The Masterbuilder_July 2013_Concrete Special

7/14/2019 The Masterbuilder_July 2013_Concrete Special

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Your feedbac ks are w elc om e andshould be sent to: T he Editor,

T he Masterbuilder, 1 0 2 /1 1( N e w N o . 4 6 /1 1) , Tr i pt i A p ar t me n ts ,

Marshalls Road, Eg m ore, Chennai,I n d i a. P h o ne : + 9 1 4 4 2 8 55 5 24 8

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O f a l l t he m a t e ri a l s c on s u me d b y m a n ki n d , p e r h ap s c o n cr e t e i s on e o f t h e

m o s t c om p l e x an d f i er c e l y d e b a te d s u b je c t s i n m o d er n m a t e ri a l s c ie n c e.

Reams of pages have beendevoted to depi ct the hi gh l evel of sustai nabi l i tyof

concrete as a materi al . Exampl es rangi ng f rom the 2000- year- ol d Pantheoni n

Rome to the Burj Khal i f a have been ci ted to prove thi s ubi quitous materi al 's

versati l i ty and durabl e nature. Whi l e concrete as a product i s extremel y green,

but unf ortunatel y the manuf acturi ng process that i nvol ves cement i n the

m a k i ng o f t h e co n c r et e , c o n tr i b ut e s g r ea t l y t o t he l e ve l o f c a r b on d i o x id e i n

the atmosphere. The l evel s are as hi gh as one tone of carbon di oxi de ri ses up

f o r e v er y t o nn e o f t h e fi na l p r od u ct . T h e ma n uf a ct u re o f P or t la n d ce m en t

accounts f orr oughl y 6% of al l human- generated greenhouse- gas emi ssi ons.

R e c en t l y, m a n y R & D h o u se s h a ve b e en w o r ki n g to r e c om m e nd i m p ro v e d

manuf acturi ng methods and f ormul ati ons to deal wi th thi s ri si ng i ssue.

C u t ti n g d o wn o n e m i ss i o ns w o u l d m ea n m a s t er i n g t hi s c o m p le x m a t e ri a l ,

w h i ch i s ea s i er s a i d t h a n d o n e. T h e g o o d n e w s t h o ug h i s th a t r e s e ar c h er s

around the worl d are tryi ng thei r best and the resul ts are qui te encouragi ng.

T h e C a r bo n C a p t ur e a n d S t or a g e ( C C S) t e c h no l o gy h a s r e c en t l y c o m e t ohi ghl i ght. H owever, concerns rel ated to hi gh- capi tal costs and l ong- term

r e l i ab i l it y o f m e t ho d s t h a t r e qu i r e p i pi n g c a r bo n d i o x id e e m i s si o n s, r e m a in .

P u m pe d s t o r ag e o f l i q ue f i ed c a r b on d i o x id e i s a n o th e r a r e a , k n o wl e d g e

about whi ch remai ns hazy.

P e rh a p s t h e w a y f o r wa r d l i e s i n t w e ak i n g t he r e c i p e o f c o n cr e t e. A r e s e a r ch

t e am fr o m t h e U ni v er s it y o f C a li f or n ia , B e rk e le y, h a s f o un d o u t h o w a n

extraordi nari l y stable compound cal ciumalumi num- sil i cate- hydrate (C- A-S- H )

i s behi nd the enduri ng structures of the anci ent Roman Empi re. The research

t e a m h a s ar r i v ed t o t h e co n c lu s i on t h a t t h e pr o d uc t i on o f l i m e f o r R o m an

concrete was much cl eaner, requi ri ng temperatures that are two-thi rds of that

m e a nt f o r m a k in g P o r tl a n d c e me n t . O n e o f t h e c r u c ia l i n g r e di e n ts i n R o m an

concrete was vol cani c ash. It i s al so amazi ng as to how some of these Roman

s t ru ct u re s e n du r ed t h e h a rs h s a lt w at e r e n vi r on me n t. W hi l e t he e a r li e ri ngredi ents cannot be used now f or the si mpl e reason that they requi re more

h a r d en i n g ti m e , r e s e ar c h i s g o in g o n i n v a r i ou s p a r ts o f t h e w or l d t o fi n d o ut

h o w b e s t vo l c a ni c a s h c o u ld b e ut i l iz e d fo r p r o d uc i n g c o n cr e t e , f o r t h e y o f f er

an excel l ent alternati ve where f l yash i s not avai l abl e.

Several other al ternati ve reci pes have emerged owi ng to i ntensi ve research

such as Sl ag- PC cements made f rom ground granul ated bl ast f urnace sl ag

( GB F S) , S u pe r su l fa t ed c e me n ts , C a lc i um A l um i na t e c e me n ts , C a lc i um S u lf o -

a l um i na t e c e me n ts , B e li t e C a lc i um S u lf o al u mi n at e c e me n ts , a n d M a gn e si u m

Phosphate cements, among other al ternati ves that are doi ng the rounds.

F i nd i n g o u t t h e a l t er n a t iv e is o nl y h a l f t h e b a t t le w on . I n m a k in g th e m a

commerci al l y vi abl e opti on remai ns the bi gger chal l enge. There are al ready a

f ew encouragi ng si gns, though. A Cal i f orni a- based company, Cal era cl ai ms

to have f ound a carbon- negati ve method of cement manuf acturi ng. Carbondi oxi de emi ssi ons are f i l tered through seawater creati ng a chal ky carbonate

b y pr o du c t, w hi c h i s u s ed f o r m i xi n g wi t h a g gr e ga t e a nd w a t er f o r c r ea t in g

concrete. The method enabl es sequesteri ng carbon emi ssi ons and the need

t o h e at t h e i n gr e di e nt s , s a ys t h e c o mp a ny. N o va c em , a n E n gl i sh c e me nt

manuf acturer says that i t has come out wi th a method usi ng magnesi um

si l i cates, whi ch do not emi t carbon di oxi de duri ng combusti on. It al so cl ai ms

t h a t t h e c e m en t a bs o r b s f a r m o r e c a r b on d i o x id e a s i t ha r d e ns , f u r th e r

of f setti ng the amount generated duri ng the manuf acturi ng process. These

are sure moti vati onal f actors f or the research wi ngs as wel l as the commerci al

i nvestors. The study i n thi s li ne is bound to i ntensi f y consi deri ng the massive

c o n s um p t io n o f c e m en t .

F i ngers crossed. H opi ng a breakthrough i n cement i s just round the corner.

EDITOR'S COMMENT

K . P. P r a d e e p , Editor- in- Chiefeditor@ma sterbuilder. co. in

Tweaking the Recipe



Contents

E d i t o r ' s C o m m e n t . . . . . . . . . . . . . . . . . . . . . . . . .

Classification Index..........................

N e w s & E v e n t s. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. .

12

18

22

C e m e n t: A n a l ys i s

Sadag opan Sesh adri

C h i e f - C o n t e n t D e v e l o p m e n t , C E - I n f r as t r u c tu r e - E n v i r on m e n t

Indian Cement Industry in Global Perspective

48

14 ·T h e M a s t e r bu i l d er - July 2013 www.masterbuilder.co.in

' R et h in k in g C o nc r et e ': L i fe C y c le o f t h e I n di a n C o nc r et e I n du s tr yC h a i ta n y a R a j G o y a l

Concrete: LCA

Sustainability

Adm ixtures

D e e p ak K a n i tk a r, G M – Te c h n o lo g y a n d B us i n e s s D e v e l op m e n tChembond Chemicals Limited (Construction Chemicals Division)

56

68

76

80

N e w C o n c re t e Te c h n o lo g y i n C o n s t ru c t i on A gg r e g at e s -T h e i r R o l e i n C on c r e te a n d th e ' G r e e n A g e n d a’C h r i st o p h e r A n d r e w C l e a r, B r i t is h R e a d y -M i x e d C o n c r e t e A s s o c ia t i o n

C h e m ic a l A d m i x tu r e s f o r Co n c r et e : A n O v er v i e w

88

98

Waterproofing

Concrete Recycling

P o s i ti v e W a t er p r o of i n g f r o m N e g a t i v e S i d eS amir S urlaker, Managing Director, MC-B auchemie

C o nc r et e R e cy c li n g: T he N e ed o f t h e H o urB h a v a ni B a l a k ri s h n a

138

148

172

Concrete: Rheology

Cem ents

A R e v i ew o f F r es h C e m en t a n d C o nc r et e R h eo l og yS o nj o y D e b, B . Te c h, C i vi l A s so c it a t e E d i t o r

L o w C a r b on C e m e n ts a n d C o n cr e t e s i n M o d e rn C o n s t ru c t i onA J o h n W H a r r is o n , M a n a gi n g D ir e c t o r, T ec E c o

Concrete Flooring: Densifiers

An Ins ight into Liquid Floor De ns ifie rs

180 Structural Health M onitoring

S t r u ct u r a l H e a l th Mo n i t or i n g : A Di r e N e e d o f I n d i a

188U s e o f F R P C o m p os i t e s f o r R e h a b il i t at i o n o f H e r i ta g e S t r uc t u r e s

R e p a i r a n d R e h a b

128128

H i g h P e r f o r m a nc e C o n c re t e us ing Mic ros ilic aS u r e nd r a S h a r ma , G e n e r al M a n a g er - Co n c r e t e. E l k e m S o u t h A s i a .

D e v e l op m e n t o f M o d e rn P r es t r e ss e d C on c r e te B r i d ge s i n J ap a n1 1 1H i r o s hi M u t s u yo s h i , N g u y e n D u c H A I a n d S . V. T. J a n a k a P e r e ra

1S t r u c tu r a l M a t e r ia l L a b , D e p a rt m e n t o f C i v i l a n d E n v i r on m e n t al E n g i n e er i n g ,S a i t a ma U n i v e rs i t y

108

114

High Perform ance Concrete

Prestressed Concrete

4848

172172

9898

138138

A d m i xt u r e s f o r T al l S t r u ct u r e sB r u n o D' s o u z a, R e g i on a l B u s i ne s s S e g me n t M a n a ge r , A d m ix t u r e s ,A s i a P a c i f ic , B A S F

P e r f or m a n c es a n d B e n e f it s o f C o n c re t eA d m i xt u r e s i n C o n c r et e D u r a b il i t yP h i l ip p e O r t e g a, V i c e T ec h n i c a l D i r e c to r, C H RY S O S A S, F r a n c e

AnkitaAdhikary

F R P C o m p os i t e s

Form work

C e l l u l ar C o n c r et e

Advertorial

194

200

216

224

R e c e n t A d v a n ce s i n S t r u ct u r a l R e t r of i t ti n gUs ing Pre c ure d FRP Profile

Factors Affecting the Selection, Economics Involved in FormworkSameer S. Malvankar, Dy. Manager - Engineering, GammonIndia Ltd.

Cellular Concrete: An Alternative forSustainable Design & ConstructionBhavani Balakrishna

Versatile Aluminum Formwork Systems Storm Indian Market



Contents

16 ·The Masterbuilder - July 2013 www.masterbuilder.co.in

62 CENTRILIT NC: Concrete Additive Based onPozzolanic Alumosilicate

221

222

226

228

230

240268

270272

274

276

280

303

299

Pioneering Foam Concrete Technology

A Testimony to Top Quality and Performance

Greaves Rolls Out High Capacity Concrete Pumps withS Valve Technology

Stay Ahead of the Curve Via Strategic Training and Development

Magnox ILW Interim Storage Facility, Berkeley

Fiber Reinforced Concrete & Its Advantages

Building Trust through Quality Focus

DURAboardHD100: Bitumen Free Joint Filler

Crack Injection System

Interarch's Contribution to Aviation Sector in India and Abroad

Industrial Overhead Doors: Making the Right Choice

Hitech Concrete Solutions Chennai: A State-of-the-artConcrete Testing Center

High Performance Liquid Membrane Series Launched

Advanced Multipurpose Waterproofing Coatings

64

104

164

168

170

198

210

214

232

244

250

256

262

278

284

Magnox ILW Interim Storage Facility, Berkeley

Evercrete Everwood and Evercrete Top Seal:

Waterproof, Preserve and Enhance Life of Wooden Structures

Eco-friendly AAC Block is Here to Stay

Pioneering Innovative and Sustainable Products

Leading the RMC Revolution

Offering a Wide Array of Construction Solutions

Blazing a New Trail in Formwork Systems

Top Notch Engineering Solutions

The Use of Steel and Synthetic Fibres in Concrete underExtreme Conditions

1 2 3 4Don Wimpenny , Wolfgang Angerer , Tony Cooper and Stefan Bernard1 2Principal Materials Engineer, Halcrow Pacific Senior Tunnel Engineer,

3 4Halcrow Pacific Consultan t Elasto Plastic Concrete Consultant, TSE

Concrete Batching Plants: Emphasis on Quality andVariety of Concrete Drives Continual Demand

Concrete Placing Equipment: Application RequirementsDictate Market TrendsM.K. Prabhakar, Associate Editor

Concrete Transportation Equipment: On the MoveM.K. Prabhakar, Associate Editor

Concrete Product Machinery: Shaping Up WellM.K. Prabhakar, Associate Editor

Growing Opportunity in India's Construction SectorDraws Global Attention

The Indian Construction Chemicals Market:

Building a Sustainable FutureM.K. Prabhakar, Associate Editor

Concrete: Fibres

Equipment: Concrete Batching Plants

Equipment: Concrete Placement

Equipment: Concrete Transportation

Concrete: Block Machinery

Events

Construction Chemicals: Industry Analysis

M.K. Prabhakar, Associate Editor

256256

25025044244

284284

Communication Feature



Contents

A dv er ti se rs I nd ex / C la ss if ic at io n

A A C a n d C L C B l o c k s- F o a m m a ki n g m a c h in e

A A C B l oc k s

A dhesives and S ealants

A utomation D oors

B lock Making Machinery

B uilding Materials and P roducts

C ement Manufacturers

C oncrete C utting Machine

C oncrete C utting S pecialist

C oncrete D ensifier-Lithium S ilicate

C oncrete G rinding and P olishing S olutions

C oncrete Machinery and Equipment

C oncrete P roducts

C oncrete testing Equipment

C onstruction C hemicals

Iyantra 21 5

B rickwell 28 1

Citadel Eco-Build So lutions 21 9

Methra Industries 16 5

Dow Corning India P vt. Ltd. 7 5

Wacker Chemie India Pvt L td. 6 5

Gandhi Automations Pvt Ltd 1 3

Columbia P ako na E ng ineering P vt. L td. 25 5

Hess Concrete Ma chiner y In dia Pvt. L td. Gatefold

S ri P arijatha M ach iner y W ork s P vt. L td. 26 5

Fabtech S terling B uilding TechnologiesP vt. Ltd. Cover Pag e

Zu ari Cement Italcementi Group 13 1

P rime Te chnolo gies 12 1

A bcon Tech & Build Aids Pvt L td 28 9

Waltar Enterprises 17 5

S urie Polex 19 7

A jax Fiori Engineering (I) Pvt. Ltd. 16 3

E v e r e st E q u i p me n t s P r i v at e L i m i te d 28 3

Greaves Cotton Limited 25 3

Linhoff India P vt. Ltd 34 7

K yb-Conmat Pvt. Ltd 22 2

S chwing Stetter (India) Pvt Ltd 3 5

Tosh niwal S ys tems & Instruments P vt. L td . 27 3

U n i v e rs a l C o n s tr u c t io n M a c h i n e r y &Eq uipment Ltd. 161 / 23 5

B uildtech India Corporation 27 7

Techn ical & Scientific Sa les(TAS S) 17 9

A mit Trading Corporation 10 5

B ASF The Chemical Company 5 1

Cera-Chem Private Limited 6 3

Chembond Chemicals Limited Back Inner

Cico Techn ologies Limited 7 1

Contech Chemicals 28 9

Fo sroc Chemicals (India) P vt. Limited 8 5

Max Civi Chem Private Limited 5 9

MC-Bauchemie (India) Pvt. Ltd. 5 3

Multich em Group Flap Cover

S.N. En gitech Developers Pvt. Ltd. 199

Structwel D esigners & consultants P vt. L td. 177

Sanrachana Structural S trengthening P vt. Ltd . 117

Gandhi Automations Pvt Ltd 13

Leister Techn ologies In dia Pvt. Ltd. 151

Asons Enterprise 239

Atul fastners 269

Hindalco Everlast A luminium

Roofing & S tructurals 2 2 / 23

Robo Silicon Pvt Ltd 125

Metecno India Front inner

Te k la I n di a P v t L t d 1 41

Bekaert Industries Pvt. Ltd. 29

Kasturi Metal Composites(P ) Ltd 227

Stewols India (P ) Ltd. 279

Igloo tiles 231Te chny ch emie 10

H & K Rolling Mill E ngineers P vt. L td. 1 7 / 19

BAS F The Chemical Company 51

Cera-Chem Private Limited 63

Chembond Chemicals Limited Ba ck Inner

Cico Tec hnolo gies Limited 71

Contech Chemicals 289

Fosro c Chemica ls (India) P vt. Limite d 85

Max Civi Chem Private Limited 59

MC-Bauch emie (India) P vt. L td. 53

Multichem Gro up F lap cover

Nuha Construction S olu tions 289

Penetro n India P vt. Ltd. 91

Perma Construction Aid s Pvt. Ltd. 279

Pidilite In dustries L td. Front Inner

Polyflex 31

Razon E ngineering C o mpan y P rivate L imited 101

Sika India P vt Ltd 97

The S upreme Industries 45

Trade Winds 283

JK Cement L td. 21

Te xsa India L td. 95

R e p a i r a n d R e t r o fi t t i n g

R o l l in g S h u t t er s

R oofing

R oofing Fastners

R oofing S heets

S and Making Machine

S andwich P anels

S o f t wa r e f o r C o n c r e te

S t e e l F i b e r R e i n f or c e d C o n c r e t e

Tiles-Thermal Insulation

TMT Technology S upplier

Wall P utty

Waterproofing Membrane

Nuha Con struction So lutions 289

P enetron India Pv t. L td. 91P erma Co nstructio n A ids Pvt. Ltd. 279

P idilite Indu stries Ltd Fro nt InnerP olyflex 31

R azon E n gineering C ompany Private Limited 101

S ika India Pv t Ltd 97

Th e S upreme Industries 45

A ction Con struction Equipment Ltd. 259

Wirtgen India 33

Marini India (Fayat Group) 145

C a s e N e w H o l l an d C o n s t r u c ti o n E q u i p m e n t(India) Pvt. Ltd. 39

ConMechA uto Consultants I ndia P vt L td 261

A mman n A pollo 36 / 37

R oth o R obert Thomas 277

K ern eos A luminate Techn ologies 15

Excon -2013 291

ICI-CPWD 29 3

U B M C o nc r et e S h ow - 2 01 4 2 9 4

Construction Chemicals R egionalC o n f e re n c e ( C 3 R ) 2 9 5

I C I - IW C ( 2 0 1 3 ) 2 9 6 / 2 9 7

B i g 5 C o n s tr u c t I n d i a - 2 0 1 3 2 9 8

S E W C - 2 0 1 3 2 9 9World o f Con crete 30 0

R eylon Facility 27 2

B ekaert In dustries P vt. Ltd . 2 9

Cipy P olyu rethanes Pvt. Ltd. 7 9

JB A ssociates 18 3

K asturi Metal Composites(P ) Ltd 22 7

Neocrete Technologies Pvt. Ltd. 13 5

R ecro n 3S 24 3

S ilicone Concepts Intl. Pvt. Ltd. 8 3

S TA Concrete F looring Solutions 159 / 19 3

S tewols India (P) Ltd. 27 9

K eltech Energie s Ltd. 13 7

Maco Corp oration (I) P vt. L td. 28 1

Intera rch Building S ystems 9

MNF Metals and F orming Pvt. Ltd. 12 3

A .N.P rakash Construction P rojectMana gemn et Co nsultants Pvt.Ltd 4 1

R & M International 18 5

C o n s t ru c t i o n M a c h i n e r y a n d E q u i p m e nt

C uring C ompounds

D ry Mix Mortar

Events & C onferences

Facility S ervices

Flooring

Light Weight C oncrete

Material H andling Equipment

P EB

P roject Management C onsultancy

R epair & R estoration/R ehabilation-S erviceP roviders

18 ·T h e M a s t e r bu i l d er - July 2013 www.masterbuilder.co.in



P a lf i n ge r M a ri n e L a un c h es I t s M a ri n e / O f f s ho r eC r a n e s a t Os lo F a ir

N e ws & E v en t s

M a n i t ex h a s u n v e i l e d t h e 1 9 t o n 1 9 7 0 C

b o o m t r u c k m ou n t e d o n a t w o a x l e 4 × 2

c h a s s i s . T h e c r a n e i s o n e o f t h e h i g h e s t-c a p a c i ty c r a n e s a v a i l a b l e o n a t w o a x l e

c h a s s i s . T h e 1 9 7 0 C o f fe r s a 2 1 . 3 m e t r e

t h r e e s e ct i o n s y n c h ro n i z e d te l e s c o pi c

b o om , w i th o p ti o na l t wo s e ct i on e x t en -

s i on f or a 36 .7 me tr e m ax i mu m t i p

height. I t also features a two sp eed p lan-

e t a r y h o i s t , f u l l l o a d m o m e n t in d i c a to r. I t

o f f e r s g r e a t e r p a y l o ad p o t e nt i a l o n t h e

t r u c k . “ T h e 1 9 7 0 C b o o m t r uc k h a s b e s t

f e a t u re s p r i c e d r e a s on a b l y a n d i s u s e r

f ri en dl y, “A nd y R ob er ts on d ir ec to r o f

sales and marketing said.

M a n it ex R o lls O u t N e w 19 Ton 1970 C Boom Truck

H a u lot t e L a u n ch e s En t r a pm e n t

Prevention System

French Material HandlingEq u ip m en t M ajo r H a u lot t e

Opens New Subsidiary in India

CONSTRUCTION EQUIPMENT

20 ·T h e M a s t er b u i l de r - July 2013 www. masterbuild er. co. in

P a l f i n g e r D r e g g e n a n d P a l f i n g e r

Neddeck were unveiled at the Nor-

S h i pp i ng t r a d e f ai r i n O s l o f or t h e f ir s t

t i me . T he s u c ce ss fu l i n te g ra ti o n o f

P a l f i n g e r D r e g g e n a n d P a l f i n g e r

Neddeck is contributing to the unabated

g r ow th , a c o m pa ny s po ke s p e rs on

s ai d. A t t he t ra de f ai r i n O sl o, t he

company was successful in p ositioning

i t s el f a s t h e l e a di n g m a nu f ac t ur e rw o r l d w i de o f c u s t o mi z e d m a r i n e a n d

o f f s ho r e c r a n e s a s w e l l a s l a u n c h a n d

recovery sy stems. Palfinger Marine has

p lans to exp and its sales network by

o p en i ng n e w s a l es o f fi c es i n R i o deJ an ei ro , B ra zi l, H ou st on , U SA an d

Singapore. The company plans to

s e rv e t h e st r o n g g r ow t h m a r k e t s of

S o u t h A m e r i c a a n d A s i a .

F r an c e b a s ed H au l ot t e G r ou p h a sa n no u nc e d t h e l a u nc h o f i t s E n tr a p-m e nt P r e ve n ti o n S y st e m , A C TI V 'S h i el dB a r. T h e s y st e m i s b e i ng l a u n c h ed i nresp onse to demands from the industryto p rotect op erators from this ty p e ofr i s k , a n d r e a ff i r m s H a ul o t t e 's c o m m i t -m e nt t o s a fe w o r ki n g a t h e ig h t. H a ul o t te ' ss y s t e m a l e rt s t h e o p e r a to r t o p o t e n ti a lentrap ment situations and is unique int h at i t f e at u re s a S a f et y G a p, w h i ch c a np r o t e ct t h e o p e r a t or f r o m fu l l e n tr a p -

m e nt a n d p o te n ti a l ly a l l ow t h em t o g e to u t o f d a n g e r. F o l l ow i n g t h e a l e r t o n l yr e v e r s e / l o w e r i n g m o v e m e n t s a r ep ermitted, allowing the p ossibly p anickedo p er a t or t o g et o ut o f t r ou b l e w i th o utm a ki n g t h e s i tu a ti o n w o rs e . A n d, a f te rb e in g t r ig g e re d , t h e sy s te m i s e a sy t oreset and reactivate from the basketwhich means there is no machine down-t i m e . T h e s y st e m h a s be e n d e s i g ne d t op reserve the machine's working enve-l o pe , m a i nt a i n e a s y a c ce s s t o c o n t ro l s ,w hi ch m e an s n o c ha ng e i n w or ki ngp r a c t ic e f o r t h e o p e r a t o r

Witha rated liftingcap acity of 85 U.S. Tons,the newSany SRC885 rough-terrain crane

has been added to the p roduct line to filla g a p i n t he m a rk et a n d m e et t he g r ow i ngd e ma n d f o r h i g he r c a p ac i t y c r a n e s . S R C8 8 5 d e l iv e r s l i ft i n g p o we r, p i ck a n d- c a rr yc a pa b il i ty a nd o pe r at in g s ta bi l it y o nv i r tu a ll y a n y j o bs i t e, r e g ar d le s s o f t e rr a i n,K yl e N ap e , s e ni o r v i c e p r es i d en t , S a n y

America Lifting Group said. The SanyS R C8 8 5 p r ov i de s re a ch o f u p t o 2 0 9. 7f t . ( 6 3 .9 m ) t hr o u gh a f i ve - s ec t io n , f u ll -p ow er b oo m. I t ca n a ch ie v e t he r at ed8 5 - t o n ( 7 7 t o n n e) l i f t i n g c a p ac i t y a t a 1 0 -f t. ( 3. 05 m ) r a di u s. W i th a n o v er a ll w ei g hto f 1 1 5 ,8 8 0 l b . ( 5 2 5 6 2 k g ) , t h e S an y S R C

8 8 5 is w e ll s i z ed fo r a v a r ie t y o f a p p l i ca -t i o n s w h i l e s ti l l b e i n g e a s y t o t r a n s p or t .T h e ne w S R C8 8 5 is e q ui p pe d w it hC u m m i ns en g i n e , B r a d e n w i n c h es an dh o i s t s , a D a n a t r a n s m is s i o n a n d Pa r k e rh y d r a u l i c s . T h e S R C 8 8 5 a c h i e v e sm an eu ve ra bi li ty a nd a s mo ot h r id et h ro u g h 4 × 4 h y dr a u li c p o we r ed s t e er i n gand earthmover-sty le ty res.To p rovides t a bi l i ty i n a d ve r s e g r o un d c o n d it i on s ,t h e S R C8 8 5 r o u gh - te r r ai n c r a ne f e at u r est h r e e -p o s i t i on o u t r i g ge r s t h a t l e v e l t h ec ra n e w i th u p t o 12 .4 i n. ( 31 5 mm ) ofg r o u n d p e ne t r a t i on a n d m a x i m u m , h o r i -

z on ta l e xt en si on o f 2 4 f t. ( 7. 32 m ) . T he

2 75 -h p ( 20 2 k N) C um m in s T ie r 4 i e ng i nei n t e g ra t e s w i th t h e h yd r a u l i c s y s t e m f o rp recision control, and multi-function load

s h ar i ng . H yd ra u li c j oy st ic ks p ro vi des m o o t h , v a r i a b l e c o n t r ol o f c r a n e f u n c -t i o n s , a n d t h e t w o - s p ee d s w i n g s y s t e mr o t a t e s 3 6 0 d e g r e e s i n e i t h e r d i r e c t io n .Standardop erator comfort, convenienceand safety features of the SRC885 includea s pa c io us , e r go no mi c c a b w i th a l l- s te elc o ns t r uc t i on , h y dr a ul i c j o ys t i ck c o nt r o ls ,o p ti m u m v i s ib i l it y, t i nt e d s a f et y g l a ss , a no p en i ng s k yl i g ht w i th v i s or a n d w i pe rs y s t e m , a s l i di n g d oo r o n t h e l ef t s i de o f

t h e c a b , a f r a me d sl i d i n g w i n d o w o n t h er ig ht si de , a co us ti c fo am fo r no is es u p p r es s i o n a n d i n s u l a ti o n , h e a t a n d a i rc on di ti o ni n g. A s i x- wa y a dj us ta b le s e atw i t h m e c ha n ic a l s u sp e ns i o n f e at u re sa r m r e s ts an d a he a dr e st . A n i n -c a bm o n i t o r p r o m i n e n t l y d i s p l a y s t h emachine's op erations and p rovides full-machine diagnostic capabilities, enablingop erators and maintenance p ersonnelto p erform onboard sy stem checks.



INFRASTRUCTURE

N e ws & E v en t s


C I L t o S e t U p S e ve n N ew C oa lPreparation Plants on PPP

M o de T h i s Fi s ca l

PM Lays FoundationS to ne o f 8 50 MW R at le H yd ro

Ele c t r ic Po w e r P r o je ct

Adani Power CommissionsT hi rd 6 60 M W T he rm al

P o we r P la n t A t T iro d a

Coal I ndia Ltd (CI L) has p rop osed to set

u p s ev en c oa l w as he ri es at an e st i-

mated cost of ` 2 , 0 0 0 c r o re b y t h e e n d

o f t h is f i sc a l . T h is w a s an n ou n ce d b y

Adani Power, a subsidiary of Adani

E n te r pr i s es , h a s c o m mi s s io n ed t h e t h ir d

6 6 0 MW u ni t o f i t s th e r m a l p o w e r p l a n t

a t Ti rod a in M ah ar as ht ra . “ Wi th t hec o m m i s s io n i n g o f t h i s 6 6 0 M W u n i t a t

T i r o d a p l a n t i n M a h a r a sh t r a t he t o t al

p o w e r g e n e r a t i o n c a p a c i t y o f t h e

c o m pa n y r e a ch e d 7 , 26 0 M W, ” A d an i

P o w e r s a i d i n a s t at e m e n t. A d a n i P o w e r

M a h a r a s ht r a , a u n i t o f A d a n i P o w er L t d ,

is constructing a 3,300 MW thermal p ower

p l a nt i n T i ro d a, c o m mi s s io n ed i t s f i r st t w o

u n it s of 6 6 0 MW i n l a s t f i na n c ia l ye a r

2012-13 and has a current generation

c a p ac i t y o f 1 , 98 0 M W. T he T i r od a p r oj e ct

w i l l h e l p M a h a r a s ht r a m e e t i t s e l e c t r i c i t y

T h e P r i me M i n is t er D r. M a n mo h an S i ng h

a lo ng w it h U PA C ha ir pe rs on S on ia

G a n d hi l a i d t he f o u nd a t i o n s t o n e of t h e

T. K . S i nh a, g en er a l m a na g er ( pr oj e ct

m on it or i ng d iv i si o n) . T he p r oj ec ts w i ll b e

t a ke n u p o n p u bl i c -p r iv a t e- p ar t ne r s hi p

m o d e l w i t h a w a s h in g c a pa c i t y o f 1 5 - 16

m i l li o n t o nn e s c a pa c i ty. C I L n o w h a s 1 7

washeries washing around 35 million

t on ne s o f c oa l . W i th g r ow i ng d em a nd C ILp l an s f or s e tt in g u p a r ou nd 1 8 w a sh er i es

withwashing cap acity of 98 milliontonnes,

d u r i n g th e 1 2 t h p l a n p e r i o d.

8 5 0 MW R a tl e H yd r o E l e c t r i c P o w er

p r o j e ct a t K i s h t w a r, C h o u g an g r o u n d o f

J a m m u r e g i o n . T h e p r oj e c t t o be d e v e l -

op ed at a cost of ` 550 crore and isexp ected to be comp leted over the next

fivey ears.ThePrimeMinisteralsoassured

t h a t a ll s t e p s w i l l b e ta k e n b y t h e c e nt r e

t o e x p l o i t o v e r 1 4 , 0 0 0 M W H y d r o P ow e r

p o te n ti a l i n t h e s t a te . T h e c e nt r e w i l l

s u pp l y a n a d di t io n a l 1 5 0 M W p o we r t o

o v e r c o me t h e c u r r en t p o w e r c r i s i s i n t h e

state.

POWEROWER

Alstom T&D India Bags ` 2 0 0 C ro r e O r de r F r om B a j aj I n f ra

Alstom T&D I ndia has been awardeda c on tr a ct b y B aj a j I nf ra s tr uc tu reD e v e l op m e n t Co m p a n y, t o s u p pl y e -B oP ( El ec tr ic al B a la nc e of P la nt )P a ck a ge f o r t h ei r u p co m in g 3 x 6 6 0MWSup erThermalPowerProject(TPP)i n L a l it p ur, U t ta r P r a de s h . T h e c o nt r a ct

i s w or t h a p p r o xi m a t e l y 2 0 0 c r o r e . T h eL a l it p ur p l an t wi l l b e a m a jo r p o we rs u pp l i er t o t h e s ta t e o f U t ta r P r a de s hi n n or th er n I nd ia , w hi c h h a s a r ou nd 2 00m i l l i o n i n h a b i ta n t s . E l e c t r i ca l B a l a n c eo f P l a n t s y s te m s ( e B o P) f e e d p o w ert o t h e e q ui p m e n t w it h i n a p o w e r p l a n tt o m a x i m i s e a v a i l a b i li t y o f t h e p o w e rp la nt 's e l ec tr i ca l s ys te m . T he y a r eessential for efficient and stable op er-ations. Under thiscontract, Alstom T&DI n d i a i s r e s po n s i b l e f o r t h e d es i g n ,e n gi n ee r i ng , s u pp l y a n d i n st a ll a t io no f t he e Bo P a t t he L al i tp ur p la nt , w hi ch

i n c l u de s s up p l y o f S t a t i o n Tr a n s f o rm -e r s, U n it Tr a ns f or m e rs a n d o t he rE l e c t r ic a l s f o r t h e p r oj e c t . T h e e q ui p -ment will be manufactured at AlstomT & D ' s s t a t e - o f - t h e - a r t t r a n s f o r m e r

f ac il i ty i n N ai ni , U tt ar P ra de s h. C om -m e nt i ng o n t h i s s u cc e ss , R a t hi n B a su ,M an a gi ng D i re ct or, A ls t om T & D I n di as a i d, “ T hi s i s B a j aj I n fr a s tr u c tu r e' s f i rs tp o we r p r oj e c t u s i ng s up e rc r i ti c a lt e ch n ol o g y. A l st o m T & D I n d i a h a s w o ns e v er a l e - B oP p r o je c t s i n I n di a ,p a rt i c ul a r ly i n t h e h i g h e n d s e g me n ta b o v e 3 0 0 MW a n d f or 6 0 0 / 6 6 0 MWp o w e r p l a n t s. A s o f n o w, a r o u n d 9 0 0 0M W o f p r oj e ct s a r e u nd e r e x e cu t io n

b y A l s to m T& D, w h ic h h i g hl i g ht s ou re x p e r ti s e a n d l e a de r s h i p w i t h i n t h e e -B oP s eg me nt .” T he La li tp ur S up erT h e r m a l Po w e r P r o j e c t i s s ch e d u l edt o b e c o m m i s s i o ne d i n 2 0 1 5 .



N e ws & E v en t s


INFRASTRUCTURE

o f t h e a l l - w e a th e r r a i l c o n n ec t i v i t y t o t h eV a l le y w a s c o m m i s si o n e d a ft e r t h e s t a t -u to ry i ns pe ct io n b y t he C om mi s si o ne rof Rai lw ay Sa fety (CRS) for runni ngp as s en ge r t r ai ns . T hi s o pe ni n g o f t he r a ill i n k w i l l b e a n a l t e r n a te r o u t e t o J a w a h a rTu nn el t he o nl y l i nk i n w i nt er m o nt hs . T herail link will reduce the distance betweenBanihal and Qazigund from 35km to 17km.The 18-km Banihal-Qazigund sectionp a ss i ng t h r o ug h P i r P a nj a l r a ng e s h a sb e e n c o n s tr u c t e d a t a c o s t o f ` 1,691crore.

The Dedicated Freight CorridorC or po ra ti on o f I nd ia L td ( DF CC IL )h as a cq ui re d 8 9% o f t he 1 0 ,6 67h e c t a r e l a n d r e qu i r e d f o r t h e 3 , 3 2 6k m w e s t e r n a n d e a s t e r n c o r r i do r s ,w h ic h a r e b e in g d e ve l op e d a t acost of ` 3 3 ,0 0 0 cr o r e. T h e la n dthat remains to be acquired is ont h e S on na g ar- Da nk un i s e ct io n o f

t he E a st er n C o r ri d or i n W e st B e ng a l .T h is w a s a n n ou n ce d b y R K G u pt a ,m a na g in g d i re ct or, D FC CI L . T hec o rp o ra t i on h a s a cq u ir e d ma j o rp or ti on w he n c om pa re d t o 5 55h ec ta re s i n 2 0 10 . T he ex cl us i vef r e i g h t c o r r i do r p r o j e ct e n vi s a g e s1,801-km Ludhiana-Dankuni sectiono n t h e E a s t er n s e g m e n t a n d 1 , 5 25 -k m D e l h i -J N P T s t r e t c h ( M u m b a i)o n t h e We s te r n c o r ri d or. T h e co r r i-d o r s a r e b e i n g d e v e l o p ed w i t h h e l pfrom World Bank and Jap an I nter-national Coop erationAgency (JI CA).

The dep artment is p lanning toe ns ur e d el i ve ry i n t im e a nd h a ul a geo f o v er d im en si o na l c ar g o o nc e t hec o rr i d or b e co m es o pe ra t io na l . C i vi la nd t r ac k w o rk ha s s t a rt e d o n b o t ht h e W e s t er n a n d E a s t e r n C o r r i d or s .O n t h e m u l t i m o da l l o g i st i c s f a ci l i tyf r on t , p l a n s a r e f o r f r e i g ht c o n s o li d a -t io n c en tr e, a ut o p ar k c um l oa di ngf a c i l i ty, i n d u st r i a l c e n t r e f o r p r oc e s si nd us t ry, a nc i ll ar y s er v ic es s uc h a s

c u s to m s b o n de d w a r eh o us i ng a n dc o l d s t o r a g e , a m o n g o t h e r s .

K a r na t a ka g o v er n me n t w i t h R a i lw a y s h a sp lanned to sp end ` 600 crore to take uprail p rojects in the current financial y ear,U ni on R ai lw ay M in is te r M M al li ka rj un aK h a r g e s a i d . T h e c en t r e w i ll f u n d a nadditional ` 3 0 0 c r or e t o t ak e u p s o m eworks p ending for long to be comp letedw it hi n t en m on th s. T he r ai l p ro je ct si n c l ud i n g K a du r- C hi k m a g al u r, K o la r -C h ik k ab a l la p ur a , G a dw a l -R a i ch u r a n dB id a r- G ul b ar g a w i ll b e t a ke n u p o n p ri o ri ty

basis.

Qazigund-Banihal railway line was dedi-c a t e d t o t he n a t i o n b y t h e P r i m e M i ni s t e rM a n m o ha n S i n g h a n d U PA c h a i r p e r so nS o n i a G a nd h i o n J u n e 25 . T h i s w i l l b e am a j or l i n k t o c o nn e ct th e r e s t o f t h ec o u n tr y w i t h K a s h m i r V a l le y. T h e t r i a l r u n

c o n v e r si o n o f 6 2 k m - l o ng n a r r o w g a u g e

l i n e t o b r o a d ga u g e b e tw e e n D h o l p ura n d S a r m a t h ur a . “ T h e b r o a d g a u g e l i n ew i l l b e e x t e n d ed u p t o G a n g a pu r c i t y, ”he said.

A broad gauge line will be constructedto link theholy city Nathdwara in Rajasthan

w h e r e la k h s o f p i l g r i ms v i s i t e v e r y y e a r.N a t h d wa r a w i l l b e l i n k e d w i t h M a n d i a nat ha t i s 1 1 k m a wa y f ro m t he c it y. T hi s w asa n n o un c e d b y t h e t h e n R a i l w a y M i n i s te rC P J o sh i . N a t hd w ar a is fa m o us fo r i t s1 7 t h c e n t ur y L o r d K r is h n a t e m pl e w h i c hh o u s e s t h e i do l o f S h r i n a th j i t h e s ev e n -y e ar -o l d i n ca r n at i o n o f K r is h na . A p r i ma r ya l i gn m en t h a s b e e n i d en t if i ed t o c o nn e ctt h e t e m pl e t o w n , a n d a d e t a i l ed s u r v e yw i l l b e u nd e r t a k en s o o n t o l ay t h e b r o a dg a u ge l i n e. T h er e w i l l b e a m o de r n s t a t i o na t N a t h dw a r a t o w n, M i ni s t er s a i d. J o sh ihas also sanctioned ` 212.23 crore for

R a ilwa y s , K a rn a t a ka G o v tt o S pe nd ` 6 0 0 C ro r e o n R ai l

Projects This Fiscal

B a n ih a l- Q a zig u nd s e c t ion o fUdhampur-Srinagar-

Baramullahr a il lin k c o m m iss io n e d

Br oa d g au ge l in e t olin k h o ly c it y N a t h d w ar a

with Mandiana

8 9 % o f l a nd a c qu i re d f o rd e d ic a te d f r e ig ht c o r rid o r

project

d e ma n d. T h e c o mp a ny i s ta r g et i ng a

c a pa c i ty o f n e ar l y 1 0 ,0 0 0 M W by M a r ch2 01 4 a nd a im t o g en er at e 2 0, 00 0 M W b y

2 02 0 , G a ut am A da n i, C ha ir m an A da ni

G r ou p s a i d. A da ni P ow e r n o w h as a t ot a l

g e n e r a t i o n c a p a c i t y o f 7 , 2 6 0 M W

including 4,620 MW from the Mundra

p r o j e ct i n G u j a r a t a n d 66 0 M W fr o m

K a w a i P ow e r P l a n t i n R a j a s t ha n .

RAILWAYSAILWAYS




N e ws & E v en t s

INFRASTRUCTURE

I L & F S Tr a n s p or t a t i o n N e t w o r ks L i m i t edh a s s i g n ed a M e m o r a nd u m o f U n d e r-s t a n d i n g ( M o U ) w i t h E a s t N i p p o nE x pr e s sw a y C o mp a ny L i m it e d t o w o rkt o g e t he r t h r o u g h a s t r a t e g ic a l l i a n ce f o rI mp le me nt at io n o f P PP r o ad p r oj ec ts .The alliance aims at utilizing Jap aneset e c h no l o g y a n d f u nd s t o c a r ry o u t t e ch -

n i ca l a n d p r ef e as i b il i t y s t u d i es , a n d o t he rr e l a t e d w o r ks o f p o t e nt i a l r o a d p r o j e c t sin India forimplementation.Mr. K Ramchand,M an ag in g Di re ct or o n b eh al f o f IT NLa nd M r. H i ro s hi H i ro se , P r es i de nt &C EO w as t he s ig na t or y o n b eh a lf o f t heNEXCO in the pr esence of Mr. Rav iP a rt h as a r at h y, C h ai r m an I L &F S g r o up .M r. H i r o s e a n d M r. R a v i P a r t ha s a r a t hys t a te d t h at t h i s M oU w a s a n e x te n si o no f t h e i nc r e a s i n g i n d u st r y l e v e l p a r t n er -s h i p b e i n g p r o m o t ed b y t h e t w o co u n -tries.

T he M in is tr y o f R oa d Tr a ns po rt a ndHighway s have decided to use newm a t e r i a ls a n d t e c h ni q u e s i n N a t i o na l

H i gh wa y p ro je ct s i n t he c ou nt ry o n a ne x p e r i me n t a l b a s i s , i n o r d e r t o p r o m o tei n n o v at i o n a n d u s e o f n e w t e c h no l o g y i nhighway construction. I n this regard, it hasb e e n d e c i de d t o a d o p t i n n o v a ti v e , n e wm a t er i a ls o n a t l e as t o n e km s t r et c h i nwidening and strengthening p rojects.T he p ro mo te r o f t he s e n ew m a te ri a lss h a l l b e r e q ui r e d t o b e a r t h e e x t ra c o s ti nv ol v ed in t he pr op os a l. B ei ng th ee x pe r i me n ta l p r o je c ts , f a il u r e i f a n y o f t h et r i a l r e a c h, w o u l d n o t b e t r ea t e d a s t h er e s p o ns i b i l i t y o f t h e I m p l em e n t i ng a n d

G u ja r a t M a r it i m e B o a r d ( G M B) h a s p l an st o d ev e lo p a m a r it i m e c l u st e r a n d tw op o r t ci t i e s si m i l a r t o t h at a v a i l ab l e i nS i n g a p o r e a n d D u b a i . T h i s w a sa nnounced by A K Ra mesh, Vice

I n o rd er t o m ee t t he d ea dl in e o fD ec e mb er 2 01 6 , a g r ee n s tr i p o f o ve r t enm e t e r s w id t h w i l l b e d ev e l o p ed o n b o t hsides along the 270 kilometer Agra -L uc kn ow e xp re ss wa y s oo n. T hi s w a sa nnounced b y Uttar P radesh Chi efS e c re t a ry J a we d U s m a ni . T h e s i x- l a nee x pr e s sw a y c o ve r s s e v en c i ti e s A g r a,F i r oz a b ad , E t a wa h , M a i np u ri , K a nn u aj ,Hardoi and Lucknow and is constructedat a cost of ` 9 , 5 0 0 c r o re r u p e e s . C h i e fSecretary has asked the officials to designthe exp ressway to connect the outskirtso f t h e c it i e s .

E x e c u ti n g Ag e n c i es . T h i s e n d e a vo u r o f

t h e M i n is t r y w o u l d r e s ul t i n s a v in g n a tu r a lresources like stone aggregates andb i tu m en . T h is m a y a l s o re s ul t i n s a v in gi n l i f e c y c l e c o s t o f r o a d c o n s t r uc t i o n a s

c o m p a r ed t o r o ad c o n s tr u c t i on u s i n gc o n v e nt i o n a l m a t e r ia l s . T h e t i m e f r a m eo n c o ns t r uc t io n w i l l s i g ni f i ca n tl y c o med o wn o n u s i ng l a te s t e q ui p me n ts . T h en ew m a te r ia l s w i ll b e t es te d u nd er I nd ia nc o n d i ti o n s , t r a f f i c, r a i n f a ll , d r a i n a ge , s o i lconditions etc. before being p ut to use.

C a b in e t Ea se s N o r m s f o r Ex p a n sio n o f H ig h w a y s

The cabinet has allowed exp andingh i g h w a ys u p t o 1 0 0 k m w i t h ou t e n v i -ronmental clearance and wideningb y a n a d d i t i on a l 40 m e t r es b a s ed o nt h e r e c o m m e n d a t i o n s o n t h eK a s t u r i r a n g a n C o m m i t t e e . E a r l i e re n v i r o n m e n t a l a p p r o v a l w a s n o t

r e qu i r ed f or r o ad e x pa n s io n u p t o 3 0k m a n d w i d e n i ng u p t o 2 0 m e t r e s .The Cabinet has also cleared thep r op o sa l t o e x em p t f r o m e n v ir o nm e ntc l ea r a nc e m i n in g o f s o il i n a n a r e a u pto 2 hectares for lay ing the foundation

f o r r o a ds . M o re t h a n p r oj e c ts w o r t h ` 5 0 , 0 0 0 c r or e w e r e p u t o n h o l d e a r l i erdue to environment clearance madem a n d a to r y f o r m i n i n g c o m m o n s o i l .

IL &F S Tr a n s po r t a tio n a n d Ea s tNippon Expressway Join Forces

t o Ta ke U p R oa d P ro je ct s

In n o v at iv e M a t e ria ls an dTe c hn iq ue s to B e A do pt ed I n

National Highway Projects

G u j ar a t M a ri t i me B o ar d t oD e ve l op M a ri t i me C l us t er

Agra Lucknow Expressway

P ro je ct t o B e C om p le te d B ef or eD e ce m be r 2 0 16

ROADSOADS

PORTS & DAMSORTS & DAMS



N e ws & E v en t s

INFRASTRUCTURE


s to ra ge an d h an dl in g. T he CF S i s

e qu ip pe d wi th a ll m o de rn h an dl in gequip ments.

J a w a h a r l a l N e h r u P o r t T r u s t h a s

p rop osed to invest ` 2,000 crore to set

u p a m a r in e t e rm i n a l m a i n l y c a t e r i ng t o

l i q ui d c a r go e s l i k e o i l , a c i ds a n d c l e an i ng

c o m p o un d s . L & T R a m b o l l i s d e s i g n i ng

and doing the p roject management

c o n s u lt a n c y a n d h a v e s u b m i t te d th e

draft Detailed Project Rep ort (DPR) for

the marine terminal to enhance the

q u a n ti t y t o 3 0 m i l l i o n t o n n es p e r a n n u m. At p resent, there is a twin berth liquid

c a r go t e rm i n al o f B P CL a n d IO C w it h a

c a pa c i ty o f 5 . 5 m i l li o n t o nn e s p e r a n nu m .

J N P T h a s a l so a p po i n t e d U R S S c o t t

W i ls o n a n d H ow e a s c o ns u lt a nt s t o c ar r y

o u t a f e as i b il i t y s t u d y a n d t o p r e pa r e D P R

f o r s e t t i ng u p a m e g a c o n t a in e r t e r m i n al

n ea r N ha va Is la nd . J NP T c ur re nt ly

h a nd l es 44 pe r c e nt of t h e c o un t ry ' s

c o nt a i ne r c a r go . T h e f i sc a l e n di n g M a r ch

2 01 3 s a w c ar g o h an dl e d b y t he 1 2 m a jo r

p o rt s to 5 4 5 m i l li o n t o nn e s, f r om 5 6 1

m i l l i o n t o n n e s i n 2 0 1 1 - 1 2.

The Central Warehousing Corp oration

(CWC) has commissioned its 38th

Container FreightStation(CFS)at Pipavav

P or t o n J un e 24 , 2 0 13 . T he f a ci l it y w a si n a ug u ra t e d b y S h r i R . L . M e en a , C o m-

m iss ioner of Cus tom s, Ja mnaga r i n

p re s en ce o f S hr i T. K . D os hi , D i re ct or

( M &C P) , C WC , C O, N e w D e l hi . M /s N i rm a

Limited brought first consignment of

Exp ort and M/s HMT brought first

c o n s i g nm e n t o f I m p o r t a t t he C F S . T he

t o ta l a re a of C F S i s 22 7 0 6 s q m w i t h

c o v e r e d a r e a o f 6 6 0 0 s q m a n d op e n

p a v e d y a rd o f 1 0 0 0 0 s q m t o f a ci l i t a t e

cargo storage and I mp ex Container

C ha i rm a n a nd C hi ef E x ec ut i ve o f t heb oa r d. G MB w i ll d e ve lo p a p o rt c i ty a tM u nd r a i n K ut c h d i s tr i ct w h i l e Gu j a ra t

I n d u s t r i a l D e v e l o p m e n t C o r p o r a t i o n

( G ID C) , a s ta te -r u n b o dy f or a tt r ac ti ngi n du st r ia l i nv e st m en ts , w i ll b u il d a s e co ndo n e a t P i p a va v. T h e p o r t c i ty p l a n ne d i nM u n d r a w i l l b e s p r e a d o v er 2 5 0 - 5 0 0 s q .k m , a n d t h e o n e a t P i p a v a v w i l l b e s m a l l e ra t 1 0 0- 15 0 s q. k m . T h e g o ve rn m en t p l an st o d ev el op t he c it i es i n p ha se s t o e me r gea s i n d e pe n d e nt e c o n om i c h u b s w h endevelop ed.

J N PT t o S e t U p a M ar i neTerminal at a cost of ` 2000 Crore

I nd ia t o D ev el op M ul ti - P ur po seC o n t ain e r Te r m in a ls

at Port Of Chabahar, Iran

H UD CO t o P ro vi de ` 3000 CroreS o f t Lo a n f o r U t t a r ak h a n d

Rehabilitation

C o n t ain e r F r e igh t S t a tio nC o m m iss io n ed A t P ip a v a v Po r t

I n d i a ' s b i g g e s t s t a t e - o w n e d p o r t s ,

K a n d l a p or t a n d J a w a h a r l al N e h r u p o r t

h a v e p r o p o s e d t o d e v e l o p m u l t i -

p u r p o s e c o n t a i n e r t e r m i n a l s a t

C ha b ah a r p or t i n s ou th -w es te r n I ra n.

