM, Siliceous Pulverized Fuel Ash –
Class F, Calcareous Pulverized Fuel Ash - Class
20
C
 Sampling of PFA for testing
• The method and procedure of sampling shall be in
accordance with IS 6491
• As per IS 3812 (Part 2):2003, the supplier shall afford
every facility, and shall provide all labour and materials
for taking and packing the samples for testing PFA and
for subsequent identification of PFA sampled.
• May be taken by
– Purchaser of his representative
– Or by any person appointed to superintend the work for
purpose of which PFA is required or by latter’s representative
• For testing refer IS 1727:1967
21
 Chemical requirements of PFA as per IS 3812
part II 2003
Sr. Characteristic Requirements
No.
Siliceous Pulverized Calcareous Pulverized
Fuel Ash Fuel Ash
1 Silicon dioxide (SiO2) + Aluminum oxide
( Al2 O3) + iron oxide (Fe2 O3) in 70 50
percentage by mass Min
2 Silicon dioxide (SiO2) in percentage by 35 25
mass Min
3 Magnesium oxide (MgO) in percentage 5 5
by mass, Max

4 Total Sulphur as Sulphur trioxide (SO3) 5 5

in percentage by mass, Max
5 Available Alkalis as Sodium Oxide 1.5 1.5
(Na2O) in percentage by mass, Max

6 Total chloride in percent by mass, Max 0.05 0.05

7 Loss on ignition in percent by mass, Max 5 5

22
 Physical requirements

Sr. Characteristics Requirement

No. values

1 Fineness -Specific surface in m2/Kg by 200

Blaine’s Permeability method, Min

2 Particles retained on 45 micron IS sieve 50

(wet sieving) in percent, Max

3 Soundness by autoclave test - Expansion 0.8

of specimens percentage, Max

23
 Delivery of PFA
• Supply can be in bulk by using wagon/truck or may be supplied in
bags bearing the net mass (may be 15 kg, 30 kg, 300 kg, 600 kg as
agreed to between the purchaser and supplier).
• Each bag/consignment should be marked with following
information
– Identification of the manufacturer of PFA
– Type of PFA
– Form of PFA
– Batch /Control unit number
– Net mass
– Month and Year of packing
– Any other identification mark as required by the purchaser
• Tolerance requirements for the mass of PFA packed in bags is as follows

24
• The number of bags in a sample showing a minus error greater than 2 % of
specified net mass shall not be more than 5 % of bags in a sample.
• Also the minus error in none of such bags in the sample shall exceed 4 % of
the specified net mass of PFA in the bag.
• The number of bags in a sample shall be as given below
Batch Size Sample Size
100 to 150 20
151 to 280 32
281 to 500 50
501 to 1200 80
1201 to 3200 125
3201 and over 200

• The bags in a sample shall be selected at random (Refer IS

4905).
• In case of a wagon or truck load of 5 to 25 tonne, the overall
tolerance on net mass of PFA shall be 0 to +0.5 percent. 25
 Storage of PFA on site
• PFA may be stored in accordance with the recommendations given
in IS 4082.
• Easy access for proper inspection and identification of each
consignment.
• Fly ash in bulk quantities shall be stored in stacks similar to fine
aggregates
• Fly ash in bags shall be stored in stacks not more than 10 bags
high.
• In case of bulk storage, the fly ash should be suitably covered to
avoid getting airborne.
• PFA in bulk storage for more than 6 months or in bags for more
than 3 months after completion of tests, may be re-tested before
use and may be rejected, if it fails to confirm to any requirements
of IS 3812 (Part 2) :2003. 26
 Benefits of addition of PFA in concrete
• Properties of fresh concrete
– Less w/c ratio
– Less segregation and bleeding
– Less heat of hydration
• Resistance to chloride attack
• Resistance to sulphate attack
• High resistance against alkali aggregate reaction
• Abrasion resistance
• Less permeability
• Resistance to corrosion of steel
• Resistance to freezing and thawing
27
 SCC used at Kaiga Atomic
Power Project, Karnataka
Material Mix
Cement 225 Kg
Fly ash 225 Kg
Water 165 Kg
Coarse 708 Kg
aggregate
Fine aggregate 982 Kg
HRWR- 1.8 Kg
Naphthalene (Glenium)
Viscosity 1.17 Kg 28
Modifier
 Satara- Kolhapur- Kagal Road, NH-4
• Fly ash used for Dry Lean Concrete (DLC) and
Pavement Quality Concrete (PQC)
• 20 - 25% cement replaced by fly ash
• 7865 tonnes of fly ash used
• 56 days strength used as criteria for acceptance
• Actual composition of mix:
- OPC 292.5 kg plus fly ash 97.5 kg
- Coarse aggregates 1290 kg
- Fine aggregates 775 kg
29
 Satara- Kolhapur- Kagal Road, NH-4
Fly Ash Concrete Pavement- Strength
• 28 days cube specified 40 MPa, actual 54 MPa
• 56 days cube specified 40 Mpa, actual 62 MPa
• Flexural strength
- Specified 4 MPa at 28 days
- Actual 5.9 MPa at 28 days
6.5 MPa at 56 days
• Benefits : Improved workability
Decreased permeability
More economical
30
 Use of Fly Ash
Bandra Worli Sea Link Project
• Various percentages of fly ash used for different
components based on mix design
• Pile cap 33% of cement replaced
• Pier 25% - do –
• Cable stay tower 25% - do –
• Tremie seal 55% - do –
• Made possible by on site addition in batching
plant; would not have been possible with PPC
31
 Oxide composition of cement clinker, fly ash
and GGBS
Sr. No. Constituents Percentage content
Cement clinker Blast furnace slag Fly ash
(IS 12089- 1987)
1 Lime CaO 60-67 30-45 1.0-3.0

