SDPL UHPC INDIA
SDPL UHPC INDIA
Concrete Technology Break Through
One of the biggest breakthrough in 21st century is the
invention of ultra-high-performance fiber reinforced concrete
(UHPFRC)
⚫ Concrete Grade 150/165 above
⚫ With usable structural ultimate tensile strength (> 8 MPa)
and ultimate flexural strength more than 30 MPa.
⚫ at least 4-6 times stronger than normal concrete (in
compressive strength)
⚫ at least 100 times more durable than conventional
concrete
⚫ Longer service and design life
⚫ Lower carbon footprint
SDPL UHPC INDIA
DURA Group of Companies
SDPL-DURA India
SDPL UHPC INDIA
How UHPFRC Compare to Reinforced Concrete?
Reinforced Concrete UHPFRC
⚫ Aggregate up to 20mm ⚫ Eliminate aggregate
⚫ Mainly using steel bar as ⚫ Mainly using steel fiber as
reinforcement reinforcement
⚫ Steel bar is compulsory ⚫ Steel bar is optional
⚫ Concrete cover detailing ⚫ Concrete cover is not
rules needed compulsory
⚫ Less workable in slender ⚫ Highly flowable and
element mouldable
⚫ Honeycomb possible ⚫ Honeycomb almost
impossible
Mixing of Concrete
Pouring of Concrete
SDPL UHPC INDIA
How UHPC Compare to Steel & Concrete?
(Force Vs Displacement)
STEEL
UHPFRC
Force Concrete
Strain
hardening
Elastic
Strain
Softening
Elongation
SDPL UHPC INDIA
Flexural-Tensile 4 Point Test
Dura® - UHPFRC
Displacement
Hardening
Grade60 HPC
SDPL UHPC INDIA
MRT Tunnel Liner
(Normal SFRC)
Normal Concrete
CT Scan on X-Rays Scan on
core sample
normal sample
12 cored samples
Fiber QTY = 158kg/m3 (2% vol.)
34 mil fibers; Total Length = 643 km/m3
SDPL UHPC INDIA
The Advantage of using DURA®
DURA UHPFRC doesn’t shrink and minimal creep
Cost Saving;
Span up to 100m, thus reduce foundation cost significantly
Cheaper & better solution against Steel Structures
Lighter and thin sections
Extremely Durable due to ultra denseness of concrete
Better Bridge Material compare to conventional (Factory Product)
Easier Handling & Transport (Lower Tonnage Crane Required)
Shortened Construction Period. (more than 20%)
SUSTAINABLE ASSET
Value for MONEY!!!
SDPL UHPC INDIA
Structural Standards (NF P 18-710, 2016)
SDPL UHPC INDIA
Batu 6 Bridge, Single Span 100m
PCI 2016 Design Award – Best International Transportation Structure
Match Casting
Unload Segments at
Site using 45t crane
45t mobile
crane
Completed After 1 Year
17.6m wide RC deck
Supported by 3 beams per span
To Construct a Viaduct at Section 49, Laluan 4
(KM 157 Gerik - Kota Bahru), Ecological Corridor
at Central Forest Spine (CFS), Gerik, Perak D.R.
Fully Integral bridge
without expansion joint
Fully Integral Bridge
5.9m 5.9m
To Construct a New Bridge from Kg Baharu to Kg. Teluk, Manjung
District, Perak D.R (2017)
To-date, Malaysia longest
UHPC composite bridge
(13.7m wide x 420m long)
KB-KT Bridge (10 spans x 42m – 420m), Deck Width 13.6m;
2 beams per span (6.8m c/c) Total 20 UHPC U-Beams Used
Integral bridge with
one expansion joint
SDPL UHPC INDIA
Introduction of UHPFRC Bridge Construction Technique
in India
We SDPL UHPC INDIA have done Technology Transfer Arrangements
with DURA for UHPFRC applications in bridge Construction.
Proposal for construction of first UHPFRC bridge in India was approved by
MoRT&H, Govt of India through National Panel of Experts Committee.
Design and Drawings are approved by IIT, Mumbai and bridge is
successfully competed and opened for traffic near Latur, Maharashtra
where we are EPC Contractor.
Original proposal was of 112m bridge length with span arrangements as
19.5m x 2 Nos and 24m x 3 Nos
Present proposal is UHPFRC superstructure with 2 Nos of 56m span
SDPL UHPC INDIA
Establishment for dedicated Specialized casting yard at Pune and is fully
operation from 01.11.2021
Production set up is with facility of UHPFRC 2 Nos of concrete plant of 8
Cum batch capacity each.
