Performance of Flowable Concrete For Application in Underground Structures - NATM Tunnel and Station Box of Mumbai Metro Project

11 IV April 2023
https://doi.org/10.22214/ijraset.2023.50060
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue IV Apr 2023- Available at www.ijraset.com
Performance of Flowable Concrete for Application

in Underground Structures -NATM Tunnel and
Station Box of Mumbai Metro Project
Sandip Sonule1, H. Jayarama2, Mainak Roy3, C.M Jadhav4, Dr. K. C. Tayade5
1
Construction Quality Control Manager, Shanghai Tunnel Engineering Co., Ltd Mumbai Metro Project Package- UGC-07
MML-3, Mumbai, Maharashtra, India
2
Project Manager, Larsen & Toubro Ltd, Mumbai Metro Project, Package- UGC-07 MML-3Mumbai, Maharashtra, India
3
Chief Resident Engineer, GC, MAPLE, Mumbai Metro Project Package- UGC-07 MML-3, Mumbai, Maharashtra, India
4
Chief Project Manager, Mumbai Metro Rail Corporation Ltd, Mumbai Metro Project, Package- UGC-07 MML-
3Mumbai, Maharashtra, India
5
Additional General Manager-Quality Assurance and Quality Control, Maharashtra Metro Rail Corporation, Nagpur,
Maharashtra, India
Abstract: High-performance flowable concrete offers special combinations of performance, uniformity, and consistency
requirements that cannot be possible by traditional normal slump concrete. It is an advanced concrete than traditional concrete
with high workability without segregation, bleeding and it is suitable for placing in structures with congested reinforcement of
structure, long distance pumping concrete-like inside NATM tunnel, cross passages, and underground station box concrete
structures. Flowable concrete can be flow itself but does not have the self-compacting capability. Flowable concrete required
vibration to ease flow to reach each corner of formwork and compaction for achieving a smooth surface finish after de-
shuttering. Mix proportion of flowable concrete must ensure a good balance between deformability and stability. The behavior of
concrete can be affected by the characteristics of selected ingredients in concrete and the mix proportions. It becomes necessary
to evolve a procedure for mix design of flowable concrete. The paper presents an experimental procedure for the mix design of
flowable concrete for grade M40 and implementation of the same mix at the cast in situ Base slab, Roof slab Rcc walls for
underground metro stations, NATM tunnel & cross passages in Mumbai Metro Project, package -UGC-07. The test results for
acceptance characteristics of M40 grade flowable concrete such as flow table test, compressive strength at the ages of 7, 28, and
56 days determined, and results are included here. Successful production of temperature control flowable concrete from
batching plant, transportation, placement procedures, and proper planning of handling and execution of flowable concrete at
the site are presented in this article.
Keywords Flowable Concrete, Mix Design, Fresh concrete Properties, Hardened Concrete Properties, Application at site
I.INTRODUCTION
Rheological properties and behaver of flowable concrete or self-compacting concrete are advanced than traditional normal slump
concrete. The hardened concrete is dense, homogeneous, and has the equivalent properties as traditional normal slump concrete.
Flowable concrete is suitable for a fast rate of concrete placement, with faster construction times and ease of flow around congested
reinforcement without vibration or little bit surface tamping to get better surface finish. “It ensures good homogeneity, pumping
ability, best surface, finish and consistent concrete strength and durability to the concrete structure. The workability of concrete
describes the flowability, mobility, and stability of fresh concrete.
Specific measurement limits of Slump, Slump flow, Flow table cannot be fixed and its totally depends on placing condition of site,
however concrete should be homogenies, cohesive, no settlement and no bleeding in mix”[1]. The mechanical properties of concrete
like compressive strength, flexural strength, split tensile etc. are mainly affected by composition of concrete ingredients. In Mumbai
region river sand is not available and therefore construction industries are totally depending on manufactured sand. In M-sand it is
difficult to maintain required fractions of sieve sizes for getting appropriate zone of sand i.e., zone II as per IS383:2016 [2].
According to site requirements only flowable concrete was suitable due to long distance of pipe installation, pumping and congested
reinforcement in the structure.
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Hence flowable concrete was developed by conducting several numbers of concrete mix trials and concluded that trials were only
achieving standards requirements for flowability by slump flow, flow table tests and sieve segregation resistance tests as per
specification mentioned in European standard [3]. Chemical admixtures i.e., superplasticizers required for optimized the
cementitious content and minimize the W/C ratio for production of high performance flowable concrete [4]. Appropriate selection
of supplementary cementitious materials such like GGBS, Ultrafine GGBS-Alccofine, Crystalline growth admixture etc. are also
required for improving durability, decreasing permeability, aiding in pumpability and finish ability, mitigating alkali reactivity and
improving the overall hardened properties of concrete. The improved construction practice and performance, combined with the
health and safety benefits of structure, high performance flowable concrete is the better solution for cast in situ civil engineering
construction.
II. CONCRETE INGREDIENTS