I ndia has p rop osed to invest $100

m il li on t o d ev el op C ha ba ha r p or t t o

H o u s i ng & U r b a n D e v e l op m e n t C o r p o -

r a t io n L t d. ( H UD C O) h a s b e en i n s tr u ct e d

to p rovide long term soft loans of ` 3000

c r o r e f o r 2 0 ye a r s du r a t i o n f o r c o n s t ru c -

t i on o f h o us e s a nd f o r r e co n st r uc t i on o f

I n f r as t r u c t ur e f a c i l i t i es i n U t t a r a kh a n d ,

S h ri D .S . N e g i, O f fi c e r o n S p ec i a l D u ty

( J NN U RM & R AY ) sa i d . T h e M i ni s t ry f o r

H o u s i ng & U r b a n P o v e rt y A l l e v i a ti o n w i l l

h e lp i n p l an n in g , d e si g ni n g a n d r ec o n-

s tr uc ti on o f d ev as ta te d h ou se s b y

d e p u ti n g a t e c h n ic a l t e a m d r a w n f r o m

b oo st e xp or ts t o A fg ha ni st an a nd o ff er

I r an e a s y a c c es s t o t h e I n di a n O c ea n .

I nd ia , I ra n a nd A fg ha ni st an h av e a n

a g r ee m en t o n p r ef e re n ti a l t r e at m en t

a nd l ow t ar iff s f or g oo ds m ov ed t hr ou gh

C ha b ah a r p or t, w hi ch a l so ha s a fr ee

t r a d e a n d i nd u s t r i al z o n e i n i t s v i c i n i ty. A

del ega tio n led by s hippi ng secr etar y

P r a d e ep K u m a r S i n h a v i si t e d C ha b a h a r

p o r t a n d h a d p u t up t h e p r o po s a l f o r t h e

p r o j e ct . T h e c u r re n t m o v e i s a l s o s e en

a s a s t r a t e g y t o co u n t er C h i n a 's r e ce n t

t a k e o v e r o f t h e d e e p - s e a p o r t a t

Gwa da r in south wes tern Pakis tan,

w h i c h i s s o m e 7 2 na u t i c a l mi l e s a w a y

f r o m C ha b a h a r. O n a p p r o va l t h i s w i l l b e

t he f i r st o v e rs ea s i nv es tm en t b y a ny o f

t he 1 2 p or ts co nt r ol l ed by t he In di a n

government. The investment in Chabahar

i s e xp ec te d t o be r ou t ed th r ou g h a

c o m p a ny i n w h i c h K a n d la a n d J N po r t s ,

w h ic h o p er a t e a s tr u st s in I n di a , w o ul d

h o l d e q u i t y s t a k e s .

URBAN INFRASTRUCTURERBAN INFRASTRUCTURE



Union Cabinet Approves ` 2 3 , 1 3 6 C r o re M u m b a i

M e t r o L in e - 3 C o r rid o r

L u ck n ow Me t ro P h a se 1 toBegin by Year-End

PM Sets ` 115,000 CrorePPP Investment Target

p roject is estimated at ` 2 3 , 1 3 6 c r or e

c o v e r i ng a t ot a l l e ng t h o f 3 3 . 5 k m ( fu l l yu n de r gr o u nd ) . T h e g a ug e w o ul d b e

s t an d ar d g a ug e , a s p e r t h e D e ta i l ed

P r o j e ct R e p o r t ( D PR ) . T h e p r o j ec t o f t h e

Mumbai Line 3 is scheduled to be

c o m p l et e d i n s i x y e a rs t h a t i s by M a r c h ,

2 0 1 9 fr o m t he d a t e o f s t a r t of w o r k i n t h e

f i na n c ia l y e ar 2 0 13 - 1 4. T h e e x i st i ng s t at e

l e v e l S P V f o r i m p l e m en t i n g t h e p r oj e c t ,

n a m e l y, t h e M M R C s h a ll b e c o n v e r t e d

i n t o a j o i n t ow n e r s h ip ( 5 0 : 5 0 ) S PV o f G o I

a nd G oM o n s im il ar p at te rn a s f or t he

D e l h i M e t r o , B a n g a l or e M e tr o , C h e n na i

Metro and Kochi Metro. The joint owner-

s h ip c om pa ny w i ll c on ti n ue t o b e n am e d

a s M M R C. T h e pr o m o t er s , t h e Go I a nd

t h e G o M , s h a l l n o m i na t e f i v e D i r ec t o r s

e a ch t o t he B oa r d o f D ir ec to r s o f t he S P V,

w h i c h s h a l l h a v e 1 0 n o m i n ee D i r e c t o rs .

T h e S e cr e t ar y, M i ni s t ry o f U r ba n D e ve l -

o p me n t, G o I wi l l b e th e e x- o ff i ci o

C h ai r m an o f t h e B oa r d. T h e i mp l em e n-

t a ti on o f t he p ro je ct w o ul d p ro vi de m uc h

needed additional transp ort infrastruc-

ture to Mumbai.

T h e U n i o n C a b i n e t a p p r o v e d t h e

Mumbai Metro Line-3 Colaba-Bandra-

Santacruz Electronics Exp ort Processing

Zone (Colaba-Bandra-SEEPZ) corridor.

I t h a s f u r t he r a p p r o ve d t h e c o n v er s i o n

o f t he e xi s ti ng S ta t e l ev e l S p ec ia l P u rp os e

Vehicle (SPV) Mumbai Metro Rail

C o rp o ra t i on ( M MR C ) i n to a J o in t V en t ur e

C om pa ny o f t he Go v er nm en t o f I nd ia

( G o I ) a n d G o v er n m e n t o f M a h a r a s ht r a

( G o M) , w i t h e q ui t y p a r ti c i pa t i on o n 5 0 : 5 0

b a s is . T h e t o ta l co m pl e t io n c o st o f t h e

T h e c o ns t r uc t i on w o r k o f L u ck n ow M e tr o

P h a s e 1w i l l c o mm e n c e by t h i s y ea r e n d

w i t h t h e s t a t e c a bi n e t g i v i n g i t s n od f o r

t he p ro je c t. T he d ec i si o n w a s t a ke n a ft er

a m ee ti ng ch a ir e d b y c hi ef m i ni s te r

Akhilesh Yadav and headed by the Chief

S e c r e t a ry. T h e f i rs t p h a s e w i l l c o v e r 2 3 -

k m s tr e tc h f r om A m au s i ai r po r t to

Munship ulia and will have 21 stations.

T h e N o r t h- S o u t h c o r r i d or w i l l h a v e t h re e

underground stations while remaining

P ri m e M i ni st er M an mo ha n S i ng h

h a s s e t a n i n v e s t me n t t a rg e t o f `

1.15 lakh cr ore in PPP (p ub li cp r iv a t e p a rt n er s hi p p r i va t e p a r t-

nership ) p rojects across infra-

s t ru c tu r e se c to r s in r a i l, p o rt a n d

p o we r i n t h e n e xt s ix m on t hs . T h is

was announced at the meeting

c o nv e ne d w i t h k e y i n fr a s tr u ct u re

m i n i s t r i e s . P r i m e M i n i s t e r

p ro po se d t ak in g u p o f M um b ai

e l e v a t e d ra i l c o r r i do r a t a c o s t o f `

3 0 ,0 0 0 c r o re , t w o i n te r na t i on a l

a i r p o r t s i n B h u b a n e s w a r a n d

I m p h a l a t a c o s t o f R s 2 0 , 0 0 0 c r o re

a n d p o w e r a n d T r a n s m i s s i o n

p rojects at a cost of ` 40,000 crore.

T h e r e i s a p r o po s a l t o s e t u p a r a i l

t a r if f a u th o r it y. F i na n ce M i ni s te r P

C h id a m ba r a m, P l a nn i ng C o mm i s -

sion Deputy Cha irm an Montek

S i n gh A h lu w a li a a nd M in is te rs o f

Power, Coal, Railway s, Roads, Ship -

p i ng a n d C i v il A v i at i o n w e r e p r es e nt

at the meeting to finalise infra-

s t r u c t ur e p r o j e ct s f o r 2 0 1 3 - 1 4.

1 8 w i l l b e bu i l t o n e l e v a t ed p l a t fo r m s .

The cost of the p roject is exp ected to bea r o u n d 7 , 0 00 - 8 , 0 00 c r o r e r u p e e s . O f f i -

c i a l s s a i d , t h e p r o j e ct w ou l d l a r g e l y b e

f u n de d b y e x t e r na l f i n a n c i ng a g e n c i e s

a nd t he r e ma i ni ng c os t w ou l d b e s ha r ed

b e t w e en t h e C e n t ra l a n d s t a t e g o v e r n-

m e n t s i n 5 0 : 5 0 r a t i o.


INFRASTRUCTURE

H U D C O, B u i l d in g M a t e r i al a n d Te c h -

n ol og y P r om ot io n C ou nc i l ( BM TP C) ,

H i nd us ta n P r ef ab L i m i te d ( H PL ). T he

g o ve r nm e nt w i ll c o v er a l l a ff e ct e dMunicip alities / Notified Area Councils in

U t t a r a kh a n d u n de r R a j i v A w a s Yo j a n a

(RAY) as a sp ecial case to sup p ort

r e co ns tr u ct io n o f h ou se s o f t he p oo r

a n d r ec o n s tr u c t an d r e de v e l o p t h e s e

d e v a s t at e d h o u s e s. M i n i s t ry o f H o u s i ng

a nd U rb an Po ve rt y Al le vi at io n h as

contributed ` 1 . 2 5 c r o r e f o r r e h a b i l it a -

t i on / r e c on s tr u ct i on w o r ks f or t h e f l oo d

a n d l an d s l i de v i c t im s a s pa r t o f C S R

initiative.



40 ·T h e M a s t er b u i l de r - July 2013 www.masterbuilder.co.in

N e w s & E v e nt s

Union Government ProposesTo L au nch N U L M S c he me

Draft National WaterF r ame w o rk B i l l R e l eas e d

UP Announces 'IndustrialS e r vi c e s G uar ant ee A c t '

C he nnai C o r po r at i o n t o i ns t al l

bio-methanation plantst o p o we r s t re e t l i gh t s

T he M in is tr y o f H ou si ng an d U rb an

Po ve rt y A ll e vi at io n h as p ro po se d t o

l a un c h a “ N at i on a l Ur b an L i ve l ih o od s

M i ss i on ( N UL M )” i n 1 2 th F i ve Ye a r P l an ,

w h i c h w i l l r e p l ac e t h e e x i s t i ng S w a r na

T he Ut ta r P ra de sh g ov er nm en t h as

announced introduction of 'Uttar P radesh

T h e C h en n ai C o rp o ra t io n h a s p r op o se dt o i n s t a l l s m a ll b i o - m e t h an a t i on p l a n tst h a t w i l l p o w e r l i g h t s. T h e c i v i c b o d y h a sidentified Villivakkam s laughterhous e tos e t u p t w o p l a nt s a n d o n e m o re a t t h eg a rb a ge t r an s fe r s t at i on i n R o ya p ur amzone. The pilot project is expected to b eset up in three months. The b io-m e t h an a t i o n p l a n ts w i l l b e f u e l l e d w i t hvegetab le and food was te and will emitmethane. The gas will b e captured andu s ed t o g e ne r at e p o we r. T h e b y- p ro d uc t ,s lurry, can b e us ed as manure.

J a y a n t i S h a h a r i R o z g a r Y o j a n a

( SJ SR Y) .N UL M w ou ld f oc us o n t he

p r im a ry i s su e s p er t ai n in g t o u r ba n

p o v e rt y s u c h a s i m p ar t i n g sk i l l t r a in i n g ,

enab ling entrepreneurs hip develop-

ment, providing wage employment and

s elf-employment opportunities to the

u r ba n p o or. T h e p ro p os al o f N U LM i s a t

approval s tage. The annual targets under

N U L M w i l l be f i xe d a ft e r f i n a l a p p ro v a l

a s p e r b u dg e t a l lo c at i on f o r i t s i m pl e -

mentation.

I n d u st r i a l S er v i c e s Gu a r an t e e A c t ' a n

e x c l u si v e l a w t o e n s u re i s s u a nc e a n d

clearances to indus tries in a s tipulated

time.Thepolicytob edraftedb ytheUdyog

B a n dh u w i l l e n v i sa g e p r o vi s i o n s f o r

d e l i v er i n g no t i f i ed s e r vi c e s w i th i n t h e

s pecified time frame limits and fixing

a c co u nt a bi l i ty o f l i c en s in g a u th o ri t i es

a nd e rr in g of fi ce rs f or t he d el ay b y

i m p o si n g a pe n a l t y. I n t h e f i r s t p h a seindustries, power, pollution departments ,

l a b o ur a n d f ac t o r i es w i l l b e i nc l u d e d

under the proposed act.

T he Mi ni st ry o f W at er R es ou rc es ha s

released Draft N ational Water Framework

B i l l, D r af t R i ve r B a si n M a na g em e nt B i l l

a n d Dr a f t Na t i o n al P o li c y G u i d el i n e s

prepared b y the M inistry of Water

R esources. The department has released

t h e bi l l f o r g e t t i ng c o mm e n t s o n W a t e r

S h ar i ng , D i st r ib u ti o n a mo n gs t s ta t es ,

u n i o n t e r r it o r i e s a n d r e l at e d m i n i s tr i e s

t h r o ug h e x p e r t c o m mi t t e e s. T h e s a m e

h a s a l s o b e e n u p l o ad e d o n t h e m i n i s-

t r y ' s w e bs i t e h t t p : // w r mi n . n ic . i n . A l l t h e

s ta ke ho l de rs c an s en d t he ir s ug ge s-

t io ns o r c om me nt s b y J ul y 3 1, 2 01 3 on

nps [email protected]

R o ad M i nis t r y Pr o pos e s St r i nge nt R ul e s t o M ak e H i g hway s S af e

T h e M i n i s t r y o f R o a d w a y s h a s

p r o po s e d t o b ri n g in s l e w o f c h a n ge s

o n t o l l r u l e s t o p ro t e c t t h e i n te r e st o f

the cus tomers and make highwayss a f e. To d i s c o u r ag e o v e r l o ad i n g o f

v e h i cl e s t h e M i n i s t ry h a s p l a n ne d t o

i n cr e as e t he p e na l ty b y t h re e o r f o urtimes apart from unloading the extra

w e ig h t. T h e Mi n is t ry p l an s to b ri n g

trans porter or trans port agent into the

n e t b y a l so pe n al i z in g t h em . N o w i th a s b e e n m a d e m a n da t o r y t h a t t h a t

all conces s ionaires b uilding roads on

P PP m u st h av e we i g ht - in - mo t i on

b ridges to detect s uch violations. Thereis als o a propos al to charge truckers

a n d t h e i r o w n e rs i n vo l ve d i n d a ma g in g

pub lic property.

POLICY



N e ws & E v en t s

42 ·T h e M a s t er b u i l d er - July 2013 www. masterbuild er. co. in

R e a l Es t a t e R e g ula t o ry B il l t o B e I nt ro du ce d

This Monsoon Session

K a r n at a k a G o v e rn m e n tP la n s To R e g ula r is e

U n a u t ho r is e d C o n st r u c t io n

P u n ja b G o v e rn m e n t t o

R e g ula r ize 5 , 0 0 0 U n a u t ho r is edC o lo nie s a c ro s s t he S t a t e

T h e r ea l e s t at e r e g ul a t o r y b i l l w il l b e

i n tr o du c ed i n t h e m o ns o on s e ss i o n o f

Parliament, a top government official said.

T h e b i l l i s e x pe c t ed t o b r i ng t r a ns p ar e nc y

a n d a c c ou n ta b i li t y i n t h e r e al t y s e ct o r.

T h e R e a l E s t a t e ( R e g u l a ti o n a n d D e v e l -

o pm en t) B i ll w a s a pp ro v ed b y t he c a bi ne t

t o p r o v i d e a u n i f o r m r e g u l a to r y e n v i r on -

ment to the sector.

Karnataka government has p rop osedt o i nt r od u ce a n a m e nd m en t t o th e

Karnataka Land Revenue Act 1964 to

regularise unauthorised constructions

o f d w e l l i ng h o u s e s i n g o v e r n me n t l a n d s

i n u rb a n a r ea s, o ff ic i al s ou rc es s ai d.

K a r n a t a k a L a n d R e v e n u e ( S e c o n d

Amendment) Bill, 2012 that was p assed

i n b o th t h e H ou s es o f t h e L eg i s la t ur e i n

t h e ea r l ie r r e g im e w a s r et u rn e d by t h e

G o v er n or H . R B h ar d wa j c i ti n g t h at t h e

B i ll m a y l e a d t o i l le g a l gr a b bi n g o f

government land.

T h e P u n j a b c a b i ne t h a s g i v e n a p p r o va l

f or r eg ul ar iz at io n o f a bo ut 5 ,0 00 u n-

a u th o r is e d c o l on i es i n t h e S t at e . Tw o l a k h

i n di v i du a l p l ot o r b u il d i ng o w ne r s ' a c r os st h e s t at e w i l l b en e f i t , a n o f f i c ia l s p o k es -

m a n s ai d. B as ic c iv i c a me ni ti e s wi l l be

p r ov i de d f o r t h e r e si d en t s o f t h e u n -

a u t h o ri s e d c o l o n i e s . T h e r e g u l a r i z a t io n

scheme will be ap p licable to those unap -

p rovedcolonies constructed before Ap ril

1 , 2 0 1 3 a n d w i l l b e fo r a pe r i od o f o n e

y e a r. T h e r e s i d en t s h a v e t o p a y c o m p o -

s i t i o n f e e v a r y in g f r o m ` 2 . 5 l a kh t o ` 15

l ak h f or a n a cr e. E ac h i nd iv id ua l m us t

p ay ` 50 to ` 5 0 0 a s q u a r e y ar d f o r r e g u -

l a r i z a t i on w h i c h w i l l b e u s e d t o pr o v i d e

b as ic f ac il it ie s. T he p ol ic y d oe s n otc ov er c ol on ie s, w hi ch a re s et u p o ve r

l a n d b e l o n gi n g t o t h e S t a t e , C e n t r al

G o v e r n m e n t s , P u b l i c U n d e r t a k i n g s ,

Pa nc ha ya t l an ds , W aq f B oa rd , L an d

u n d e r t h e P u n ja b L a n d P r e s e rv a t i o n A c t

( P L PA ) . T h e C a b i n e t a l so g a v e t h e n o d

t o t h e a m e n dm e n t i n t h e L a n d P oo l i n g

P o l i cy t o e na b l e th e l a nd o w ne r s t o

b e c o m e p a r t n er s i n t h e d ev e l o p me n t

p r o c e ss . U n d e r t h e a m e n d me n t , a f i xe d

s um o f t he v a lu e o f l a nd w o ul d b e e ns ur e d

to the land owners.

D e lh i G o v er n m e n t L ik e ly To A llo w H igh - R is e B u ild ing s

The Delhi government is mulling overt h e p r op o sa l f o r v e r ti c a l g r ow t h i n t h ec it y a nd h as pl a ns t o r ev i ew t heM a s t e r P l a n o f D e l h i 2 0 2 1 a n d f i n a l i seon a number of amendments,includingallowing high-rises and increasingt h e ex i s t i ng f l o or a r e a r a ti o ( FA R ) .D e lh i g o v er n m en t h a s s o ug h t c e nt r e 'sassistance to develophigh-rise building

a c r o s s t h e s t a t e . D e l h i U r b a n D e v e l -o p me n t M i n i s te r A r v in d er S i n gh L o v el y

s a i d, “ B as i c s e r vi c es l ik e d r ai n a ge ,w a t er s u pp l y a n d p o we r d i st r i bu t io nnetwork will have to be strengthenedi f v er ti ca l ex pa ns io n i s al lo we d. ”O p t i m um u s a g e o f l a n d r e s o ur c e f o rverticalgrowth will addressthe p roblemo f s h or t a ge o f h o us i n g s e ct o r, M i n is t ers a i d. T h e D e lh i D e ve l o pm e nt A u th o r it yap p roved the land p ooling policy that

p e r m i t s d e v el o p e r s o r l a n d o w n e r s t op o o l i n l a n d fo r c o n s t r uc t i n g r e s i d e n-tial blocks.

REALTY



N e ws & E v en t s


U S t o u n v e il $7 b illion p la n t ou p gr a de A f ri c an p o we r n e tw o rk s

Geodynamics commissions1 M W g e o t h er m a l p ilo t

plant in Australia

F r ee t r ad e a g re e me n t be t we e nC hi na a nd S wi tz e rl an d

t o b o os t t ra d e

INTERNATIONAL

p rovide a thermal resource equivalento f 5 0 b i ll i on b a rr e ls o f o il . Ta ta P ow erintends to have a 20-25 p ercent contri-b u ti o n f r o m " c le a n p o w e r s o u rc e s ", w h i ch

w i l l in c lu d e a m i x o f h y dr o , s o la r, w i nd ,geothermal and waste gas generation.G e o th e rm a l e n er g y h a s b e en a k e y f o c u sa r e a f o r t h e c o m p a ny o u t s i de I n d i a . Ta t aP ow er i s t he o n ly I nd ia n p la ye r i n g eo -t h e r m a l e ne r g y s e c t o r a n d i s a l s o i m p l e-menting a 250MW geothermal p rojecti n I nd on es i a i n p ar t ne r sh ip w it h O r ig i nE n e r g y a n d P T Su p r a c o. T h e c o m p a nyh a s i nv e st ed i n g e ot he r ma l e ne rg y b o thc o nv e nt i o na l a n d E G S i n G e o dy n am i c s,a n A u s t r a l ia - b a s e d g eo t h e r m al e n e r g yc om pa ny, i n 2 00 8. S pe ak in g o n Ta taP ow er ' s c om mi t me nt t o c l ea n a nd g r ee n

e n er g y A n il S a r d a na , M a na g i ng D i r e c-t o r, Ta t a P ow e r, s t a te d , “ T he co m m is -s i on i ng o f t he 1 M W g e ot he r ma l p il o t p la nti s a s i g n i f i c a n t m i l e s to n e f o r t h e p r o j e cta n d wi t h t h is w e p la n t o s tr e ng t he n o u rf o ot p ri n t i n t h e i n t er n at i o na l m a r ke t s. W ea r e c o m m i tt e d t o r e du c i n g o ur c a r b o nf o ot p ri n t t h r ou g h c l ea n a n d r e n ew a b lee ne rg y g en er a ti on . O ur a i m is t o h a ve2 0- 25 p er c en t of o ur g e ne r at io n p or t-f o li o fr o m c l ea n e n er g y. ” G e ot h er m a le n e r g y i s t h e n a t u ra l h e a t f o u nd w i t h i nt h e e a r t h , w h e r e t e m p e r at u r e i n c r e a s e sw it h d ep th , t yp ic al ly b y 1 0- 50 de gr eeC e ls i u s/ k m. I n E G S t e ch n ol o g y, h e at i sextracted from granites located at ad ep th o f a m or e th an 4 ,0 0 0m b y c i rc u-l at in g w at er t hr ou gh t he m i n a n e ng i-n e e r e d ar t i f i c i al r e s e r v o ir. T h e h e a te dw a t e r r e t u r ns t o t h e s u r fa c e u n d er p r e s -s u r e a n d i s c o n v e r t e d i n t o e l e c tr i c i t y v i aa h e a t e xc h an g er a n d c on v en t io n algeothermal p ower p lant. EGS technologyc a n p o te n ti a l ly e n ab l e t he s e t ti n g u p o fb a s e l o a d p ow e r p l a n t s t ha t a r e b a s e do n n a tu r a l h ea t , t h er e b y m a ki n g t h em ac l e a n e n e r g y s o u r c e f o r t h e fu t u r e .

U S P r e si d en t B a ra c k O ba m a w i ll b eu n ve i l in g a $7 b i ll i o n p l an t o up g ra d e

Ta t a P o w e r a n n o u nc e d t h e s u c c e s s f ulc o m m i s s io n i n g o f a 1 M W g e o t h er m a lp i l ot p l an t i n A u st r a li a , b y G e o dy n am i c s,an associate of Tata Power. Geody namicsi s t he i nd us tr y l ea de r i n e nh anc edgeothermal sy stem (EGS). Geody namicsh a s g e o t h e r ma l e x p l o r a t io n i n t e r e st s i nt h re e A us t r al i a n s t at e s , a n d ho l ds t h el i c e n s e t o e x p lo r e 2 , 0 00 s q k m o f t h eC o op e r B a s in . G e od y na m i cs t e ne m e nt si n t h e C o op e r B a s in c o nt a i n t h e h o tt e stg r a n i t es o n e a r t h a n d a r e es t i m a t ed to

b a u m a A f r ica m a id e n in t e r n at io n a l f a ir a t J o h a n ne s b u rgfrom 18 -21 September

T h e f i r s t ba u m a A f r i ca , I n t e r na t i o n a lTr a de F ai r f or C on st ru ct io n M a ch in -ery, Building Material Machines, MiningMachines and Construction Vehicles,is scheduled to take p lace at Johan-n es bu r g f ro m 1 8 t o 2 1 S e pt e mb er t hi sy e a r. T h e e ve n t wi l l t a ke p l a ce a tG a l l a g h er C o n v en t i o n C e n t r e a n d t heo r g a n i z er s H i g h l in e To u r s & Tr a v e le x p e c t o v e r 5 0 0 e xh i b i t o rs o n 6 0 0 0 0s q m o f e xh ib i ti on s pa ce . E m er g in g

Africa market as well as South Africa'ss t a t u s a s t h e g a t e wa y i n t o A fr i c a , t h a tled to the first bauma Africa event,”s a ys MM I S o ut h A f ri c a C E O E l a in e

C r ew e . T h e e ve n t wi l l h ou s e n in ec ou nt r y p av i li on s fo r 2 00 o f t he k eyinternational exhibitors from Austria,China, Finland, Germany, Great Britain,Italy,Korea,NorthernIrelandandSpain.

C hi na h a s s i g ne d i t s f i r st f re e t r ad e a c co rdw i th S wi t ze r la nd a n o n- EU m em b er o fI c e la n d i n B e i ji n g a m i d e s c al a t in gtensions withthe Europ ean Union.China'sc o m m e r ce m i n i s t e r G a o H u c h en g a n dS w i s s E c o n o m y M i n i s t e r J o h a n n

Schneider-Ammann signed the bilaterala g r e e m e nt i n B e i j i n g. T h e a g re e m e n t i se x p e c te d t o b o o s t tr a d e b e tw e e n t h et w o e c o n om i e s . C h i n a i s t a r ge t i n g t h eEU wi ne i ndustry in r etali ati on for ad is pu te w i t h t he E u r op ea n U ni o n o ve rc h e a p C h i n es e s o l a r p a n e l s.

African p ower networks and ensurep o w e r s u p p ly t o tw o - t h ir d s o f t h e p o p u -l a t i o n t h a t i s w i t h ou t e l e c t ri c i t y. A m e r i c aw i ll f oc us o n p r oj ec ts i n E t hi o pi a , G h an a,K en y a, L i b er i a , N i g er i a a n d Ta n za n iaw h ic h w i l l b e b u il t b y P o we r A f ri c a . T h e

P r e si d en t of A m er i c a w i l l m a k e a nannouncement during his visit to Cap eTo w n . U S E x p o r t- I m p or t B a nk w i l l f u n dm a jo r a mo un t o f $ 5 b i l li o n f or d ev el o p-m en t of p ow er p ro je ct s . A cc or di ng t ot h e I nt e r na t i on a l E n er g y A g e nc y, s u b-S a h a r a n A f r i c a w i l l n ee d i n v e s tm e n t o fm or e t ha n $ 30 0 b il li on t o a ch ie veu n i v e r sa l e l e c t r i c it y a c c e s s b y 2 0 3 0 .




C o n cr e t e: L C A

ChaitanyaRajGoyalChaitanyaRajGoyal

'RETHINKINGCONCRETE':'RETHINKINGCONCRETE':LifeCycleof the IndianConcrete IndustryLifeCycleof the IndianConcrete Industry

ife cycle asse ssme nt (LCA) is

t o d ay ' s s u s t a i na b i l i ty b u z zw o r d,La n d t h e i n d u st r y i s f i l l e d w i th l i v el y

d e b at e a bo u t i ts i m p ac t . A s m an y r a t -

i n g s y s te m s l i k e L E E D, e t c . f i n d t h e i r

p l a c e i n t h e m o v em e n t, i n c r ea s i n g e m -

phasis is place d upon the importance

o f e x a mi n i n g a l l a sp e c t s o f a s t r u c tu r e .

The se include not just the building itself,

b ut t he e mb od ie d e ne rg y o f m at er ia ls ,

the long-term e ffects of manufacturing

p r o ce s s es , t h e s t a g es o f c o n st r u c t io n ,

building pe rformance and ope rations,

d u r ab i l i t y a n d ma i n t en a n c e o f e x i st i n g

s t r uc t u r es , a n d i n t h e e n d - d em o l i ti o n ,

mate rials re cycling, and future land use

corollary.

E ve n t ho ug h, 8 0% o f a b ui l di ng 's

CO2 emissions are generated not by

t h e pr od u ct i on o f m a te ri a ls u s ed i n i t s

c o n st r u c ti o n , b u t i n t h e e l e ct r i c u t i l i t ie s

o ve r i t s l i fe - cy c le , o n e b u il d i ng m at e ri a l,

w hi c h j us t c an no t b e i gn or ed i s C em en t

C o n cr e t e a n d n e i t h er c a n o n e o v e rl o o k

a de v e loping nation which is producing

m or e th an 3 00 m il l io n c ub ic m et er o f i t

p e r a n n u m!

I n d i a n C e m e nt C o n c r e t e I n d u st r y : C u r -

rent times

Concre te witne sse s a production of

1 0 b il l io n t on s e ac h y ea r w or ld wi de .

The total concre te market in India is e sti-

m a t e d at 3 0 0 - 35 0 m i l li o n c u b i c m e t er s

p er a nn um , o f w hi ch t he co mm er ci al

plant produce d share is 55-65 million

c ub ic m et er s. I nd us tr y p la ye rs es ti -

mate that this share is e xpe cte d to go

u p g r a du a l l y f r o m t h e pr e s en t l ev e l o f

l e s s t h a n 9 % of t h e t o t a l c e m en t pr o -

d u ct i on t o t he g lo b al a v er a ge o f 7 0-

7 5% . A co mp ar is on o f c on cr et e p ro -

duction figure s from diffe re nt countrie s

also re v e als that the organize d Indian

c o n c re t e i n du s t ry i s t h e t h ir d l a r g es t

c o n c re t e i n d u st r y i n t h e w o r l d.T h is i n du s tr y o c cu p ie s a n i m po r -

t an t p la ce in t he In di an e co no my

be cause of its strong linkage s to se c-

t o r s s u c h a s c o n st r u c t io n , t r a n sp o r ta -

tion, coal and powe r. The growth of Indian



C em ent

W aterC oncreteadditive

G ravel

R e c y c li n g a s g r a v elreplacem ent

C oncretegranules

LandfillB uilding

c o n s t r uc t i o n =processing

L i fe t i me o fbuilding

D ism antling

R eady-m ixconcrete

C o n c re t e : L C A

49www.masterbuilder.co.in · T h e M a s t e rb u i l de r - J u ly 2 0 1 3

Obv iously, large amounts of e ne rgy

a n d m a te ri a ls , i n a d di t i on t o f i na n ci a l

r e s ou r c es , a r e w a s t e d w h e n s t r u ct u r es

d e t er i o r at e or f a i l p r e ma t u r el y w h i c h, i n

f a ct , h a s b e en t h e c a se w it h s o me r e-

c e nt l y b u il t r ei n fo r ce d c o nc r et e b r id g es ,

buildings and other structure s in India.2. Ce me nt manufacturing - The prin-

c i pa l b in de r i n c on cr et e i s Po rt la ndc em en t, t he p ro du ct io n o f w hi ch i s a

m a jo r c o nt r ib u to r t o g r ee n ho u se g a s

e missions. The popular Portland ce me nt

m i x e s a p o w de r o f a l u m in a , s i l i c a, l i m e ,

i r on o x id e , a n d m a gn e si u m o x i d e, w h ic h

i s t h en h e at e d at t e mp e ra t ur es u p t o

1,450 degrees Celsius.He ating and grinding the ce me nt

m a t er i a l s c on s u m es a n a v e ra g e o f 4 - 5

g i ga j ou l es o f e n er g y p e r c e me nt t o n.

The industry as a whole uses billions of

g i g a jo u l e s e a c h y e a r. C e m en t p r o d u c -tion-through ce me nt plant's fossil-

b a se d e n er g y c o ns u mp t io n , t h e C O2

b u r n ed of f w h e n l i m e st o n e i s h e a t ed ,

ce me nt industry also substantiate s the

growth of country's concrete se ctor.I n di a i s t h e s ec o nd l a rg e st p r od u ce r

o f q ua li t y c em en t i n t he w or ld , a nd i ts

c e m en t i n d u s t ry c o m pr i s es 1 8 3 l a r g e

c em en t p la nt s a nd o ve r 3 65 m in i c em en tp l a n ts . C u r r en t l y, t h e re a r e 40 p l a ye r s

a c r os s th e c ou n t r y a n d th e i nd u s t ry i s

e xpe cte d to add 30-40 million tonnes

p er a nn um ( MT PA ) o f c ap ac it y i n 2 01 3

from the e xisting capacity of 324 MTPA,

ope rating at 75-80 pe r ce nt utilization.T h er ef o re , i n v i ew o f t h e g r ow t h t h at

the concrete sector in India is unde rgo-

i n g , a n d t h e l a r g e sh a r e it c l a i m s in

i n t e rn a t i on a l c on c r et e i n du s t ry, i t i s

impe rativ e that industry le ade rs realize

t he ir a cc ou nt ab il it y t ow ar ds g l ob als u s t ai n a b il i t y c o n c er n s an d i m pr o v e

t h e i r f o c u s on l i f e c y c le o f c o n c re t e m a n-

ufacture d and use d in India.

P r od u ct i on : H o w d o es c o n c re t e f i t i n

t h e b i g p i ct u re ?

S t ep p ed o n f o r h u nd r ed s of y ea r s,

concre te rare ly ge ts the re spe ct it de -

se rv e s. Pe rhaps the most omnipre se nt

b u i l d in g m a t e r ia l , i t s m a n u fa c t u ri n g i s

also among the most e nergy-consuming

and polluting industrial proce sse s and

analysts e xpe ct gre e nhouse gas e mis-sions from global concre te production

to be come a conside rable contributor

to climate change in the ne xt 20 ye ars.E ve n t ho ug h c on cr et e c om pa re s

f a vo ra b ly t o o t he r b u il d in g ma t er i al s

s u c h a s s t ee l , w o od a n d a sp h a l t wh i l e

analyzing e nergy consumption and CO2

e m i ss i o n s bu t w h e n i t c o m e s t o s us -

tainable de v e lopme nt, the re is always

a n o pp or tu ni ty f or i mp ro ve me nt a nd

t h i s is e sp e c i al l y a p p l ic a b l e i n c a s e o f

I n di a . F or a v ar i et y o f r ea s on s , t h e c o n-c r e t e c o n st r u c t io n i n d u st r y i s n ot s u s-

t a in a bl e ; t h e t h re e pr i me r ea s on s

be ing:1 . R e s ou r c e p r o du c t i v it y t h i s i n d u s-

t ry i s t he l ar ge st co ns um er o f v ir gi n

m a te r ia l s s u ch a s s a nd , g r av el , c r us h ed

r o ck , a n d fr es h w at e r. I t i s c on s um i ng

Portland and modifie d Portland ce -

m e n t s a t an a n n ua l r at e of m o r e t h a n a

b i l l i on m e t ri c t o n s. T h e c em e n t p ro d u c -

t i on i n t u rn c o ns u me s v as t a m ou n ts o f

limestone and clay.

C e m e nt P r o d u ct i o n a c c o u nt s f o r n e a r l y 7 % o f g l o b a l g re e n h ou s e g a s e mi s s i o n s

L i f e C y c l e o f C o n c r et e (S ou r ce: BM G E ngi neer i ng)



50 ·T h e M a s t e rb u i l d er - July 2013 www.masterbuilder.co.in

w e en 3 3 % a n d 5 7% o f t h e C O 2 e mi t t e d

f r o m c a l c i na t i o n w i l l be r ea b s or b e d

t hr ou gh c ar bo na ti on o f c on cr et e s u r -

face s ov e r a 100-ye ar life cycle .D e s pi t e a l l s u c h b e n ef i t s , t h e i n d u s -

t r y i n I n d i a i s s t i l l s t ru g g l i ng t o c a p i t a l i zeon the inhe rent and re se arche d be ne -

fits of this amazing mate rial and as dis-

c u ss ed be f or e, e v en t h ou g h c o nc r et e

i s a n e nv ir on me nt al ly f ri en dl y c ho ic e

w i t h o n e o f t h e l o we s t c a rb o n f o o tp r i n t s

among building mate rials, there is always

s c o pe f o r g r o wt h w h e n i t c o m e s to c o n -

se rv ing the e nv ironme nt and pre v e nt-

ing adv e rse climatic change s!

F r om p r od u ct i on t o d e mo l it i on : D o i ng

it better

A sustainable concre te structure is

one that is constructe d so that the total

socie tal impact during its e ntire life

cycle is minimal and the re fore, the life -

cycle cost analysis proce ss must e v al-

uate e ne rgy use and e nv ironme ntal im-

pact during the e ntire life of concre te .

This proce ss must include e xtracting

a n d p r o ce s s in g r a w m a t er i a l s, m a n u -

f a c t ur i n g , t r a n sp o r t in g , m a i n ta i n i ng , r e -

c y c l i ng , a n d r e t ur n i n g t o t h e e n vi r o n -

me nt. Costs and be nefits must be e v al-

u a t ed a n d u n d e r s to o d i n b o t h t h e s h o rt

te rm and the long te rm.

It doe s not take a ge nius to unde r-

stand that a large -scale me chanization

f o r p r od u ct i on o f e ng i ne er e d c o n c re t e

with mine ral and che mical admixture s,

w i th t h e r ig h t q u al i t y c o nt r ol s c h em e,

c a n l e ad t o b e tt e r s u st a in a bi l i ty o f c o n-

c r e t e i n I n d i a. T h e re a re so m e w o r th y

solutions which if comprehensively, stric-

t l y, s k i l lf u l l y a n d et h i c a ll y i m p l em e n te d ,

c an h el p t he i nd ust ry a ct ual ly ' do it

be tte r'!

Industrial ecology - achieving impro-

v em e nt i n r e so u rc e p r od u ct i vi t y t h ro u gh

d u r a bi l i t y e n h an c e m en t o f p r o d uc t s i s ,

o f c o ur s e, a l o n g -t e rm s o l u ti o n f o r s u s-

t a i n ab l e d e v el o p me n t . A sh o r t- t e r m

strate gy that must be pursue d simulta-

n e o us l y i s t o p r a c t ic e i n d u s tr i a l e c ol -

o g y a t a l a rg e r s c al e t h an i s th e c a se

t o da y. S i mp l y d e fi n ed , t h e p r ac t ic e of

i n d u st r i a l e c o l og y b y a ma n u f ac t u r i ng

i n d u st r y i n v o lv e s t h e r e c l am a t i on a n d

C em en t - 5 m m

Si li ca F ume - 5 mm

F ly A sh - 1 2 mm

U lt ra -F in e F ly A sh - 5 m m

a s s oc i a t ed v e h ic l e u s e , a n d o t h er f a c -

t or s a cc ou nt fo r n ea rl y 7 % o f g lo ba l

anthropoge nic gre e nhouse gas e mis-

s i o ns . O t h e r p a r t s of t h e m a n uf a c t u ri n g

p r oc e ss s u c h a s o pe r at i ng m i n in g

e q u i pm e n t f o r e x t r ac t i n g t h e r a w m a t e-r i a l s a n d t r an s p or t a t i on o f t h e r a w m a t e-

rials to the ce me nt plant e mit re lativ e ly

small amounts of CO2.

3 . D u r a bi l i t y - M a n y c o n c re t e s t r u c-

t ur es s u ff er f ro m l ac k o f d ur ab il i ty,

w hi ch h as an a dv er se ef fe ct on t he

r e s ou r c e p ro d u c ti v i t y o f t h e i n du s t r y. I n

I n d i a, m o st c o n c r et e i s p r o du c e d b y

conv e ntional methods inste ad of using

late st me thods and e quipme nt at most

o f t h e c on s t r uc t i o n s i t e s a n d t h es e r e-

sults in:- I na de qu at e c on tr ol o n a gg re ga te s

f o r s i z e, s h a p e a nd g r a d i n g- O pt i mu m Wa te r- ce me nt r at io n ot

followed- L ab or- in te ns iv e pr od uc ti on

- T im e co ns um in g an d un or ga ni ze d

ope ration- W as ta ge o f c o st ly i np ut m at er ia ls- Dust pollution

Each of the se shortcoming's re sults

i n to a l i fe cy c le im p li c at i on i n s om e

f o rm a nd t he y t a ke a ma j or t o ll o n t h e

d ur ab il i ty o f c on cr et e. P re va le nt c or -

r u pt i on a n d u n et h ic a l p r ac t i ce s i n t h e

I n di a n c o ns t ru c ti o n i n du s tr y a l so c o n-

tribute imme nsely to this cause .

Benefits of Concrete: Time to capitalize

Concre te also brings nume rous

l a s t in g b e n e fi t s t h a t m a n y b e l i ev e f a r

o u tw ei g h t h e fr o nt - en d e ne rg y p r ob -

le ms associate d with it. This is be cause

l o c a ll y a v a i la b l e m a t er i a l s f o r p r o d uc -

t i on m e an l e ss t r a n sp o rt a ti o n a n d p o l-

l u t i on , a n d i t al s o o f f er s h i g h t h e rm a l

m a s s, c o n t ri b u t i ng t o e n e r g y e f f ic i e n cy

and comfort. Most concre te structures

t o da y a r e de si g ne d f or a 1 00 - ye a r l i fe

s p a n w h i c h i n c r ea s es t he pe r i od b et -

w ee n r ec o ns t ru c ti o n, r ep a ir a n d m a in -te nance . Also, the mate rial's light color can

prov ide re fle ctiv ity that reduce s air con-

ditioning loads and he lps re duce the

urban he atisland e ffect. Moreov er, whe n

a concre te structure is de molishe d,

m u ch o f t h e ma t er i al c a n b e re c yc l ed .

F ur t he r mo r e, a si g ni f ic a nt p or t io n o f

the CO2 produce d during manufactur-

ing of ce me nt is re absorbed into con-

cre te during the product life cycle

through a proce ss calle d carbonation.

One re se arch study e stimate s that bet-

M a n y m i n e r al a d m i x tu r e s c a n b e u s e d t o pa r t i a ll y r e p l ac e c e m en t i n c o n c r et e





r e - u se o f i t s o wn w a s te p r od u c t s a n d ,

t o t h e e x t en t p o s si b l e , t h e w as t e p r od -

ucts of othe r industries, which are unable

t o re c yc l e t h em i n t h ei r o wn m a nu f ac -

turing proce ss.

R e p or t e dl y, o v er a b i l l i on t o n o f c o n -s t r u ct i o n a n d d e mo l i t io n w a s te i s g en -

e r a te d e v e r y y e a r. C o s t- e f fe c t i ve t e c h -

nologie s are av ailable to re cycle most

o f t h e w a st e a s a p a r t i a l r ep l a c em e n t

f o r t h e c oa r se a g g re g at e i n f r es h c o n-

cre te mixture s. Similarly, industrial waste

wate rs and non-potable wate rs can

s u bs t it u te f or m u ni c ip a l wa t er f o r m i x-

ing concre te unle ss prov e n harmful by

te sting. Ble nde d Portland ce me nts con-

t a in i ng f l y a sh f r om c o al - fi r ed p o we r

p l an t s, s i li c a f u me s, a n d g r ou n d- g ra -nulate d slag from the blast-furnace iron

industry prov ide e xce lle nt e xample s of

i n d u st r i a l e c o lo g y b e c au s e t h e y o f f er a

h o li s ti c s ol u ti o n f o r r e du c in g th e en vi -

ronme ntal impact of se v e ral industrie s.T h e c o ns t ru c ti o n i n du s tr y a l re a dy

use s concre te mixture s containing

c e m en t r e p l ac e m en t m a t er i a l s, s u c h

a s 1 5% t o 3 0% f ly a s h o r 3 0 % t o 40 %

s l a g b y m a s s. W i t h c o n ve n t i on a l m a t e-

elasticity, shrinkage, creep, etc. are hardly

spe cifie d.It must be re alize d that today con-

c r e t e is n o l o n ge r a m e r e mi x t u r e of

ce me nt, aggre gate s and wate r. Now-a-

days, concre te produce d from re ady-m i x e d c o n c re t e f a c i l it y i n c o rp o r at e s

m o re t h an o n e v a ri e ty o f m i ne ra l a n d

c h e mi c a l a d m i xt u r e s a nd w i t h t h e i r u s e

t h e d e si g n i ng o f c o n c re t e m i xe s h a s

b e co me m o re c o mp l ex . T h is i s b e ca u se

the use of diffe re nt admixture s affects

m o s t of t h e p ro p e rt i e s of c o n c re t e i n i t s

f re sh a nd h a rd en ed s ta te s, s uc h a s

w or k ab i li t y a n d w or k ab i li t y r et e nt i on ,

c om pa ti bi li ty b et we en c em en t an d

supe rplasticize r, compre ssiv e stre ngth

d e v el o p m en t , l a t er a g e s t r en g t h s, s e t -t i n g t i m e , r e s is t a nc e to i ng r e ss of

aggre ssiv e che micals, e tc.The re fore, it is difficult to write pre -

scriptiv e spe cifications that e ncom-

p a s s t h e se d ev e l op m e nt s . F u r th e r, i n

re ce nt ye ars, it has be e n obse rv ed that

m a n y s t r u ct u r es c on s t ru c t e d s t r i ct l y

following pre scriptiv e spe cifications

h a v e n e ce s sa r i l y n o t p e r fo r m ed w e l l ,

e s p ec i a l l y w i t h r e g ar d s t o th e i r d u r a bi l -

r i a l s a n d t ec h n o lo g y ; i t i s n o w p o s si b l e

to produce high-pe rformance concre te

mixture s containing 50% to 60% fly ash

b y m a s s o f t h e b l e n de d c e m en t i t i ou s

mate rial.

Also, the ce me nt industry can re -d u c e i t s ow n w a st e b y r e c yc l i n g mo r e

t ha n 7 5 p er ce nt o f c em en t k il n d us t

(CKD) dire ctly back into the ce me nt kiln

a s r a w m a t er i a l . B y d o i n g s o , m a n u fa c -

ture rs can conse rv e e ne rgy and re duce

t h e u se o f l i me st o ne a n d o th e r v i rg i n

r a w m a t er i a l s.P 2 P I n it i at i ve ( P re s cr i pt i ve t o P e r-

formance Specifications for Concrete)-

a l th o ug h t h e us e of m o de rn p l an t a nd

e q u i pm e n t i n t h e p r o du c t i o n, d e l i ve r y

a n d pl a c e me n t of c o n c re t e h a s in -c r e as e d i n I n d i a, t h i s ha s n o t ma t c h ed

improv e me nt in the concre te spe cifica-

t i on s . O n a m a j or i ty o f t h e c on s tr u ct i on

jobs, concre te is still spe cifie d by its 28-

d a y c o m p re s s iv e s t r en g t h a n d s l u mp

a t p ou r l oc at io n. A m en ti on i s a ls o m ad e

r e g ar d i n g t h e u se o f p u m p o r o t h er w i se

d u ri n g p l ac e me nt . O t he r m e ch a ni c al

p r o pe r t i es o f c o n c re t e , n a m el y, f l e x ur a l

s t r en g t h , t e n si l e s t r en g t h , m o d u lu s o f

R M C c a n d e l i ve r h i g h q u a l i ty , d u r a b le a n d g r e e n c o n c r et e




i t y. T h e re i s t h u s an u r g en t n e ed t o f o r a

change in spe cifications from pre scrip-

tiv e to pe rformance .Pe rformance spe cifications pro-

v ide concre te produce rs more fle xibil-

i t y t o o p t i mi z e c o n cr e t e m ix t u r es f o r i n -te nde d pe rformance and thus re duce

t h e e n v ir o n me n t a l i m p a ct , i n c l u di n g

CO2 e missions. Traditionally, construc-

t i on s p ec i fi c at i on s f or c o nc r et e h av e

r e q ui r e d un n e ce s s ar i l y h i g h q u a n ti t i e s

o f P o rt l a n d c e me n t a l o n g w it h o t h er l i m -

i ts o n t he u se o f s up pl em en ta ry c e-

m e n ti t i o us m a t e r i a ls . T h e se l i m i t s a r e

i n c o rp o r at e d i n t h e i n d u st r y ' s s t a n -

d a r d s a n d s pe c i f ic a t i on s . T h e P2 P I n i -

tiativ e propose s to e liminate many of

t h es e l i mi t s a n d e vo l ve t o p er f or m an c e-base d standards.A d op t in g R e ad y M ix C o nc r et e - it

w o u ld n ' t b e w r on g t o s a y t h a t q u a li t y

a n d d ur a b i li t y a l w a ys t a k e t h e ba c k

s ea t i n I nd ia n c on st ru ct io n i nd us tr y

along with e co frie ndly and e thical prac-

t i c e s. T h i s i s s ub s t an t i a t ed b y t h e fa c t

t h a t i n I n d i a, t h e ca p t i ve c on s u mp t i o n

o f c e m en t t hr o u gh R M C i s j us t h ov e r -

i n g a r ou n d 7 - 8% o f t h e t o ta l c e m en t

p r o du c e d . T h e c a p a c i ty u t i l i za t i o ns a r e

i n t h e ra n ge o f j u st 3 0 -4 5% , i n di c at i ng

s e ve r e u n d e r ut i l i z at i o n ; t h e o p e r a t in g

m a r gi n s ar e i n t h e ra n g e o f 4 - 6 % a n d

the ROCE for most ce me nt companie s

in RMC busine ss is ne gativ e . All this is probably be cause the cost

o f R MC is 20 % h ig he r t ha n t ha t p ro -

duce d at site by mixing machine s and

1 2 % h i g h er t h a n t h a t p r o d uc e d at s i te

b y l ar ge B at ch in g Pl an ts . B ut w ha t

m an y f ai l t o u nd er st an d i s t ha t w it h R MC

one can achie v e almost 15.5% sav ings

i n c o n st r u c ti o n c o s ts in t e r ms o f f a c t or s

s u ch a s q u al i ty & w a st a ge - av oi d an c e

a n d t he c l a im e d se r v ic e l i fe o f 1 0 0

ye ars can actually be e stablishe d.

F u r th e r mo r e , e v en t h o u gh t h e r e is as e p ar a t e c od e o n r e a dy - m ix e d c o n-

c r e t e ( I S 4 9 26 : 2 00 3 ) , i t i s u n f o rt u n a te

t ha t c og ni za nc e o f t hi s c od e i s n ot t ak en

i n many contracts. Ev en when using

R M C, o n m a ny o c ca s io n s, r e fe r en c e i s

m a de t o on l y I S 4 56 , t h e BI S s p ec i fi c a-

t i o n o n p l a i n a n d r e i n fo r c ed c o n c r et e .T h e q u al i ty c o nt r ol pr o ce s s i n I S

4926:2003 has be e n div ide d into thre e

c o mp o ne n ts , “ f or w ar d Co n tr ol ” , “ I m-

m e d i at e C o n t ro l ” a n d “ R e t ro s p ec t i v e

C o n tr o l ' a n d t h e r e f or e , p r e pa r e s I n d i a n

RMC manufacture rs for producing and

s u p p ly i n g b e st q u a l i t y g r e en a n d d u r a -

b l e c o nc r e t e us i n g a va r i e ty o f m i n e ra l

and che mical admixture s.

Conclusion

Mate rial scie nce has a lot of pote n-

tial to re v olutionize the te chnological

sce nario in v arious walks of life towards

c o s t- e f fe c t i ve n e ss a n d q u a l i ty i m p r o-

v e m en t . To d a y C o n cr e t e t e c h no l o gy i s

re v olutionize d globally, but India has to

y e t t o c a t c h u p w i t h t h e a dv a n c em e n ts .

T h e k ey i s i n t h e h a nd s o f p r o fe s s io n a l s

and builde rs and one ne e d to use the

k e y t o r ea c h a n d av a i l t h e tr e a su r e ofdurability.

