CE 3420 Concrete Technology, Jan.-Apr.

2016
ASSIGNMENT 2

Submitted by:
Vishal Ramesh
CE13B083

DESCRIPTION:
For your structure (i.e., the structure selected in Assignment 1), explain the possible
construction methods. If there are many options, choose one and explain why you prefer it.
What are the restrictions imposed by the type of construction method on this structure. Can
this structure benefit from the use of an unconventional (special) concrete? Explain the
characteristics and typical properties of the conventional or special concrete that you suggest.
For your structure and the concrete chosen previously, give the components recommended,
mix design guidelines, formwork requirements and recommendations for transportation and
placing of concrete. Any other specific problems to be addressed?

MILLAU VIADUCT

THE MILLAU VIADUCT

Source: http://www.tourisme-aveyron.com/
The Millau Viaduct is a 343-metre long cable stayed bridge in near the city of Millau in
southern France. At a height of 270 metres, it is also the tallest bridge in the world.
Constructing a structure of such mythical proportions in such a pristine valley would
inevitably place tremendous restrictions and pose great challenges in determining the method
of construction, the choice of materials to use, the design and so on. This article attempts to
analyse the various decisions made by the designers to overcome the specific challenges
related to the construction of this bridge.
METHOD OF CONSTRUCTION
There are traditionally two methods available for the construction of cable-stayed bridges
The balanced cantilever method and the Incremental Launching method.
The balanced cantilever method of construction is preferred for bridges having a few spans
of length ranging from 50 to 250 metres. The construction commences on both the piers
though the cast in situ method using formworks and then, this portion is used as the support
and erection platform for all the subsequent concrete segments. A travelling formwork is
usually employed that moves along the bridge with the segment being constructed. Finally,
both the ends are made to meet in the middle and are joined. These cast in situ segments are

generally 3mm to 5m in length. During construction, stability of the end cantilever is

maintained through use of temporary piers.
Although this is a flexible method widely used in bridge construction with repetitive units
increasing the efficiency, it is relatively slow. This limitation has been partially mitigated
through the use of precast segments. Working at the large heights demanded by the geography
of the valley in with the viaduct is located poses significant risks to the safety of the workers
and the costs involved in lifting materials to heights larger than 200m are tremendous. The
high altitude winds encountered are further enhanced by the tunnelling effect created by the
presence of mountains. A cantilevering deck would be extremely unstable at such extreme
conditions and so this method was deemed inappropriate.
The longitudinal launching method is a method made technologically and economically
viable by developments in launching equipment. In this method, the bridge is generally cast in
situ at one end of the abutments in segments. After the construction is completed, the whole
arrangement is pushed forward by the length of one segment with the help of launching
equipment and bearings, and the next segment is constructed against the first. A vertical jack
is used in order to lift the bridge at multiple points simultaneously, and a horizontal jack
pushes the structure forward. Once the launching is completed, the vertical jack relaxes and
the whole structure is laid down on a temporary pad beam. The procedures of lifting,
launching, descending and withdrawing are performed over and over again until the bridge
deck reaches the other end.
Step 1 LIFTING: The entire structure is lifted off the pad beam through the activation of the
lifting oil cylinder.
Step 2 LAUNCHING: The upper part of the launching system and the structure are moved
forward with the help of the launching oil cylinder.
Step 3 DESCENDING: The bridge deck structure is released and made to rest on the pad
beam through the relaxation of the lifting oil cylinder.
Step 4 WITHDRAWING: A relaxation of the launching oil cylinder causes the whole
launching system to come back to its initial state, indicating the completion of one launching
cycle. The system then awaits the next segment so that the procedure can be performed again.

THE INCREMENTAL LAUNCHING METHOD.