A. Cement
Ordinary Portland cement (Grade 53) of M/s Ultratech is used. Physical & Chemical properties are as given in Table 1 & 2.
B. GGBS
Ground granulated blast furnace slag (GGBS) of M/s JSW obtained from Pen, Raigad, Maharashtra, India. The physical and chemical
properties of GGBS are given in the Table 1 and Table 2, respectively.
C. Ultrafine GGBS -Alccofine

Ultrafine GGBS commercially available as Alccofine-1203 is a low calcium silicate-based mineral additive which is generally used as
a replacement of silica fume in high-performance concrete [5]. Alccofine 1203 is a slag based SCM having ultra-fineness with
optimized particle size distribution [6].
Table 1. Physical Properties of Cement, GGBS and UGGBS-Alcofine 1203

Physical Properties Cement GGBS UGGBS-Alccofine
(OPC-53) 1203
W-M-Y 14-04-2021 14-04-2021 14-04-2021
Specific Gravity 3.13 2.9 2.92
Fineness(m2/kg) 288.2 482.5 -
Particle size, micron
D10 1.6
D50 - - 4.5
D90 9.2
D95 10.8
Normal consistency (%) 29.0% - -
Soundness (Autoclave) (%) 0.020 0.020 -
Setting time (min.) -
130
Initial -
215
Final
Strength (N/mm2)
36.5
3days
46
7days
69
28days
Slag Activity Index, %
a) At & 7 days
92.5
b) At & 28 days - 72.8
108.4
85.4
Table 2. Chemical Properties of Cement. GGBS and UFGGBS-Alccofine 1203

Chemical Properties Cement GGBS UGGBS-Alccofine
1203
Loss on ignition, % by
2.98 0.10 0.32
mass
Glass content, % by mass - 87.24 86.92
Magnesium Oxide
1.76 0.17 7.56
(MgO)
Total Sulphur (SO3), %
2.9 0.25 0.22
by mass
Insoluble residue, % by
0.93 - -
mass
Alkali Content, % by
0.22 0.2 0.22
mass
Total Chloride content,
0.017 0.011 0.015
% by mass
OPC 53 grade Cement, GGBS and UGGBS-Alccofine are conformed to Indian Standard Specifications IS: 269-2015, IS 16714-
2018and IS 16715-2018 [7], [8] [9]
D. Chemical admixtures and crystaline growth waterproofing admixture

Poly carboxylic ether-based superplasticizer admixture brand name Sika ViscoCrete 5138 & Sika ViscoCrete 5229NS M/s Sika are
used to bring out the required water reduction and maintain the dispersing effect during time required for transportation and
placement at site. Crystalline growth waterproofing admixture brand name SIKA 101 H of M/s Sika. The use of crystalline
admixtures (CA) has a potential of improving the durability and reducing permeability of concrete structures especially those
exposed to environments like extradosed structure of underground structures [10]
Table 3. Physical Properties of Chemical admixtures

Characteristics Product Name- Sika Product Name-Sika
ViscoCrete 5138 ViscoCrete 5229NS
Specific gravity 1.125 1.115
pH 6.43 6.69
Dry material 42.49 38.45
content
Chloride (as Cl), < 0.01 < 0.01
% by Mass
Table 4. Physical Properties of Crystalline Waterproofing admixture (C.W.A)

Characteristics C.W.A-Product Name
Sika 101 H
Appearance Gray Powder
Density (kg/lit) 1.3
Dosage (%) by mass of cement 0.8-1
Permeability to water vapor at 3 Impermeable
bar pressures
Initial set time at 30 deg 40 minutes
temperature
Concrete admixtures are conformed to Indian Standard Specifications I S: 9103:1999 [11] and Crystalline Waterproofing admixture
confirmed to manufacturer technical product data sheet.
E. Aggregates
In Mumbai region, Maharashtra, India, river sand is not available and therefore construction industries are totally depending on
manufactured sand.
Coarse aggregate and Manufactured sand are obtained from nearest source i.e., Kunde vahal, Panvel,,Raigargh, Maharashtra . Fine
aggregate- M/sand and coarse aggregate are conformed to Indian Standard Specifications IS: 383-2016 [2].
Table 5 shows the physical properties of the coarse and fine aggregates.
Table 5. Physical Properties of Coarse and Fine Aggregates