1 Nos 1.5 cum mobile UHPFRC production plant is operational
Specialized Quality Control laboratory established.
Trained Design & Development team for UHPC projects is in place along
with Association of HSS Engineering, Malaysia and Indian Associate
Designer SPA, Mumbai
Latur Bridge – Pilot Project
SDPL UHPC INDIA
SDPL UHPC INDIA
Original GAD
SDPL UHPC INDIA
Present UHPFRC Superstructure GAD
SDPL UHPC INDIA
Conventional Vs UHPC (Tender GAD) Vs UHPC (Designed)
Conventional concrete DURA superstructure
DURA superstructure % reduction
Sr No Concrete Quantity UOM superstructure (RCC (UHPC)U Girder - 3
(UHPC) U Girder - 4 Nos in scope
Composite I-Girder) Nos
1 Piles(1.2m dia.) Nos 56 nos(596 RM) 24 nos(242 RM) 24 nos(242 RM) 57%
2 Pilecap Cum 789 434 434 45%
3 PCC below pilecap Cum 40 21 21 48%
piers
4 (intermediate) Cum 100 30 30 70%
5 Abutement pier Cum 112 9.27 9.27 91%
6 piercap Cum 181 72 72 60%
7 Pedestal Nos 60 16 12 80%
8 Bearings Nos 60 16 12 80%
9 Superstructure Cum 1070 751 661.4 38%
Inaugural Meeting for Introduction of UHPFRC Technology
SDPL UHPC INDIA
NPE Malaysia Visit
SDPL UHPC INDIA
Latur Bridge in Photographs
STAGE 1 (b) : ARRIVAL OF SEGMENT ON SITE
SDPL UHPC INDIA
STAGE 2 : ERECTION OF SEGMENTS ON STAGING
SDPL UHPC INDIA
STAGE 3 : PRE STRESSING OF SEGMENTS
SDPL UHPC INDIA
SDPL UHPC INDIA
Completed Photo of Bridge
SDPL UHPC INDIA
Inauguration of Bridge by Hon’ble Minister Shri Nitinji Gadkari
on 25th November 2021
SDPL UHPC INDIA
Projects Currently Execution
Major Creek Bridge of 182.50 length at Mangalore Karnataka with UHPC Span
arrangement ( 50 m + 65 m + 67.50 m)
2 Bridges with single spans of 52 m on the prestigious Samruddhi Mahamarg for
Canal and highway crossing.
Viaducts with UHPC spans 72m on NH17 at Kashedi Ghat Section
9 Bridges including record breaking 118 m span bridge for M/s R.K. Chavan
Infrastructure Pvt Ltd.
1 Major Bridge and Minor Bridge awarded to us by M/s A.C. Shaikh Constructions
Pvt. Ltd.
1 Major Bridge and 2 Minor Bridges along Mumbai Goa (NH66) National Highway
Successfully completed Repair and Rehabitation of rigid pavement damaged
panels 10 no's on trial on Mumbai-Pune Expressway, Maharashtra
Total Cumulative orders of - 8000 Total Cumulative orders of 21
cum (in hand) Bridges (in hand)
Projects Under NHAI
Major Creek Bridge of 182.50 length at Mangalore Karnataka with UHPC Span
arrangement ( 50 m + 65 m + 67.50 m)
Original GAD
SPAN ARRAGEMENT – 16.8 + 16.8 + 32.5 + 32.5 + 32.5 + 32.5 + 16.8
Present UHPFRC Superstructure GAD
Photographs Under Execution - Substructure
ABUTMENT A1
67.5 M SPAN
PIER P1
65 M SPAN
PIER P2
50 M SPAN
ABUTMENT A2
MoRTH Circular dated 22nd Feb 2022.
Use of Ultra high performance fiber reinforced concrete in
design and construction of structures/bridges of National
Highways
New Development
MoRTH Precast Policy Circular dated 8th April
2022.
National Highway Pre-cast Concrete Policy
SDPL UHPC INDIA
Specialised UHPC Production Plant
@ Kiwale, Pune
T-Beam
(BT1500)
Casting in
progress
Stressing Activity for Kashedi Ghat Porject –
Mumbai Goa Highway
U-Beam
(UBG2250)
Casting in
progress
SAMRUDDHI EXPRESSWAY
BRIDGE SUPERSTRUCTYRE
CASTING
STEAM CURING ASSEMBLY
Finished Product
BT 1500 – Mumbai Goa
Highway
UBG 2250 - For 50 m Span at Phalguni River (Kullur Bridge)
Thank You
SDPL UHPC INDIA
