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6/8/2012

Deepak Kanitkar is currently working with M/s Chembond


Chemicals Limited in the Construction Chemicals Division.
He completed his B. Sc. in Chemistry at Mumbai University
and completed his Diploma in Paint Technology at UDCT
Mumbai.

Innovations in Chemical
Admixture Technology as Related
to Sustainability, Part 2
ACI Spring 2012 Convention
March 18 21, Dallas, TX

OUTLINE

Combinations of poly carboxylate


ethers and lignosulfonates in
chemical admixtures for special
performance.
DeepakKanitkar
DGM Technology&BusinessDevelopment
ChembondChemicalsLimited
INDIA
ACISpringConvention2012,Dallas

Sustainableconcrete
Materialsforchemicaladmixtures
CombinationsofLignosulfonatesandPolycarboxylate
Ethers
Experimentalwork
Resultsanddiscussions
Conclusions
Pathforward

CONCRETE

C ombination of
O rganic (Synthetic) and
N atural ingredients
C ast and Cured with / without
R einforcement in the
E nvironment using
T echnology and
E ffective human resources

SUSTAINABLECONCRETE

6/8/2012

ROLEOFCONCRETEADMIXTURES

HOWTO

Reduced
cement

Optimization
ofmaterials

Improvement
and
optimizationof
structures

SUSTAINABLE
CONCRETE

Recyclingand
waste
management

Innovationin
materialsand
processes

Reduced
W:Bratio

ReducedCO2
emission

Reduces

CONCRETE

Permeability

ADMIXTURES

Increased
workability
retention

Increased
compressive
strength

Reduces
element
mass

Reduces
rejections/
repairs

LIGNOSULFONATES(LS)
Green and sustainable chemical
CO
Carbon content of LS is 400 gm. / kg.
1.5 kg of CO is withdrawn from
atmosphere/kg of LS
Steric + Electrostatic repulsion.
Excellent compatibility with SNF, SMF and PCEs.
Most grades are compatible with Alternative Cementitious
Materials.
2
1.5
kg

MATERIALS

SULFONATEDNAPTHALENE
FORMALDEHYDE(SNF)

POLYCARBOXYLATEETHERS(PCE)

Excellent dispersion helps high strengths


Steric repulsion results in good water reduction at very low
dosages.
SCC can be made most of the times, without the use of VMAs
Opens opportunities to obtain results with variety of cement
types and ACMs.
Dosage is very sensitive.
Compatibility with retarders and defoamers is critical.

MadeusingNapthelene,FormaldehydeandHSO.
Workswellforconcretesupto60MPa.
BetterinitialslumpthanLS.
CompatiblewithmostretardersandLS
Longretentionofslumpispossible.
GenerallynotcompatiblewithPCEs.

6/8/2012

ASPECTS

COMBINATIONSOF
LIGNOSULFONATEANDPCEs

Synergy
Cost
Versatility
Foamingtendency
Compatibility
Workability
Strengthdevelopment
Cementcompatibility

SCOPE
StudyCaLSandNaLScombinationswithPCWR.Theresults
arecomparedwithSNF:LScombinations
NaLSfrom2differentsources,PCEsfrom3differentsources
andCaLSfromsinglesource
Concretetrialsattwodifferentdosages

CONCRETEPROPORTIONS

EXPERIMENTALWORK

COMBINEDGRADATION

6/8/2012

Sample1

Sample2
PhysicalProperties

Admixture Formulations
(%)
56
24
20
100

%NVM
40.33
1.1
SG@250C
pH@250C
6.52
VISCOSITYFCB4
250C
52

1.5

2.5

3.5

Timeinhour

7Day
0.90%

300
250
200
150
100
50
0

@0.7%
Dosage

28day

0.5

Sample3
(%)
24
30
46
100

VISCOSITYFCB4
250C

1.5 2 2.5 3
Timeinhour

TestMix
PCWR1
NaLignoB
Water
Total

3.5

70
60
50
40
30
20
10
0

1Day
7Day
0.70%

0.90%
Dosage%

(%)
40
21.6
38.4
100

VISCOSITYFCB4
250C

1.5

VISCOSITYFCB4
250C

0.5

1.5

2.5

52

Compatibility
ViscosityAfter24
Hrsat250C
52
ViscosityAfter7
0
55
Daysat25 C
ViscosityAfter30
55
Daysat250C