Physical tests Coarse aggregate Fine aggregate
M-sand
Specific gravity 2.78 2.72
Water Absorption (%) 1.89 2.91
Bulk density (kg/m3) 1470 1730
III.CONCRETE MIX COMPOSITIONS

The concrete mix is designed as per absolute volume method according to the Indian standard -Concrete mix proportioning
Guidelines [12] to meet environmental exposure condition of Mumbai city, Maharashtra i.e., considered sever condition. The
properties of the concrete ingredients differ from one state to another state of the same country, and it is totally depending on actual
environmental exposer condition of site and quality of available concrete ingredients for making suitable concrete mix [13].
Concrete mix compositions are presented in Table 6 & Table No-7.
Table 6. Concrete Mix Proportions for Tunnel NATM Lining concrete M40 Grade.
Sr. Mix Cement GGBS UGGBS Powd W/P C.A F.A C.A /FA Water Superplastici
No. (Kg/m3) (Kg/m3) (Kg/m3) er Ratio (Kg/m3) M-Sand ratio (%) (Kg/m3) zer-Sika
(Kg/m (Kg/m3) ViscoCrete
3) 5138
(Kg/m3)
1 TR1 330 150 20 500 0.3 999 883 53/47 150 9.0
2 TR2 350 150 20 520 0.317 930 851 52/48 165 7.02
3 TR3 360 160 20 540 0.309 1029 773 57/43 167 8.1
4 TR4 360 160 20 540 0.296 927 848 52/48 160 8.64
5 TR5 330 200 20 550 0.32 778 981 44/56 176 7.7
Five concrete mix design trials were taken of M40 Grade and finalized TR 5 for NATM Lining flowable concrete for implementing
in NATM tunnel and Cross passages of underground Mumbai Metro Project in Package- UGC-07, Line -3. Coarse aggregate
content, fine aggregate content and cementitious content were optimized, until a slump flow of 500-700 mm is achieved by slump
flow test. For each trial, tests are carried out in order that the trial mix satisfies slump flow test, Flow table test and Sieve stability
tests.
Table 7. Concrete Mix Proportions for the structures -Base slab, RCC walls and Roof slab Flowable Concrete M40 Grade
Sr. Mix Cement GGBS UGGBS Powd W/P C.A F.A C.A /FA Water Superplastic C.W.A
No. (Kg/m3) (Kg/m3) (Kg/m3) er Ratio (Kg/m3) M-Sand ratio (%) (Kg/m3) izer-Sika (Kg/m
(Kg/ (Kg/m3) ViscoCrete 3)
m3) 5229 NS
(Kg/m3)
1 TR6 315 145 20 480 0.313 1049 816 56/44 150 7.2 4.8
2 TR7 260 200 20 480 0.304 1064 814 56/44 146 6.72 4.8
3 TR8 260 200 20 480 0.313 1035 810 56/44 150 6.24 4.8
4 TR9 245 200 15 460 0.35 988 889 53/47 161 5.98 4.6
Four concrete mix design trials were taken for the structures -Base slab, RCC walls and Roof slab Flowable Concrete M40 Grade
for metro Station in UGC-07 of Mumbai Metro Project, Line -3. Satisfactory results obtained in trial mix no-TR 9. Coarse aggregate
content, fine aggregate content and cementitious content were optimized, until a slump flow of 500-700 mm is achieved by slump
flow test. For each trial, tests are carried out in order that the trial mix satisfies slump flow test, Flow table test and Sieve stability
tests.
A. Test Methods
Flowable Concrete is able to flow under its own weight without segregation, bleeding with some vibration and these behavior of
concrete can be ensured by tests like Flow table test ,Slump flow, Slump test , and Sieve stability tests of concrete to determine the
flow ability, passing ability and segregation resistance of SCC mixtures according to BS: EN 12350 Part 2, 5,8, 9, 10, 11, and 12
[14]
Fig.1 Flow Table Test Fig.2 Slump Flow Test
Fig.3 Slump Test Fig.4 Funnel test
Fig 5. L-Box test Fig 6. U- Box Test
Fig 7. Sieve Segregation resistance Test
Table 8. NATM Lining flowable concrete M40 Grade - Flowing ability, passing ability and segregation resistance are checked after
3 hrs. and results are as below.
Sr.No Mix Slump Flow Slump V- V- L-box U-box Segregation Remarks
flow Table (mm) funnel funnel Blocking Difference Resistance
(mm) (mm) Tf (sec) T5min ratio(H2/H1) (mm)
(sec)
1 TR1 430 520 190 98 103 0.25 280 - Not achieved
