construction quality improvement- Presentation

Dr.L.R.Manjunatha BE,MBA,PhD
Associate Vice President – Direct Sales
JSW Cement limited, India,
Email: manjunatha.ramachandra@jsw.in
Mobile : 9480682100
Construction Quality Improvements using sustainable materials
Sustainable constructions through Alternative
materials
JSW Customer Connect Webinar Series -4
10 th June 2021

Presentation outline
 Introduction
 Back ground
 What is meant by Construction Quality Management
 Why Construction quality is so important
 What are the factors which affect Construction Quality
 Which are the best steps which help to improve construction quality
 What is Meant by sustainability
 What are sustainable materials.
 Which are the sustainable materials used in Constructions.
 Green cements –blended cements
 Sustainable fine aggregates (Sands)
 Sustainable concretes
 Sustainable paints
 How sustainable materials improve quality in constructions
 Conclusions

JSW is a $14 billion conglomerate with presence across
key sectors
5
India’s leading
integrated steel
producer with
18 MTPA steel
capacity
Started in
October
2019,VJNR and
Vashind
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

The JSW Cement Journey
SALES
VOLUMES
TIME
2009: JSW PSC
Launch
2012: Nandyal plant
established, JSW enters all
markets in S. India
2016: Gets ‘The Best
Enterprise Award’ by
Europe Business
Assembly
2016: Launch of PSC in
Eastern market
2013: JSW Cements
gets its First
Greentech award
2017: Expansion of
VGNR- 3.2 MTPA 2019: Comp Cem
Launch
VISION
To become a 20
MMT company
2017: Commissioning of
Salboni in July (2.4 MTPA)
2019:
Jajpur 1.2 MTPA
Fujairah 1 MTPA
2018: Expansion of
Dolvi -2.20 MTPA
2012
2009 2013 2016 2017 2018 Future 
5
2019
2016: Launched
Concreel HD in South
India

Capacity expansion planned across plants in the next 3-5
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) –
Under execution
Odisha
6

The objective
Construction Quality Control Process: It is very important to have a good quality
control process on a project. Depending on the project or the client or executing
agent for construction the QC/QA process could be very proscriptive
 QC – Usually the contractor(or a third party) is responsible for performing Quality
Control (QC) which is ultimately just making sure that they are completing the work
safely and in compliance with the contract.
 QA – Usually the Government or outside third party is responsible for performing
Quality Assurance (QA). QA is spot checking contract compliance, test results, and
ultimately just making sure that the Quality Control Processes is working.

Back ground-Construction Industry requirements
There is requirement for robust quality management program with an effective and
efficient process in place, overseen by knowledgeable and trained partners
To be supported by involved staff, as well as senior management, as a key requirement
to delivering superior quality and adding value to the project delivery process.
Many organizations in the construction industry struggle to some degree in achieving
acceptable levels of quality in their project delivery .
Many construction firms either have no formal quality management processes
Firms do not train their project staff in quality management processes or procedures.
Construction quality Management

Need of the Hour
It is common to expect the superintendent or the project Manager to be responsible for the overall
project delivery process, oversee production, coordinate subcontractor efforts, resolve issues, solve
problems, maintain the schedule, control cost, and manage performance, as well as ensure the
achievement of the expected level of project quality.
Hence there is an urgent need for Construction Quality Management Process and Systems in the
construction Industry

Ø Zero defect on project handover
Ø Identify & solve the problems before
customer does
Ø Establish true quality control by making
quality BUILT IN & not INSPECTED IN
quality Management objectives

QUALITY
It is the totality of features and
characteristics of a product
(buildings/civil works) that bears
on it’s ability to satisfy the stated
or implied CUSTOMER’S needs .

What is Quality?
 User-based: “In the eyes of the
beholder”
 Manufacturing-based: “Right the first
time”
 Product-based: Precise measurement

Defination
 Quality in construction industry can be defined as the attainment of acceptable levels of
performance from construction activities. ... The quality of any product or service is
achieved when it conforms to the desired specifications.

History of quality management….

EVOLUTION OF QUALITY MANAGEMENT
Inspection
Quality
Control
Quality
Assurance
TQM
Salvage, sorting, grading, blending, corrective actions,
identify sources of non-conformance
Develop quality manual, process performance data, self-
inspection, product testing, basic quality planning, use of
basic statistics, paperwork control.
Quality systems development, advanced quality planning,
comprehensive quality manuals, use of quality costs,
involvement of non-production operations, failure mode
and effects analysis.
Policy deployment, involve supplier & customers, involve
all operations, process management, performance
measurement, teamwork, employee involvement.

