NATIONAL SEMINAR ON,

R.C.C CONSTRUCTION AT GREAT HEIGHTS

- BY INDIAN CHAPTER OF
ACI

KUNAL TALSANIA

PRESENTATION :

THERMAX
BASF
LAFARGE CEMENT
NINA INDUSTRY
L & T CEMENT
SIKA

(1) THERMEX - BY H&K ROLLING MILL ENGINEERS

TMX (Thermax) steel is High Quality TMT steel bar.

Quenching & Self Tempering Process is involved.
Quenching means to cool Hot Metal by thrusting into Water
Why this technology comes into market?
General Requirement of High strength Rebar with Minimum Yield
point 500MPa.
What is advantage to Use High Strength Rebar?
Saving in Reinforcement
Easy Processing due to high weldability,
Reduce overall civil construction cost etc.
What was the option in Earlier Days ?
CTD Bars Cold Twisted Deformed Bars/Torsteel Which was made
from very costly Alloying elements & normally Used to achieve High
Strength.
Main Disadvantage :Weldability & Elongation

Thermax Cooling Technology introduce THERMAX QST REBARS

Best Replacement of CTD Bars
Main Advantages :Elongation value can be achieved between 16 to 23% - Where
standard Norm says It should be minimum 14.5% in Seismic
Zone.
High Ductility
Better Corrosion & Temperature Resistant
Saving 20% steel consumption - using Thermax 500 in place of
CTD bars
Better Weldability & Fatigue Resistance
Last but not Least It is Ideal choice for Seismic Zone as 60%
INDIA is under High Seismic hazard category.

(2) BASF :- THE CHEMICAL

COMPANY

One of the most Leading chemical company Presence in

more than 80 countries.
Large varieties of construction chemicals.
Among top ten skyscrapers in the world they are involved in 3
major skyscrapers.

BURJ KHALIFA :

One of the Tallest Building in the World.

Height :- 828 meters 2722 ft.
169 stories & 12000 workers @ site.
Total Area :- 4,65,000 Sq.Meter
Required around 22 Million Man Hrs.
Finished in 5 Years (2004-2009).
High demand for man & Material Both.
What were the major Problems at site?
Extreme climate condition 10 Degree - 50 Degree.
Complicated Architecture
Pumping of Concrete up to 600 meter.
Segregation, Curing
Slump value
Evaporating Retarders to avoid Cracks &
Quality Control

1.
2.
3.
4.

To Overcome all those Problems BASF introduce Super Plasticizer

called as
GLENIUM SKY
This concrete additives are based on Poly carboxylate Ether"
Polymers.
Advantages :High range Water reducing Agent.(Up to 30-40%)
Producing Extended Slump Life
Prevent Segregation & Bleeding Problem as they have
Homogeneous plasticizing property.
It allows usage of Cementitous supplementary materials such as
Silica fume, fly ash etc.
Great flowability @ High Pressure.
Therefore PCE is mainly used for,
High Performance Concrete
Self compacting Concrete
Pumpable/Flowable Concrete &
Light Weight concrete

BURJ KHALIFA FOUNDATION DETAILS :

Massive Raft foundation with 3.7m Thickness.

Concreting was done in 4 Layers.
Raft foundation Supported on Bored Reinforced
concrete piles (194 Nos.) with 1.5 M Dia. &
50 meter in Depth.
Each pile is designed to carry almost 3000 Ton.
They Used C-50 Grade of Self Compacting Conc.
with Glenium sky Super plasticizer.
Total concreting in Raft was 12,500 m3.