To achie v e the obje ctiv e of incorpo-

rating sustainability will be a he rcule an

t a s k. To s t a r t w i t h , r e a so n a bl y a c c u ra t e

d a t a is r e qu i r ed , w h i c h i s w oe f u l ly l a c k -

i n g a n d r e li a bl e in f or m at i on o n r u di -

me ntary data like the total concre te pro-

d u ct i on i s d i ff i cu l t t o o b ta i n. T h e c e me n t

i nd us tr y a ls o n ee ds t o p la y a c ri ti ca l r ol e

in he lping attain the de sire d targe ts.

Indian ce me nt manufacture rs ne e d

t o i m p r ov e t h e e n e rg y e f f i ci e n c y o f t h e

e n t i r e m a n u f a c t u r i n g p r o c e s s b y

u p g r ad i n g p l a n t s w i t h s t a t e- o f- t h e - ar t

e quipme nt and should improv e prod-

u c t f o r mu l a t i on t o r e d u ce e n e r gy o f p r o -

d u c t i on a n d m i n i mi z e t h e u s e o f n a t u ra l

r e s ou r c es . A l s o, m o r e r e s ea r c h n e ed s

to be conducte d on ce me nt and con-

c r e t e t ow a r ds i m p r o vi n g t h e i r e n e rg y

e fficie ncy and durability.

It is to be e xpe cte d that rating sys-

t e ms s u c h a s t h e L EE D ( L ea d er sh i p i n

Ene rgy and Env ironme ntal Design) sys-

te m and ECBC (Ene rgy Conse rv ationBuilding Code ) will be come the norm in

n e ar f u tu r e, a n d m a te ri a l s u pp l ie r s s u ch

as concre te produce rs will be pre sse d

t o co m pe t e o n t h e b a si s of e n vi r on -

m en ta ll y f ri en dl y p ri nc ip le s, t ha t i s,

r ed u ce d e n er g y c o ns u mp t io n , r e du c ed

life -cycle costs, and the use of re cycle d

m a te ri a ls . T h er e i s re a so n t o b el i ev e

that the concre te industry is we ll posi-

t i o n ed f o r s u c c es s , g i v en t h e t oo l s ou t -

line d he re in.W i t h R M C o n e ca n a c h i ev e a l m o st 1 5 . 5 % s a v i n gs i n c o n s t ru c t i on c o s t s





56 The Masterbuilder - July 2013 • www.masterbuilder.co.in

New Concrete Technology inConstruction Aggregates - Their Role in

Concrete and the ‘Green Agenda’Christopher Andrew ClearBritish Ready-Mixed Concrete Association

Sustainability

For a concrete technologist the term ‘Green Agenda’ is a rathermore difficult concept to understand than either ‘Aggregates’

or ‘Concrete’. Having said this it is the authors opinion there is

a degree of ambiguity associated with all three terms. This

paper sets out what ought to be considered important to

consider with respect to sustainable construction and a brief

consideration of how aggregates and concrete support such

an initiative.

The Green Agenda

A problem with the green agenda is that it is often not presented

as a list of important environmental, social and economic

considerations but as a banner around which those affectedby some form of change to their environment gather to resist

the change.

However, with respect to building construction the position

is changing as a comprehensive technical description of the

green agenda is being set out across a set of International and

European Standards. EN 15643-1[1] entitled ‘Sustainability of

construction works — Sustainability assessment of buildings

— Part 1: General framework’. This European Standard forms

part of a suite of the European Standards that set out a system

for the sustainability assessment of buildings using a life cycle

approach. The sustainability assessment is quantified to

assess the environmental, social and economic performance

of buildings using quantitative and qualitative indicators but

benchmarks or levels of performance are not set. It should be

noted that currently it is only buildings that are covered by the

EN 15643-1 framework, but there are proposals for standards

to cover the sustainability assessment of civil engineering and

other construction works.

In carrying out assessments, scenarios and a functional

equivalent are determined at the building level. This level means

that the descriptive model of the building with the major

technical and functional requirements has to be been defined Figure 1: EN 15643 concept of sustainability assessment of buildings

Sustainability of construction works is such an important topic that it should not be discussed by rather imprecise and emotiveterms such as ‘The Green Agenda’. Therefore this paper deals with the sustainability assessment of building with respect to their

environmental, social and economic performance before briefly covering how concrete and its aggregate constituent play a part insustainable construction.

in the client’s brief or in the regulations as illustrated in Figure1, abstracted from EN 15643-1.

EN 15643 Part 1 is the general framework, and Parts 2[2], 3[3]

and 4[4] the individual frameworks for environmental, social

and economic performance respectively. All four parts contain

a version of Figure 1, and in their draft stages the ‘Environmental’

box was coloured green, the ‘Social’ box coloured red and the

‘Economic’ box coloured blue. The use of colour in what might

otherwise be considered rather dull documents such as

standards is to be applauded, however it is unfortunate that in

this case it reinforces the misconception that ‘The Green Agenda’

is concerned only with Environmental issues, whereas it

should encompass Social and Economic issues as well.

In Figure 1 the boxes within the thick red dashed box are

those covered by the European Technical Committee entitled

‘Sustainability of construction works’, CEN/TC 350. As the

EN 15643 standards state when describing the integrated

building performance at the concept level, the environmental,

social and economic performance are one part, and the

technical and functional performance are another. Both parts

are intrinsically related to each other as shown in Figure 2,



www.masterbuilder.co.in • The Masterbuilder - July 2013 57

where the CEN/TC 350 work programme is represented by

the boxes shaded grey as set out in EN 15643-1.

Sustainability assessments can be undertaken for the whole

building, for parts of the building which can be used separately,

or for elements of the building. This is in a complete contrast to

some simplified interpretations of the ‘Green Agenda’ which

may largely restrict consideration to just the environmental

impacts of the various building products from which the building

is made.

15643-4 for Economic performance. The indicators included

in EN 15643 Parts 2 to 4 are summarized in Table 1. It should

be noted that the items in the middle column come from a

pre-Standard dated 2010, and the final lists within EN 15643

parts 2 and 4 changed significantly from the equivalent listings

in their pre-Standards.

Although the evaluation of technical and functional performance

is beyond the scope of CEN/TC350 standards, the technical

and functional characteristics are considered by reference

to the functional equivalent. The functional equivalent of a

building or an assembled system (part of works) shall include,

but is not limited to, information on:

- Building type (e.g. office, factory, school)

- Pattern of use (e.g. occupancy)

- Relevant technical and functional requirements (e.g.

regulatory framework and client’s specific requirements);

- required service life

There is an explicit requirement that the assessments shall be

established on the basis of specified realistic scenarios thatrepresent the whole building life cycle.

To ensure the results of the assessment of environmental,

social and economic performance can be readily understood

they need to be presented in a systematic and transparent

method, where Figure 3 shows the groups of information

required.

The standard EN 15643-1 makes it explicitly clear that tin the

assessment report the results shall be expressed with all the

defined indicators set out in EN 15643-2 for Environmental

performance, EN 15643-3 for Social performance and EN

Figure 3: The organisation of the result of the assessment in accordance with

EN 15643-1 life-cycle stages and the information groups

Table 1 is not a complete list as and EN 15643-2 includes a

list of further environmental indicators, and these are listed in

Table 2.

The detailed calculation method for the environmental

performance of buildings using the environmental indicators

set out in EN 15643-2, is set out in EN 159785 entitled

‘Sustainability of construction works — Assessment of the

environmental performance of buildings — Calculationmethod.’ This standard sets out a methodology on how to

calculate and most importantly how to display the modular

information for the different stages of building assessment.

Figure 4 shows the general format for the output where for

each stage A1, A2, A3, B1… there will be a number required

for each of the environmental impacts as listed in column 1 of

Table 1, and those in Table 2 where appropriate. The natural

extension is to list the social and economic impacts as well but

the Standards for these have yet to be drafted. It is important

to remember that the eventual Table of results is for the whole

building for its whole life, so a scenario has to be developed to

cover the construction, use and end of life stages.On the specific challenge with respect to Global Warming

Potential impact (measured by CO2

equivalent) the concrete

options to meet the demand for low-energy housing specific

research was commissioned and reported6. Figure 5 shows an

example of the results where the cumulative CO2

emissions,

embodied and operational, have been modelled for a 60 year

period for both lightweight (timber) and medium weight (block

work walls) simple semi-detached house. Due to predicted

increase in summer temperatures resulting from climate change,

the lightweight house needs air conditioning by 2021, whereas

for a medium weight home it would not be needed until 2041.

Sustainability

Figure 2: Work programme of European Technical Committee CEN/TC 350

Sustainability of construction works




A typical concrete and masonry house with a medium level

of thermal mass has about 4% more embodied CO2

than a

lightweight house, but this could be offset in as little as 11

years due to energy savings provided by its thermal mass.

The simple semi-detached house is the sort of scenario

required for the EN 15978 analysis, but for a complete EN

15978 analysis then a further 20 environmental impacts should

be considered in addition to the single Global Warming

Potential shown in Figure 5. The EN 15978 standard is clear that

the communication of results may be limited to a selection of

indicators, and so the use of a single indicator is within scope

and the standards notes that the graphical representation

of results like that shown in Figure 5 may be useful to com-

municate results. It is also evident that trying to carry out an

assessment to encompass all or even just a majority of the

indicators may be an overly cumbersome exercise and so a

client may wish to restrict the range to those considered of

greatest importance.

What the EN 15643 series of standards clear state is that the

‘The results of possible further aggregation of these indicators

shall be clearly separated from the assessment results as

additional information’. This is an important facet as it is

evident that where environmental indicators are normalised

and/or weighted it is possible to present the assessment

results in a way that appears to represent the just the bias

Environmental indicators EN 15643-2: 2011Annex B.1 (informative)

Categories for social aspects prEN 15643:2010

Economic Indicators EN 15643: 2012Annex C (informative)

environmental impacts (LCIA impact categories)- abiotic depletion potential

(elements and fossil fuels)

- acidification of land and water resources- destruction of the stratospheric ozone layer

- eutrophication — formation of ground-level

ozone

- global warming potential

resource use (environmental aspects)- use of non-renewable primary energy excluding

non-renewable primary energy resources used

as raw materials

- use of renewable primary energy excluding

renewable primary energy resources used as raw

materials

- use of non-renewable primary energy resources

used as raw materials

- use of renewable primary energy resources usedas raw materials

- use of secondary materials

- use of non-renewable secondary fuels

- use of renewable secondary fuels

- use of freshwater resources

other environmental information (environmen-tal aspects)- components for reuse

- materials for recycling

- materials for energy recovery

- non-hazardous waste to disposal

- hazardous waste to disposal (other than radioac-

tive waste)

- radioactive waste to disposal

- exported energy

Health and comfort- Thermal performance

- Humidity

- Quality of water for use in buildings- Indoor air quality

- Acoustic performance

- Visual comfort

Accessibility- Accessibility for people with specific needs

Maintenance- Maintenance requirement

Safety/security- Resistance to climate change

- Fire safety

- Security against intruders and vandalism

- Security against interruptions of utility supply

Loadings on the neighbourhood

- Noise- Emissions

- Glare

- Shock/vibrations

Cost- economic performance expressed in cost terms

over the life-cycle Financial value

- economic performance expressed in terms offinancial value over the lifecycle

Table 1. Indicators listed in EN 15643-2 for Environmental performance, prEN 15643-3 for Social performance and EN 15643-4 for Economic performance

Further Environmental indicators EN 15643-2: 2011 Annex B.2 (informative)

environmental impacts (LCIA impact categories)— biodiversity

— ecotoxicity

— human toxicity

— land use change

resource use (environmental aspects)— use of non-renewable resources other than primary energy

— use of renewable resources other than primary energy

other environmental information (environmental aspects)— use of environmentally sustainably managed materials (grouped per ma-

terial type e.g. PEFC, FSC, responsibly sourced materials BS 8902:2009)

— use of environmentally sustainably managed fuels (grouped per fuel

type e.g. Sustainability criteria for bio-fuels ISO 13065)

Table 2. Further indicators listed in EN 15643-2 for Environmental performance

Sustainability




of those responsible for the manipulation system. Figure 6

below shows the results of a particular ‘E-points’ system as

applied to a tonne of coarse aggregate and a tonne of CEM

I (Portland cement), where the higher the E-points the less

environmentally desirable is the material.

Unfortunately, many clients want to be seen to be complying

with a green agenda and as all the tools and expertise to carry

out a comprehensive sustainability assessment are not readily

available the temptation is to go down a simplified route.

Such a simplified route, like those based on an E-points type

system, can give arguable results. For example we know that

the cement represents a global warming potential equivalent

to about 850 kg of CO2e/tonne[7], and that such emissions

considering world production of over 3,300,000,000 tonnes

of cement a year is generally considered to have a negative

impact on the environment. According to the E-point system

the extraction and use of one tonne of coarse aggregate in

concrete is about as half environmentally damaging as the

production and use of one tonne of cement, or say two

tonnes of coarse aggregate is equivalent to the environmental

impact of a tonne of cement. This cannot be sensible as a

tonne of cement will initially put about 850 kg of CO2e into

the atmosphere whilst even if the two tonnes of coarse

aggregate is used to make concrete it is still available. That is

the aggregate is still aggregate through the service life of the

building but also be an aggregate in a subsequent life where

as part of recycled concrete it is likely to be used either as an

unbound or bound aggregate application.

The important conclusion is that the term ‘Green agenda’ isthe wrong term and its use should be deprecated. Indeed

‘Green Agenda’ is often regarded as synonymous with

‘Environmentally friendly’ and even this is the wrong term. The

correct term to use is ‘Sustainability of construction works’

and until the necessary standards are developed for civil

engineering works the more appropriate term is ‘Sustainability

Figure 4: Display of modular information for the different stages of building

assessment in accordance with EN 15978: 2011

Figure 5: Cumulative Global Warming Potential, CO2 emissions

(air-conditioned)

assessment of buildings’ in accordance with the EN 15643

series and supporting standards.

Aggregate

There is a suspicion that as far as a large number of Engineers

are concerned aggregates for concrete are natural aggregates,

and should be in accordance with BS 882: 1992[9] entitled

‘Specification for aggregates from natural sources for concrete’.

To these engineers it may be a bit of a shock that BS 882 was

withdrawn on 1 June 2004, when it was replaced by EN 12620

‘Aggregates for Concrete’ which was first published in 2002

but was subsequently amended in 2008[10]. To the EuropeanStandard aggregate is ‘granular material used in construction.

Aggregate may be natural, manufactured or re-cycled’ where it

is evident that the widest range of usable materials is included.

This type of standard supports sustainable construction as

it means that any suitable materials can be used to make

concrete, but it is up to the specifier to ensure that the correct

aggregate and concrete properties are specified to suit a

particular application.

In the past it may have been considered reasonable to specify

a high performance natural gravel or crushed rock for even the

lowest grades or performance concrete classes, and where

environmentally, socially and economically a high performance

natural aggregate can be justified then that is perfectly

acceptable. However, it should be equally acceptable that where

there is a technically sound but lower grade of aggregate

available to make a particular concrete then this will normally

be the more sustainable option. If nothing else it would help

preserve the resources of higher quality aggregates for more

demanding concrete performances or other applications.

Sometimes it may be possible to use Recycled Concrete

Aggregate (RCA) or Recycled Aggregate (RA) providing the

source and quality meet all the necessary limits with respect

Sustainability




Sustainability

to particular impurities and other materials that may be

deleterious to concrete performance. Recycled aggregates

are produced in conformity with the ‘Quality Protocol for

aggregates produced from inert waste’[11] where the material

produced must also conform to EN 12620. To help ensure that

aggregate for concrete is specified in the most appropriate

manner guidance is available as BSI Published Document

PD 6682-1[12] entitled ‘Aggregates – Part 1: Aggregates for

concrete – Guidance on the use of BS EN 12620.’

Concrete

The European Concrete Standard, EN 206-1[13], and its

complementary UK counterpart, BS 8500[14], are increasinglybeing made more flexible, and hence supportive of sustainable

construction. The general concept will be that general suitability

is established at European level for; natural normal weight

aggregates, heavy-weight aggregates and air-cooled blast

furnace slag conforming to EN 12620 as well as lightweight

aggregates conforming to EN 13055[15] and aggregates

reclaimed by the concrete producer. In addition at National

level recycled and manufactured aggregates with an identified

history of use may be used as aggregate for concrete if the

suitability is established. In summary sustainable construction

is supported by widening the range of materials deemed

suitable for use in concrete, but the specifier may have to givesome additional consideration to ensure that the materials

specified are suitable for a particular application.

Conclusions

Sustainability is an issue of increasing importance to everyone,

and sustainable construction is of particular importance to

all those involved in the construction industry. Sustainable

construction is not well served by the use of ill-defined jingoistic

terms like ‘green-agenda’ and it use of this term should be

deprecated by the construction industry and its suppliers.

Concrete and aggregates have a role to play in sustainable

construction, but the sustainability assessment needs to be in

environmental, social and economic terms at the building level.

Acknowledgements

The author is grateful for all the input received from members

of the British Ready-Mixed Concrete Association as well his

colleagues and members of the Mineral Products Association.

References

1 British Standards Institution. BS EN 15643-1:2010 Sustainability ofconstruction works. Sustainability assessment of buildings. Part 1

General framework. BSI, London, 25 pp.

2 British Standards Institution. BS EN 15643-2:2011 Sustainability ofconstruction works. Sustainability assessment of buildings. Part2 Framework for the assessment of environmental performance.

BSI, London, 32 pp.

3 British Standards Institution. BS EN 15643-3:2012 Sustainability

of construction works. Sustainability assessment of buildings.Part 3 Framework for the assessment of social performance. BSI,

London, 25 pp.

4 British Standards Institution. BS EN 15643-4:2012 Sustainability ofconstruction works. Sustainability assessment of buildings. Part4 Framework for the assessment of economic performance. BSI,

London, 36 pp.

5 British Standards Institution. BS EN 15978: 2011. Sustainability ofconstruction works — Assessment of the environmental performanceof buildings — Calculation method. BSI, London, 60 pp.

6 HACKER, J. ET AL. Embodied and operational carbon dioxideemissions from housing: A case study on the effect of thermalmass and climate change. Energy and Buildings 40. 2008.

7 Mineral Products Association, Cementitious Slag Makers Association, UK Quality Ash Association. Fact Sheet 18. EmbodiedCO2e of UK cement, additions and cementitious material.Camberley, Undated but published 2012. 8 pp.

8 World Business Council for Sustainable Development. Cement

Sustainability Initiative Progress Report, June 2012. Geneva. 6 pp.

9 British Standards Institution. BS 882: 1992. Specification foraggregates from natural sources for concrete. BSI, London, 14 pp.

10 British Standards Institution. BS EN 12620: 2002+A1:2008. Aggregates for concrete. BSI, London. 56 pp.

11 Waste Resources Action Plan. Quality protocol for the production

of aggregates from inert waste, September 2005. 12 pp.

12 British Standards Institution. PD 6682-1: 2009 Aggregates – Part 1:

Aggregates for concrete – Guidance on the use of BS EN 12620.BSI London, 28 pp.

13 British Standards Institution. EN 206-1:2000. Concrete — Part 1:Specification, performance, production and conformity. March2006. BSI, London. 69 pp.

14 British Standards Institution. BS 8500: 2006+A1: 2012. Concrete

— Complementary British Standard to BS EN 206-1 – Part 1:Method for specifying and guidance for the specifier. Part 2Specification for constituent materials and concrete. BSI, London.59 & 44 pp.

15 British Standards Institution. BS EN 13055-1: 2002. Lightweightaggregates — Part 1: Lightweight aggregates for concrete mortarand grout BSI, London. 40 pp.

Figure 6: E-points for coarse aggregate and CEM I showing contribution for

mineral resource extraction and climate change (Global Warming Potential)



C o m mu n i c a ti o n F e at u r e


Contr ol Mix

Micr osilica

C e n t ri l i t N C

1 d ay

2 8 d a ys

+ 33%

+ 30%

S t re n gt h D e v e lo p me n t o f C e nt r il i t N C

e ntrilit NC (nano-crystallize r) isa p o z z ol a n i c c o n c re t e a d d i ti v eb a s ed o n a m o rp h o u s a l u m o-C

silicate . It conce rns a synthe tically man-u f a c tu r e d m a t er i a l , n o t a n i n d u st r i a l b y -p r o d uc t . A p a r t f r o m a h i g h u n i f or m i t y, a

long-te rm av ailability is also e nsured.New generation materials like Centrilit

NC base d on spe cial nano-crystallize rsh a ve b ee n r e ce n tl y d e ve l op e d. T h es en e w m a t er i a l s i m p ro v e t h e p r o p er t i e s

t h a t a re c r u ci a l f o r t h e d u ra b i l it y o f h i g h -

p er fo rm an ce c on cr et e. I n a dd it i on t or e d u ci n g c h l o ri d e m i g ra t i o n, a n e x c ep -

tional che mical and acid re sistance ofthe high-pe rformance concre te can be

a c hi e ve d w i th C en t ri l i t N C . T h e c o nc r et es t r u ct u r e i s s i m u lt a n eo u s ly r e i nf o r c edr ig ht do wn t o N an o s ca le , d en si ty i s

i m pr ov e d a n d c o mp r es s iv e a n d f l ex u ra ls t r en g t h a s w e l l a s a b r a s io n r e s is t a n ceof the high-pe rformance concre te is in-

creased.T h e un i q u e pr o p er t i e s o f C e n tr i l i t

N C c an b e u ti l i s ed i n a l l a re a s o f r e a dy -made and pre -cast concre te produc-t i on t h at n e e d h i gh d u ra b il i ty, e . g. : p r e-

c as t c on cr et e, H PC in t he en er gy,waste water and che mical industry. Duet o h ig h h om og en ei ty a nd re du ce d

t a c k in e s s c o mp a r ed w i t h M i c r os i l i c a-b a se d c o nc r et e , w or k ab i li t y i s i m pr o ve d

significantly. In many instance s, this e ve ne n a bl e s t he p r od u c t i on o f h i g h - pe r f or -mance concre te that can be pumpe d. A

d i s t in c t i m pr o v em e n t of t h e b ui l d i n gstructure 's ae sthe tics is gaine d due to

the fair appe arance of the concrete sur-f a ce . C en t ri l i t N C p e rf or m s o ve r t h e

s om e o f t h e d is a dv a nt a ge s o f O t he rSuperfine Pozzolans:

- G ra de d fo r d is pe rs io n i n c on cr et e- Gr ad ed par ti cl e si ze

- O pt im iz es m ix in g ti me w it hi n c on -cre te

- G oo d d i sp er si on r ed uc es u nr ea ct edm a t er i a l i n t h e m i x a n d i n c re a s e' sp a ss i va t io n b y C - S -H g e l o n a g gr e-

gate surface- R ed uc es r is k o f A lk al i S il ic a R ea c-

t i on b y A g gl o me r at i on o f a l um i no -

silicate particle s

G e ne r al A d va n ta g es o f u s in g C e nt r il i tN C i n C o nc r et e

- I nc re as ed c o mp re ss iv e an d f le x-ural stre ngths- R ed uc ed p er me ab il it y ( in cl ud in g

c h l o ri d e p e r me a b il i t y ), I n c r ea s e dre sistance to che mical attack andhe nce incre ase d durability

- R ed uc ed p ot en ti al f or e ff lo re sc en ce ,w hi c h o cc ur s w he n c al c iu m i s t ra ns -

porte d by wate r to the surface whe rei t c om bi ne s w it h c ar bo n d io xi defrom the atmosphe re to make cal-

c i um c a rb on a te , w h ic h p r ec i pi t at e son the surface as a white re sidue

- R ed uc ed e f fe ct s o f a l ka li -s il ic a r ea c-t i v i ty ( A S R)

- E nh an ce d w or ka bi li ty, B et te r p um -p a b i li t y a n d f i n i s h i ng o f c o n c re t e

- Re du ced sh ri nk ag e i n c on cret e,due to "particle packing" making con-cre te de nse r

- Improved color by l ightening thec o l or o f c o n c re t e m a k in g i t p o s s i b l eto tint lighte r inte gral color

- E n dl e ss qu a nt i t ie s a s i t i s a Fa c to r ymade Homoge nous product

- R ed uc ed d os ag e o f s up er p la st ic iz er

M C -B a uc h em i e (I n di a ) Pv t . L t d.

manufacture s this product along with ah o s t o f o t h er C o n st r u c ti o n C h e mi c a l s i n

te chnical and financial collaborationw it h M C- Ba uc he mi e, G er ma ny. M C-B au ch em ie (I nd ia ) P vt . L td . i sa n I SO9001:2008 certified Company.

C EN TR IL IT N C: C on cr et e A dd it iv e B as ed o n

Pozzolanic Alumosilicate

F o r f u rt he r d et a il s :

M C – B au ch em ie ( In di a) P vt . L t d.4 1 1, A r en j a C o rn e r, S e ct o r 1 7 , V as h i,

Navi M u m bai - 400703,

Ph :+ 91-22-27892856/27880803,

Fax:+ 91-22-27893870,

E-m ail: Inf o. india@ m c-bau ch em ie. com

Web: www. mc-bau ch em ieindia. comCentrilit NC: A vailable Form s





he Interme diate Le v el Waste (ILW)

I n te ri m S t or a ge F ac i li t y ( I SF ) a t t h es i te o f t h e f o r m er B er k el e y N u c l ea rT

P ow er S t at i on i s on e of s i x n ew h i gh l y-

e ngine e re d industrial grade Magnoxf a c i li t i e s to p r o vi d e p ro t e c ti o n f o r d u c -

t i l e c a st i r o n I L W c on t a i ne r s u n t il t h ee v e ntual ge ological disposal facility isa v a il a b l e f o r p e r ma n e nt d i sp o s al . T h e

p u r p os e o f t h e I SF s i s t o ke e p t h e I LWcontaine rs in a secure and controlle de n vi r on m en t fo r u p t o 15 0 ye ar s . S t o-

r ag e of I LW t hr ou gh I SF s is p ar t of ane w and innov ativ e Magnox approach

w h e re b y I LW i s s t o re d i n r o b us t se l f -shie lding transportable containe rs, min-i m i z in g t h e n e e d f o r s h i el d i n g w i t h in t h e

b u il d i ng s t ru c tu r e, a n d t h us s i gn i fi c an t lyre ducing de commissioning costs andtime frame s.

T h e D e s i gn

T h e s i x I S Fs a r e o f v a r yi n g s i z e, a n d

a s c a l a b le d e s i g n h a s b e en d e v el o p edt o a c co m mo d at e t h e v a ry i ng n u mb e r o f

ILW containe rs and stacking arrange -m e n ts a t e a c h s i t e. T h e d e s ig n a i m s t ominimise mainte nance and maximise

low-e ne rgy passiv e me asure s to pro-v ide the re quire d storage e nv ironme nt,w h il e a l so i n cl u di n g a c ti v e e n vi r on m en -

tal monitoring and control me asure .

S e l ec t i o n o f d e s i g n f e a t ur e s :

- A l on g- li fe , g al va ni se d s te el fr am eand insulate d aluminium standingse am roofing and cladding syste m.

- A c ur ve d ov er ha ng in g ea ve s a ndno rainwate r gutte rs re duce mainte -nanceandpotentialsourcesofleaks.

- A n e le ct ri c o ve rh ea d c ra ne us ed tomov e the containe rs.

- P r ef a br i ca t ed r e in f or c em e nt e d geb ea m s, w al l p a ne l s a n d r ol l o u t m a ts

use d to spe e d up the constructionof the 400 tonne s of re inforce ment.

Interoperability with Revit model

O n t h i s p ro j e ct , t h e s tr u c t ur a l en g i -ne e r's mode l was importe d using the

industry-standard ope n IFC format (In-d u st r y F ou n da t io n C l as s) i n to Te k laStructure s and use d this as a base to

produce the cast in-situ re inforce d con-cre te de tails. The re inforce me nt modelwas the n e xporte d into Te kla BIMsight

t o ov e rl a y w i th t h e en g in ee r 's m od e la n d is s ue d t o Ar u p f o r c h ec k in g a nd

proble m solv ing alongside the draw-

ings and sche dule s prov ide d.

M a gn o x I LW I n te r im S t or a ge Fa c il i ty, Be r ke l ey

F o r f u rt he r d et a il s:

Te k la I n di a P v t. L t d .Unit no: 1 1 2– 1 15 , Building no-2 , Sector- 1 ,

MBP, Mahap e, Navi Mum bai- 4 0 0 7 10 .Ph: + 91-22 61387777,

E- m ail: [email protected] omWeb: w w w.tekla.c om

Tekla BIMsight Model

M ag nox Project

Tekla BIMsight Model

A vo id in g c la sh e s w it h e xi st in g p il edfoundations

The framing contractor, Cara Con-s t ru c ti o n, r e qu e st e d f or d e ta i le d p r e-f a br i ca t ed c a ge s w h er e p o ss i bl e , w h ic h

could be manufacture d off-site and sig-

n i fi c an t ly s p ee d u p t h e c o ns t ru c ti o n p r o-c e ss . T h is w ou l d g e ne r al l y b e a r el a ti v el ys t ra i gh t fo rw a rd t a s k , b u t o n B er k el e ywas made more complicate d by the re -

use of e xisting pile d foundations, whichh a d b ee n i n s t al l e d i n s o m e c a s es u p t o3 00 mm o ff a r eg ul ar g ri d. T he A ru p

mode l containing the surv e ye d pile cappositions was re fe re nce d into our Te kla

mode l, and we were able to accurate lyde tail around these to e nsure there wouldbe no clashe s once the cage s re ache d

t h e s i te . A ne w c o lo u r c o de d d r aw i ngsyste m was utilise d to he lp with the fab-rication of the re inforce me nt cage s and

place me nt of re bar.




Chemical Admixtures for Concrete: An Overview

Use of Chemical Admixtures in Concrete

One of the most important and critical ingredient of modern

concrete is the chemical admixture. The introduction ofadmixtures have changed the way we can work with the

cement concrete. As the Power’s Equation states, Vp=100w/

c-36.15 . The Porosity of concrete is inversely proportional

to W/B ratio. The first and most important role of chemical

admixtures is to reduce the water : binder ratio.

Specifications and Test Methods

IS 9103, ASTM C-494, ASTM C 1017, BS 5075 (withdrawn)

and BS EN 934 part 1, 2, 6 with supporting test methods

are commonly used, for classifying and testing chemical

admixtures for concrete. There are different classes of

admixtures, based on their effect on concrete properties. ASTM standard C-494 classifies admixtures in 8 types from

A to G and S. Apart from reducing the mixing water, chemical

admixtures have various functions such as slump retention,

set retardation or acceleration, strength acceleration and

more. Each type needs to meet different criteria, specified in test

specifications. Moreover, there are other types like air entraining

admixtures as per ASTM C-260, integral water proofing

admixtures meeting the water impermeability requirements as

per DIN 1048, anti- wash out admixtures, corrosion inhibitors,

shrinkage reducing admixtures, foaming agents, corrosion

inhibiting admixtures and shotcrete accelerators.

Polycarboxylate Ether Based Admixtures

Chemical admixtures are based on various chemistries.

Water reduction greatly depends on the type of chemistry a

formulator uses, to design the admixture. As we know, the best

water reduction is achieved using PCE based admixtures.

This is a result of very efficient dispersion of the binder which

PCEs offer. The effectiveness of PCEs is more evident when

the W/B ratio goes below 0.35. The versatile chemistry of PCE

polymers, ensures their use in almost every Admixtures mix

design. SCC has been mostly associated with PCE based

admixtures. Along with the excellent water reduction, they also

Deepak Kanitkar GM – Technology and Business DevelopmentChembond Chemicals Limited (Construction Chemicals Division)

Admixtures

produce flowing concrete without segregation. In a properly

designed SCC mix using a PCE based admixture, there is

either no need for VMAs or their usage could be limited. Now

a days modified PCE based admixtures are available whichalso offer good rheology control. One of the challenges in

earlier PCEs was the increased stickiness of the concrete mix,

now there are some molecules which offer excellent reduction

in stickiness. This is often necessary while designing very high

strength mixes which have a tight water cement ratio and

high fines. There are other issues associated with PCEs such

as, rapid loss of slump, dosage and temperature sensitivity,

sensitivity to moisture content. Due to such factors concrete

producers generally avoid the use of PCE based admixtures

in lower strength mix designs. Modified PCEs are useful in

meeting the requirements of lower strength mixes. Often,

due to use of manufactured sand or stone dust, there areissues with regard to slump retention or segregation, these

need to be addressed by smart formulations of blended PCE

molecules.

Shrinkage Reducing Admixtures

As described earlier apart from the traditional use as water

reducing agents and slump retainers, admixtures are

nowadays used for more functional roles. Shrinkage reducing

admixtures is an example. These are very effective in reducing

cracks caused due to drying and autogenous shrinkage, also

known as selfdesiccation. They act on very fine capillaries

with diameters between 2.5 to 50 nm in diameter, by reducingsurface tension within pore solution. This helps in preventing

collapse of capillary walls, thereby reducing cracking. Their

use in heavy duty industrial floors, enables increased the

spans and reduction in the requirement for number of joints.

SRAs are mainly based on Ethylene and Propylene Glycol

derivatives. While using SRAs, one must consider their effect

on final compressive strength and air entrainment. In general,

at same W/B ratio, 10-15% reduction in final compressive

strengths, have been observed. It is imperative that by

adjusting the W/B ratio, one can actually maintain the desired

compressive strengths.




The shrinkage could to some extent be determined from an

equation derived by Tomita et al

- (sh) = 390 + 2.89W - 21.77X-4.758E (x10-6)

- Where W, X and E corresponds to unit contents 3 (kg/m )

of water, SRA and expansive additives respectively.

- This suggests that SRA are more than 4 times as effective

than the expansive additives or the effective dosage of

SRAs is only 20-25% that of the expansive additives.

Corrosion Inhibiting Admixtures

Preventing or rather delaying corrosion of steel in concrete is

achieved by at least three methods. Use of corrosion inhibiting

concrete admixtures, CP systems and protective covering or

penetrative treatments. The most important factors are chloride

ingress and carbonation, apart from sulphates and other

corrosive contaminants. CIAs are mainly based on inorganicchemicals such calcium Nitrate / Nitrite or bipolar acting agents

based on amino alcohols and Amino polycarboxylates. Various

products are available in the market and are in most of the

cases equally effective. The mechanisms are different, so as

the dosages.

Internal Curing Agents

Use of Internal curing agents for concrete are also gathering

momentum. They act by providing additional moisture in concrete

for a more effective hydration of the cement and reduced

selfdesiccation. Internal curing means the introduction of a

curing agent into concrete to provides this additional moisture.Two major methods currently available.

- Use of saturated porous lightweight aggregate (LWA) in

order to supply an internal source of water.

- Super-absorbent polymer (SAP) particles can absorb a

very large quantity of water during concrete mixing and

form large inclusions containing free water, thus preventing

self-desiccation during cement hydration.

For optimum performance, the internal curing agent should

possess high water absorption capacity and high water desorption

rates.

Admixtures For Sprayed Concrete or Shotcrete

Most tunneling work will never be complete without the use of

gunniting or the sprayed concrete. Spraying concrete is a very

sensitive application. The nozzlemens’ job will not be easy

without the use of an accelerating admixture. Typically, quick

setting is as critical as controlling the reheology of sprayed

concrete. Accelerators combine both these requirement, thus

reducing the rebound to a great extent and achieving quick

setting.

There are more and more applications which could be discussed.

Admixtures for making pervious concrete, colorants for decorative

concrete, admixtures used for stopping the rejected concrete

from setting for a period as long as 24hrs are available.

Concrete Mix Proportioning – Science and Art What is

mix design?

Concrete proportioning or designing of a concrete mix, is anart more than science. Although it involves a lot of statistics

and material science, more depends on the actual feel of the

concrete during the mixing and placing stages.

In general concrete mix has 4 main constituents viz. cementitious

materials, aggregates, water and chemical admixtures.

More precisely, concrete consists of coarse aggregates which

are bound by a mortar made of a paste of hydraulic binders

mixed with fine aggregates.

Mix proportioning involves, physical formulation of these

ingredients to achieve certain properties. Main criteria remains

that of mechanical properties but without achieving the fresh

concrete performance, mechanical properties can never really

be attained.

In order to achieve the desired level of workability and a

cohesiveness concrete mix, the gradation as well as granularity

of both coarse and fine aggregates, cement content, water to

binder ratio and use of a suitable chemical admixture, play a

vital role.

While doing this, apart from getting the desired performance,

one has to also remember economy and properties of available

resources, including water.

Ingredients Properties

Cement Strength Grade Type Fineness Alkalinity - -

Fine Agregates Zone or Gradation Shape Absorption Reactivity Density Mineralogy

Coarse AggregatesMaximum Size and

Gradation

Shape / Crushing

methodAbsorption Reactivity Density Mineralogy

Admixtures Type Chemistry Dosage - - -

Pozolanic additions

Mineralogy

/ Chemical

Composition

Particle size Dosage - - -

Ingredients and their important properties

Admixtures




Air in concrete is also a critical factor. Controlling the amount

of air in the mix can to a certain extent be controlled during

mix designing stage. There are two classes of concrete

viz normal (Non Air Entrained) concrete and air entrained

concrete. The amount of allowed air varies considerably in

both types. Air entrainment is achieved through the use of airentraining admixtures. More recently, it is also known that Self

Compacting Concrete (SCC) requires a different approach,

than these two types.

Essentials of a Mix Design

Following are typically the most important factors, which need

to be taken into account while deciding the mix proportions.

- Characteristic Strength

- Air content

- Workability requirements

- Climatic conditions / exposure conditions.

- Handling conditions / Automation

- Durability

- Economy

- Aesthetics and appearance

We will take a look on, how some of the above factors help in

arriving at a desired mix proportion.

1. Characteristic strength: Compressive strength of a mix

is typically the most important mechanical characteristic.

Once we know the strength requirements, it becomes

simple to select the grade of cement, water content or W/B

ratio as well as fine aggregate content. It is well known that

reducing the W/B ratio, directly increases the compressive

strength.

2. Air Content: Air in concrete is not always desirable. In non

airentrained concrete it is desirable to have an air content

less than 1 % more than the control mix or a maximum

2.5% by its volume. A little air helps in getting better slump

and finishing of the concrete. As the air content increases,

it starts decreasing the strength and simultaneously

increase the permeability. We need to take this air into

consideration, as the density and yield depend on the

percentage of air in the mix.

3. Workability: It is the ability of fresh concrete which allows theplacement and finishing at a particular point after mixing.

The slump as it is called is measured using a slump cone

at mixing point and at the point and time of placement.

Depending on the actual application and placement

technique, the value of slump can vary between almost

zero for a pavement grade roller compacted concrete to

a flowable consistency for the SCC. Apart from this point

measure, the slump or workability may be required to be

retained, up to a certain period of time. So, the required

workability at a given time needs to be considered, while

designing a mix.

4. Climatic conditions and Exposure:Whether the concreting

is taking place in winter or summer matters a lot. It is also

imperative to understand the variations during the day

and nights. Under water placement, needs anti washout

admixtures and set accelerators.

We have to also consider the exposure conditions. If thereis a chance of moderate to heavy exposure to sulphates,

one needs to consider the use of sulphate resistant

cement or pozolanic additions such as fumed silica. in

case of chloride based environment, use of corrosion

inhibitors based on calcium nitrite or bipolar types, may be

necessary. Industrial environment, may necessitate use of

hydrophobic agents / corrosion inhibitor, along with low

permeability mixes.

5. Handling conditions / Automation: Whether the concrete

is hand placed, pumped, roller compacted or placed in

moulds at a precast facility, will mean a different approach

to the mix design. Each method has different requirementof consistency, viscosity and slump retention.

6. Durability: Air entrained concrete in Freeze – Thaw zones,

use of pozolans in marine environment, low permeability

concrete in areas with heavy rain fall, use of internal curing

agents or Shrinkage Reducing Admixtures in concretes

prone to selfdesiccation, are some of the examples,

how the durability needs to be accounted at mix design

stage.

7. Economy: The skill of a concrete technologist is in

designing the best mix which meets optimum performance

requirements within the allowable economy / cost. Lowcost resources such as sand and gravel, need to be

taken from the closest possible quarry. Major contribution

to the cost of these materials, comes from freight and

handling. Adjustment in gradation of these aggregates

and minimizing the cement content will automatically

result, in good economy of the mix.

8. Aesthetics and Appearance: Whether you require a plain

finish or a texture, coloured concrete or a stamped finish,

all such factors need to be considered during finalizing the

mix design.

Effect of ingredients on Properties of Concrete Cement

Grade of cement decides maximum achievable compressive

strength of a mix. Type of cement generally decides exposure

conditions as well as water demand and compatibility with

admixtures.

Fineness of cement is important to decide water demand,

initial workability, setting time as well as retention of slump.

Alkalinity is responsible for both short term and long term

performance parameters.

IS Codes : 12269, 456, 8112

ASTM codes : C-150

Admixtures




Fine Aggregates

Fineness modulus and gradation of sand plays an important

part in deciding the workability and cohesiveness of concrete

mixes. Shape determines the flow, segregation and bleed

characteristics. Absorption value determines the amount of

water needed for adjustment after deciding free water content.

Reactivity if any mainly with alkali needs to be mitigated using

proper means such as pozolans, Lithium Silicates etc. Density

which is generally determined by mineralogy affects yield.

Coarse Aggregates

Size of aggregates decides the amount of mortar required

to coat all coarse aggregates. It also decides the maximum

thickness up to which the concrete can be cast. Heavy density

aggregates are generally used in radiation shielding concrete.

The shape and size of aggregates is also critical in achieving

desired workability and cohesiveness. Coarse aggregates canhave round, angular, or irregular shape. Rounded aggregates

because of lower surface area will have lowest water demand

and also have lowest mortar/paste requirement. Hence they

will result in most economical mixes for concrete grades up

to M35. However, for concrete grades of M40 and above

the possibility of bond failure will tilt the balance in favour

of angular aggregate with more surface area. Flaky and

elongated coarse aggregate particles not only increase the

water demand but also increase the tendency of segregation.

Flakiness and elongation also reduce the flexural strength of

concrete.

IS Codes : IS 383

ASTM Codes : C 33

Admixtures

Admixtures play a very important role in today’s concrete

industry. Faced with a lot of environment, space and resource

constraints and add to that the challenges of the modern day

structural requirements and design diversities, no concrete

today can really be considered without the use of chemical

admixtures. We are having a detailed discussion on this topic

at the end of this article.

IS Codes : IS 9103

ASTM Codes : C-494, C-1017, C-260

Pozolanic Materials

Use of pozolanic materials has now become common. Both

separate additions as well as blended cements are available.

Microsilica (Fumed Silica), Fly ash, Slag, Meta Kaolin, Risk

Husk Ash are predominant. Various specifications and test

methods are used to determine the quality of these materials.

IS Codes : IS 3812

ASTM codes : C-1240, C-311, C-441, C-618, C-989

There are different approaches to concrete mix design. We are

showing a typical example of M-30 grade concrete, designed

as per guidelines from IS 10262 : 2009. Here we have used

KEM SUPLAST 128 UT which SNF based Concrete Super

plasticizer conforming to ASTM C-494 type G and IS 9103.

Mix Design Calculations as per IS 10262:2009 Stipulation

for Proportioning

Grade of concrete 30

Type of Cement OPC

Type of mineral admixture Fly Ash

Maximum nominal Size

of aggregate 20mm

Minimum cement content 320Kg/cum

Maximum water- cement ratio 0.45

Type of exposure Severe

Method of concrete placing Pumping

Degree of Quality Control Very Good

Type of aggregate Crushed

Maximum cement(OPC) content 450Kg/cum

Chemical admixture type Superplasticizers

Chemical Admixture brand KEM SUPLAST128 UT

Test Data for Material

A) Cement

a) Cement brand used U/T OPC

b) Specific Gravity of Cement 3.15

B) Fly Ash

a) Fly ash brand used Dirk

b) Specific Gravity of Fly Ash 2.15

C) Water

a) Source Local

Sieve Size % Passing 50 50 % Passing Specification as per IS 383

10 mm 20 mm 10 mm 20 mm Combined 100% 10 mm 20 mm

40 mm 100.00 100.00 50.00 50.00 100.00 100 100

20 mm 100.00 89.60 50.00 44.80 94.80 100 85-100

10 mm 85.40 0.25 42.70 0.13 42.83 85-100 0-20

4.75 mm 0.00 0.00 0.00 0.00 0.00 0-20 0-5

2.36 mm 0.00 0.00 0.00 0.00 0.00 0-5 -

Admixtures




D) Admixture

a) Type & brand Kemsuplast 128UT

b) Specific Gravity of Admixture 1.24

c) % of dosage 1.2%

E) Coarse Aggregate

a)Source Local Source

b) Specific Gravity (SSD) 20mm 2.80

c) Specific Gravity (SSD) 10mm 2.78

d) Combine Sp. Gr. 2.79

e) Water absorption % 20mm 0.0%

10mm 0.0%

f) Free surface moisture 20mm 0.0%

10mm 0 . 0 %

Coarse aggregate Sieve Analysis

F) Fine Aggregate

River Sand

a) Source of River sand Local Source

b) Specific Gravity of River Sand 2.65

c) Water absorption 0.0%

d) Free moisture 0.0%

Crushed Sand

a) Source of Crushed sand Local Source

b) Specific Gravity of

Crushed Sand 2.68

c) Water absorption 0.0%d) Free moisture 0.0%

e) Combine Sp gr of total F.A. 2.7

Combination of Fine Aggregate Fractions

Design Calculation:

Target Mean Strength 30 + 1.65 X 5

fck+1.65X SD 38.25

Selection of Water/Cement ratio

From Table 5 of IS 456, maximum water-cement ratio for M30

=0.45

On trial experience base adopted water- cement ratio for this

mix design is 0.42

0.42 < 0.45 Hence OK

Selection of Water content

From table 5 of IS 456, maximum water content

for 20m – 50 mm slump

for 20 mm MSA =186Kg/cum

Estimated water content

for 120 mm slump =208Kg/cum

Since use of superplastisizer

will reduce 15 – 20% of water & above on trial with present

superplastisizer water reduction achieved is 17% So the

water content I =173Kg/cum

Calculation of Cement content in design mix

Water-cement ratio =0.42

water content =173Kg/cum

Total Cementitious content will be =410Kg/cum

As per IS 456 minimum

cementitious content is =320Kg/cum

410Kg/cum > 320Kg/cum Hence OK

Total cement (OPC) content =308Kg/cum

Fly Ash content % by weight

of cement @ 25% =103Kg/cum

IS Sieve % Passing Individual Combination Combine % Lower Limit Upper Limit

R.Sand C.Sand 30 70

4.75 100.00 92.70 30.00 64.89 94.89 90 100

2.36 83.60 72.20 25.08 50.54 75.62 60 95

1.18 52.40 51.60 13.14 36.12 49.26 30 70

0.6 35.60 40.20 4.68 28.14 32.81 15 34

0.3 22.90 20.40 1.07 14.28 15.35 5 20

0.15 12.80 6.40 0.14 4.48 4.61 0 10

Pan 0.00 0.00 0.00 0.00 0 0 0

F.M= 3.17 Zone= ZoneI

I.S. Sieve Size inC.A % F.A% Total %

passing

Specifications

56.00% 44.00% Min Max

40 56.0 44 100.00 100 100

20 53.1 44 97.09 85 100

10 24.0 44 67.98

4.75 0.0 41.8 41.75 30 50

2.36 33.3 33.27

1.18 21.7 21.68

0.6 14.4 14.44 10 35

0.3 6.8 6.75

0.15 2.0 2.03 0 6

Admixtures




Proportion of volume of coarse aggregate& fine aggregates

From table 3 of IS 10262(2009), Vol of CA corresponding to

20 mm size aggregate and FA (Zone I) for W/C ratio of 0.50

= 0.60.

In present case W/C ratio is 0.42 Therefore Vol of CA is requiredto be increase to decrease the FA content as the W/C ratio is

lower by 0.08 the proportion of vol of CA is increased by 0.02

So corrected vol of CA=0.62

For Pumping Mix this value should be reduced by 10%

So Total vol of CA =62 X 0.9

=0.56cum

Total Vol of FA = 1.00 – 0.56 = 0.44 cum

Percentage of Fine aggregate and Coarse aggregate are

arrived after conducting sieve analysis and combined grading

as follows

Percentage of C.A. To

total aggregates =56%

Combination ratio of 20mm:10mm =50:50 %

Percentage of F.A. To

total aggregates =44%

Combination ratio of

R.Sand : C.Sand =30:70 %

Combination Of All Aggregates Fractions

Fine Aggregates % =44%

Coarse Aggregates % =56%

Mix Calculations

a) Volume of Concrete = 1cum

b) Volume of Cement = Cement Qty./Sp.Gr x

1 /1000

= 0.098cum

c)Volume of Fly ash = Fly Ash Qty./Sp.Gr x

1 /1000

=0.047cum

d) Volume of Admixture @ = Admixture Qty./Sp.Gr

x 1/1000

=0.004cum

e) Volume of Water =0.173

f) Total cementitious material

+ water + admixture = 0.322cumg) Total volume of all

aggregates =1-f

=0.678cum

h) Total quantity of

coarse agg. =g x Vol of CA x Sp. Gr.

Of C.A x 1000

=1062Kg/cum

Quantity of 20mm =531Kg/cum

Quantity of 10mm =531Kg/cum

I) Total quantity of Fine agg. =g x Vol of FA x sp. Gr.

Of F.A x 1000=793Kg/cum

Quantity of River Sand =238Kg/cum

Quantity of Crushed Sand =555Kg/cum

MaterialMaterial Dry wt Moist. W.A. SSD

& Source kg/M3 % % kg/M3

Cemmenti-tious

OPC 53 308 308

Fly Ash 103 103

Aggregates

CA2: 20 MM 531 0 0 531

CA1: 12 MM 531 0 0 531

FA2: R.Sand 243 0 0 243

FA1: C.Sand 567 0 0 567

Admixture Kem Suplast 128 UT 4.9 4.9

Water Local source 173 173

Theoretical plastic density - = 2460 2460

Water / Cement Ration = 0.42 0.42

Constituent Materials

Concrete Temperature 27oC Mix Cohesive

Workability

Initial Slump - Collapse

Slump After 60 Min - Collapse

Slump After 120 Min - 210 mmSlump After 150 Min - 180 mm

Slump After 180 Min - 140 mm

Test Results

Age Weight Density Load Strength N/MM2

Days KG KG/Cum KN Strength Average %

1 8.350 2474 250 11 11 37

7 8.300 2459 500 2222

74

7 8.400 2489 510 23 76

28 8.380 2483 890 40

40

132

28 8.390 2486 885 39 131

28 8.370 2480 892 40 132

Compressive Strength Data

Note

The above Mix is for guidelines purpose only, all the aggregates

are considered as in SSD condition & their Sp. Gravity are

considered according to materials available in Mumbai

region. For practical purpose it is always advised to conduct

the confirmatory trials at site conditions. Our representatives

will be available for further advise if necessary.

Admixtures




Admixtures for Tall Structures

Mumbai saw large-scale rural-urban migration in the 21st

century. Mumbai accommodates 12.5 million people, and

is the largest metropolis by population in India, followed by

Delhi with 11 million inhabitants. Witnessing the fastest rate

of urbanization in the world, as per 2011 census, Delhi’s

population rose by 4.1%, Mumbai’s by 3.1% and Kolkata’s by

2% as per 2011 census compared to 2001 census. Estimated

population, at the current rate of growth, by year 2015 ofMumbai stands at 25 million, Delhi and Kolkata at 16 million

each, Bangalore and Hyderabad at 10 million.

Hence with urbanization increasing at such a fast pace,

especially so in a developing economy such as India, puts

more pressure on available land. This answers why construction

companies in India are looking vertical space, kick-starting

the trend of high-rise buildings dotting the country scape.

Builders and architects are concentrating on building

skyscrapers primarily because they are convenient. It allows them

to create a lot of real estate on a relatively small ground area. Until

the 1990’s, the world of tall buildings was dominated by theNorth American continent and the United States in particular. In

1990, 80% of the world’s tallest 100 buildings were located in

North America. Two decades later, these numbers have fallen

to 35%. This trend is the result of a dramatic and continuing

increase in tall building construction in both Asia and the

Middle East. The construction of the Petronas Twin Towers in

Kuala Lumpur built to a height of 452 m, Taipei 101 standing

at 508 m and now the Burj Khalifa in Dubai at 828 m which

stands 773 metres higher, or 15 times taller, than the world’s

first “tall building”, the Home Insurance Building completed in

Chicago in 1885, are a testimony to this fact.