BASIC CONCEPTS OF QUALITY
 QUALITY
 QUALITY CONTROL
 QUALITY ASSURANCE
 QUALITY MANAGEMNT
 TOTAL QUALITY MANAGEMENT
 ISO SYSTEM

THE CONCEPT OF QUALITY :
 Perfection
 Consistency
 Eliminating waste
 Speed of delivery
 Compliance with Policies &
Procedures
 Good product features
 Doing it right first time
 Delighting customers
 Total Customer service

Two points focus of quality
• 1] Meeting the customers needs and expectations
• 2] Doing it in an effective manner
 Q = P / E
 Q – Quality
 P – Performance
 E – Expectations
• Q>1, indicates customer has a good perception about the
goods or service

Dimensions of Quality
• Performance
• Aesthetics
• Special features: convenience, high tech
• Safety
• Reliability
• Durability
• Perceived Quality
• Service after sale

Significance of Quality
 Lower costs (less labor,
rework, scrap)
 Motivated employees
 Market Share
 Reputation
 International competitiveness
 Revenues generation
increased (ultimate goal)

Why Quality in construction so important?
 Customers expect instant
response to complaints
 Unhappy customers
spread the word quickly
 It is 6 times costly to get a
new customer than keep
an existing customer
 In Japan, customer is an “
Honoured Guest “

Quality Aspects in construction
 Quality CIVIL Engineers
 Quality Construction Workers
 Quality building Materials
 Adhering to BIS codes for
building constructions.
 Well Equipped Laboratory.
 Material Testing
 Execution as per
Specifications

Quality Aspects in Construction
 Execution as per
building plans
 Elimination of Wastes.
 Maintaining Records.
 Following quality
procedures.
 On time delivery of
projects.

The Factors affecting quality
in Constructions
Low Quality Materials
Unskilled workforce
Suppliers and Vendors Failures
Subcontractors mishandling
Failure to document the changes in the design and drawings
Last minute changes
Miscommunications among teams (Architects-Engineers-
MEP-Landsape-Fire-Interiors-Security systems)
Lack of regular quality Audits and Quality assurance
systems
Lack of project management systems

OVERVIEW OF
NATIONAL BUILDING CODE
OF INDIA 2016
)
Bureau of Indian Standards
25

NEED FOR BUILDING REGULATION AND
CONSTITUTIONAL POSITION
Subjects relating to land and buildings fall under the State List (Seventh
Schedule )
35. Works, lands and buildings vested in or in the possession of the State.
49. Taxes on lands and buildings.
Schedule (referred to under Article 243W) added by the Constitution (74th
Amendment) Act, 1992 (w.e.f 01.06.1993),
1. Urban planning including town planning.
2. Regulation of land-use and construction of buildings.
3. Planning for economic and social development.
4. Roads and bridges.
5. Water supply for domestic, industrial and commercial purposes.
6. Public health, sanitation conservancy and solid waste management.
7. Fire services.
26
Source:NBC:BIS

8. Urban forestry, protection of the environment and promotion of
ecological aspects.
9. Safeguarding the interests of weaker sections of society, including
the handicapped and mentally retarded.
10. Slum improvement and upgradation.
11. Urban poverty alleviation.
12. Provision of urban amenities and facilities such as parks, gardens,
playgrounds.
13. Promotion of cultural, educational and aesthetic aspects.
14. Burials and burial grounds; cremations, cremation grounds; and
electric crematoriums.
15. Cattle ponds; prevention of cruelty to animals.
16. Vital statistics including registration of births and deaths.
17. Public amenities including street lighting, parking lots, bus stops
and public conveniences.
18. Regulation of slaughter houses and tanneries.
27
NEED FOR BUILDING REGULATION AND
CONSTITUTIONAL POSITION
Source:NBC:BIS

CONTENTS OF NBC 2016
28
Part No. Title
Part 0 Integrated Approach – Prerequisite for Applying Provisions of the code
Part 1 Definitions
Part 2 Administration
Part 3 Development Control Rules and General Building Requirements
Part 4 Fire and Life Safety
Part 5 Building Materials
Part 6 Structural Design
Part 7 Constructional Management, Practices and Safety
Part 8 Building Services
Part 9 Plumbing Services (including Solid Waste Management)
Part 10 Landscape Development, Signs and Outdoor Display Structures
Part 11 Approach to Sustainability
Part 12 Asset and Facility Management Source:NBC:BIS

