Steel industry by products for sustainable constructions

Dr.L.R.Manjunatha BE,MBA,PhD
Associate Vice President-Direct Sales, JSW Cement limited, India,
Email: manjunatha.ramachandra@jsw.in
Mobile : 9480682100
.
Steel Industry By Products for Sustainable Constructions
Steel Industry by products for sustainable
Constructions
Use of slag from steel Industry as SCM and Fine
aggregates in Concrete
Webinar on-8.7.2021,Kota RajasthanTechnological
University

JSW is a $14 billion conglomerate with presence across key
sectors
5
India’s leading
integrated steel
producer with
18 MTPA steel
capacity
Arrived ( Vasind
& Vijaynagar)
Services the
entire energy
value chain with
a total capacity
of 4,531MW
Operates
environment
friendly seaports
& terminals with
capacity of
200 MTPA
Manufacturer of
‘Portland Slag
Cement’ and
‘GGBS’ with
capacity of ~
14 MTPA

OUR CONTRIBUTION TO INDIA’S PROGRESS
4

Capacity expansion planned across plants in the next 2-3 years to
become a 20 MTPA player
UAE
Andaman &
Nicobar
Tamil Nadu
Kerala
Karnataka
Andhra
Pradesh
Maharashtra
Goa
Salboni GU- 2.4 MTPA
Expansion planned-
2.4 to 4.8 MTPA
Shiva- 0.2 MTPA
Clinker capacity
Expansion Planned
0.2 to 1 MTPA
Nandyal
Integrated Unit
4.8 MTPA
Vijaynagar GU- 3.2 MTPA
Expansion planned-
3.2 to 5.2 MTPA
Dolvi GU- 2.2 MTPA
Expansion planned-
2.2 to 4 MTPA
West
Bengal
Fujairah (UAE)
Clinkerization unit
(1 MTPA)
Jajpur Grinding Unit,
Orissa (1.2 MTPA)
Odisha
4

From the House of JSW cement
5
JSW
SCREENED
SLAG

JSW –GGBS & PSC Production in India
PLANT CAPACITY IN
mMT
GGBS PSC
VIJAYANAGAR 1.5 3.1
NANDYAL 1.5 4.8
DOLVI 1 2.2
WEST BENGAL-SALBONI 2.4
TOTAL 4 12.5
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The Challenges for the Future World
By 2050 9.8 billion
people on the planet
• 80% of that will live in
urban environment
• Majority live on coastal
area
• Leading to
development of
massive urban
infrastructure
More concrete
jungles
• Urban floods
• Urban heat high
lands
• powerful
typhoons
Considerable
damage to the
lives of people
• Impact on social
and Environment
conditions
• Global worming
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Call for achieving
Global
sustainability

Availability of clean air in the world
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GREEN HOUSE EFFECT
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Urban heat highland Effect
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Sector wise CO2 Emissions
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BUILDING
INDUSTRY –STEEL
AND CEMENT
CONTRIBUTE
ABOUT 12%