CompressiveStrengthAnalysis

@0.7%
Dosage
@0.9%
Dosage
3

3.5

Timeinhour

28day

2.5

Timeinhour

54

Compatibility
ViscosityAfter24
54
Hrsat250C
ViscosityAfter7
54
Daysat250C
ViscosityAfter30
0
Daysat25 C
55

AdmixtureFormulations
TestMix
(%)
PCWR1
40
NaLigno R
Water
Total

80
60
40
20
0

1Day
7Day
0.70%

0.90%

28day

Dosage%

3.5

70
60
50
40
30
20
10
0

1Day
7Day
0.70%

0.90%
Dosage%

PhysicalProperties
%NVM
39.93
1.13
SG@250C
5.6
pH@250C

21.6
38.4
100

VISCOSITYFCB4
250C

28day

300
250
200
150
100
50
0

@0.7%
Dosage
@0.9%
Dosage
0

0.5

1.5

65

Compatibility
ViscosityAfter24
65
Hrsat250C
ViscosityAfter7
71
Daysat250C
ViscosityAfter30
0
Daysat25 C
70

CompressiveStrengthAnalysis

WorkabilityChart
Slumpinmm

@0.9%
Dosage

CompressiveStrengthin
MPA

Slumpinmm

@0.7%
Dosage

@0.9%
Dosage

PhysicalProperties
%NVM
40.12
SG@250C
1.12
pH@250C
6.03

(%)
56
12.8
31.2
100

300
250
200
150
100
50
0

CompressiveStrengthAnalysis

300
250
200
150
100
50
0
0.5

3.5

Sample6
PhysicalProperties
%NVM
39.81
1.14
SG@250C
5.77
pH@250C

WorkabilityChart

WorkabilityChart

Sample5
AdmixtureFormulations
TestMix
PCWR1
CaLignoB
Water
Total

2.5

AdmixtureFormulations

Slumpinmm

@0.9%
Dosage

CompressiveStrengthin
MPA

Slumpinmm

@0.7%
Dosage
1

32

Compatibility
ViscosityAfter24
Hrsat250C
32
ViscosityAfter7
0
35
Daysat25 C
ViscosityAfter30
34
Daysat250C

CompressiveStrengthAnalysis

WorkabilityChart
150
100
50
0
0.5

Sample4
PhysicalProperties
%NVM
39.97
SG@250C
1.15
pH@250C
5.3

AdmixtureFormulations

1.5

Timeinhour

Dosage%

TestMix
PCWR1
NaLigno
Water
Total

45

Compatibility
ViscosityAfter24
Hrs at250C
45
ViscosityAfter7
0
Daysat25 C
47
ViscosityAfter30
Daysat250C
46

WorkabilityChart

1Day

0.70%

VISCOSITYFCB4
250C

CompressiveStrengthin
MPA

80
60
40
20
0

(%)
40
21.6
38.4
100

2.5

Timeinhour

3.5

CompressiveStrengthin
MPA

0.5

CompressiveStrengthin
MPA

Slumpinmm

@0.7%
Dosage
0

TestMix
PCWR1
NaLigno B
Water
Total

CompressiveStrengthAnalysis

WorkabilityChart
300
250
200
150
100
50
0

PhysicalProperties
%NVM
40.54
SG@250C
1.13
pH@250C
5.62

AdmixtureFormulations

Slumpinmm

TestMix
PCWR1
PCSR1
Water
Total

Compatibility
ViscosityAfter24
Hrsat250C
52
ViscosityAfter7
0
52
Daysat25 C
ViscosityAfter30
52
Daysat250C

