Concrete

Self compacting concrete for structural components

Published

5 years ago

October 14, 2021

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Satander Kumar, Scientist (Retd), talks about the importance of Self Compacting concrete and the other technical aspects of the same.

Concrete, which may be manufactured at site, occupies unique position among modern materials. Concrete has its own limitation- it can not, on its own, flow into nooks and corner of the form work. Through compaction, often using vibration is essential for achieving strength and durability of concrete. It has its own limitation depending on the types of structures, its dimensions, and types of reinforcement, location of structures etc. Self compacting concrete (SCC) may provide remedies to these problems. Developed by Prof. Okamura and his team in Japan in 1986, SCC has evolved as new innovative technology, capable of achieving status of being an out-standing advancement in the sphere of concrete technology. There are now many countries who are working on SCC viz Sweden, Thailand, UK, India etc.

"No vibration" is necessary for SCC which can flow around obstructions, encapsulate the reinforcement and fill up the space completely under self weight. The salient advantages are; ensure through compaction employing unskilled labour, minimise repair of finished surface, ensure good finished surface, reduced manpower for casting and finishing, increase in speed of construction and reduces requirements of coarse aggregates and minimises electrical and mechanical energy. Development of SCC is not nascent in stage now. IRC: 112 also recommend use of SCC in concrete bridges and the same is under draft stage to be put in rigid pavement and cell fill pavement by IRC. Studies on SCC and cell fill pavement (which requires SCC also) is largely being undertaken by PL Bongirwar Advisor L&T and Prof BB Pandey, IIT Khargpur. However, it has been tried in the field on many projects in India now. As a safe guard against separation of water, use of a viscosity modifying agent is usually essential to minimise shrinkage due to high powder content in SCC besides additional requirements of fines passing 125 micron. There are typical mixes of SCC similar to conventional concrete where risk of cracking due to shrinkage and thermal stresses could be reduced. Addition of fly ash and other siliceous mineral admixtures such as silica fume, ground granulated slag in conventional concrete in addition to chemical admixtures, make sustainable ‘SCC’. There are many organisation/academic institutions/cement companies (CRRI, NCB, SERC, CBRI, L&T, ACC, Ultra-Tech, Ambuja Cements in India who are working hard in the laboratory and field for the advancement and use of SCC in structures to minimise carbon emission and making cost effective construction product. There is a need to formulate IRC/BIS specifications/ guidelines for the use of SCC in respective structures based on the experience/data gained in India. Guidelines are published by Hampshire, UK (EFNARC-2002)/contract documents on use of SCC in Nuclear Structures. For more details on mix design, materials required, and its different applications reference of June Issue (No. 6 2004) of Indian Concrete Journal may be made. The paper reviews some of the R&D activities carried out in India and abroad. A constant strive to improve performance and acceleration of productivity led to the development of self-compacting concrete (SCC). Traditionally placed concrete mix is compacted with the help of external energy inputs with vibrators, tamping or similar actions. On the other hand, SCC mix has special performance attributes of self-compaction/consolidation under the action of gravity.

Comparison between conventional and SCC

The concrete that is able to flow and consolidate under its own weight, completely fills the formwork even in the presence of dense reinforcement, whilst maintaining homogeneity and without the need for any additional compaction is called Self-compacted fresh concrete. It has the ability to fill formwork and encapsulate reinforcing bar only through the action of gravity, and with maintained homogeneity. The ability is achieved by designing the concrete to have suitable inherent rheological properties. SCC can be used in easy way in most applications where traditionally vibrated concrete is used taking precaution on size of coarse aggregate which kept smaller than conventional size of aggregates. This also depends on spacing of reinforcement (not more than two times the spacing between steel bars. For mould ability, a concrete mix should have the ability to fill the formwork as well as encapsulate reinforcing bars and other embedment in fresh state maintaining homogeneity. In case of conventional mix, it is achieved by means of ensuring a minimum level of slump at fresh state and placing it with the help of external energy. However, a fresh SCC mix shall have appropriate workability under the action of its self-weight for filling all the space within form work (filling ability), passing through the obstructions of reinforcement and embedment (passing ability) and maintaining its homogeneity (resistance to segregation).