TEAM APPROACH
Sl. No Major Stages Corresponding Team Purpose
1.
Location/siting
Design team
Proper integration of
various design inputs
Conceptualization &
planning
Designing and
detailing
2.
Construction/
execution
Project Management &
Construction
Management Teams
Accomplishment in
accordance with
designs and
specifications in a
stipulated time and cost
framework.
3. Maintenance and
repair
Operation &
Maintenance Team or
Asset Management
Team or
Estate Management
Team
Operation, maintenance
and repairs to be
executed with least
inconvenience and
without any mismatch/
damage to structure,
finishings, fittings, etc. Source:NBC:BIS

MULTI DISCIPLINARY TEAM OF BUILDING
PROFESSIONALS
Each team to be multi-disciplinary team of need based professionals,
depending upon type, size, magnitude, complexity in the project; such as:
Architect
Civil Engineer
Structural Engineer
Geotechnical Engineer
Electrical Engineer
Plumbing Engineer
Fire Protection Engineer
HVAC Engineer
Lift, Escalator & Moving Walk
Specialist
Acoustics Specialist
Information/Communication
Technology Engineer
Health, Safety & Environment
Specialist
Environment/Sustainability
Specialist
Town Planner
Urban Designer
Landscape Architect
Security System Specialist
Interior Designer
Quantity Surveyor
Project/Construction Manager
Accessibility & Universal
Design specialist
Asset/Facility Manager
Other subject specialists
Source:NBC:BIS

CATEGORIES OF MATERIALS
 ALUMINIUM AND OTHER LIGHT
METALS AND THEIR ALLOYS
 BITUMEN AND TAR PRODUCTS
 BUILDER’S HARDWARES
 BUILDING CHEMICALS
 BUILDING LIMES
 CEMENT AND CONCRETE
(including concrete
reinforcement)
 CEMEMT MATRIX PRODUCTS
 CLAY PRODUCTS FOR BUILDING
 CONDUCTORS AND CABLES
 DOORS AND WINDOWS
 ELECTRICAL WIRING FITTINGS
AND ACCESSORIES
 FILLERS, STOPPERS AND PUTTIES
 FLOOR COVERING, ROOFING
AND OTHER FINISHES
 GLASS
 GYPSUM BUILDING MATERIALS
 LIGNOCELLULOSIC BUILDING
MATERIALS (including timber,
bamboo and Products thereof)
 PAINTS AND ALLIED PRODUCTS
 POLYMERS, PLASTIC AND
GEOSYNTHETICS/ GEOTEXTILES
 SANITARY APPLIANCES AND WATER
FITTINGS
 STEEL
 STONES
 STRUCTURAL SECTIONS
 THERMAL INSULATION MATERIALS
 THREADED FASTENERS AND RIVETS
 UNIT WEIGHTS OF BUILDING
MATERIALS
 WATERPROOFING AND DAMP-
PROOFING MATERIALS
 WELDING ELECTRODES AND WIRES
 WIRE ROPES AND WIRE PRODUCTS
Source:NBC:BIS

32
NEW / ALTERNATIVE BUILDING
MATERIALS
 Suitability for End Application
 Strength Properties
 Durability
 Fire Resistivity
 Thermal Properties
 Acoustical Properties
 Ease of Working/Handling
 Energy Conservation/Environment
Sustainability
Source:NBC:BIS

CEMENT
IS No. Title
IS 269:2015 Specification for ordinary Portland cement (sixth revision)
IS 455:2015 Specification for Portland slag cement (fifth revision)
IS 1489 (Part 1):2015 Specificity on for Portland pozzolana cement:
Part 1 Flyash based (fourth revision)
IS 1489 (Part 2):2015 Specification for Portland-pozzolana cement:
Part 2 Calcined clay based (fourth revision)
IS 3466:1988 Specification for masonry cement (second re vision)
IS 6452:1989 Specification for high alumina cement for structural use (first
revision)
IS 6909:1990 Specification for super sulphated cement (first revision)
IS 8041:1990 Specification for rapid hardening Portland cement
(second revision)
IS 8042:2015 Specification for white Portland cement (third revision)
IS 8043:1991 Specification for hydrophobic Portland cement (second
revision)
IS 8229:1986 Specification for oil-well cement (first revision)
IS 12330:1988 Specification for sulphate resisting Portland
IS 12600:1989 Specification for low heat Portland cement
IS 16415:2015 Specification for composite cement
33
Source:NBC:BIS