Source: http://en.vsl.cz/files/images/incremental-launching-method/d3en.gif

In case of the Millau viaduct, the deck was made of steel and not of concrete and this
procedure was suitably adapted to the variation. This method can be used for the construction
of bridges with mild curvatures of a constant radius and as this structure is curved with a
radius of 20 km, this method was deemed appropriate. Also, adoption of the incremental
launching method eliminates the need for temporary piers. In bridges like these where the
valley in inaccessible, and obstructions to the flow of the river below are undesirable, this is a
huge advantage. Also, the bridge is located in an environmentally protected area and minimal
disturbance to the environment is a high priority. As this method needs a much smaller but
more concentrated area for superstructure assembly, the surroundings are not disturbed.
Considering all these advantages, the incremental launching method was decided upon for the
construction of the Millau Viaduct.
Despite the numerous advantages, this method poses many challenges as well. A launch of
this scale had never been attempted before and new equipment had to be developed. Sections
of the deck were launched from both ends of the valley to meet at the middle over the river
Tarn where no supports could be constructed. The weight of the deck caused it to sag with the
worst deflections occurring near the destination pier. An arrangement to lift the structure was
designed to avoid interaction between the deck and the pier. Problems due to the unanticipated
early deterioration of the Teflon lubrication had to be handled and other system failures
occurred, as it had not been tested before.

Source:http://www.fzt.hawhamburg.de/pers/Scholz/dglr/hh/text_2010_10_28_Millau_Viaduct.
pdf
NEED FOR AN UNCONVENTIONAL CONCRETE
The harsh conditions existing at high altitudes and the excessive forces on the piers call for
high design strengths. As high strength inevitably means congested reinforcement where
vibration would be a problem, self-compactibility was desired. These, along with various
other factors, led the designers to conclude that High Performance Self Compacting Concrete
would be appropriate for the piers of the structure. Due to the high strengths, the diameter and
bulkiness of the pillars could be reduced. This led to more slender looking pillars that had
high aesthetic appeal, a factor vary important in this case considering the natural beauty in
which this structure is located. The need for vibration was also eliminated, thus creating a
cleaner working environment with minimal damage to the surroundings and an enhanced
level of safety for the workers. Another advantage of self- compactibility is the reduced time

required for construction. Faster construction implies less time for which capital and
equipment is needed and hence, reduced costs.
The properties of high performance self-compacting concrete can be understood by analysing
the properties of high strength concrete and self-compacting concrete. High mechanical
strengths are displayed by high strength concretes due to an optimized granular skeleton and a
higher water cement ratio. The optimized granular skeleton has a lower pore size and
connectivity that leads to high durability. Ordinary self-compacting concretes may have lower
compressive strengths but have a very high fluidity. The self-compactibility of any concrete
can be assessed by its three properties passing ability, filling ability and stability against
segregation. High performance self-compacting concretes show a mixture of both the abovementioned properties, with high compressive strengths and good self-compactibility.
In order to achieve the desired properties, it is generally necessary to add expensive chemical
admixtures and a high cement content. Thus, cost is a disadvantage of HPSCC. The addition
of a high quantity of cement also has undesirable side effects like high heat of hydration and
high autogenous shrinkage. Replacing a part of the cement with mineral admixtures mitigates
the effects to a considerable extent.

PROPERTIES OF HIGH PERFORMANCE SELF COMPACTING CONCRETE

The unique properties of HPSCC are primarily due to the different water-cement ratio and the
addition of various mineral and chemical admixtures. The various fresh and hardened
properties of HPSCC incorporating mineral admixtures such as silica fume, fly ash and
natural zeolite are discussed below.
FRESH PROPERTIES:
Using varying amounts of superplasticizer, the concrete was designed to have a slump flow
diameter of 600 mm. The superplasticizer demand varies with the type and concentration of
the mineral admixture employed. Concrete using silica fume has the highest superplasticizer
demand, a property that can be attributed to the fineness of the fume particles. The adsorption
of superplasticizer on to the surface of fly ash particles is high due to the large surface area of
the particles. The amount of superplasticizer available to interact with the cement grains is
lesser and this leads to a lower fluidity. In case of fly ash, the superplasticizer demand actually
decreases. This is primarily due to the lubrication provided by the spherical glassy silica fume
particles through a ball bearing effect. In summary, the addition of mineral and chemical
admixtures lead to a concrete that is highly flowable. The aggregates used in HPSCC are
smaller and hence, the mix shows excellent passing ability. Stability against segregation is
achieved through the use of superplasticizer and mineral fines.
COMPRESSIVE STRENGTH:
The compressive strength of high strength self-compacting concrete is larger than that of
conventional concrete. This is achieved through the use of cementicious mineral admixtures