Construction Industry out look
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Fine and ultrafine materials are being used for over 2000 years
and their use has justified
DURABILITY and SUSTAINABILITY of CONCRETE
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Sustainability
What is sustainability
How much of this are we
addressing w.r.t. concrete?
‘What’ is sustainable, and
for ‘Whom’; e.g. ‘Bad
concrete’ is sustainable 
General consensus:
•Lower CO2
•Lower energy
•Prolonged life
‘Global’ vs. ‘Local’ solutions
Wikipedia
Triple bottomline
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What is a green building?
 High-performance building that reduces its environmental footprint through
sustainable site selection and conservation of energy and resources, while
improving the health and productivity of its occupants
 With more and more people going green in an effort to save the environment,
the demand for eco-friendly green homes has been on the rise.
 . Green homes are not only beneficial for the environment but also for the
economy.
 Green homes are designed to be energy efficient and environment friendly.
 These buildings use natural sustainable materials provides many benefits not
found in traditional building materials in terms of comfort and economy.
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Sustainability in Concrete making
 Various ways to implement sustainability in concrete:
Ingredients Approach
Cement Reduce consumption of OPC per cum by replacing with
supplementary cementitious materials-Flyash /slag
Aggregates Recycle – fresh Concrete / Demolished waste-substitute of
recycled for virgin materials
Fine Aggregates Reduce River sand use – Alternate CSS/Slag sand
Water Recycle water, Recharge Ground water
Improved durability By doubling the service life of structure brings down half
the amount of materials needed for replacement.
Doubling the concrete strength for strength controlled
members
Brings down the requirement of materials
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Some necessary points for achieving Durability
(Performance).
 In mix design we give importance to packing of course materials we
should give importance to particle packing of materials in the binders
 To keep the water/binder ratio as low as possible.
 Should use good quality fine materials like slag, fly ash etc.
 GONE ARE THE DAYS OF EXCESSIVE USE OF OPC & WATER
HOWEVER CURING IS VERY VERY IMPORTANT
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NEW GENERATION GREEN MATERIALS FOR
CONSTRUCTIONS
Mineral admixtures
Chemical admixtures
Alternative to river sands
Alternatives to coarse aggregates
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River sand-Has become the rarest commodity ?
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Local sand Issues
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Media reports on demand for River sand
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UN Report on mining of sand across the world
 Mining operations outside the U.S., in Asia, Africa and the Middle East, pose a different set of
problems, although the market driver for sand worldwide is much the same--urbanization.
According to the UN, cities are expanding at an historic rate. Half the world’s population now lives
in an urban area. Since 1950, city populations have grown by 400 percent. Today there are 4
billion metropolitans.
Over the next 30 years, another 2.5 billion will be moving in. Serving their needs will require
concrete—a lot of it. Housing, office and retail spaces, roads, schools, hospitals, stadiums and
more all require sand.
Global demand for mined materials stands today between 47 to 59 billion tons. Gravel and sand
comprise 68 to 85 percent of the total. As people move into cities, the demand for sand and
aggregates moves with them.
The explosive growth of the global sand market comes with consequences. Mining’s impact on
the environment and society is surprising—more than that it is disturbing.
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A boat is stranded on the Poyang Lake in east China, site of one of the world’s biggest sand mines.
Photograph: Xinhua/Barcroft Image
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Completely depleted river due to
excessive sand mining

