Application of Self Compacted Concrete in Precast Industry : Sustainability Technology with Green Concrete

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1 Application of Self Compacted Concrete in Precast Industry : Sustainability Technology with Green Concrete by : Gambiro Soeprapto (PT Wijaya Karya Beton)

2 SELF COMPACTED CONCRETE Self-compacting concrete (SCC) is an innovation of concrete which not require for placing and compacting. Concrete is able to flow : Gravity or self weight Fill the mould with full compactness Pass through the closed reinforcement. Concrete has density, homogenous, engineering properties and durability as well as with concrete which is compacted in conventional method. 1

3 CRITERIA : Self Compaction : the level of fluidity of proportion is able to compact concrete itself without external energy. Deformability : concrete mixing is homogen in formwork during and after placing. Flow Ability :Easy to flow and breakthrough the closed reinforcement. High Resistance to Segregation : coarse aggregate can be float in mortar without segregation [stablilizer/viscosity-modifying agents, fines material (< 150 m)] 2

4 MATERIAL COMPOSITION OF SCC 3

5 SCC Type based on mortar composition 1. Powder Type Reduction of water/powder ratio (material < 0.1 mm) Sufficient in resistance to segregation. Super plasticizer dan air entraining admixture as requirement of deformability. 2. Viscosity-modifying agent (stabilizer) type To use viscosity modifying admixture to obtain resistance of segregation. Super plasticizer dan air entraining admixture as requirement of deformability. 3. Combination Type Reduction of water/powder ratio, viscosity modifying admixture to reduce fluctuation the quality of fresh concrete due to the variation of 4 surface moisture content and gradation of aggregate during production.

6 ADVANTAGES of SCC 1. Improve Concrete Quality: Concrete easy pass in tight reinforcement, difficult access etc.. (passing ability) Concrete able to fill the gap around the reinforcement and space between the reinforcement and formwork (good filling ability) 2. Protection to Environment and Human Health : SCC can reduce the noise around factory, site and surroundings. SCC reduce vibration effect of compaction tool for the health of worker. SCC shortens construction or production time with acceleration process, especially for precast industry. 5

7 3. Economical and time savings : Easy concrete placing will reduce the worker and tool, so it improve productivity and save the cost.. SCC reduce usage time and mold defect, so it extend durability of mold. SCC can reduce the number of worker. Normally it is needed 1.5 manhours, whereas SCC can minimize it to be 0.35 manhours SCC reduce cost and energy consumption, because it has high fluidity and concrete can be placed without vibration. SCC can reduce cost and worker for finishing to precast component. SCC can increase capability of concrete supplier to give better consistency during delivery. ( continued) 6

8 3. Economical and time savings : (continue.. ) Worker capability in steel reinforcement assembly does not affect construction with SCC. Reducing of toll can prevent work accident. SCC can be made as production mass. 7

9 EFFECT TO ENVIRONMENT The reducing of cement will contribute positive effect to environment such as : Energy for cement production can be saved. Heat of cement hydration can be reduced.. Excessive heat of cement hydration will increase temperature around it. 8

10 Flowability and resistance to segregation of SCC Flowability and resistance to segregation of SCC are obtained by : 1. More fine particles are subtitute coarse aggregate partially. The coarse aggregate content is limited to prevent seggregation (lubricate coarse aggregate). 2. The low water/powder ratio [powder = cement + filler (fly ash, silica fume etc..)] can prevent seggregation. 3. Superplasticizer can be increase flow ability (reduction liquid limit and improve workability) (Okamura dan Ouchi, 2003 dan Audenaert et al., 2002) 4. Viscosity modifiers admixture can prevent seggregation (increase viscosity. 9

11 THE ROLE OF ADMIXTURE Admixture Type 1 High Performance Superplasticizer (HRWR) Functtion Improve the cement dispersion (workability and flow ability) 2 Viscocity Modifying Admixture Segregation Resistance 10

12 Performance of water reducing admixtures Modified (MLS) ligninsulphonates Typical Dosage (ratio to cement weight) Water reduction % until 10 % Melamine sulphonates (SMF) % until 25 % Napthalene sulphonates (SNF) % until 25% Polycarboxylic ethers (CE) % Until 40 % 11

13 Wika Beton Experience Wika Beton applies SCC for non-centrifugal member such as I girder, box girder, sheet pile, square pile etc. SCC gives saving such as : 1. Reduce % for consumption of cement. Cement saving can be get with 2 methods : Usage of superplasticizer will reduce water consumption. With constant w/c ratio and water reduction, it also will reduce the cement. Usage of silica fume as cementitious material can reduce the cement. 2. Saving until 3 % for energy consumption. 3. The number of concreting worker can be reduced until 50 %. 4. Concrete placing time can be saved % 12

14 Constraints in application of SCC 1. The knowledge about SCC is not still limited. Sometimes SCC just mean only flow concrete. 2. Indonesia does not have code about SCC. Slump control with spread measurement is still assumed as uncommon method. 3. Quality of natural materials have not been ensure continuously. 4. Additive material as substitution of cement has not been assume as needs, even so the usage of additional materials as cement replacement is not essential, even sometimes is not permitted. 13

15 THANK YOU

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