Bruno D’souzaRegional Business Segment Manager, Admixtures, Asia Pacific, BASF

Admixtures

There’s been an increasing trend toward construction of

structural concrete super-tall buildings for several good reasons

discussed in the following section of the paper. Whilst using

such concretes, one needs to pay greater attention not only

to aspects such as the mix design but also to its performance

with respect to handling, pumping, placing, finishing and curing.

Structural MaterialFor many years, steel was the material of choice for the tall

building, a fact displayed in the first 12 world’s tallest buildings.

Currently, composite, concrete and mixed-structure construction

is much more prevalent in tall structures. Only 24% of the

world’s current 100 tallest structures contain a purely steel

structural system, down from 57% in 1990.

Reinforced concrete provides twice the dampening effect

compared to steel, reducing forces on super-tall buildings due

to wind and the cost of construction. Concrete buildings are

quiet and structural concrete is naturally fire resistant. Modern

formwork systems for horizontal and vertical castings greatly

increase productivity and improvements in concrete pumping

equipment and techniques, make easy and fast delivery of

concrete possible.

Advancements in concrete technology because of newly

developed materials such as chemical admixtures have assisted

in improving the properties of concrete, including strength and

modulus of elasticity (E) making high-rise construction more

attractive. Self-Compacting Concrete is increasing in use too,

mainly due to the utilization of admixtures classified as Viscosity

Modifying Agents (VMA) and Viscosity Enhancing Agents (VEA)

and the availability of more economical fines or fillers.

Tall buildings or skyscrapers are constructed for several reasons. One reason being the creation of a status symbol, for example,the Burj Khalifa, the world’s tallest building which was constructed to symbolize Dubai as a world city. Other more obvious reasons

for the presence of such structures would be part and parcel in the construction of central business districts in cities and alsourbanization of populations. Urbanization is taking place at a faster rate in India than most places in the world. Urbanization in

India was mainly caused after independence, due to adoption of a mixed system of economy by the country which gave rise tothe development of private sector. Population residing in urban areas in India, according to 1901 census was 11.4%. This count

increased to 28.53% according to 2001 census, and crossing 30% as per 2011 census, standing at 31.16%. According to a surveyby UN State of the World Population report in 2007, by 2030, 40.76% of country’s population is expected to reside in urban areas.

As per World Bank, India, along with China, Indonesia, Nigeria and the United States, will lead the world’s urban population surgeby 2050.




Chemical Admixtures

Super-tall construction requires that the concrete to be

economical and yet deliver high performance characteristics.

High performance characteristics being properties such as

high strength, low water/binder ratio, flowable for extended

periods at ambient temperatures fluctuations from say 10

deg. C to 50 deg. C and most of all, pumpable to heights in

excess of 600 m.

To meet these challenges posed by various stakeholders

including engineers, contractors and ready mixed concrete

producers for the construction of such super-tall structures,

BASF embarked on an intensive R&D project. The aim of

the project was obviously to develop & deliver products

capable of meeting the demands and needs necessary for

the manufacture of such high performance concrete even in

harsh environments. The R& D work resulted in an innovative

concept being developed. This new concept is termed TotalPerformance Control (TPC). TPC concept ensures that the

stakeholders achieve a concrete that is of the same high

quality as originally specified; starting from production at

the batching plant, to the delivery and application into place

and followed by its hardening process. TPC is the state-

of-the art technology that provides improved short and

long term performances of concrete by controlling the two

distinct features essential for high-quality concrete: extended

workability and low water/binder ratio. These features are the

key to the success of such an admixture system.

The key element of the Total Performance Control is

the Glenium SKY superplasticiser. Glenium SKY is an

innovative superplasticiser based on second-generation

polycarboxylate ether (PCE) polymers. It is derived directly

from the TCP concept and is specially engineered to

provide high water reduction and slump retention for ready

mix concrete simultaneously. As compared with other PCE

superplasticisers, it is possible to obtain a high quality concrete

mix with accelerated strength development and extended

workability without delayed setting characteristics. Glenium

SKY is made using nanotechnology. A nanometer is a millionth

of a millimeter – the dimension of molecules and polymeric

chains. In-house expertise in nanotechnology allows BASF to

control the chemical and physical behavior of polymers andtheir interactions with cement by augmenting chain length,

side chain length and density, and electrical charges as well

as free functional groups. For the first time, nanotechnology

allows local requirements and conditions to be better met.

Self-Compacting Concrete produced using the TPC

concept provides a concrete mix with exceptional placing

characteristics, accelerated cement hydration for high early

strength development and quality concrete. The addition

of a Viscosity Modifying Agent (VMA) to Self-Compacting

Concrete with Glenium SKY superplasticiser enhances the

robustness of the mix by providing excellent cohesion and

anti-segregation properties. Robustness of a mix is desirable,

especially when such mixes are expected to perform under

high pump pressures and also flow for long horizontal

distances and remain stable when dropped from heights into

structural members such as columns and beams.

Mechanism of Action

The dispersion effect of superplasticisers is based on the

adsorption of molecules on cement particles, imparting a

negative charge that causes electrostatic repulsion and

steric hindrance between them and, therefore dispersion.

The hydration, and particularly the ettringite formation, works

against the superplasticiser. Already adsorbed molecules

are covered by the ettringite lawn, thus are ineffective. The

particular configuration of the Glenium SKY molecules

allows its delayed adsorption onto the cement particles and

disperses them efficiently over a long period of time.

The molecular structure is essential for the early development

of strength. With superplasticisers based on conventional

polycarboxylate ether, the molecules cover the entire surface

of the cement grain and build a barrier against contact with

water. Therefore, the hydration process takes place slowly. The

Glenium SKY molecules, on the other hand, leave sufficient

room on the cement surface to allow a rapid hydration reaction,

resulting in high early strength development.

A schematic representation of the mechanism of action of

a normal PCE superplasticiser versus Glenium SKY is given

below.

Application

Burj Dubai, called Burj Khalifa since its opening, is the tallest

building in the world by a large margin. Concrete admixtures

from BASF have made a substantial contribution to its

construction. The world’s tallest construction, reaching up 828

metres into the Dubai sky with the number of floors reported at

189, was opened on 4 January, 2010. Both, the second largest

construction, the 610-metre Canton TV Tower in Guangzhou,

China, and the second largest “house”, the 509-metre Taipei

Financial Center in Taiwan, pale in comparison with these

Admixtures




80MPa – which is roughly equal to the pressure the total weightof a small car would exert on a big toe. The high strength also

provides the concrete structure with a long service life and

ensures the sustainable usage of the building.

Conclusion

Concrete with specialized & tailored admixture systems

utilizing nanotechnology & unique polymer science can deliver

the following benefits to stakeholders of tall structures:

- Ensuring a constant high-quality concrete even at a low

water/binder ratio

- Providing concrete with extended workability at hightemperatures, without delayed strength development

- Guaranteeing a concrete that meets the original specification

from the fresh to the hardened stage

- Offering a single, versatile admixture system for many types

of applications and conditions

Refrences

- Abalos, I., & Herreros, J. (2003). Tower and Office: From Modernist

Theory to Contemporary Practice. Cambridge, MA:MIT Press.

- In L.S. Beedle & D. Rice (Eds.), Proceedings of the 4th World

Congress of the Council on Tall Buildings and Urban Habitat:

Tall Buildings- 2000 and Beyond. Chicago, IL: Council on Tall

Buildings and Urban Habitat, 3-12.

- Ali, M.M. (2001). Art of the Skyscraper: The Genius of Fazlur

Khan. New York: Rizzoli.

- Ali, M.M. (2005). The skyscraper: epitome of human aspirations.

In Proceedings of the 7th World Congress of the Council on Tall

Buildings and Urban Habitat: Renewing the Urban Landscape

[CD-ROM]. Chicago, IL: Council on Tall Buildings and Urban

Habitat.

- Ali, M.M., & Armstrong, P.J. (Eds). (1995). Architecture of

Tall Buildings. Council on Tall Buildings and Urban Habitat

Monograph. New York: McGraw-Hill.

- Taranath, B. (1998). Steel, Concrete, & Composite Design of Tall

Buildings. New York: McGraw-Hill.

figures. Concrete admixtures from BASF’s GLENIUM® SKY

product line brand have made a substantial contribution to

this new world height record.

Construction went on for five years in extreme climatic

conditions. Burj Khalifa put great demands not only on the

2,400 construction workers deployed around the clock. Thestaggering heights, a demanding architectural design, and

the climate required exceptional performance from concrete

admixtures as well: The hyperplasticiser of the GLENIUM

SKY brand enabled the concrete to be pumped up to a

height exceeding 600 metres without interruption. In all,

about 180,000 cubic metres of concrete with GLENIUM SKY

were used for the structure’s foundation plate as well as the

superstructure construction.

The climatic conditions posed a further challenge during the

construction of the world’s tallest building: Temperatures in

Dubai not only fluctuate between 10 °C in winter and 50 °C in

summer, but there are also temperature differences between

day and night of up to 20 °C. GLENIUM SKY and the BASF

team’s expertise counteracted these conditions and ensured

a consistently high concrete quality.

In addition, the staggering height of the Burj Khalifa and the

resulting weight of the construction cause enormous pressure

within the concrete structure. Through the use of GLENIUM

SKY, the concrete acquires a compressive strength of up to

Admixtures




Performances and Benefits of Concrete Admixtures in Concrete Durability

As larger and larger amounts of concrete will be required

worldwide in the future, the need for developing

sustainable construction solutions has been pro-

gressively growing in our building industry, depending oneach country sensitivity and awareness. Concrete is in fact

is one of the most durable –and cost effective – construction

material in use. Its durability is characterized by the capacity

to keep over time its values in use for which it was designed

(structural purpose, safety, comfort of users), while maintaining

maintenance costs as low as possible.

In order to guarantee this durability, it is still common in India, as

well as in other countries, to see project designers prescribing

a fixed concrete mix design, based on ultimate strengths

associated with a workability target. However, based on the

experience collected over the last decade, we can state that

durability should be rather understood by considering a larger

set of criteria: physico-chemical characteristics of the concrete,

production and placement process, as well as a perfect

knowledge of the exposure conditions.

In a new approach considering durability more in terms of

performance aspects, to take better into account all the

criteria mentioned above, we will see that the role of concrete

admixtures becomes of great importance, and we will detail

how they can directly or indirectly improve some durability

factors.

Approaching Concrete Durability Performance Wise

Traditionally, many project designers are used to specifying the

durability of a concrete in terms of ultimate strengths, together

with a pre-established mix design fixing typically a maximum

Water / Cement ratio, a minimum cement content, even

sometimes a definite dose of admixture. This “prescriptive”

approach is able to provide a certain durability for the concrete,

as it will ensure a reasonable compacity. Nevertheless, the

mechanical strength of a concrete does not determine

alone the durability. As an example, two concrete with same

strengths can show very different behaviours in terms of

resistance against sulphate attacks or alkali-silica reaction.

Philippe Ortega Vice Technical Director, CHRYSO SAS, France

Admixtures

Even though the compacity would be comparable, the way

the pores are distributed in the concrete, their size, will influence

for example the diffusion properties of aggressive chemicals,

and lead finally to different durability performances.

The experience collected in the last years allows now to better

optimize concrete mix designs in terms of durability while

taking into account the real performance of the concrete.

This “performance” approach requires knowing precisely the

conditions playing a role on the durability:

The concreting process: it is essential to respect the best

practices in terms of concreting process. From mixing to curing,

the way the concrete is handled will affect its quality, and,

as a consequence, its durability. For example, a concrete

can be properly designed for the exposure conditions, but

may finally lack durability if not properly cured, because ofa non optimal cement hydration. Another key point is the

rheological behaviour of the concrete: workability, viscosity,

cohesiveness, will provide more or less ability for placement

and consolidation, which is also essential for keeping concrete

structures durable.

The physico-chemical concrete properties: beside the classical

particles packing density that determines the compacity of the

concrete, the chemical nature of the raw materials (aggregates,

cement, SCM materials…) plays an important role: it is well

documented for example that slag and pozzolanic materials

have a positive impact on durability, since they are able to

reduce the corrosion rate by increasing the resistivity of the

concrete. Furthermore, the potential reactivity between con-

stituents has also to be considered (aggregates sensitive to

ASR reaction, e.g.).

The exposure conditions: taking precisely into account the

environment in which the concrete structure will be located

and the risk of attacks it will be exposed to during its service

life is necessary to optimize the durability performance of the

concrete. In Europe, a first step towards this performance

approach has been achieved, by introducing in the EN 206-1

(European Concrete standard) some specific exposure classes




related to corrosion induced by chlorides, by carbonation,

freeze-thaw attacks and chemical. Using these classes, the

project designer will be able to prescribe a minimum ultimate

strength, cement content and maximum water to cement ratio,

as well as the type and nature of some constituents.

In some countries like France, this performance approach has

been further investigated. Some specific durability indicators

have been defined, in association with operating modes (like

oxygen permeability, chloride diffusion, speed and depth of

carbonation). Work is still in progress to link such parameters

with the real life span of concrete structures. As an example,

we can mention the construction of the Euro-tunnel, designed

for 120 years: water permeability tests had been performed,

which confirmed the low porosity (7 % to 8 %) of the concrete,

allowing to select the final mix design parameters, especially

the water to cement ratio of 0,32 (Rc 28D between 66 to 69

MPa).

Approaching this way the durability performance wise, many

benefits can be be found using concrete admixtures, since they

will help to optimize some physico-chemical characteristics of

the concrete and even the concreting conditions.

How Admixtures can Improve Durability Related to the

Concreting Conditions:

One condition for guaranteeing durable concrete is a proper

cohesiveness. It starts with the mixing process: according to

the Indian standard IS 456, concrete should be mixed until

there is a uniform distribution of the materials and the mass is

uniform in color and consistency. Mixing aid admixtures can

help in that regard, as they will reduce efficiently the mixing

time, especially in case of concrete containing high volumes

of cementitious materials, particularly hard to defloculate.

Also the placing of the concrete around the reinforcement,

fully compacted, has got a very important influence on the

final durability. It is therefore essential for the workmanship to

respect the best practices of pouring and vibrating concrete.

In addition, with the most advanced admixture technologies,

like PCP based superplasticizers, it is possible to optimize

this process, by producing highly flowable concrete that will

require less effort to place. Some of these products allow also

keeping a better control over other rheological parameters

of the mix, like thixotropy: this reversible thickening force can

lead to an early concrete stiffness, especially at low water cement

ratios, disturbing consequently the placement process.

Admixture suppliers have now developed specific molecules

to decrease this effect.

Not only the easiness of placing , but also its regularity is

another key point for a consistent and guaranteed durability:

the new generation superplaticizers allow to make for example

Self Compacting Concrete, that do not require any more

vibration. As the quality of compaction does not depend any

more on the human factor, it is possible to expect a more

regular placement quality, favourable for the durability. The

regularity is also obtained by improving the robustness of the

Class Des-ignation Description of the environment Informative examples where exposure classes may occur

4 Corrosion induced by chlorides from sea water

Where concrete containing reinforcement or other embedded metal is subject to contact with chlorides from sea water or air carying salt originating from sea

water, the exposure shall be classified as follows:

XS1 Exposed to airbome salt but not in direct contact

with sea water

structure near to or on the coast

XS2 Permanently submerged Parts of marine structures

XS3 Tidal, splash and spray zones Parts of marine structures

5 Freeze/thaw attack with or without de-icing agents

Where concrete is exposed to significant attack by freeze/thaw cycles whilst wet, the exposure shall be classified as follows:

XF1 Moderate water saturation, without deicing agent Vertical concrete surface exposed to rain and freezingXF2 Moderate water saturation, with deicing agent Vertical concrete surface of road structures exposed to freezing and airbome de-icing agents

XF3 High water saturation, without de-icing agent Horizontal concrete surface exposed to rain and freezing

XF4 High water saturation, with de-icing agent or sea

water

Road and bridge decks exposed to de-icing agents:

Concrete surface exposed to direct spray containing de-icing agents and freezing splash zones

of marine structures exposed to freezing

6 Chemical attack

XA1 slightly aggressive chemical environment Concrete exposed to natural soi l and ground water according to table 2

XA2 Moderately aggressive chemical environment concrete exposed to natural soil and ground water according to table 2

XA3 Highly aggressive chemical environment concrete exposed to natural soi l and ground water according to table 2

Extract from the EN 206-1: Description of some exposure classes

Admixtures




fresh concrete to different variables: first cement chemistry

variations (the soluble alkali content especially) can lead to non

regular water and superplasticizer demand, thus impacting

workability. Today, products like alkyl phosphonate based

superplasticizers have been designed to cover a large range of

cement chemistries, and are proved to be much less “cementspecific” than the regular PCPs. Then, other variations come

also often in India from the aggregates particle size distribution:

variable fine contents, in crushed sands particularly, increase

sometimes a lot the risk of bleeding and segregation, and

therefore the durability. For that, admixture suppliers have

now in their offer some efficient molecules, known as Viscosity

Modifying Agents, able to smooth up these variations and

ensure a more regular concrete cohesiveness.

Finally, another variation that may affect the placing process is the

workability loss over time. Whereas PNS based old generation

superplasticizers were hardly able to retain workability more

than one hour, some PCP based superplasticizers, along with

other newly developed technologies called “slump extenders”

allow concrete open times up to 3 hours or more. Also, being

able to maintain constantly over time a cohesive concrete

-from the time of mixing until the time of placing - avoids

producing a concrete with a too high initial workability at the

edge of segregation, as observed sometimes in India, which

minimizes the risk of getting a non homogeneous concrete at

the pouring point.

After placing, curing is the next step which is essential for

avoiding a too quick drying of the concrete surface, leading

to drying shrinkage responsible for cracks. Most admixture

manufacturers offer already different types of curing agents,

mineral or water based, that protect efficiently the concrete

surface, and therefore improve durability. Considering the

relatively high outside temperatures in India, it makes fully

sense to develop the use of such products compared to

traditional solutions - typically water spraying - less efficient

as they require many more repeated applications. To some

extend, it is also possible to minor the shrinkage phenomena

by using two other chemical types of solutions, known as

Shrinkage Compensating Agents (SCA) and Shrinkage

Reducing Agents (SRA). These liquid admixtures are able

to help reduce the capillary forces while concrete is drying

and their efficiency is excellent. As much as the SCA use

remains confidential and some time difficult to control, the

SRA technology is widely available and robust.

How Admixtures can Improve Durability Related to the

Physico-Chemical Characteristics

Getting a microstructure as dense as possible is a well

known key driver for improving concrete durability. Beside

waterproofing agents dosed in the concrete mass, able to close

to a certain extent the capillaries, and decrease consequently

the risk of penetration of aggressive substances, the super-

plasticizers play a major role, as the most recent ones – the

new generation PCPs - are able to offer almost an unlimited

reduction of the water to cement ratio. The consequence

is the possibility, together with mix design optimization, to

increase regular concrete compressive strengths up to 120

MPa and Ultra High Strength concrete (UHPC) up to 200

MPa in commercial applications. The consecutive reduction

of the porosity allows today the designers to build concrete

infrastructures up to sometimes 300 years.

However, reducing too drastically the water to cement ratio

will increase significantly the solid volume fraction in the

paste, and consequently the viscosity, as it is predicted by

the universal Krieger and Dougherty law. In India, due to

high proportions of cementitious materials necessary to

reach safely the strengths requirements, this practical limit

is often exceeded, and people start to complain about too

much “stickiness”. Some further admixture developments –

modified PCPs and alkyl phosponate based superplasticizers

– can now help about this issue, by reaching an acceptable

compromise between rheological and strengths properties.From a bleeding mix…to a cohesive SCC mix using a Viscosity Modifying

Admixture

Admixtures




, by increasing the freeze-thaw resistance of concrete. Also,

the so-called “corrosion inhibitors”, based mostly on calcium

nitrite or more recently on amine technologies, will directly

fight against the aggressive agents - chlorides in that case.

These admixtures will chemically neutralize the chlorides,

slowing down or stopping their penetration in the concrete.Some simplified tools (e.g. the American software Life-365)

can be actually used to simulate their benefit on the life span

of the structure.

Unlike these admixtures specifically designed for durability

purposes, it is interesting to bring up the case of products that

found a secondary function as durability enhancers. Surface

retarders is one typical example: normally designed for aesthetic

purpose (it allows to produce exposed aggregate concrete, by

removing the outer ‘skin’ of cement paste to uncover decorative

coarse aggregate), they can be advantageously used to ensure

the continuity of reinforcement at construction joints between

two concrete pours, which is a guarantee for a good durability

of the whole structure. Instead of hammering the upper surface

of the first concrete to make it rough, as we can still see on

some Indian job sites, this surface can be treated instead with

a surface retarder, providing a more regular surface attack.

The aggregates are then perfectly exposed for receiving the

new concrete, ensuring a good bound at the joint.

Conclusion

Following a mix design prescription that fixes ultimate strengths

has been often considered as a sufficient guaranty for

qualifying concrete durability. However, many other factors

related to concrete properties (more than just the porosity),

environmental conditions and production process, have a

direct influence on the durability. As we saw, concrete admixtures

producers can play a significant role in all these fields, as

they have now well understood the new potential of their

product on the durability aspect. Their contribution however -

especially with the newest superplasticizer technologies - will

be only complete if the project designers accept to approach

durability more performance wise, a trend seen more and

more in European concrete regulations.

Impact of the W / C ratio decrease thanks to a PCP based superplasticizer on

water permeability

The admixture chemistry can be also very helpful to support

the use of some particular concrete raw materials, like theSupplementary Cementitious Materials (SCM). Within blended

cements or added separately as a partial replacement for the

Portland clinker, SCM materials contribute to a significant

reduction of the carbon footprint, improving directly the durability

of the concrete, sustainability wise. Furthermore, many of them, like

fly ash or slag are able to improve some physico-chemical

characteristics of the concrete related to durability: one the

physical side, they improve further the compacity of concrete

mixes thanks to their fineness, on the chemical side they

can fight against aggressive exposure conditions, like

corrosion induced by chlorides, sulphate disorders or alkali

silica reactions (ASR). Also, the risk of thermal cracks, dueto young concrete heat generation wave and its volume

variation (expansion / contraction), especially in massive

concrete works, can be minimized using SCM materials.

Well documented, the synergy between such materials and

conventional retarding admixtures has been proven years

ago, to help to maintain temperature gradients into concrete

at acceptable levels. However, putting high amounts of

SCM materials can affect some concrete properties: often

a decrease of the workability window, due to less soluble

alkalis in the total binder, or a delay of setting times and early

strengths. Admixture suppliers are now well aware of these

issues, and they adapt their chemistry, especially the PCP

based superplasticizers, to be fully compatible with SCM

materials, by speeding up the strengthening process or by

adding some specific slump extender admixtures to retain

properly the workability.

It is worth mentioning that some admixtures were specifically

developed in order to improve specific durability performances

related to physical or chemical concrete characteristics: air

entraining agents for example, that avoid cracks due to the

volume expansion of the frozen water left in the concrete pores.

Such admixtures, providing a closely and uniformly distributed

network of air bubbles, work therefore as real durability enhancers

Author Bio

Philippe Ortega is a graduate in Chemistry from Lille

university (France). He joined CHRYSO in 1998 in order tostart the first developments on Self Compacting Concrete

in the German Precast and Readymix industry. From 2002

up to now, he works in the CHRYSO concrete business

unit, in charge of the technical development and support

in many countries (India, USA, European countries…),where he has been given the opportunity to participate to

the achievement of big job sites (ex. Nancy creek Tunnel,

USA, Millennium Bridge, Poland…).

Admixtures




Positive Waterproofing fromNegative Side

W

ith the increase in infrastructural projects, use of

underground constructions is tremendously increased.

Scarcity of land at ground level necessitates underground

metros in crowded cities. Distances of rail and roads are

lowered by tunelling through mountains and under the bed

of water. Deeper basements are part of construction activities

civil and geotechnical engineers are facing challenges firstly

to gather geotechnical data and later to select construction

techniques to complete projects on schedule. In spite of

technological advancements in geological strata mappings,

the real problems are faced while actual construction is going

on. Since the exact nature of strata cannot be predetermined,

civil engineers have to resolve problems at site. Rehabilitation

of underground structures pose major problems as usually

only the internal face is accessible and the problem is always

on the other side. Movement of water is one of the majorimpediment to underground construction. Leakages can

be uncontrollable and have to be repaired immediately. If

leakages are not arrested early, the consequential damages

to structures can be time consuming and costly to repair

throwing the deadlines out of gear and endangers the very

stability of structures. Fig 1 shows different types of Cracks in

Tunnel linings. Fig 2 shows critical water ingress.

Any repair based on predetermined material is bound to

be ineffective. Sound principles of civil engineering is the

Samir SurlakerManaging Director, MC-Bauchemie

Waterproofing

base to all repairs, rehabilitation or retrofitting. So positive

waterproofing is possible from negative side.

In many waterproofing projects, damp-proofing systems arespecified and waterproofing is expected of them. There is a

major difference between waterproofing and damp-proofing.

As per ACI Committee 515 report, waterproofing and damp-

proofing is defined differently. Waterproofing is a treatment of

a surface or structures to prevent the passage of water under

hydrostatic pressure. Dampproofing is a treatment of surface

or structure to resist the passage of water in the absence

of hydrostatic pressure. While designing the waterproofing

system, actual service conditions are to be borne in mind. It

should be decided at this stage whether damp-proofing is

required or waterproofing is desired.

Positive side waterproofing systems are applied on the same

side as the applied hydrostatic pressure and negative side

waterproofing systems are placed on the side opposite

the applied hydrostatic pressure. Previously negative side

waterproofing was only adopted when access to positive side was

unavailable as in case of common boundary lines. Negative

side waterproofing systems were also used as repair strategy

because the positive side was inaccessible and the back fill or

protective layers had to be removed. There is an increasing trend

in the country to specify negative side waterproofing.

If the negative side waterproofing systems are unavoidable,

extreme care should be exercised during the construction

process. First and foremost, the concrete cast should be of

very low permeability without honeycombing, cracks, crevices or

any other surface defects. Efficient drainage systems are

mandatory. Provision of water stops is also mandatory, as this

is first line of defense in case of negative waterproofing. Fig

3 shows schematically the positioning of positive side and

negative side waterproofing.

It should be clearly borne in mind that negative side waterproofing

accords no protection to concrete if soils contain corrosive

chemicals. Extreme precautions should be taken at joints




between walls and floors and careful detailing is required to

maintain integrity and water tightness. In every case it seems that

negative waterproofings are chosen over positive waterproofing

on account of ease of application and this trend should be

discontinued in favour of positive waterproofing. Negative

side waterproofings are also inefficient against high vapour

permeability and therefore are ruled out when the interiors are

to be used for humidity sensitive applications.

Waterproofing as a System

Waterproofing treatments cannot be carried out by application

of single material on new concrete or existing treatments. There

cannot be a single material that is right for every structure. Most

of the failures in the waterproofing treatments are on account of

this misconception. The only way to ensure reliable treatment

is by considering the waterproofing treatment as a system.

System for waterproofing can be defined as combination of

materials, preparation of specifications, application techniques

designed by taking into considerations the requirement of theclient or home owner, which would provide efficient, reliable

and long term protection to concrete structures with minimum

maintenance costs. Waterproofing should never begin with a

specific material in mind. The properties of material are to be stated

and then the material is to be selected as per the merit.

In case of underground structures the design has to consider

the soil mechanics aspect like variable strata, unsuspected

Crack Injection

• Structural injection for dry cracks

• Structural injection for damp cracks

• Sealing of cracks and cavities for waterproofing

• Sealing against pressurized water

• Injections for imparting stability in Masonry structures• Frictional Sealing of loose masonry

• External sealing using curtain injection technology

• Grid injection for dampness

Table 1 : Different types of Crack In jection

Fig 2: Water Ingress which can be stopped

Fig 3 : Comparison of Positive Side & Negative Side Waterproofing

streams etc. which may contribute to the hydrostatic pressure.Efficient drainage systems should be designed to avoid build

up of hydrostatic pressure due to stagnation of water against

waterproofed surfaces. If necessary, the path of water should

be re-routed with proper grading to control surface runoffs.

Well connected network of perimeter drains connected

to vertical drainage system is the key to achieving perfect

waterproofing of subgrade structures. Fig. 4 shows basement

waterproofing system designed with efficient drainage for a

very high water pressure. Geotextile filter fabrics are normally

designed for a narrow range of permeability. The filters are

efficient guard against silt collection in aggregate drainage

system as they avoid clogging of drainage conduits. Difficultground water conditions can be overcome by providing well

designed geodrainage systems which would eventually lower

the hydrostatic pressure on waterproofing barrier system. If a

sump is provided the pumping system should be proportionate

to collection of water.

Reasons for Crack Injection

The other major avenue for water entry into structures are

cracks. Cracks threaten the durability of buildings. Moisture

ingress restricts the usage of buildings and may ultimately

lead to adverse economic effects inclusive of collapse of

Waterproofing




effectively at a later date. The material used for such cases

must display excellent flow properties. Fig 7 shows usage of

different materials for different Injection types.

Guideline for Material Selection

The selection of material for injection in the crack largely depends

upon the investigation and primarily the following factors:

- Pattern of cracks

- Width of the crack

- Movements in the crack faces

- Due to temperature variations

- Due to dynamic loadings

- Moisture in the crack

- Dirt in the crack

Available Options

Duromer Resins: Duromer Resins have been used for many

Fig 4: Subgrade waterproofing system with drainage

Fig 5 : Grid Injection Principle

structures. The combined effect of moisture ingress and frost

may even aggravate existing damage. Due to its increased

volume, ice causes more serious crack damage and large-

area frost heave. Cracks can endanger the stability of entire

buildings. Apart from the structural aspects, the entire

appearance of a building – an important criterion for the valuationand assessment of buildings – is considerably impaired by

cracks and deterioration that is brought about by water entry

and chemicals ingress. Table 1 shows various reasons for

Injection. Usually three different systems are specialised

applications to solve critical problems:

Grid Injection: Water penetration is often caused by bad

concrete compaction, honey combing or defective seals.

This is rectified by using grid injection systems a special

technology developed from the standard injection process.

Fig 5 shows a Grid Injection Principle and Fig. 6 shows the

process.

Waterbar Injection: A special injection application is waterbar

injection where waterbars are used to seal joints in moving

structures against pressurised water. However, the concrete often

proves to be a weak point in the area of the waterbar because

of inadequate compaction. Waterstop Injections effectively

clear off this defect and render structure waterproof.

Reinjectable hose Injection: Other critical areas with regard

to the watertightness of a building or structure are expansion

joints that are not sealed with waterbars. Inserting injection

pipes provides the possibility of sealing expansion joints

Various Injection Material Bases

PU/Hydrostructural Elastomers

• Water foam and bubble

• Adhere extremely well to wet substrates

• Good Performance with water

Cementitious• Water is a parpt of the curing process

• Must have water to build healing crystals

• Good Adhesion

Good Performance with water

EP / Duromers

• Foam and bubble with water

• Bubbles contain air, reduced strength

• Poor adhesion

• Bad Performance with water

Acrylic Gel/ Hydrostructure

• Consists of 80% water

• Adhesion is reasonable

• movement is excellent

• Good Performance with waterTable 2 : Different Injection Materials

Fig 6 : Process of Grid Injection

Waterproofing




years for the rigid injection of cracks in dry structural sections.

Epoxy resins of very low viscosity can be injected into the finestof cracks. This guarantees a strong permanent bridging of

both sides of the crack, thus restoring bearing capacity for the

designed loads planned. This process can also be carried out

where the structure is also subject to vibration. Duromer resins

of varying viscosity can be used for injection and impregnation

depending on the width of the crack.

Elastomer Resins: If rigid injection material is used the cracks

become visible after injection or new cracks develop adjacent

to old cracking. High quality elastomer resins are a solution

for avoidance of such occurences. Elastomer resins can be

designed with distinct pore structures. An homogenous closedcell structure is formed which enables safe sealing. The

integrated compression and decompression reserves in the

cell structure absorb the expansion and the contraction in

the crack. The effectiveness and permanency of the seal is

guaranteed by the ability to expand and contract in sympathy

with the crack movement while maintaining the tenacious

bond to crack surfaces.

Hydrostructural Resins: Hydrostructural resins cure to form

elastic membrane and impervious seals when encountered

with water. This property is very useful when the external of

building is not accessible like in buried structures and when

the external waterproofing envelope is damaged. By drilling

How to choose the right product - Job Conditions

These are problems which injection can solve

Sealing

Coming from

• movement cracks

• stationary cracks• construction joints

• expansion joints

• bad construction

• All needs flexible filling

Strengthening

Cracks coming from

• mechanical damages damages caused by earth movements

• general wear and tear

• Bad construction

• All needs rigid filling

Table 3: Selection of Materials

Fig 7: Crack V/s. Materials to be used

Fig 8: Showing Hydrostructure Resin PU Foam

through the structure to the interface between existing water-

proofing membrane or protection board, hydrostructure

gels can be injected to recreate the seal. Hysdrostructure

resins can be designed for high chemical and mechanicalresistances. Fig 8 shows water reactive Pu Foam. They

guarantee permanent elasticity, tenacious and isotopic bonding

and unique skin effect. Fig. 7 different material for different

injection types.

The Process of Injection

After completion of diagnosis and selection of materials for injection

the work of injection passes through following stages.

- Preparation of the crack

- Location of points (nipples) for injection

- Fixing of injection points

- Surface sealing of cracks

- Injection of resin proper

- Removal of nipples and plugging

- Removal of sealing material

- Final surface treatment after injection resin/grout hardens

Components and Machinery

Proprietary materials and machineries are available for treating

the cracks by injection system. The materials are mostly

synthetic resin based or cement based. The synthetic resins

are usually two component materials based on epoxies and

polyurethane. The cement based materials are invariably

modified with polymers to impart flowability, non shrinking

characteristics, better bonding etc.

The first step is selection of packers. It is important that packers

are in the form of metal or plastic tubes. They should be able

to be connected to the injection nozzle, so that the pressure

if any should not be lost. Thereafter, it should be possible to

tie or seal the packers, so that the resin is not lost and they

should be removable to enable the surface smoothening.

Normally there are two types of packers.

Waterproofing




Waterproofing

The packers, which can be stuck to the surface of the structurealong the line of crack, if the surface is even and packers

which are to be introduced in the structure after boring and

inclined at 450C to the crack plane. The spacing of injection

points depend upon the width of crack as well as the porosity

of concrete. However, as a thumb rule, in case of adhesion

packer, the spacing should be about 50% of concrete cross

section. Adhesion packers should not be used for high pressure

injections exceeding 60 bars. Fig. 9 shows both types of

packers.

Packer or Packer Systems are the link between the structure

and face of the crack and the injection nozzle. Packers must

be of adequate size to gurarantee the flow of injection resin to

the desired place with or without being displaced or debonded

due to injection pressures or rebounds. The critical selection

depends upon the access to crack, quality of surface, surface

condition as well as pressures used in injection process. Table

5 shows Technical data about packers.

There are Normally Three Types of Packers used Under

General Conditions

Adhesion Packers: for the injection of dry cracks, cavities and

substrates with epoxy and polyurethane resins where surface

conditions are suitable.

Drill or Bore Injection Packers: for the injection of dry, moist

and water bearing (pressurized and Non-presurrized) cracks,

cavities and substrates with epoxy, Acrylic and Polyurethaneresins

Hammer Packers: for the injection of cement injections and

acrylic gels. Fig. 10 shows different packers for Injection.

The more sophisticated the machinery, the better the control

and therefore the performance. Secifications written in

office can be perfectly adhered to at site and controlled via

good supervision. Present day gel injections with a very low

setting and reaction times require 2 component machineries

which can mix materials at the nozzle. Fully computerized

attachments can measure the pressure, control per point, idle

time, time taken for injections and this data can be mentionedfor documentation purpose. Further such data can be used by

owner to control the quantity of repair process and materials

respectively. The supervision at site is very essential to ensure

that the specifications are strictly adhered to. The temperature

plays very important role in the performance of some resin

based systems: and therefore manufacturers instructions as

to the environmental temperature as well as the temperature

of the component in which the material in injected are to be

followed.

The simplest of the injection method is the brush injection.

The resin is brushed on the non moving surface cracks and is

absorbed in capillary action. In case of pressureless injection

the material is poured into the packers especially in case of

pipes acting as packers, the use of such injection depends

largely on the dimensions of the crack. In case of structural

cracks of the width 0.2 - 1.0 mm, it is advisable to resort to low

pressure injection. This low pressure can either be created

with hand guns (sealant guns, grease guns etc) or a normal

compressor used at site. The pressure developed is around

6 - 10 bars. Depending upon the crack widths and depths,

high pressure injections can be resorted to for structural

crack repairs. It is possible to develop pressures to the tune

of 500 bars using mechanical or pneumatic transmissions.

The injection method should be clearly specified prior to

the commencement of the work and should be supervised

to conform with the specifications. Fig 11 shows Injection

Machineries.

Modern Injection Techniques

When problems cannot be resolved by conventional methods

of grouting and injections the resort can be made to modern

injection techniques in which external envelope can be

created by working from inside the structures. This means

creating positive waterproofing from negative side. This

Fig 9: Different Packers for Injection

Fig 10: Showing Different Packers




technology involves new machineries, new materials and

trained applicators as the technology is state of art. In order

to ensure durability and, in particular, bearing capacity, the

permissible crack width in the relevant norms is confined to a

harmless size. If this width is exceeded, there is a danger of

further secondary damage to the building or structure. Crackssmaller than the permissible maximum width can, when

penetrated with water, also detrimentally affect the structure

concerned. To maintain and restore operational use, any cracks

appearing in a building or structure must be sealed. Various

injection procedures are used depending on the cause of the

crack and individual requirements. The material is injected into

the crack through injection packers and a specially designed

machine. The objective is the closing and sealing of the crack

as well as the expandable or rigid bridging of the sides of the

cracks.

Epoxy resins have been used for many years for the rigid

injection of cracks in dry structural sections. Epoxy resins of

very low viscosity, can be injected into the finest of cracks. This

guarantees a strong permanent bridging of both sides of the

crack, thus restoring bearing capacity for the loads planned.

This process can also be carried out where the structure is

subject to vibration. Epoxy resins of varying viscosity can

be used for injection and impregnation depending on the

width of the crack. Mineral injection systems also fulfil the

requirements of rigid injection.

The newly developed cement based suspensions are suitable,

in particular, for injecting moist cracks bearing pressureless

water as well as dry cracks and can even be used for the rigidinjection of cracks down to 0.2 mm vide.

Even newly erected buildings and structures often show

signs of defects in the form of cracks or cavities caused by

damage. Mineral injection systems really come into their own

in these cases because they are not sensitive to the moisture

contained in new concrete. Rectifying defects with mineral

polymer cement injection makes the building or structure

appear as a unified entity for inspection purposes as well as

restoring the structural integrity.

Structures located in groundwater and pressure waterenvironments, e.g. tunnels, reservoirs, etc., often display

pervious areas, which can considerably impair the use of the

structure in question. These pervious areas can be caused

by cracks, voids or faulty seals. Water-bearing cracks make

particular demands on injection technology. The objective

is to seal an existing structure to prevent water penetration

without impeding the normal expansion and contraction

of the structure. Structures with water-bearing cracks are

normally accessible from one side only. If the actual seal can

only otherwise be repaired at a great expense, the only truly

economical way of achieving permanent success is to use

injection technology developed polyurethane-based injection

systems for such cases and these have proved successful

over many years. Permanent seals are achieved by using

PU Injection with its outstanding material properties which

was by forming an even closed pore structure. The result

is a plastic workable product which makes flexible injection

sealing possible. Even cracks bearing pressurized water

can permanently sealed. In this case, a fast-foaming water-

stopping polyurethane, can be used.

Water penetration is often caused by bad concrete compaction,

honey combing or defective seals. This is rectified by using

grid injection systems, a special technology developed from

the standard injection process. Fig. 5 shows the principle ofgrid injection of creating positive waterproofing from negative

side. Fig. 6 shows the process of injection and grid matrix.

A special injection application is waterbar injection where

waterbars are used to seal joints in moving structures against

How to choose the right product - Site Conditions

Few are only 2 site conditions which has to be taken into con-

dition when injection shall be attempted

Wet Cracks

• movement cracks• stationary cracks

• construction joints

• expansion joints


• Needs Hydrostructure Resins and gels for flexible filling

Dry Cracks

• Non moving cracks

• mechanical damages

• damages caused by earth movements

• general wear and tear


• Needs Duromers for Rigid filling

Table 4 : Selection of Materials Fig 11: Injection Machineries

Waterproofing




pressurized water. However, the concrete often proves

to be a weak point in the area of the waterbar because of

inadequate compaction. This technology is further proof of

the effectiveness of solving structural problems with special

injection systems.

Other critical areas with regard to the watertightness of a

building or structure are expansion joints that are not sealed

with waterbars. Inserting injection pipes provides the possibility

of sealing expansion joints effectively at a later date.

The material used for such cases must display excellent flow

properties. Viscocities play a major role in injection techniques.

The reaction times also are very important. Secondary injections

are a must.

All cracks are different. They vary depending on the construction

material, cause, location and environment. Quite often,

cavities in the fabric of construction materials, construction

joints or foundations with insufficient load-bearing capacity

require injection measures. One single system is not able

to achieve durable and reliable results. Various solutions

based on different materials which are tailored to specific

application needs are now available to users. Table 2 showsdifferent available materials. A range of solutions is essential

depending upon job and site conditions. Table 3 and 4 shows

selection of materials with respect to these conditions. The

use of unsuitable materials or techniques may necessitate

costly subsequent reconstruction, which are more expensive

than correct action right at the outset. These additional costs

are avoidable through technical approach. Experience has

shown that a superficial solution will necessitate further repair

measures.

Very low-viscosity, highly cross-linked series of duromers

easily penetrate into the crack also filling the so called crack

root. This ensures a seamless, rigid bonding of the crack edges.

These highly cross-linked duromer resins are also the right

choice for critical joints, where all important static forces are

being transmitted. The properties of the injection material

must be compatible with the parent material. The structuralmechanics of the injected element should remain unaffected.

This is an important aspect when carrying out construction

works on concrete or masonry buildings that are classified as

historical monuments. Cement suspensions are insensitive to

varying moisture levels in the building. Even large volumes of

injection are possible with cementatious suspensions suitably

modified to low viscosities and having non shrink properties.

They ensure a high degree of efficiency enabling a reduction

in restoring costs.

Conclusion

Occurrence of cracks is practically unavoidable in structures.The modern building chemical technology coupled with

proper equipment can solve almost all types of rehabilitation

problems thereby providing economical solution in comparison to

demolition and reconstruction of structures. The specifications

should be very clear and unambiguous. The specifications

should at least cover points like material, viscocity, techniques

to be adopted, the equipment to be employed, type of nozzles

and spacings, pressure to be applied etc.

The supervision at site is very essential to ensure that the

specifications are strictly adhered to. The temperature plays

very important role in the performance of some resin basedsystems: and therefore manufacturers instructions as to the

environmental temperature as well as the temperature of the

component in which the material in injected are to be followed.

New Injection technology accommodates not only new

materials but also advanced machineries and trained

applicators. The latest injection methods and processes can

arrest heavy water leakages in couple of minutes and therefore

require precision mixing proportions and split second

timing to achieve immediate gelation. It must therefore be

first determined what is the purpose of injection and from

this decision one should proceed to selection of materialand adequate packers and machineries. Right decision at

this stage is prerequisite for avoidance of failure. Planning

therefore and technical guidance becomes key factor in the

process of decision making sound knowledge of soil structure

interaction, technical know how of material chemistry coupled

with trained applicators are required to successfully carry

out the job under actual site and job condition. Any repair

based on predetermined material is bound to be ineffective.

Sound principles of civil engineering is the base to all repairs,

rehabilitation or retrofitting. So positive waterproofing is possible

from negative side.

Packers

Adhesion

PackerDrill Packer

Hammer

Packer

Material SteelAluminium-

base alloy

Plastic

Measurements

Plate 38 x 43

mm shank 23

mm

115 x 13 mm 115 x 23 mm

Valve Orifice 1.5 mm 1.5 mm 4.5 mm

Permitted max

pressure in

concrete

60 bar 200 bar 30 bar

Permitted max

pressure in

masonry

20 bar 20 bar 30 bar

Loss of pressure 10 - 15 bar 10 - 15 bar < 1 bar

Table 5 : Technical data about packers

Waterproofing




Concrete Recycling

Bhavani Balakrishna

Concrete Recycling:The Need of the Hour

s l a n d f i ll c o s t s f o r c o n s t ru c t i o n,

d e mo l it i o n, a n d la n d- c le a ri n g Ad e b r is c o n t i n ue t o r i s e , a n d t h e

l a n d fi l l s b ec o m i n g h e a v i ly r e g u la t e d , i t

makes commercial sense to seek alter-

n a ti v e m ea n s of d i s po s al o f c o nc r et e

f r o m c o n s t ru c t i o n a n d d e m o l i t io n o p e r -

a ti on s. H ow ev er, i n m an y p ar ts of t he

w o r l d t h e p o t e n ti a l t o r e c o v e r c o n c r et e

i s o v e r l oo k e d , a n d i t e nd s u p a s u n n ec -

e s s a r y w a s t e i n l a n d fi l l .I t is estimated that roughly 25 billion

t o n n e s o f c o n c re t e a r e m a nu f a c tu r e d

g l o b al l y e a c h y e a r. Tw i c e a s m u c h c o n -

c re te i s u se d i n c on st ru ct io n a ro un d t he

w o r l d t h a n t h e t o t a l o f a l l o t h e r b u i l di n g

m a te r ia l s, i n cl u di n g wo o d, s t ee l , p l as -

t i c a n d a l u m in u m . A b o u t 1 , 3 0 0 m i l l i on

t o nn e s o f w a st e a r e g e n e ra t ed i n E u ro p e

e ac h y ea r, o f w hi ch a bo ut 4 0 %, o r 5 10

m i ll i o n t o nn e s, i s c o ns t ru c ti o n a n d d e-

m ol it io n w as te ( C & DW ). Th e U S p ro -

duces about 325 milliontonnes of C&DW,

andJapan about 77 milliontonnes. Given

t h a t C h i na a n d I n di a a r e n o w p r o d uc -

i n g an d u s in g o v er 5 0 % o f t h e w or l d' s

c on cr et e, t he ir w as te g en er at io n w il l

also be significant as development con-

tinues. A study conducted by the Jawaharlal

N e hr u N a ti o n al U r ba n R e ne w al M i s si o n

( J N N UR M ) s t a t es t h a t i n I n d i a, t h e c o n -

s t r u c ti o n i n d u s tr y g e n e ra t e s a b o u t 1 0 -1 2 m i l l i o n t o n n e s o f w a s t e a nn u a l l y. T h e

c o n s t ru c t i o n a n d d e m o l it i o n i n d u s tr y i s

o n e o f t h e c o u n t ry ' s l a r g e st w a s t e p r o -

ducers, contributing around 17 percent

o f w a st e th a t i s s en t to l an d fi l l . C o n-

c r e t e , s h u t t er i n g m a t e ri a l , p a i n t, b r i c ks ,

t i l e s , w o o d , m e t a l , d e b r is a n d m a s o nr y

a cc ou nt f o r s uc h c on st ru ct io n w as te .

M o st o f t h is c a n b e r ec y c le d b ut c o n -

c r et e a n d m a s o nr y, w h ic h c o ns t i tu t es

o v er 5 0 % o f t h e c o n st r uc t io n w a st e , a r e

n o t b e i n g r e c y c l ed i n I n d i a.I n s o me c o u n t ri e s , w a st e c o n cr e te

i s ty p i c a ll y p u t i n l a n d fi l l b u t c o u n t ri e s

l i k e N e t h e rl a n d s , J a p a n, B e l g i um a n d

G e r m an y a r e en s u r i ng h i gh l e v e l s o f r e -

c o v e r y t h r o u gh m a n d at o r y p o l i c ie s a nd

l ev ie s . S ca rc it y o f a gg re ga te s i s al s o

ma ki ng r ec ov ery n ec es sa ry. I n t he

N e t h e rl a n d s , c r u s hi n g w a s t e c o n c r e t e

t o r e c y c le i t h a s b e e n c o m m o n p r a c t i c e

f o r m a n y y e a r s du e t o a s h or t a g e of n a t -ural aggregates and a lack of available

landfill space.T h e r e co v e r y a n d r e us e o f c o n c r et e

is achievable and will contribute to sus-

t a i n ab l e b u i l d i n gs a n d u r b a n s o c i e ti e s

o f t h e f u t u re t h r o u gh s a v i ng s i n n a t u ra l

resources, materials and energy

S i g n if i c a nc e o f C o n c re t e R e c y cl i n g

Concrete recycling reduces the use

o f v i r g in a g g r eg a t e a n d i t s as s o c i a te d



Concrete Recycling

99www. masterbuild er. co. in · T h e M a s t er b u i l d er - J u ly 2 0 13

processed to produce aggregates suit-

a bl e fo r u se i n n ew c on cr et e. T he p ro -

c es si ng , a s w it h m an y n at ur al a g gr e-

g at es , g en er al ly i nv ol ve s c ru sh in g,

g r a di n g an d w as h i n g . T h i s re m o v es

c o n t am i n a nt m at e r i al s s u ch a s r ei n -

f o rc i ng st e el , r e mn a nt s o f f o rm w or k ,

g y p s u m b o a r d, a n d o t he r f o r e i gn m a t e -

rials. The resulting coarse aggregate ist h e n s u i t a bl e f or u s e in c o n c r et e .

T h e f i n e a g g r eg a t e , h o w e v e r, g e n -

e r a l ly c o n t a in s a c o n s i de r a b le a m o u n t

o f o l d ce m e n t p a s t e a n d m o r t ar. T h i s

tends to increase the drying shrinkage

a nd c r ee p p ro pe rt ie s o f t he n e w c on -

c r e t e, a s w e l l a s l ea d i n g to p r o b l em s

w i t h u n w o r ka b l e m ix a n d s tr e n g th . T h e

c h l o r id e c o n t e nt of r e c y c l ed ag g r e -

g at es i s o f c on ce rn i f t he m at er ia l i s u se di n r e i n fo r c e d c o n c r et e . T h e a l k a li c o n-

e n vi r on m en t al c o s ts o f e x pl o i ta t io n a n d

t r an s po r ta t io n . I t s u s e c a n p o te n ti a ll y

s h or t en p r oj e ct d e l iv e ry a s a r e su l t o f

e x p e d it e d c o n s t r u c ti o n s c h e d ul e s d u e

to reduced haul times. The potential for

i n c r e as e d m a t e r i a l t r a n s p o rt a t i o n s a v -i n g s is e v e n g r e a te r w h e n t h e r e i s n o l o -

cally available aggregate, and aggregate

has to be trucked in from farther away.I t also reduces unnecessary landfill

o f v a l u ab l e m a t e ri a l s t h a t c a n b e r e c o v -

ered and redeployed. According to the

Construction Materials Recycling Asso-

ciation, recycling concrete from demo-

l it io n p ro j ec ts c an r es ul t in c on si de r-

able savings because it saves the cost

o f h a u l i ng br o k e n c o n c re t e t o la n d f il l s

and eliminates disposal costs.R e c o v er i n g c o n c r e te , h o w e v e r, h a s

n o a p p r ec i a b l e i m p a ct o n r e d u ci n g

g r e e nh o u s e ga s e m is s i o n s a s i n t h e

p r o d uc t l i f e c y cl e o f c o n c re t e , t h e m a in

s o u r c e o f c a r b on e m i s s io n s i s th e ce -

m e n t p r o d uc t i o n p r o c es s ( c e me n t i s

added to aggregates to make concrete).

C o n c re t e R e c y cl i n g S o u rc e s

W h il e c o nc r et e c a n b e r e cy c l ed f r om

r e tu r ne d c o nc r et e t h at i s f r es h ( w e t) f r om

r e a d y- m i x t r u c ks , p r o d uc t i o n w a s t e a t

a pr e -c a st p ro d uc t io n f a ci l i ty o r w a st e

f r om c o ns t ru c ti o n a n d d e m ol i t io n , t h e

most significant source is demolition

waste.