2 TR2 450 535 195 91 98 0.3 230 - Not achieved
3 TR3 470 565 200 65 69 0.5 140 - Not achieved
4 TR4 510 600 210 29 42 0.5 122 11.2 Results are found
satisfactory for
flowability only
more satisfactory in
flowability
requirements and near
to passing ability tests
Trial mix no TR 4 has achieved all the requirements of filling ability but could not achieve the requirements of passing ability. In
trial No-TR 5 achieved all the requirements of filling ability and could not achieve the requirements of passing ability but values are
found closer to the requirements. Trial mix no TR5 has been finalized based on above-mentioned tests results values with
considering TR5 can be achieved all the parameters of flowing and passing ability at site if apply some vibration during casting the
structure. Details of final NATM Lining flowable concrete M40 Grade mix design trial mix no- TR5 is as below.
TABLE 9: Table showing the finalized mix proportion for the high performance flowable concrete Trial Mix No- TR 5 NATM
Lining flowable concrete M40 Grade (12.5 MSA)
Coarse
Cementitious (Kg) Fine Aggregate aggregate
Water (Kg) Superplasticizer (Kg)
M-Sand (kg) (12.5 MSA)
(Kg)
`Cement GGBS UGGBS
176 981 778 7.7
330 200 20
Table 10. Test Results of NATM Lining flowable concrete M40 Grade in Laboratory
Observation Characteristics Acceptance Limits Initial 1hr 2hrs 3 hrs.
Slump-flow class Flowability/Filling
≥ 520mm, ≤ 700mm 630 6 10 580 540
SF1 Ability
Flowability/Filling
Flow Table 500-700 700 690 660 620
Ability
Flowability/Filling
Slump Test --- 230 230 220 215
Ability
V Funnel Tv Viscosity Flowability ≤ 10s 15 18 22 28
L Box (H2/H1) Passing Ratio ≥ 0,75 0.75 0.72 0.7 0.7
U Box Deference Height difference 30 mm Max 0 5 7 15
Sieve Segregation Segregation Resistance < 23 % 9.5 9.2 8.4 7.9
Ambient
26.5 27.5 28.2 29.4
Temperature
Mix proportion of selected mix design TR5 implemented at site for Tunnel NATM concrete and NATM cross passages and total
11426 cum concrete quantity is executed from 25th Feb 2020to 30th june’2021.
The flowing ability and passing ability of concrete mix are checked according to conformity criteria for the properties of Flowable
concrete [3] at site and observed results are as below.
Table 11. The Average Test Results of Site executed High performance Flowable concrete mix during concreting for Tunnel NATM
Lining Concrete.
Before pouring Remarks
Results of
at site (around 1 (Comparison
Observation Characteristics Acceptance Limits Batching
to 2 hrs after with 2 hrs
Plant
batching time) results of TR5)
Slump-flow class Flowability/Filling -20 mm than
≥ 520mm, ≤ 700mm 630 560
SF1 Ability TR 5
Flowability/Filling -10 mm than
Flow Table 500-700 700 650
Ability TR5
Flowability/Filling
Slump Test --- - - Not Taken
Ability
V Funnel Tv Viscosity Flowability ≤ 10s - - Not Taken
L Box (H2/H1) Passing Ratio ≥ 0,75 - - Not Taken
U Box Deference Height difference 30 mm Max - - Not Taken
- - Not Taken
Sieve Segregation Segregation Resistance < 23 %
Ambient
26.5 27.5 28.2 29.4
Temperature
All the parameters of tests are not checked at site because shifting of all testing apparatus could not practically possible during
concreting at site, but Slump flow and Flow table tests were carried out for 1904 Transit Mixers and their average values are
mentioned in above table.
Some tests could not be conducted at site laboratory due to non-availability of enough testing equipment’s at in house laboratory.
Hence samples of specimens were sent to authorized NABL laboratory for conducting tests are as below.
Table 12. Hardened Concrete Test results for Tunnel NATM Lining Concrete.
Sl. NO. Test Description Acceptance Requirement Actual Results obtained
1 RCPT 1000 Coulombs 782.0 coulombs
2 Permeability 10 mm 6 mm
3 Flexural strength > 0.7 √fck 6.25 n/mm 2

