Ultra Polypropylene Fibre Concrete(UPFC) is versatile and can be used in most applications. UPFC is added to the concrete during batching. Thousands of individual fibres are then evenly dispersed throughout the concrete during the mixing process creating a matrix-like structure.

Applications
  • Roof-slabs
  • External slabs (driveways, yards, etc.)
  • Roads, pavements, driveways, kerbs
  • Overlays, patch repair
  • Water retaining structures, marine applications
  • Security applications such as safes and strongrooms
  • Deep lift walls
Final Concrete Performance
  • Reduced plastic cracking means a reduction in surface permeability.
  • Enhanced durability.
  • Bleed water control inhibits migration.
  • Improved flexural properties.
  • Increased resistance to spalling at higher temperatures and hence….
  • better fire resistance.
Features and Benefits Plastic state advantages
  • The addition of fibres helps to maximize the intrinsic early strength of the concrete and specifically.
  • Improves concrete’s resistance to plastic shrinkage cracking, due to which frequency of plastic cracking is reduced.
  • Inhibits formation of micro-cracks due to dimensional change, hence durability will be improved and permeability will be reduced.
  • Reduces sedimentation, which decreases the risk of plastic settlement cracking over re-bar.
  • Polypropylene fibres actually help inhibit the formation of cracks in concrete, whereas steel mesh has only functional value once the concrete has cracked.
Working improvements
  • Polypropylene fibres offer many installation advantages, enabling a better job to be achieved in less time.
  • Due to Increased cohesion of the mix settlement is reduced and is easier to finish.
  • No requirement of crack control steel mesh.
  • Easier positioning of joints.
  • Concrete placement and crack control in ONE operation.
  • Easier finishing of the concrete surface

Every project is different. Some are more technical, others more aesthetic. Whatever the challenge, all must be completed on time and within the budget.
While conventional compacted concrete has its limitations with placement, often requiring considerable manpower, machinery and time, USCC provides faster solutions.
Highly fluid, USCC is the ultimate self-compacting concrete. It can be poured quickly, flowing and spreading effortlessly to provide an exceptional, highly aesthetic finish. And it’s not just time and money that can be saved; USCC also reduces noise and eliminates vibration, considerably improving conditions on site.

How It Works

USCC uses innovative mix technology to combine the benefits of two seemingly opposite physical properties; fluidity and stability. Fluidity is essential to provide easy concrete placement and a high quality finish with minimum effort. Stability is necessary to prevent segregation. Together, this dynamic fusion delivers the ultimate free flowing, self-compacting concrete.

The Science Of Concrete

USCC’s product formulae are a culmination of the latest discoveries in organic chemistry, mineral chemistry and fluid mechanics. It is these innovations that allow USCC to retain fluidity for more than two hours with no need to add water on site while achieving early compressive strength that is comparable to conventional concrete.
The strength of USCC lies not just in its fluidity but also in its flexibility. It is suitable for a wide range of applications, including horizontal, vertical and complexly shaped structures.

Uses

The characteristics of USCC confer increased efficiency in filling formworks with a complex geometry, ensuring a better quality of visible faces. USCC helps create the most unique and surprising forms. It is especially used in applications which require consistent quality, dense and uniform surface, higher durability and shortening of the construction time

  • Simple or poorly reinforced concrete
  • Concrete pumped in casing works (e.g. : tunnels)
  • Works with reduced sections (pilots, high-depth foundations, etc.)
  • Majority of applications (e.g.: foundations, walls, pillars, belt beams, etc)
  • Vertical elements with congested reinforcement
  • Horizontal elements (floor slabs)
  • Elements with complicated geometry
  • Reduced labour required for placing, levelling and finishing
  • Suitable for challenging designs and complex formwork
  • Enhanced workability and excellent early strength
  • Self-leveling reducing placing time
  • No compaction necessary
  • Sets with a smooth surface that requires minimal further finishing
Benefits - Fast Flowing

Free flowing USCC concrete can be placed quickly, with the material consolidating easily and effortlessly into the required pour locations.