2 Silica SiO2 17-25 30-38 35-60

3 Alumina Al2O3 3.0-8.0 15-25 10-30

4 Iron Oxide Fe2O3 0.5-6.0 0.5-2.0 4-10

5 MgO 0.1-4.0 4.0-17.0 0.2-5.0

6 MnO2 ----- 1.0-5.0 ---------

7 Glass ------ 85-98 20-30

8 Sp. gravity 3.15 2.9 2.1-2.6

32
 Vizag Sea Port
Multipurpose Berths EQ 8 & EQ 9
• GGBS extensively used for various components
such as piles, pile caps, diaphragm walls and
superstructure
• About 75000 cum of concrete, using GGBS as
mineral admixture, replaces 70% of cement
• GGBS sourced from RINL Vizag; Andhra
cements did the grinding, packing and
marketing
33
 Vizag Sea Port
Concrete Mix Grade M40
• Cement (30%) : 123 kg
• GGBS (70%) : 287 kg
• Total Cementitious material: 410 kg
• Water : 135 kg
• Admixture : 3.5 kg
• a/c ratio : 4.70
• w/c ratio : 0.33

34
 Use of GGBS in India- Other Cases
Project Concret OP GGB
e grade C % S %
Construction of marine jetty for
Chennai Port Trust at Ennore M45 30 70

Construction of 7 km long
concrete road into the sea for M26 50 50
Chennai Port Trust at Ennore
Hi-Tech city in Hyderabad M50 50 50
Construction of Bharat Forge M30
factory in Pune 70 30

Vizag Port Trust M45 60 40

35
 Silica fume/Microsilica/CSF
• Undensified form with bulk density
200 - 300 Kg/m3
• Densified form with bulk density
500- 600 Kg/m3
• Micro palletized form with bulk
density 600 -800 Kg/m3
• Slurry form with bulk density 1400
Kg/m3
• It must confirm the requirements of
IS 15388 –2003 or ASTM C 1240 -
2000
• Dosage 5-8 % of cement
• Fed into batching plant as powder;
alternatively can be mixed with
water and fed.
• At least 85% of silicon dioxide in
non crystalline form.
• Particle size with diameter in
between 0.1 to 0.2 micron which
is 100 times finer than cement
particle.
• Min specific surface area is 15000
m2/kg
• Spherical particle shape
• Ultrafine spheres fill gaps between
cement grains, resulting in dense,
impermeable, durable concrete
• Sp. Gravity 2.2
In India marketed by Elkem
metallurgy Ltd. Vashi Navi
Mumbai, M/s Mc-Bauchemie Pvt
Ltd under the trade name Centrilit
fumes (Slurry form) 36
 Silica Fume
(CSF)

Silica-Fume Slurry

Silica fume powder samples 37

 Silica fume/Microsilica/CSF
• Water demand increases with addition of silica
fume for 1 % of cement replaced with 1 % of
silica fume. Overall in concrete with max of 20
mm aggregate particle size, addition of 10 % of
silica fume will have increased water demand of
about 20 lit/m3.
• Produces concrete with zero bleeding.
Precautions are required to avoid development
of plastic shrinkage cracks.
• Special curing is required. 38
 Use of Silica Fume
Important Structures in India
• Bandra Worli Sea Link 8000 t
• Tehri hydel project 4500 t
• Tall hydel project 4200 t
• MSEB Mintudu 2200 t
• Automic Power Project 3850 t
• JJ flyover 1100 t
• Ship uplift Pr Karwar 990 t
• High rise buildings 3000 t
• Industrial floorings 530 t 39
 Characteristic strength 60 Mpa
Target strength 74 Mpa
Cement 320 kg
Micro silica 45 kg
Fly ash 80 kg
w/c ratio 0.31
Admixtures 10 kg
Slump 120 mm
28 day strength 75 Mpa