that enhance the strength of the concrete through pozzolanic reactions and the densification of
the concrete matrix. Pozzolanic reactions are reactions between amorphous silica present in
mineral admixtures and the calcium hydroxide produced during the hydration of cement, to
produce strength giving calcium silicate hydrates. Calcium hydroxide crystals are weak and
they accumulate along the edges of aggregates, creating weak spots. In ordinary concretes, the
weakest spot where failure occurs is the interfacial transition zone between the aggregates and
the cement paste. The replacement of calcium hydrate with calcium silicate hydrates
strengthens the interfacial transition zone and the compressive strength increases. Another
reason for this increase is the filler effect due to the fine admixture particles that causes a

PERFORMANCE CRITERIA FOR HPSCC

Source: Mechanical and durability properties of self consolidating highperformance concrete
incorporating natural zeolite, silica fumeand y ashFereshteh Alsadat Sabet, Nicolas Ali
Libre, Mohammad Shekarchi
densification of the concrete matrix. The 28-day compressive strength of HPSCC usually
ranges from 50 to 80 MPa and the 180-day compressive strength ranges from 60 to 90 MPa,
depending on the mix proportions and various other factors. Analysis reveals that very high

compressive strengths can be obtained using a 20-percentage replacement by fly ash. The
incorporation of silica fume increases the strength more than in the case of natural zeolite, and
this can be attributed to the higher pozzolanic activity of the former than the latter. However,
it should also be noted that the compressive strength does not increase indefinitely for
increases in mineral admixture dosage. It is reported that replacing 50 percent of cement by
fly ash will cause a 50 percent decrease in compressive strength when compared with the
control mixture.

ELECTRICAL RESISTIVITY:
As it is one of the most important factors contributing to the resistance against corrosion,
electrical resistivity is an effective indicator of concrete durability. An electrical resistivity of
20-kilo ohm-cm is the minimum limit for corrosion propagation in a steel rebar and corrosion
will be less in a concrete with values above that. In HPSCC, which incorporates mineral
admixtures, the electrical resistivity increases with age. This is largely because pozzolanic
reactions occur at a much slower rate in comparison with normal cement hydration reactions.
Furthermore, higher the replacement level of cement with mineral admixtures, higher will be
the recorded electrical resistance. The 28-day electrical resistance of mixtures incorporating
silica fume is generally very high at about 110 kilo-ohms, a value 4 or 5 times greater than in
the case of fly ash or natural zeolite. This observation is primarily due to the higher
pozzolanic reactivity of silica fume, which results in a denser paste structure. The paste in a
concrete mix is considered to be more conductive than the aggregate phase.
WATER ABSORPTION:
Water absorption is another very important property contributing to concrete durability. This
is because water contains large quantities of corrosive ions that can harm the steel rebars and
the concrete matrix. HPSCC generally has very low water absorption levels, primarily due to
its limited pore volume and pore size resulting from the addition of mineral admixtures. Also,
the pore connectivity is very low and water cannot be transported to the interior. Hence, a
concrete with limited porosity and water absorption generally has a good durability.
CHLORIDE DIFFUSION:
There are various mechanisms for the ingress of chlorides in concrete. These include
diffusion, capillary suction, migration or a combination of these mechanisms. The decrease in
the internal relative humidity or the self-desiccation of high performance self compacting
concrete affects these transport mechanisms of chloride ingress, and as chloride is a very
corrosive material, the durability is enhanced. It is also noted that the addition of mineral
admixtures improves causes a reduction in the chloride concentration at various depths, an
observation that is due to the refined microstructure and pore structure.
Apart from the various advantages of using HPSCC, many challenges need to be overcome.
Due to the strengthening of the interfacial transition zone and the matrix, the failure becomes

