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Self Compacting Concrete for the

Tallest Building in India

S.A. Reddi Value Engg. Consultant

Dy MD (Retd), Gammon India Ltd

ACECON, IIT- Madras 07 Dec,2010

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SCC in Palais Royale, Mumbai

320m tall residential green building, Mumbai

Columns earlier designed with 60 MPa concrete& Fe 415 reinforcement; large size of columns,

congested reinforcement not accepted80 MPa Self Compacting Concrete (SCC) withFe 500 reinforcement to reduce congestion

SCC enabled concreting without vibration80 MPa concrete reduced column sizes

About 30% reduction in cost of columns

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Why High Strength SCC ?

Reduced water content, adding mineral

admixtures modify the micro-structure of conc

Reduced water content results in decreased

porosity, refinement of capillary pores in matrix

Water content ranges between 120 150 ltrs

per m3 of concrete; flowability ensured by

adding PC based super plasticizer

M 80 SCC ( first time in India ) reduces space

occupied by columns, increases floor area

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Self Compacting Concrete

Impact on LEED Rating

In the fresh state SCC ensures flowability and

pumping qualities, reduces segregation,

bleeding and plastic shrinkage

Concrete containing fly-ash enables reduction

in cement content, helps in Green Rating

21 of the min 26 points reqd for LEED Certifi-

cation realized by appropriate use of concrete

Palais Royale, Mumbai is a Platinum Rated

Construction.

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High Strength SCC for High Rise Buildings

International Experiences

Trump Tower Hotel, Chicago used SCC for the

foundation raft and columns in certain regions

High Strength SCC up to 110 MPa (Cylinder)

3800 m3 SCC pumped in 24 hours for the raft

30 different concrete mixes used; mixes contain

different %ages of super plasticizers, differentamounts of cement, fly-ash, slag, silica fume

SCC mix has max aggregate size of 10mm

Modulus of Elasticity tested thoroughly

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Palais Royale Tower, Mumbai

Brief Description

Height : 320m Tallest in India (2008)

Foundations : Raft, upto 3.5m thick, Grade M40

- Basements, Superstructure

- Columns : SCC M80, M60- Slabs, Beams : M60 Concrete

- Pre-tensioned flat slabs at lower levels

Basement + 80m height utilized for car parks, sportsfacilities, Building Management Systems (BMS)

Precautions against Fire & Fire Fighting measures

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320m Tall Palais RoyalePlatinum Rated Green Building, Mumbai

Extensive use of natural light, ventilation, wind

mill for power, solar panels for hot water

Wind tunnel tests for the tall structure and for

interference from neighboring high-rises

Structural design proof checked by US

Consultants

Separate Consultants for BMS, Services,

Electrical, Acoustic, Lift, Environment, Fire,

Windows, Faade, Waterproofing, Waste Mgt

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Materials for SCC

OPC 53 Grade from selected factory

Processed fly-ash from Nashik

Silica Fume imported / MetakaolinPC based super plasticizer imported

Coarse aggregates from local quarries

Fine aggregates from Gujarat / Crushed Sandfrom Local Sources

Water from local sources

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Mix Proportioning, Trial Mixes

Trial Mixes from April 2007 onwards

No Ready Mix Supplier willing to provide SCC

80 Mpa Grade ; Concrete mixed at site

Cement content limited to 400 Kg. per m3

Processed Fly-ash : 200 Kg.

PC based super plasticizers : 0.8 1.2 %All trial mixes conducted at site, with concrete

produced by computer controlled batch plant

Slump flow : 700 800mm

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Sensitive to small changesSCC is much more sensitive to small changes

in materials, mix proportions & production

variables than conventionally placed concrete;

the potential consequences can be severe

Control of workability critical; If the slump flow is

less, there is no opportunity to vibrate; if more,

SCC significantly increases the potential forsevere segregation

Engineers at site specially trained

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Test MethodsFilling Ability evaluated by slump flow test

Passing Ability evaluated with the J ring test

Segregation Resistance with the columnsegregation test

These tests are conducted during mix

proportioning stage; once the mix is approved,only slump flow and T50 tests are continued

during actual production

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Modulus of Elasticity ACI 237R

Related to compressive strength, aggregate type and

content, and unit weight of the concrete

Adjustments in mix proportions, will influence the

elastic modulus of the SCC

For equal compressive strength, the elastic modulus

of SCC can be as much as 10 to 15% lower than that

of conventional concrete of similar compressivestrength due to the required adjustments of mixture

proportions to make SCC

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Modulus of Elasticity

Site TrialsA Large no of trials conducted at the site

laboratory

The values varied in the range of 30-50 gPa

The structural designs re-evaluated

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Mock up Trials for Segregation

Full scale mock ups conducted with different

levels of free fall of concrete

With free fall more than 0.5 m, segregation

noted ; The top half of the column consisted

only mortar

Free fall restricted to less than 0.5 m

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Aesthetics

SCC provides improved surface appearances

and aesthetics in finished concrete.