Smoother Surfaces

USCC provides an excellent, smooth surface quality that can be laid perfectly flat for slabs and floors, eliminating the need for floating.

Easier Placement

Placement is not only quick, it’s easy. Fewer pour points, less formwork, reduced manpower, no vibration, excellent surface finish and flexible applications make USCC easy to work with to speed up your construction schedule.

Total Flexibility

Whatever your project be, there is an USCC for the job. For horizontal applications its self-levelling qualities enable fast coverage of large surfaces. Complex vertical constructions can be filled simply and quickly, while it can also be easily used alongside reinforcing cages for deep foundations.

No Vibration

By eliminating vibration and greatly reducing noise pollution, working conditions on-site are greatly improved while pours can be safely carried out even in built-up environments.

Ultra Smart Dynamic Concrete (USDC) is an innovative concrete that does not require vibration for placing and compaction. It is able to flow under its own weight, completely filling formwork and achieving full compaction, even in the presence of congested reinforcement. The hardened concrete is dense, homogeneous and has the same engineering properties and durability as traditional vibrated concrete.

USDC

Self Consolidating Concrete (SCC) has tremendous benefits increasing productivity and overall efficiency and is poised to be very successful since its evolution in Japan (‘80s). However, the cost per cubic metre of SCC became deterrent in the matured markets of India and ASEAN countries,. Hence SCC could never dominate traditional vibratable or pumpable concrete.
In today’s context, almost 65% of the traditional vibratable concrete classes are between 20 – 30 MPa. To convert these strength classes to classical SCC is a big challenge, especially the balance required between stability and fluidity of the concrete mass owing to sensitivity of the mix owing to ever changing scenario in concrete constituents. By default, classical SCC requires high fines content and any SCC specified by the consultant and subsequently produced by the concrete producer is an “overdesign”.
Today, low fines self-consolidating concrete, i.e. < 340 – 380 kg / m3 of cementitious content has become a reality for the lower grades of concrete. Low fines yet self consolidating concrete uses a new state of the art synthetic viscosity modifying agent (VMA) incorporated in special Polycarboxylate ether (PCE) based hyper plasticizer. These low fines, self-consolidating, sustainable solution will help boost productivity and efficiency to help engineers, owners, concrete producers, realise their respective dreams. Low fines SCC (referred to as Ultra Smart Dynamic Concrete) realises a host of benefits - economic (reduction of fines), enduring (durable), ecological (low fines) and ergonomic (almost negligible vibration).

Benefits - Economical
  • Savings on cement
  • Up to 40% faster placing
  • Up to 5 times higher labour productivity
  • Easy to produce
Ecological
  • Less fines
  • Higher durability
  • Specification Clause
Application
  • High-tolerance floors
  • Difficult access areas
  • Architectural requirements
  • Long delivery distances
  • Slow pours
  • Heavily reinforced columns, high walls (with fewer lifts), very complex shapes and piling (Tremie)
Ergonomic
  • No vibration
  • No noise
  • Low stickiness

One of the greatest benefits for constructors and builders is higher productivity in the concrete placement process. The ease of application requires less manpower and reduced claims for defects, voids and honeycombs.

Ultra Stamping Concrete (USC) Systems are cast-in-place concrete flooring & paving that adds a distinctive architectural touch to any project, together with the durability to stand up to the toughest traffic loads and environmental conditions.
USC Systems have offered homeowners and design professionals a virtually limitless palette of colors, textures, and patterns at a fraction of the cost of traditional materials.
USC Systems gives you more than 100 patterns and custom tooling options with a wide variety of standard and custom coloring options.