= 5.42 N/mm2
4 Split tensile strength > 0.5 √fck 5.01 n/mm 2

= 3.87 N/mm2
5 Drying Shrinkage 0.05 % (Max) 0.026 %
6 Moisture Moment 0.03 % (Max) 0.018 %
7 Chloride content 0.5 % (Max) 0.34 %
8 Sulphate content 3.7 % (Max) 0.35 %
Table 13. The Cube Compressive Strength for Successful Trial Mix no TR-5 for M40 NATM Lining Flowable Concrete in N/mm2
Compressive Compressive Avg. Strength

Age of
Sr. No No. Specimen Strength of Specimen Strength of Sample in of Samples in
Cubes
in N/mm2 N/mm2 N/mm2
1 39.6
2 41.2 40.81
3 41.63
4 38.5
5 7 days 9 41.24 39.58 40.14
6 38.99
7 41.66
8 38.99 40.02
9 39.41
10 58.54
11 63.49 59.52
12 56.53
13 63.21
14 59.56 60.33
15 58.22
16 59.73
17 63.24 62.45
18 64.38
28 days 18 61.34
19 62.98
20 61.22 61.63
21 60.69
22 59.77
23 58.55 61.66
24 66.66
25 60.12
26 58.9 62.45
27 68.33
28 76.22
29 75.02 70.46
30 60.14
31 67.43
32 56 9 66.23 68.69 68.88
33 72.41
34 68.93
35 67.73 67.49
36 65.81
After achieving all the parameters according to the requirements of site conditions for Flowable concrete for grade M40 then same
mix is implemented site for the construction of NATM tunnel lining and cross passages. The compressive strength results of site
casted cubes for 7 days,28 days and 56 days are represented in table and graph as below.
Table 14. The Compressive Strength of site casted cubes for M40 grade High Performance Flowable Concrete (in N/mm2)
Avg. Strength of Standard
No. % Of Strength Coefficient of
Sr.No Age of Cube Samples Deviation
Sample Gaining Variation (%)
(N/mm2) (N/mm2)
1 7 days 8 40.14 100.35
2 28 Days 35 60.22 150.55 1.82 3.03
3 56 days 8 65.09 162.73
70 7 days strength
Compressive Strength in Mpa
60
28 days strength
50
56 days strength
40
30
1
8
Sample Number
Fig 8. Graphical representation for Compressive Strength of site casted cubes for 7 days, 28 days and 56 days
Concrete cubes were casted for testing of compressive strength of working structures and results are found satisfactory. Samples
taken for cube compression strength of working structures, average compressive strength, standard deviation, and coefficient of
variation are represented in graph as below.
Graphical Representation of Cube Compressive Strength for NATM Tunnel Lining HPFC M40 grade
Compressive Strength in N/mm2
70
Cube Compressive Strength in N/mm2
Avearage Comressive Strength in N/mm2