Rally for Rivers
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River sand vs M-Sand
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Need for Manufactured Sand
 Scarcity of natural river sand
– Quantity deficit
– Seasonal Availability
– Cost factors if River front is away
 Environmental Issues
– Environmental Degradation
– Ecological Considerations
 Legal Issues
– Ban on extraction
– Ban on movement from one State to another
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Shortage of River Sand
ENVIRONMENTAL ISSUES
Alternative Aggregates
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Manufactured sand River sand
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Manufacturing Sand Process
 3 stage crushing
– Primary :- Jaw crusher to create Raw feed stock pile
– Secondary :- Size reduction through cone crusher
– Tertiary :- Shape improvement through VSI/Cone
SI. No. Primary stage Secondary Stage Tertiary stage
a) Jaw crusher Cone Crusher Vertical Shaft Impact (VSI)
b) Jaw Crusher Cone Crusher Cone Crusher
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Manufacturing Sand Process
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M-Sand advantages
 Offsets Construction Defects
M-Sand has optimum initial and final setting time as well as excellent fineness which will help to
overcome the deficiencies of concrete such as segregation, bleeding, honeycombing, voids
and capillary.
 Economy
Usage of M-Sand can drastically reduce the cost since like river sand, it does not contain
impurities and wastage is NIL. In International Construction Scenario, no river sand is used at
all, only sand is manufactured and used, which gives superior strength and its cubical shape
ensures significant reduction in the cement used in the concrete
 Eco-Friendly
M-Sand is the only alternative to river sand. Dredging of river beds to get river sand will lead to
environmental disaster like ground water depletion, water scarcity, threat to the safety of
bridges, dams etc.
 Beside with the Government ban on dredging of River beds to quarry river sand, as part of the
growing concern for environment protection, M-Sand will be the only available option.
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M-Sand advantages
 Greater Durability
M-Sand has balanced physical and chemical properties that can withstand any aggressive
environmental and climatic conditions as it has enhanced durability, greater strength and
overall economy. Usage of M-Sand can overcome the defects occurring in concrete such as
honey combing, segregation, voids, capillary etc.
 High Strength
The superior shape, proper gradation of fines, smooth surface texture and consistency in
production parameter of chemically stable sands provides greater durability and higher
strength to concrete by overcoming deficiencies like segregation, bleeding, honey combing,
voids and capillary.
 Greater Workability
The crusher dust is flaky and angular in shape which is troublesome in working. There is no
plasticity in the mortar which makes it even difficult for the mason to work, whereas the
cubical shape with grounded edge and superior gradation gives good plasticity to mortar
providing excellent workability.
 _________
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Slag Sand – An Eco-Friendly Fine Aggregate
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 To reduce the burden on the environment, alternative aggregates have been
extensively investigated.
 Looking to the quantum of requirement, quality and properties future lies with
one material - Slags
 Slag aggregates has been proven as a suitable material for replacing natural
coarse and fine aggregates .
 In all developed countries, the use of Slags as aggregates to replace natural
sand/rocks is well established and is in regular practice.
Alternative Aggregates
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What is slag ?
 “Slag” is a non-metallic product, consisting of glass containing
silicates and Alumino Silicates of lime produced in steel industries.
 Slag is a byproduct of metal smelting processes, Manufactured
under quality-controlled conditions.
 Granulated slag is obtained by rapidly chilling (Quenching) the
molten slag from the furnace by means of water or steam and air.
 Does not contain organic matter, clay, silt and shells.
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Slag Generation
Coking coal
Iron ore
Fluxes
IRON MAKING STEEL MAKING
350 Kgs/T 200 Kgs/T
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Slag Dumping
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IRON
MAKING
STEEL
MAKING
Air Cooled
LD Slag
Coarse
Granulated
BF Slag
Fine
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Slags as Aggregates - Issues
 Properties differ from natural aggregates specifications
 No standards or specifications for alternative aggregates
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PROPERTIES RIVER SAND GBFS
Size IS 383 - Zone II / Zone I IS 383 - Zone II / Zone I
Deleterious Material 0.2 % Nil