Pour lines, bug holes, honeycombs, and other

surface imperfections are largely reduced

The fluidity of SCC and the elimination of

vibration will result in improved aesthetics

Selection of form-release agents is important in

achieving the desired smooth finish.

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Choice of AdmixturesAlways include PC based super-plasticizer;

Viscosity Modifying Agent (VMA) optional

Aim at reasonable Workability Retention (max.

one hour from the time of mixing)

Evaluate suitability of dosage in lab & product-

ion trial batches; dosage adjusted to reach

target slump flow once the mix is proportioned

As PC based admixtures are generally tailor-

made, uniformity & quality should be ensured

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Cement ContentCement content should be minimized; powder

content composed of mineral admixtures such

as fly-ash, GGBS etc.

SCC in Nuclear Power Projects in India,

cement limited to 250 Kg/m3 ; and fly-ash also

250 Kg/, m3 for concretes up to 50 MPa

For 80 MPa concrete, mix successfully

designed with cement content not exceeding

350 Kg/m3

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Should not be VibratedVibration not needed for SCC, it may be

detrimental; vibration damages the three

dimensional structure.

Works Cube Test : The concrete should be

filled in one layer for the full height of the cube

mould; the sides of the mould may be lightly

tamped with a wooden mallet; otherwise noother form of vibration should be attempted

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Transit mixer

SCC delivered to a job site by concrete truck

. Because of the fluidity of SCC mixes the

volume of SCC placed into a truck should not

exceed the 80% capacity of the drum (ASTM C

94/C 94M).

Monitoring is important to ensure that SCC does not

spill out of a concrete truck (rear or front discharge)whenever the truck goes up or down a steep

incline.

S lf C ti C t

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Self Compacting ConcretePilot Test Batches (Production Conditions)

Conduct full-scale production trial batches

(mock-ups) for each proposed SCC mix, to

verify filling ability, passing ability and

segregation resistance

Visually observe concrete flow around

reinforcing bars and the lack of honeycomb,

aggregate or mortar pockets, surface air void

The elements should have similar dimensions,

reinforcement configuration as the work

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1ST LEVEL [14] SKY APARTMENT

2ND LEVEL [15] SKY APARTMENT

3RD LEVEL [16] SKY APARTMENT

4TH LEVEL [17] HACIENDA APARTMENT

6TH LEVEL [19] 1ST REFUGE FLOOR

[12] GIRDERLEVEL

[9] 1STAMENITY

[10] 2ND AMENITY

[11] 3RD AMENITY

[13] SERVICE FLOOR

[2] PODIUM1

[3] PODIUM2

[4] PODIUM3

[5] PODIUM4

[6] PODIUM5

[7] PODIUM6

[8] PODIUM7

13THLEVEL [26] 2NDREFUGE LEVEL

2NDSERVICE LEVEL24THLEVEL [37] 1STSKY VILLA LEVEL

3RDSERVICE LEVEL

4THSERVICE LEVEL




9TH LEVEL [22] SKY APARTMENT

10THLEVEL [23] SKY APARTMENT



14THLEVEL [27] HACIENDA APARTMENT




18THLEVEL [31] 3RDREFUGE LEVEL



21STLEVEL [34] HACIENDA LEVEL

22NDLEVEL [35] HACIENDA APARTMENT

23RDLEVEL [36] 4THREFUGE LEVEL

25THLEVEL [38] 2NDSKY VILLA LEVEL

26THLEVEL [39] 5THREFUGE LEVEL


28THLEVEL [41] 3RDSKY VILLA LEVEL

T LE EL + 1 .

LVL02 +10.9

LVL03 +15.1

LVL04 +19.3

LVL05 +23.5

LVL06 +27.7

LVL07 +31.9

LVL08 +36.1

LVL09 +44.5

LVL10 +52.9

LVL11 +69.7

LVL12 +78.1

LVL13 +82.3

LVL14 +86.5

LVL15 +90.7

LVL16 +94.9

LVL17 +101.8

LVL18 +108.7

LVL19 +115.6

LVL20 +122.5

LVL21 +129.4

LVL22 +136.3

LVL23 +140.5

LVL24 +144.7

LVL25 +148.9

LEVEL +285.5 0M

LVL26 +153.1

LVL27 +160.0

LVL28 +166.9

LVL29 +173.8

LVL30 +180.7

LVL31 +187.6

LVL32 +194.5

LVL33 +201.4

LVL34 +208.3

LVL35 +215.2

LVL36 +222.1

LVL37 +229.0

LVL38 +239.5

LVL39 +247.9

LVL40 +254.8

LVL41 +261.7

LVL42 +272.2

J . :

LE :

. : 203 - EL : EFLI

VII

CT

TITL

* Y I I TI E I E I E L

* F I E I E FE T I E LY T .

L Y I T T E I E I T E F L L E .

E L E E I T T E I TE T E F E

E E I T E K .

* F T T L E T I L E FE

. . . L T T ' I .