Provisions on Use of Aggregates from
other than Natural Sources in IS 383:2016
Aggregate type Slag / Waste included Maximum utilization
in
Plain Concrete Reinforced
Concrete
Lean Concrete (less
than M15 grade)
1) Coarse Aggregate
i) Iron slag coarse aggregate 50% 25% 100%
ii) Steel slag coarse
aggregate
25% Nil 100%
iii) Recycled concrete coarse
aggregate (See Note 1)
25% 20% (only upto
M25 grade)
100%
iv) Recycled coarse
aggregate
nil Nil 100%
2) Fine Aggregate
i) Iron slag fine aggregate 50% 25% 100%
ii) Steel slag fine aggregate 25% nil 100%
iii) Copper slag fine
aggregate
40% 35% 50%
iv) Recycled concrete fine
aggregate (See Note 1)
25% 20% (only upto
M25 grade)
100%
v) Bottom Ash Nil Nil 25%
NOTES
1 The source concrete for recycled concrete aggregates should not be deteriorated concrete and it is desirable to
source these from site being redeveloped for use in the same site.
2 In any given structure, only one type of manufactured coarse aggregate and one type of manufactured fine
aggregate shall
be used.
3 The increase in density of concrete due to use of copper slag and steel slag aggregates need to be taken into
consideration in the design of structures.
Source:NBC:BIS

Concrete
a) Plain & Reinforced Concrete (IS 456)
b) Concrete Mix Proportioning (IS 10262:2009)
(revised version under publication)
a) Prestressed concrete (IS 1343: 2012)
b) Ready-mixed concrete (IS 4926: 2003)
c) Concrete for dams and other massive
structures (IS 457)
d) Structural safety of tall concrete
buildings (IS 16700:2017)
Source:NBC:BIS

Steel Reinforcement
 Mild steel and medium tensile steel bars
[ IS 432(Part 1)]
 High strength deformed steel bars
(IS 1786: 2008)
 Hard-drawn steel wire fabric (IS 1566)
 Grade A of structural steel (IS 2062)
 High strength deformed stainless steel bars
(IS 16551: 2017)
36
Source:NBC:BIS

Part Name Status
Part 1 Sampling of fresh concrete Under Publication
Part 2 Determination of consistency of fresh concrete Under Publication
Part 3 Determination of density of fresh concrete Under Publication
Part 4 Determination of air content of fresh concrete Under Publication
Part 5 Making and curing of test specimens Under Publication
Part 6 Tests on fresh self compacting concrete Under Publication
Part 7 Determination of setting time of concrete by
penetration resistance
Under Publication
Part 8 Determination of water soluble and acid soluble
chlorides in mortar and concrete
Draft being
prepared
Part 9 Analysis of freshly mixed concrete Draft being
prepared
REVISION OF IS 1199 METHODS OF SAMPLING, TESTING
AND ANALYSIS OF FRESH CONCRETE
37
Source:NBC:BIS

Part Name Status
Part 1 Testing of strength of hardened concrete Draft being
prepared
Part 2 Properties of hardened concrete other than
strength
Section 1 Density of Hardened Concrete and
Depth of Water Penetration Under Pressure
Section 2 Initial Surface Absorption
Under Publication
Draft completed
wide circulation
Part 3 Making, curing and determining compressive
strength of accelerated cured concrete test
specimens
Draft being
prepared
Part 4 Sampling, preparing and testing of concrete cores Under Publication
Part 5 Non-destructive testing of hardened concrete
Section 1 Ultrasonic Pulse Velocity Testing
Under Publication
REVISION OF IS 516 METHODS OF TEST FOR
HARDENED CONCRETE
38
Source:NBC:BIS

Part Name Status
Part 6 Determination of drying shrinkage of
concrete for samples and moisture
movement
Draft ready for
issuing for public
comments
Part 7 Determination of creep of concrete
cylinders in compression
Draft being
prepared
Part 8 Determination of modulus of elasticity
in compression
Draft being
prepared
Part 9 Wear resistance Draft being
prepared
Part 10 Bond in reinforced concrete Draft being
prepared
REVISION OF IS 516 METHODS OF
TEST FOR HARDENED CONCRETE
39

CERTIFICATION
BIS operates a third party certification under
the BIS (Certification) Regulations, 1988
which plays a very important role in quality
assurance. The third party certification not
only encourages the producers/beneficiating
agency but also guides them for in-process
quality control including regarding the
beneficiation, segregation and processing,
etc.
40
Source:NBC:BIS

What is a sustainable Material
materials

The sustainable materials improving quality in
Constructions
Blended cements in constructions
1.PPC –Portland Puzzolona Cement
2.PSC –Portland Slag Cement
3. Composite Cement
4.Masonry cement
5.LC 3 Cement

2.SCMs in RMC
 GGBS
 Flyash
 Micro silica
 Ultrafine flyash
 Ultrafine ggbs,
 Metakoalin
 Rice husk ash
 Ultrafine Materials(Modified and processed materials)

Metakaolin
GGBS
Micro silica
Mineral admixtures – (IS 456:2000, clause 5.2)
SCM - A material that, when used in
conjunction with Portland cement,
contributes to the properties of the
hardened concrete through hydraulic or
pozzolanic activity or both (CSAA
3001, 2003)
materials