Soundness Good Good
Density, Kg/m3 1400 - 1700 1000 - 1100
Sp Gravity 2.6 - 2.8 2.3
Water Absorption 1 – 3 % 4 -6 %
Fine
Aggregate
GBFS can
replace Sand
If meets specs
of IS-383
• Size
• Deleterious Material
• Soundness
• Bulk density
• Sp Gravity
• Water absorption
Granulated BF Slag as Fine Aggregate (River sand)
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Comparison of River sand and Granulated BF Slag
River Sand Granulated BF Slag
Lower density in slags is due to its vesicular structure with presence of micro pores
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Processing of BF slag
 Step 1: Altering granulation parameters
 Step 2: Shaping and Screening
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Processed Granulated BF slag – Slag Sand
• Particles shapes have improved.
• No sharp edges and the needle shaped particles.
• The processed granulated blast furnace slag (PGBS) was similar to true river sand.
Granulated
BF Slag
Processed
Granulated
BF Slag
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Processed Granulated BF slag
Gradation Size and Shape
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Properties
PROPERTIES RIVER SAND GBS PGBS
Size IS 383 - Zone II (Fine) IS 383 - Zone I (Coarse) IS 383 - Zone II
Density, Kg/m3 1400 - 1700 1000-1100 1500
Sp Gravity 2.6 - 2.8 2.3 2.65
Water Absorption 1 – 3 % 4 -6 % <3%
RIVER SAND SLAG SAND
Marine Products 2 - 4% Nil
Oversized Materials 6 - 10% Nil
Clay & Silt 5 - 20% Nil
Advantages Over River Sand
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Microscopic Examination
• Shape of the granulated slag sand is similar to river sand.
• Microscopically also, river sand and manufactured slag sand are similar.
Can be used 100 % individually and also in combination with River sand, Crusher Dust
and M-sand
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Chemical Tests - Inert
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Mortar/Concrete Tests
Fine Aggregate 7th day Strength
(N/mm2)
28th day Strength
(N/mm2)
100% Natural Sand 38-42 48-52
100% GBS 36.5 45.5
100% PGBS 42.9 53.3
50% PGBS + 50% NS 39 52
50% PGBS + 50% M - Sand 40.8 52.3
50% PGBS + 50% Crusher Dust 30.9 49.7
Flowability
Durability
Cube Testing
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Slag Sand preparation unit at JSW Vijayanagar Works
First of its kind
in the country
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Can be used in ……
Plain Concrete
Reinforced Concrete
Standard Ready-Mix Concrete
Dry Lean Concrete
Pavement Quality Concrete
Rapid-setting Concrete
Asphalt Concrete
Advantages
Environmental friendly alternative.
Controlled Physical and Chemical Properties.
No deleterious material.
Available through out the year.
Graded products to meet specific needs.
Suitable for Roads, Concrete, Plaster, Mortars,
RMC Plants etc.
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Recognitions
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Applications at JSW Steel
Roads at SMS-III
Foundation, Flooring and Roads at CRM-II Complex
Paver blocks at Township Plastering at BRM-II
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Usage at JSW – Project site
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FLOORINGS FOR HEAVY LOADS
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CSR Activities - Concrete Village Roads Roads & Canteen
Building at ACC Kudtini
Pavements / Roads at
Ozone Urbana Bangalore
Usage in nearby areas
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Plaster application with Slag sand in Building works
Location: Nirmiti Kendra Administrative Office Building, Bellary
Slag sand stock pile at work location
Plastering work on ceiling in the new office building of Nirmiti Kendra
Discussion and Interaction with government Civil Engineers by JSW staff
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Laying of GSB Using GLDS
Laying of DLC
Usage in Roads
KPCL-Sultanpur Road, Bellary
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Used in all three Layers
PQC – Pavement
Quality Concrete
DLC –Dry lean
Concrete
GSB – Granular Sub-
Base
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Constructed Road Portion – Capable of taking heavy loads
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Blast Furnace Slag sand used in village roads
Jumanal village, Bijapur district, Karnataka
by
Karnataka Rural Infrastructure Limited (KRIDL)
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Hospet-Bellary- (NH-63)
• Gammon Utilizing slag in GSB, DLC and PQC
• First time in India - a complete slag based road
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BIS – IS-383 Amendment
2nd - Revision 3rd - Revision
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Quantity
114407
192434
163655
400000
0
50000
100000
150000
200000
250000
300000
350000
400000
450000
2015-16 2016-17 2017-18 2018-19
Dispatch in Tonnes
Till Nov’17
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USE OF SLAG AS SCM IN CONCRETE
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 GGBS
 ULTRAFINE GGBS

