Lopamudra Sengupta, Sr. Vice President (Technical services)
Dr. L.R.Manjunatha, Vice President - Direct Sales & Sustainability Initiatives
Abhishek Awasthi & Abhijeet Landage, Concrete Technologist, JSW Cement

Use of Industrial By-Products in Concrete Production
As every one ton of Cement (OPC) produced, emits 0.96 tons of CO2, there is an urgent need to promote blending materials (ex. GGBS &PSC) and screened slag, to achieve lower CO2 emissions, reduce greenhouse gas effect, reduce exploitation of natural resources, use alternate industrial byproducts in the production of concrete, and encourage alternate fuel usage, etc.

The need of the hour is “greener or lesser polluting cements or cementitious products” by use of industrial byproducts such as Ground Granulated Blast Furnace Slag, which is otherwise a waste, if not consumed.

Use of Industrial By-Products in Concrete Production
Slag is a non-metallic and non-hazardous byproduct of the Steel industry, having cementitious properties. The cement industry utilizes slag in cement manufacturing and ground granulated blast furnace slag in concrete production.

The Portland slag cement & GGBFS thus produced imparts many properties to concrete and other applications where cement is being used. Screened slag from the house of JSW Cement is an excellent replacement of natural or manufactured / crushed sand (replacement level is fully or partly depending on design requirement). The screened slag conforms to IS 383 and grants excellent strength and durability in concrete/mortar works, along with conservation of natural resources.

PSC/GGBS as an Eco-Friendly product
Use of Industrial By-Products in Concrete Production
  • JSW provides products that are Sustainable & Environmental Friendly
  • Pollution (air, water & land) free environment ensures no adverse impacts on the health of nearby communities
  • Utilization of slag and other by-products minimizes burden on landfills
  • Reduced virgin material usage
  • Reduced fossil fuel usage
  • Creates sustainable sites using PSC /GGBS concrete
  • Builds concrete with low embodied energy using PSC/GGBS
  • Use concrete that contains recycled materials
  • By use of PSC & Ground Granulated Blast Furnace Slag, Low carbon concrete can be produced, reducing carbon dioxide emission and at the same time quality of concrete is improved.
Use of Industrial By-Products in Concrete Production

Advantages of JSW green products for end-consumers
Use of Industrial By-Products in Concrete Production
  • Long term strength of concrete made with JSW green products is greater than concrete made with OPC and PPC cement
  • The concrete provides protection against corrosion of steel reinforcement
  • Concrete made with JSW green products is almost impermeable
  • Concrete cover remains intact
  • Concrete provides resistance to sea water attack in marine environment
  • Concrete offers better resistance to sulphate, chloride, harmful gases attack and ingress of atmospheric water
  • Ensures long design life/durability of structure with low maintenance cost
  • Cracks are minimized and reduced in structures.
The following products are available from JSW Cement
  1. JSW Portland Slag Cement (JSW PSC)
  2. JSW OPC
  3. JSW Concreel HD
  4. JSW Ground Granulated Blast Furnace Slag ( JSW GGBS)
  5. Granulated Blast Furnace Slag Sand (GBS Sand)
Use of Industrial By-Products in Concrete Production

Portland Slag Cement (PSC) & its Application
Use of Industrial By-Products in Concrete Production
JSW PSC is a blended cement wherein some portion of OPC is replaced with GGBFS to make the structures long lasting and durable. GGBFS present in PSC helps in secondary hydration, producing more C-S-H gel in system for improved performance of concrete.

Some of the major advantages of JSW PSC are:
  • Reduced thermal cracks due to lower heat of hydration as compared to OPC
  • Reduced shrinkage cracks as compared to OPC, PPC
  • Improved workability and smooth finish
  • Improved cohesion
  • Better resistance against chemicals such as chlorides, sulphates and carbon dioxide
  • Higher long-term strength
  • Improved durability
  • Green product
Use of Industrial By-Products in Concrete Production
JSW PSC can be used in all types of civil engineering works – both structural and non structural applications. In fact, it has got a wide spectrum of applications compared to OPC, which is not suitable for works such as mass concrete, industrial structures, marine structures, effluent and sewage treatment plants. On the other hand, PSC is ideal for these works, which makes it an all-purpose cement.