High deformability can be achieved by appropriate employment of super plasticizer, maintaining low water powder ratio and viscosity modifying agent (VMA), if needed. These are the basics to achieve the flowability and viscosity of a suspension to achieve self compacting properties. The rheological characteristics of fresh concrete mix is not only necessary for workability to achieve desired mould ability but they also help in achieving desired in-situ strength and durability attributes at the hardened state. The difference between the SCC and conventional concrete exists in the performance requirements during fresh state;

Potential techno-economic advantages

The advantages of SCC are:

i) Enhanced productivity,

ii) Reduction of costly labor and noise discomfort at site.

iii) Improved surface finish

iv) Improved quality of hardened concrete

v) Improvement of working condition

vi) Usage of higher dosages of fly

vii) Enhancement in flow ability

The SCC is a therefore preferred option considering these properties for structures and road (both in insitu and precast components) noting the fact that dense compact concrete in line and level is a prime requirement. Minimum efforts or zero efforts in vibration means light and ordinary screed/needle/side compactor may require in certain situation to get surface in line and level and dense concrete. SCC is therefore ideal solution for rigid pavement and structures.

Material

Following materials are generally being adopted in making SCC; mineral Admixtures (IS 456-2000) viz fly ash, silica fume, ground granulated slag.Chemical Admixture (nathalene based, malamine based, polycaroxylic (PC) based, Geleniun based, viscosity modifier etc. Binder (PPC).

Rhelogy

Rheology is the study of flow and deformations of all forms of matter. The basic property influencing the performance of the fresh concrete in casting and compaction is its rheological behavior. Rheology has thus been central in the development of SCC. Rheology of concrete, mortar as well as paste are all valuable tools in understanding the behavior and optimisation processes.

In workability terms, self-compatibility signifies the ability of the concrete to flow after being discharged from the pump hose, a skip or similar, only through gravity and to fill intended spaces in formwork to achieve a zero-defect and uniform-quality concrete. Self-compatibility as a fresh state property can be characterised by three functional requirements: Filling ability, resistance to segregation and passing ability.

Workability test

Slump-flow test: The slump-flow diameter is a test to assess the flowability and the flow rate of self-compacting concrete in the absence of obstructions. It is based on the slump test described in EN 12350-2, IS 1199, Testing fresh concrete – Part 1: Sampling, EN 9103, Testing fresh concrete – Part 2: Slump test. Visual observations during the Slump flow test and/or measurement of the T500 time can give additional information on the segregation resistance.

Prepare the cone and baseplate as described in EN 12350-2. Fit the collar to the cone if being used (Figure 1). Place the cone coincident with the 200 mm circle on the base plate and hold in position by standing on the foot pieces (or use the weighted collar), ensuring that no concrete can leak from under the cone. Fill the cone without any agitation or rodding, and strike off surplus from the top of the cone. Allow the filled cone to stand for not more than 30s; during this time remove any spilled concrete from the baseplate and ensure the baseplate is damp all over but without any surplus water. Lift the cone vertically in one movement without interfering with the flow of concrete. Without disturbing the baseplate or concrete, measure the largest diameter of the flow spread to the nearest 10 mm. Then measure the diameter of the flow spread at right angles to the nearest 10 mm and record,Check the concrete spread for segregation. The cement paste/mortar may segregate from the coarse aggregate to give a ring of paste/mortar extending several millimetres beyond the coarse aggregate. Segregated coarse aggregate may also be observed in the central area.

