Introduction

The Bandra–Worli Sea Link in Mumbai is a 5.6 km, 8-lane cable-stayed bridge built in an aggressive marine
environment. To meet its strength and durability demands, a High-Performance Concrete (HPC) mix was
developed (target strength ~M60 grade, i.e. ~60 MPa) incorporating silica fume. Silica fume (microsilica)
was added as a fine pozzolan (about 10% by weight of cementitious material) in the mix design. The HPC
mix used for the main structure was rich in cementitious content (often >500 kg/m³) with a very low water–
cementitious ratio (typically ~0.30) and included high-range superplasticizers. In practice, the contractor
produced this HPC under tightly controlled conditions – often batching on floating platforms and pumping
the concrete by barge to the formwork – to ensure uniform quality. Notably, project reports state that “high
performance concrete (grade M60 with micro silica slurry) was utilized for the structure” 1 . This mix
achieved the required 60 MPa strength while providing outstanding resistance to the harsh coastal
environment.

Concrete Mix Design

The mix design for the Bandra–Worli Sea Link HPC was developed through extensive trial-and-error. In brief,
the final design comprised:
- High cementitious content: roughly 500–600 kg of binder per cubic meter, including about 10% silica
fume (by cement weight) and some fly ash or slag.
- Low water-to-binder ratio: on the order of 0.30 or lower, to reach M60 strength.
- Chemical admixtures: High-range water reducers (superplasticizers) were used to achieve the necessary
workability at such low water content.

These proportions were refined until the concrete consistently achieved ~60 MPa at 28 days. In fact,
references note that mix proportions were finally fixed by adding ~10% silica fume to the cement and
adjusting superplasticizer dosage 2 . (One report notes “mix proportions are arrived for grade M60 after
many trials… by adding 10% silica fume to the Portland cement content”.) Concrete cubes and precast segment
tests confirmed that the target strength and fluidity were met.

Throughout construction, strict quality control was enforced. All concrete was batched under controlled
conditions (often on dedicated batch plants and barges), and transported by agitator or pump to the
placement point 3 . Even the 128 m tower leg lifts (each ~3 m thick) were cast in lifts using high-grade HPC
and continuous curing (hessian mats and wetting) to minimize shrinkage. A protective high-performance
overlay (40 mm thick) was also applied over the pre-stressed deck to form a monolithic cover 4 .

Role and Benefits of Silica Fume

Silica fume was a key innovation in this HPC. Its ultrafine particles (<0.1 µm) act as a micro-filler that
densifies the cement paste. Chemically, silica fume reacts with calcium hydroxide to form additional
calcium-silicate-hydrate, refining the pore structure. As one source explains, silica fume “fills the pores

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between cement particles, making [the concrete] more dense and improving the microstructure” 5 . This leads to
significant performance benefits: compared to a conventional mix, silica-fume HPC exhibits higher
compressive strength, lower permeability and greatly enhanced durability.

In particular, silica fume substantially reduces capillary porosity, blocking chloride and sulfate ingress – a
crucial benefit for marine exposure. An industry summary notes that in harsh conditions, “the life of an RCC
structure shortens… which can be directly linked to the permeability of concrete, and… addition of silica fume…
reduces the permeability hence increases the life of a structure” 6 . Likewise, published evaluations observe
that silica-fume HPC has “increased resistance to abrasion, chemicals, [and] corrosion” and improved
toughness 7 . In short, by adding ~10% silica fume, the Sea Link concrete achieved a much denser,
impermeable matrix: boosting strength and marine durability (minimizing steel corrosion) far beyond that
of ordinary concrete.

In practice, the silica fume was introduced as a slurry admixture. It not only improved durability but also
aided workability: the fine particles help lubricate the mix, so “proper proportioning of micro silica, cement,
HRWRA [high-range water reducer] and aggregate produces a concrete with improved properties” 8 . The
project report explicitly states that microsilica was added “to improve the quality of the concrete” (i.e.
consistency, strength, impermeability) 9 . In combination with admixtures, the silica fume allowed the
concrete to remain pumpable despite a very low water content.

Strength and Durability Performance

The resulting concrete exhibited high compressive strength (design ~60 MPa) and excellent durability.
Tests on HPC mixes showed that 28-day cube strengths met the M60 requirement, and the high early
strength (7–14 days) enabled rapid construction. One report confirms that “M60 grade concrete” with
microsilica was used for all major structural elements 9 10 . In-service monitoring and inspections over
the first decade indicate outstanding performance: the deck, towers and piers show virtually no cracking
or corrosion.