You can choose from many natural textures including
  • Slate
  • Granite
  • Limestone
  • Cobblestone
  • Used brick
  • Many others...
Properties
  • High tensile strength – Capacity to bear more load and absorb more deformation. The hooked ends anchor in to the concrete, enabling the transfer and distribution of stress effectively. USFRC has more corrosion resistance –Extends concrete life span. Improves impact resistance/performance under dynamic loading, by reducing stress concentration and higher energy required to pull out fibers from matrix. Improves wear ability by 50% & fatigue resistance by 100% (Typical values). Simple addition process –Easy to construct, saves labor & time. The fibers impede crack formation and development of hairline cracks in to major cracks by acting as tiny bridges. Prevent formation of random cracks. Higher energy is required to pull out fibers from the matrix. Hence first crack flexural strength and modulus of rupture are enhanced remarkably. Flexural toughness increases by addition of steel fibers. Offer improved abrasion resistance, cavitations resistance and erosion resistance. Fibers absorb and dissipate energy more efficiently than normal concrete. Hence normal concrete is brittle while USFRC is ductile. Steel Fibers mix well with concrete unlike loose fibers which tend to form fiber balls.
Improvement in Concrete Properties (typical)
Characteristics Improvement over Normal Concrete(without fibers)
Compressive Strength up to 30%
Cracking Flexural strength 100 to 200%
Fatigue Resistance 100%
Resistance to impact 100 to 300%
Shock absorption 15 times
Abrasion Corrosion resistance 40to 50%
Ductility Several times
Application Areas
  • Flooring for warehouses
  • Factory flooring
  • Commercial buildings
  • Residential buildings
  • Porticos
  • Ports
  • Aircraft hangars
  • Car parks
  • Bridge decks
  • Roads, Highways & Airstrips



Sl.No Feature Benefits
Hardened state advantages
1 Increases flexural toughness / residual strength Increased load bearing capacity of concrete. Potential reduction of concrete slab depth.
2 Provides post-crack performance Concrete retains load carrying capability after cracking has occurred
3 Increased impact and abrasion resistance Increased durability and reduced maintenance costs
Working improvements
4 No requirement for crack control steel mesh No need to purchase and store additional material. No delays to fast track schedule. Easier positioning of joints
5 Concrete placement and crack control in ONE operation Reduced site labour requirement for on-site handling and cutting of steel reinforcement. No secondary steel mesh is required and reinforcement is automatically positioned
6 Cost effective alternative to conventional steel mesh reinforcement Reduced project costs
Final concrete performance
7 Controls cracking which occurs in the hardened state Enhanced load bearing capability
8 Even distribution of fibres throughout the concrete Improved flexural properties
9 A tougher surface with fewer bleed holes Reduced absorption of water, chemicals etc.
Cost benefit analysis
  • Cost savings in secondary reinforcement steel mesh for ground supported slabs
  • Faster construction (removes the need to lay mesh and spacers etc.)
Cost benefit analysis
  • Advantages of USFRC Concrete Flooring
  • Increased load bearing capacity of concrete
  • Reduction of concrete slab thickness
  • Load capacity is not diminished by concrete cracks
  • Increased durability
  • Low maintenance costs
  • Improved flexural properties
  • Reduced absorption of water, chemicals, etc.
  • Can be used on fast trackEasier positioning of joints
  • Reduced site labor for managing steel reinforcement
  • Reduced project costs
  • Increased impact and abrasion resistance
  • Even distribution of fibers throughout the concrete
  • Tougher surface with fewer bleed holes
  • Savings will be greater for heavier crack control systems

Ultra Ready Mix Concrete Private Limited (URMC) does not “simply manufacture concrete”, but develops solutions based on the thorough knowledge and application of concrete technology. Leveraging years of experience, a worldwide pool of knowledge, and state-of-the-art expertise about the different concrete constituents and their interaction, URMC offers its customers “concrete by design”—tailor-designed concrete.
URMC concrete technologists are able to modify the properties of concrete through the use of innovative chemical admixtures, combined with the proper proportions of the various concrete constituents. For example, depending on the type of application and jobsite requirements, we can design concrete that is more fluid, stronger, develops strength faster, and also retains workability longer.
Through the development of chemical admixtures solutions, researchers at URMC R & D lab, design special concretes that fulfill the construction industry’s increasingly demanding performance requirements. URMC offers a special concrete portfolio, comprised of various range of products.