very brittle. This is an undesirable property as it reduces the time available for evacuations.
The risk of spalling is also higher as the structure is so dense that in case of fires, the
expansion of pore water due to vaporization cannot be accommodated and the concrete may
explode suddenly. The shrinkages are faster and more pronounced and this could lead to
shrinkage cracking. The high density of the matrix prevents bleed water from coming up to
the surface to replace evaporated surface water and this can lead to excessive shrinkage
cracking if curing is not performed properly.

COMPONENTS RECOMMENDED
The design of HPSCC involves the addition of mineral and chemical admixtures to obtain the
desired properties of high compressive strength, durability and self-compactibility. Mineral
admixtures that need to be added include supplementary cementicious materials like fly ash
and silica fume. Silica fume is rather expensive and fly ash is an excellent alternative for
developing countries, especially considering that it is a waste product from thermal power
plants. The replacement of a part of cement with these mineral admixtures reduces problems
like thermal cracking and autogenous shrinkage. To maintain good workability in spite of the
low water cement ratio, superplasticizers have to be added. In the case of the Millau Viaduct,
the superplasticizer used was CHRYSO Fluid Optima 175. Depending on the dosage and type
of the mineral admixtures used, viscosity-modifying admixtures may also have to be used.
MIX DESIGN GUIDELINES
Mix design is extremely important in the production process of concrete.This step is required
in order to determine the most suitable proportions of the constituents needed to fulfill the
required properties of fresh and hardened concrete for a particular application. In the mix
design of conventional concrete, the compressive strength required is taken as the primary
criterion. But, in the case of high performance self-compacting concrete, compressive
strength, durability and self-compactibility are all taken into account.
The mix design method described below considers the HPSCC to be made up of two phases
The aggregate phase and the paste phase. The gradation of the aggregate blend is calculated
according the packing theory developed by Funk and Dinger with the value of the exponent q
taken ad 0.25. Next, the void content of the compacted aggregate blend is takes as the basis
for determining the paste content. The required self-compactibility is brought about by
modifications in the paste volume, dosage and type of mineral admixtures and the
superplasticizer dosage. The water-binder ratio and the pozzolanic efficiency of the mineral
admixture are accounted for in order to determine the compressive strength. The steps
involved are described below.
STEP 1: Void content of the compacted aggregate blend is determined.

The ratio of aggregate components is calculated using the Funk and Dinger theory with the
value of the exponent q taken as 0.25. An optimum ratio will lead to a particle size
distribution that follows the ideal curve with low levels of deviation. Using the ratio of
aggregate components determined by the above method, the bulk density of the compacted
mix can be calculated. Next, with the help of the density of the aggregates, the void content
can be calculated.
STEP 2: Primary paste volume determination.
As it is needed to fill the void volume between aggregates, the paste volume in HPSCC is
considerably higher than in normal concrete. Also, this large paste volume ensures the
lubrication of the surface of the aggregates, reducing the friction between them, so that the
required flowability is attained. The paste volume for HPSCC should generally be in the range
of 30% to 42% by volume.

PROCEDURE FOR MIX DESIGN OF HPSCC

Source: The mix design for self-compacting high performance concrete containing various
mineral admixtures.
Ha Thanh Le, Matthias Mller, Karsten Siewert, Horst-Michael Ludwig.

Step 3: Determination of the w/b ratio.

