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Services through Innovation & Application Center

We Provide

TECHNOLOGY
Solutions related to Technical materials, Technical trainings, Testing Facilities
Cement &
ENGINEERING
Concrete Research on High performance Concrete, Concrete designs, Mix
design optimization, Project QA & QC & Technical Support

ENVIRONMENT
Blended Cements, Green building Solutions & Low cost housing

© 2012 Holcim Group Support Ltd


Conduct trainings for industry – Government Auditors

© 2012 Holcim Group Support Ltd


Quality Variations in Sri Lanka Cements

HLL Technicale Service Department © 2012 Holcim Group Support Ltd


BASICS Matters…
28-day Compressive Strength Vs W/C ratio Irrespective of
45.0 cement type
40.0 brand…,
Compressive strength (Mpa)

35.0

30.0

25.0 Water to
20.0 Cement
15.0

10.0
ratio is
05.0 really
00.0
0.55 0.60 0.65 0.70 0.75 0.80
matters….
W/C ratio

C1 C2 C3 C4 C5

© 2012 Holcim Group Support Ltd


We continuously train our staff to serve you better…
Technical Workshops

Technical Trainings

© 2012 Holcim Group Support Ltd


Promote Sustainable Construction practices…
ConWOOD Gre
Wood like Innov
concrete ceme
produ
Green Walls
Innovative Perv
cement Con
products Rech
groun

Pervious
Concrete
Recharge
ground water

© 2012 Holcim Group Support Ltd


Publications – Concrete Basics, Low Cost Housing booklets

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Publications – Home for Life booklet

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Initiatives by Holcim…

HLL Technicale Service Department © 2012 Holcim Group Support Ltd


We Partner with Experts in the Country
UOM – 15th February 2013
Sign agreements with 3 engineering
faculties of the country to do
necessary applied researches

UOP – 31st May 2013 UOR – 10th January 2013

© 2012 Holcim Group Support Ltd


Collaborative effort…

Innovation & Application Center

EFFECT OF SUPPLEMENTARY CEMENTING MATERIAL


(SCM) SUCH AS NANO SILICA, MICRO SILICA, FLY ASH
AND BOTTOM ASH ON PROPERTIES OF CONCRETE

Thushara Priyadarshana1, Madhuwanthi Rupasinghe3


Gamini Chandrasena2, Priyan Mendis3, and Ranjith Dissanayake1

© 2012 Holcim Group Support Ltd 11


Introduction

supplementary cementing material (SCM) such as nano silica, micro


silica, fly ash and bottom ash have been evaluated for optimal
level of replacement as blending material in cement. The physical and chemical
properties of above materials were first analyzed. Then properties of concrete of
fixed mix design (G35 concrete) were investigated. Mainly this study focused on
compressive strength of concrete with different mixes at different age of concrete.

Nano Silica 10nm micro Silica 10μm Fly ash Bottom ash

© 2012 Holcim Group Support Ltd 12


Results & Discussion: Chemical Analysis
SiO2 Al2O Fe2O CaO MgO SO3 K2O Na2O Cl LOI
(%) 3 (%) 3 (%) (%) (%) (%) (%) (%) (%) (%)
Cement -
20.38 4.79 3.26 64.40 0.98 2.21 0.04 0.01 3.7
Micro Silica - - - - - -
98.93 0.31 0.17 0.57
Nano Silica - - - - - - -
99.59 0.33 0.06
Fly Ash 52.03 32.31 7.04 5.55 1.30 0.07 0.68 1.00 - 1.73
Bottom Ash 46.09 23.69 5.81 7.04 1.18 - 1.15 0.69 - 14.34

it showed that fly ash can be categories as class F according to general standards. This fly ash low
in lime 5.55% (under 15%), and contain a greater combination of silica,
Alumina and iron 84.34% (greater than 70 percent). Nano silica and micro silica has purity
of 99.59% and 98.93%. Bottom ash contains a greater combination of silica, Alumina and iron
69.78%.

© 2012 Holcim Group Support Ltd 13


Results & Discussion: Chemical Analysis

micro silica Nano silica

Fly ash

2013-04-22 © 2012 Holcim Group Support Ltd 14


Compressive strength of concrete with micro silica
70.0

65.0

60.0

55.0

50.0

45.0
7day 28 day 60 day 90 day
MICRO Silica 1% MICRO Silica 3% MICRO Silica 5%

MICRO Silica 10% MICRO Silica 20% Controlled - 100% cement

cement can be easily replaced by micro silica up to 10% without losing strength of concrete at all ages.
The best amount of micro silica in concrete would be 3-8%. Main issue when dealing with
micro silica is losing workability of concrete mix at higher percentages of micro silica. High range
super plasticizers are always recommending using with micro silica.