65 Acceptance Compressive Strength in N/mm2
60
55
Average Compressive Strength - 60.22 N/mm2
Compressive Strength ( Min- max) - 57.79 - 65.58 N/mm2
50
Standar Deviation -1.8 2
Coefficient of Variation-3.03
45
40
35
0 5 10 15 20 25 30 35
Sample No
Fig 9. Graphical Representation of site casted Cube Compressive Strength for Tunnel NATM lining flowable concrete M40 Grade.
Table 15. RCC works Flowable Concrete M40 Grade - Flowing ability, passing ability and segregation resistance are checked after
3 hrs. . and results are as below.
Sr.No Mix Slump Flow Slump V- V- L-box U-box Segregation Remarks
flow Table (mm) funnel funnel Blocking Difference Resistance
(mm) (mm) Tf (sec) T5min ratio(H2/H1) (mm)
(sec)
1 TR6 380 410 155 - - - - - Not achieved
2 TR7 450 535 195 - - - - - Not achieved
3 TR8 450 535 195 91 98 0.3 230 6.8 Not achieved
more satisfactory in
flowability
requirements and near
to passing ability tests
In trial No-TR 9 achieved all the requirements of filling ability and could not achieve the requirements of passing ability but values
are found nearer to the requirements. Trial mix no TR 9 has been finalized based on above-mentioned tests results values with
considering TR9 can be achieved all the parameters of flowing and passing ability at site if apply some vibration during casting the
structure.
Details of final RCC works Flowable Concrete M40 Grade mix design trial mix no- TR 9 is as below.
TABLE 16. Table showing the finalized mix proportion for Flowable Concrete, Trial Mix No- TR 9 RCC works Flowable Concrete
M40 Grade (20 MSA)
Coarse C.W.A
Cementitious (Kg) Fine Aggregate aggregate (Kg)
Water (Kg) Superplasticizer (Kg)
M-Sand (kg) (20 MSA)
(Kg)
GGBS
`Cement UGGBS 889 988 4.6
161 5.98
245 200 15
Table 17. Test Results of RCC works Flowable Concrete M40 Grade in Laboratory
Observation Characteristics Acceptance Limits Initial 1hr 2hrs 3 hrs.
Slump-flow class Flowability/Filling ≥ 520mm, ≤
600 580 530 520
SF1 Ability 700mm
Flowability/Filling
Flow Table 500-700 690 670 640 610
Ability
Flowability/Filling
Slump Test --- 220 220 215 205
Ability
V Funnel Tv Viscosity Flowability ≤ 10s 25 28 32 59
L Box (H2/H1) Passing Ratio ≥ 0,75 0.65 0.6 0.55 0.5
U Box Deference Height difference 30 mm Max 0 5 7 15
Sieve Segregation Segregation Resistance < 23 % 9.5 9.2 8.4 7.9
Ambient
26.5 27.5 28.2 29.4
Temperature
Mix proportion of selected mix design TR9 implemented at site for RCC structures i.e., Base slab, Roof slab and RCC walls and
total 32508 cum concrete quantity is executed from 18th March 2020to 30th june’2021.
The flowing ability of concrete mix are checked according to conformity criteria for the properties of Flowable concrete [3] at site
and observed results are as below.
Table 18. The Average Test Results of Site executed high performance flowable concrete mix during concreting for RCC structures.
Remarks
Before pouring
Results at (Comparison
at site (around 1
Observation Characteristics Acceptance Limits Batching with 2 hrs
to 2 hrs after
Plant results of
batching time)
TR 9)
Slump-flow class Flowability/Filling Not Taken at
≥ 520mm, ≤ 700mm 550 -
SF1 Ability site
Flow Table 500-700 630 580
Ability TR9
Slump Test --- 230 200
Ability TR9
V Funnel Tv Viscosity Flowability ≤ 10s - - Not Taken
L Box (H2/H1) Passing Ratio ≥ 0,75 - - Not Taken
U Box Deference Height difference 30 mm Max - - Not Taken
- - Not Taken
Sieve Segregation Segregation Resistance < 23 %
Ambient
26.5 27.5 28.2 29.4
Temperature
All the parameters of tests are not checked at site because shifting of all testing apparatus could not practically possible during
concreting at site, but Slump flow and Flow table tests were carried out for 5118 Transit Mixers and their average values are
mentioned in above table.
Some tests could not be conducted at site laboratory due to non-availability of enough testing equipment’s at in house laboratory.
Hence samples of specimens were sent to authorized NABL laboratory for conducting tests are as below.
Table 19. Hardened Concrete Test results for RCC works Flowable Concrete M40 Grade
Sl. NO. Test Description Acceptance Requirement of Actual Results obtained
contract specifications
1 RCPT 1000 Coulombs 652.5 coulombs
2 Permeability 10 mm 4 mm
3 Flexural strength > 0.7 √fck 6.10 n/mm 2

= 5.42 N/mm2
4 Split tensile strength > 0.5 √fck 4.66 n/mm 2

= 3.87 N/mm2
5 Drying Shrinkage 0.05 % (Max) 0.009 %
6 Moisture Moment 0.03 % (Max) 0.011%
7 Chloride content 0.5 % (Max) 0.22 %
8 Sulphate content 3.7 % (Max) 1.87 %
Table 20. The Cube Compressive Strength for Successful Trial Mix no TR-9 for M40 Grade high performance flowable concrete in
N/mm2.
Avg. Strength
Age of Compressive Strength Compressive Strength
Sr.No No. Specimen of Samples in
Cubes of Specimen in N/mm2 of Sample in N/mm2
N/mm2
1 34.6
2 36.2 35.81
3 36.63
4 33.5
5 7 days 9 36.24 34.58 35.14
6 33.99
7 36.66
8 33.99 35.02
9 34.41
10 52.54
11 57.49 53.52
12 50.53
13 57.21
14 53.56 54.33
15 52.22
16 53.73
17 57.24 56.45
18 58.38
28 days 18 55.34
19 56.98
20 55.22 55.63
21 54.69
22 53.77
23 52.55 55.66
24 60.66
25 54.12
26 52.9 56.45
27 62.33
28 73.22
29 72.02 67.46
30 57.14
31 64.43
32 56 days 9 63.23 65.69 65.88
33 69.41
34 65.93
35 64.73 64.49
36 62.81
After achieving all the parameters according to the requirements of site conditions for Flowable concrete for grade M40 then same
mix is implemented site for the construction of RCC structures i.e., Base Slab, Roof slab and RCC walls. The compressive strength
results of site casted cubes for 7 days,28 days and 56 days are represented in table and graph as below.
Table 21. The Compressive Strength of site casted cubes for M40 grade High Performance Flowable Concrete (in N/mm2)
Avg. Strength of Standard
No. % Of Strength Coefficient of
Sr.No Age of Cube Samples Deviation
Sample Gaining Variation (%)
(N/mm2) (N/mm2)
1 7 days 9 33.87 84.68%
2 28 Days 35 50.81 127.03 1.77 3.48
3 56 days 9 61.91 154.78
70
7 days
Compressive Strength in Mpa
strength
60
50 28 days
strength
40
56 days
30 strength
1
9
Sample Number
Fig 10. Graphical representation for Compressive Strength of site casted cubes for 7 days, 28 days and 56 days
Concrete cubes were casted for testing of compressive strength of working structures and results are found satisfactory. Samples
taken for cube compression strength of working structures, average compressive strength, standard deviation, and coefficient of
variation are represented in graph as below.
Graphical Representation of Cube Compressive Strength for flowable concrete M40 Grade for RCC
60 Structures
Cube Compressive Strength in N/mm2
Compressive
55 Strength in
N/mm2
50 Avearage
Comressive
Strength in
45 N/mm2
Acceptance
Compressive
40 Average Compressive Strength - 50.81 N/mm2 Standar Deviation -1.77 Strength in
N/mm2
Compressive Strength ( Min- max) - 45.79 - 56.58 N/mm2 Coefficient of Variation-3.48
35
0 5 10 15 20 25 30 35
Sample No
Fig 11. Graphical Representation of site casted Cube Compressive Strength for flowable concrete M40 Grade
IV. EXECUTION OF THE CONCRETE POURING AT SITE