Already established relationships between the water cement ratio and the compressive
strength of conventional concrete can be used in the case of HPSCC as well. As the type and
dosage of mineral admixtures are known, the water-binder ratio can be computed. The w/b
ratio for high performance self-compacting concrete usually ranges from 0.25 to 0.4. A water
binder ratio lower than 0.25 can be used when the superplasticizer and paste composition
yields a small enough value of plastic viscosity.
STEP 4: Calculation of the mineral admixture, cement and water content.
The content of each of the mineral admixtures, and of the water can be determined with the
help of the previously determined paste volume, water-binder ratio, and the cement quantity
replaced by the mineral admixtures. For the HPSCC intended for the construction of the
Millau Viaduct, the suggested range for the binder content is in the range of 425 and 625 kg
per cubic meter. It must be ensured that the cement content is not lower than that required for
durability and the maximum allowed water content is 200 kg per cubic meter.
Step 5: Aggregate content determination.
The aggregate content and the proportion of the individual aggregate components can be
computed based on the ratio of aggregate components and the known paste volume. The
coarse aggregate content of the mix should be in the range of 28% to 38% by volume.
Step 6: Superplasticizer dosage determination.
The saturation superplasticizer dosage is considered as the primary superplasticizer demand
for the mix. The saturation superplasticizer dosage is defined as the saturation dosage above
which there are no significant changes in flowability. It is calculated using the mini cone
slump flow test, as explained in the EFNARC.
Step 7: Water content adjustment.
The water content needs to be adjusted after taking into account the absorption by the
aggregates and the water content of the superplasticizer. This is necessary to ensure that there
is sufficient water in the mixture to ensure workability and hydration. Saturated surface dry
condition of aggregates is generally preferred.
STEP 8: Trial mixtures and adjustments.
Using the proportions computed above, trial batches are made and tested for the compressive
strength and self-compactibility. If the values obtained through the quality tests do not meet
the requirements of the HPSCC, adjustments are made until they do so. For instance, if the
passing and filling abilities are substandard, the superplasticizer dosage is increased. If the
required values still cannot be attained by modifying the superplasticizer dosage, an increase
in the volume of the paste enhances filling and passing abilities at a constant superplasticizer
dosage.

The above procedure only gives a brief explanation of the mix design methodology. A more
detailed account is presented in the paper referred to in the previous page.
FORMWORK REQUIREMENTS
The piers of the Millau Viaduct are made of concrete and considering the height of the piers,
their tapering cross section and the harsh conditions present, innovative formwork had to be
developed. The formwork would have to be able to resist wind speeds of up to 140 kmph and
should also be able to withstand high speed concreting pressures of 2100 psf. The viaduct is to
be constructed in a valley of pristine beauty and it is imperative that the structure does justice
to these surroundings. The formwork needs to be able to provide a smooth surface with no
horizontal plywood joints and sharp edges and corners. The formwork also has to be able to
adjust to the varying cross section and geometry. In order to achieve these purposes, the job of
designing the formwork was given to PERI, who chose a specially designed steel formwork.

SELF-CLIMBING FORMWORK
Source:https://www.engineersireland.ie/EngineersIreland/media/SiteMedia/groups/Divisions/
civil/The-Formwork-to-the-Millau-Viaduct.pdf?ext=.pdf
After every cycle, the entire formwork was lifted hydraulically, without the use of cranes. For
the interior formwork, a crane-assisted system was used. The exterior formwork is a selfclimbing system (ACS) designed by PERI. In this arrangement, the scaffolding brackets are
connected to the pier at all times, and climbing with this system takes only 25 minutes. The
units have three levels of telescopic working platforms, and standard crabs are use to attach
the steel formwork. This greatly simplifies stripping and erection. The entire system of forms,
platforms and scaffoldings climbs as a single unit with the help of two hydraulic jacks

attached to the finished concrete below. Due to the high altitudes, safety was a major concern
and all the levels were enclosed by a wire mesh with appropriate access points for the
movement of workers. Slabs were cast into the unicellular part of the piers at intermediate
levels, at a spacing of 4 meters, to facilitate construction and to stiffen the tubular piers. This
barred the use of self-climbing formwork for the interior and a crane-assisted system was
used. The formwork was also designed such that it could adapt to the varying cross section
along the height by sliding mechanisms.