R e c y cl e d C o n c re t e A p p l ic a t i on s

C o nc r et e i s b r ok e n d o wn i n to a g gr e -

g a te f or u s e i n a n ew l i fe . T h is n e w l i fe i s

u s u a ll y r o a d w o r k s a g g r eg a t e s, b u t i n

s o m e a re a s , i t i s a l s o u s e d as a g g r e-

g a te s i n n e w c o nc r et e . R e cy c le d a g gr e -

g a te a c c ou n ts f o r 6 % t o 8 % o f a g gr e -

gate use in Europe -the greatest usersarethe U nitedKingdom,the Netherlands,

Belgium, Switzerland and Germany.

U se a s A gg re ga te i n R oa d B as e a nd

Pavements

The recycled concrete aggregate

( R C A ) c a n b e d e f i n ed a s c r u s h e d c o n -

crete composed of aggregate fragments

c o at e d w i th c e me n t p a st e or c e me n t

m or ta r f ro m th e de mo li ti on o f t he o l d

structures or pavements that has been

Recycled ag g re-g ate accounts f or 6% to 8% of ag g reg ate use in Europ e -the greatest users are theU n i t e d K i n gd o m , t h e N e t h e r l a nd s , B e l g iu m , S w i t z er l a n d a n d G e r m a n y.

T h e p r a c ti c e o f r e c y c li n g d e m o l it i o n w a s t e t o p ro d u c e a g gr e g a te f o r u s e i n r o a d b a s e i sp o p u l ar a n d w i d e s p r e ad .




R e u s e f o r E m b an k m e n ts & D r a i na g e

Fills

Recycled concrete that has not

b e e n s u b j e ct e d t o a n y a d d i ti o n a l p r o -

c es s in g o th er t ha n c ru sh in g c an b e u se d

f o r m a n y t y p e s o f g e n e ra l b u l k f i l l s , p r o -

t e ct i on o f r o ad s i de ba n ks , a s a fi l l f o r

d r a i na g e s t r u ct u r e s , f o r r o a d c o n st r u c -

t i o n o r a s e m b a nk m e n ts a n d n o i s e b a r -

r ie rs . I n g ene ra l, re cy cl ed c on cr et e

a g g re g a t e h a s g o o d d u r ab i l i t y a n d r e -

sistance to weathering anderosion, good

s t a b il i t y a n d l i tt l e p o s t co m p a ct i o n s e t -

tlement. However, the recycled concrete

a g g re g a t e c a n i n d u c e c o r r os i o n i n a l u -

m i n u m o r g a l v an i z e d s t e el p i p e s i n p r e -

s e n c e of m o i s t ur e d u e t o i t s h i g h a l k a-

linity.

Reuse in an original form for land-

s c ap i ng a n d o t he r p u rp o se s

R e us e o f b l oc k s i n t h ei r o r ig i na l f o rm ,

o r b y c u tt i ng t h e m in t o s ma l le r b l oc k s,

h a s e v e n l e s s en v i r o nm e n t al i mp a c t

a l t h ou g h o n l y a l i m i t e d m a r k et c u r r e n t ly

e x i s t s. I m p ro v e d b u i l d i ng d e s i g n s t h a t

a l l o w f o r s l a b r e us e a n d b ui l d i n g tr a n s -

f or ma ti on w it ho ut d em ol it io n c ou ld

i n c r ea s e t h i s u s e . H o l l o w c o r e c o n c re t e

s l a b s ar e e a s y t o d i s ma n t l e an d t h es p an i s n o rm a ll y c o ns t an t , m a ki n g t h em

g oo d f or r eu se . S ev er al b ro ke n c on -

crete blocks and crushed concrete are

e ff ec ti ve l y u se d f or l an ds ca pi ng . F or

i n st a nc e , t h e N i s s an A d va n ce d Te c h-

n o l o g y C e n t e r i n J a p an u s e d a l l t h e c o n -

crete debris from demolished univer-

s i t y b u i l di n g s w i t h i n t h e s it e w it h 7 0 % of

t he d eb ri s u se d a s p av em en t s ub gr ad e

a n d 3 0 % a s g r e e n e m b a nk m e n t f i l le r s

f o r o u t d o or l a n d s ca p i n g.

R e u s e i n s t r u ct u r a l c o n c r e t e

W h i l st t h e u s e o f r e c y c le d a g gr e -

gate has a reasonable track record in

l o w g r a de a p pl i c a t io n s , i t s us e i n s t r u c-

t u r a l g r ad e c o n c r e te i s a r e l a t iv e l y n e w

a r ea , t h ou g h s o me n o t ab l e s tr u ct u ra l

projects have been completed.

Ne ed fo r Ed uc at io n & Po li ci es fo r

A d o p ti o n o f R e c y cl e d A g g r eg a t e s

Government policies and initiatives

promoting or encouraging waste mini-

t en t a nd t yp e o f a gg re ga te i n t he s y st em

a r e p r ob a b l y u n k n ow n , a n d t h e re f o r e , i f

m i x e d w i t h u n s u i ta b l e m a t e ri a l s , a r i sk

o f a l k a li - s i l i c a r e ac t i o n i s p o s s i b l e .The practice of recycling demolition

w a s t e t o p r o d uc e a g g r e ga t e f o r u s e i nroad base is popular and widespread.

I t i s w e l l e s t a bl i s h e d o v er s e a s , d a t i ng

b a c k t o t h e r e bu i l d i ng o f E u r o pe a f t e r

W o r ld W a r I I . F r o m a s u s ta i n a bi l i t y v i e w -

p o i n t , t h e s e l o w -g r a d e u se s c u r r e nt l y

p r o v i de t h e o p ti m a l o ut c o m e i n m o s t

circumstances.W he n u se d a s a b as e a nd s ub -b as e,

recycled aggregate has been found to

h a ve s u p e r io r s t re n gt h t o v i r gi n a g gr e -

g a te , p r ov i d in g a v e ry g o od c o ns t ru c ti on

base for new pavement. Aggregate BaseC o ur s e, o r t h e u n tr e at e d a g gr e ga t es

u s ed a s fo u nd a ti o n f o r r o ad w ay p av e -

m en t, i s t he u nd er ly in g l ay er w hi ch f o rm s

a s tr uc tu ra l f ou nd at io n f or p av in g. A

c r o s s s ec t i o n o f p a v e me n t w o u ld s h o w

d i r t , o r s u b g r a de , a s t h e l o w e s t o f t h r e e

l e v e l s, w i t h t h e a g gr e g at e b a s e c ou r s e

a t t h e c en t e r a n d p av e m e n t (w h e t h er

concrete or asphalt) at the surface.T h e m a i n d r i v e rs fo r r e c y c l in g c o n -

c r e t e as a g g r e ga t e o r r o a d m et a l i n t h e

U S a r e r e g i on a l s h o r ta g e s /d e p l e ti o n o f

v i r g i n m a t e ri a l a n d r e l a t e d t r a ns p o r t a-

t i o n c o s t s an d t h e p o t e n ti a l t o cl a i m

c r e d it s u n d e r t h e L E E D c e r t i fi c a t i on f o r

b ui ld in gs by t he US G re en B ui ld in g

C o u n c il . C r e d i ts a r e a w a r d e d f o r d i v e r t-

ing demolished concrete from landfilld i s p o sa l b y r e c y c l in g i t i n t o a g g r e g a te

f o r r o ad b as e s o r c o ns t ru c ti o n f i ll a nd

f o r u s in g a p r op o rt i on o f r e cy c le d c o n-

crete aggregate for the project.R e c y c le d c o n c r et e c a n b e u s e d a s

c o ar s e a n d/ o r f i ne a g gr e ga t e i n P or t la n d

cement concrete (PCC) pavements.

However, concrete incorporating more

t h a n a b o u t 1 0 to 2 0 p e r c e nt f i n e R C M

a gg re ga te s c an s u ff er a re du ct io n i n

q u al i ty b e ca u se o f t h e h i gh a m ou n t o f

w a te r r e qu i re d t o m a in t ai n a d eq u at ew o r k ab i l i t y o f t h e c on c r e te m i x . T h e u s e

o f R CA i n n ew c on cr et e pa vi ng m ix -

t u r e s ha s b e e n r e p o rt e d , a n d r es e a r c h

f o r m a k i ng R C A a m o re v i a b l e o pt i o n

f o r n e w c o n c re t e p a vi n g m ix t u r e ap p l i -

c a t i on s h a s b e e n p e r f or m e d . R e s e a rc h

h a s s ho w n t h a t R C A c an b e u s ed s u c -

c e s s f ul l y a s b o th c o a r s e a n d fi n e ag g -

r e ga t e i n s u ch a p pl i c at i o ns . I n A u st r a-

l i a , R C A i s a l l o w ed a s a c o a r s e a g g re -

g a t e in n e w c o n c re t e m i xt u r e s f o r c u r b s

and sidewalks.

R e us e o f b l o ck s i n t h ei r o r ig i na l f o r m, o r b y c u tt i ng t h e m i n t o s m al l er b l o ck s , h a s e v en l e ss e n v i ro n m en t ali m p a c t al t h o u g h o n l y a l i m i t e d ma r k e t c u rr e n t ly e x i s t s.

Concrete Recycling




mization/recycling and proposed land-

f i l l l e v i e s c a n t o a l a r g e e x t e n t d ri v e t h e

a do pt io n o f r ec yc le d c o nc re te . I n t he

Netherlands, RCA is considered a prod-

u ct r at he r t ha n a w a st e m at er ia l, a nd

i n du s tr y i s i n vo l ve d i n t h e p ro c e ss i ng

procedures.M a ny E u ro p ea n c o un t ri e s pr o hi b it

discarding material in landfills that can

o t h e r wi s e b e r e c yc l e d . Ta x e s o n m a t e -r i a l s e n t t o t h e l an d f i ll a n d / o r t a x e s o n

t he m in in g o f v ir gi n a gg re ga te a ls o h el p

p r o m ot e al t e r n at i v e u s e s f o r R C A . T h e

r e cy c li n g r a te o f c o ns t ru c ti o n a n d d e -

m ol i ti on w as te i n D en ma rk , f or e xa m-

p l e , i n c r e as e d f r o m u n d er 2 5 p e r c e n t i n

1 98 7 , w he n a l an df il l ta x wa s in tr o-

d u c e d, t o 9 0 p e r c en t i n t h e f o l lo w i n g 1 4

y e ar p e ri o d , d u ri n g wh i ch i t w as i n cr e -

a se d t en -f ol d. I n 2 00 2, t he U K i nt ro -

d u ce d a l ev y o n n a tu r al a g gr e ga t e of

£ 1 .6 0 pe r t o nn e , w h ic h w a s i n cr e as e d

t h is y ea r t o £1 . 95 p er t o nn e ($ 5 ) . T h is

t a x in c r e as e d t he c o s t o f v i r g i n a g g r e-

gate from around 15 percent in London

a n d t h e H o me C o u n t i e s t o o v er 6 0 p e r -

c e n t i n s o m e r ur a l a r ea s . S o m e 2 5 pe r -

c e n t o f t h e U K ' s a g gr e g a te d e m a n d i s

n o w p r o d u ce d f r o m r e c y cl e d a n d s e c -

o n d a ry s o u r c es .The practice of recycling waste con-

crete as aggregate is also well estab-

l i sh e d i n t h e US , b u t no t t o t he e x t en t

t h at i t i s in E u ro p e. T h is m a y b e d ue t o

r a b i li t y p a r am e t e r s o f r e c y c le d a g g r e-

g a te c o nc r et e m ad e w it h r e cy c l ed

coarse aggregate collected from differ-

e n t s o ur c es . A l so , t h e s u it a bi l it y i n c o n-

s tr uc ti on o f b ui ld i ng s h as b e en s tu d-

i e d. T h e p r op e rt i es of r e cy c l ed c o n-crete aggregates RAC has been estab-

l i s h e d a n d d e m o ns t r a t ed t h r o u g h s e v -

eral experimental and field projects suc-

c e ss f ul l y. I t h a s be e n c o nc l ud e d t ha t

R C A c a n b e r e ad i ly u s ed i n c o ns t ru c -

t i o n o f l o w - r i se b u i l di n g s , c o n c r et e p a v -

i ng b lo ck s & t i le s, f lo or in g, r et ai ni ng

w a l l s , a p p ro a c h l a n e s, s e w e r ag e s t r u c-

t u re s , s u b ba s e co u rs e o f p a ve m en t ,

d ra in ag e l ay er i n h ig hw ay s, d ry l ea n

c o n c r et e ( D L C) e t c . i n I n d i an s c e n ar i o .

C o mm o nl y c i te d r ea s on s f or l i mi t -i n g t h e u se o f R C A i n cl u d e c o nc e r n s

related with the performance and qual-

ity o f RCA . For exampl e, a common

c o nc e rn i s t he u se o f R C A f r om c on -

crete previously exhibiting materials re-

l a te d d i st r es s . T h er e h a ve b e en s t ud i es ;

h o w e v er, t h a t d e m o ns t r a t e h o w p r o p er

m i t i ga t i o n e f f o rt s c a n m a k e R C A f r o m

s u c h c o n c r et e s o u r c e a v i ab l e o p t i on .

Contractors are also concerned that

RCA will result in inconsistent quality.

Educating contractors and owner-

agencies about methods for effectively

i n c o r po r a t e d R C A i nt o n e w c o n c r et e

m i x t ur e s c o u l d h e l p t h e i n d u s tr y o v e r -

c o m e th i s l i m it a t i o n. S u c h a n e d u c a ti o n

would require understanding the char-

a c te r is t i cs o f R C A , r e vi s i ng s p e c if i ca -

t i o n s f o r a g g re g a t e a s ne c e s s a ry, u n -

d e r s t an d i n g th e i m p ac t o f t h e u s e of

R C A o n f r es h a n d h ar d en e d c on c re t e

p r o p er t i e s a nd o n t h e d u ra b i l it y o f p a v e -

ments, and making appropriate adjust-

m e nt s in t h e d e ve l o pm e nt o f m i xt u re

p r o p or t i o n s a n d p r o du c t i o n m e t h od s .T h is e d uc a ti o n w o ul d s h ow c o nt r ac t or s

that RCA can be a cost-effective mate-

rial that will not compromise the quality

a n d re s u l t in a n i n d u s tr y w i d e ch a n g e i n

p e r c ep t i o n a b o u t t he u s e o f R C A .

T h e r e i s m o me n t u m a nd a n a p p e -

t i t e f or t h e r e cy c l i n g an d i n d ee d u p -

c y c l i ng o f w a s t e c o n c re t e . T h i s i s s e n -

s i bl e f ro m a n um b er o f p e rs p ec t i ve s ,

n o t l e as t o f w h ic h i s s o c ie t al e x p e ct a -

tion surrounding the issue.

the fact that the U SA is not a signatory

to the Kyoto Protocol and there is not a

n a t i o na l l a n d f i l l o r v i r g i n a g g r e g a t e t a x .I n c o u n tr i e s w h e re t h e c o s t t o p r o -

d u c e RC A m ay b e g re a t e r t h a n t h e c os t

o f a c q u i ri n g v i r g i n a g g re g a t e s, g o v e rn -

ment incentives and efforts to educate

t h e p u b l i c o n t h e en v i r o nm e n t al b en e -

f i t s as s o c i a te d w i t h t h e u s e o f R C A ar e

k e y t o p r o m o ti n g i n c r ea s e d a n d a lt e r -native applications As per the Cement Sustainability

I n i t i at i v e ( C S I ) , g o v e r nm e n t s a n d o t h e r

k e y s t ak e ho l de r s ar o un d t he w o r ld

should aim at developing economic in-

centives and legislation to promote more

r ec yc li ng , p ar ti cu la rl y t hr ou gh g re en

building initiatives. I t recommends set-

t i n g us a g e t ar g e t s fo r r e c y c le d c o n -

c r e t e i n r o a d c o ns t r u ct i o n a n d b u il d i n g

a n d c a ll s o n t h e c o ns t ru c ti o n i n du s tr y

t o g a t h e r w a s t e d at a t o g e n e r at e r e l i -

able global statistics.I n I n di a , S c ie n ce a n d E ng i ne e ri n g

R e s e a rc h C o u n c il ( S E R C) , G h a z i ab a d

d i d a n e x t e n si v e r e s e a rc h o n R e c y c li n g

a nd Re us e o f D em ol i ti on a nd Co n-

s t ru c ti o n W as t e s w it h t h e a im o f d e ve l -

o p i n g t e c h n iq u e s / m e t h od o l o g ie s f o r

u s e r e c y c l e d a g gr e g a te c o n c r e t e . T h e

experimental investigations were car-

r i e d o u t i n M a t S ci e n c e l a b o ra t o r y a n d

I n s t i tu t e s a r o un d D e l h i /G B D t o e v a l u -

ate the mechanical properties and du-

M a n y E u r o p ea n c o u n t ri e s p r o h i b it d i s c a r di n g m a t e r ia l i n l a n d f i ll s t h a t c a n o t h e r wi s e b e r e c y c l ed .

Concrete Recycling





atural wood is used in housing

a nd o th er c on st ru ct io n p ro -j e ct s i n v a ri o us a r ea s s uc h a sN

on landscaping garde ns and podiums,

d ec ks , p or ch , e tc . T he na tu ra l w oo da d d s t o th e ae s t he t i c l o o k o f t h e p r o -j e ct . T h er e a r e m a ny r o w h o us es an d

cottage s that are e ntire ly made out ofwood.

Natural wood structure s ne e d to be

p r o te c t e d we l l s o t h a t t h ey l a s t l o ng .T h e n a t u ra l w oo d g e ne r al l y c r ac k s w h en

the natural moisture from the woode s c ap e s t he w o od o v e r a p e r io d o ft i m e . A l s o d ue t o t h e m oi s t u re i n t h e a i r

a n d th e c on t ac t o f w oo d wi t h w a te r, i tmay le ad the wood to e xpand or crack.

Ev e rcre te Ev erwood is wate r base da n d i s r ea d y t o u s e on n a t u ra l w o od e nsurface s Ev e rcre te Ev e rwood re acts

w it h t he c el lu lo se i n t he wo od a nde n t ra p s th e na t u r al m oi s t u re o f t h ew o od . T h i s d e l a ys t he c ra c k i n g o f t h e

w o od , a n d t he w oo d e n s t r u ct u r es l a stlonge r. Ev e rcre te Ev e rwood also pro-

t e c t s th e w oo d f r om f u n g us , m o l d s,a n d i n s ec t d a m a g e, a n d r e du c e s t h ep ow de r f or ma ti on t ha t m ay g en er al ly

b e se e n i n w o od e n s u r fa c e s.W o o d e n s u r f a c e s t r e a t e d w i t h

Ev e rcre te Ev e rwood can be painte d or

p o li s he d e as i ly, w i th o ut t h e u se o f ap r i m er. E v e rc r e te E v e r w oo d h e l p s t o

e n h a nc e t h e b o nd i n g o f t h e p o l is h , e t c

w i t h t h e w o o d en s u r fa c e s.Once the woode n surface is tre ate d

w i t h E v e rc r e t e E v e rw o o d, i t i s r e c om -m e n de d t o a p p l y E v e rc r e t e To p S e a lo ve r i t. E ve rc re te To p S ea l i s w at er

b as ed , r ea dy t o u se wa te r r ep el le nt .Ev e rcre te Top Se al will re pe l the wate rthat comes in contact with the wood.

Evercrete Everwood and Evercrete Top Seal: Waterproof, Preserve and Enhance Life of Wooden Structures

It is not mandatory to use Ev e rcre teEv e rwood and Ev e rcre te Top Se al in

c on ju nc ti on w it h e ac h o th er. T he y c anbe use d indiv idually as we ll.

I n f a c t E v e rc r e te To p S e a l c a n a l s o

b e u se d on n a t u ra l s to n e s, t o p re v en t

t h e g ro wt h o f f u ng u s, m os s , a l ga e , e t c.Ev e rcre te Top Se al maintains the natu-r a l l oo k o f t h e s to n e , d o e s n o t c ha n g et h e na t ur a l co l ou r o r t h e te x tu r e o f t h e

s t o ne s . I t c a n a l s o be u s ed o n c o n c re t estructures which don’t need to be painted,

tomaintainthenaturalconcretelook.

F o r f u rt h er d e ta i l s:

Poly FlexE- m ail: p olyflex@p olyflex.c o.in

Web: w w w.p olyflex.c o.inT h e r i gh t s i de o f t h e p i ec e o f n a t ur a l w o od i s , t r ea t ed w i t h E v er c re t e E W . T h e c h an g e i n c o lo u r i s u n i f or m a n d n e gl i gi b l e

Th e rig h t side of th e piece of natu ral wood is treated with Evercrete EW and Evercrete TS. Th e area treated

w i t h E v e r c re t e T S , d o e s n o t a b s o r b w a te r.

T h e a r e a t r e a t e d w i t h E v e r c r e t e E W a n d E v e r c r e t e T Sdoe s abs orb wate r, e ve n during rains .

Th e rig h t side treated with Evercrete Top Seal does

not absorb water.




High Performance Concreteusing Microsilica

Surendra Sharma General Manager-Concrete.

Elkem South Asia.

High Performance Concrete

Need for High Performance Concrete

Concrete structure gets deteriorated on account of chemical

reactions such as corrosion of rebar or physical effects likeporosity which permits easy access of harmful ions into the

main body of concrete which makes concrete resistance weak

there by shortening the life cycle of concrete. Some of the

factors which affect durability of concrete are reinforcement

corrosion, chloride diffusion, carbonation, sulphate attack,

alkali silica reaction, frost action, leaching of concrete etc.

In practice, most of this deterioration of concrete cannot be

seen as they developed as concrete grow older.

Fig.1 below shows some of the damages and therefore as a

practicing engineer one need to design and place concrete

which is durable and sustainable in the long run.

Therefore as a good practicing engineer, the best way of

protecting these damages is to make concrete less permeable

as high degree of water saturation is seen as one of the causes

for durability problem. It becomes very essential to design

concrete with less porosity to protect the concrete as water

Fig. 1

is only medium through which chlorides, sulphate and other

harmful trace element can enter into concrete structure and

cause damages to concrete from inside .i.e. corrosion.

All major infrastructure projects are designed for 100+ years

and capital intensive. It becomes very essential to increase the

life cycle and produce the concrete which can last for longer

period and boost the nation’s economy. Replacing concrete

or structure is a costly affair.

ACI defines High Performance Concrete as “concrete meeting

special combinations of performance and uniformity require-

ments that cannot always be achieved routinely using con-

ventional constituents and normal mixing, placing and curing

practices.

Microsilica: Elkem Microsilica® is one of the principle productssupplied by Elkem Silicon Materials. It finds a wide range of

applications in high-strength concrete, High Performance

Concrete other building materials such as roof tiles and facade

cladding, and fire proof products for heavy industry.

Microsilica is also used for sealing tunnels and drilling oil

wells. Microsilica is proven mineral additive which has been in

use since many years to provide high performance concrete

solution to construction Industry. Worldwide 10 Million m3 or

even more concrete is produced with Microsilica. The ACI

defines Silica fumes as “very fine non crystalline silica produced

in electric arc furnaces as a by- product of the production

of elemental silicon or alloy containing silicon. Microsilica®

is having a very fine particle. The average particle size of

Microsilica is 0.15 µm.

The specific surface tested on BET method is minimum 15000

m2/Kg (See SEM Fig 2). Which provide better filler effects

and make concrete less porous and robust and it helps in

improving concrete resistance to chloride and sulphate attack.

Usually Microsilica available in condensed from. There are

two type of Microsilica available in the market.

1) Undensified Microsilica




2) Densified Microsilica

During Microsilica production, Undensified Microsilica is

densified by use of hot air which helps in increasing its bulk

density. It is essentially a non-hazardous material and fall into

general category of nuisance dust, which is similar to cement

and many other fine particles.

The relevant standard for Microsilica in India is IS 15388-2003.

Please see below the other physical and chemical properties

specification of Microsilica as outlined by different standard.

How does it work?

Microsilica has minimum 85%-99% of SiO2 which, make itvery reactive pozzolanic material in concrete. As we all know,

water is an essential element in the cement hydration process

and when one adds water to concrete; generally following

chemical reaction takes place.

Cement hydration

Portland cement (C3S, C

2S) + water = CSH + Ca (OH)

2

Secondary Pozzolanic reaction with Microsilica

Pozzolana (SiO2) + Ca (OH)

2+ water = CSH

Meaning you get more,

CSH-gel (binder)Denser concrete/good interface

Higher compressive strength.

Also, above chemical equation shows that free lime, Ca(OH)2

which detrimental to concrete is turned to something good

meaning more C-S-H (Calcium-Silicate-Hydrate) gel meaning

additional binder for given concrete which provide improved

strength and durability characteristics both at early age and

later age besides improving plastic properties.

Other value attributes of Microsilica in Plastic stage of

concrete

Generally the recommended dosage of Microsilica is 5 to 10%

Fig. 2

High Performance Concrete 0.45um

Bulk Density - Undensified Microsilica

Densified Microsilica

130 to 480 Kg/m3

480 to 720 Kg/m3

Specific Gravity 2.2

Physical properties of Microsilica.

USAASTM C

1240-2004

EUROPECEN prEN

13263: 1999

INDIAIS 15388: 2003

CANADA CSAA23.5-98

NORWAYNS 3045

AUSTRALIAAS 3582

Sio2

%> 85.0 85.0 85.0 85.0 85.0 85.0

SO3%< 2 1 3

Cl %< 0.3 Report if > 0.10 Report

CaO %< 2

MgO

Si (free) %< 0.4

Total Alkalies 1.5

Free C

Moisture Content %< 3 3 2

LOI %< 6 4 4 6 5 6

Specific Surface

m2 /gm>15 15-35 15 12





by wt of cementitious content depending upon the specific

characteristics that need to be improved in the concrete mix.Microsilica as stated earlier is a very fine material and it need

proper dispersion well in concrete matrix and it occupies

space between cement grains thereby improving permeability

of concrete mass. Typically it is said that in one grain size

of cement, 100 Microsilica grains can exits. It also helps in

improving mobility of concrete when energy is applied to

concrete.

Through the permeable structure of concrete the ingress

of chloride and sulphate ions can damage the concrete as

stated earlier and addition of Microsilica largely improved this

and protects the concrete.

Fine particles also hold other constituent of concrete better and

therefore other value addition of Microsilica is better cohesion.

This property largely helps in short creating operation as well

as helps in pumping the concrete. In addition it reduces

bleeding and segregation and aids in efficient finishing and

helps in slip form because of better finish.

These plastic properties have its own value and are of equal

important while placing and finishing concrete. The first and

foremost principle a concrete mix designer should bear inmind is to make the concrete cohesive enough with limited

stickness, good mobility and finishability at a given workability

which enable concrete to hold its constituent together under

pressure which will be excreted during mixing, transportation

and placing of concrete. What is the use of a great mix design

made in the laboratory which cannot be placed in field? And

therefore these plastic properties becomes equally important,

Once cohesion of concrete is satisfactory then mechanical

properties such as compressive strength, E-Modulus etc and

durability characteristics tested on durability standard in terms

of permeability ,I-Sat, Rapid Chloride Penetration, Sorptivity,

Water Penetration, chloride diffusivity etc are to be taken careof. These plastic, harden and durability characteristics have

been seen as remarkable improved by addition of Microsilica.

If someone is using higher content of cement, by adding

Microsilica he/she can reduce cement content and make

concrete less sticky too this would be a desirable largely in

pumping operation. It also help us to reduce heat of hydration

while strength is maintained which ultimately help to prevent

early age cracking.

Other value attributes of Microsilica Hardened stage of concrete.

In fully hydrated Portland cement paste, approximately

1/4th of the hydration product by mass consists of oriented,heterogeneously distributed and weekly bonded layers of

calcium hydroxide crystals; which de-bond easily under

tensile stress thereby serving as potential sites for formation

of micro cracks. Therefore, transformation of most of this

calcium hydroxide into the calcium silicate hydrate paste

(which is the predominant phase produced by hydration of

Portland cement) would result in a much more homogeneous

hydration product.

At hardened stages, it helps in,

- Improving Strengths,

Bulk Density Report Report

Pozzolanic Activity Index

%>

105%-7d accel cur-

ing, w/cm=variable

100%-28d Normal

Curing w/p ration=0.5

85%-7d IS 1727

Factor N=1

85%-7d accel’d

curing

95%-28d Normal

curing w/cm=0.5

Report

Retained on 45 micron

sieve %< 10 10 10

Density, kg/M3

Autoclave Expansion %< 0.20%

Canadian Foaming Test No visible foam

Notes

Characteristic values.

Not an official standerd

in the approval process

Requirement of

limiting alkali only

in case of reactive

aggregares

charateristic values

Fig. 3 Fig. 4





Building Name Location App. Height (M) Date

Burj Khalifa Dubai 828 Tallest structure in the world, completed 2010

International Commerce Centre Hong Kong 484 Completed 2010

Petronas Twin Towers Kuala Lumpur 452 Tallest twin buildings in the world, completed 1998

Taipei 101 Taipei 508 Completed 2004, tallest LEED rating building

Guangzhou West Tower Guangzhou 432 Completed 2010

Trump Tower Chicago 423 Completed 2009

Two International Finance Centre Hong Kong 413 Completed 2003

Burj Al Arab Dubai 321 One of the world’s tallest hotels, opened 1999

311 South Wacker Drive Chicago 293 Completed 1999

Trianon Frankfurt 186 Completed 1993

World One Mumbai 442 On going

Polais Royal Worli Mumbai 320 On going

Oasis Towers Worli Mumbai 372 On going

Minerva Tower Mumbai 302 On going

Ireo Victory valley New Delhi 178 On going

- Reducing Permeability,

- Improving Acid Resistance,

- Improving Abrasion-erosion Resistance,

- Improving Durability

As you all, are aware addition of extra cement beyond certain

mass depending upon cement type, per cu.m of cement

does not increase your strength and highly uneconomical.

And if one wants to design for higher strength and high

performance concrete, addition of Micro silica helps a lot

to achieve the desired plastic and hardened properties of

concrete with robust and workable design. There are other

mineral admixtures available based on Fly ash and GGBS,

however they have their own limitation on SiO2 content and

other and largely influence setting characteristics of concrete

as they influence hydraulic properties of concrete and in

today’s age everyone need high early strength to speed up

the construction and high ultimate strength to go vertical in

building high rise structure.

If you see, fig 3 and fig 4, fig 3 is a hardened concrete surface

of concrete made with only cement and fig.4 is hardened

concrete surface of concrete made with Microsilica and if you

closely look at the interface of matrix or a cement glue (see

letter A in the Fig 3 & 4), you will find that Microsilica concrete

is having much less thickness of cement paste or glue or

matrix and holding the aggregate better meaning economical

use of cementitious materials.

Besides this, there are enumerable advantages of Microsilica

in the concrete and Microsilica is playing very important role

to redefine High Performance concrete and allowing structuralengineer to think of reduced size of structural elements and

dream higher in the sky. And incorporation of Microsilica at

designed stage of structure results in direct saving for the

project. As a concrete mix designer we all should strike a

balance between performance and economy and it is seen

that reduced material cost per cu.m of concrete is taken only

as means of economic mix design which is not true.

Therefore concrete cost must not be compared with material

cost per cu.m but a comprehensive cost analysis is needed

which includes all cost associated right from placing to

maintenance of the structure till its design period is to be taken

in to account which will the serve the purpose in longer run.

Also there is need to go for performance based specification

rather prescriptive based specification and Microsilica will

ensure to meet the specifications.

Please see the summary of high rise executed in the recent

past where Microsilica has been used in the project which

one proves value additions of Microsilica.

References

- Silicafume user’s manual 2005

- Internal references from Elkem ASA





Development of Modern PrestressedConcrete Bridges in Japan


For more than half a century prestressed concrete (PC) is one

of the most important construction materials in not only Japan

but also all over the world particularly in the field of bridge

construction. The increased interest in the construction of PC

bridges can be attributed to the fact that the initial and life-cycle

cost of PC bridges, including repair and maintenance, are

much lower than those of steel bridges. Moreover, comparing

to the reinforced concrete (RC) bridges, PC bridges are more

economically competitive and aesthetically superior due to

the employment of high-strength materials. In Japan, the first

PC bridge, Tyousei Bridge, was built in 1951 and since then,

the construction of PC bridges has grown dramatically (Figure

1). However, deterioration of bridges is becoming a big social

issue since many bridges are getting older over 50 years.

In recent years, many PC bridges have been deteriorating

even before their designed service-life due to corrosive

circumstances, alkali-silica reactions, and other environmental

effects. Hence, the durability has become a particular concernand should be seriously considered in the design and con-

struction of PC bridges apart from structural safety, aesthetical

appearance and economical viewpoint. In Japan, a number of

innovative techniques have been developed to enhance not

only the structural performance but also the durability of PC

bridges. These include the development of novel structural

system and the advance in new construction materials. This

paper presents an overview of such innovated technologies

of PC bridges including a brief detail of their development

and background as well as their applications in the actual

construction projects. Figure 1 Trend of construction of different types of bridges in Japan

Hiroshi Mutsuyoshi1 , Nguyen Duc HAI1 and S.V.T. Janaka Perera1

1Structural Material Lab, Department of Civil and Environmental Engineering,Saitama University

Prestressed concrete (PC) is being used all over the world in the construction of bridge structures. In Japan, the application ofPC was first introduced in the 1950s, and since then, the construction of PC bridges has grown dramatically. This is largely dueto several advantages such as lower initial and life-cycle cost compared to steel bridges, and superior characteristics concerningeconomical and aesthetical aspects compared to reinforced concrete bridges. However, many PC bridges have been deterioratingeven before their designed service-life due to corrosion and other environmental effects. Therefore, the durability has becomea particular concern and should be seriously considered in the design and construction of PC bridges. In Japan, a number ofinnovative techniques have been developed to enhance both the structural performance and the durability of PC bridges. These

include the development of new materials such as pre-grouted internal tendon, high-strength concrete and structural systems suchas external prestressing, highly eccentric external tendons, extradosed prestressing and corrugated steel web. This paper presentsan overview of such innovated technologies of PC bridges including a brief detail of their development and background as well astheir applications in the actual construction projects.

Development of Innovative Materials for PC Bridges

In Japan, most of PC bridges were constructed using internally

post-tensioning tendons with grouting in sheaths. Recently,

however, problems regarding grouting condition have been

of much concern because the insufficient grout of internal

tendons was found in some existing PC bridges (Mutsuyoshi2001). Many researches have been carried out recently for the

development of new materials to enhance the performance

and longterm durability of the PC bridges. In this section,

application of pre-grouted internal tendons and high-strength

concrete are explained with brief overview on their applications

in actual PC bridge projects.

Pre-Grouted Prestressing Tendon

Pre-grouted prestressing tendon was first developed in Japan

in 1987. It is made by coating a prestressing strand with

unhardened epoxy resin and a polyethylene protective tube

(Figure 2) and is embedded directly into concrete with the




polyethylene protective tube as a tendon for posttensioning.

Time of hardening is set for the epoxy resin filled in the

polyethylene protective sheath so that post-tensioning process

can be completed before hardening or the epoxy resin. The resin

has viscosity like grease before hardening, and it naturally

hardens with certain time after the completion of tensioningof prestressing steel and bonds with concrete to form an

integrated member.

As the grout is injected into the polyethylene sheath, complete

grouting is ensured in this technique. Furthermore, con-

struction work can be saved as neither in-situ insertion of

prestressing tendonds nor grouting process is required.

Sheath and epoxy resin also provide double layer corrosion

proection to the prestressing tendons. This technique also

ensures stronger bond with concrete than conventional

cement grouting technique. Moreover, smaller diameter

of sheath makes concrete placement relatively easier and

provide higher efficiency in prestressing can be achieved as

polyethylene sheath and unhardened resin reduce the friction

during prestressing.

Pre-grouted prestressing tendon, primarily in the form of

single strands, was generally applied to transverse prestressing

of deck slabs or other work. Application to main tendons

has just started in view of the above benefits (see Figure

3). When pre-grouted prestressing strands are used for

main tendon, more prestressing strands are required than

when conventional multiple strands are used. Numerous

prestressing strands therefore should be anchored in a limited

anchorage region. Hence, attention should be paid in designfor the arrangement of pre-grouted prestressing tendons and

details of anchorage.

High-Strength Concrete

High-strength concrete (HSC) has become common in

building construction in recent years as it enables the use of

smaller cross-sections, longer spans, reduction in girder height

and enhanced durability. In addition to this application, there

are a few instances of HSC being applied to PC structures

(Figure 4) (Mutsuyoshi et al. 2010). The chief advantage ofusing HSC is the possibility of achieving higher prestressing

force compared to the normal concrete which will lead to

smaller crosssection and reduction in the overall weight of the

structure. Hence, the use of HSC has a good potential in the

construction of large structures.

The lower water/binder ratio in HSC may, however, cause the

increase in autogenous shrinkage which will lead to decrease

in effective prestressing force and cracking due to restraining

caused by the reinforcing steel. Conventional method of

reducing autogenous-shrinkage-strain is to use expansion-

producing admixture and shrinkage-reducing agents. However,

these materials are expensive. This problem has been

overcome by the development of new type of artificial light

weight aggregate called as “J-Lite” (Figure 5). J-lite is made

from environmentfriendly coal ash and is twice as strong

as conventional light weight aggregate. Low shrinkage ultra

HSC termed as “Power Crete” with compressive strength as

high as 120 MPa, has been developed with the use of J-lite

Figure 2 Pre-grouted prestressing tendon

Figure 3 Use of pre-grouted prestressing strand for main tendons

Figure 4 AKIBA pedestrian bridge constructed with HSC (f’c = 120 MPa) in

Akihabara





together with expansion-producing admixtures and shrinkage

reducing agents. As strength development in lowshrinkage

HSC is independent of the curing condition, it can be used for

cast-in-place applications as well.

flexural failure (so-called second-order effect). One possible

method of enhancing the flexural strength of externally PC

structures is to make the tendons highly eccentricity (Figure

7). This kind of construction is possible only when external

prestressing is used, since this allows the tendons to be

placed outside the concrete section of girder. In this concept,

Figure 5 J-lite

Development of Modern Structural Systems in PC Bridges

External prestressing technique is widely being used in the

construction industry. Externally prestressed PC bridges

are designed with prestressing tendons placed outside

the concrete section, but still remaining within the bounds

of the cross section of girder (Figure 6). The concept of

external prestressing has become increasingly popular in the

constructions of medium- and longspan bridges due to itsseveral advantages such as reduced web thickness, possibility

to control and adjust tendon forces, and ease of inspection

of tendons during construction. The Japan Highway Public

Corporation (abbreviated for JH; it is changed to three highway

companies at present), has actively adopted the concept of

fully external tendons for box girder bridges (Figure 6) since

1999 due to the improved durability performance compared

to that of internally grouted tendons. It is of importance to note

that, recently, a new construction of PC bridges with internally

grouted tendons has been forbidden by the JH due to the

bad quality of grouting of internal tendons in some existing

PC bridges (Mutsuyoshi 2001). For the better performanceof the externally prestressed concrete bridges, various new

technologies have recently been developed in Japan.

PC Bridges with Highly Eccentric External Tendons

Although externally prestressed PC bridges are well recognized

to have several advantages, however, they have lower flexural

strength compared to that of bridges with internally bonded

tendons (Virlogeux 1988). This is due to the smaller tendon

eccentricity, which is limited by the bounds of concrete section

of girder (i.e., at the bottom slab in case of box-girder bridges)

as well as the reduction in tendon eccentricity at the ultimate

Figure 6 Typical layout of an external PC box girder bridge

Figure 7 Ordinary vs. highly eccentric external tendon

the compressive forces are taken by concrete and the tensile

forces by external tendons, thus taking advantages of both

materials effectively (Mutsuyoshi 2000).

There has been extensive research conducted at Saitama

University both analytically and experimentally to study the

fundamental behavior of girders with highly eccentric external

tendons (Aravinthan et al. 1999, Witchukreangkrai et al. 2000).

From the test results of single-span beams, it was found

that by increasing tendon eccentricity, the flexural strength

can be significantly improved or, conversely, the amount of

prestressing reduced; the result is more economical structures.

By extending the concept of highly eccentric external tendons

to continuous girders, the structural performance can be

further improved. In addition, the girders consisting of linearly

transformed tendon profile were found to have the same

overall flexural behavior (Figure 8). This gives the designer to

take advantage of arranging the external tendon layout freely,

depending on the site conditions.

To verify the application of this concept to the segmental





construction method, the behavior of segmental girders with

highly eccentric external tendons was also investigated and

found to be nearly the same as that of monolithically cast

girders. Hence, this gives considerable flexibility in selecting

the method of construction when designing the bridges with

highly eccentric external tendons. One of the concerns raisedfor this type of structure was the shear capacity as the girder

height is considerably reduced. It was verified, however, from

the experiment on shear characteristic of model specimens

that the shear capacity of the girder with highly eccentric

external tendons is much higher than that of the conventional

girders due to the large increase of tensile force in external

tendons.

The world’s first application of the prestressing with highly

eccentric external tendon to a continuous-span girder was

in the construction of the Boukei Bridge in Hokkaido, Japan.

Considering the site conditions, the bridge was designed with

a two-span continuous and unsymmetrical girder having a

total length of 57 m as shown in Figure 9. The effective width

of the bridge varies from 3.0 m at the abutments to 6.0 m at

the central pier. A completed view of the bridge is shown in

Figure 10.

The characteristic of this innovative bridge is that the external

tendon layout takes the similar shape of the bending moment

diagram as shown in Figure 11. The structure was designed

to form a pseudo truss, with the main girder made of concrete

as compression chords, the external tendons as tension

chords, and the steel deviators as diagonal members. This

allowed the girder height to be reduced significantly, thusmaking the bridge lightweight. The external tendons are

placed below the girder in the midspan region by means of

steel struts, the function of which is similar to a truss. At the

intermediate support region, it is placed above the bridge

deck and covered with a fin-shaped concrete web member.

The combination of the subtended tendons and the fin-

shaped concrete web makes this bridge a unique one with

aesthetically pleasing appearance.

Figure 8 Linear transformation of tendon layout

Figure 9 Layout diagram and dimension of the Boukei Bridge

Although having several advantages, PC bridges with highly

eccentric external tendons should be carefully designed and

constructed concerning the following important points. Since

the main girder, struts and highly eccentric external tendons

form a truss in this type of structure, construction precision of

individual members has a significant influence on the structure.For this, it is necessary to give special consideration to the

techniques and procedures for constructing the falsework,

formwork and external tendons. Moreover, the vibration

characteristics under service load may be of concern due to

the smaller stiffness of the main girder caused by the reduction

in girder height. Nevertheless, the authors believe that this new

concept of prestressing would pave way to a wider use of

external prestressing technology in the construction industry,

leading to improved structural performance as well as cost

effective PC bridges. The research is in progress regarding

the possibility of applying these kind of structures to highway

bridges using precast segmental construction.

Extradosed PC Bridges

An extradosed prestressing concept, which was first proposed

by Mathivat in France (Mathivat 1988), is a new type of

structural system in which the tendons are installed outside

and above the main girder and deviated by short towers located

at supports. Considering its definition, this type of bridge is

placed between cable-stayed bridges and ordinary girder

bridges with internal or external tendons.

Extradosed PC bridges have several positive characteristics.





The girder height may be lower than that of ordinary girder

bridges, thus reducing self-weight of structures. As shown

in Figure 12, the ratio of the girder height to the span length

(H/L) in extradosed bridges ranges between 1/15 and 1/35,

while it is approximately 1/15~1/17 for box-girder bridges.

Comparing to cable-stayed bridges, the height of the maintower in extradosed bridges is lower; hence, a reduction in

labor costs of construction can be achieved.

The major difference among box-girder, extradosed and

cable-stayed bridges can be further revealed by comparing

the relationship between materials used with span lengths. In

box-girder bridges, the average concrete thickness increases

with the span length, since the girder height is a function of

the span length. On the other hand, in cable-stayed bridges,there is almost no increase in the average depth of concrete

because the girder height is generally designed to be 2.0~2.5

m, regardless of the span length. It is interesting to note that

extradosed bridges are placed between these two types, and

the rate of increase is also thought to be midway between the

rates of the other two types of bridges.

Similarly, with increasing span length, the quantity of prestressing

tendons in box-girder bridges shows a more increase than

that in cablestayed bridges, whereas extradosed bridges yield

the intermediate value between the other two types. From the

above discussion, it can be concluded that an extradosed

bridge is similar in construction and appearance to a cable-

stayed bridge. In the light of structural properties, however,

an extradosed bridge is closed to ordinary PC girder bridges,

and the design specifications may be considered to be the

same for both types of bridges.Figure 10 Completed view of the Boukei Bridge

Because of a lower main tower in extradosed bridges, vertical

loads are partly resisted by main girders and stress variations

in stay cables produced by live loads are smaller than those

in cable-stayed bridges. This is quite similar to the behavior of

box-girder bridges, where the main girder itself has a decisive

influence on the structure rigidity and live loads produce onlylimited stress variations in tendons. Based on these facts, the

Japan Road Association has recommended that the safety

factor for the stayed cables in extradosed bridges under

design loads shall be taken as 1.67 (0.6 fpu; fpu = tensile

strength of tendons), which is same as that for tendons in

ordinary girder bridges. For cablestayed bridges, this value is

specified to be 2.5 (0.4 fpu) (Japan Road Association 2002).

Figure 11 Schematic view of layout of external tendonFigure 12 Comparison among externally box-girder, extradosed and cable-

stayed PC bridges





In case of extradosed bridges it is necessary to provide an

structural rationale rather than simply assuming an allowable

stress of 0.6fpu in design of the bridges. In this point, attention

focuses on the distribution ratio of vertical load carried by the

girders and the stay cables. Figure 13 shows the relationship

between the distribution ratio of vertical load ( ) and maximumstress change of stay cable due to design live load ( ) of

various cable-stayed bridges and extradosed bridges con-

structed in Japan. As shown in the figure, it is difficult to clearly

distinguish between extradosed bridges and cable-stayed

bridges in terms of structural mechanics since many of the

cablestayed bridges are very similar to extradosed bridges. In

designing stay cables, stress change due to design live loads

provides an effective index that can be easily determined

through the design process.

Approximated Design Method for Stay Cables

The fatigue limit state is usually critical in the design of staycables. When bridge structures reinforced by stay cables, the

design of stay cables would be structural rationale by focusing

on the stress change in the stay cables rather than defining

whether bridges are cable-stayed or extradosed by assuming

allowable stress for the stay cables. This would make it possible

to design each stay cable separately and enable the allowable

stress to be set individually for each stay cable. Unlike

suspension bridges, the stress change in a cable-stayed bridge

will differ depending on the stay cables and it is not rational to

define the allowable stress using a single value of 0.4fpu. This

is reflected in the “Specifications for Design and Construction

of Cable-Stayed PC Bridges and Extradosed Bridges” (JapanPrestressed Concrete Engineering Association 2009). The

specification allows two kinds of design method. Method A is

normal fatigue design using fatigue load and design lifetime

of a bridge. However, it is usually difficult to estimate the

amount of future traffic and heavy trucks, especially in local

roads. In that case, method B using stress change in stay

cables due to design vehicular live loads is introduced. Figure

14 shows the relationship between the allowable tensile

stress (fa) of stay cable for highway bridges and the stress

change due to live load regulated in the specifications.

The difference in fatigue strength between prefabricated wire

type and strand type is considered. By using prior experience

in Japan with cable-stayed, extradosed and similar bridges

having spans of up to about 250 m, method B is defined soas to ensure adequate safety in comparison with bridges

designed using method A. Fatigue design was performed

for the estimation line of stress range for two million cycles

(2E6

) including secondary flexural bending due to girder

deflection (determined according to design conditions on

a design service life of 50 years and average daily traffic of

70,000 mixing 50% trucks) by using the structural models

of the Odawara Blueway bridge, the Tsukuhara bridge, and

the Ibi River bridge as shown in Figure 13. Based on the

calculations the stress change due to fatigue load is about

1/3 of that due to design live loads and the stress level due

to secondary flexural bending is the same as that due to axial

forces of stay cables. It is noted that the estimation line of

2E6is assumed to be 2(1/3)(Max

L). The safety margin of

method B can be confirmed by comparing2E6

with fatigue

strength (fscrd

) divided by a safety factor ( b).

In the stay cables designed by method B,L

is determined

to require a safety factor of about 2.0 for 2E6 with respectto f

scrd/ b, in order to take into consideration the fact that the

method includes more uncertainties than method A, and in

order that the safety of stay cables does not vary greatly from

that of cable-stayed and extradosed bridges constructed to

date. In the most of extradosed bridges and some cable-

stayed bridges, the tensile stress of 0.6fpu can be used

because stress changes are low (20 to 50N/mm2). Moreover

the most rational point of this specification is that we can

choose the tensile stress in each stay cable from 0.4fpu to

0.6fpu continuously. This is based on the concept that one

value of tensile stress in one bridge is not structurally rational.

Figure 14 Allowable tensile stress and stress change of stay cable

Figure 13 Distribution ratio of vertical load and stress change of stay cable





Figure 15 shows the Odawara Blue-Way Bridge, which is the

first extradosed PC box girder bridge in the world and was

completed in 1994. This bridge was designed with a three-

span continuous box-girder with extradosed prestressing,

having a middle span length of 122 m, a tower height (h) of

10.5 m, and a girder height at supports (H) of 3.5 m. The ratiosof h/L and H/L are approximately 1/12 and 1/35, respectively.

Figure 16 shows the prospective view of the Shin-Meisei

bridge on Nagoya Expressway No. 3 crossing the class-

1 Shonai River in western Nagoya. From both aesthetic

and economic viewpoints, the bridge was designed with a

threespan continuous rigid-frame structure with extradosed

prestressing, which is to become a landmark of Nagoya’s

western threshold. The length of the middle span (L) is 122 m,

a tower height (h) of 16.5 m, and a girder height at supports

(H) of 3.5 m, giving the ratios of h/L and H/L of 1/7.4 and 1/35,

respectively.

Corrugated Steel Web Bridges

In PC bridges with corrugated steel webs, light-weight

corrugated steel plates are used instead of concrete webs.

The corrugated steel plate webs are capable of withstanding

shear forces without absorbing unwanted axial stresses due

to prestressing, thus enabling efficient prestressing of top and

bottom concrete deck slabs, thus resulting in an “accordion

effect” (Figure 17). Moreover, the corrugated webs also

provide high shear buckling resistance. Use of light-weightcorrugated steel plates for webs causes a reduction of self

weight of about 25% of main girders. Therefore, this enables

the use of longer spans and reduction of construction cost.

The weight of a segment to be cantilevered during erection

can also be reduced, thus longer erection segments can be

adopted and construction period can be shortened. This also

eliminates assembly of reinforcement, cable arrangement

and concrete placement for concrete webs. Thus, saving

of construction manpower, quality enhancement and

improvement of durability are expected. In addition, replacing

the damaged deck slabs is easier than that in ordinary PC

bridges.

Recently, the use of corrugated steel web has been applied to

a variety of new constructions of PC bridges in Japan (Figure

18). In addition to the rigid or box girder bridges, the concept

of corrugated steel web was also successfully adopted in the

constructions of extradosed and cable-stayed PC bridges.

Figure 15 Odawara Blue Way bridge

Figure 16 Shin Meisei bridge (prospective view)

Figure 17 Typical section of PC bridge with corrugated steel web

Figure 18 Ginzanmiyuki bridge with corrugated steel web





Rittoh Bridge located in the southern edge of Lake Biwa, is the

first extradosed PC bridge with corrugated steel web whose

main girder has a three-celled cross section, making it suitable

for a bilaterally suspended structure with a wide roadway. The

bridge consists of four-span and five span continuous rigid-

frame structure with total span length of 495m and 555m,respectively (Figure 19).

term durability, which is becoming one of the serious problems

in concrete structures nowadays.

Considering the development of new construction materials,

the application of pregrouted internal tendons and use of

low-shrinkage HSC were discussed. In light of new structuralsystems, external prestressing with highly eccentric tendons

and extradosed prestressing are excellent examples of a

wider use of external prestressing technology to achieve a

PC bridge with improved structural performance as well as

cost-effective outlook. The corrugated steel webs, which

take advantages of steel and concrete, have proved to be

one of promising solutions that can reduce the selfweight of

main girders, thereby enabling the use of longer spans and

reduction of construction cost.