Bandra Worli Sea link 40

 Bandra-Worli Sea Link
Details of Concrete Mixes
Tremie Pile CS
Structure Pile Pier Deck Miscellaneous
Seal Cap Tower

Concrete Grade M50 M30 M60 M60 M60 M60 M30

W/C Ratio 0.33 0.34 0.31 0.3 0.31 0.29 0.4

OPC 400 180 300 320 320 420 400

Microsilica 40 0 40 40 45 42 0

Flyash 0 220 100 80 80 0 0

Cement+ Mineral
440 400 440 440 445 462 400
admixture

41
 Rice Husk Ash
• Produced by burning rice husk at controlled
temperature, contains large proportion of silica
• Essentially consists of amorphous silica (90 %
of SiO2).
• Particle size 25 micron
• India produces around 125 MT of paddy every
year. Each tonne of paddy produces around 40
kg of RHA.

42
 Rice husk ash

Characteristics Supplementary Cementitious materials

• Silica 85 % min Silica fume Metakaolin RHA
• Moisture content 2 %
Silica 90-94 48-55 92
max
• Alumina 1-3 40-45 0.5
Colour grey
Iron oxide 1.5-2.5 1-2 0.2
• Ph value 8
Lime 0.5 2-4 0.5
MgO 1-3 0.12-1 0.5
Alkalies <2 < 0.5 2-4
Fineness m2/g 25-27 15-20 20-25

43
 Metakaolin
• Manufactured in factory by using Kaolin clay.
• The product is easily available in India and
extensively used by paint and paper industry.
• Production process involve dehydroxylization
or sometimes called as calcining.
• ASTM C 618. IS 456:2000 recommends the use
of metakaolin in concrete.
• 5 to 15 % of cement can be replaced by using
metkaolin.
• Cost of this material is 50 % less as compared to
cost of Silica fume. 44
 Metakaolin
• Applications: Production of
– High performance concrete
– High strength concrete
– Glass fiber reinforced concrete
– Structural concrete
• Effects of addition of metakaolin
– Increases compressive and flexural strength of concrete
– Reduces permeability
– Increases resistance to chemical attack
– Increases resistance to alkali aggregate reaction
– Reduces shrinkage
– Improves finishability, colour and appearance
45
Surkhi / Calcined clay pozzolana

IS 1344 1981 For use in mortar/ concrete

IS 1727 1967 Testing of material

46
Defects in concrete due to
inadequate curing

47
 Curing of concrete
• Water curing – Immersion, • Specification
ponding, spraying, wet covering. • Availability of curing
• Membrane curing- Bituminous,
materials
polyethylene or polyester films,
rubber compounds etc. • Economics
• Application of heat- Steam • Type of concrete
curing at ordinary pressure, High structure
pressure steam curing, Infrared
• Shape and size of
radiation, electrical curing.
• Miscellaneous-Use of calcium concrete surface
chloride, formwork coating. • Aesthetic appearance

48
49
 Curing Compounds
• Mainly used to avoid evaporation of water from
concrete surface.
• Suitable for structures located in area where
scarcity of water is there or where continuous
supervision is not possible.
• The are suitable for concretes where w/c ratio is
more than 0.38.
• It is necessary to apply curing compounds only
after 2 to 3 days of water curing.
50
 Curing compounds
• Curing compounds are broadly classified as
– Synthetic resin
– Wax
– Acrylic
– Chlorinated rubber
• Resin and wax compounds form the film on concrete surface and
there efficiency reduces as time increases. After 28 days they get
disintegrated or pilled off from the surface. Test results shows
that there efficiency will be 96 % for 24 hrs, 84 % for 72 hrs, 74
% for 7 days, and 65 % for 14 days. The overall efficiency of
these products will be 80 %.
• Emcoril AC from MC-Bauchemie,

51
• Acrylic base curing compounds will have better adhesion
with the subsequent plaster. Hence suitable for walls
where plastering needs to be done.
• The membrane doesn’t crumble down or it need not to be
washed with hot water.
• Chlorinated rubber compounds not only form the film on
concrete but also fill the pores which are present in surface
of concrete. The surface film will wear out eventually.
• BIS codes are not available hence agencies can refer codes
like
• ASTM C 309 of 80 Liquid membrane forming compounds for
curing concrete
• ASTM C 156 of 80 a Water retention by concrete curing
materials
52
 Application Procedure
• Can be applied by brush or by spraying.
• Need to applied only after drying of bleeding water.
• Incase of beam, column they need to be applied
immediately after removal of formwork.
• Incase of road pavement where texturing is required,
curing compounds must be applied immediately after
texturing.
• Before applying the curing compound make sure that
surface should be damp.
• The container need to be well stirred before use.
• Liquid membrane forming compounds need to be applied
in 2 coats. 53