Properties of Materials from Mineral Admixtures Range
Material
Specific Area
(sq. m./kg)
Average
Particle
Size
(μm)
Bulk
Density
(kg/cubic
m)
Specific
Gravity
Fine
Pozzolanic
Materials
Cement 260-300 22-24 1300-1400 3.12
Fly Ash (FA) 300-500 (1.43) 20 900-1100 2.3
GGBS 300-500 (2.43) 20 1000-1200 2.9
Ultrafine
Pozzolanic
Materials
(Avg.
particle
size less
than
10 μm)
Ultrafine Fly
Ash (UFFA)
700-900 (2.86) 4 600-700 2.3
Ultrafine Slag
(UFS)
1000-1200 (3.93) 3 600-700 2.9
Silica Fume
(SF)
15000-20000
(62.5)
0.15 200-300 2.2
Metakaolin
(MK)
9000-12000
(41.7)
2 350-450 2.4-2.6
N.B.: Numerals in parenthesis indicate how many times product is finer than cement.

Qualities of Concrete made with Cementitious Materials
 Lower the heat of hydration and thermal shrinkage
 Increase the water tightness
 Reduce the alkali-aggregate reaction
 Improve resistance to attack by sulphate soils and sea water
 Improve extensibility
 Improve workability
 Lower susceptibility to dissolution and leaching
 Lower costs
materials

Superiority of Concrete with Cementitious Materials
 Increases the later age strengths by 25 - 40%
 Reduces the heat of hydration by 35%
 Reduced pore volume in concrete by 60%
 Increased water tightness in concrete by 34%
 Resistance to Sulphate attack in concrete by 60%
 Resistance to Chloride attack in concrete by 90%
 Resistance to Alkali-Aggregate reaction in concrete by 86%
materials

Requirements of Quality of Concrete in different Environmental Conditions (TableIS:456:2000)
Sr 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
Note:
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 may be taken into account in the concrete.
composition with respect to the cement content and water-cement ratio if the suitability is established & As Long As The
Maximum Amounts Taken Into Account Do Not Exceed The Limit Of Pozzolana And Slag Specified In IS 1489 (Part
I) & IS 455 Respectively
2. Minimum grade for plain concrete under mild exposure condition is not specified
IS 456: 2000 RECOMMENDS THE USE OF BLENDED CEMENT AT
DIFFERENT CONDITIONS.
materials

Alternatives to river sand.
1.M Sand (CRF)
2.Slag Sand
3.Copper slag sand
4.Pond Ash as fine Aggregates
5 C& D Waste fine Aggregates

Slag Sand – An Eco-Friendly Fine Aggregate
materials

 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
materials

IRON
MAKING
STEEL
MAKING
Air Cooled
LD Slag
Coarse
Granulated
BF Slag
Fine
materials

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)
materials

Processed Granulated BF slag
Gradation Size and Shape
materials

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
materials

Sustainable Aggregates
 C& D Wastes aggregates
 Steel slag aggregates
 Sintered fly ash aggregates
 Artificial Aggregates
 Lightweight Aggregates

Steel Slag Aggregates
materials

STEEL
MAKING
Air Cooled
LD Slag
Coarse
materials

Basic Oxygen Furnace
Process (LD)
Electric Arc Furnace
Process (EAF)
Granulation
Fine Aggregate
Granulation
Fine Aggregate
Air Cooling
Coarse Aggregate
Air Cooling
Coarse Aggregate
Steel Making Processes
materials

Applications
Fine aggregate/Grit
Raw Material in Cement Manufacture
Performance Improver in cement making
Blending Materials in cement making
Blasting material
Filter Media
Filler in bricks, tiles, railway sleepers
Coarse Aggregate
GSB Material in Roads
Pavement Works
Grit
Filter Media
Fine Aggregate Coarse Aggregate
materials

From the House of JSW cement
61
JSW
SCREENED
SLAG

Introducing “COMP CEM” from JSW Cement
JSW Composite is cement the first Composite cement to be accepted by Government of Maharasht

JSW Comp Cem
A result of world class manufacturing process, JSW COMP CEM is a
Perfect blend of high strength clinker, ground granulated blast furnace slag (more than 95% glass content)
and Fly Ash from single source , to give consistent & superior product.
 State of the art ‘Separate Grinding’ provides excellent blending of raw materials and ensures best
possible grain size distribution
It is an Environment friendly product provides high concrete strength , durability, better cohesion and ease
of working.
It is a perfect solution for concrete and other applications.
JSW COMP CEM confirms to IS 16415:2015

