V N Heggade
V N Heggade
V N Heggade
V N Heggade
Executive Director (Technical)
Gammon Engineers & Contractors (P) Ltd.
• Despite the current energy efficiency, production of OPC consumes the energy of 5-8 GJ /ton
& steel consumes 30-60 GJ/ton.
• 1.8 GJ energy sustains 1 house hold for 1 month
• There is a need to reduce energy consumption during production itself by
Improving energy efficiency by upgrading plants with the state of the art equipment.
Improve product formulation to reduce energy of production and minimise the use of
natural resources.
Conduct research to develop new applications for improving energy efficiency.
Also 0.9 t & 2 t CO2 emitted for cement & steel respectively for 1 ton production should
be captured in some form and should be used again for production of CaCO3
SUSTAINABILITY OF RIGID PAVEMENTS
Many features during various
phases of the life cycle affect
the sustainability. Phases are :
Design,
Material selection,
Construction,
Operation & Maintenance
Rehabilitation &
Reconstruction
There are relationships between
these features and the life-cycle
phases and again among the
features themselves.
Design phase
PQC design mainly focusses on joint
spacing, load transfer, slab support
Two lift
considerations, drainage, and edge
support etc.
From sustainability considerations
further, emphasis can be given to
surface texture, light color, long life, Pre cast
and improved storm water quality
during the design process.
Innovative pavement types can be
explored, like fiber reinforced
concrete, two-lift concrete pavement,
roller-compacted concrete (RCC),
precast concrete and concrete pavers, RCC
and thin concrete pavement (TCP)
etc.
Material selection phase
The energy consumption and emissions generated
through the acquisition, processing, and transportation of
materials used in the construction, maintenance, and
rehabilitation of pavements impact the overall
sustainability of the system.
Camp-I @ Km 318+00
NH-63
Batching plants
120Cum/Hr- 2 Nos
60 cum/hr-1 nos
TORANGALLU BYPASS
CH. KM 312+160 TO CH. KM 316+600
Length=4.44 km
HOSPETE
KUDITHINI BELLARY
288
289
290
291
292
293
294
295
296
297
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301
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376
4 KM
TORANGA
14 KM
LLU
AP/KARNATAKA BRODER
NH-13
Camp-II @ 350+000
Bypass
Anthapur Quarry & Crusher Batching plants
Ch,. km 320+000 120 cum/hr - 2 Nos
9 km 60 cum /hr-1 nos
In the country for the first time perhaps sustainability measures for highway project is
adopted for Design, Material processing and Construction phases to such a large
magnitude.
But for the codal and other constraints like inability despite the circular from Ministry
of Environment and Forest to procure flyash from nearby JSW, BEML and KPCL
thermal plants for embankment and subgrade, green concepts could have been
enhanced to a large extent.
Scope of work
OPC & Aggregate replacement potential
JSW Torangallu Plant was in the vicinity of the
project which also has captive coal based thermal
power plant.
Hence, Ground Granulated Blast Furnace Slag as
well as Fly Ash was available for concreting.
Different types of Iron and Steel Slags were
available to be used as aggregates in concrete
and GSB.
Apart from that pond ash was available for
embankment from JSW, BEML and KPCL
plants.
Design of the PQC
At the planning stage all the available ways and means to optimise the process and
product from economical and sustainable point of view were explored considering all
physical and technical constraints.
As per the contract, the design of concrete pavement was done as per IRC:58 and IRC
SP:62.
On the basis of traffic studies conducted, considering the future forecast, the cross
section was arrived at.
Embankment filling
The depth of embankment varied
across the stretch. Mass haul
diagram was adopted to minimize
the earthwork for cut and fill.
Over all around 55,00,000 cum of
earthwork was required to be
done.
The bottom ash and pond ash
available in the captive power
plants of JSW, BEML and KPCL
were envisaged to be used as an
alternative to burrow earths from
sustainability consideration.
This replacement has the
potential of saving 2,16,000 T,
CO2 emission and 1,35,000 GJ
energy consumption.
Granular Sub Base (GSB)
It was planned to utilize the
Steel Slag as an alternative to
aggregates manufactured from
local rock.
The total quantity of the GSB
was around 10,00,000T.
This has the potential of
saving 10,000T, CO2 and
5,00,000 GJ energy
consumption to posterity.
Dry Lean Concrete (DLC)
Total DLC required for the
Project being 296,039 cum
The entire fine aggregates
used was Processed Iron
Slag Sand in accordance
with IS 383- 2016
The mix was designed with
120 kg Cement and 30 kg
of Fly Ash.
This was the minimum
allowable Cement content
as per MoRTH Rev. 5
Section 600.
Pavement Quality Concrete (PQC)
Total PQC required for the
Project being 4,76,951 cum
The thickness of the PQC was
reduced from 300 mm (as
prescribed) to 290 mm (as per
the design done as per IRC
58). This itself reduced the
quantity by 3.33%
50% fine aggregates to be
used was planned to be
Processed Iron Slag Sand as
per IS 383 2016.
Two mixes have been used
Cement : 310 kg and Fly Ash : 78
kg
Cement: 255 kg and GGBS: 120 kg
Structural Concrete
Different grades of Structural Concrete were designed
using Cement + GGBS.
Whenever possible the Nominal Maximum Size of Aggregate
was selected as 40 mm instead of 20 mm. This results in
approximately 30 Kgs of cementicious material saving per
cum of concrete.
The mixes were designed with ternary cementicious blend
(OPC + Fly Ash + GGBS) but the same was not approved by
the AE owing to his interpretations of MoRTH. The same
would also require additional Silos in smaller batching plant
so this issue was not pursued further.
The adopted mixes were done with GGBS (70 % replacement
for lower grades and 50% replacement for higher grades)
CARBON & ENERGY FOOTPRINT FOR
PQC,DLC & STRUCTURES
MIX DESIGN – DLC
20 mm 10 mm Crushed Water
Cement Fly Ash Slag Sand
Grade (Kg/ (Kg/ Sand
(Kg/ Cu.m) (Kg/cum) (Kg/ Cu.m)
Cu.m) Cu.m) (kg/cum) (Kg/ Cu.m)
Crushed Slag
Grade Cement Fly Ash 31.5 mm 20 mm 10 mm Water Admix.
Sand Sand
M20 102 238 450 337 336 575 192 153 1.02
M25 108 252 451 338 337 577 192 144 1.08
M30 111 259 456 341 340 583 194 133 1.48