Acknowledgement

The authors wish to acknowledge the members of theinternational committee of Japan Prestressed Concrete

Engineering Association (JPCEA) for providing valuable

information. The authors would also like to extend their gratitude

to Nippon Expressway Company (NEXCO).

References

- Aravinthan T, Mutsuyoshi H, Hamada Y, and Watanabe M (1999)

“Experimental Investigation on the Flexural Behavior of Two Span

Continuous Beams with Large Eccentricities”, Transactions of

JCI, 21, pp. 321-326.

- Japan Prestressed Concrete Engineering Association (2009)

“Specifications for Design and Construction of PrestressedConcrete Cable-Stayed Bridges and Extradosed Bridges”, (in

Japanese).

- Japan Road Association (2002) “Japan Specification of Highway

Bridges-Part I Common Part, Part II Steel Bridges, Part III Concrete

Bridges”, (in Japanese).

- Mathivat J (1988) “Recent Development in Prestressed Concrete

Bridges”, FIP Note, Feb., pp. 15-21.

- Mutsuyoshi H (2000) “State-of-the-Art Report on External

Prestressed Concrete Bridge with Large Eccentricity”, Concrete

Journal, 38(12), pp. 10-16 (in Japanese).

- Mutsuyoshi H (2001) “Present Situation of Durability of Post-

Tensioned PC Bridges in Japan”, Proceedings of the 1st fib/

IABSE Workshop on Durability of post-tensioning tendons,Belgium, pp. 75-88.

- Mutsuyoshi H, Ichinomiya T, Sakurada M, and Perera S V T

J (2010) “High-strength concrete for prestressed concrete

structures”, CPI Trade Journal for the Concrete Industry, August,

pp. 42- 46.

- Virlogeux M P (1988) “Non-linear Analysis of Externally

Prestressed Structures”, Proceedings of FIP Symposium, Israel,

pp. 319-340.

- Witchukreangkrai E, Mutsuyoshi H, Aravinthan T, and Watanabe M

(2000) “Analysis of The Flexural Behavior of Externally Prestressed

Concrete Beams with Large Eccentricities”, Transactions of JCI,

22, pp. 319-324.

Figure 19 Rittoh Bridge (Extradosed PC bridge with corrugated steel web)

Conclusions

Recent techniques in design and construction of PC bridges

in Japan were presented in this paper, with emphasis on their

background and development as well as their applications in

actual structures. Not only to improve the structural properties

in terms of safety, aesthetic and economical aspects, such

innovated technologies were developed to enhance the long-





C e m e n t: A n a l ys i s

S a d ag o p an S e s ha d r iC h i e f - C o n t en t D e v el o p me n t , C E - I n f r as t r u ct u r e - E n v i ro n m en t

Indian Cement IndustryI n G lo ba l P er s pe ct iv e

ement is vital to the construc-

t i o n s e c t o r a n d a l l i n fr a s t ru c t u reCp r o j e ct s . T h e ce m e n t i n d u s tr y

occupies an important place in the I ndian

e c o no m y b e ca u se o f i t s s t ro n g l i nk a ge s

w it h o th er s e ct or s s uc h a s c on st ru c-

t i o n, t r an s po r ta t io n , c o al a n d p o we r. T h es e c t o r n o t a bl y p l a y s a c r i ti c a l r o l e i n t h e

e co no mi c g ro wt h o f t he c ou nt ry i n i ts

j o ur n ey t o wa r ds a n i n cl u si v e an d d e-

c i de d ly c o nc l u si v e g r ow t h. T h e c o n-

s t r u c ti o n s e c t o r a l o n e c on s t i t ut e s 7 p e r

c e n t o f t h e c o un t r y ' s g r o s s d o m e s ti c

product (GD P).G i ve n t he r i gh t d ri ve rs , n o d ou bt

I ndia has become the second largest

produce r of quality cement in the

w or ld . T he c em en t i nd us tr y i n I nd iacomprises 183 large cement plants

a n d o ve r 3 6 5 m i ni c e me n t p la n t s . C u r -

r e n t l y, t h e r e a re 4 0 p l a y e r s i n t h e i n d u s -

try across the country.

Trend & 'Demand-Supply'Match

T he d e ma nd f o r c em en t, b ei ng a

d er iv ed o n e, d ep en ds m a in ly o n t he

industrial activities, real estate business,

c o n s t ru c t i o n a c t i v it i e s a n d i n v e s t me n t

i n t h e i n f r a s tr u c t ur e s e c t o r. T h e c e m e n ti n du s t ry i n I n di a co n ti n ue s t o e x pe r i-

e nc e a bo om o n a cc ou nt o f o ve ra ll

g r o w th i n t h e e c o no m y.

D e m an d p a t t er n f o r c e m e nt in I n d i a

i s c y c l i c al ; b a r ri n g s h o r t- t e r m d i sr u p -

t io ns , i t gr ow s la rg el y i n t an de m wi th

economic growth. The growth in demand

d ri v en b y G DP h as b ee n a bl y c at er ed o n

t h e s u p pl y s i d e b y g r ow t h i n p r od u ct i o n

t o fi l l up t h e c o ns u mp t io n g r ow t h o n a l l

s e c t o rs o f t h e e c o n o my. ( S e e f i g ur e s 1 ,

2 & 3 )

Major policy and fiscal initiatives initiated to catalyze infrastructure, housingand industrial development continue to spur the demand for cement



P r o du c ti o n o f C e m en t ( M T)

300

250

200

150

100

50

0

FY07 FY07 FY09 FY10 FY11 FY12E

F i g u r e 2 S u pp l y : G r o w th i n C e m e n t P r o d u ct i o nS o u r c e: D e p a rt m e n t o f I n d u s tr i a l P ol i c y a n d P r o m ot i o n , A r a n c a R es e a r c hN o t e s : M T - M i ll i o n To n n e s , E - e st i m a t e

156168

182

207

228

247

C e m e n t: A n a l y si s

129www. masterbuild er. co. in · T h e M a s t er b u i l de r - J u ly 2 0 1 3

Product Offerings

T h e I n di a n c e m e nt i n d u st r y i s i n v o l-

v ed i n p ro du ct i on o f s ev er al t yp es o f

cement such as Ordinary Portland Cement

( O PC ) , P or t la n d P oz z o la n a C e me n t

(PPC), Portland Blast Furnace Slag Ce-

m e nt ( P B FS ) , O i l We l l C e me n t, R a pi d

Hardening Portland Cement, Sulphate

R e s i s ti n g P o r t la n d C e m e n t , W h i t e C e -

m e n t , e t c . T h e y a r e p r o d uc e d s t r i c tl y a s

pe r t he B ur eau o f In di an S ta nd ard s

( B I S ) s p e c i fi c a t io n s , a n d t h e i r q u a l i ty i s

comparable to the best in the world.

M a r k et S i z e & G r o w th A r e a s

T he c em en t in du st ry o f I nd ia i s

e x p e c te d t o a d d 3 0- 4 0 m i l l io n t o n n es

p e r a n nu m ( MT PA ) o f c a pa c it y i n 2 0 1 3.T h e in d u s t ry h a s a c ur r e n t c a p a ci t y o f

324 MTPA and operates at 75-80 per

cent utilization."I t is anticipated that the cement

i n d u s tr y p l a y e rs w i l l c o n t i n ue t o i n c r e -

a s e t h e i r a n n u al c e m e n t o u tp u t i n c o m -

i n g y e ar s , a n d th e c o un t r y ' s c e m e nt

p r od u ct i on w i l l g r ow a t a c o mp o un d

a n nu a l g ro w t h r a te ( C A GR ) o f a r ou n d

12 per cent during 2011-12 - 2013-14 to

r e ac h 3 0 3 m i ll i on m e tr i c t o nn e (M M T ),

according to a report titled 'I ndianC e m e n t I n d u st r y F o r ec a s t t o 2 01 2 ' , b y

r e s e a rc h f i r m R N C O S .T h e r e h a v e b e e n s t r o ng d e ma n d

d r iv e rs e ve n i n t h e n e ar t e rm in t h e f o l-

lowing sectors of economy.

1 . H ou si ng g ro wt h

The Housing segment accounts for

Source: A mbit C a pit a l, A ra nca Resea rch

16%

12%

8%

4%

0%

-4% 1 9 9 4

1 9 9 5

1 9 9 6

1 9 9 7

1 9 9 8

1 9 9 9

2 0 0 0

2 0 0 1

2 0 0 2

2 0 0 3

2 0 0 4

2 0 0 5

2 0 0 6

2 0 0 7

2 0 0 8

2 0 0 9

2 0 1 0

2 0 1 1 E

2 0 1 2 E

2 0 1 3 E

GDP gr o wth Yo Y (%) Cement demand gr o wth Yo Y (%)

Tr e nd i n G D P a n d G r ow t h i n C e m en t D e m an d

F i gu r e 1 G r o wt h i n D e ma n d



FY0 8 FY09 FY1 0 FY11F FY1 2F FY13 F

A l l I nd ia

163.4177.5

196.4210.2

236.3

265.9CAGR 10%

F i gu r e 3 : G r ow t h i n D o me s ti c c o ns u m pt i o n o f c e me n t ( mt p a)S o u r c e: C M A , E d e l we i s s , A r a n ca R e s e a rc h ; N o t e : M T PA - M i l l i o n To n n e s P e r A n n u m


d em an d fo r o ff ic e sp ac e in I nd ia i s

b e i n g dr i v e n b y t h e i n c re a s i ng n u m be r

o f m u l t i na t i o na l c o m p an i e s a n d t h e

g ro wt h o f t he s e rv ic es s e ct or. S tr on g

g r ow t h i n t o ur i sm , i n cl u di n g b o th b u si -

n e s s a nd l e i s ur e t r av e l , h a s b o os t e dt h e c on s tr u ct i on o f h o te l s t hr o ug h ou t

the country.E s t i ma t e d de m a n d b y r e a l e s t a t e

s e gm e nt b et w ee n 2 0 10 a nd 2 01 4 :

O f f i ce ( 2 4 0 m i ll i o n s q f t ) , R e t a il ( 5 5 m i l -

l io n s q f t) , H os pi ta li ty ( 78 m i l li on r oo m

nights)

M a i n P l a y er s

Although the I ndian cement indus-

t r y h a s s om e m ul t in a ti o na l c e me n t

g i a n ts , l i k e H o lc i m a nd L a fa r g e , w h i c h

h a ve i n te r es t s s u c h a s AC C , A m bu j a

C e m e n t a n d L a f ar g e B i r l a C e m e n t, t h e

I n di a n c e me n t i n du s tr y i s b r oa d ly h o me -

g r o w n. U l t r at e c h C e m e n t, t h e c o u n tr y ' s

l a r g es t f i rm i n t e r m s o f c e m e nt c a p ac -

i t y, h o l d s ar o u n d 2 2 % o f t h e d o -m e s t i c

market, with ACC (50%-owned by Holcim)

Indust rial4%

Resident ial63%

13%Commercial

Infrast ruct ure20%

a ma jo r p or ti on o f t he t ot al d om es t ic

d e ma n d f o r c e me n t i n I n di a . B e tw e en

2 0 1 0 a n d 2 0 1 4, d e ma n d f o r h o us i ng

units is estimated to be 4.3 million, lead-

i n g to a h i gh e r d e m a nd f o r c e m e nt f o r

h o m e bu i l d i ng . G r o w i ng u rb a n i s at i o n ,

a n i nc re as in g n um be r o f h ou se ho l ds

a n d h i g he r e m p l o ym e n t a r e p ri m a r il y

driving the demand for housing.I n i t ia t i v e s b y t h e go v e r nm e n t a r e

expected to provide an impetus to con-

s tr uc ti on a ct i vi ty i n r ur al a nd s e mi u rb ana r e a s t h r o ug h l a r g e i n f r as t r u ct u r e a n d

housing development projects.

2 . I nf ra st ru ct ur e g r o wt h

T h e g o ve r nm e nt i s s t ro n gl y f o cu s ed

on infrastructure development to boost

e c o n o mi c g r o w t h. I t p l a n s t o i n c r e as e

i n v e s tm e n t in i n f r as t r u c tu r e t o US D 1

t r il l io n i n t h e 1 2 th F i ve Ye a r P l an ( 2 0 12 -

1 7) , c om pa re d w it h U SD 51 4 b il l io n

u nd er t he 1 1 t h F iv e Ye ar P la n ( 20 0 7- 1 2) .

I n f ra s t r u ct u r e p ro j e c t s su c h a s D e d i-

cated Freight Corridors as well as new

a n d u p g ra d e d a i rp o r t s , a n d p o r ts a r e

e x p e c te d t o f u r t h e r d r i v e c o n st r u c t io n

a c t i v it y. T h e g ov e r n me n t i n- t e n d s t o

e x p a nd t h e c a p a c it y o f t h e r a i l w ay s a n d

the facilities for handling and storage to

e a se t h e t r an s po r ta t io n o f c em en t a nd

reduce transportation costs.3 . C om me rc ia l r e a l e s t at e g ro wt h

T h e de m a n d f o r c o m m e rc i a l r e a l

e s ta t e se g me n ts , c o mp r is i ng r e ta i l

s p a c e, o f f i c e sp a c e a nd h o t e l s , a s w e l l

a s c i vi c f a ci l it i es , i n cl u di n g h os p it a ls ,

m u l t ip l e x e s a n d s c ho o l s , h a s b ee n r i s -

i n g du e t o t he g r o wt h i n e c on o my. T h e

F i g u re 4 T h e ' C o n s u m pt i o n A r e a s' S p r e ad

A l l I n di a

66. 1% 1. 4%

15. 0%

7. 5%

10. 0%

A m buja Cem ent

A CC

Ultratec h Cem ent

Jaypee Cem ent

Others

F i g u r e 5 : M a r k e t s h a r e b y i n s t a l le d c a pa c i t y ( 2 0 1 1 )

GDP ( PPP) (2011) US$4.42bn

GDP/capita (2011 est.) US$3700

Population (July 2012) 1205.1m

Are a 3,287,263kmIntegrated plants 146

Integrated c apacity 302Mt/yr

Grinding plants 55

Grinding c apacity 63. 5Mt/yr

TOTAL C APACITY 365.5Mt/yr

Ta b l e 1 : S u m m a ry S t a t i st i c s - I n d i a &The Cement Ind ustry

C e m e nt : A n a l ys i s




a n d A m bu j a ( 5 0 % -o w n e d b y H o l ci m )

h av ing 1 5% an d 1 3% s har es re sp ec -

tively.M an y o f t he r em ai ni ng d oz en t op

p l ay e rs a r e I n di a n a n d a r e (i n o r de r o f

diminishing market share); Jaiprakash Associates (10%), The I ndia Cements

L t d ( 7 % ) , S h r e e C e me n t s ( 6 % ) , C e n t u ry

Te x t i l e s a nd I n d u s t ri e s ( 5 % ) , M a d r as

C e m e n ts ( 5 % ), L a f a rg e ( 5 %) , B i r l a C e -

ment (4%) and Binani Cement (4%).B et we en t he m, t he t op 1 2 c e me nt

firms have around 70% of the domestic

m ar ke t. A ro un d 1 00 s m al le r p la ye rs

p r o d uc e a n d g ri n d c e m en t o n a w i d e

r a n ge o f s c a l e s b u t ar e o ft e n c o n f i ne d

to small areas.

An understanding of what factorsi n f l ue n c e d i n t h e m a k in g o f t h e c o m po -

s i t i o n o f t h i s i n d u s tr y a s it i s , e s s e n t i a l t o

m a k e pr u d e nt d e c i si o n s o n w h a t ar e

interventions needed and whether these

i s s u e s w i ll b e i n s t r u me n t a l i n s t e e r in g

t h e I n d i an C e m e nt I n d u s tr y t o w a rd s a

c o n s o li d a t i on o v e r t h e n e x t y e a r s . M o s t

a n s w er s m a y l i e i n ,' W h a t d o e s a n e w e n t r an t e x pe r i -

e n c e i n t h i s s e c to r ? ' ,

W h i c h c a n b e s u m ma r i l y p u t a s :

- E nt ry b ar ri er s a re hi gh a s h ug e c ap i-tal investments required present

s u b s t an t i a l b a r ri e r s t o e n t r y a n d

achieving economies of scale.

- B uy er s' p ow er - Su bs ta nt ia l m ar ke t

c o n c e nt r a t io n a m o n g l a r g e p l a y e r s

e ns ur es l o w b ar ga in in g p ow er o f

buyers.

- S ub st it ut es t hr ea t - C em en t, a s o f

n o w h a s p ra c ti c al l y n o s u bs t i tu t es

and this is positive.

- P la ye rs ' r iv al ry t hr ea t - T he I nd ia n

c e m e nt ma r k e t i s ol i g o p ol i s t i c i nn a t u re , c h a r ac t e r i se d b y t a c i t c ol l u -

s i o n , w h e r e la r g e p la y e r s pa r t i al l y

c o n t ro l s u p p l y f o r b e t t e r p r i c e d i s c i -

p l in e . T h er e ha v e b e en o f f l a te C CI

trying though to intervene to set this

r ig ht . B u t a s o f n ow c em en t f ir ms

rule the roost.

G o v e rn m e n t - T h e R i g h t I n i ti a t iv e s

I ndia would require overall cement

c a pa c it y o f a r ou n d 4 8 0 M T. T h e i n du s -

S om e o f t he m aj or i nv es tm en ts i n t he

s e c t or a r e a s fo l l o ws :

- B ar in gs Pr iv at e E qu it y A s ia h as p ic ke d

u p a 14 pe r c en t m in or it y s ta ke in

t he In di an u ni t o f c em en t m aj or

L af ar ge , f or ` 1,427 crore (U S$

257.11 million)

- S in om a In te rn at io na l E ng in ee ri ng

( H o n g K o n g ), a p a rt o f t h e C h in e s e

s t a t e -r u n N a t i o na l M a t e r i a ls G r o u p

C o r p , h a s e n t e r e d t h e I n d i a n

c e me n t e q ui p me n t i nd u st r y b y a c -

q u i r i ng a m a j or i t y s t a k e i n C h e n n ai -

b a s e d e q u i p m e n t m a n u f a c t u r e r

LNV Technology

- D al mi a C e me nt pl an s t o i nv e st

` 1,800 crore (U S$ 324.32 million)to increase the company's cement

m an uf ac t ur in g c ap ac it y o v er t he

n e xt t w o y ea r s. T h e c om p an y a l so

p l an s t o s et u p a 2 . 5 mi l l io n t o nn e

(MT) greenfield unit in Karnataka

- A mb uj a C e me nt s p la ns to in ve st

` 2,000 crore (U S$ 360.33 million)

to enhance its cement capacities in

R a j a st h a n a n d n o r t he r n r e g i o n. T h e

p r o p o s e d p r o j e c t a t R a j a s t h a n

w o u l d ad d f i v e M T c ap a c i t y t o t h e

t o t a l c e m en t p r o d u c ti o n o f I n d i a- R el ia nc e Ce me nt C om pa ny ( RC C) ,

a su b s i d ia r y o f R e l i an c e I n f ra s t r u c-

t u r e L t d , h a s c o m m en c e d p r o du c -

t i on o f c e me n t fr o m it s f i rs t m an u -

f a c t ur i n g un i t a t B ut i b o r i, N a g p ur i n

Maharashtra

H o l c i m, t h e S w i t z e rl a n d -b a s e d c e -

m e n t m aj o r, s a y s I n di a i s a m o n g t he

r o b u st o f m a r k et s i n A s i a . I t h as s a i d s o

a t a t im e w h e n t h e c o un t r y ' s c e m e n t

s e c t o r f a c e s r is i n g c o s t s a nd p o o r e r-

t h an e x pe c te d d e ma n d, d e sp i te t h i s

being the peak construction period.T he co mp an y o pe ra te s i n I nd ia

t hr ou gh g ro up c om pa ni e s AC C an d

Ambuja Cements. I t has said its out-

l o o k f o r A s i a c o nt i n u e s to b e p o s i ti v e

a n d t h at I n d i a, I n d o ne s i a a nd P h i l i p-

pines rank among the most promising

g r o w th m a r ke t s . I t s l a t e s t a n nu a l r e p o r t

s a y s p r o s pe c t s f o r t h e c o n s t ru c t i o n

i n du s t ry a r e v e ry g o od i n t h es e c o un -

t ri e s, g iv en t he h ig h d em an d fo r i nf ra -

t r y w i l l ha v e to a d d an o th e r 1 5 0 M T of

c a p a ci t y d u r i ng t h e p e r i od , a c c o r di n g

to the latest report from the working

g ro up o n t he in du st ry f or t he 12 th F iv e

Year Plan (2012-17).T h e m a jo r p o li c y a n d f i sc a l i n it i a-

tives are expected to catalyze infra-

structure and industrial development in

t h e r eg i o n , s p u r ri n g t he d e ma n d fo r

cement.

Investments: Confidence Makers

The cement and gypsum products

s ec to r h as a t tr ac te d f or ei gn d ir ec t

investments (FD I ) worth ` 11,779.04

c r o r e ( U S$ 2 . 1 2 b i l l i o n) b e t w e e n A p r i l

2 0 0 0 t o Fe b ru a ry 2 0 1 3, a c co r di n g t o

t h e d a t a p u b l is h e d b y t h e D e p a rt m e n t

of I ndustrial Policyand Promotion (D I PP).


Someof the initiatives takenbytheGovernment to furtherpromote the

sectorare asunder:

Ÿ

Ÿ

Ÿ

Ÿ

Excisedutyrationalisedforpack-aged cement,whether manufacturedbyminicementplantsorothers.

Packagedcement,whetherman-ufac ture d by mini-ce me nt plants oro th er s, a tt ra ct s d if fe re nt ia l e xc is eduty dependi ng on the retail salep ri ce p er b ag . I t i s p ro po se d t o p re -sc ribe aunifie drate of12pe rc e nt+`120 (US$ 2.16) PMT for non-minic em en t p l an ts a nd 6 p er c en t + ` 1 20(US$ 2.16) PMT for mini-cementp la nt s. I t i s p ro po se d t o c ha rg e t hi s

duty on the retail sale price lessabatementof30percent

The Indian construction industryhas shown significant developmentove r the ye ars with e mine nt and e ffi-ci ent engi neers at th e h el m an d isamong the best in the world, saidAnand Sundaresan, ManagingDirec-

tor,SchwingStetter(India)whileinau-gu ratin g a conf erence o n 'LatestTrendsinConstructionIndustry'

The private sec tor is e xpec te d to

contribute44percentofthetotalpro- je cted spe nd of US$ 100 billion onroads and highways overthe TwelfthFiveYearPlan(2012-17) period.



133www. masterbuild er. co. in · T h e M a s t er b u i l de r - July 2013

s t ru c tu r e e x pa n si o n p r oj e ct s , a s we l l

as the need for low-cost housing.

Holcim is expanding its production

c ap ac it y i n I nd ia . A CC p la ns t o r ai s e

t h i s f r o m t h e e x i s ti n g 3 0 m i l l i o n t o n n e s

p er a nn um ( mt pa ) t o 3 5 m tp a, i n ap h a s ed m an n e r t i l l 2 0 1 5 . A s pa r t o f t h i s

p ro je ct , a n ew p la nt a t Ja mu l in t he

s t at e of C h h at t ig a rh i s un d er p r oc e ss .

Also at Jamul, grinding capacity is

b e i n g r e p l ac e d . P a rt o f t h e c l i n k er p r o -

d u ce d in J a mu l is e ar m ar k ed f or t h e

expanded Sindri grinding plant (in

J h ar k ha n d) a nd f or t h e n e w g r in d in g

p l a n t i n K h a r ag p u r ( W e s t B e n ga l ) .

ACC and Ambuja have a combined

c ap ac it y o f 5 7 mt pa , a ro un d 1 6 p er

c e n t o f I n d i a' s o v e r a l l c e me n t m a k in gc a p a ci t y o f 3 6 0 m t p a .

Lafarge plans to expand its I ndia

o p e r at i o n s a c r o ss t h e c o u n t r y d e s p i te

a n a n ti c ip a te d s lo w do w n, t h e Fr e nc h

m aj or 's c ha ir ma n a nd C EO B ru no

L a f o nt s a i d c i ti n g a n e w s t u d y t h a t s ay s

I ndia will become the world's third-

l a r g es t co n s t r uc t i o n m a r ke t by 2 0 2 5 , t o

s u pp o rt hi s b u oy a nc y. T h e s t ud y b y

G l o b al C o n s t ru c t i o n P e rs p e c t iv e s a n d

Oxford Economics expects I ndia to

a d d 1 1 .5 m i ll i on h o me s a y ea r t o b e-

c o me a $ 1 - tr i ll i on , o r a b ou t 5 9 l a kh c r or e ,

a y ea r m ar ke t, e ve n t ho ug h i t h as cu t

I ndia's short-term growth prospects.

" T he a tt r ac t iv e gr o wt h o f t h e c o n-

s t r u ct i o n i n d u s tr y w i l l b e h i g h er t h a n t h e

s h or t t er m e co n om i c g r ow t h. I n di a i s

o ne o f o ur f oc us c ou nt ri e s, a s w e w a n t t o

e x p a nd o u r o p e r at i o n s f r o m t h e N o r th

E a s t t o t h e r e s t o f t h e c o u n t ry, " L a f o n t

told ET.L a f a rg e i s p r es e n t i n 6 5 c o u nt r i e s

and Lafont says there is no easy coun-

t r y t o w o rk i n . " T he p a th t h at t h e In d ia n

a u t h or i t i e s i s t a k i ng i s w o r k i n g ; w e a r eh a pp y i n I n di a ," h e s a ys , b u t ad d s t ha t

Lafarge would like to see a "simplifica-

t i on o f t h e f ra m ew o rk o f r e gu l at i o ns s o

projects can move faster."L a f a rg e , w h i c h h a s op e n e d a l a bo -

ratory in I ndia to promote innovations that

a r e c l o se t o t h e m ar k e t , w i l l f o cu s o n

I ndia'sboomingTier2cities,Lafontsays.

Industry trends; Healthy & Wise

T h e r e h as b e e n a n i n c r ea s i n g p re s -

e n c e o f s m a l l a n d m i d - si z e c em e n t

p l ay e r s. M a rk e d o b se r va t io n i s o f n e w

entrants and existing marginal ones'

c a p a ci t y a d d i t io n s ,

- P re se nc e o f s ma ll a nd m id -s iz e c e-

ment players across regions is in-

creasing, which helps to diminish mar-

ket concentration of industry leaders- S ma ll an d m id -s iz e p la ye rs ha ve

b e en c o ns t an t ly i n cr e as i ng t h ei r i n -

s t a l l ed c a pa c i t y t o c a te r t o i n cr e a s -

ing cement demand

M o re o ve r, t h er e i s a n I n cr e as i ng s a le

o f b le nd ed c e me nt , w hi ch w as n o t s o

earlier.- T he p ro po rt io na te s al es o f b le nd ed

v a ri e ti e s o f c e me n t - P or t la n d P oz z o -

lana Cement (PPC) and Portland

Blast Furnace Slag Cement (PBFC)

- h a s ri s e n o v e r t h e y e ar s

- D ur in g 2 01 1, bl en de d c em en t

a cc ou nt ed fo r 7 5 pe r c en t o f t ot al

c e m e n t p ro d u c t io n i n t h e c o u n tr y

The third factor that has emerged is

t h e s e r i o us a t t e m p t o n C o s t r e d u ct i o n

t h r o ug h t h e u s e o f a l t e rn a t e f u e ls

- M aj or c em en t m a nu fa ct ur er s i n I nd ia

are increasingly using alternate fuels,

s u ch a s ev e n b i o- e ne r gy t o fi r e c e -

ment kilns

- T hi s i s n ot on ly h el pi ng to re du ce

p r od u ct i o n c o st s o f c e me n t c o m-

panies, but is also proving effective

i n r e d u ci n g e m i s s i o n s

Bruno LafontC E O , L a f a r g e

" Th e a tt ra ct iv e g ro wt h o f t hec o ns t ru c ti o n i n du s tr y w i ll b eh ig he r t ha n t he s ho rt t er me c o n om i c g ro w t h . In d i a i s

o n e o f o u r f o cu s c o un t ri e s,as we wa nt to e xp an d o uro pe ra ti on s f ro m t he N or thE as t to t he r es t of t hecountry,"




An illustration of successful imple-

m e nt a ti o n o f a l te r na t e f u el u s ag e i n

c e m e nt p r o d u c ti o n t o r e d u c e p r od u c -

t i o n c o s t s i s sh o w n i n F i g u re 6 .

The Sustainability Score

Energy efficiency: The I ndian cement

i n du s tr y i s o ne o f t h e mo s t e ne r gy e f fi -

cient, according to the World Business

Council for Sustainable D evelopment's

( W B C S D ) C e m e n t S u s t a i na b i l i ty I n i t ia -

tive's (CSI ) Getting the Numbers Right7

(GNR) data programme.D e s p it e t h e l a rg e c a p ac i t y o f I n d i an

c e me n t i n du s tr y, t h e c o un t ry p e rf o r-

m e d e xt r em e ly w e l l i n t e rm s o f s p ec i fi c

e ne rg y c on su mp ti o n p er t on ne o f c li n-

ke r p ro duc ed, w it h a n a ve rag e 3 13 0

M J / t a c ro s s t h e 5 0 % o f c e m e n t c ap a c -

c o m p l em e n t in g f a c t o r s . F i r s t l y, t h e f a c t

that (expensive foreign) coal, the domi-

n a n t f u el f o r t h e I n d i an c e m e n t i nd u s t r y

a c t s as a s t r on g d r i ve r t o w a rd s e f f i-

ciency. This is complemented by a skilled

knowledgeable engineering force thatmaximizes operating 'equipment & sys-

t e m s ' e f f i c ie n c y l e v e l s. C o a l i s a r e li a b l e

a n d st a b l e k i l n f u e l th a t ha s h e lp e d

I n di a n k i ln s to be v er y f i ne l y t u ne d f o r

better efficiency.G HG e mi ss io ns : i n t he m at te r o f

C O 2 e m is s i on s p e r t o nn e o f c l i nk e r,

I n d i a p e r f or m s n o t t h a t w e l l , a s C O2

r e le a se d i s 8 3 7 kg / t o f c l in k er t h ou g h

t h i s i s c l o s e t o t he g l o b a l av e r a ge . I n

t h is r e sp e ct c e me n t, i n du s t ri e s w i l l h a ve

t o s w i t ch t o a l t e rn a t e f ue l s o f w h i c h G e r -m an y i s o ne o f t he be st ex am pl es .

I n d i an c e m e nt i n d u s t r y t o o h a s e n t e r ed

t h i s a re n a ( S ee f i g . 8 ) b u t t hi s i s a n

a s p e ct t h a t h a s t o b e f u l l y c u s t o mi z e d

s o t h at a p r o pe r b a la n ce i n b e t- w ee n

c a r b on f o o t p ri n t a n d e f f i c ie n c y i s m a i n -

tained.

F in al ly, ' Lo w C ar bo n Te ch no lo gy

R o a d ma p ' f o r t h e I n d i an c e m e nt i nd u s -

t ry i s a lr ea dy u nd er l au nc h. T he ro ad -

m a p w i l l o u tl i n e a po s s i b l e t r a n si t i o n

p a th f o r t h e c em e nt i n du s tr y t o r e du c e

i t s d ir e ct e m is s i on s b y 1 8 p e r c e nt b y

2 0 5 0 . I n d i an c e m e n t m a j o rs AC C L t d ,

S h re e C em e nt a n d U l tr a te c h h a ve

s i g n e d a c o op e r a ti o n p a c t t o s u p po r t

l ow -c ar bo n i nv e st me nt s in I nd ia . T he

p a c t wa s s ig n e d in G e n e v a w i t h m e m -

b e r c o mp a ni e s o f t h e Wo r ld B u s i ne s s

C o u n c il ( W B C ) f o r S u s t ai n a b le D e v e l -

i t y t h at t h e G N R p r og r am m e re c ei v e d

d a ta o n ( r ef e re n ce 2 0 10 t h e mo s t

r e c e nt y e ar f o r w h i c h d a t a i s av a i l a bl e ) .

B r a z il a n d Ch i n a , w h i c h a l s o ha v e r ap -

idly-developing large cement indus-

t r i e s , p e r f or m e d s l i g h tl y l e s s we l l . ( S ee

Figure 7)F or a l l t he t h r ee c o u nt r ie s , i t i s t he

r ec en t ex pa ns i on o f t he i nd us tr y t ha t

provides this thermal efficiency, an obvi-

o us c on se qu en ce o f t he n ew ly i ns t al l ed

m o d e r n p l a n ts be i n g m o r e e f f i ci e n t

t ha n o ld er o ne s. T he c om pa ri so n e vi -

d en tl y i s w it h t he E U 27 g r ou p o f c ou n-

t r i e s ( a n d t he U S A t o a g r e a t e r e x t e n t) ,

w h i c h h a v e o l d e r u n i t s .I n t he I nd ia n c as e, e ff ic ie nc y a ch i-

evement and its sustenance in the new

capacity additions is attributable to two


Compan y/Plant Strategy Benefits

Ma dra s C ement ' sA la t hiy ur pla nt

India C ement s Lt d' sDa la voi pla nt

Ult ra Tech' s Guja ra tC ement W orks

La fa rge' s A ra smet apla nt

A n n u al c o s t s a v i n g s o f U S D 1 . 7 m i l l i o n

A nnua l sa vings of USD6500 a pprox.

Reduct ion of a bout 30,000 t onnes ofca rbon emissions a nnua lly

Higher energy sa vings a ndlower ca rbon emissions

Use bioenergy t hroughb u r n in g o f c o f f e e h u s t

a n d c a s h e w n ut s h e l l s

U s e L o w S u l ph u r H e av yS t o ck ( L S HS ) s l u dg e

a s a l t er n at e f u e l

Use t y re chips a ndrubber dust a s

a lt erna t e fuel

S u b s t it u t e 1 0 % o fc o al u s ed i n k il n s

wit h rice husk

F i g u re 6 : I l l u s tr a t i o n o f S u c c e ss f u l u se o f a l t e rn a t e f ue l s i n c e m e n t p r o d uc t i o n

USA Germa ny EU27 Bra zil W ORL D C hina India0

500

1000

1500

2000

3000

3500

4000

4500

2500

S p e c i f i c e n e r g y c o n s u m p t i o n ( M J / t

c l i n k e r )

C hina USA I ndia Braz il W ORLD EU27 Germa ny0

100

200

300

500

400

700

800

900

1000

600

S p e c i f i c e n e r g y c o n s u m p t i o n ( M J / t

c l i n k e r )

F i g u re 7 E n e r gy E f f i c i en c y Fig ure 8 GHG Emissions




o p m e nt ' s C e m e n t S u s t a in a b i li t y I n i t ia -

tive and I nternational Finance Corpora-

t i o n ( I F C ) .

A d d i t i o n a l c a p a c i t y r e q u i r e m e n t -

W h a t t o E x p e ct ?

An improved capacity utilization not-

w i t h s ta n d i ng t he s u rg e i n c o n t i nu e d

d e m a nd i s p u s h i ng u p i n c r ea s i n g ly t h e

n e e d f o r i n s t a ll e d c a p a c i t y a d d i t io n .I n s t al l e d c a p a ci t y i n c r e as e d at a

C AG R o f 1 3 .6 p er c en t ov er F Y0 6- 11

w h il e p r od u ct i o n w i tn e ss e d a n i n cr e as e

o f 9 . 1 p e r c e n t d u ri n g t h i s p e ri o d .To ta l ca pa ci ty o f 3 31 M T i s es ti -

m a t e d to h a v e b e e n c r e a te d i n F Y 1 2 .C on si de ri ng th e s ha rp g ro wt h i n

c o ns t ru c ti o n, i n fr a st r uc t ur e a n d r e al e s -

p r i m ar i l y b a s e d o n t h e p a c e o f a c t i v i t i es

i n t h e b u si n es s , f i n a nc i al , r e al e s t at e a n d

infrastructure sectors of the economy,

a l l o f w h ic h a r e r a ci n g a h ea d , c e me n t

demand will continue to demonstrate

h ea lt hy g ro wt h t re nd . C eme nt b e in gthe most preferred building material

w or ld wi de f o r a ll c o n st ru ct io n w or ks

from housing and industrial construc-

t io n t o th e cr ea ti on o f i nf ra st ru ct ur es

l i ke p o rt s , r o ad s , p o we r p l an t s, e t c. t h e

i nd us tr y w il l ex pa nd by l ea ps an d

b ou nd s. A s fo r t he I nd ia n c em en t in -

d u s t ry, i t i s g l o b a ll y c o m p e ti t i v e w i th t h e

i n d u s tr y h a v i ng d e m o n s t r at e d h e a l t h y

t r en d s in t e rm s o f c o s t c o nt r ol a n d a

continuous technology upgradation.While I ndia is experiencing growth

i n a ll a re as , t he i nd us tr y a nd t he c em en t

m a rk e t i s mo v i ng ah e ad ev e n i n t h e

w a ke o f w o rl d -w i de ec o no m ic r e ce s -

s i o n . T h e d om e s t i c e n v i ro n m e n t t o o is

s pu rr ed u p b y i ni ti at iv es t ak en b y t he

G o v e r nm e n t o f I n d i a to v a r i o us i n f r a -

s t r u c tu r e p ro j e c t s , r o a d n et w o r k an d

housing activities with a huge 1.15 lakh

c r or e i nv e st m en t b as k et . T h e ri g ht

moves by the government should be a

b i g c o mp l im e nt t o a n i n du s tr y w h ic h

t o o h as d o n e a l o t o f g o o d w or k o n

c a p a ci t y a d d i ti o n , u t i l i z at i o n , e f f i ci e n c yand environmental measures.

References

1 . A C C L t d. h t tp : // w ww. a cc l im i te d .c o m/

2 . W or l d B an k I n di c at o rs w e bs i te .

3 . U n i t ed S ta t e s G e o l og i c al S u rv e y.

4 . C em en t Ma nu fa ct ur er s' A ss oc ia ti on

w e b s i t e : ' h t t p : / / w w w . c m a i n d i a . o r g

/portal/static /DynamicHistory.aspx

5 . ' Gl o ba l C em en t D ir ec to ry 2 01 3, ' P Ro

P ublications Inte rnational Ltd., Epsom,

U K , N o ve m be r 2 01 2 . G l ob a l C em e nt

http://www.globalc e me nt .c om/ 6 . S in gh , S .P. ' As se ss me nt o f c om pe ti -

t i on i n c em e nt i n du s tr y o f I n di a ,' C o m-

p et it io n C om mi ss io n o f I nd ia & V in od

G up ta S c ho o l o f M an ag em en t, I IT,

Kharagpur,.

7 . W or l d B u si n es s C o un c il fo r S u st a in -

able De ve lopme nt, Ce me nt Sustaina-

bility Initiative .

8 . G l o b al Ce m e n t w e b si t e , ' C e me n t

i n du s tr y i n I n di a ,' h t tp : // w ww. i be f. o rg /

i n d us t ry / ce m en t- i n di a . as p x, U p da t ed

N o v e mb e r 2 0 1 2.

t a t e i n t h e I n d i an e c o n o my, I t i s l o g i c al

t h at t h e 1 2 t h F i ve Ye a r P l an e s ti m at e s

a d di t io n al c a pa c it y r e qu i re m en t w i l l

s u re l y r e ac h 1 3 9. 7 M T b y F Y 17

What lies 'Ahead'?

B y v ir tu e o f C e me nt 's d em an d b ei ng


A l l I n di a

78 7 7

82

FY1 1F FY1 2F FY13F

Fig ure 9 : Forecasted cap acityu t i l i z at i o n l e v e l s of c e m e n t pl a y e r s ( %)

450

400

350

300

250

200

2 0 1 1

2 0 1 2

2 0 1 3

2 0 1 4

2 0 1 5

2 0 1 6

100

95

90

85

80

75

70

65

60

55

50

A m o u n t o f C e m e n

t ( M t )

C a p a c i t y u t i l i s a t i o n r a

t e ( % )

t hA d di t io n al c a pa c it y c r ea t io n a s p e r t he 1 2 F i ve Ye a r Pl a n

12. 9 13.4

25. 3

30. 2

35.538. 7

FY12 FY13 FY14 FY15 FY16 FY17

F i g u r e 1 1 C a p a ci t y v / s Ca p a c i ty U t i l i z at i o n

F i g u re 1 0: C a p a ci t y C r e a ti o n





A Review of Fresh Cement and

Concrete Rheology

Rheology is the science of the deformation and flow

of matter, and the emphasis on flow means that it is

concerned with the relationships between stress, strain,

rate of strain, and time. Available literatures have helped to

overcome perceptions of the difficulty of rheology with its

often mathematically complex relationships. Flow is concerned with

the relative movement of adjacent elements of liquid and

in shear flows liquid elements flow over or past each other,while in extensional flows elements flow towards or away from

each other. In a shear flow, imaginary parallel layers of liquid

move in response to a shear stress to produce a velocity

gradient, which is referred to as the shear rate, equivalent to

the rate of increase of shear strain. Elongation or stretching

flows are rarely found in cement systems but there may be

some elongation at the entry or exit of a pipe. They will not be

considered further here. The rich variety of material behaviour

can be characterised in various ways, of which the flow curve

showing how shear stress and shear rate are related is very

common, but equally data may be presented as the variation

of viscosity (the ratio of shear stress to shear rate) with shear

rate or time.

Basic Information on Rheology

Rheology is the scientific description of flow. The rheology

of concrete is measured with a concrete rheometer, which

determines the resistance of concrete to shear flow at various

shear rates. Concrete rheology measurements are typicallyexpressed in terms of the Bingham model, which is a function

of:

- Yield stress: the minimum stress to initiate or maintain flow

(related to slump)

- Plastic viscosity: the resistance to flow once yield stress is

exceeded (related to stickiness)

Concrete rheology provides many insights into concrete

workability. Slump and slump flow are a function of concrete

rheology. Refer Figure 1 for a typical rheometer and typical flow

curve.

Sonjoy Deb, B.Tech,

Civil Associtate Editor

Concrete: Rheology




Figure 1: Rheometer and Typical Flow Curve

Workability versus Rheology

- Workability tests are typically empirical

- Tests simulate placement condition and measure value

(such as distance or time) that is specific to the test method

- Difficult to compare results from one test to another

- Multiple tests needed to describe different aspects of

workability

- Rheology provides a fundamental measurement

- Results from different rheometers have been shown to be

correlated

- Results can be used to describe multiple aspects or

workability

Some Concrete Rheometers are shown in Figure 3 below:

Rheology Testing Methods for Cement Based Materials

There are well−established rules for the sizes of apparatus

and sample to ensure that rheological measurements arereliable, chiefly that any gap must be 10 times the size of the

largest particles and that the ratio of outer cylinder radius to

inner must be less than 1.2. For coarse granular materials like

concrete this means that a coaxial cylinders viscometer is

impracticably large, requiring a sample volume of 2.5m3 [1],

whereas a specially designed one for mortar is feasible [16,17]

and cement pastes are well within the capability of any of the

wide range of laboratory instruments available commercially.

These principles are equally applicable to other geometries

and mean, for example, that the cone and plate viscometer

cannot be used for suspensions because the gap is zero

under the apex of the cone. This led to the development ofthe truncated and annular plate and cone geometries [8].

Fresh concrete

Because of the impracticability of using a coaxial cylinders

viscometer of anything like ideal dimensions for fresh concrete,

Tattersall and co−workers developed a highly successful

and practical apparatus in which an interrupted helical

impeller rotates in a cylindrical bowl of fresh concrete and the

Concrete Flow Curves

- Flow curves represent shear stress vs. shear rate

- Bingham model is applicable to majority of concrete

- Other models are available and can be useful for specific

applications (e.g. pumping)

- Very stiff concrete behaves more as a solid than a liquid.Such mixtures are not described by these models.

Refer a Flow curve in Figure 2.

Rheology Measurement: Typical Geometry

- Rheometers must be uniquely designed for concrete

(primarily due to large aggregate size)

- Results can be expressed in relative units (torque vs.

speed) or absolute units (shear stress vs. shear rate)

Concrete: Rheology

Figure 2: Flow Curve




behaviour is analysed using the theory of mixing [1]. This has

been developed further by Domone and Banfill [18] and the

current computer assisted model of the Two−point apparatus

is available commercially [19]. Following calibration it can

deliver the yield stress and plastic viscosity of fresh concrete

in fundamental units. Other, broadly equivalent, approachesto the measurement of fresh concrete rheology have

produced the IBB rheometer [20], the BML rheometer [21]

and the BTRHEOM [22]. These instruments were developed

in different countries and the question naturally arose as to

whether the results can be compared. The first attempt to

answer this was a programme of comparisons achieved by

bringing all four instruments together at a single location with a

fifth, the Cemagref−IMG [23], a large (0.5m3) coaxial cylinders

instrument used as a standard, all under the sponsorship of

the American Concrete Institute [24]. While each instrument

characterised fresh concrete as a Bingham material and the

yield stresses and plastic viscosities measured on the 12concretes tested remained in the same rank order, the results

fell into two groups. The Cemagref−IMG and BTRHEOM

agreed well, and the Two−point and BML agreed well,

with the second group giving a generally lower yield stress.

Pairwise correlations were highly significant and enable the

result of one test to be predicted from another. Since the

BTRHEOM uses parallel plates, the Cemagref− IMG uses

coaxial cylinders, the Two−point uses an interrupted helix

rotating in a cylinder and the BML uses coaxial cylinders this

agreement is encouraging.

Mortar

Mortar can be considered to be fresh concrete without the

coarse aggregate and its testing has attractions for the study

of the effects of ingredients at small scale. A coaxial cylinders

viscometer, while feasible, proved to be inconvenient and

Banfill described the use of the Viskomat as a small calibrated

mixer for mortar testing [25]. More recently Jin [26] used a

scaled down interrupted helix (like the Two−point impeller)

in an extensive study of the mortar fraction for design of self

compacting concrete and demonstrated that its rheology

could be predicted with a high degree of certainty from tests

on the rheology of the mortar.

Progress with cement paste

Experimental challenges for testing cement pastes and

slurries are the risks of slippage at the walls of the viscometer,

sedimentation of the particles and plug flow. Depletion of

particles at the viscometer surface can result in a thin (<1mm)

layer of water which facilitates bulk flow of the sample,

superimposed upon the shearing flow within the rest of the

material. The result is an underestimate of the stiffness of the

sample [27]. The slip can be avoided using a roughened

surface and Mannheimer [28] showed convincingly that

slippage reduced measured yield stress by 85%. This is

supported by comparisons between smooth coaxial cylinders

and a vane−in−cup apparatus: slippage in the formerreduced the measured yield stress by 50% but oscillatory

measurements at lower stresses were indistinguishable [29].

However, proof that slippage does not occur with roughened

surfaces above the yield stress has been elusive. At the high

water contents representative of concrete, the particles in

cement pastes may separate gravitationally and centrifugally

and this can cause errors. When measurement geometries

include devices to keep the paste homogeneous the results

are much more satisfactory. These include angled blades

to lift the particles [30], recirculating pumps [31], blades

with interlocking fingers [32] and more conventional mixers

[33]. The problem of plug flow, when the shear stress doesnot exceed the yield stress everywhere in the sample and

some part of the sample does not shear, was first raised by

Tattersall and Dimond [34] but has never been satisfactorily

resolved. They found that hitherto irreconcilable anomalies

in breakdown measurements were explained when filming

the flow in the gap of a coaxial cylinders viscometer revealed

that a solid plug of paste formed and was either stationary

(rough cylinders) or slid round slowly (smooth cylinders).

No satisfactory explanation has ever been offered for this

anomalous plug flow but its existence casts doubt on all

experimental data where full shearing flow has not been

confirmed visually.

Rheological Results of Cement Based Materials

It might be expected that the rheology of the more complex

material, concrete, containing a wider range of particle sizes,

would be more complicated than that of one of its constituent

materials, cement paste, but in fact fresh concrete has proved

to be simpler and considerable practical progress has been

made with it and, more recently, with mortars.

Concretes

Much work has been done on the effects on the rheology of

Concrete: Rheology

Figure 3: Rheometers




concrete of mix constituents and their relative proportions,

cement properties and admixtures and cement blending

agents [1,17,20,21,35]. Concrete conforms to the Bingham

model and does not show structural breakdown over the

range of shear rates used in the test. Yield stress and plastic

viscosity vary in a complex fashion with composition and this

makes rheology measurement a versatile way of controlling

the quality of fresh concrete production: tests carried out on

the fresh concrete can show up changes in the mix composition

which may have implications for the concrete’s hardened

properties and performance in use [35]. With the recent advent of

self−compacting concrete, characterised by a very low yield

stress, it has been found that the thickeners used to prevent

segregation in use by raising the viscosity of the water also

change the flow curve from the normal Bingham behaviour to

Herschel− Bulkeley type behaviour (see below) [26].

Mortars

Mortars undergo structural breakdown and measured data

are sensitive to the previous shear history of the sample,

but the equilibrium flow curve conforms to the Bingham

model [25] The effects of composition are similar to those

observed in fresh concrete and mortar tests can be used as

small scale predictors of concrete rheology [26, also Banfill,

unpublished].

Cement Pastes

There are qualitative and quantitative disagreements between

the results for cement paste reported by different research

workers. The flow curve has been reported to fit several different

mathematical forms, all of which indicate the existence of a

yield stress:

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Where A, B and C are constants.

Additionally the numerical values reported for the rheological

parameters cover a very wide range, which cannot be wholly

explained by variations in the materials used. It can only beaccounted for by accepting that differences in experimental

technique and apparatus of different workers have a much

greater effect than has been generally realised. Differences

in the shear history at the time of test, undetected plug flow

and slippage at the smooth surfaces of a viscometer could

all combine to give experimental variations as large as those

reported. However, there is general agreement on two fun-

damental qualitative aspects of the behaviour of cement pastes.

Material Cement paste, grout Mortar Flowing concreteSelf-compacting

concreteConcrete

Yield stress N/m2 10-100 80-400 400 50-200 500-2000

Plastic viscosity Ns/m2 0.01-1 1-3 20 20-100 50-100

Structural breakdown Significant Slight None None NoneFigure 4: Rheology of cement paste, mortar and concrete

Concrete: Rheology




Concrete: Rheology

Comparison of Cement Pastes, Mortar and Concrete

Figure 4 shows that there is a trend in the rheological properties

of cement−based materials, as quoted in the literature, which

can be explained semi quantitatively by the presence of

aggregate in the coarser grained materials. The flow properties

of suspensions are governed by the interfaces between solid

and water and, in terms of the surface area of contact, the

dominant contribution is due to the cement−water interface.

This is progressively diluted by the presence of aggregate. Thus,

for example in one comparison, two cements which gave pastes

whose rheological parameters differed by a factor of two

produced concretes of indistinguishable flow behaviour [1].

The yield stress and plastic viscosity increase as the maximum

particle size increases. This is because in a typical concrete at

least 50% by volume is in the form of aggregate which is capable

of withstanding the applied stresses without deformation:

consequently the yield stress is higher, a point confirmed bythe increase with increasing aggregate content in concrete [1].

The increased plastic viscosity is partly due to the increased

interparticle contact and surface interlocking, as demonstrated

by the fact that for two concretes with the same yield stress

containing rounded and angular coarse aggregates, the

plastic viscosity of the latter is higher. It is also partly due to

the inability of the aggregate to be sheared: when an overall

shear rate is applied to an imaginary concrete consisting of

aggregate and paste 50:50 per cent by volume, the shear

rate within the solid aggregate particles is zero and that in the

paste is. This higher shear rate results in a higher stress and

resistance to flow in the paste which in turn accounts for theincrease in measured plastic viscosity of the bulk material.

In contrast, the yield stress and plastic viscosity of cement

paste increase as the cement gets finer [44], which reflects

the dominance of the water−cement interface in this system.

Evidently the influence of particle size is a surface area effect in

fine grained pastes and a simple volume effect in the coarser

grained concretes. Perhaps further work on particles suspended

in dispersions will suggest the particle size range where the

change from one influence to the other occurs.[45]

Models for Particular Situations

Pumping

Transport of fresh concrete by pumping through pipes to

the point of placement has been used since the 1930s and

is an obvious candidate for rheological study, to help select

pumping equipment and conditions. Pipe flow of a Bingham

material is well characterised and the variation of shear stress

from a maximum value at the wall of the pipe to zero at the

centre line means that a plug of solid unsheared material

moves surrounded by a zone of shearing flow from which

pressure−flow rate equations have been derived [1,7].