JSW PSC is a sustainable material. Since the production of PSC ensures the conservation of natural resource (limestone), savings in energy during production, and limiting the emission of carbon dioxide, it is regarded as eco-friendly.The properties of PSC have been specified by BIS in, IS: 455-2015, and CII – IGBC have certified, JSW PSC as a green product.
 
Use of Industrial By-Products in Concrete Production
Concreel HD & its Application
JSW Concreel HD is a cement with a high initial strength, high final strength, quick setting, superior cohesion, most durable, chemical resistant, and is a green product that conforms to IS: 455 – 2015. It is an ideal product for all kinds of concreting works and can be used right from foundation to plastering.

GGBS & its Application
Slag is a by-product of steel plants. It is obtained from the blast furnace during the separation of iron from the iron ore. The process of granulating of the slag involves cooling of molten slag through high-pressure water jets, which 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.

The benefits, application and performance of GGBS are same as that of PSC. In case of PSC, predetermined dosage of GGBS is added, whereas GGBS (separately combined with OPC) offers flexibility of using any particular dosage, depending on the choice of the user.

Use of Industrial By-Products in Concrete Production

Some of the major advantages of JSW GGBS concrete, as compared to pure OPC concrete or flyash-based concrete are given below:
  • Reduced thermal cracks due to lower heat of hydration
  • Reduced shrinkage cracks
  • Improved workability and smooth finish
  • Improved cohesion
  • Better resistance against chemicals such as chlorides, sulphates and carbon dioxide
  • Higher long-term strength
  • Improved durability
  • JSW GGBS meets the requirements of IS:12089-1989 and is an eco-friendly product
  • It can be used as partial replacement for OPC cement in concrete production at RMC batching plants and site batching plants
Use of Industrial By-Products in Concrete Production

Granulated Blast Furnace Slag Sand (GBS sand) & its Applications
Fine aggregates are an integral part of mortar, concrete, and plaster. River sand is regarded as an ideal fine aggregate. However, in recent years, due to non-availability of good quality river sand, crushed rock fines (CRF), are being used as fine aggregates. But CRF has some limitations, such as lack of moisture retention, making the mix non-cohesive/harsh and has a higher water demand.

GBS sand is an alternate to river sand as well as CRF. Slag obtained from blast furnace of steel plant is in the form of granules and looks like river sand, but is little greyish in colour. It is an inert material and is suitable for concrete and mortar, and can replace natural sand or CRF, up to a certain percentage (subject to field trials). The method of application of GBS sand is same as that of river sand / CRF. GBS sand had been tested, both in India and internationally, and found to be suitable to be used in mortar and concrete.

Use of Industrial By-Products in Concrete Production

GBS sand is superior to river sand because the latter contains fossils and other irregular particles like clay and silt that affects quality and durability. Also, dredging of river sand is not eco-friendly.

Use of GBS helps in maintaining harmony with the ecology as there is no quarrying, depletion of natural resource, and there is energy saving in crushing of the rocks. Like other products of JSW Cement, it is eco-friendly and JSW Slag sand meets all the requirements of IS:383-2015. GBS sand can be used as replacement of natural sand or CRF in concrete and mortar.
Enhancing Corrosion Resistance of Steel Bars in Reinforced Concrete Structures
Reinforced concrete is a composite material which is made using concrete and steel bars. Concrete takes the compressive forces and steel bar takes tensile forces. Concrete around the steel bar protects it from corrosion by providing an alkaline environment

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Moving toward workability retention to rheology retention with low viscosity concrete technology
Amol Patil, Sr. Specialist - General Manager (Admixture and Specialty Products), Master Builders Solutions (India), and Nilotpol KAR, Managing Director, Master Builders Solutions (South Asia), present a paper on the concept of low viscosity concrete in

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Cement industry innovating eco-friendly packaging
Cement companies are constantly innovating to meet global sustainability standards and improve logistics, shelf life, and utility of cement, while reducing wastage. Thei aim is to reduce their environmental impact without compromising their product

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IIT Madras uses Solar Thermal Energy to Recycle Waste concrete
Researchers at the Indian Institute of Technology Madras have developed a treatment process using solar thermal energy to recycle construction and demolition debris. Waste concrete from demolition was heated using solar radiation to produce recycled concrete

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Textile Reinforced Concrete - A Novel Construction Material of the Future
As a new-age innovative building material, TRC is especially suited for maintenance of existing structures, for manufacturing new lightweight precast members, or as a secondary building material to aid the main building material. Textile Reinforced Concrete

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Technological Innovation for Use of Bottom Ash by-product of Thermal Power Plants in the Production of Concrete
The day is not far for the adoption of this innovative, eco-friendly, and cost-effective bottom ash – concrete process technology by construction agencies undertaking road/infrastructure project works, real estate developers, ready mix concrete (RMC) operators

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Headed Bars in Concrete Construction
Using headed bars instead of hooked bars offer several advantages like requirement of reduced development length, less congestion, ease of transport and fixing at site, better concrete consolidation, and better performance under seismic loads.