70
60
50
40
30
20
10
0

1Day
7Day
0.70%

0.90%

28day

Dosage%

6/8/2012

Sample7

Sample8

21.6
45.2
100

VISCOSITYFCB4
250C

44

1.5

NaLigno
Water
Total

2.5

3.5

Timeinhour

80
60
40
20
0

7Day
0.90%

21.6
38.4
100

@0.7%
Dosage

28day

0.5

VISCOSITYFCB4
250C

@0.9%
Dosage

3.5

@0.7%
Dosage
@0.9%
Dosage
2

2.5

3.5

Timeinhour

SNF (42%)
Water
Total

60
50
40
30
20
10
0

1Day
7Day
0.70%

0.90%

66.8
20.4
100

VISCOSITYFCB4
250C

100
80
60
40
20
0

@0.7%
Dosage

0.5

28day

1.5

2.5

3.5

@0.9%
Dosage

Timeinhour

VISCOSITYFCB4
250C

51

Compatibility
ViscosityAfter24
51
Hrsat250C
ViscosityAfter7
51
Daysat250C
ViscosityAfter30
0
51
Daysat25 C

AdmixtureFormulations
TestMix
(%)
PCSR1
80
Water
Total

@0.7%
Dosage
2

2.5

Timeinhour

3.5

Slumpinmm

Slumpinmm

300
250
200
150
100
50
0
1.5

70
60
50
40
30
20
10
0

1Day
7Day
0.70%

0.90%

28day

Dosage%

PhysicalProperties
%NVM
40.01
1.1
SG@250C
6.51
pH@250C

20
100

VISCOSITYFCB4
250C

38

Compatibility
ViscosityAfter24
38
Hrsat250C
ViscosityAfter7
38
Daysat250C
ViscosityAfter30
0
38
Daysat25 C

WorkabilityChart

WorkabilityChart

17

Compatibility
ViscosityAfter24
17
Hrsat250C
ViscosityAfter7
18
Daysat250C
ViscosityAfter30
Daysat250C
18

Sample12
PhysicalProperties
%NVM
40.2
1.1
SG@250C
6.5
pH@250C

20
100

0.5

0.90%

CompressiveStrengthAnalysis

WorkabilityChart

Sample11
AdmixtureFormulations
TestMix
(%)
PCWR1
80

28day
0.70%

PhysicalProperties
%NVM
39.98
1.2
SG@250C
6.15
pH@250C

Dosage%

Water
Total

7Day

Dosage%

AdmixtureFormulations
TestMix
(%)
Na Ligno
12.8

Slumpinmm

140
120
100
80
60
40
20
0
1.5

18

Compatibility
ViscosityAfter24
18
Hrsat250C
ViscosityAfter7
19
Daysat250C
ViscosityAfter30
Daysat250C
20

CompressiveStrengthAnalysis
CompressiveStrengthin
MPA

Slumpinmm

WorkabilityChart

2.5

1Day

70
60
50
40
30
20
10
0

Sample10
PhysicalProperties
%NVM
40.41
1.2
SG@250C
6.6
pH@250C

47.6
30.8
100

0.5

Timeinhour

Sample9
AdmixtureFormulations
TestMix
(%)
NaLigno
21.6

1.5

43

Compatibility
ViscosityAfter24
43
Hrsat250C
ViscosityAfter7
44
Daysat250C
ViscosityAfter30
Daysat250C
44

CompressiveStrengthAnalysis

300
250
200
150
100
50
0

Dosage%

SNF(42%)
Water
Total

VISCOSITYFCB4
250C

WorkabilityChart

1Day

0.70%

PhysicalProperties
%NVM
40.36
1.14
SG@250C
5.12
pH@250C

CompressiveStrengthin
MPA

CompressiveStrengthin
MPA

Slumpinmm

@0.7%
Dosage
@0.9%
Dosage
0.5

AdmixtureFormulations
TestMix
(%)
PCWR3
40

CompressiveStrengthAnalysis

WorkabilityChart

300
250
200
150
100
50
0
0

Compatibility
ViscosityAfter24
44
Hrsat250C
ViscosityAfter7
45
Daysat250C
ViscosityAfter30
Daysat250C
43