BURJ KHALIFA SUPER STRUCTURE :

High Performance SCC including Super Plasticizers were used in

Superstructure.
C-80 & C-60 Grade of Concrete was used in majority of Walls & Columns.
( Portland Cement + Fly ash + silica fumes (Micro silica)+ Local
aggregates + super Plasticizers )
Superstructure Concrete Volume = About 3,20,000 m3
KEY POINTS :Young Modulus E = 45000 N/mm2 @ 90Days.
Cube Strength @ 28 Days = 80 N/mm2
Water : Cement Ratio = < 0.3
Slump Retention = Up to 3 Hrs.
Construction speed = One storey / week
Two of the Largest concrete Pumps (Putzmeister) in the World, used to
deliver concrete to heights over 600m in single stage.
Pump Pressure = Varies between 140-190 bar ( 1 bar = 0.1 N/mm2)
Concreting was poured at Night to avoid cracks due to 50 Degree Temp.
BASF had used 50 Different Admixtures in this Dream Project.

(3) LAFARGE CEMENT :

One of the top Leader in Building Materials, specially in

Aggregates & cement.
Presence in 80 Countries & more than 80000 workforce.
Lafarge Cement is involved in LODHA Builders dream Project
WORLD ONE TOWER in Upper Worli,Mumbai.
It will be one of the Tallest Residential Tower in
the World upon Completion.
Height :- 450 Meter (1450 ft.)
Over 117 Storeys with 300 Exclusive Homes.
Total 3 Residential Tower.
Concrete Consumption Estimate = 250000m3
Steel Consumption Estimate = 35000 M.TON

WORLD ONE PROJECT :( A ) RAFT FOUNDATION :

3 m Depth Raft Supported on Pile Foundation.

Diameter of Pile :- 1200 mm & Depth of Pile :- 30 meter.

They Used M-40 Grade for Raft Foundation & M-60 for Piling
work.

Total Volume of concrete in Raft 15000 M3 SCC ( Self

Compacting Concrete )

KEY POINTS :Ingredient for M95 Grade Concrete :OPC + Micro silica + GGBS ( Ground Granulated Blast Furnace
slag )+
Fly ash + Super Plasticizer ( CHRYSO Fluid Optima S624)
Young Modulus E = 39 TO 46 GPA
Cube Strength @ 28 Days = 110-120 N/mm2
Water : Cement Ratio = 0.27
Slump Retention = Up to 3 Hrs.
Pumping Rate = 25-40M3/Hr.
V-Funnel Test Results :- Flow time Tf < 15 Sec.
Pump ability = 250-300 Meter in single stage.

( 4 ) NINA INDUSTRY :

Nina Industries are Basically involved in,

Water Proofing
Retrofitting and Restoration
Civil Finishing Works
Exterior Cladding and facades
Specialty Building Products
Floor Finishes
They are also involved in Fiber mesh Production
which is manufactured by PROPEX CONCRETE
SYSTEM

 FIBERMESH

:- (Polypropylene Fibers)

Fibermesh

are specially used in concrete and mortars as a

secondary reinforcement.
They are designed to provide an uniform three dimensional
distribution without any clogging or clumping.

ADVANTAGES :-

It

provides homogeneous concrete mix without segregation

problem taking place, resulting in denser concrete mix with
drastically reduced honeycombing and bleeding problems.
It reduces shrinkage cracks by over 90% and also provide effective
crack control to temperature cracks and thermal cracking in mass
concretes.
It reduced permeability of the concrete also protects the steel
reinforcement from corrosion by preventing ingress of water and
other harmful pollutants.
It improves Impact Resistance of Concrete ( Almost Double) as well
as increase Absorption Resistance by 50%.
It prevents explosive spalling of concrete due to fire, by the fibers
melting and providing millions of microscopic vapour channels.

APPLICATIONS

: Industrial floor slabs, pavements, wearing courses, car parks,

etc.
Roof slabs, Basement Raft and Retaining Walls, Sloping Slabs,
Cantilevers and Thin sections and all general reinforced concrete
elements.
Water retaining structures and effluent treatment plants
Marine structures.
External and Internal plaster.
Tunnel linings, canal linings, spillways.
Structures in seismic areas.
Concrete encasements of steel sections for fire resistant
purposes.
Precast and prestressed concrete elements.
Pumped Concrete and Slip-formed structures.
Bridge decks
IPS Screeds, Toppings.
Precast Walls. Etc.