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Sustainability of Cement Concrete - Research Experience at CRRI on Sustainability of Concrete from Materials Perspective
It can be said that ever since the publication of the document of World Commission on Environment and Development [1], the focus of the world has diverted towards sustainability. Gro Harlem Bruntland [1] defined sustainable development as “development

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Shrinkage, Creep, Crack-Width, Deflection in Concrete
The effects of shrinkage, creep, crack-width, and deflection in concrete are often ignored by designers while designing structural members. These effects, if not considered in some special cases such as long span slabs or long cantilevers, may become very

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Concrete Relief Shelve Walls - An Innovative Method of Earth Retention
Relief shelve walls are a unique concept that use only conventional construction materials like PCC / RCC / steel reinforcements, and work on a completely different fundamental to resist the lateral load caused due to soil. Information on the various dimensions

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Carbon Neutrality in Cement Industry A Global Perspective
Increasing energy costs, overcapacity, and environmental pollution are the top concerns of the cement industry, which is one of the major contributors to CO2 emissions. Dr S B Hegde, Professor, Department of Civil Engineering, Jain College of Engineering

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Finnish company Betolar expands to Indian concrete markets with a cement-free concrete solution
Betolar, a Finnish start-up, and innovator of geopolymer concrete solution Geoprime®, has expanded its operations to Europe and Asian markets including India, Vietnam and Indonesia. Betolar’s innovation Geoprime® is the next-generation, low carbon

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Why Fly Ash Bricks Are Better Than Clay/Red Bricks
It is estimated that in India each million clay bricks consume about 200 tons of coal and emit around 270 tons of CO2; on the other hand, with fly ash bricks production in an energy-free route, there are no emissions. Dr. N. Subramanian, Consulting

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Low Fines, Low Viscosity, Self-Consolidating Concrete for Better Impact on CO2 Emissions
Production of low fines SCC with increased robustness in a highly flowable, less viscous condition meeting true SCC specifications is now a reality to help realise the architect’s and engineer’s dream of various complex profiles and shapes in

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Methods & Factors for Design of Slabs-on-Grade
Sunitha K Nayar, gives the grouping of slabs-on-grade based on the design philosophies and a brief overview of the different design methods, the commonalities between design strategies in terms of the input parameters, assumed and estimated parameters, and the

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FIBERCRETE®: Synthetic Fibers for Concrete Reinforcement
Kalyani Polymers is offering world-class made-in-India Synthetic Micro & Macro Concrete Fiber Products for the Construction Industry under the brand name FIBERCRETE®. Concrete is an integral part of any construction project, it can be roads, tall structures

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Climate Control Concrete
Leading cement and concrete maker ACC has unveiled a revolutionary thermal insulating climate control concrete system in India. Sridhar Balakrishnan, MD & CEO, ACC Limited, discusses its attributes, applications, and benefits for home builders, architects

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Innovations in Crack Bridging with Self-Healing Bacteria in Concrete
Dr. Manjunatha L R, Vice President - Direct Sales & Sustainability Initiatives, and Raghavendra, Senior officer, JSW Cement Limited, discuss bacterial concrete that can meet the requirements for strength, durability, and self-healing of cracks.

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Sustainable Development Through Use of Self-Curing Concrete
Dada S. Patil, Assistant Professor, Civil Engineering Department, AIKTC, Panvel, Navi Mumbai, Maharashtra; Dr. S. B. Anadinni, Professor & Associate Dean (Core Branches), School of Engineering, Presidency University, Bengaluru; and Dr. A. V. Shivapur, Professor

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Developing a Corrosion Resistant RCC Structure
Samir Surlaker, Director, Assess Build Chem Private Limited, emphasizes the importance of a clear cover for a concrete structure since concrete as a porous material needs protection of its reinforcement. Along with the thickness (quantity) of cover, the porosity of

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