Following points were ensured at site before and during placement of high performance flowable concrete.
1) Assessment for the placement situations of HPFC either by using boom placer, long distance pipe pumping, direct placing via a
chute or a concrete bucket placement.
2) Shutter were designed for the capability and withstanding in the forces of lateral pressure of fresh concrete.
3) Concrete pour plans were prepared for every concrete pour for maintaining sequence of concrete production from batching
plant, placing at site, movements of pump and pipe’s location during concreting to maintain the concrete pour rate and avoid
formation of cold joints.
4) Quality control tests and checks at batching plant before despatching the concrete and same tests were performed at site also
before pouring at the structure.
5) Avoid direct free fall of HPFC more than 1.5 m height.
6) During concrete pouring visual checks were carried out on potential segregation inside the formwork and found no segregation.
7) Concrete pour rate was maintained to avoid entrainment and to limit the pressure on the formwork.
8) Shutter vibrators, needle vibrators were used according to placing condition to ease of flow and reach each corner of formwork
and compaction for achieving smooth surface finish after de-shuttering.
.
Fig 12 Actual site photographs during concrete placing at site showing two stages of concrete pouring and nos of bends to reach at
placement point.
A. Quality Control Checks &Concrete surface finish after De-shuttering of the Structure
Appropriate technical team and testing equipment’s were deployed at Batching plant, TM checking point and placement point.
Flowable concrete has been placed successfully in formwork without any break downs and obstacles due to proper planning and
systematic arrangement. After De-shuttering NATM tunnel lining, Cross passage lining RCC walls concrete surfaces found smooth.
Fig 13. Smooth surfaces of the cast in situ high performance flowable concrete
V.CONCLUSION
1) High performance flowable concrete can be developed with partially fulfills the requirements of self-compacting concrete and
implemented at site also according to site situations.
2) High performance flowable concrete can be easily placed in long distance pumping and congested reinforcement structure with
some vibration during the placement.
3) Crystalline waterproofing admixture plays effective role for reducing permeability and increase durability of the structures.
4) Water permeability tests and RCPT values found less in low cementitious concrete i.e., TR 9 due to adding of crystalline
waterproofing admixture as compared to high cementitious concrete trial mix no TR 5.
5) More impermeable and durable concrete can be developed in optimized cementitious content using crystalline waterproofing
admixture in concrete.
VI.ACKNOWLEDGMENT
The authors are thankful to Director Projects of Mumbai Metro Rail Corporation and PMT Head of Shanghai Tunnel Engendering
Co., Ltd for their motivational inputs and supports.
Compliance with ethical standards