What is slag ??
(Ground Granulated Blast furnace slag)
 Slag is by-product from steel plant , which is obtained from blast
furnace , during the separation of iron from iron ore. The process of
granulating of the slag involves, cooling of molten slag through
high-pressure water jets. This rapidly quenches the slag and forms
granular particles. The resulting granular material comprises
around 95%, non-crystalline calcium-alumino silicates.
 The granulated slag is further processed by drying and then
grinding in a vertical roller mill or rotating ball mill to a very fine
powder, which is called GGBS.
 GGBS is used in Ready mix concrete production or at site based
batching plants , along with OPC cement ( replacement level of OPC 25
%-70%) to make strong & durable concrete
 JSW GGBFS is confirming to IS 16714-2018
Slag confirming to IS 12089
64

Chemical Composition Of Slag
As per IS 12089:1989 & IS 16714: 2018
SILICA
LIME
ALUMINA
IRON
MAGNESIA
GLASS CONTENT
CHEMICAL
COMPOSITION
RANGE (%)
Microscopic examination reveals the
glassy nature of GGBS particles
27 - 32
30 - 40
17 - 31
0 - 1
0 - 17
85% MIN.
65
Slag exhibits both hydraulic and siliceous properties
 Non metallic product.
 Consisting of glass containing silicates
and aluminates of lime.
 Developed simultaneously with iron in
blast furnace.
 Obtained by rapidly chilling or
quenching with water or steam and
air.

Fly Ash
Fly ash exhibit pozzolanic activities. A pozzolana is defined as “a siliceous or
aluminous material which itself possess little or no cementitious value but which will,
in finely divided form and in the presence of moisture, chemically react with
Calcium hydroxide, at ordinary temperature to form Compounds possessing
cementitious properties.”

High
strength
Most
Durable
Improved
Workability
Resistance
to chemical
attack
Superior
smooth
finish
Green
Product
Super Six advantages of Comp Cem
6

6
Comp Cem is the best cement in the market, far better than any
Category ‘A’ OPC and PPC cement
Premium Category ‘A’ Brands in the Market Cement Comparison: Comp Cem vs. OPC & PPC
Header title COMP CEM OPC Cement PPC Cement
High Initial Strength1
High Final Strength2
Quick Setting
Chemical Resistant
Increased Durability
Superior Cohesion
Green Product
Low Heat of
Hydration
Lesser Cracks
Reduced bleeding

Concreel HD offers 6 ‘Super Advantages’ unlike any other
cement in the market
6

Introducing ‘CONCREEL HD’
7
Specially made for
CONCRETE applications
CONCRETE STEEL

7
We will offer you a cement that will challenge all the OPC &
PPC players in the market
Key Properties of OPC and PPC Cement
We Will Offer A Product With Additional Superior
Properties
High early strength
Quicker setting
Chemical Resistance
Improved Cohesion
Superior Long Term Strength

7
Therefore, Concreel HD is the best cement in the market, far
better than any Category ‘A’ OPC and PPC cement
Header title OPC Cement PPC Cement
High Initial Strength1
High Final Strength2
Quick Setting
Chemical Resistant
Superior Cohesion
Green Product
1) Based on 1 day strength
2) Based on 28 day strength
Premium Category ‘A’ Brands in the
Market
Cement Comparison: Concreel HD vs. OPC
& PPC

Concreel HD is best suited for Concrete applications , specially slabs,
beams, columns.
7

JSW Portland Slag Cement
JSW PSC is a blended cement, wherein some
portion of OPC is replaced with Ground
granulated blast furnace slag (GGBFS), to make
the structures long lasting & durable.
GGBFS present in PSC helps in secondary
hydration, producing more C-S-H gel in system
for improved performance of concrete.
It conforms to IS: 455 – 2015.
74

7
PSC has an added advantage over OPC/PPC as it increases
durability against environmental conditions due to slag content
OPC
Cement
Water
C-S-H
gel
Ca(OH)2
Prone to
environmenta
l attacks
Primary Reaction
Slag
C-S-H
gel
Secondary Reaction
Double hydration and
subsequent CSH
leads to a reduction in
pores over time
3 days 7 days 28 days
Pores
CSH gel
filling pores

HOW PSC STOPS DETORIATION IN CONCRETE ?
Electro micrograph of Electro micrograph of
Structure made with structure made with
Ordinary OPC , PSC
having more pores with modified
and hence susceptible pore structure and
to greater environmental increased impermeability.
Attack Chances of environmental
Attack are minimized.

