Interns @ Ultratech

ULTRATECH CEMENTS(Aditya Birla Group) 2
 A US $35 billion corporation, the Aditya Birla Group
is in the League of Fortune 500
 Anchored by an extraordinary force of over 133,000
employees, belonging to 42 different nationalities
 Over 60 per cent of its revenues flow from its
overseas operations.
 The Group operates in 33 countries

BUSINESS
 The world’s most cost-efficient aluminium and
copper producers. Hindalco-Novelis is the largest
aluminium rolling company.
 No.1 in viscose staple fibre
 The largest producer of carbon black
 The 4th largest producer of insulators
 The 5th largest producer of acrylic fibre
 Among the top 10 cement producers
 Among the best energy-efficient fertilizer plants

 A top fashion player (branded apparel – Van Huesen,
Louis Phileppe, Peter England , Allen solly etc…….)
 The 2nd largest producer of viscose filament yarn.
 The largest producer in the chlor-alkali sector.
 Among the top three mobile telephony companies.
 A leading player in Life Insurance and Asset
Management.
 Among the top two supermarket chains in the retail
business.
 Among the top 10 BPO companies

 UltraTech cement is the 8th largest cement producer in
the world
 UltraTech is the country's largest exporter of cement
clinker( 45% of total exports)
 UltraTech and its subsidiaries have a presence in 5
countries through
 11 integrated plants,
 1 white cement plant,
 1 clinkerisation plant,
 15 grinding units,
 2 rail and 3 coastal terminals and
 101 RMC plants.

OBJECTIVE OF CEMENT COMPANY??
6ULTRATECH CEMENTS(Aditya Birla Group)
 To be No.1
 How?
 “ To sell as many bags possible”
○ Possible when they INNOVATE.
○ Whitetopping is one such innovative concept
promoted by cement manufacturers across
world

WORK ASSIGNED?
 To do a study on Whitetopping technology.
 Concrete mix design using blended cements
for 7th day serviceability of road.
 Portland Pozzalana cement and
 Portland slag cement

WHITETOPPING
 Definition : It’s a PCC overlay on top of
existing bituminous pavement.
 How old is technology?
 Very old , works date back to early 1900’s
 Pretty new to India.

WHY WHITETOPPING?
 Rutting of bituminous pavement is a real
problem in hot climate like India, with heavy
truck loads, operating under frequent
start/stop conditions.

ADVANTAGES
 Extended service life
 Increased structural capacity
 Reduced maintenance requirements and
 Lower life-cycle costs
 Improvement in safety in view of the increased
reflection of light
 Improving the environmental benefits – as
concrete roads are much greener and less
polluting.

VARIETY OF WHITETOPPING
 Classification based on degree of bonding
between the underlying bituminous layer with
PCC overlay and the thickness of the overlay
 Conventional Whitetopping:
 Thin Whitetopping(TWT):
 Ultra-Thin Whitetopping (UTWT):

 Conventional Whitetopping( No bonding
considered)
 Thickness of 200 mm or more
 Designed as new rigid pavement
 Thin Whitetopping( often bond considered
but not mandatory)
 Thickness > 100mm but < 200mm
 Ultra-Thin Whitetopping ( Bonding is
mandatory)
 Thickness less than or equal to 100mm

CONSTRUCTION
Scraping of the existing Bitumen Road to get
key

Cleaning of the scraping grit

Aligning of rails for paver movement

Receiving of first pour of concrete

Paver Machine in operation

Bull float operation

Surface Texturing being done

ULTRATECH CEMENTS(Aditya Birla Group) 20Quality check – controlled slump most essential
Day
Night

Spraying of Curing Compound

Covering Fresh Concrete with plastic Sheets
to prevent moisture loss and wind

Groove cutting in progress

Finished surface

STEPS IN DESIGN
1. All the needed information for the project
are collected
2. Target average flexural and compressive
strength is estimated on the basis of minimum
specified strength.
3. Water-cement ratio is determined.
4. Gradations of coarse aggregate, fine aggregate
to give required combined aggregate grading.
5. Required workability is chosen
6. Proportions of all ingredients of mix are found

Goal
 To achieve minimum of M35 strength on
7th day.
 Flexural strength of 4 Mpa as
recommended by IRC.

1. PSC MIX PROPORTION
Cement = 410 kg
Coarse aggregate 20 mm = 640 kg
12.5 mm = 523 kg
Manufactured sand = 775 Kg
Water = 139.50 Kg
Admixture(dosage @ 0.5% by weight of cement) = 1.863 litres
Total density = 2487.5 kg/m3

2. PPC MIX PROPORTION
Cement = 410 kg
Coarse aggregate 20 mm = 640 kg
12.5 mm = 523 kg
Manufactured sand = 775 Kg
Water = 139.50 Kg
Admixture(dosage @ 0.4% by weight of cement) = 1.64 litres
Total density = 2487.5 kg/m3
(NOTE: The quantities above are for 1 m3 of concrete)

TESTING
 At CIVIL-AID TECHNOCLININC PVT LTD
(A Bureau Veritas Group company),
Bengaluru

RESULTS
SL.
NO
CEMENT
TYPE
NO OF
CUBES
CASTE
D
FOR COMPRESSIVE
STRENGTH
ON/AFTER
AVERAGE
STRENGTH
RECOMMENDED
Mpa
AVERAGE
STRENGTH
OBTAINED
Mpa
1 PSC 15 7 Days 35 37.87
15 28 Days >35 >50
2 PPC 15 7 Days 35 39.28
15 28 Days >35 52.09

CONCLUSION
 The criteria of achieving strength of 35Mpa
on 7th day can be successfully obtained by
adopting the above mentioned mix
proportions, there by reinforcing the belief
that even the “blended” cements can be
used for the design of concrete roads.

THANK YOU

Interns @ Ultratech

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