The customer wanted a hassle-free, versatile solution that can be used for multiple concreting requirements in various parts of the house which included the casting of structural elements as well as finishing floors and bathrooms.
Ability to work within the allocated budget was of paramount importance while building a house that lasts for generations.

Perfect for casting typical structural elements such as slabs and columns. Strength grades C15 to C45, with 20 -150mm slump falls within this category of concrete which can be pumped up to about 5 floors of a building.
Workability is moderate. Ideal for small sized commercial buildings, houses, culverts, factory floors and lower levels of taller buildings.

Pumping concrete to high-rises require extra flowability. Therefore, the solution must carry the right blend of cementitious materials and admixtures to enable easy pumping to great heights using stationary pumps.

This design is specially formulated to deliver enhanced flowability with minimum segregation, which makes it easier to pump concrete to heights exceeding 150m and flows easily through reinforcement bar matrix. Rheology characteristics are Slump 225mm and Slump Flow 450-600mm.
Given the scale and the intensity of project timelines, the ability to supply the required bulk quantities just-in-time were key supplier evaluation criteria set by the multinational consultants overseeing this landmark project. Having the largest fleet of modern pump cars and bulk mixing trucks gave us the edge over others in meeting the customer needs.

One of the main requirements for piling work is smooth flowability, which allows the concrete to reach every corner of the bore hole, usually fixed with a steel reinforcement cage. Since piling takes a longer duration, maintaining a homogeneous mix design through the entirety of the piling phase is very important.

This formula is especially designed with a slump of 180mm – 220 mm making it ideally suited for in-situ bored piles, that are usually fed through ‘trimy pipes’ requiring extra-high flowability. Critical fresh state properties such as homogeneous mix without segregation and the first truck’s slump retention up to reaching of the last truck to site are achieved by using proper aggregates and admixtures.
Diameters of piles typically used in Sri Lanka range from 600mm to 2000mm and depths of 25mm to 45m. Commonly used strength grades range from C30 to C50

In high rise buildings, columns at the bottom most levels become significantly large due to the weight of the total structure they have to bear. This impedes space availability in lower levels, mostly used as parking bays or as prime commercial space.
The necessity to maximize space and improve visual appeal demands the reduction of column sizes, thus calling for high-performance concrete that is robust yet versatile. This demand can only be met by ultra-high strength grades such as C70 and C85.

To date TOKYO SUPERMIX is the only concrete in Sri Lanka to achieve both strength grades C70 and C85, and was the winning criteria in becoming the only approved supplier to this landmark project. The superior strength gaining characteristics of NIPPON CEMENT PRO OPC Cement is the main contributory factor along with other constituent materials in the design such as the water reducing Poly Carboxylic Ether type admixture. The modern testing machines for such grades are available only with TOKYO SUPERMIX labs and a few other places, attesting our ability to meet a very specific niche in demand.

Post tensioning of slabs, precast girders, slip-form construction and in-situ bridge girder constructions requires early strength gaining property

This special mix design garners early strength and enables the post-tensioning process, early removal of form work, intermittent shifting of formwork etc. as the case may be.
Cement quality and maintenance of water cement ratio plays a vital role to achieve the precise strength required to apply tension on rebars and removal of form work generally after 2 days and in the slip-form concrete to move formwork at the rate of 15-30 cm per hour. This enables minimizing of beams on slabs and reduces overall size of structural members and continual progression of concreting respectively

Durable concretes have become an integral part of structures coming up along the Colombo coast line and Colombo city in general. Durable concrete conforms to requirements like sulphate and chloride resistance and low water absorption etc., and is normally prescribed for harsh environments such as marshy or marine by the consultants

The chemical and water resistance in durable concrete comes from using TOKYO SUPER PLUS or Fly Ash blending amongst the use of other ingredients such as silica fume and slag (GGBS) in the special mix designs. These designs give a denser closely packed concrete structure resistant to chloride penetration and sulphate attack.
TOKYO SUPERMIX laboratories are equipped to carry out the required tests to certify the chemical properties, in addition to only one state university who is equipped to do these tests.

These specific projects sought to maintain high and/or unique aesthetic value and had inbuilt special architectural features, which required additions be made to the basic structure without the burden of added weight. Especially in mixed-development sites such as hotels and condominiums that include kitchens and swimming pools located on higher floors, special structural adjustments that are versatile and lighter are required.

Light weight concrete is typically used to fill voids in the structures that needs filling-up to raise floor levels to achieve functional requirements. The unique technique used to achieve very low density (600 – 1200 Kg/m3 ) is so far mastered only by TOKYO SUPERMIX. The proprietary foam blending technology and the process followed enables this achievement

In structural elements such as thick raft foundations and large-sized columns, temperature of the ‘core’ or center need to be maintained below 72oC - 75oC depending on the consultant discretion.

Formulation of low temperature concrete needs total temperature control of all ingredients such as fine aggregate, coarse aggregate, water and cement. Such mix designs require scientific expertise and technological insights to use the right mix of cementitious materials and admixtures, along with the mechanics to maintain ingredient temperature control.
In addition, a range of specific ancillary equipment such as high capacity water chillers, ice crushing machines and freezer containers are necessary in achieving this precision-driven solution mixing. Equipped with state-of-the-art machinery and batching plants, TOKYO SUPERMIX has achieved temperatures as low as 26°C for some of our projects, similar to the prominent names featured above

A key structural requirement in this context was the ability to prevent the concrete from cracking due to fluctuating extreme temperatures that occur inside a typical cold storage facility.

Fly Ash blending and use of other special ingredients enabled creating a special concrete mix to meet varying demands of frozen and thawed cycles, and withstand sudden expansion and shrinkage resulting from water freezing.