ADVANTAGES OF JSW PSC
 Long term strength of PSC is greater than OPC,PPC
 Provides protection against corrosion of steel reinforcement
 PSC makes concrete impermeable
 Allows Concrete cover to remain intact
 Resistance to sea water attack
 Resistance to sulphate , chloride, atmospheric water & harmful gases attack
 Long design life /durability of structure with low maintenance cost
 Lesser development of cracks
JSW PSC should be used over OPC,PPC as its long term strength
is maximum . Besides, it provides high durability and resistance to
chemicals and is an environmentally friendly cement.

7
PSC - APPLICATIONS
• PSC is an all purpose cement and can be used
for plastering ,brick work and also in all other
cement based applications
• 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

JSW Slag Products ( PSC/ GGBS)
- Eco Friendly
The products of BF Slag are highly regarded as environment friendly materials that can protect the
environment by limiting the exploitation of natural resources and reduce the amount of energy
consumed in the mining of natural Resources.
 Recycled byproduct-No new materials used for
production.
 Durability-Longer Life span of the building
 Lowered co2 emissions reducing green house
gases.
 Lower Embodied Energy
7
9

OPC 40%
Slag 40%
Fly ash 20%
Strength:
28-day 48 MPa
91-day 62 MPa
Atlantic Ocean Road, Norway
National Road Concrete – M80
Structures World over where Slag products were used
Akashi Kyko ,Japan
Nathpa Jhakri Power corporation ,
HP
JFK International airport , USA

Major structures built using JSW Slag based products in India
Examples:
1. Paradeep Port trust , Odisha
2. Tata steel expansion , Kalinganagar
3. Lodha World one , Mumbai
4. LNG Petronet ,Dahej
5. Naval Dockyard, Jetty Project, Colaba Mumbai
6. Bangalore Metro , Bangalore
7. Port trust (L&T and ECC geo structures) , Ennore
8. IOCL projects ,Ennore
9. Mumbai Metro
10. Mumbai Port trust
11. Bandra Worli Sewage outlet pipeline
12. Kolkata Metro

5th oil berth at Jawahar Deep by ITD Cementation for Mumbai Port Trust –
Concrete Grade M40
Mumbai Port Trust –Mazgaon, Mumbai
JSW Slag Cement used in sea water concrete

High Rise- Raft Foundation with Slag based products
GGBS reduces thermal gradients in mass concrete
83

20
220
420
620
820
2013-14
2014-15
2015-16
2016-17 (upto
Aug'16)
719
537
441
392
Kg CO2/t Cementitious Material
(-) 45%
CO2 Emissions
Note: Cementitious material includes GGBS
Material Kg CO2 per ton
Clinker 920
OPC 870
PPC 640
PSC 490
GGBS 65
CO2 emission in PSC is lower by 44% and 24% in comparison to OPC and PPC respectively. 84

Quality control in concreting
 Introduction
 Q.C. Functions in Concrete
 Quality control standards and Specifications
 Various Tests

Concrete - Ingredients
ADDITIVES
86
"Concrete is an artificial stone and
is produced from a mixture of
cement, aggregates (gravel, sand)
and water – usually also with
concrete admixtures and concrete
additions (concrete additives) –
through hardening (hydration) of the
cement paste (cement-water
mixture)."

3. Sampling and testing
 Sampling and testing shall be as per IS 516, IS 1199 and other
relevant Indian or equivalent International standards.

The frequency of testing shall be as per IS 456 OR as mutually agreed with the
customer by the producer of concrete.

KEY ASPECTS OF SAMPLING, CUBE
MAKING, CURING AND TESTING
REPRESENTATIVE SAMPLE FROM TRUCK MIXER
REMIXING OF SAMPLE
FULL COMPACTION OF EACH LAYER
MAINTAINING CUBE MOIST OVERNIGHT
OBSERVATION OF CUBE FAULTS,
ACCURATE MEASUREMENT OF DIMENSION & WEIGHT
ACCURATE MEASUREMENT OF DENSITY & STRENGTH
CURING CUBES UNDER STANDARD CONDITIONS
STANDARD CUBE MOULDS ASSEMBLED AND OILED

-40 -30 -20 -10 0 +10 %
TRUE AVERAGE CUBE STRENGTH OF
BATCH OF CONCRETE (100%)
SAMPLING ERROR
FAILURE TO REMIX SAMPLE
DISTORTED CUBE MOULD; LACK OF
MOULD OIL
INCOMPLETE COMPACTION OF CONCRETE
CURING TEMPERATURE OUTSIDE
OF PERMITTED RANGE
LACK OF CONTINUOUS
MOIST CURING
FAULTY CUBE LOCATION IN MACHINE OR
OTHER OPERATOR FAULT
FAULTY TEST MACHINE
Strength of cube relative to true
average cube strength of batch of concrete