However, this assumes that the material is homogeneous,

whereas pumped concrete actually forms a layer of paste

which lubricates the wall and facilitates flow. Therefore the

pumpability of a concrete is mainly governed by its ability to

form and maintain this layer under the pumping conditions

and an acceptance test has been developed [48]. In fact,

practical problems with blockage of pipe work have meant

that most pumping trials have had to be done at full scale,

which is both costly and inconvenient.

Interactions at the Surface of Formwork

A related problem requiring a knowledge of friction at a

concrete−wall interface is the pressure on formwork, which is

lower than the equivalent hydrostatic pressure because of the

yield stress within the material and the friction at the wall [50],

but empirical predictions underestimate the actual pressures

measured for modern highly fluid concretes. Friction between

steel and fresh concrete was measured in a tribometer based

upon moving a steel plate between opposed pressurized

cylinders filled with concrete which exert a known stress

normal to the surface [51,52,53]. Applying the coefficient

of friction between steel and concrete determined in this

apparatus enabled preliminary estimates of the formwork

pressures exerted by fluid and self compacting concrete to

be compared with those measured in full size formwork up to




12 meters high. This confirmed the complexity of the factors

affecting formwork pressure and showed that it is about 25%

less than hydrostatic for a self−compacting concrete, but

the contribution of friction depends on surface roughness,

concrete rheology and particle size distribution.

Vibrational Compaction

Vibration is the most popular means of compacting fresh

concrete into formwork and around reinforcement and there

is an extensive literature on the effects of such features as

frequency, amplitude and acceleration, but several recent

papers have significantly advanced understanding. Practically

vibration removes the yield stress of fresh concrete which

then flows under its own weight [54,55] and the important

characteristic of the vibration is the peak velocity. The fluidity

of vibrated concrete, defined as the reciprocal of its low shear

rate viscosity, is proportional to peak Vibrational velocity up to

a critical value, above which it is constant, and the viscosityof the vibrated concrete is proportional to the plastic viscosity

of the unvibrated concrete [56]. This work enabled the effect

of vibration to be defined phenomenologically but a more

rigorous investigation was recently completed by Teixeira et

al [57].

The Action of Superplasticisers

It has long been established that superplasticisers can have

spectacular but sometimes unpredictable effects on the

rheology of cement systems. The yield stress of cement and

concrete are reduced to very low values by the dispersion

of flocculated cement particles [1]. However, the progressof the hydration reactions causes stiffening (slump loss)

and this can be a serious practical problem. Flatt and Houst

proposed that there are three components of the behaviour of the

superplasticiser added to the system [59].The first part is consumed

by intercalation, coprecipitation or micellization within the

hydrating cement minerals, forming an organo−mineral phase.

The second part is available for adsorption at the surface of

cement particles and is effective in dispersing the flocs, but

the adsorbed amount is not easily measured since current

analytical methods are based on the amount removed from

solution and this cannot distinguish between admixture

consumed in the first part and adsorbed on surfaces [60,61].

Conclusion

Rheology is important because of the scope it offers for

characterising fresh cement paste, grout, mortar and concrete,

and for understanding how they perform in practical applications.

Without satisfactory fresh properties it is unlikely that the

desirable properties of the hardened materials can be achieved.

Their rheology is dominated by the structure that exists in the

cement paste, but in mortar and concrete the structure has

been partially or fully broken down during mixing. As a result

they conform closely to the Bingham model and their behaviour

during pumping, vibration and in formwork can be explained

by reference to that model. Reliable instruments for testing

the coarser grained materials are available and experience

in comparing the data is growing. In contrast there remain

apparently conflicting results for cement pastes, which are

probably due to the different experimental techniques usedby different workers. The important effects of shear history,

mixing energy and wall slippage on the results obtained in

viscometers are only now being generally understood. Rheology

can be optimized to ensure concrete performance

Reference

[1] Tattersall, G.H., Banfill, P.F.G. The rheology of fresh concrete, Pitman,(1983), 356pp

[2] Banfill, P.F.G. (editor) The rheology of fresh cement and concrete,Spon, (1991), 373pp.

[3] Bartos, P.J.M, Marrs, D.L., Cleland, D.J. (editors) Production methodsand workability of concrete, Spon, (1996), 541pp.

[4] Skarendahl, A., Petersson, O. (editors) First international RILEMsymposium on self−compacting concrete, Spon, (1999), pp.786.

[5] Nonat, A. (editor) Why does cement set? An interdisciplinaryapproach, 2nd International RILEM workshop on hydration and

setting, RILEM Publications Sarl, (1997), 419pp.

[6] Barnes, H.A., Hutton, J.F., Walters, K. An introduction to rheology,

Elsevier, (1989), 199pp.

[7] Barnes, H.A. A handbook of elementary rheology, Institute of

Non−Newtonian Fluid Mechanics, University of Wales, (2000),200pp,

[8] Banfill P.F.G., Kitching, D.R.Use of a controlled stress rheometer tostudy the yield value of oil well cement slurries, The rheology of fresh

cement and concrete, Spon, (1991), pp125−136.

[9] Bombled, J.P. A rheograph for studying the rheology of stiff pastes:

application to cement setting, Revue des Materiaux de Construction,no. 673, (1970), pp.256−277.

[10] Barnes, H.A., Carnali, J.O. The vane−in−cup as a novelrheometergeometry for shear−thinning and thixotropic materials, Journal of

Rheology, vol.34. (1991), pp.841−866.

[11] Gregory, T. The measurement of early strength development in

polymer modified cement pastes, 5th International congress onpolymers in concrete, (1987), pp.205−208.

[12] O’Keefe, S.J. Rheological properties of polymer modified cementpastes, PhD thesis, Bristol Polytechnic, (1991), pp.232

[13] Banfill, P.F.G., Carter, R.E., Weaver, P. Simultaneous rheological andkinetic measurements on cement pastes, Cement and Concrete

Research, vol.21, (1991), pp.1148−1151.

[14] Schultz, M.A., Struble, L.J. The use of oscillatory shear to study flow

behaviour of fresh cement paste, Cement and Concrete Research,

vol.23, (1993), pp.273−282.

[15] Keunings, R. A survey of computational rheology, 13th internationalcongress on rheology, (2000), vol.1, pp.1.7−1.14.

[16] Banfill, P.F.G. Feasibility study of a coaxial cylinders viscometer formortar, Cement and Concrete Research, vol.17, (1987), pp.329−33.

[17] Banfill, P.F.G. A coaxial cylinders viscometer for mortar: design andexperimental validation, Rheology of Fresh Cement and Concrete,

Spon, (1991), pp.217−226.

[18] Domone, P.L.J., XuYongmo, Banfill, P.F.G. Developments of the

two−point workability test for high−performance concrete, Magazineof Concrete Research, vol.51, (1999), pp.171−180.

For complete list of the reference kindly view the digital edition.

Concrete: Rheology




Low Carbon Cements and Concretesin Modern Construction A John W HarrisonManaging Director, TecEco

There are some significant problems facing humanity includingclimate change, ocean acidity and food shortages, land

degradation and water pollution by wastes. At the 2007 “Driving

CO2 Reduction” National Conference held in Melbourne on

13 & 14 September 2007 M K Singh stood up and said “I want

the cement industry to be the saviour of the world”. Concrete

can be and those in the industry who take on this challenge

will succeed. We must however think outside the square and

develop new technical paradigms1.

Cement production was 3.4 billion tonnes in 2011 and the

concrete produced with it roughly 28 billion tonnes. The annual

carbon emissions from the cement in this huge material

flow amount to roughly 2.9 billion tonnes of carbon dioxide,

or 8.8%2 of total anthropogenic carbon emissions making

cement a significant source of emissions. If other associated

supply chain releases are included, significantly more.

China and India between them are now consuming 40 times

more cement and concrete than the USA. India currently

produces around 210 million tonnes of cement, second to

China at around 2 billion tonnes (25).

There is a solution to global warming, salinity and many other

global problems and it is potentially very profitable. TecEco

Gaia Engineering utilises the huge flow of concrete to createan enormous CO2

sink and I will explain this as I go through

the options and issues for cement and concrete in modern

construction.

According to the British Research Establishment (BRE) we cannot

address de-carbonation without changing the composition

of cement and fuel derived emissions will diminish slowly for

purely economic reasons (19). Papers describing numerous

different binder formulations abound and I have written some

of them.

The BRE are applying the wrong emphasis. The composition ofFigure 1 - Predicted Global Cement Demand and Emissions (19)

Cements

A multidisciplinary analysis and review of low carbon cements and concrete is provided. Options are set out in a table and explainedin the context of a wide range of disciplines and concepts. The paper takes a lateral thinking approach and calls for a change in mindset,

teaching methods and the way standards are written so that the business model of cost cutting prevalent in the industry can change. It findsthat significant de-carbonation will result not so much by changing the chemistry of existing cements or by developing new ones butby focussing on properties affecting lifetime energies and making CO

2and other wastes resources to manufacture synthetic carbonate

aggregates and introducing carbon capture during manufacture or Portland and other hydraulic cements.

cement does not have change so much as the composition ofconcrete. Cement is only around 10% of concrete. The use of

a high proportion of SCM’s coupled with synthetic carbonate

aggregates made from flue CO2 and waste magnesium ions

and other materials effecting properties3 would make concrete

made with any hydraulic cement currently associated with

emissions a very green material with net sequestration.

Mehta summarised some of the techniques used by architects

for dematerialisation (15) but did not consider the effect of

dematerialisation on lifetime or operational energies and

TecEco have realised the potential of carbon capture during

manufacture.

These and other alternatives are summarised with reference

to Table 1 that follows. I then address the options, dealing with

those that have been dealt with in the literature adequately

more briefly than others that have not.

Alternative Binders

There are a large number of alternative binders and many

options to improve the energy and emissions associated with

their manufacture. Given necessary brevity and the fact that

they have been dealt with extensively by others most of them

are presented as Table 2 - Future Binder Contenders with




Differentiated Supply Chain Options on the next page. Data

on production emissions with and without capture in most

cases is included.

Noticeably the hydraulic cement group dominated by Portland

cement is the largest and there are many variants providing

high early strength, sulphate resistance etc. Many of the newcements are variants of a Portland cement theme.

Hydraulic Cements

There is significant potential for carbon capture with cements

made with a calcination step such as most if not all hydraulic

compositions. This potential is covered in more detail under

the heading Alternative Manufacturing Processes.

Slag-lime or slag – Portland Cement (PC) cements. Slag is made

from ground granulated blast furnace slag (GBFS) which is

a waste and latently hydraulic. It can be used with activators

such as Portland cement (PC), lime and/or reactive magnesia

(according to our patents) to make a cement4.

Calcium sulfoaluminate cements & belite calcium sulfoaluminate

cements are low energy cements that can be made from

industrial by products such as low calcium ( class F) flyash and

sulphur rich wastes. The main hydration product producing

strength is ettringite. Their use has been pioneered in China and

more recently in the UK.

Calcium aluminate cements are hydraulic cements made from

limestone and bauxite. The main components are monocalcium

aluminate CaAl2O

4(CA) and mayenite Ca

12 Al

14O

33(C12A7)

which hydrate to give strength. Calcium aluminate cements are

chemically resistant and stable to quite high temperatures.

Belite cements can be made at a lower temperature and contains

less lime than Portland cement and therefore has much

lower embodied energy and emissions. Cements containing

predominantly belite are slower to set but otherwise have

satisfactory properties. Many early Portland type cementssuch as Rosendale cement were rich in belite phases. (See

http://www.tececo.com/links.cement_rosendale.php.)

Reactive magnesia blended with other hydraulic cements and

Supplementary Cementitious Materials (SCM’s)5 Reactive

magnesia (rMgO)6 is a powerful new tool in hydraulic cement

blends. 15-30% improvement in compressive strength and

greater improvements in tensile strength, much faster setting,

better rheology and less shrinkage and cracking, less bleeding

and long term durability have been demonstrated with 50 %

replacement and more of PC by flyash and GBFS. We believe

autogenous shrinkage has been solved.

7

rMgO is an ideal

Figure 2 - Mehta’s Triangle (15)

Option Description Players Drivers BarriersStandards &

Guides

Alternative Binders Numerous and described in Table 2- Future Binder Contenders with Dif-ferentiated Supply Chain Options

Scientists(CementChemists)

Sustainability andprofit.

Conservatism, out dated software. Prescrip-tion standards and approvalssystems (see http://www.tececo.com /sustainability.permissions_rewards.php.)

A few guides anddraft standards (e.g.with Geopolym ers)

CO2

Capture duringManufacture

Reduce process emissions. Cementsthat involve calcination can be madewithout releases.

Scientists.TecEco andCalix.

Sustainability,carbon taxes.

Inability to think laterally. Fear of change Common sense!

Replacement ofPortland cement byLimestone

Blending with Limestone with ce-ment to reduce net emissions hasmet with some success and is now

incorporated into many standards.There are however issues.

Cementtechnologists

Economiccost/benefit,sustainability,

Leed, GBC, r & d& procurementPolicies.

Buyer hesitancy. New standardsemerging becauseindustry driven.

Replacement ofcement by SCM’s

Blended cements that contain a highvolume of replacement materials(SCM’s) such as fly ash, slag ce-ment (gbfs), pozzolans, silica fume,rice husk ash etc. High replacementcement concretes often have im-proved properties such as rheology,less shrinkage, greater durability etc.The use of reactive MgO makes theuse of higher proportions ofSCM’s possible.

Cementtechnologists

Economic cost / benefit,sustainability,Leed, GBC, r & d& procurementPolicies.

Conservatism, out dated software. Prescrip-tion standards and approvalssystems (see http://www.tececo.com/sustainability.permissions_rewards.php.)

Mix design methods.LCA & LCCA. Newbetter software.

Cements




additive as it aids the dissolution of SCM’s and contributes

positively to many other properties (See REPLACEMENT OF

CEMENT BY SCM’S 7

Chemical Cements

Magnesium Phosphate Cements are chemical cements that

rely on the precipitation of insoluble magnesium phosphate

from a mix of magnesium oxide and a soluble phosphate. They

include some of the oldest binders known8 and are potentially

very green if the magnesium oxide used is made with no

releases or via the nesquehonite (N-Mg route) which is part

of the TecEco Gaia Engineering solution (See ALTERNATIVE

MANUFACTURING PROCESSES. It would also be good if a

way is found to utilise waste phosphate from feedlots9.

Carbonating Cements

Reactive Magnesia Based Carbonating Binders can, like

lime, be used for full thermodynamic cycle binders such as

carbonating mortars. Reactive Magnesia (rMgO) has the

advantage of also taking on water of crystallisation so the

solid produced for input mass ratio is higher than for lime

based carbonating binders. rMgO can also be made without

releases10.

Lime Based Carbonating Binders can, like magnesia, be used

for full thermodynamic cycle binders such as carbonating

mortars. As water of crystallisation is not also taken up, the

solid produced to input mass ratio is lower than for magnesium

based carbonating binders which is a disadvantage.

Other Cements

Geopolymers are potentially very green but suffer from a

number of fundamental flaws that will restrict their use and

increase risk outside factory environments where they are

currently being mainly used. They suffer from the nanoporosity

durability flaw and the fact that water is not consumed in their

setting with the result that making them fluid enough for easy

placement is difficult.

Because geopolymers are nanoporous soluble aggressive

agents can get into them and attack aggregates. What makesthem risky to use is the variability of results obtained. The

problem is that the amount of water added is critical - too

much and they are insufficiently alkaline or too little and they

cannot be placed. Getting over these problems has been the

main area for research and some success has been achieved

as geopolymer premix concretes are commercially available

as at the time of writing in Australia for non - structural

applications.

Sialites are a neologism for rocks made in a manner mimicking

natural rock forming processes. 11 The technology is not new

Dematerialisation Innovative architecture and engineer-ing. More durable concretes.

Architects&Engineers

Economic cost / benefit,sustainability,Leed, GBC, r & d& procurementPolicies.

Prescription standards and approvals systems(see http://www.tececo.com/sustainability.permissions_rewards.php.)

Design codes, LCA& LCCA

Mix Optimisation Appropriate particle packing, betteradmixtures and use of brucitehydrates to release water for morecomplete hydration

Cementtechnolo-gists

Economiccost/benefit,sustainability.

Conservatism, inappropriate software.Prescription standards and approvals systems(see http://www.tececo.com/sustainability.permissions_rewards.php.)

Mix design methods.LCA & LCCA.New better software.

Product Differentia-tion and Specialisa-tion

Mineral composites other thanconcrete with just stone aggregatecan improve sustainability. E.g.composites with a high “R” value

Materialsscientists

Economiccost/benefit

Inability to think outside the box. Fear ofchange

Standards, LCA &LCCA

Changing theemphasis

An emphasis other than on the bind-er to improve sustainability. E.g. Useof synthetic carbonate aggregate. Agreater focus on properties having ahigh impact on lifetime energies.

Scientists Sustainabi li ty,economic cost/ben-efit. Technical merit

Inability to think outside the box. Fear ofchange. Technical issues (?).

Common sense!

The Right BusinessModel Although not a technical matter theright business model is essential forprogress to be made.

Consultants Profitability in achanging businessenvironment

Conservatism, standards and legislativeenvironment.

The Right Frameworkto Operate in

Legislative restrictions and standardsthroughout the world are prescrip-tive in nature and this and a lack oftraining is holding back innovation.There is a strong need to throw awaydogma for what it is and get back toscience.

ScientistsandConsultants

The need tochange

Conservatism, inability or unwillingness tochange.

Table 1 - Ways to make Cement and Concrete More Sustainable.

Cements




PC Conventional .266 0.498 .764 .004 .760 Ordinary portlandcement

Most denseconcretes

Normal premix. No sup-plementary cementiousor pozzolanic materials

PC Permeableblockformulation

.266 0.498 .764 .144 .620 Carbonated ordinaryPortland cement blocks

Gas permeablesubstrate

No supplementarycementious orpozzolanic materials

42% PC 8%MgO 25%Flyash 25%GBFS

.199 .209 .408 .001 .407 Terniary mix withMgO additive.

Most dense concretes Faster setting andhigher early strength

PC With capture .266? .266? .004 .266? Recapture duringcalcination.

Most denseconcretes

No supplementarycementious orpozzolanic materials

MgO 750-1000oC

Conventional .240 1.092 1.322 -1.092 .240 Eco- Cements sorel &magnesium phosphatecements.

Historic andconventional

Sorel and Mg phos-phate cements. TecEcoEco-Cement Forcecarbonated pure MgO(Cambridge University)

MgO <750oC Tec-Kiln(with capture)

.240 .240 -1.092 -.851 Eco-cement Brucite(MgO) boards

TecEco, CambridgeUniversity

Sorel and Mg phos-phate cements. TecEcoEco- Cement Forcecarbonated pure MgO(Cambridge University)

MgO <450o

C MgCO3 .3H2OConventionalcalcination

.378 .007 .385 -1.092 -.706 Eco-cement concrete,pure MgO concretes TecEco, Universityof Rome La Sapienza. TecEco, University ofRome La Sapienza.

MgO <450oC MgCO3

.3H2OTec-Kiln(with capture)

.378 -1.085 -.706 -1.092 -1.798 Eco-cement concrete,pure MgO concretesNovacem concretes?

TecEco N-Mg route TecEco

MgO <450oC20% PC 80%MgO

MgCO3

.3H2O

Tec-Kiln(with capture)

.369 -.743 .374 -.874 -1.248 Eco-cement concrete,pure MgO concretesNovacem concretes?

TecEco N-Mg route TecEco

Silicate route Novacem, Calix? After Klaus Lackner?

CaO Conventional .266 .785 1.051 .785 .266 Carbonating lime mortar Calera, British LimeAssn & many others

CaO CaCO3

Tec-Kiln

(with capture)

.266 .266 .785 -.518 Carbonating lime mortar Calera, British Lime

Assn & many others

Small net sequestration

with TecEco kiln

C3S Conventional ? 0.578 >0.578 ? >0.578

C2S Conventional ? 0.511 >0.511 ? >0.511 Belite cement Chinese & others

C3A Conventional ? 0.594 >0.594 ? >0.594 Tri calcium aluminatecement

Increased proportion

C4A3S Conventional ? 0.216 >0.216 ? ? Calcium sulfoaluminate cement

Chinese & others

Geo polymers Flyash + NaOH 0.16 0.16 Geopolymer Alliance,Geopolyer Institute,University Melbourne

Cements

C e m e n t s B a s e d o n

P r o c e s s

P r o c e s s

C O

2 ( t o n n e s C O

2

/

t o n n e o u t p u t )

D e c a r b o n a t i o n C O

2

( t o n n e s C

O 2

/ o n n e o u t p u t )

T o t a l E m

i s s i o n s ( t o n n e s

C O

2 /

t o n n e o u t p u t )

R e – a b s o r p t i o n ( t o n n e s

C O

2

/ t o n n e o u t p u t i n 1 y e a r )

N e t E m i s s i o n s ( S e q u e s t r a -

t i o n ) ( t o

n n e s C O

2

/ t o n n e

o u t p

u t i n 1 y e a r )

E x a m

p l e o f C e m e n t

T y p e

T y

p e a p p l i e s

t o / p r o p o n e n t

C o m m e n t




Table 2 - Future Binder Contenders with Differentiated Supply Chain Options

Notes to Table 2 - Future Binder Contenders with Differentiated Supply Chain Options

1. http://www.tececo.com/files/spreadsheets/TecEco-CementLCA15Jan2013.xls, 2. Quillin, K. and P. Nixon (2006). Environmentally Friendly MgO-based cements to support sustainable con-struction - Final report, British Research Establishment., 3. http://www.geopolymers.com.au/science/sustainability Much of the thermodynamic data used in this table has been calculated usingTecEco’s LCA Tool downloadable from the TecEco web site at http:// www.tececo.com/files/spreadsheets/TecEco-CementLCA15Jan2013.xls. The tool is in the form of an editable Excel spreadsheet with no password that calculates energy and emissions to the factory gate only. Please send any corrections or suggestions to [email protected]

Cements

as it has been known by some for years how to solidify some

fly ashes12 for example.

Alternative Manufacturing Processes

So far the industry response has mostly been to:

- Modernise and upgrade plant

- Convert wet to dry plant processes

- Convert shaft to rotary kilns

- Install preheating, more efficient burners etc.

- Improve grinding and other efficiencies.

- Burn cheaper waste fuels. Burning waste materials withhigh calorific value including timber, tyres, solvents, waste

oil, animal fats, carbon waste from the aluminium industry

(14) etc. has met with opposition in some countries

because of the associated pollution.

- Reduce kiln temperatures and adjust the composition of

cement accordingly with more aluminates and less alite13.

Capture During Manufacture

Significant sequestration can be achieved with capture of

CO2 from kilns but the problem, which has not been solved

yet for any form of sequestration, is what to do with it. One

approach taken by Ramesh Suri of ACC in 2006/7 was touse Algae to consume the CO

2and produce bio fuel14. The

problem lies in the sheer volume of CO2

produced and in

making the sequestration process profitable. To meet this

challenge TecEco is developing the N-Mg sub-process of

Gaia Engineering that will sequester huge amounts of CO2

as synthetic carbonate that can be used as aggregate or as

feedstock to make rMgO for its cements15.

Manufacturing Taking Advantage of Full Thermodynamic

Cycles

The manufacture and use of Portland cement does not involve

a full thermodynamic cycle and there is therefore little point insplitting the process into the endothermic16 and exothermic17

sub processes18 with one or two exceptions such as the

manufacture of Syngas19.

It is a different situation with carbonating cements containing

rMgO such as TecEco Eco-Cement. Recapture occurs with

net sequestration possible if CO2

is also captured during

calcination.

The real game changer and pinnacle of industrial ecology is

our N-Mg sub process of Gaia Engineering that will produce

large quantities of nesquehonite (MgCO3.3H

2O) from waste

magnesium cations such as found in oil process water and bitterns

and if this source runs out then from any brine containing

Mg++(step 1).

Nesquehonite can then be calcined in our Tec-Kiln without

releases (step 2) to make rMgO and the CO2

fed back into

the process (step 1) to precipitate more nesquehonite.

The rMgO is then used as a binder to agglomerate massive

amounts of nesquehonite to make synthetic carbonate

aggregate or in TecEco Eco-Cements where it re carbonates

(step 3).

The sequestration into synthetic carbonate aggregate without

saturating the market for aggregate is sufficient to solve the

global carbon problem as can be seen from the graph in Figure

6 below.

Eco-Cement binders according to TecEco Pty. Ltd.’s patents

are ideal for agglomerating synthetic carbonate aggregate

and from the graph the total sequestration possible given

2011 – 12 concrete production is over 22 billion tonnes which

is around 2/3 of that needed to consume all anthropogenic

emissions. As a matter of proportion, the particular cement

used in the future becomes less important in relation to the

total sequestration possible in concrete if the focus is also onaggregate.

TecEco call this breakthrough technology Gaia Engineering

and it is a whole new way of thinking about industrial ecology

and associated molecular flows. Gaia Engineering can

profitably solve the problem of global warming and related

problems such as ocean salinity and in doing so mitigate

other problems such as pending food shortages15.

Replacement of Portland Cement by Limestone

Limestone is now routinely being added to Portland cement

in varying proportions around the world and some successis being claimed mainly as a result of the improved particle

packing.

Compton and Chandler make it clear that Portland cement

is not the best possible additive however when they say

“limestone is generally considered to be the poorest potential

performer of the available suite of mineral additions and as

such considerable effort is focused on developing Portland-

limestone cements that achieve the current general purpose

Portland cement performance” (2)

By adding limestone to Portland cement the industry may be




reducing the effectiveness of better and more suitable mineral

additions such as rMgO and supplementary cementing

materials (SCM’s) classified and ground as necessary to

optimise particle packing. The SCM’s most commonly used

include fly ash, ground granulated blast furnace slag and

silica fume. Greater consumption of such wastes should beencouraged not compromised by a lowering of pH caused by

the addition of limestone.

Hooton, Nokken and Thomas make it clear “One area where

there is very little data is on the influence of limestone cements

when used in conjunction with SCM’s. A question that needs

to be answered is whether the use of limestone cements will

reduce the replacement levels of SCM’s that can effectively be

used.” (8) A theoretical analysis of the issue is on our TecEco

and Gaia Engineering web sites20

At the present time “considerable effort is focussed on

developing Portland-limestone cements that achieve thecurrent general purpose Portland cement performance” (2).

The goal is to find out just how much ground limestone can

be added without compromising the properties of normal

cements too much. The argument is that “limestone is the

obvious choice for most cement manufacturers. It is a

fundamental raw material at cement plants, and high grade

limestone is readily available through its use as a supplement

to amend raw meal chemistry. Limestone is abundant, pure

and soft and makes an ideal mineral addition to be inter-

ground with clinker and gypsum during cement milling” (1)

Given the theoretical evidence I present on the TecEco web

site20 it is essential that cement that consists of clinker and

gypsum in the right ratio with 5 % or less of limestone 21 and

nothing else continues to be made available for downstream

blending as the economics of other mineral additions will

change and many work much better such as rMgO which

would otherwise compete with limestone for interstitial sites

between cements grains.

Reactive magnesia blended with Portland cement and SCM’s

results in significant improvements in properties as detailed in

the next section. The problem is that best results are achieved

if it is fine enough to also fill interstitial sites between grains of

Portland cement.

Replacement of Cement By SCM’S

Portlandite should not be left in a concrete because it is far too

reactive. On the other hand consuming it all in the pozzolanicreaction also has technical issues. Mistakes are routinely

made. Portland cement can be blended with pozzolans such

as flyash which will consume Portlandite (Ca(OH)2) in the

pozzolanic reaction. It is important however that not all of the

Portlandite is consumed as calcium will start leaching from

CSH22 if it is. As an alternative pH buffer we recommend the

addition of rMgO which hydrates to brucite. The equilibrium

pH of Brucite is approximately 10.5 and the pH of CSH

Figure 3 - Options for Portland Cement Manufacture

Figure 4 – Manufacture of MgO from Magnesite with and without Capture

around 11.2 (22). The pH of a CSH and Brucite assemblage

in equilibrium will not fall much below 10.5.

According to the 12th plan in India around 10 million tonnes

of GBFS are produced annually (10). In a recent article by Dr

Yashpal Singh a figure of around 175 million tonnes of flyash

was estimated for 2012 (20).

As most SCM’s are wastes their use is obviously more

sustainable than digging up limestone, grinding it and adding

it to cement and the paradox is that the use of limestone may

compromise the use of SCM’s as explained in the previous

section.

In many parts of the world builders are negative about the

use of SCM’s because when added, concretes take longer

to gain strength. Grinding cement finer to compensate for

the negative chemical effects of limestone should have been

considered as one way of making it more reactive with SCM’s

such as flyash however this costs money. Another is to air

classify pozzolans increasing their reactivity.

A way of accelerating the setting of mixes containing a high

proportion of SCM’s is to include about 8-10 % rMgO as a

proportion to PC in a mix. The reason is because when

dissolved in water Mg2+ has a profound effect on the polarity

of all species in solution that can be polarised. Of particular

Cements




dimensional distress in the proportions we recommend and

does not act in the same way.

Dematerialisation

Dematerialisation is a technique for reducing the materials

used by design and has been practiced for many yearsby some architects. As the subject was covered by Mehta

extremely well (15) I will not elaborate. I refer readers to Figure

2 - Mehta’s Triangle on page 3 and comment that the impact

of dematerialisation on lifetime energies must be considered.

Mix Optimisation

Mix optimisation is mostly an art and should be a science.

It is not practiced widely enough and there are a lot of

shortcuts in the software used. More often than not the “rule

book” of prescriptive standards is religiously followed without

questioning why. For example the use of gypsum to prevent

flash set even when blended with SCM’s. An important aspect is particle size and charge. It is not

just what is in the mix but the particle size range of each

component and how they fit together in 3D space. The smaller

Figure 5 - The N-Mg Sub-Process of Gaia Engineering

interest in relation to cement are water and its disassociation

species.

Mg++ is a strong kosmotrope and strongly attracts electrons

and brucite (including microcrystallites) has a strongly chargedsurface. Water dipole strength is increased and propagated

in mix water. Water and its disassociation species such as

hydroxides have reduced negative electron clouds around

protons. Dissolution of SCM’s by proton wrenching occurs

more readily, speeding up reactions and making their use

more acceptable to builders24.

With about 8-10% of reactive magnesia (rMgO) added, 50%

or more of (SCM’s) can be used and the resulting concretes

still outperform ordinary Portland cement concretes25. This

may not be achievable with higher additions of inter-ground

limestone. Surely the goal should be to use SCM’s most of

which are wastes.

The focus of my efforts in the past few years has been to find

ways of making reactive magnesia much more cheaply so it

will be blended with Portland cement and SCM’s as a matter

of routine as it should be. Readers should however be aware

that some manufacturers are actively selling magnesia for use

in concrete without stating the reactivity in possible breach

or circumvention of our patents and possibly dangerously as

well because magnesia that is not highly reactive can cause

Figure 6 – Sequestration capturing CO2 from the air in the N-Mg process usingTecEco’s Tec-Kiln Figure 7 - The Sequestration Potential for Synthetic Carbonates in Concretes

Assumptions

Tec-Cement concret with synthetic magnesium carbonateaggregate

Percentage by weight of cement in concrete 12.00%

Percentage by weight of rMgO in Tec-Cement 9%

Percentage by weight Ca (OH)2 in cement 29%

% of Ca(OH)2 in concrete that carbonates 10.00%

Proportion cement that is flyash and/or GBFS 20%

1 tonne Portland Cement 0.867 Tonnes CO2

Proportion concrete that is aggregate 80.0%

CO2 captured in 1 tonne aggregate 1.084 Tonnes CO2

Net CO2 sequestration 1 tonne rMgO (N-Mg route, 1 completerecycle)

1.794 Tonnes CO2

CO2 captured hydration and carbonation of tonne Cao (in PC) 0.785 Tonnes CO2

Cements




Cements

the average size of each addition the more particle charge

becomes important26.

What is or is not included should be carefully considered with

end use in mind and many changes are suggested in this

paper. RMgO for example accelerates first set because it goes

negative at the surface as the pH rises as demonstrated in

Figure 10 above/

It is important to realise that packing considerations apply

to all components in a mix, not just the cement and that small

component substitutions can make a big difference to pro-

perties and the amount of cement required to achieve a

given strength. Less cement for a given strength is more

sustainable.

A pioneer in this field is de Larrard from France (13)(12) and

the TecSoft27 project at TecEco has been initiated to implement

some of his math.

Mix optimisation is also too focussed and should be better

connected with need as discussed in the section with the title

Product Differentiation and Specialisation.

Product Differentiation and Specialisation.

It has been said in the industry that “all that is grey is great, all

we make goes out the gate”. Significant amounts of energy

would be saved with specialisation for differentiated market

niches. Market penetration would also increase with the

development of new concrete product.

With rising energy costs and an urgent need to improvesustainability additions to cementitious composites that

improve lifetime or operating performance are an import

part of a profitable future. Many waste streams can offer a

wider range of properties for purposes such as thermal

insulation or weight reduction. With the use of rMgO any toxics

are encapsulated as well as immobilised and bonding to

alternative included materials such as agriculture or domestic

wastes is dramatically improved as are fire resistant properties.

Concretes with high thermal mass for heat retention and

concretes with greater elasticity and plasticity for road pavement

are other examples.

New mineral composites incorporating waste streams with

low thermal flow characteristics will be in high demand (e.g

sawdust blocks) in the future and will drive this differentiation.

Cementitious composites such as concrete can take a lead

role in reducing lifetime energies and become part of the

solution instead of the problem.

Changing the Emphasis

It is essential to think of concrete not just cement as each

component has a role in the performance at every stage. It we

think whole of concrete as recommended by Ken Hover (9)

and many others then it becomes much easier to understand

the material and issues concerning it such as sustainability.

There is too much emphasis on strength and not enough on

durability and properties. As discussed under the headingProduct Differentiation and Specialisation. Concretes with a

wider range of properties such as low conductance or light

weight could play a major role in reducing the lifetime or

operational energies of structures.

About seven years ago now I realised that aggregate is 80%

or more of most concretes and therefore represented an

opportunity to sequester huge amounts of carbon dioxide as

synthetic carbonate in our Gaia Engineering process explained in

this document under the heading Capture during Manufacture

and in a lot more detail at www.gaiaengineering.com.

The Right Business Models

For a long time a cost cutting model has dominated the efforts

of players in our industry however if we are to move forward

and fulfil the potential of solving many of the world’s problems

this will have to change. New innovation based business

models will have to be adopted.

Most governments have realised that innovation is important

and in relation to this some interesting statistics are coming

Figure 8 - Gaia EngineeringFigure 9 –The Mg++ ion drags electrons to it exposing more electro positiveprotons23




out of the Department of Industry, Innovation, Science,

Research and Tertiary Education in Australia that conclusively

demonstrate that innovative companies perform better (See

Figure 11)

trading the industry should also consider using standards,

modified as suggested, as a way of providing benchmarks for

minimum embodied energy and emissions. Existing standards

could be relegated to a role as guides.

Legislative Frameworks fall into the same trap as standards

with too much restriction although some governments such

as my own here in Australia pay lip service to the need for

change as evidenced by renaming departments with the

word “innovation” included. The way forward surely lies in

better education and training and the conversion of standards

to guides. The concrete industry produce and place the most

used and important materials in construction yet in many

countries no qualifications of even basic training are required

by those practically involved. This deplorable situation must

improve and hopefully the training is not rote but such that it

awakens minds to the possibilities.

The Right Policies to Support Research and Developmentto Improve Sustainability

Few governments have ever managed to get the mix of

stick, incentive and procurement right or even remotely

efficient. The level of control continues to increase without

the leadership to drive it. As Lord Stern made clear in his

review of the economics of climate change (23) there are

huge opportunities for emissions reduction in building and

construction, not just in reducing the embodied energy and

emissions of the materials we make but by changing the way

we design structures and the way we utilise the materials we

use to build them.

The biggest problem is that governments do not follow their

policies through the supply chain. It is no good supporting the

Research and development of for example carbon capture

methods without making sure there are financial sticks and/or

incentives to encourage the changes required to the process

of making cement.

Back to Science

There are too many non - scientific dogmas in the cement and

concrete industry.

At TecEco we have relied on science to explain what we

Figure 10 The Change in the Surface Charge of Metal Oxides with pH. (21)

Companies in the construction sector including the concrete

industry do not spend much on research as shown in Figure

12. The main reason why is because our industry is bound

by a framework of standards, legislation and conservatism

that has resulted in low margins. It is no wonder cost based

business models prevail.

The Right Framework to Operate in

The concrete industry in most countries operates with a

restrictive framework of standards and guides and supporting

legislation that breeds conservative managers who do not

innovate and a cost cutting business model. Our engineersare taught to rely on out of date dogma not rely on science or

their common sense. Change must occur if we are to move

forward on sustainability and take advantage of emerging

opportunities for carbon trading. Given the lack of training and

education at the base level this will be a difficult challenge.

An Inappropriate Permissions and Rewards Systems

At Concrete Solutions 09 (6) I spoke about the tremendous

potential for players in the concrete industry to make money

as a result of inevitable change yet many barriers still exist as I

have discussed. One of the greatest remains our ill-conceived

permissions and rewards systems28 designed with the false

notion that they protect the status quo. There is a rising current

of change that I helped initiate and prescriptive standards and

inappropriate legislation is getting in the way.

Standards for cement and concrete are still prescription based

in most countries and even the Green Building councils in the

US, Australia and elsewhere have fallen into the same trap of

locking in the status quo and stifling innovation. Prescriptions

should be confined to guidelines on how to do things. Standards

should set out minimum performance requirements in a chosen

range of categories. In order to take advantage of carbon Figure 11 - Increases in Business Performance by Innovation status 2008 – 9 (4)

Cements




observe. By using science rather than applying dogma it is

easier to understand what is really happening and see a way

forward for improvement.

Conclusions

It is time cement companies adopted a business model thatconnects innovation with profitability. In many other industries

profitability is understood to be a function of research and

development and that the regular release of new technically

improved product generates revenue growth. Progress towards

de-carbonation will be slow unless this occurs.

Engineers should be taught science not dogma and standards

need to be rewritten as benchmarks not prescriptions. The

legislative framework in many countries needs a broom through

it and governments need to realise that the concrete industry

could in fact be the saviour of the world as M K Singh bravely

arose and said

29

. All this can only be achieved if there is a change in mindset,

a strong desire to move the agenda towards greater sustain-

ability forward, a willingness to throw away the rule book, a

whole new modern scientific lateral thinking.

Last century there were many different mineral cement

contenders and Portland cement was only one of them. By

1900 it emerged as the dominant formulation. In the future a

new differentiation of product based on properties will probably

occur and this will be a good thing as it will result in greater

margins and product more suited to particular use such as,

for example, the development of binders suitable for utilisingwood waste to make insulating composite products for the

outside of buildings including rMgO for fire retardation. The

major barrier to implementation will be the mindset of our

managers and out dated prescription based standards.

John Phair said at the conclusion to his paper that “Further

developments and new techniques must continue to be

introduced into the cement and concrete industry. Green

chemistry will play a significant role in facilitating a holistic

industrial ecological approach to cement from a fundamental

level. This will provide distinct alternatives to an OPC dominated

cement market.” (18). There will be greater diversification and

alternatives but in my view the market will still be PC and PC

derivative based but only if new formulations and production

processes that include capture are implemented such as our

N-Mg process which produces synthetic carbonate aggregate.

Chemistries that fix known “sleeper” issues such as Portlandite

content will need to be embraced including our own Tec and

Eco-Cement technologies. With the use of a high proportion

of SCM’s, particularly if pre - blended the addition of gypsum

and limestone are questionable. As Paul Hawken makes clear

in “The Ecology of Commerce,”concrete that is more durable

is more sustainable(7).

By adopting a whole of concrete approach there is much more

scope for sustainability. The obvious target in construction

is to lower lifetime or operational energies so we should be

thinking properties as well as strength and durability and this

will require product diversification.

Paradigm changes such as our Gaia Engineering project will

modify the supply chain to focus on carbon capture and then

use the CO2

produced to manufacture synthetic carbonate

aggregate.

A new approach to cement and concrete formulation cannot

evolve without the realisation that concrete can be part of the

solution not the problem.

Portland cement concretes are the most ubiquitous and will

probably remain so because immense economies of scale

make them relatively cheap and sustainability problems canbe overcome by carbon capture with CO

2used as synthetic

carbonate aggregate and a reformulation excluding limestone

and gypsum and including reactive MgO and a mix of classified

fine and normal SCM’s in high proportion.

Footnotes

1 The technology paradigm defines what is or is not a resource.

2 The Chinese government (16) estimate that 861 kg (net) of CO2

areemitted for every tonne of Portland cement clinker produced. Theproduction of 3.4 billion tonnes cement would results in emissions of2.9 billion tonnes CO

2.Global emissions are around 33 billion tonnes

(17) so the current contribution of cement production globally as 2.9/33

x 100%, or 8.8%.3 The inclusion of additions that introduce properties such as thermal

capacity and lower heat transfer rates have significant scope to reducelifetime or operational energies. Many of these additions can besourced from waste streams.

4 We include for convenience GBFS in our definition of hydraulic cementsin our patents in most countries and claim the right to reMgO GBFSmixes. Beware of infringements. We do not think reactive magnesia(rMgO) a good activator but it is an excellent additive and facilitatesmore rapid dissolution

5 The NRMCA’s CIP 30 – Supplementary Cementitious Materialsincludes pozzolans which by themselves do not have any cementitiousproperties and other materials such as ground blast furnace slag thatdo.

6 The magnesia must be reactive and be wary of imitations that are notFigure 12 – Australian R & D Expenditure by Industry Size (Bubble diameter)Employment and Gross Value Added. (3)

Cements




7 Much more detailed information is available in the TecEco web site inthe downloads area.

8 Dung + MgO in ancient Indian stupas.

9 Thereby solving an environmental pollution problem.

10 See under the heading Alternative Manufacturing Processes.

11 The name Sialite is attributable to Dr Henghu Sun and others of the

Pacific Resources Research Center in California, in collaboration withTsinghua University in Beijing; see (24) for a description.

12 Depending on the composition

13 Pers comm. WA (Tony) Thomas – Chief Engineer Concrete, BoralConstruction Materials

14 http://www.tececo.com/files/newsletters/Newsletter64.htm

15 See www.gaiaengineering.com home page and some of the latestmovie downloads at http://www.gaiaengineering.com/movies.php

16 Calcination of limestone.

17 Reaction of quicklime (CaO) with clays, shales etc to produce clinker.)

18 More processes result in more process energy.

19 Dr Sheila Devasahayam at the SMaRT Centre, School of MaterialsScience and Engineering, The University Of New South Wales, isresearching pyroprocessing CaCO

3

with an additive to produceSyngas

20 In the technical areas of www.tececo.com and www.gaiaengineering.com under the heading “Ground Limestone in Portland Cement - AGood Idea or Lost Opportunity”.

21 Preferably none at all

22 Properties will change and CSH is thought to become more brittle (5).

23 Water is in equilibrium with hydroxide and hydronium ion ions. Whenacidic or basic compounds are dissolved the equilibrium is pushedtowards more hydronium or hydroxide ions respectively. e.g.: H2O<=> H3O+ + OH The hydronium ion is highly solvated and H5O2+, H7O3 + and H9O4 + are increasingly accurate descriptions of theenvironment of a proton in water. Chemists represent a hydronium ionas just a hydrogen ion (H+, as in the figure) in place of H3O+

24 See the web page Reactive Magnesia - A Theoretical Explanation of

Properties in the technical area at www.tececo.com25 See Presentation 50 at http://www.tececo.com/document.conference_

presentations.php

26 It is not well known that electrostatics plays a significant role in thesetting of concrete (11)

27 See www.tecsoft.com.au

28 See also http://www.tececo.com/sustainability.permissions_rewards.php

29 See Introduction

References

1 CHALMERS, DES, MARSTON, ERIK. Principles and practices in theuse of limestone mineral addition in general purpose cements. 2012,38(1):

2 Compton M, Chandler J. Elevated limestone mineral addition impactson laboratory and field concrete performance. Concrete in Australia.2012, 38(1):27 - 33.

3 Department of Industry, Innovation, Science, Research and TertiaryEducation (Australia). Australian Innovation System Report 2012 [Internet].Department of Industry, Innovation, Science, Research and TertiaryEducation (Australia); 2012. Available from: http://www.innovation.gov.au/Innovation/Policy/AustralianInnovationSystemReport/AISReport2012.pdf

4 Department of Innovation, Industry, Science and Research (Australia). Australian Innovation System Report 2011 [Internet]. Departmentof Innovation, Industry, Science and Research (Australia); 2011. Avai lablefrom:ht tp:/ /www.innovation.gov.au/Innovation/Policy/ Australian Innovation System Report/ AISR2011 /wp-content/ uploads/2011/07/Australian-Innovation-System-Report-2011.pdf

5 Glasser FP. Pers. comm. 2002,

6 Harrison AJW. The Implementation and Advantages of Carbon Tradingin the Concrete Industry. In: Concrete Solutions. Luna Park, Sydney:Concrete Institute of Australia; 17-19 Sept 09.

7 Hawken P. The Ecology of Commerce. New York: Harper Collins;1993.

8 Hooten, R. D, Nokken, M, Thomas, M.D.A. Portland-Limestone Cement:Stte-of-the- Art report and Gap analysis for CSA A 3000. University ofToronto for the Cement Association of Canada; 2007.

9 Hover, Kenneth C. Concrete Design and Construction from the InsideOut. In: Concrete in the Third Millenium. Brisbane, Australia: ConcreteInstitute of Australia; 2003.

10 Indian Bureau of Mines. Indian Minerals Yearbook 2011 [Internet]. 2011,[cité 2013 janv 15] Available from: http://ibm.gov.in/IMYB%202011_Slagl.pdf

11 Labbez C, Nonat A. The Cement Cohesion: an Affair of Electrostatics.In: Iutam Sympiosium on Swelling and Shrinkage of Porous Materials.Petropolis, Brazil: 2007.

12 De Larrard F, Sedran T. Mixture-proportioning of high-performance

concrete. Cement and Concrete Research. 2002, 32(11):1699.13 DE LARRARD F. Concrete Mixture Proportioning: A Scientific Approach.

E & FN Spon; 1999.

14 MCGRATH TM. Sustainable cement and concrete. Concrete in Australia. 2012, 38(1):15-15.

15 MEHTA PK. Global Concrete Industry Sustainability. ConcreteInternational. 2009, Vol 31(2):4.

16 MEP. Technical Requirements for Environmental Labeling Products:Low-carbon Cement (Discussion Paper) [Internet]. Ministry ofEnvironment Protection, China; 2012. Available from:http://www.mep.gov.cn/gkml/hbb/bgth/201112/W020111208396803781008.pdf (inChinese)

17 PETERS GP, MARLAND G, LE QUERE C, BODEN T, CANADELL JG,RAUPACH MR. Rapid growth in CO2 emissions after the 2008-2009

global financial crisis. Nature Clim. Change. 2012, 2(1):2-4.

18 PHAIR JW. Green chemistry for sustainable cement production anduse. Tutorial Review. 2006,

19 QUILLIN K. Low-CO2 Cements based on Calcium Sulfoaluminate[Internet]. Available from: http://www.soci.org/News/~/media/Files/ Conference%20Downloads/Low%20Carbon%20Cements%20Nov%2010/Sulphoaluminate_Cements_Keith_Quillin_R.ashx

20 SINGH, YASHPAL. Fly Ash Utilisation in India [Internet]. [cité2012 janv 15] Available from: http://www.wealthywaste.com/fly-ash-utilization-in-india

21 SMALL RJ, PETERSON ML, ROBLES A, KEMPA DK. Using a bufferedrinse solution to minimize metal contamination after wafer cleaning[Internet]. MicroMagazine.com. 2005, Available from:http://www.micromagazine.com/archive/98/01/small.html

22 SPENSE, ROGER FP. Chemistry of Cement Solidified Waste Forms. In:Chemistry and Microstructure of Solidified Waste Forms Symposium.Oak Ridge: D. Lewis Publishers; 1992. p. 1 - 39.

23 STERN N. The Stern Review on the economics of climate change[Internet]. 2007, Available from: http://www.hmtreasury.gov.uk/ independent_reviews/stern_review_economics_climate_change/ stern_review_report.cfm

24 SUN, HENGHU, JAIN, R, NGUYEN, K, ZUCKERMAN, J. Sialitetechnology: Sustainable alternative to Portland cement. CleanTechnologies and Environmental Policy. 2010, 12503 - 516.

25 USGS. Mineral Commodity Summary - Cement [Internet]. 2012, (2012): Available from: http://minerals.usgs.gov/minerals/pubs/commodity/ cement/mcs-2012-cemen.pdf

Cements





t won't be wrong to say that this is the

a g e o f e n v ir o n me n t- f r i en d l y b u i l di n gm a te ri a ls a n d s t ra t eg i es . A u to c la v edIae rate d concre te (AAC) blocks can be

counte d among the most popular e co-

frie ndly building mate rials that are av ai-l a b l e. W h i l e t h er e a r e s e ve r a l b r an d s

a va i la b le , C el l O C o n a u to c la v ed a er -ate d concre te blocks from Me thra In-dustrie s India has carv e d its own dis-

tinct identity.The se concre te blocks are cure d in

a n a u t o cl a v e, w h i c h i s a la r g e p r e ss u r e

v e ss e l m ea s u ri n g 4 5 m et e r l e n gt h a n d3 m et e r i n d i am e te r. S t ea m i s f e d in t o

t h e a u to c l a ve a t h i g h p r e ss u r e i .e . 8 0 0kPa, and a te mpe rature of 180 degre e sCe lcius. The AAC blocks are produce d

u s i n g Po r t l an d c e m en t , l i m e a n d p u l -v er i ze d f u el a sh o r P or t la n d c e m en t , l i mea n d f i n e s a n d. A sm a l l q u a n ti t y o f g y p -

sum is also adde d. Autoclav ed ae rate d concre te is quite

d i f f er e n t f r o m d e n se c o nc r e t e, b o t h i nt h e p ro d u c ti o n a n d i n t h e c om p o si t i o no f t he f in al p ro du ct . I n t he c as e o f d en se

c o n c re t e i t g a i n s s t r en g t h a f t er a b o u tt w o d ay s a n d mo s t o f i t s s t re n g th a f t era mo nt h. O n t he c on tr ar y, a s s oo n a s

the AAC blocks are removed from thea u t oc l a v e a n d c o o le d , t h e y a r e r e a dy

f o r u s e .

M a n u f a ct u r i n g P r o c e ss

As part of the manufacturing pro-c e s s, c e m en t , l i m e , a n d P FA a r e mi x e dto form a slurry. Fine aluminum powde r

i s a dd ed t o p ro du ce a c el l ul ar s tr uc tu re .T h e de n s it y o f t h e fi n a l pr o d u ct v a ri e s

d e pe nd i ng u p on t h e q u an t it y o f a l um i -n u m p o w de r a d d ed t o t h e s l u r r y. S l u r ryis poure d into moulds, and the re after,

two proce sse s occur simultane ously.The ce me nt hydrates to normally pro-duce e ttringite and calcium silicate

hydrate s and the mix gradually stiffe ns

to form the gre e n cake .T h e g r e en c a k e r i s es i n t h e m o u l d

d u e t o t h e e v ol u ti o n o f h y dr o ge n g a sf o r me d f ro m t he r e ac t i o n b e t we e n t h e

fine aluminum particle s and the alka-line liquid. The se gas bubble s giv e themate rial its ce llular structure .

W h e n t h e c a k e h a s ri s e n t o t he r e-quire d he ight, the mould mov e s along

the track whe re the cake is cut to ther e q ui r e d b lo c k s i ze . D e p en d i n g on t h ea c tu a l p r od u ct i on p r oc e ss , t h e c a ke

may be demolde d entire ly onto a trolle y

b ef or e c ut ti ng , o r i t m ay b e c ut in t hemould after the side s are remov e d. The

c a k e i s c u t b y p a s si n g t h r ou g h a s e r i eso f c u t t i ng w i r es .