Metakaolin
GGBS
Micro silica
Mineral admixtures – (IS 456:2000 : Clause 5.2)
SCM- SUPPLEMENTARY CEMENTATIOUS MATERIAL
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Micro silica
Alccofine
Rice Husk Asjh

Requirements of Quality of Concrete in different Environmental Conditions (TableIS:456:2000)
SI No. Exposure Plain Concrete Reinforced Concrete
Minimum Maximum Minimum Minimum Maximum Minimum
Cement Free W -C Grade of Cement Free Water - Grade of
Content Ratio Concrete Content Cement Concrete
kg/m3 % kg/m3 Ratio
(1) (2) (3) (4) (5) (6) (7) (8)
i) Mild 220 0.60 - 300 0.55 M20
ii) Moderate 240 0.60 M15 300 0.50 M25
iii) Severe 250 0.50 M20 320 0.45 M30
iv) Very severe 260 0.45 M20 340 0.45 M35
v) Extreme 280 0.40 M25 360 0.40 M40
NOTES
1. Cement content prescribed in this table is irrespective of the grades of cement and it is inclusive of additions mentioned in
5.2. The additions such as fly ash or Ground Granulated Blast Furnace Slag (GGBS) may be taken into account
in the concrete. composition with respect to the cement content and water-cement ratio if the suitability is established.
IS 456: 2000 RECOMMENDS THE USE OF BLENDED CEMENT AT DIFFERENT CONDITIONS.
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CHEMICAL COMPOSITION-GGBS
Parameters JSW Slag IS:12089 Limits
SiO2 32.73% ---
Al2O3 18.42% ---
Fe2O3 1.11% ---
CaO 37.34% ---
MgO 7.71% 17% max
MnO 0.12% 5.5 % max
LOI 0.41% ---
IR 1.59% 5% max
Sulphide Sulphur 0.39% 2% max
Glass Content 90-95% 85% min
( CaO + MgO + ½Al2O3 ) / (SiO2 + Al2O3 ) > 1
( CaO + MgO + Al203 ) / SiO2 > 1
Microscopic examination reveals
the glassy nature of GGBS
particles
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CLASS CONCENTRATION OF
SULPHATES AS SO3
TYPE OF CEMENT MINIMUM
CEMENT
CONTENT
Kg/m3
MAXIMUM
WATER /
CEMENT
RATIO
IN SOIL
(TOTALSO3)
(WT %)
IN GROUND
WATER (g/l)
(1) (2) (3) (4) (5) (6)
1. < 0.2 < 0.3 OPC,PSC OR PPC 280 0.55
2. 0.2 – 0.5 0.3 – 1.2 OPC,PSC OR PPC
SRC OR SSC
330
310
0.50
0.50
3. 0.5 – 1.0 1.2 – 2.5 PSC OR PPC
SRC OR SSC
350
330
0.45
0.50
4. 1.0 – 2.0 2.5 – 5.0 SRC , SSC 370 0.45
5. > 2.0 > 5.0 SRC, SSC WITH
PROTECTIVE
COATING
400 0.40
IS456 : 2000
DURABILITY OF CONCRETE:
(Table 4 Requirement for Concrete exposed to sulphate attack )
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Application GGBS replacement %
On the ground concrete structures with higher early age
strength requirement
25-35%
Underground concrete structures with average strength
requirement
35-50%
Mass Concrete or concrete structures with strict temperature
control requirement
50-65%
Speciality concrete structures with higher requirement on
durability i.e. Corrosion resistant marine structures, sewerage
treatment plants, etc.
50-70%
Replacement levels of OPC with GGBS in Concrete.
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Advantages of using JSW Cement Products
➢Improves Ultimate &
Flexural Strength of
Concrete
➢Max. Reduction in heat
of hydration.
➢High Impermeability.
➢Resistance to Chemical
Attacks
➢Dispersion
of Cement
Particles
➢ Particle
Packing
Effect
➢Secondary
Reaction

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Improved
resistance to
water
permeability
Best in class
resistance to
Sulphates &
Chlorides
(Coastal Area)
Lowest heat of
hydration-
least cracking
Long term
gain in
strength
Highest
ultimate
strength
Based on extensive research, it is found that Superior Concrete
Performance can be achieved with GGBS blends
Steel Industry by products for

/ PSC
Constructions

Case studies on GGBS Blended concretes in the
Indian context
1. Tricon RMC ,Pune
2. Sobha Indhraprastha, Bengaluru
3. Bangalore Metro Rail Corporation (BMRCL), Bengaluru.
4. Rmc Readymix
5.Hiranandhani
6.Salarpuria.
7.PWD
8.SN C
9.Irrigation Steel Industry by products for sustainable
Constructions