V-funnel test: Clean the funnel and bottom gate, the dampen all the inside surface including the gate. Close the gate and pour the sample of concrete into the funnel, without any agitation or rodding, then strike off the top with the straight edge so that the concrete is flush with the top of the funnel. Place the container under the funnel in order to retain the concrete to be passed. After a delay of (10 Â¦ 2) s from filling the funnel, open the gate and measure the time to 0,1 s, from opening the gate to when it is possible to see vertically through the funnel into the container below for the first time. The time determined is the V-funnel flow time. (Figure 2 (a))The slump flow requirement for different application is given in Table 1.

Specification

The filling ability and stability of self-compacting concrete in the fresh state can be defined by four key characteristics. Each characteristic can be addressed by one or more test methods as shown in Table 2. As per conformity given in Table 3.

Tentative mix proportion

Mix designs are often use volume as a key parameter because of the importance of the need to over fill the voids between the aggregate particles. Some methods try to fit available constituents to an optimised grading envelope. Another method is to evaluate and optimise the flow and stability of first the paste and then the mortar fractions. The absolute volume of all proportion shall be 1 cu m including volume of admixture/air. (Table 4.)

Self compacted concrete is the need of the hour where heavy compaction is not required without utilising scarcely available electricity, equipment and fuel for driving them at remote places/ pavement. More R&D is needed for finding performance of such concrete products.

Satander Kumar, Scientist (Retd) Central Road Research Institute, New Delhi

Concrete

ABB Extends Drive Lifespan at ACC Cement Plant Without Production Shutdown

Published

4 hours ago

November 12, 2026

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ABB reconditions 25 drives at ACC’s Jamul cement plant, avoiding 16 tonnes of CO₂ emissions while improving reliability through predictive maintenance.
Chhattisgarh

ABB has signed a multi-year Motion OneCare service agreement with ACC Limited, part of the Adani Group, to modernise ageing industrial drives at its Jamul cement plant in Chhattisgarh, improving operational reliability while avoiding approximately 16 tonnes of carbon dioxide (CO₂) emissions without disrupting production.

Announced on 27 October 2026, the agreement combines scheduled drive reconditioning, digital condition monitoring and energy appraisals to extend equipment lifespan, improve plant uptime and optimise maintenance costs. The initiative marks a shift from conventional equipment replacement towards a more resource-efficient approach to industrial asset management.

The first phase, completed in April 2026, involved the on-site reconditioning of 25 ABB ACS800 variable speed drives without a major plant shutdown. By retaining the existing cabinets and restoring the drive modules rather than replacing entire panels, ABB helped ACC preserve capital investment, minimise material consumption and avoid approximately 16 tonnes of CO₂ emissions.

A second phase, covering an additional 25 ACS800 drive modules, is scheduled for the fourth quarter of 2026. The programme is designed to improve long-term equipment reliability while allowing maintenance activities to be aligned with the plant’s operational schedules.

The ACS800 drives, installed at Jamul in 2010, had delivered more than a decade of near-continuous service in demanding cement manufacturing conditions. However, ageing electrical components and changing fault patterns had begun to affect their ability to meet the plant’s reliability requirements.

Rather than opting for complete equipment replacement, ACC engaged ABB’s certified engineers to conduct a comprehensive asset health assessment. The evaluation found that the existing cabinets and enclosures remained structurally sound, making targeted reconditioning a technically viable and cost-effective alternative to full replacement.

Drawing on nearly two decades of experience with ACC’s equipment and operating requirements, ABB developed a maintenance framework tailored to the plant’s shutdown windows, budget cycles and production priorities.

The Motion OneCare agreement incorporates planned equipment restoration, condition-based monitoring and energy assessments, enabling ACC to adopt a more systematic approach to maintaining critical electrical infrastructure.

As part of the programme, ACC has implemented ABB Ability™ Digital Powertrain Insights to monitor drive performance and identify emerging operational issues before they result in equipment failures.