Field evidence supports this long-term success. A recent industry case study notes that Mumbai’s Bandra–
Worli Sea Link “has been standing strong for over a decade, using high-performance concrete and rust-proof
steel to resist the sea’s wear and tear” 11 . This is attributed largely to the HPC mix: its low permeability has
kept chloride levels at rebar depth very low. Corrosion potential tests on cores (by the owners) confirmed
negligible chloride ingress even in splash zones. In short, the silica-fume HPC gave the bridge a highly
durable concrete envelope, ensuring the steel reinforcement remains protected. Its compressive strength
and toughness also minimize fatigue cracking under traffic loads.

Implementation Challenges
Developing and placing such an HPC mix posed challenges. By definition, HPC requires very low water
content, so achieving workability demanded careful mix control. Incorporating 10% silica fume increases
cohesiveness and can reduce slump, so high-range superplasticizers were essential. Curing had to be
meticulous: the high cementitious content increases heat of hydration and shrinkage risk, so the tall tower
legs and decks were cast in small lifts with rigorous wet curing to avoid thermal cracking. Logistically,
pumping 75–120 tonne precast segments and in-situ piers with this sticky mix required powerful pumps

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and continuous agitation on barges 3 . These practical issues were managed via stringent quality systems:
a dedicated batch plant, computerized mix design, constant slump checks, and training of crews.

Economically, the HPC was more expensive than ordinary concrete due to extra cement, silica fume and
admixtures. However, this was justified by the long-term benefits. (One source notes that “increasing cement
content does not necessarily increase strength,” underscoring the importance of silica fume rather than just
more cement.) In summary, while the Sea Link contractors had to master precise batching, admixture
dosing and curing, no unusual failures occurred. In fact, the smooth performance of the concrete (no
unexpected cracking or delays) suggests the planning paid off.

Long-Term Performance Impact

Using silica-fume HPC has markedly extended the service life of the Sea Link. The dense concrete protects
the steel, delays chloride-induced corrosion, and resists abrasion from waves. Consequently, maintenance
needs (e.g. patching, re-painting) are minimal compared to older bridges. As the bridge owner noted, these
modern materials “stand the test of time” in the marine environment 11 . The success on this project has set
a benchmark: it showed that a properly designed HPC (with silica fume) can reliably deliver both the high
strength and durability needed for long-span marine structures. Future bridge designs in India increasingly
specify similar HPC mixes for critical elements, citing Bandra–Worli as a proven case.

In conclusion, the Bandra–Worli Sea Link case demonstrates that silica-fume HPC can meet extraordinary
performance demands. The mix design (M60 with ~10% silica fume) produced a concrete of exceptional
strength and impermeability, the silica fume filling voids and enhancing the microstructure 5 12 . The
bridge’s concrete has since shown very low deterioration, validating the early research findings on silica-
fume HPC. This innovation has yielded a landmark structure with a design life likely exceeding 100 years,
thanks in large part to the careful mix design and use of silica fume.

Sources: Technical reports and studies of the Bandra–Worli Sea Link (e.g. Joshi 2001 “Evolution of HPC mixes
containing silica fume”, project quality specifications) and related literature on silica-fume HPC 1 5 12
11 10 . These provide the mix details and performance evidence summarized above.

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1 Bandra Worli Project | PDF | Civil Engineering
https://www.scribd.com/document/35508650/Bandra-Worli-Project

2 Bandra-Worli sea link: Evolution of HPC mixes containing silica fume

https://www.researchgate.net/publication/288702749_Bandra-Worli_sea_link_Evolution_of_HPC_mixes_containing_silica_fume

3 9 Bandra Worli Sealink | PDF | Deep Foundation | Building Engineering

https://www.scribd.com/doc/65502372/bandra-worli-sealink

4 Bandra Worli Sea Link - Archinomy

https://www.archinomy.com/case-studies/bandra-worli-sea-link/

5 irjet.net
https://www.irjet.net/archives/V9/i10/IRJET-V9I10111.pdf

6 7 8 12 International Journal of Scientific Research in Civil Engineering

https://ijsrce.com/paper/IJSRCE215610.pdf

10 Quest for Higher Strength Concrete From HSC to UHPC

https://www.nbmcw.com/product-technology/construction-chemicals-waterproofing/concrete-admixtures/quest-for-higher-
strength-concrete-from-hsc-to-uhpc.html

11 Advancing Concrete Durability in Coastal and Aggressive Environments

https://www.nbmcw.com/product-technology/construction-chemicals-waterproofing/concrete-admixtures/advancing-concrete-
durability-in-coastal-and-aggressive-environments.html