© 2012 Holcim Group Support Ltd 15


Compressive strength of concrete with fly ash
70.0
65.0
60.0
55.0
50.0
45.0
40.0
35.0
30.0
7day 28 day 60 day 90 day
Fly Ash 5% Fly Ash 10% Fly Ash 20% Fly Ash 30%
Fly Ash 40% Fly Ash 50% Controlled - 100% cement

cement can be replaced by fly ash up to 20% - 30% without losing strength of concrete at late ages (60day
and 90 days). However, early strength of concrete is affected by fly ash when it uses more than 20%. The
best amount of fly ash in concrete would be 10% by considering optimum benefits towards
strength. Main benefits of fly ash are workability of concrete mix even at very high percentages. These
are really useful for concrete which is to be pumped for longer distances, especially for high rise structures.
© 2012 Holcim Group Support Ltd 16
Compressive strength of concrete with all SCM
55.0
50.0 7 days
45.0
40.0
35.0
30.0
0% 10% 20% 30% 40% 50%
Nano Silica Micro silica Fly Ash Bottom Ash Controlled

65.0
60.0 28 days
55.0
50.0
45.0
40.0
0% 10% 20% 30% 40% 50%
Nano Silica Micro silica Fly Ash Bottom Ash Controlled

2013-04-22 © 2012 Holcim Group Support Ltd 17


Recomendations
In Sri Lanka, in most of the projects fly ash are used in the range of 20-25%. Fly ash blended
cement produced by Holcim (Lanka) Limited (Holcim Extra) contain 25% fly ash and fly ash are
inter-ground at the cement plant to get better performance. Micro silica with fly ash is used in
most of the high rise building projects in the world to get higher strength and extended durability.
However, nano silica is still new to construction industry due to its availability and cost.

It is always recommend optimizing mix designs either with blended cement,


cement replacement materials such as fly ash (with or without micro silica or nano
silica) to get highest performance with the concrete.

Note that we can get grade 80 Concrete even low cement content (400Kg) if you mix with 100kg
fly ash (18%) and 50kg micro silica (9%) as shown in the Burj Dubai example. So, it is not
recommended to just increase the cement content to enhance strength and other properties of
concrete. There will always be a better option with blended cement or blended materials with
ordinary Portland cement.

© 2012 Holcim Group Support Ltd 18


G80 concrete
columns and walls
level 109~126 Lotus
18% (100Kg)
Tower
Fly Ash
9% (50Kg)
micro Silica

Cement 400Kg,
sand 830 kg,
coarse aggregates
(10mm) 847 Kg,
admixtures 3% and
water: binder ratio
was 0.3.

World

Sri Lanka
25%
Fly Ash
828m (Holcim Extra) © 2012 Holcim Group Support Ltd
Materials

© 2012 Holcim Group Support Ltd


Lotus Tower - Concreting

Challenges

4200 m3 at single pour

Continuously in 24 hrs

6 concrete plants

Civil engineers play a great role here…

© 2012 Holcim Group Support Ltd


Heat generation in concrete mix
Heat generally
peaks and
Significant heat is then drops
generated during the during cooling
hardening stage

A very brief
heat spike
occurs Does not generate
during heat during the
mixing dormancy stage

Minute
2 to 4 hours 2 to 4 hours Years
s

© 2012 Holcim Group Support Ltd


© 2012 Holcim Group Support Ltd
© 2012 Holcim Group Support Ltd
Temperature in Concrete…

© 2012 Holcim Group Support Ltd


© 2012 Holcim Group Support Ltd
Residential…
"Reflections at Keppel Bay" in
Singapore - a symphony of towers

World
A total of 320,000 m3 of concrete

Sir Lanka
On Three 20 Project
I&A Center Supported to address heat of
Hydration in thick concrete slab at Podium level
with University of Moratuwa

© 2012 Holcim Group Support Ltd


Transport infrastructure - tunnel projects…
The Gotthard Base Tunnel: An innovative journey to a
world record – 9.7 billion CHF, 57 Km tunnel between Zurich and
Milan, AlpTransit Gotthard Switzerland. 2000-2016. 1,300,000 m3
of Concrete
World Underwater, around the clock: a new railway tunnel
under a sea-freight canal and a tidal river in Belgium, 2008 - 2012.
500,000 m3 of Concrete

Linking Brisbane to the airport: The Airport Link,


some 6.7 km long (mainly underground) with costs of USD 5.1
billion, in Australia. 425,000 m3 of Concrete

Sir Lanka
Uma Oya Project
This tunnel is supported by concrete pre cast lining
produced using Holcim Cement after drilling by TBM

© 2012 Holcim Group Support Ltd


Different Types of Concretes…

© 2012 Holcim Group Support Ltd


Self Compacting Concrete (SCC)…

© 2012 Holcim Group Support Ltd


Roller Compacted Concrete (RCC)

© 2012 Holcim Group Support Ltd


© 2012 Holcim Group Support Ltd
© 2012 Holcim Group Support Ltd