CASE STUDY 1 - Location: Tricon RMC, Pune
Grade
Mix design Concrete compressive strength
GGBS mix Fly ash mix 7 days 28 days
Cement GGBS Cement Fly ash Fly ash GGBS Fly ash GGBS
M20 200 125 245 85.0 11.2 12.4 26.8 28.3
M25 210 140 265 90.0 15.8 16.9 32.5 34.9
M30 230 140 300 90.0 17.3 19.2 36.0 39.4
M35 255 145 340 80.0 22.5 25.6 41.7 46.0
M40 295 135 370 70.0 24.9 28.4 46.5 49.2
M45 325 135 400 60.0 30.5 32.3 52.3 55.2
M50 337 140 450 50.0 42.4 36.9 57.0 62.0
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Case Studies –Tricon RMC at Pune
30
34.5
40
44.7
51.5
56.3
61
34
40.9
46.2
51
58.2
61.2
65
0
10
20
30
40
50
60
70
M20 M25 M30 M35 M40 M45 M50
Fly ash
GGBS
Grade of Concrete
Compressive
Strength
at
28
days
Variation of Compressive strength of different grades of concrete with respect to Fly ash and GGBS content . From
Figure 1, we can clearly say that 28 days compressive strength of GGBS based M20 grade concrete is higher over
Fly ash based concrete and the similar trend is carried for different grades also.
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CASE STUDY 2 – Location : Sobha Indraprasta , Bengaluru
sustainable Constructions

Elevation-Sobha Indraprashta project once fully completed
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Technical requirements achieved using GGBS
for M50 SDC.
1. Slump obtained:650+30mm
2. Compressive strength at 7 days: 42Mpa
3. Compressive Strength at 28days: 63.1Mpa
4. Compressive Strength at 90days:72.5Mpa
5. Compressive strength at 181days: 78.6Mpa
Monolithic structure, Sobha Indhraprastha
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Long term strength gain of GGBS blended concrete at Sobha
Indhraprastha (Snap shot from laboratory records)
Courtesy :Sobha Limited :Indraprasta technical team
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OPC+GGBS:170+170

Case study -4: Bengaluru Metro Rail Project – Phase 2
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Sl.
No
Type of
Work
Grade of
Concrete
Cementiti
ous
material
in Kg/m3
Slump in mm
Cube Compressive strength
in MPa
30 Min
60
Min
90
Min
120
Min
1
days
3
days
7
days
28
days
1 Pile M35
400
(200+200)
collapse Collapse
180mm
or above
150mm
or
above
- - 31.5 47
2
Pier and
Segment
M50
500
(400+100)
Collapse Collapse
120 to
150mm
90 to
120mm
16 38 57 70
Constructions
Case Study - 4
BMRCL

