4. Construction and Performance of India’s First High Volume Fly Ash (HVFA) Concrete Road in Ropar, Punjab

April 2005 to March 2006
Gujarat Ambuja Cements Ltd., Ahmedabad (R)

Present Status and Progress
India has very huge infrastructure needs. Concrete roads are having proven advantages over the traditional bituminous roads except that of high initial costs.

The use of fly ash upto 50% reduces the cost of concrete road substantially making it almost at par with bituminous roads. Further, use of fly ash in concrete roads increases durability and performance. For the first time in India, Gujarat Ambuja Cements Ltd. constructed a High – volume fly Ash (HVFA) concrete road at Ropar in the state of Punjab, India. The road has been constructed with the use of 50% fly ash, available from the Ropar Thermal Power Plant, replacing cement, and providing high performance and durable concrete. The road was designed by M/s Gujarat Ambuja Cements Ltd. for Indian conditions on the line of technology used in U.S.A. and Canada. Construction of this two-lane (7 metre wide), 300 mm thick and 0.75 km long road was completed within two and half months. No paver machine was used for the construction of this small section of HVFA concrete road. Conventional concrete mixture machine, vibrating tools, normal pond curing method were adopted.

The road is performing very well under heavy load vehicular traffic. (More than 500 trucks/commercial vehicles per day with an average weight of 15 to 45 MT.)

(i) High-volume Fly Ash (HVFA) concrete roads are one of the possible answers as an economical alternative for flexible pavements, and would be beneficial for developing countries.

(ii) HVFA concrete in which, ordinary Portland cement is replaced by 50% fly ash, provides high strength, high performance durable concrete.

(iii) For new roads, the cost of HVFA concrete is almost at par with bituminous roads.

(iv) Like the conventional concrete roads, HVFA concrete road has high service life without major maintenance, needs less lighting, is not affected by rains, allows smooth traffic flow, causes low were and tear of vehicles, provides savings in fuel, and is environmental friendly.

(v) HVFA concrete is ideal for rural roads, district roads, state and national highways.