The digital platform provides continuous visibility into parameters such as temperature, current, vibration and fault patterns. These insights allow maintenance teams to detect early signs of equipment deterioration, schedule interventions more effectively and reduce the likelihood of unexpected downtime.

Amit Gupta, Local Division Manager, Motion Services, ABB India, said: “We know what unchecked wear costs over time: a small inefficiency that eats away at ROI for years. At Jamul, the evidence pointed clearly to assets with productive life still in them.”

“Our job was to restore them properly and give the team the tools to stay ahead of the next problem. At ABB, we don’t just fix what fails. We want to protect what works.”

The initiative also demonstrates the growing relevance of circular economy principles in cement manufacturing, where extending the service life of existing industrial equipment can reduce capital expenditure, material consumption and the environmental impact associated with manufacturing replacement components.

According to ABB, drive reconditioning can reduce lifecycle emissions by 50 to 80 per cent compared with complete equipment replacement. By preserving functional components and restoring critical modules, the process helps retain the economic and material value of existing industrial assets.

The addition of energy appraisals in subsequent phases will further expand the programme beyond equipment restoration, enabling ACC to assess drive performance, identify energy-saving opportunities and improve operating efficiency.

For cement manufacturers, variable speed drives play an important role in controlling motors and optimising energy consumption across production processes. Maintaining their reliability and efficiency is essential for minimising operational disruptions and managing electricity costs.

Vinod Bahety, CEO – Cement Business, Adani Group, said: “Moving from reactive firefighting to a structured maintenance plan was exactly what this operation needed. That kind of peace of mind doesn’t come easily. It comes from a partner that understands how your business runs.”

“We didn’t need a full system overhaul; we needed expert support, actionable insights, and a plan we could execute around our schedule. That’s what we got.”

The project supports ACC’s broader strategy to improve manufacturing efficiency through digital transformation, preventive maintenance and sustainable asset management.

ACC, a subsidiary of Ambuja Cements and part of the Adani Group, operates 20 cement manufacturing facilities and 119 ready-mix concrete plants across India. The company has been advancing initiatives focused on renewable energy, circular economy practices and technology-driven operational improvements.

Alongside Ambuja Cements, ACC is part of a large-scale building materials business committed to achieving net-zero emissions by 2050, with near-term and net-zero targets validated by the Science Based Targets initiative (SBTi).

The Jamul initiative aligns with these sustainability objectives by demonstrating how equipment life extension and digital monitoring can contribute to resource efficiency without requiring large-scale replacement of existing infrastructure.

ABB, a global technology company specialising in electrification and automation, brings more than 140 years of industrial expertise and employs approximately 110,000 people worldwide. Its Motion Services business supports industrial customers through equipment maintenance, modernisation, digital monitoring and lifecycle management solutions.

The agreement also reflects a wider shift in industrial maintenance practices, with manufacturers increasingly adopting predictive technologies to improve equipment availability, manage costs and reduce unplanned shutdowns.

With 25 drives already reconditioned and another 25 scheduled for restoration, ABB’s collaboration with ACC illustrates how targeted modernisation, digital monitoring and circular maintenance practices can extend the operational life of critical equipment while supporting more efficient and sustainable cement production.

Concrete

ABB Drives Digital Transformation at TCI MAX Cement Plant in J&K

Published

5 hours ago

November 12, 2026

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ABB deploys advanced process control at TCI MAX’s Srinagar cement plant to improve clinker quality, energy efficiency and sustainable manufacturing.

Kashmir

ABB has deployed its advanced process control technology at TCI MAX Cement’s Srinagar facility in Jammu and Kashmir, marking the region’s first reported implementation of advanced process control (APC) in cement manufacturing and strengthening efforts towards more efficient, digitally enabled production.

Announced on 5 November 2026, the deployment of ABB Ability™ Expert Optimizer at the facility, operated by Trumboo Industries Pvt. Ltd., aims to improve process stability, clinker quality, energy efficiency and overall plant productivity. The implementation forms part of TCI MAX’s strategy to modernise its manufacturing operations through automation and digital technologies.