contractor IL & SF
Cement - JSW PSC (W11-2016) 403 kg
CA - 20 mm 559 kg
CA - 10 mm 559 kg
FA - M sand 742kg
free water 145.8 kg (after correction)
Plasticiser - Master poly heeo
8632(BASF) 0.6%
Slump - a) Initial Collapse
b) 1 hr 200mm
c) 2 hr 165mm
*Comp Strength - a) 7d 37.5 MPa
- b) 28d 45.8 MPa
Concrete : M35
Cement : PSC
Fine agg : Manufactured sand
Plasticiser : PC based
Design mix: 1:1.84:2.77
Min. Cement: 403 kg/Cu.m
w-c ratio : 0.36
Slump after 2 hrs: 150-170 mm
Concrete Mix Design – Bangalore Metro Railway Corporation Ltd.
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Source: Bureau Veritas (CivilAid), Blore
M35
Concrete with PSC has continued to show higher strengths beyond 28 days in comparison to those
made with OPC and PPC
32
M25 M35
Comparative study on Concrete strength development
Source - CivilAid
0
10
20
30
40
50
60
3d 7d 28d 56d 90d 180d 365d
OPC
PPC
PSC
0
10
20
30
40
50
60
70
3d 7d 28d 56d 90d 180d 365d
OPC
PPC
PSC
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RMC Industry in India
 Industry commenced in early 1990’s
 Early Commercial plants : Pune RMC in 1992 & Unitech Prefab in Mumbai in 1993
 Real growth commenced from 1995
 Housing and infrastructure: Main drivers
 Faster speed and quality: Main demands
 RMC industry responded positively to meet the demands
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1st Phase of Development
• Establishment of RMC
facilities in metropolitan
centres
Mumbai
Bangalore
Kolkata
Delhi
Chennai
Hyderabad
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2nd Phase of Development
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1 Amritsar 29 Mangalore
2 Ahmedabad 30 Mohali
3 Baddi-HP 31 Mumbai
4 Bangalore 32 Mysore
5 Bhubneswar 33 Nashik
6 Chennai 34 Nagpur
7 Coimbatore 35 Navi Mumbai
8 Derabasi 36 NOIDA
9 Durgapur 37 Panchkula
10 Faridabad 38 Pune
11 Giaspura 39 Ranchi
12 Ghaziabad 40 Raipur
13 Gurgaon 41 Rajkot
14 Gauhati 42 Rudrapur
15 Goa 43 Sahibabad
16 Hyderabad 45 Sonepat
17 Hubli 46 Surat
18 Indore 47 Surajpur
19 Jalandhar 48 Thane
20 Jaipur 49 Trichy
21 Kochi 50 Tuticorin
22 Kolkata 51 Trivandram
23 Kolhapur 52 Thrissur
24 Lalkuan 53 Vapi
25 Lucknow 54 Vijaywada
26 Ludhiana 55 Visakhapattanam
27 Madura 56 Vadodara
28 Manipal
56 Major Cities
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Size of Organized Concrete Industry*
Year Cement Consumption through
RMC Route
App. Concrete
Production
2012-13 7.5% 87 million m3
2017-18 10% commercial+ 10% captive
plants
100 million m3
+100 million m3
(Rough Estimates)
Assumptions
• Production figures include concrete produced from all sources using modern batching and mixing plants
(commercial and captive plants plus plants belonging to major contractors
• Concrete production figure is based on the yearly cement production and is calculated by assuming that the
average cement consumption is 300 kg/m3
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Concrete Market Growth
100
100
300
Volume, (millions, m3)
Commerical RMC
Site Based Captive RMC
Manual Concrete
2600 Ready mix plant in India and out
of that about 900are commercial
RMC penetration is 20% of total
concrete requirement
10% cement out of 300MnT is going
for commercial RMC, which is
equivalent to 100Mnm3@300kg/m3
Constructions

GGBS
Indian Scenario
 Globally, GGBS is a well established and proved Cement
Replacement in Concrete mixes and have replaced upto 80%
Cement in certain applications
 Indian code (IS 455) permits use of GGBS to replace OPC Cement
between 25-70% of Total Binder Content
 GGBS is technically more accepted SCM in comparison to other
alternatives by virtue of its consistency in quality- GGBS raw material
generation is from a high process controlled, Quality Intensive
Production of Steel
Constructions

RMC Industry & SCM Usage
Indian Scenario
 Indian RMC Industry is estimated at about 100 M. cm per annum
 Indian RMC Industry started use of Fly Ash blending in Concrete from
around 1995 as a Supplementary Cementitious Material
 GGBS blending in RMC Industry started around 2009
 Separate Blending of SCM in RMC batching plants is necessary to
customize the project design requirements wrt Concrete Properties
Constructions

GGBS Consumption areas & applications as green product

RCC in all types of foundations
and super structure works.
General building construction.
Express ways.
Mass concrete works in Dams,
Spillways, Canals, Foundations etc
Under ground works, Retaining
walls, culverts and drainage works
Effluent and sewage treatment
plants
Grouts and Mortars and Cement
based products
Waterproofing, Plastering, brick
work and finishing works
Marine works
PSC / GGBS - APPLICATIONS
Constructions