* I T T E L E,

TH

T

* T E LI I T T I I T E E K EI T E I T I T E T L E E F T T I L YF TE E E I F I TI F I E I F E E TITE

e v i s io n a t e e sc r i pt i o n

E I I : 8 . 0

TE : 29/12/07

3RD SKY VILLA

2RD SKY VILLA

1st SKY VILLALVL 37 +229.0

LVL 38 +239.5

LVL 41 +261.7

LVL 42 +272.2

LEVEL +285.5

TOP LEVEL +317.60M

Apartment

Refuge

3RD SERVICE LEVEL

4TH SERVICE LEVEL

25TH LEVEL [38] 2ND SKY VILLA LEVEL

26TH LEVEL [39] 5TH REFUGE LEVEL


28TH LEVEL [41] 3RD SKY VILLA LEVEL

.

LEVEL + 285.5 0M

LVL37 +229.0

LVL38 +239.5

LVL39 +247.9

LVL40 +254.8

LVL41 +261.7

LVL42 +272.2

Elev 229 to 285.5

Sky VillasDuplex Ht ~10.5m

Each Sky Villa will

have car park, car lift,swimming pool,

garden etc.

Palais Royale TowerElevation

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Palais Royale Tower Worli, Mumbai

Raft completed

~

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Palais Royale Nov 08

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Palais Royale

Concrete Placer Boom in Action

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Palais Royale

Reinforcement

Fe 500 grade

Couplers replace laps

40 dia bars for columns;

grouping reduces congestion

Prefab reinforcement cages

for columns, beams & slabs,

manufactured at site usingcomputerized equipments &

lifted by tower cranes

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Palais Royale Tower

80 MPa SCC

Cement : 350 - 400 kg

Silica fume : 10 %

Water : 135 litres

Aggregates : Local

PC based admix : 0.8 1.0 %

Viscosity Modifier : 0.2 %

Concrete produced at site batch plant

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Palais Royale TowerSCC - Issues Addressed

Workability : slump flow requirements

Free fall of concrete vs segregation

Slump loss - production to placementMaximum dosage of PC based admixtures

Use of viscosity modifier

Choice of quality fine aggregateMaximum size of coarse aggregate

Formwork pressures : DIN 18218 Pressure of

Fresh Concrete on Vertical Formwork (draft)

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Palais Royale TowerSCC - Issues Addressed (concluded)

Mockup trials on full scale columns

- verification of filling ability

- surface finish quality

- cores to verify uniformity thru the height- cores tested for compressive strength,

compared with corresponding cube strength

In production from March 2008; 28 days workstrength range : 90 - 100 MPa

Standard deviation of works cubes ~ 3 MPa

40000 cum of SCC already placed (Oct.2010)

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Palais Royale TowerSCC - Problems Encountered

Slump flow : the end user insists on a slump

flow of more than 800mm, against international

norm of 650-700 mm; higher slump flow means

heavy dosages of admixtures, resulting in moreair bubbles in concrete, possible segregation of

concrete during placement etc.

Coarse aggregates : the originally contractedquarry encountered difficulties in supply;

aggregates from alternate quarry are flaky

Admixtures : variable quality by same supplier

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SCC Production

2 Nos. 45m3 Batch Plants installed at site

Max Conc temperature at pour point : 30 0 C

Chilling Water Plant installed at siteQC lab at site with 300 t cube testing machine

Equipment for cement testing, slump flow test,

V funnel flow time, L box, T-500 at siteFresh SCC properties tested at the Batch Plant

and at the delivery point

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SCC Production

Full scale trials for mixing time to ensure

complete mixing

Trials for mixing time of 30,45, 60, 75, 90 secs

One minute (60 secs) mixing time chosen

based on properties observed during trials

Silica fume : Use as powder / slurry; after

extensive discussions with International

Experts and the authors observations in

Europe, used as powder

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SCC Transportation, Placement

Transported by 6 m3 truck mixers

Placed by High Pressure concrete pumps

located at ground level and special 125mm dia

concrete pipeline

Concrete pipeline fixed vertically; self climbing

concrete placer booms distribute the concrete

at the floor level

Concrete placed in columns through flexible

pipe fitted to the 125mm pipeline

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Quality Checks for Fresh Concrete

Routine tests for each truck load of concrete :

- slump flow test (700 800mm)

- flow time test by V Funnel (5 7 seconds)

- passing ability test by L Box (90 95%)- T 500 test (3 5 seconds)

Tests were conducted at the delivery point

before concrete was discharged by the truckmixer; only mixes satisfying the norms were

fed to the concrete pump

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Quality Checks for Hardened Concrete

Standard 150mm cubes tested

Concrete filled to the top of the mould in one

operation

No tamping rod for compaction

Entrapped air expelled by lightly tamping the

outside of the mould with wooden mallet

Curing & Testing specimens as per IS Codes

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Any comments, queries,

suggestions are welcome

[email protected]

scc 80 mpa

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