FORMWORK ON THE PIERS

Source:https://www.engineersireland.ie/EngineersIreland/media/SiteMedia/groups/Divisions/
civil/The-Formwork-to-the-Millau-Viaduct.pdf?ext=.pdf

TRANSPORTATION AND PLACING REQUIREMENTS

For the construction of the Millau Viaduct, the concrete for the foundation and the piers was
produced at a plant onsite, to minimize transportation costs. Also, quality control for the
HPSCC had to be thorough and an onsite facility was deemed to be appropriate for the
purpose. When mixing the concrete in the truck, it should not be filled to more than 80%. It is
also suggested that the truck drum must be rotated at small speeds of about 1 to 4 rpm during
transport, and at higher speeds for a few minutes before unloading. The recommendation for
the diameter of the pump used for placing is 4 or 5 inches and he length should not exceed
300 meters. The highest permitted free drop altitude is given as 5 meters and the lateral flow
distance should not exceed 15 meters. It must also be noted that the pumping speed at the
outlet of the pipe must be in the range of 10 to 20 cubic meters per hour.
It is extremely important to ensure that the air is allowed to escape when placing the concrete,
as entrapped air can cause voids, which weaken the structure and create irregularities. The
aesthetics of the structure is very vital and a uniform surface finish must be obtained.
Additionally, to ensure that the formwork in not damaged due to the pressure exerted by the
high performance self-compacting concrete, the vertical casting velocities must never exceed
2 meters per hour. To ensure good quality concreting, cold joints must be avoided. So, if there
is a delay in placing concrete, the existing fill must be vibrated before the next layer is poured.
Curing is very important in HPSCC as bleed water does not come to the surface. In order to
avoid cracking, curing must be done effectively for 7 days.

REFERENCES:

1.http://www.bath.ac.uk/ace/uploads/StudentProjects/Bridgeconference2007/conference/main
page/Saxton_Millau.pdf
2. http://theconstructor.org/structures/balanced-cantilever-method-of-bridgeconstruction/6137/
3. https://structurae.net/structures/millau-viaduct
4. The New Incremental Launching Construction Technology of Jiubao Bridge Long-span
Hybrid Arch-girder Structure - C.Y. Shao
5. http://www.chryso.com/upload/t_documents/Fichier_L2/48610/ViaductMillau_GB_BD.pdf
6. From ordinary rheology concrete to self compacting concrete: A transition between
frictional and hydrodynamic interactions.
Joumana Yammine, Mohend Chaouche, Michel Guerinet, Micheline Moranville , Nicolas
Roussel.
7. http://civil-resources.blogspot.in/2010/06/high-performance-concrete.html
8. Mechanical and durability properties of self consolidating highperformance concrete
incorporating natural zeolite, silica fumeand y ash - Fereshteh Alsadat Sabet, Nicolas Ali
Libre, Mohammad Shekarchi
9.https://www.engineersireland.ie/EngineersIreland/media/SiteMedia/groups/Divisions/civil/T
he-Formwork-to-the-Millau-Viaduct.pdf?ext=.pdf
10. http://www.concreteconstruction.net/images/Viaduc%20de%20Millau_tcm45-590487.pdf
11. The mix design for self-compacting high performance concrete containing various mineral
admixtures
Ha Thanh Le, Matthias Mller, Karsten Siewert, Horst-Michael Ludwig.
12.http://www.jsce.or.jp/committee/concrete/e/newsletter/newsletter01/recommendation/selfc
ompact/1.pdf`