Innovative Concrete Product
Previous Concrete
Allows drainage of water
Contributes to the environment and
health
Uses : Drainage, retaining wall drains
exposed, Parking lots, driveways,
pathways
Stamped Concrete
 Desired design can be
obtained on concrete
Uses: Durable compare to other
decorative solutions, hotels and
parking areas
Self Compacted
Concrete
Reduce labour, repair work,
better finish, reduce noise (no
vibrator) , cost reduction
Uses : Fair face finished concrete
,intricate architectural designs, high rise
structures.
Constructions

Innovative Concrete Product
Ultra Thin White
Topping
 Reduce the thickness of road
payment as compare to normal
concrete road (PQC)
 High flexural strength (1day – 4MPa)
Uses : Road work (Trafficking is
possible in 24 hours)
Fibre Concrete
Resistance to cracks and Impact
Improved mix cohesion
Uses : Precast concrete panel,
industrial flooring, improved tensile
strength.
High Early Strength
Concrete
 High early strength .
 40 N/mm2 in 24 hours .
Self level
Uses : Speedy construction, precast
and pre stressed concrete, Airport
runways
Constructions

Innovative Green Concrete Product
Highly Durable
Concrete
RCPT value less than 500 colums
 Lesser water permeability and good
against ACID attacks
Uses : Construction near sea,
foundation concrete
Pot hole Repair
Solutions
High paste mortar for concrete and
bitumen road repair pot holes solution
 Open for traffic in 6 hours
Life is 1-2 years
Uses : Pot hole repairs
Uses :
Colored Concrete
Decorative concrete and does not
need other finishing, Available in any
color
No need to paint
Uses : vertical walls, Public building,
museums ,school, airports etc
Constructions

Road – Ultra Thin White topping
Basic Properties
 Road thickness 100mm
 Early high flexural
Strength possible
 Low permeable
 Self compacted in
nature
 Curing time 7-14 days
Constructions

Constructions
GOVERNMENT
APPROVALS &
SPECIFICATIONS OF
GGBS

Constructions
Karnataka PWD Schedule of Rates
Approving PSC &GGBS

GGBS approved by Indian Road Congress Code upto 50% Cement
replacement in Concrete Pavements
Based on CRRI investigations,
IRC has reviewed the usage of
GGBS in PQC and on 3rd Nov
2017 the new IRC 15:2017 has
been released
The revised IRC 15: 2017 has
approved use of GGBS in
Pavement Quality Concrete
upto 50% replacement of OPC
NHAI and other Infra projects are the next Big
Trigger for GGBS growth in India
Constructions

Approvals from Consultants for NHAI Projects - 1
Constructions

LIST OF ESTEEMED GGBS CUSTOMERS
Constructions

Infrastructure Projects-
Metro Rails, Roads, Bridges & Highways, Ports & Jetties

Ready Mix Concrete & Concrete Product Industries-
Commercial RMC, AAC Blocks, AC Sheet & Precast

Environmental Friendly Aggregate
• Slag is non hazardous, non toxic.
• Slag is free of any impurities like silt clay etc
• Used extensively for civil/road construction in developed countries
• Slag sand, if used can stop mining of river sand
• Consider slag sand as a Green Material
Constructions

For mass foundation concrete we can use higher % of GGBS
Cost effective as compare to normal concrete
Require positive approach from Owners/Architects / Contractors
Take higher strengths into consideration when designing ( or 56 days strength instead
of 28 days Strength)
Better Durability
Preservation of natural resources for future generation.
Use of addition of GGBS with OPC should be made mandatory expect for few special
requirements. by the govt depts, Structural consultants and Architects
Conclusions
Constructions

GREEN PRO
CERTIFICATE

Andaman &
Nicobar
Tamil Nadu
Kerala
Karnataka
Andhra
Pradesh
Maharashtra
Goa
West Bengal
1st green cement in India
Cement
Installed capacity:
Vijayanagar: 3.1 mMT
Nandyal : 4.8 mMT
Dolvi : 2.2 mMT
Salboni : 2.4 m MT

Thank you
Constructions

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