Following the integration of ABB’s advanced process control solution and supporting IT infrastructure, TCI MAX has reported improvements in operational productivity, product quality and sustainability-related performance indicators. The technology focuses on optimising the cement pyro process, a critical stage of production involving high-temperature processing and clinker formation.

Waseem Ahmed Trumboo, Director, Trumboo Industries Pvt. Ltd., said: “Introducing advanced process control at TCI MAX is an important step in how we are evolving our operations. Our focus is on improving the stability and efficiency of our processes while maintaining consistent clinker quality. We have been encouraged by the performance of the solution during commissioning and by the support from the ABB team, and we look forward to realizing its full potential.”

ABB Ability™ Expert Optimizer combines advanced process control, model predictive control (MPC) and artificial intelligence (AI) to continuously monitor and optimise manufacturing operations. By analysing process conditions, predicting operational behaviour and automatically adjusting key parameters, the system enables more consistent production while reducing process variability.

In cement manufacturing, maintaining stable pyro-processing conditions is essential for achieving uniform clinker quality and optimising thermal energy consumption. Fluctuations in operating parameters can affect fuel efficiency, production output and product consistency.

The deployment is designed to address these challenges through real-time process optimisation, helping operators maintain more stable kiln operations while improving the utilisation of fuel, electricity and raw materials.

Kapil Agarwal, Senior Vice President and Local Division Manager, Process Industries Division, ABB India, said: “Cement producers are increasingly looking to adopt digital technologies to achieve greater consistency and efficiency while addressing their sustainability priorities. ABB Ability™ Expert Optimizer brings advanced process control and deep cement process expertise together to help operators make their processes more stable and efficient. We are pleased to support TCI MAX as it takes this important step in its digital transformation.”

The technology also supports sustainability objectives by optimising fuel consumption, improving electrical energy efficiency and minimising process waste. More stable operations can contribute to lower energy intensity and reduced emissions associated with cement production.

For TCI MAX, the investment represents a move towards data-driven manufacturing, where automated control systems complement operator expertise to improve production performance and operational reliability.

The implementation is particularly significant for Jammu and Kashmir’s cement industry, as it introduces advanced process optimisation technology to a regional manufacturing facility. Its deployment could demonstrate the potential for wider adoption of digital automation across cement plants seeking to modernise their operations.

The project builds on ABB’s experience in delivering advanced process control solutions to cement manufacturers worldwide. Through the integration of industrial automation, predictive technologies and process engineering expertise, the company supports manufacturers in improving resource efficiency and maintaining consistent production quality.

As cement producers face increasing pressure to manage energy costs, improve productivity and reduce their environmental footprint, technologies such as AI-enabled process control and predictive optimisation are becoming important components of plant modernisation strategies.

ABB’s Expert Optimizer provides a platform for addressing these priorities by enabling automated adjustments based on changing process conditions, reducing reliance on manual intervention and supporting more efficient plant operation.

ABB, a global technology company specialising in electrification and automation, has more than 140 years of industrial experience and approximately 110,000 employees worldwide. Its Automation business employs around 26,000 people and provides technologies and services across process, hybrid and maritime industries.

The TCI MAX deployment reinforces ABB’s growing role in the digital transformation of cement manufacturing in India, where improving process efficiency and reducing energy consumption remain critical to the industry’s long-term sustainability.

With the advanced process control system now implemented at its Srinagar facility, TCI MAX aims to build on the initial operational improvements and further optimise production efficiency, clinker consistency and environmental performance.

Concrete

Ramco Cements’ Hard Worker Wins Eight Awards at ‘Love of Advertising Awards 2026’

Published

5 hours ago

November 12, 2026

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Ramco Cements’ Hard Worker brand wins eight awards for excellence in advertising, packaging and brand identity at the Love of Advertising Awards 2026.