Seamless super-flat floors need minimization of shrinkage to avoid crack formation.

This mix design done with carefully selected materials and appropriate admixtures result in special properties which allow better bonding of the concrete to avoid air traps. The concrete is mixed with steel fiber reinforcement since steel bar reinforcement usage can give rise to crack formation

The matrix of reinforcement steel bars in certain structural elements necessitates extra poking of concrete during placing, which is a time and labour intensive process making a significant impact on the overall project efficiency.

Self-compacting concrete, formulated using a different combination of coarse aggregates and appropriate admixtures, helps avoid high dependency on labour and reduces time taken for manual compacting of floors and slabs. This free-flowing concrete flows though the spaces in the rebar-matrix and fills up the form work without segregation. This eliminates the need for poker vibrating, whilst achieving a honeycomb free structure. Fresh state workability is measured in terms of filling ability and passing ability using V-Funnel/Slump Flow and J-Ring/L-Box apparatus respectively. Segregation resistance is also another check carried out visually during above tests.

The new multi-building office complex commissioned by the US Government required compliance to stringent quality standards with specific compliance to US regulatory requirements in engineering, sustainability and construction execution. The project is registered with the U.S. Green Building Council for Leadership in Energy and Environmental Design (LEED®) green building rating system and is projected to earn LEED® Silver status.
Since it is being built in central Colombo along the seafront, special attention is paid to corrosion resistance of the building to maintain longevity of the structure

Manufactured Sand and Blended Cement based mix design uses a PCE admixture. Quality assured M-Sand from Tokyo Super Aggregate was used to maintain material consistency. The application was carried out during night hours to maintain fresh state properties very close to specified levels.

Water proofing the structure is one of the most common requirements in any building. This need becomes a high priority for water tanks, swimming pools and basements.

A hydrophobic ingredient is added to the blended cementitious materials to arrive at a design that maintains a very low water-cement ratio. This produces a dense and low water permeable concrete, typically used for below ground level structures and water tanks.

For underwater constructions, the main challenge is to prevent cement and fine particles getting washed off when water comes into contact with fresh concrete during concrete pouring process. This requires a higher level of bonding with chemical features that can withstand various water salinity levels.

The concrete solution, placed usually through a steel casing, is enriched with a viscosity modifying agent which gives anti-washout properties.

Adopting a decorative and colourful concrete finish, for the interior design of contemporary offices or living spaces of commercial and residential buildings is a trend. Maintenance free architectural colour finish floors can be done when slabs are poured with colour concrete.

Colour pigment is added to the concrete and later the surface is cut and polished using diamond cutting wheels. The resulting floor finish hence does not need waxing or sealant application. It is a maintenance free floor that needs only mopping with water. Leaching free colour concrete design is done using the correct combination of cementitious materials and admixtures / colour pigments. The aggregate used by TOKYO SUPERMIX is clean and devoid of any foreign matter. Hence, an unblemished finish is obtained, when cut and polished using the right equipment

This exposed concrete required a smooth, seamless finish after the specially designed formwork is removed, while being durable and maintenance free.

High durability and maintenance free smooth finish are hallmarks of this particular formulation of concrete. A special mix that has high flowability and exact quantities of fine particles enables this surface finish. A superior rheology is maintained in this segregation and bleeding through controlled high slump concrete.

Decorative Concrete without any further finishing requires a high degree of uniformity in color and overall appearance. The latex form work boards used generates a "wood grain" finish on the concrete surface. The contractor adheres to a strict cleaning procedure on latex mould lined form work boards to ensure consistency of the physical implements used for the project. Our challenge was to provide consistent color and texture of final architectural finish of the concrete.

This innovative zero slump concrete design enables water draining into soil through the structural porosity of concrete in applications such as car parks, walkways, pavements etc
This helps water absorption to soil and minimize impact to ground water due to paving the surface of the earth. Pedestrian / vehicle driving safety during rains and prevention of flooding of lower roads are other benefits

Due to the scarcity / high cost of river sand and to enable fast construction an alternative to ‘manual cement rendering’ on floors was required. The skilled mason availability has also become a problem to do such finishes fast presently in projects

Unwashed Manufactured Sand with more fine particles and Blended Cement based mix design uses a PCE admixture. This combination creates the necessary pumpabilty and flowability required in this application. Flowability enables masons to lay it several times faster using longer leveling bars with the aid of pre-set levels covering larger areas in different floors of multistoried buildings.

The Highway Sections from NKB to Ingurukade Junction and Orugodawatta Junction are constructed on a steel structure. The top deck is rested on support columns on either side. The deck bottom steel corrugated plate is covered with concrete and subsequently waterproofed before finishing with an asphalt layer. The road is given a 100 years lifetime by design. Hence ‘water’ and ‘air’ penetration from possible micro cracks / capillaries on the top deck concrete
need to be prevented to avoid the corrosion of the steel bottom plate despite the protective layers of paints applied.

A shrinkage-reducing, high-performance expansive additive is used in concrete to generate the required expansion from within the concrete to compensate for the general shrinkage taking place during concrete hardening. Thus the possibilities of micro-cracks / capillary formation is eliminated and ‘water tightness’ is improved to ensure 100 years lifetime.

Soil stabilizing in excavated basements was required in the US Embassy project site. Altair project needed corrections on some peripheral piles. A cost effective thin concrete layer was the required product in such situations.

A concrete made with only fine 0-5 mm fine aggregates and 5-14 mm chips are used in Shotcrete Concrete. The mix is sprayed on to surfaces needed stabilizing or improvement using a special pumping machine with a chemical accelerator. This accelerator is simultaneously fed with the concrete mix setting in quick hardening.