Slumpinmm

NaLigno
Water
Total

PhysicalProperties
%NVM
40.28
1.14
SG@250C
4.79
pH@250C

CompressiveStrengthin
MPA

AdmixtureFormulations
TestMix
(%)
PCWR2
33.2

300
250
200
150
100
50
0

@0.7%
Dosage
0

0.5

1.5

2.5

3.5

Timeinhour

6/8/2012

SETTINGTIMES
AT0.7%DOSAGE

SETTINGTIMES
AT0.9%DOSAGES

WORKABILITY
ATO.7%DOSAGE

WORKABILITY
AT0.9%DOSAGE

COMPRESSIVESTRENGTHS
AT0.7%DOSAGE

COMPRESSIVESTRENGTHS
AT0.9%DOSAGE

6/8/2012

MARSHCONERESULTS

AIRCONTENT

COMPATIBILITY,SETTINGTIMEANDWORKABILITY

RESULTS&DISCUSSION

CompatibilityofPCWRandLScombinationshasbeen
established.
At250C,allformulationsat0.7and0.9%dosagesarenearto
therequirementofASTMC494typeG,forsettingtime.
Asthedosageislowretardationisundercontrol.
At0.7%PCWR:PCSRandtheircombination,givesgood
workabilityretention.
50:50combinationsofPCWRandNALsgivegoodinitial
workabilitybuttheslumpdropsquicklyafter30minutes.

COMPATIBILITY,SETTINGTIMEANDWORKABILITY

COMPRESSIVESTRENGTHANDAIRCONTENT

PCWR:NALs75:25combinationretainsslightlybetterthan
50:50combination.
At0.9%bothPCWRandNaLSaswellasCaLSprovidegood
retention.
NaLScombinationgivesbetterretention.
PCWRandNaLS75:25combinationprovidesbestslump
retention.
ItisobviousthattheretentionofSNF:NaLScombinationsis
nowaynearPCWR:NaLScombination.Thiscouldbedueto
averylowW/Bratioof0.3.

Bestcompressivestrengthachieved@0.7%
dosage.
Compressivestrengths
At0.7%dosage
PurePCEs>75:25PCE:LS>50:50PCE:LS.

At0.9%dosage
75:25PCE:NaLS>50:50PCE:NaLS
25:75PCWR:NaLS>75:25SNF:NaLS

Aircontentofallthemixeshasnotvaried
muchduetolowerdosages.

6/8/2012

CONCLUSIONS

PATHFORWARD

Combinations of PCEs with LS will add a significant value to


concrete sustainability.
LS has good compatibility, with all the PCE molecules used in
this study.
PCE : LS combination are most desirable where SNF:LS
combinations fail or require higher dosages.
The synergy of PCE: LS combinations, have opened up an
excellent option for Admixture formulators.
Good workability retention and comparatively higher
strengths achieved, suggest that significant cost and material
savings may be obtained, using PCE : LS combinations.

WorkInProgress
StudyinvolvingGGBFSanddifferentcementbrands.
TocheckotherPCEmolecules.

FurtherStudies
Longtermcompatibilityandcompatibilitywithvarious
cementtypes.
AthigherdosagesandhigherW/Bratios.

ACKNOWLEDGEMENTS
ACIINTERNATIONAL
MyOrganization CHEMBONDCHEMICALSLIMITED
MycolleaguesacrosstheorganizationatChembond
forsupportingmystudyinvariouscapacities
BorregaardIndiaLimitedforprovidingsamplesand
detailsonLS
Ultratechcementforprovidingvaluablesupportin
testingcementsamples

THANK YOU
Deepak Kanitkar, DGM - Technology & Business Development
Chembond Chemicals Ltd. India
ACI Spring Convention 2012 Dallas - USA