Conflict of interest - On behalf of all authors, the corresponding author states that there is no conflict of interest.
REFERENCES
[1] Chiara F. Ferraris, "Measurement of the Rheological Properties of High Performance Concrete: Sate of the Art Report," Journal of Research of the National
Institute of Standards and Technology, vol. 104(5), no. 8, pp. pp.461-478, 1999.
[2] IS 383: 201 6 Bureau of Indian Standards (New Delhi) Indian standard coarse and fine aggreagtes for concrete specification, IS 383: 201 6 .
[3] The European Guidelines for Self-Compacting Concrete Specification, Production and Use, May2005, 2005.
[4] A. I. Hassan EL-Chabib, "The performance of high-strength flowable concrete made with binary," Construction and Building Materials 47 (2013) 245–253,
vol. 47, no. 47, pp. pp 245-253, 2013.
[5] P. M. A. S. B. S. V. V. A. P. N. Ojha, "Optimization and evaluation of ultra high-performance con-crete," Journal of Asian Concrete Federation, vol. Vol. 6, no.
No. 1, pp. pp. 26-36, June 2020, June 2020.
[6] M. V. a. P. D. b. V. K. c. B. Venkatesan a, "Experimental study on concrete using partial replacement of cement by," Materials Today: Proceedings, vol.
Volume 37, no. Part 2, pp. Pages 2183-2188, 2021.
[7] IS 269:2015. Ordinary Portland Cement- Specification, 2015.
[8] IS 16714-2018. GGBS for use in cement, mortar and concrete-specifications, 2018.
[9] IS: 16715-2018 "Ultrafine Ground Granulated Blast Furnace Slag", 2018.
[10] C. Xue, "Self-healing efficiency and crack closure of smart cementitious composite with crystalline admixture and structural polyurethane," Construction and
Building Materials, vol. Volume 260, p. 119955, November 2020.
[11] IS 9103:1999, Concrete Admixtures: Specification, Bureau of Indian Standard, Delhi, pp. 1–14., 1999.
[12] IS :10262:2009 Concrete mix proportioning - Guidelines, 2009.
[13] W. OH, "Why is SCC Different from Country. Fourth International Symposium on SCC," Chicago, 2005.
[14] MSZ EN 12350, Testing fresh concrete, Part 2,5, 8, Part 9, Part 10, Part 11, Part 12, (2010), 2010.
[15] K. K. D. C. S. T. Patrick Paultre, "tructural performance of self-consolidating concrete used in confined concrete columns," ACI Struct J, 102 (7) (2005), pp.
560-568, vol. 7, no. 102, pp. pp. 560-568, 2005.
[16] A. D. Adesina, "Concrete Sustainability Issues," in 38th Cement and Concrete Science Conference, London, 2018.
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Performance of Flowable Concrete For Application in Underground Structures - NATM Tunnel and Station Box of Mumbai Metro Project

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11 IV April 2023

Performance of Flowable Concrete for Application

II. CONCRETE INGREDIENTS

C. Ultrafine GGBS -Alccofine

Table 1. Physical Properties of Cement, GGBS and UGGBS-Alcofine 1203

Table 2. Chemical Properties of Cement. GGBS and UFGGBS-Alccofine 1203

D. Chemical admixtures and crystaline growth waterproofing admixture

Table 3. Physical Properties of Chemical admixtures

Table 4. Physical Properties of Crystalline Waterproofing admixture (C.W.A)

Table 5. Physical Properties of Coarse and Fine Aggregates

III.CONCRETE MIX COMPOSITIONS

Fig.1 Flow Table Test Fig.2 Slump Flow Test

Fig.3 Slump Test Fig.4 Funnel test

Fig 5. L-Box test Fig 6. U- Box Test

Fig 7. Sieve Segregation resistance Test

2 TR2 450 535 195 91 98 0.3 230 - Not achieved

3 TR3 470 565 200 65 69 0.5 140 - Not achieved

L Box (H2/H1) Passing Ratio ≥ 0,75 - - Not Taken

U Box Deference Height difference 30 mm Max - - Not Taken

1 RCPT 1000 Coulombs 782.0 coulombs

3 Flexural strength > 0.7 √fck 6.25 n/mm 2

4 Split tensile strength > 0.5 √fck 5.01 n/mm 2

5 Drying Shrinkage 0.05 % (Max) 0.026 %

6 Moisture Moment 0.03 % (Max) 0.018 %

7 Chloride content 0.5 % (Max) 0.34 %

8 Sulphate content 3.7 % (Max) 0.35 %

Compressive Compressive Avg. Strength

Avearage Comressive Strength in N/mm2

L Box (H2/H1) Passing Ratio ≥ 0,75 - - Not Taken

U Box Deference Height difference 30 mm Max - - Not Taken

1 RCPT 1000 Coulombs 652.5 coulombs

3 Flexural strength > 0.7 √fck 6.10 n/mm 2

4 Split tensile strength > 0.5 √fck 4.66 n/mm 2

5 Drying Shrinkage 0.05 % (Max) 0.009 %

6 Moisture Moment 0.03 % (Max) 0.011%

7 Chloride content 0.5 % (Max) 0.22 %

8 Sulphate content 3.7 % (Max) 1.87 %

IV. EXECUTION OF THE CONCRETE POURING AT SITE

Compliance with ethical standards

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