Green concrete
Green Concrete means concrete having least possible
environmental impact while delivering the required fresh
and hardened concrete properties

Environmental impact of concrete
Concrete Cement
Coarse
Agg.
Fine Agg. Water
Admixtur
e
12 billion
cum.
3.6
billion
tonnes
10 billion tonnes 1 trillion
Depletion of natural resources
Produces Green
House Gases
Utilizes high
energy
Reduce
Replace cement
with material
having lower

Green Concrete
• Carbon footprint of concrete is defined as the total amount
of greenhouse gases produced directly and indirectly
during production of concrete, usually expressed in
equivalent tons of carbon dioxide (CO2)

Green concrete
• Use SCMs like fly ash & GGBS as replacement
of cement
Use material with lower
carbon footprint (Cement
contributes to 70-85% of
concrete’s carbon footprint)
• Use waste material as aggregate
• Use less water by use of admixtures
Use less amount of virgin
material (aggregate & water)
• Lower w/c ratio
• Use SCMs
• Proper cover & curing
Make concrete more durable

Use of SCM
• SCMs Like fly ash & GGBS are industrial by-products with
very little carbon footprint
• Replacing significant proportions of cement by SCMs can
result in substantial reduction in carbon footprint of concrete
• Enhances ultimate strength, impermeability and durability to
chemical attack
• Improves resistance to thermal cracking (lower heat of
hydration, increased tensile strain capacity)

Use less water
• Over 1 trillion litres of fresh water is used annually in the
production of concrete.
• 30-40% water can be
reduced in concrete
• Achieve similar
workability at lesser
water content

Use of alternate aggregate sources
• Concrete reclaimed from the demolition of old concrete
structures or pavements can be processed to produce
aggregates suitable for use in new concrete
• In general, the use of recycled concrete aggregate results
in concrete that is somewhat weaker and less durable than
concrete made with natural aggregates at the same w/c
ratio
• Other industrial waste that can be used as aggregate are
copper and iron slags, rubber, glass, wood waste, asphalt
milled waste, etc.

Carbon footprint
Ingredient
Carbon Emissions Norms (per
tons)
OPC 0.95
PPC 0.67
PSC 0.48
FA 0.01
GGBS 0.09
Silica fume 0.1
UFFA 0.1
UFGGBS 0.2
Coarse aggregate 0.01
Natural Sand 0.01
Crushed sand 0.01
Recycled aggregate 0.004
Admixture 0.05

Carbon footprint
OPC PPC PSC
OPC +
35% FA
OPC +
50% FA
OPC +
50%
GGBS
OPC +
70%
GGBS
OPC +
70%
GGBS +
MSA40
OPC + 70%
GGBS +
MSA40 +
25% RCA
OPC 360 0 0 270 233 195 120 115 115
PPC 0 360 0 0 0 0 0 0 0
PSC 0 0 380 0 0 0 0 0 0
Fly Ash 0 0 0 145 233 0 0 0 0
GGBS 0 0 0 0 0 195 280 270 270
Coarse aggregate 1297 1266 1263 1223 1178 1255 1244 1345 1008
Crushed sand 858 844 842 815 785 836 829 790 592
Recycled
aggregate (Fine +
Coarse)
0 0 0 0 0 0 0 0 396
Admixture 4.9 4.2 5.1 4.2 4.7 5.3 5.4 4.8 4.8
Water 137 137 137 137 135 137 136 131 131
Carbon footprint 637 533 482 535 497 467 389 384 371
% reduction in
comparision to
100% OPC
100.0 83.7 75.7 84.0 77.9 73.2 61.0 60.2 58.3
Carbon footprint per cum of concrete with
various mixes

New generation
alternative materials
materials
SOIL STABILIZED
BLOCKS
CONSTRUCTIONS

AAC-Autoclaved Aerated blocks
materials

New Generation Concrete materials
materials

CONCRETE TILES
materials

DRY WALLS TECHOLOGIES
materials

Bio based products
 brick made from bacterial byproducts that cement sand
particles together in a matrix that's strong enough to use for
homes and insulation created from agricultural waste
products that can grow within a wall.
 Another product in the works is bacteria-infused concrete that
reportedly fills in holes and cracks in the concrete, making it
last longer and reducing maintenance costs.
Sustainable constructions through
Alternative materials

3D Printing Technologies –Big Scope for sustainable
constructions
materials

Moving towards Net Zero Buildings
materials

Conclusions
 It is any day better to start using sustainable materials for improving quality in Constructions
 Using Sustainable materials for constructions is
 Ecological,
 Economical
 and sustainable and durable
 We urge each and every one to adopt sustainable practices for improving quality in constructions

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