Hyderabad

The Ramco Cements Limited’s construction chemicals brand, Hard Worker, has secured eight awards at the Love of Advertising Awards 2026, recognising its creative excellence across television, digital advertising, packaging design and brand identity.

Organised by the Advertising Club of Trivandrum, the awards were presented at a ceremony held at The Leela Raviz, Kovalam, on 24 October 2026. The recognition highlights Hard Worker’s integrated marketing strategy and its efforts to establish a distinctive presence in India’s competitive construction chemicals market.

The eight awards span multiple creative categories, reflecting the brand’s approach to combining product-focused communication with engaging storytelling, humour and innovative design. Through its campaigns, Hard Worker has sought to simplify technical product benefits and make construction chemicals more accessible and relatable to consumers and construction professionals.

Built around the philosophy of “Hard-working products for hardworking people”, the brand focuses on communicating practical product advantages through memorable advertising narratives while maintaining a consistent identity across different marketing platforms.

Its campaigns for Ramco Hard Worker Eco Plaster and Tile Fix have been central to this approach. The Eco Plaster campaign highlights water conservation through the product’s self-curing properties, positioning it as a solution that supports more efficient construction practices. Meanwhile, Tile Fix promotes specialised tile-fixing solutions by presenting their practical benefits through relatable situations and creative storytelling.

Beyond advertising, Hard Worker has invested in distinctive packaging and brand identity development to improve product recognition and maintain consistency across customer touchpoints. This integrated approach has helped the brand differentiate itself in a category where marketing communication has traditionally focused on technical specifications and functional performance.

A V Dharmakrishnan, CEO, Ramco Cements, said, “Winning eight awards at the Love of Advertising Awards is a proud moment for Ramco Cements and the Hard Worker team. We believe that building a strong brand requires not only quality products but also the ability to communicate their value in a compelling and differentiated manner. Hard Worker’s journey reflects our commitment to combining product performance with innovative marketing to create meaningful connections with our customers and strengthen our presence in the construction chemicals market.”

The recognition comes as building materials manufacturers increasingly focus on brand differentiation, product awareness and customer engagement to strengthen their position in the construction chemicals segment.

By using humour and storytelling to explain product applications and benefits, Hard Worker aims to bridge the communication gap between technical construction solutions and the practical requirements of contractors, applicators and end-users.

Balaji K. Moorthy, Executive Director – Marketing, Ramco Cements, said, “Hard Worker was conceived to bring a fresh perspective to the construction chemicals category, where product communication has traditionally been functional and technical. Our endeavour has been to break through the clutter with distinctive ideas, humour and storytelling, while keeping the product proposition at the heart of every campaign. The recognition across TV and digital advertising, packaging design and brand identity design demonstrates our integrated approach to building the brand. These eight awards are an encouraging recognition of the creative thinking and collaborative effort behind Hard Worker’s marketing initiatives.”

The awards add to Hard Worker’s growing portfolio of creative recognitions and reinforce Ramco Cements’ emphasis on integrating product innovation with strategic marketing.

The brand’s communication initiatives also reflect a wider shift in the construction materials industry, where manufacturers are increasingly adopting consumer-focused marketing strategies to improve product understanding and strengthen relationships with construction professionals.

With its portfolio of construction chemicals, Hard Worker aims to address evolving requirements for durability, application efficiency and construction quality. Its marketing efforts seek to complement these product attributes by building stronger awareness and encouraging the adoption of specialised construction solutions.

Ramco Cements, one of India’s established cement manufacturers, operates across cement and allied building solutions. Through Hard Worker, the company is expanding its presence in the construction chemicals segment with products designed to enhance performance, quality and durability in modern construction applications.

The latest recognition strengthens Hard Worker’s brand visibility and underscores the growing importance of creative communication in promoting technical building materials. Ramco Cements intends to continue combining product development with distinctive marketing initiatives to support the brand’s growth in India’s construction chemicals market.