At the cutting stage , the cake s are

E co -f ri en dl y A AC B lo ck i s H er e t o S ta y


M e t hr a I n d u st r i e s I n d i a P v t . L t d .6 2 Panc hali Am man Koil Street,

Arum bakkam , Chennai - 6 0 0 1 0 6

Ph: + 91-44-23638652,

E- m ail: adm [email protected]

Web: w w w.m ethras.inC ell O Con AAC B loc k

g r e en . I f t h e y a r e t oo s o f t t he c u t b l oc k s

m a y f a ll ap a rt or s t ic k t o ge t he r. I f t h eyare too hard, the wire s will not cut the m.

The cake s are loade d into the auto-clav e and ke pt inside for 8 to 10 hours.

Whe n re mov e d from the autoclav e andcoole d the blocks will achie v e their full

strength and packed re ady for transport.C e l l O C o n A A C b l o c ks ar e m a n u -

facture d using late st te chnology. The

t e s ts c o n d uc t e d o n t h e C el l O C o n A A Cb l o c ks b y t h e S t ru c t u ra l E n g i ne e ri n gR es ea rc h C en tr e, C S IR C he nn ai an d

M /S H it ec h L ab , c on fo rm t o I S 2 18 5,w h i c h v o u ch e s f o r t h e i r q u a l it y.

Key Benefits

C e l l O C o n A A C b l o c ks ex h i b i t e x-c e ll e nt i n su l at i on p r op e rt i es . A p ar t f r om

s u p er i o r t h e r ma l i n s u l a ti o n , t h e se A A Cblocks also offer e xcelle nt acoustic insu-

lation. Sound transmission class ratingsup to 60 are possible with AAC blocks.

The AAC blocks are also highly

r es is ta nt t o w at er, s un , w in d, f ir e, t er -mite s and pe sts. AAC blocks are made

up of natural inorganic mate rial that doesnot burn. This e nsures that the re is non e ed f or a n y a d di t io n al f i re p ro o fi n g

mate rial.Ease of construction is another major

adv antage with AAC blocks. Apart from

b ei n g ea s y t o tr a ns p or t , t h ey a r e a l soe as y t o h a nd l e, g r oo ve , d r il l an d na i l.U t il i t ie s c an b e e as i ly r ou t ed t h r ou g h

the AAC blocks.I n a n ut sh el l, C el l O C on A AC b lo ck s

a r e e c o- f ri e nd l y, l i gh t we i gh t , h e lp r e -d u c e d e ad l o a d , e n a bl e m o r e c ar p e t

a r e a, r e q u ir e m i n i m al e x t e r na l a n d i n -t e r na l p l a s t e ri n g a n d e n e r g y e f f ic i e n t,m a k i ng i t a f a v o r i t e wi t h c o n t ra c t or s ,builde rs and de v e lope rs.



A u t o c

l a v e d

A e r a t e d

C o n c r e t e

B l o c k s





h e I n di a n c o ns t ru c ti o n i n du s tr yhas be e n growing at a rapid rate

o v er t h e pa s t tw o de c ad e s. I t i sTn o t s ur p r i si n g t h en t h a t a h os t o f i n n o-

v ativ e products and solutions hav eb e e n h i t t i ng t h e m a r k e t r e gu l a r ly c a t er -i n g t o t h e n ee d s of t h e i nd u s t ry. H o w -

e v e r, while the re could be se v e ral ne wp r od u ct s en t er i ng ; o n ly a s el e ct f ewh a ve b e en s u cc e ss f ul i n m a ki n g a m a rk .

Two such re markable products are 'i.light'a n d ' T X A c ti v e' f r om Z ua r i C e me n ts ,

w h i c h i s p ar t o f t h e gl o b a ll y w e l l- k n o wnItalcementi Group. ZuariCement'ssteady

g r o wt h h a s s e en t h e c o m pa n y e m e rg e

a s a l e a d er w i t h a c ap a c i t y o f 6 . 2 m i l l i ont o ns . T h e co mp a ny h a s th r ee p l an t s,which include two manufacturing units

a t S i t a p ur a m a n d Ye r r ag u n t la , a n d ag r i n di n g c e n t er a t Ch e n na i . T h e c o m -pany's manufacturing units are ISO:

9 0 0 1 a n d I S O : 1 4 0 00 c e r t i f i ed , r e s pe c -t i ve ly. Z ua ri Ce me nt ha s b ee n a d-

j u dg e d as a “ P ow er B r an d ” a f te r a r i g -orous surv ey conducte dby ICMR amongconsume rs across India base d on

re ach, av ailability, de mand and growth.E a rl i er i n 2 0 11 , Z u ar i c em e nt h a s al s o

b e en a w ar d ed w i th “ M as t er B r an d ” b ythe CMO council Asia.

'TXActive'andthePhotocatalyticActivePrinciple

Zuari's innovativeproducts,'TX Active'a n d ' i .l i g h t ' , a d d t o t he s u s ta i n a bi l i t y

q u ot i en t o f a b u i l d in g . ' T X A c ti v e' w o rk so n t h e p ho t oc a ta l yt i c a c ti v e p ri n ci p lea n d i s a t r u l y i n n o va t i v e a n d u ni q u e

p r od u ct . ' T X A c ti v e' i s p h ot o c a ta l yt i cc e me n t t h at a b at e s s om e c o nt a mi n an t s

i n t h e a i r, t h er e by o f fe r in g t he p er f ec tsolution to pollution.

W h a t e x ac t l y i s p h o t oc a t a ly s i s, o n e

is bound to ask. Photocatalysis is a nat-u r a l p h en o m en o n i n w h i c h a s u b st a n c eknown as a photocatalyst use s light to

e x p ed i t e t h e r a t e o f n a t u ra l o x i d a ti o np r o c es s . U s i n g l i g h t en e r g y, p h o t oc a -

t al ys ts c an i nd uc e th e fo rm at io n o fs t ro n g o x id i zi n g re a ge n ts , w h ic h d e -compose some organic and inorganic

substance s in the atmosphere throughoxidation. Photocatalysis promote sf a s te r d e c om p o si t i o n o f p o l l ut a n t s a n d

pre v e nts the m from accumulating.I t i s p r o ve n t h a t c o nc r e te a n d c e -

me nt-base d products produce d with' T X A c t i ve ' w i l l r ed u c e p ol l u t a nt s a s so -c i a t ed w i t h m o t or v e h i cl e e x h a u st , h e a t-

i n g e x h a u st , f u e l c o m bu s t i on a n d o t h e rcomme rcial and industrial proce sse s.T h e se i n c l u d e , N i t r og e n O x i d es ( N O x ) ,

S u lf u r O x id e s ( S Ox ) , v o la t il e or g an i ccompounds (VOC's) and Particulate

M a t t er ( P M ), a m o ng o t h er s . M o r eo v er,

t h e ' T X A c ti v e' i n gr ed i en t c a n n ev e r b euse d up. This is be cause the principle

ingre die nt is a catalyst that acce le rate sthe natural oxidation proce ss and is not

c o ns u me d i n t h e p r oc e ss . T h er e fo r e,as long as the concre te re mains intact,U V l i gh t c a n t r ig g er t h e p r oc e ss , a n d

the principle re mains inde finite ly.T h e ' T X A c t i ve ' r a n ge c on s i st s of T X

Arca ce me nt de v e lope d in 1996. White

concre te made using TX Arca ce mentoffe rs extraordinary brilliance and se lf-

c le an in g p ro pe rt i es , w hi ch e ns ur es

Pioneering Innovative andSustainable Products

M ilan Lorenteg g io Eco-Tech nolog ical Com plex



C o mm u n i c at i o n F e at u r e

169www.masterbuilder.co.in · T h e M a s t e rb u i l d er - July 2013

t h a t t h e o r i g i na l b e a u t y o f b u i l di n g s l a s tf o r y e ar s . T h e T X A r ia e n vi r on m en t al l i ne

provides a comprehensive range ofc e m en t p r o d uc t s a n d b i n d er s f o r f o r -

m u la t io n i n to a l l v a ri e ti e s of m or t ar s ,

stuccos, cementitious veneers and manyothe r concre te e nd use s.

ProvenTechnology

' TX A ct iv e' p ho to ca ta ly ti c c em en ts

h av e b ee n u se d e xt en si ve ly i n t he E ur o-p ea n m ar ke t f or o ve r a de ca de . T he ire ff e ct i ve n es s h a s be en t h or o ug h ly

te ste d and thus ce rtifie d by importanti n d e pe n d en t r e s e ar c h c e n t er s ( C N R ,

ARPA, Ispra Re se arch Ce nte r). Its for-

m u l a ti o n i s th e re s u lt o f 1 0 y e a rs of r e -se arch, te sts and applications carrie d

o u t b y C T G, G r ou p Te c hn i ca l C e n tr e , ac o mp a ny i n t h e I t a l ce m en t i G r ou p w h ic hh a s l e d t o th e fi n a l f o r mu l a t i on o f t h e

p h o to c a t al y t i c a c t i ve p r i n ci p l e . T h e f i r s tp r o je c t o f r e c og n i t io n w a s t h e D iv e s o fM i se r ic o rd i a C h ur c h i n R o me , d e si g ne d

b y R i ch a rd M e ie r, a w o rl d -r e no wn e da rc hi te ct . I n a dd it io n, m an y o th er p ro -

je cts with diffe re nt applications such asp re ca st b ui ld in gs , r oa dw ay s, p av erb lo ck s, t un ne ls , e tc ., h av e b e en c om -

ple te d.The perfe ct te stimonial for the e ffi-

c a cy o f t h e s el f- c l ea n in g ' T X A c ti v e' c e -me nt can be found at Vodafone Villagei n M i l a n. C o ve r i n g 6 7 , 00 0 sq u a r e m e -

te rs, the v illage prov ide s accommoda-tion to ov e r 3,000 e mploye e s of

For further details:

Zuari CementPh: + 91-080-41194408,

E- m ail: zc lm kt@zc ltd.c om

Web: w w w.zuaric em ents.c om

V od a f on e . T h e ar c h i t ec t s c ho s e 'T X Activ e ' for it guarante e d a constantly

c l e a n f a c a de , t h a n ks t o t h e co m b i ne daction of the activ e ingre die nts and sun-

light.

Hote l de Police in Borde aux, Francei s a no t he r g o od e x am p le f o r t h e ef f i-

c ac y o f t he p ho to ca ta ly ti c p ri nc ip le . At ot al o f 7 50 p an el s, c ov er a n a re a of5 , 4 00 s q u a re m e t e rs o f a r c h it e c t ur a l

p r ec a st c o n c re t e. ' T X A c ti v e' w a s c ho -s e n t o pr e se r v e t h e a e s th e t i c q u a l it y o f

t h e b u i l d in g . S i m i la r l y, ' T X A c t i ve ' r o u ghsurface finishing was se lecte d for the

Air France He adquarte rs, Roissy-Charle s

d e G a ul l e b u il d i ng , w h ic h i s l o ca t eda m i d h i gh c o n c en t r a ti o n s o f h y d ro c a r -bons from aircraft e xhausts. In the case

o f C i m e nt s d u M a r oc ' s h e a d qu a r t er s i nC a sa b la n ca , M or o cc o , t h e b u il d in g 's

c i r c u la r s t r uc t u r e wa s m ad e w i th t r a d i-t i o n al c o n c r et e c o ve r e d wi t h a w h i t em i n er a l c o a t i n g o f ' T X A c t i ve ' .

T h e A c ad e my o f S a nt ' Eu f em i a, t h el a rg e st Yo g a c en t er i n E u ro p e, b oa s ts

o f a n e xt e rn a l p h ot o ca t al y ti c p a ve m en t ,a b ou t 3, 0 00 s q. m , m a de u p o f p h ot o -c a t a ly t i c i n t e rl o c k in g pa v i ng st o n es .

S e l f- c l e an i n g , p o l l ut i o n b u s t in g c o u r t-y a r ds h a v e b ee n d e s i gn e d u s i ng ' T X

Activ e ' in an affordable gre e n housing

p ro je ct i n t he C it y o f H ig hl an d Pa rk , amunicipality on the outskirtsof Chicago.

Anothe r inte re sting proje ct is theg a t ew a y e l e me n t s c a s t w i t h ' T X A c t i ve 'p h o t oc a t a ly t i c c e m en t on t h e n e w I n t e-

r s ta t e 3 5 W es t B r id g e s p an n in g t h e M i s-

s i s i pp i R iv e r i n d o w nt o w n M i n ne a p ol i s ,USA.

'i.light'- TheRevolutionaryPrecast Con-cretePanel

A pre cast concre te pane l that cantransmit light is a conce pt that was,

u n t i l no w, d e e me d p os s i bl e o nl y i n s c i -e n c e fi c t i o n m o vi e s o r l i t e ra t u r e. To d a yi t i s r ea l it y t h an k s, t o ' i .l i gh t ', a p r ec a st

concre te pane l that can transmit light.Obtaine d by bonding special re sins ina n i nn ov at i ve m o rt ar, ' i .l i gh t' n ot o n l y

le ts natural and artificial light in but alsoallows se e ing obje cts place d be hind

the pane l and cre ating a surprisinglytranspare nt e ffe ct.

T he s to ry o f h ow ' i. li gh t' c am e i nt o

b e i n g m ak e s f o r i n t e re s t in g r e a d in g .

' I. li gh t' w as ac tu al ly c re at ed at th ere que st of the archite ct re sponsible of

d e si g ni n g th e It a li a n P av i li o n f o r E x poShanghai 2010, who wanted a ce me n-

titious mate rial capable of transmittinglight.3,774 transpare nt pane ls of 'i.light'w e r e pr o d uc e d a n d u se d t o c o ve r a

t o ta l s ur f ac e o f 1 , 88 7 sq . m . , a m ou n t-ing to about 40% of the pav ilion's e ntires h e ll . T h e e f fe c t w a s t o cr e a te a s e -

q u e n ce o f l i g h t a n d s h ad e c o n s ta n t l yc h a n gi n g t h r o ug h o u t t h e d a y. T h e

I t al i an p a vi l io n w a s a hu g e s u cc e ss

a t t r ac t i n g o v er 6 m i l l i on v i s it o r s. I n f a c t ,the Chine se Gov e rnme nt was so

impre sse d that it de cide d to make it ap e r ma n e nt p a v i l i o n w h i c h w o u ld n o t b edismantle d after the e xpo.

Dives M isericordia

Dives M isericordia





he Indian construction industry hass ee n a s t ea d y i n c r ea s e i n d e ma n d

for ready-mix-concrete (RMC) overTt h e l a s t t w o d e c ad e s . S t r i ct e r p r o je c tspecifications, rising e mphasis on adhe -

ring to quality standards and tighte r pro-je ct de adline s hav e all be e n be hind thei n c r ea s e d p e n et r a t io n o f R M C i n I n d i a.

A name that has playe d a pione e ringr o le in t h is gr o wt h s t or y i s t h at of R M C

Re adymix (India), one of the large st RMCmanufacture rs in the country. RMC Re -adymix (India) is part of Prism Ce me nt

Limite d, India's large st integrate d buil-d i ng ma t er i al s c o mp a ny w i th a wi d e

r a n g e o f p r o d uc t s f ro m c e m en t , R M C ,t i l es & b a tc h a n d k i tc h en a c ce ss or i es .T h e c o m p an y h a s th r e e d i v i si o n s, v i z .

P r is m C em e nt , H & R J oh n so n ( I nd i a) ,a n d RM C Re a dy m ix ( I nd i a) . P r is mCe me nt Limite d also has a 74% stake

i n R a he j a Q B E G e ne r al I n su r an c e C om -

p an y L im it ed , a J V wi th Q BE G ro up o f Australia.Established in 1996, RMC Re adymix

(India) currently ope rate s88 RMC plants

i n t h r ee c i t i es a n d t o wn s a c r os s t h ec ou ntry. The company has also ven -ture d into the aggre gate busine ss and

ope rate s large quarrie s and crushe rs.RMC Re adymix (India) has be e n at the

f o r ef r o n t i n s e t ti n g h i g h s t a nd a r d s f o rp l a n t a n d m a c h i ne r y, p r o du c t i on , q u a l -i t y s y s te m s a n d p r od u c t s e rv i c e s i n t h e

ready-mixed concrete industry.

Quality Assurance

Incre asing de mand has me ant thatRMC Re adymix (India) has be e n striv -ing hard to e xpand its production capa-

c i t y. I t h a s r e ce n t l y a d d ed t w o k e y l o c a -t i o n s t o it s e x i st i n g n e tw o rk , B h o pa l , i n

t h e h e a r t o f I n di a a n d G u w a ha t i, t h e e c o -n o m i c a n d in d u s tr i a l h u b of N o r t he a s tIndia.

One of the corne rstone s of the com-p an y' s s uc ce ss st or y h as be en i tsunflinching commitme nt to quality. As

p a rt o f i t s i n i ti a ti v es , R M C R e ad y mi x( I n d ia ) h as a d de d a no t h er f e a th e r i n i t s

c ap . O ne o f i ts l ab s – a tt ac he d t o W hi te -fie ld Plant in Be ngaluru - was subje cte dt o N A B L C e r ti f i c at i o n . T h e l a b h a s a c h i -

e ve d t he di st in ct io n o f g et ti ng th ea cc re di ta ti on u nd er I SO /I EC : 1 70 25 :2 0 0 5, i n t h e f i e l d o f ' M e c ha n i c al Te s t i ng

of Aggre gate and Concre te'.

Latest Generation ConcreteT h e d em a n d f or s p e ci a l i ze d c o n-

c r e t e f o r s p e ci f i c a p p l ic a t i on s i s ri s i n gb y t h e d a y. C a t er i n g t o t h i s d e m an d ,

RMC Re adymix (India) offe rs a widev a ri e ty o f c o nc r et e to i t s c u st o me rs .

The se include :

TM- Megacrete - hi gh strength con-

cre te for large structure s.TM

- Easycrete – flow able concrete

r eq u ir i ng l e ss l a bo u r & e ff o rt f o rplace me nt.

TM- F RC cr et e – c on cr et e i nc or po ra t-

ing polypropylene & ste e l fibre s forground slabs, e liminating the ne e dfor re inforcing ste e l.

TM- Fo am cr et e – li gh t w ei gh t c on cr et e

f or t he rm al i ns ul at i on , a co us ti cs ,f i l l e rs , e t c .

TM- Col ou rc ret e – C on cret e i n a wi de

a rr ay o f c ol ou rs f o r a es th et ic p ur -

pose TM- Highdensec rete – High density

c o n c re t e f o r s p e ci a l a p p l ic a t i on ss u ch a s r a di a ti o n s h ie l di n g i n h o s-p i ta l s, r ea c to r s, e t c. a n d t o a d d d e ad

we ight to structure s.TM

- T he rm oc re te – C on cr et e a t l ow er

t e m p er a t u re s f o r m a s s c o n c re t epours.

- P er v io u s C on c re t e – c o nc r et e d e -

s i g n ed t o c a p t ur e wa t e r r u n o f f s &f o r r a i n w a t er h a r v es t i n g.

W i t h i t s q u a l it y - fo c u se d a p p ro a c ha n d ex p e rt i s e i n t h e fi e l d o f d e l i ve r i nglate st ge ne ration concre te , we are sure

to he ar more about RMC Re adymix (In-dia) in the future.

L ea di ng t h e R MC R ev ol ut io n

F o r f u r th e r d e ta i ls :

R M C R e a d ym i x ( I nd i a )Mobile : 0 9 7 6 9 80 1 9 0 3

Toll- free: 1 8 0 0 - 2 2- 3 4 5 4E- m ail: c ustom erc are@rm c india.c om

[email protected]




An Insight into Liquid Floor Densifiers

In many cases, the best floor-covering is nothing. Leaving

the concrete slab exposed and finishing it as the floor can

be economical, aesthetically successful, and sustainable.

It is so durable that it may well be the ‘ultimate’ floor – the last

floor that will ever need to be installed in the space. The key to

optimizing the performance of concrete as a floor is densifiying.

Densifiers make concrete floor more durable, and abuse-

resistant. Densification eliminates wear - induced powdering

of the surface known as dusting. It makes the surface less

permeable to liquids, improving stain-resistance and making

cleaning easier and more eco-friendly.

A dilemma sometimes faced by concrete floor contractors

and owners is what to do about a recently installed or existing

industrial floor that has a weakened surface. After concrete has

been Installed, how can contractors most effectively correct

the dusting, poor abrasion resistance, and high porosity that

characterize such a surface? (Weakened floor surfaces are

typically caused by adding excess water to the concrete, poor

finishing techniques, and a poor-quality cure.) Obviously,

removing and replacing the concrete is not a favorable option,

because it is disruptive, labor-intensive, and costly. A simpler,

less expensive option is to use a liquid chemical treatment to

harden and densify the concrete surface. Refer Figure 1 for a

hardened concrete floor.

Need for DensifierNew or existing concrete can be improved by densification.

It transforms concrete into a more practical flooring solution,

and is applicable to a wide variety of projects. Owners of retail,

commercial, and institutional environments are opting to

expose the concrete floor instead of covering it. Densification

expands appearance finishing options, enabling the success

of finishing techniques such as burnishing and polishing. A

densified, diamond polished concrete slab can achieve a

high gloss that can rival the look of natural polished stone at

a fraction of the cost. A slab burnished to a sheen after den-

sifiying can achieve almost as attractive a result, but faster

Ankita Adhikary





and even more affordably. Combined with techniques like

dyeing, staining, or grinding to expose aggregate, a broad

palette of visual options are available for taking concrete

beyond a featureless gray surface. The cost of densification

and polishing is competitive with the least expensive floor

coverings available. Even with the added expense of coloring,it is still more affordable than the lowest end carpet or stone

floors. Densifiers are also used where appearance is not a

concern because of the improved performance of the slab. As

it is easy to keep clean and safe, the densified floor is suitable

for warehouses, factories, and maintenance facilities such as

automobile service bays. Chemical densifiers (also called

hardeners or densifier / hardeners) are a small investment that

leads to long-term savings and improved performance for

decades.

About Liquid Densifier

Liquid floor hardener formulations vary from manufacturer tomanufacturer, but they usually contain inorganic compounds

that undergo a series of complex chemical reactions with the

available lime in mature concrete. Some liquid hardeners also

contain special proprietary ingredients to make treated floors

more resistant to chemical attack and wear and to improve

the aesthetics of the finished surface. Unlike solvent-based,

membrane forming sealers, which usually contain resins and

hazardous solvents, most liquid floor hardeners contain

inorganic compounds that are water soluble and comply with

today’s environmental, health, and safety regulations. Wetting

agents (surfactants) are usually added to a liquid hardener to

help the product penetrate the pores of the concrete substrate.The efficiency of the floor hardening treatment increases with

the depth of penetration, which usually ranges from 1/8 to 1/4

inch.

Though manufacturers of liquid floor hardeners sometimes

use the word “sealer” to describe their products, a liquid

hardener is actually a treatment, not a surface coating like

most membrane - forming organic sealers. A drawback to

applying a membrane to concrete is that the membrane tends

to wear away in high-traffic areas. Not only is the worn coatingunattractive, the unprotected concrete is susceptible to

chemical attack by acids and caustics. Liquid floor hardeners

not only protect concrete surfaces, they protect the concrete

down to the depth of penetration. Also, the hardeners don’t form

a coating or membrane on the concrete surface, so they don’t

scratch; peel, show tire marks, or require recoating.

Working Principle of Liquid Densifier

As soon as a liquid floor hardener is applied to a concrete

substrate, a chemical reaction takes place between the

inorganic compounds and lime (whether hydrated or unhydrated)

in the pores of the concrete matrix. The primary product ofthis reaction is a mixture of dicalcium and tricalcium silicate

compounds, which hydrate (react with water) even further to

produce a chemical compound called calcium silicate hydrate, or

tobermorite gel. The ultimate strength and binding properties

of hydrated Portland cement are primarily due to the presence

of tobermorite gel in the concrete matrix. Therefore, liquid

hardeners increase concrete strength by increasing the

concentration of tobermorite gel. Liquid floor hardeners can

also increase concrete’s density.

When the tobermorite gel forms in the concrete pores, its

crystalline growth effectively blocks voids in the concrete,decreasing the pathways for moisture movement. Since

chemicals attack concrete by penetrating the matrix, the

presence of an insoluble gel in the substrate’s pores and on its

surface greatly increases the concrete’s chemical resistance.

In addition to the benefits of strength gain and chemical

resistance, a liquid hardener can enhance the beauty of a

troweled floor by giving it a polished look. This high sheen

results when the treated floor is polished by mechanical

means. Floors treated with liquid hardeners will not dust when

abraded or polished.

The drawing below shows a cutaway view of a rough, porous

floor prior to floor- hardener treatment. When light strikes the

Figure 1: A typical hardened concrete floorFigure 2: Working Principle of concrete hardened floor versus untreated

concrete floor





irregular surface, the light is reflected in all directions. This

scattering of light makes the concrete surface appear dull.

After a floor has been treated with a liquid hardener, the pores

are filled with tobermorite gel and the concrete surface can

be polished smooth. When light strikes this smooth surface,

it is reflected uniformly, so the floor shines. Refer Figure 2 forhow concrete hardened floor works as compared to normal

concrete floor.

Application Tips of Liquid Densifier

Ideally, concrete floors should be treated with liquid floor

hardeners at least seven to 14 days after placement, or after the

cement has had sufficient time to hydrate. Cement hydration

increases the amount of available lime in the concrete, thus

increasing tobermorite gel formation. In addition, this waiting

time allows the pores of the concrete to dry, so the liquid

hardener can penetrate the concrete surface rather than

merely lying on it. It is much easier for a liquid hardener todisplace air than water in the concrete voids. True liquid floor

hardeners should not be applied to fresh concrete at the

time of initial cure, because the concrete is still saturated with

moisture. This saturated condition prevents the hardener from

penetrating the surface. Also, liquid hardeners should not be

applied as curing compounds, since they do not meet the

requirements of ASTM C 309, “Standard Specification for Liquid

Membrane- Forming Compounds for Curing Concrete.” Always

check the manufacturer’s recommendations for when to apply

its product.

The type of cure used on new floors prior to application ofchemical floor hardeners is very important. Liquid hardeners

must penetrate the concrete surface to undergo the chemical

reaction that imparts density and hardness, but they can’t

penetrate a membrane forming curing compound. If a curing

compound has been used, be sure to remove it before applying

a liquid hardener. ACI 302.1R- 89, “Guide for Concrete Floor

and Slab Construction,” recommends moist curing floors

that will later be treated with a liquid floor hardener or other

surface treatments. Surface preparation of the floor before

hardener application is also important. The surface must be

thoroughly cleaned to open the concrete pores and allow

for hardener penetration. Typical cleaning methods include

chemical cleaners and high-pressure water. Some chemical

floor hardeners contain magnesium fluosilicates, which are

low- grade toxic chemicals. When applying these products,

be sure to wear protective clothing such as rubber gloves,

boots, and goggles. Typically, fluosilicate hardeners are

supplied in concentrated form and must be diluted with water

before application.

Non fluosilicate floor hardeners, that are more commonly

used today are colorless, odorless, biodegradable, and VOC-compliant. Many manufacturers offer 10- year warranties with

these products. When using a non fluosilicate floor hardener,

apply a slight flood coat to the concrete surface, covering

about 200 square feet per gallon. Next, scrub the material into

the surface with a stiff-bristle broom or janitorial floor- scrubbing

machine for 15 to 30 minutes, until the product begins to

gel or become slippery. Wet the material lightly with a water

spray, and then rework it into the surface for another five to

10 minutes. After this process, rinse the floor and remove any

excess material with a mop or squeegee. This final step is

important, because residue is more difficult to remove if it is

allowed to dry.

Application Areas of Liquid Densifier

Typical applications for liquid hardeners include floors in

warehouses, industrial plants, shopping malls, stores, schools,

food-processing plants, and hospitals. Installation costs vary,

depending on the required surface preparation and size of

the project. The degree of surface hardness and density that

can be achieved with a liquid hardener depends on the quality

of the concrete surface. Liquid hardeners can improve the

abrasion resistance and reduce the dusting of a lower-quality

concrete floor. On higher-quality concrete surfaces (those with





a lower water-cement ratio and denser finish), the need for a

chemical floor hardener diminishes.

Many manufacturers claim that liquid floor hardeners improve

the chemical resistance of a concrete floor. This is true to a

degree, but one should carefully examine the chemical-

resistance requirements of the floor before proceeding with

hardener application. Though liquid floor hardeners improve

the chemical resistance of a concrete surface, they do not make

the surface 100% chemical resistant. Unfortunately, liquidhardeners are sometimes sold as chemical-resistant products

meant to replace truly chemical-resistant coatings, such as

two-component aliphatic urethanes. For floors exposed to high

levels of chemicals, consider using a chemical- resistant coating

instead of a liquid floor hardener.

Types of Liquid Densifier

Chemical Hardeners (Densifiers) include three basic categories

of chemicals: silicates, silicinates and silica:

A. Silicates - penetrate and harden. They are not good sealers.

Disposal of the waste material is currently an issue.

A.1 The oldest is Magnesium Fluorosilicates, which have been

around since 1905. This type of product requires multiple

applications with varying rates of dilution.

A.2 Sodium Silicates Developed initially in Germany in the

1930’s. Application of the product requires that it be applied

at an average of 200 square feet per gallon, spread and

worked until the surface tension is broken, mist with water,

allowed to gel a second time and then rinsed and wet

vacuumed to remove.

A.3 Potassium Silicates. The main difference between the

sodium silicates and potassium silicates is sodium is

more prevalent in the North American and potassium is

predominate in Europe.

A.4 Lithium Silicates. Lithium silicates were developed to

combat Alkali Silica Reaction (ASR). ASR is more prevalent

in exterior applications where there is a constant source of

water. Lithium silicates are less susceptible to solubilizationthan sodium or potassium. One of the byproducts of this

particular silicate is its ability to reduce sweating on slabs.

B. Silicinates - excellent sealer, poor hardening characteristics.

Real world typical life expectancy is 18 to 24 months, and

then it should be reapplied. Disposal of the waste material

is currently an issue.

- Silicinates are applied the same way silicates, spray, scrub,

mist, rinse, and vac.

- Silicinates can offer increased abrasion resistance over

silicates in the short term due to the coating effect of the

silicinates.- Silicinates are either potassium or sodium.

C. Silicas – are the newest and most promising of the chemical

hardeners:

- Silicas are applied simply by spraying them on the surface

of the slab and allowing them to dry. The surface should

be clean and void of any curing compound. Application

rates are between 400 to 600 square feet per gallon.

Some Photographs of Densified concrete floor (Reference: Densification for

High Performance Floors, By Steven H. Miller, Concrete Tech. Today – Densifying

Concrete)





- Silicas increase abrasion resistance over silicates or

silicinates by up to twice as much

- Silicas do not contribute to ASR

- Silicas do not raise the pH of the concrete since the product

is neutral 6.5.

- Silicas have the highest increase in abrasion resistance

- Silicas have reduced application and labor costs

- Silicas have no hazardous waste to remove or dispose

- Silicas do not contribute to silicosis and are not carcinogenic

unlike silicates which do contribute to silicosis and are

carcinogenic

- Silicas will not contribute to sweating or efflorescence

- Silicas performance is not contingent on dwell time unlike

silicates or silicinates

In a nut shell there are features and benefits to each of these

types of chemical hardeners. The upside for the silicates isthat they harden better than silicinates, Silicinates seal better

than silicates. Silicates have been directly linked to silicosis.

Silicates and silicinates have been tagged as carcinogens.

Silicates and silicinates must be disposed of as hazardous

material. There is significant research that documents the ill

effects of sodium, potassium silicates and silicinates on reactive

aggregate in concrete. Currently the best technology for

chemical densifiers is amorphous silica.

Advanced Densifiers

A new generation of densifiers based on colloidal silica is

replacing older densifiers based on chemical compounds

called silicates. Colloidal silica performs the same functions,

but makes the densification process itself faster, easier, more

affordable, and more sustainable. It is competitive in material

cost, and reduces time and labor expenses for densification

by as much as 75%. Colloidal silica has also been used to

rescue slabs that have not responded to silicate treatments.

The first generation of concrete densifiers was generally

made from silicate compounds such as sodium silicate and

potassium silicate; this range of silicate based compounds

was later broadened to include lithium silicate. All these silicate

compounds are highly caustic, with a pH of 11 to 12, similarto the alkalinity of lime itself. Sodium- or potassium-silicate

application is also time consuming and labor-intensive—the

chemical has to be worked with a broom for an hour to help

precipitate silica and scrub it into the slab surface. The process

leaves behind a caustic, gelatinous slurry that has to be

scrubbed off thoroughly and disposed of. (Sodium hydroxide,

also known as lye, is a by-product of sodium silicate densifiers

and is sometimes present in their residue.) Applicators often

try to neutralize the slurry with other chemicals before disposal,

costing additional time and money. Many silicate-based

densifiers require an overnight curing period before polishing

can begin. Inadequate removal of sodium- and potassium-

silicates often leads to concrete discoloration by salt deposits

– a problem known in the industry as “whiting.” The only way

to remove whiting is to regrind the slab, an expensive and

time consuming process. Whiting can also be a danger with

lithium silicates if the material is over-applied, tempting someapplicators to under-apply the product and ultimately fail to

adequately densify the floor. The high pH of silicate materials

also makes them dangerous and unpleasant for applicators

to handle, especially during the removal process.

With increasing restrictions on disposal of caustic substances

and construction waste, properly getting rid of the silicate slurry

has become an issue for applicators to deal with. The new water-

borne colloidal silica product, available from Lythic Solutions

(www.lythic.com) under the trade name LythicTM Densifier,

eliminates these problems. It is made from 5-nanometer

diameter amorphous silica particles, mechanically suspended

in water rather than chemically tied up in a compound. Colloidal

silica is more immediately available for reaction in concrete

than a silicate compound – the molecule has more chemically

reactive sites, and the greater pH difference between colloidal

silica and lime makes the reaction begin quickly, within minutes

after application. The particles consist of nearly pure silica, and

the colloid’s extremely low sodium content eliminates the

danger of whiting. There is no danger of over-application. The

simplified application process reduces risks and cost, and

only minimal training is required. There is no removal step (as

required with silicates) and consequently no caustic slurry to

dispose of – only a small amount of dry powder residue that can

be boomed off, or will be vacuumed up during polishing.

Conclusion

Concrete is one of the world’s oldest construction products,

but it is continually advancing to meet the needs of the times.

Improved densifiying technology is a classic example of this

process: taking advantage of the basic nature of the material,

densifiers make a concrete slab more durable, sustainable,

maintainable, and aesthetically versatile. Densification

makes the concrete slab an ideal flooring solution for the

economic and environmental requirements of our age. The

newest densifiying technology, colloidal silica, carries those

sustainability and cost advantages to the next level, and adds

new performance levels to the densification process.

Reference

1. Look at Liquid. Floor Hardeners. By John Gill and Cyler Hayes,

(www.concreteconstruction.net/.../A%20Look%20at%20Liquid%

20Floor... )

2. Comparison of Concrete Chemical Hardeners (Densifiers). By

Roger Allbrandt, B.A. Environmental Biology, (www.absolute

polishing.com / A -brief -overview -of -Concrete -and -Chem...)

3. Densification for High Performance Floors, By Steven H. Miller,

Concrete Tech. Today – Densifying Concrete




S t r u ct u r a l H e a l t h M o n i t or i n g

180 ·T h e M a s t er b u i l de r - July 2013 w w w .masterbuild er.co.in

i th a n a dv en t of a ll n ew s tr uc -t u r e s c o mi n g u p a t i m e w h e nI n d i a is c o m p e ti n g i n t o d a y' sW

competitive global market, one cannottend to ignore that fact that I ndia carriest h e b ur d e n o f n u m e ro u s o l d s t r u c tu r e so w n e d n ot o n l y b y t h e s t a t e bu t a l s o t h epeople. These old structures have knowno r u n k n ow n d e f i ci e n c i e s a n d c a nn o t b e

i d e n t if i e d u n le s s a d i s as t e r i s e x p e r i-e n c e d . H o w e v er, i t w o u l d b e t o o l a te b yt he n a s t he d am ag e w o ul d h av e a lr ea dyh a pp e ne d i n t e rm s o f h u ma n l o s s. T h i sl e a d s t o th e p r e s en t s t a te o f t h e p o o raffairs and needs a careful consider-ation to be pro-active to conduct healthm o n i to r i n g a n d p r o v i d in g p r o p e r s o l u -t io n, a nd t he n i t w o ul d b e u p t o t he o wn er,m a y i t b e p r iv a t e o r g o v e r nm e n t t o e xe -cute it in the national interest.

S t r u ct u r a l h e a l t h m o n i t or i n g ( S H M )i n g e n e ra l s e n s e i s a p r o c e ss a i m e d a tproviding accurate and timely informa-t i on a b ou t t h e c o nd i ti o n a n d p e rf o r-m a nc e o f a st r uc t ur e . I t c a n b e e i th e rs h or t te r m ( e g. r e pa i rs e f fi c ac y ) or along term (monitoring parameters con-t in uo us ly o r p er io di ca ll y) p r oc es s. An e ed fo r S H M a r is e s w i th t h e f a ct th a tp r op e rt i es o f b o th c o nc r et e a n d s te e ld e pe n ds o n a l a r ge n u m be r o f f a ct o rs ,w h i c h a r e o f t e n h a r d t o pr e d i ct i n p r a c -t i c e . T h e r e p r e se n t a ti v e p a r am e t e rss el ec te d fo r h ea lt h mo ni to ri ng o f a

s t r u ct u r e in g e n e r al c a n b e o f m e c h an i -c a l , p h y s i ca l a n d c h e m i c al i n n a t u re .I n I n d i a d ue t o n e g l i g e nc e a n d n o n

a v ai l ab i li t y o f t e ch n ol o gy, S H M h a s n o tb ee n t ak en s er io us ly a nd t he re fo re ,m i ss e s i t s f u ll p ot e nt i al . I f s a fe t y s t an -dards are emphasized and followedS H M w i l l g r o w t o i t s f u l l p ot e n t i al a n d b ean integral part of structural maintenancea n d m an a ge m en t . S a fe t y i s a s e r i ou sissue and should be addressed prop-e r l y i n t h e f u t u re .

I n t h i s p a pe r, S t ru c tu r al H e a l th M o -

nitoring basics are covered and needf o r S H M i n t h e f u tu r e I nd i an s c en a ri o .

A lso presented are experiences in someS H M w o rk , w h ic h h a s b e e n u n de r ta k ena n d it s i mp a c t o n t h e s tr u c t ur e b ot h i nthe United States and in I ndia.

Introduction

A s new materials and technologies

a r e d i s c o v e re d , b u i l d in g s g e t t a l l e r, b r i -d ge s g et l on ge r s p an s a nd t he d e- si gn sof structures become more ambitious,b ut m or e c om pl e x. I n v ie w o f t he s e d e v-e l o p m en t s , t h e r e i s a n i n c r e as e d r e q-u i re m en t t o p r ov i di n g b o t h t h e c o s t s s a v -i ng s w it h r eg ar d t o m ai nt en an ce a nd as af er e nv ir on me nt fo r b y p re ve nt in gstructural failures.

I ndia even being a developing coun-t r y h a s p i c k e d u p t h e s t r u c tu r a l d e v e l -o p m e nt s i n c l u di n g t h e n ew t e c h n ol o -g i e s . I n d i a h a s a r i c h c u l t u ra l a nd h i s -t o ri c al b ac k gr o un d w hi c h i s v er y w e llr e f l e ct e d i n t h e v a r i ed a m o u n t o f h i s t o r-i c al s t ru c tu r es . T h es e s t ru c tu r es a r e v e rywell built and have withstood the test oft i m e . B u t d u e t o t h e r e h i s t o r i c al i m p o r -t a n c e i t be c o m e s v e r y i m p o rt a n t t oa s se s s h e a lt h c o nd i ti o n o f t h es e s t r u c-t u r e s , s o t h a t a p pr o p r ia t e s t e ps c a n b etaken before it is too late.

A part from old buildings there areh i gh r i se b u i ld i ng s m ad e o f s t ee l a ndc o n c r et e w h i c h h a v e s t ar t e d t o m ak e

t he ir w ay i n I ndi a a nd as th ey n ee de xt en si ve m od el li ng , d es i gn d et ai l sand analysis before and during con-s t r u c ti o n i t b e c o me s i m p o r ta n t a n dg o o d to k n o w a b o u t w h a t h a s be e nm a d e a n d i t s b eh a v i o ur i n f u t u re .

C r i t i ca l b u i l d i n gs ( o r L i f e l i ne S t r u c -t u r e s , a s t h ey a r e a ls o c a l le d ) l i ke h o s -p it al s, s ch oo ls , p ow er p la nt s e tc a ndb u i l d in g s w i t h l a r g e p u b l ic g a t h e ri n g sl i k e s p or t s a r en a s , s t a d i um s , c o m m er -c i a l b u i ld i n g s , w h i c h c o u l d c a us e h a r mto large amount of people at a time and

a r e s o me t hi n g t o be t ak e n c a re o n ar e gu l ar b a si s , i f t h ey s u ff e r a n y d a ma g ed ue t o a ny c al am it y, e it he r n at ur al o rmanmade.

T he s a fe ty o f d am s i n o ur c ou nt ry i st h e p r i n c ip a l c o n c e rn o f t h e S t a t e a g en -c i e s t ha t a re i n v o lv e d i n t h e v ar i o u sa s p e c ts o f t h e i r i n v e s t ig a t i on , p l a n ni n g ,d es ig n, c on st ru ct io n, o pe ra ti on a nd

m a i n te n a n ce . W h i l e m o s t o f t h e da m sh a v e p e r fo r m e d w e l l, t h e r e h a ve b e e n af e w f a il u re s . T h es e fa i lu r es , e i th e r p a r-t i a l o r c o m p l et e , h i g h l ig h t t h e n e e d t or e v i e w t h e p r o c e du r e s a n d t h e c r i t er i at h a t a r e b e in g a d o p t ed b y t h e v a r i ou sS t at e s w it h t h e o bj e ct o f e s ta b li s hi n gt he b es t a ss ur an ce o f d am s af et y w it hi nt h e l i m i t a t io n o f t h e p r e s e n t s t a t e - of - a rt .

Structural Health Monitoring (SHM)is a process aimed at providing accu-r a te a n d i n -t i me i n fo r ma t io n c o nc e r ni n gs t r u c tu r a l c o n di t i o n a n d p e r fo r m a nc eo n a pr o ac t iv e b a si s . I t c o ns i s ts of ( i )p er ma ne nt c on ti nu ou s, ( ii ) p er io di c o r( i i i ) p e ri o d i c al l y c o n t i nu o u s r e co r d i ngo f r ep re se nt at iv e pa ra me te rs , o ve rs h or t o r l o ng te r ms . T h e i n fo r ma t io nobtained from monitoring is generallyu s e d t o p l a n a n d d es i g n m a i n te n a n ce ,i n c r e as e t h e s a f e t y, v e r i f y h y p o t he s e s ,r e du c e u n ce r ta i nt y a n d t o w i de n t h eknowledge concerning the structureb e in g mo n it o re d . I n s p it e o f i t s im p or -t a n c e, t h e c u l t u r e o n s t r u c tu r a l m o n i t or -

ing in I ndia is not yet widespread.Basics of Structural Health Monitoring

T h e P r o c es s o f S t r u ct u r a l H e a l t hM on it or in g i s p ro c es s s i mi la r t o t he p ai na n d i l ln e ss e x pe r ie n ce d b y h u ma n b o dya n d h o w i t i s c u r e d.

I f t he bo dy i s c on si de re d l ik e a[1 ]

s tr uc tu re . W he n a p er so n h as s om ed a ma g e or p r ob l em w i th h i s bo d y, t h eu n he a lt h y c o nd i ti o n i s d et e ct e d by t h enervous system and it sends signals tot h e br a in a b ou t t he i s s u e. P er s on r e al -

S t ru c tu r al H e al t h M o ni t or i ng : A Dire Need of India

Yo g e s h I n d o l ia , 2 1 S H M C o n s u l ta n t sD r. G o pa l R a i , R & M I n t e rn a t i o n al P v t . L t d .




181w w w .masterbuild er.co.in · T h e M a s t er b u i l de r - July 2013

i z e s t h at h e i s i l l a n d v i si t s a d o c t or i no r de r t o p r ev e nt i t s f u rt h er d e ve l op -m e nt . S y no n ym o us l y t h e s e ns o rs a ctas the nervous system and the acquisi-t i on s y s te m a ct a s a b r ai n . T h e s tr u c-

t ur al e xp er t is l ik e an d oc to r f or t hestructure and listens to the responsesand proposes a solution/ repair strategy.

The important aspects are respon-s e s i n t h e s t r u c tu r e . R e s p o ns e s wh i c hc a n b e c o mm o nl y m e as u re d c an b e i ngeneral divided in

- M ec ha ni ca l: s t ra in , d e f or ma ti on , d i s -p l a c e me n t , c r a c ks o p e n i n g, s t r e s s,load

- P hy si ca l: t em pe ra tu re , h um id it y, p or epressure

- C h em ic al : c hl o ri de p en et ra ti on , s u l -p ha te p en et ra ti on , p H, c ar bo na -t a ti o n p e ne t ra t io n , r e ba r o x id a ti o n,steel oxidation.

T he p hy s ic al d ia gn os ti c t oo l o f S HMi s t h e c o m p r e h e ns i v e i n t e g r at i o n o f v a r i -o u s s e n s i ng d e v i c e s a n d a u x i li a r y s y s -

[2 ]t e m s , i n c l u di n g :

- Sensory s ystem

- D at a ac qu is it io n s ys te m

- D at a p ro ce ss in g s ys te m

- C omm uni cat io n s ys te m

- D am ag e d et ec ti on a nd m od el li ngsystem

M on it or in g i s n ot s up po s ed t o m ak ea diagnosis. To make a diagnosis andp ro po se t he c ur e I t i s n ec es sa ry t o c ar ryo u t a d e t ai l e d i n s pe c t i o n a n d r e la t e da na ly se s. D et ec ti o n o f u nu su al s tr uc -t u r a l b e ha v i o u rs b a s e d o n m o n i to r i n gr e s u l ts i s p er f o r me d i n a c c o rd w i t h p r ed e fi n ed al g or i th m s. T h e e f fi c ie n cy o fm o ni t or i ng d e pe n ds o n b o th t h e pe r -formance of the applied monitoring sys-

tem and the algorithms employed.Aim, Needs and Benefits

T h e o b j e c ti v e o f S H M i s t o m o n i t ort h e i n -s i t u b e h a v io u r o f a s t r u ct u r e a cc u -r a t e ly a n d e f f i c ie n t l y, t o a s s e s s i t s p e r -formance under various service loads,t o d e t e ct d a m ag e o r d e t e ri o r a t io n , a n dt o d et e rm i ne t h e he a lt h o r c o nd i ti o n o ft h e st r u c t ur e . T h e SH M s y s t e m s h o u l db e a bl e t o pr o v i d e, o n d e m a nd , r e l i a bl ei n f o rm a t i on p e r t ai n i n g t o t h e s a f e t y a n di n t e gr i t y o f a s t r u c tu r e . T h e i n f o r ma t i o n

c a n t h en b e i nc o rp o ra t ed i n to b r id g emaintenance and management strate-gies, and improved designguidelines.

There are various advantages and

p o s i t i v e r a m i f i c a t i o n s o f i n c l u d i n g

S tr uc tu ra l H ea lt h M on it or in g i n c iv ilstructures.

1 . C on fi rm t he d es ig n p ar am et er :D et ec ti on o f d am ag es d ur in g co n-

s t ru c ti o n w h ic h c a n c a us e a n y c h an g e

i n p r o p er t i e s th a n e x p e c te d b y d e s i g n.

2. Quality Assurance: B y p r ov i d in g

c o n t i nu o u s a n d q u a n ti t a t iv e d at a , a

m o ni t o ri n g s ys t em h e l ps y o u i n a s se -

s s i ng t h e qu a li t y o f y o u r s t ru c tu r e du r -

i ng c on st ru ct io n, o pe ra ti on , m ai nt e-

nance and repair, therefore eliminating

t h e h id d en c o s ts o f d a ma g es c a us e db y n on a ch ie vi ng t he r eq ui re d d es i gn ed

standards.

3 . C o mp l ex S t ru c tu r es a r e w e llmanaged: L e ar n in g ho w a s t ru c tu r e

p e r f or m s i n r e a l c o n di t i o n s w i l l h e lp y o u

t o d e si g n b e tt e r s t ru c tu r es f o r t h e f u tu r e.

W h en n e w m a te r ia l s, n e w t e ch n ol o gi e s

a n d m e t h o ds a r e i n v o l v e d i n c o n s t ru c -

t io n m on it or in g is a n e ff ec ti ve w ay t o

k n ow t h e re a l b eh a vi o u r a n d t o re f in e

structural behaviour theories.

4. To Ensure safety of people, naturea n d p r o p e rt y : E a rl y d e te c ti o n o f p e rf o r-

m a n c e de g r a da t i o n c a n s a v e l i v es a n d

p r op e rt y i n t i me b y s t op p in g e x pl o it a -

t i on a n d ac c es s t o t h e s tr u ct u re . T h is

g u ar a nt e e t h e s a fe t y o f t h e s t ru c tu r e

a n d it s u s er s . I t a ls o g i ve s u s a w a y t o

a s s e s s th e p o s s i bl e d a m ag e s a f te r a

n at ur al c al am it y o r a ny o th er t yp e o f

m a jo r e v en t w h i ch c a n a f fe c t t h e s t ru c -

tural properties and condition.

5 . M on it or in g r ev ea ls h i dd en r e-

sources: M a n y t i m e s t h e s t r u ct u r e p e r -

f o rm a nc e i s be t te r t h an w h at i t i s de-s i g n e d f o r a n d t h is g i v es a n e x t r a f r e e -

d o m t o p l a y w i t h f o r f u r t he r d e s i g ns an d

construction.

E c o n o mi c a l l y s t r u ct u r a l h e a l t h m o n -i t o r i ng p r o c e s s i s a l s o v e r y r e a s o na b l ea n d i s s y n o n y m ou s t o b u y i n g a n i n s u r -a nc e po li cy f or y ou r h ea lt h. O ne p ro -t e c t s t h e i nd i v i d ua l , h i s / h er d e p e n di n gf am il y a nd fi na ll y g iv es a pe ac e ofm i nd . T h e s am e i s t r u e f or S H M P ol i c y,w hi ch g iv es a m uc h m or e p er so na l, l oc aland national image for sustainability.

- T he c os t o f i ns ta ll in g a s y st em a ndd o i n g h e al t h m o n i to r i n g a t a g i v ent i me l i ke c o ns t ru c ti o n o r r e pa i rs i s

0 . 5 % t o 3 % o f t h e t o t a l c o n st r u c t io no r r e p a ir c o s t s r e s p e c t iv e l y.

- T he co st of d oi ng S tr uc tu ra l H ea lt hM o n i t o ri n g f o r a p er i o d o f 1 0 y ea r si s 2 % t o 5 % o f t o t a l s t r uc t u r e s b u il d -

[1 ]i ng cost .

The above points shows that SHMi s v e r y e c o n o mi c a l a n d t h e r e t u rn s a r elarge and worth spending for.

S c op e o f S H M a n d i t s n e ed i n I n di a

Concrete and steel are two materi-a l s w hi c h a r e mo s tl y u s ed i n c o ns t ru c -tion today, often in the f orm o f rein-forced concrete. These two materials int h e f o rm o f r e i n fo r c e d c on c r e te h a v eb e c o me h i g h l y p o p u la r f o r c o n s t ru c t io nd ue t o i ts h ig h c om pre ss iv e s tr en gt h,r es is ta nc e t o f ir e, v er y l ow m ai nt en an cec o s t a s c o mp a r e d t o s er v i c e l i fe , a n dm o st i mp o rt a nt l y i t be i ng h i gh l y e c o -n o mi c al . B u t d u e t o it s hi g h r e qu i re -m e nt o f q u al i t y c o nt r ol a n d pr o bl e msr e l a te d t o r e l i a bi l i t y w i t h m a t e ri a l pr o p -erties it has some drawbacks. The steel

inside the reinforced concrete gets cor-r od ed . C ar bo na ti on i s a p ro bl em . A geing phenomenon of concrete isv e r y d i f f i cu l t t o p r e d i c t a nd t h i s c a n l e a dt o a cc i d e n ts a nd l o s se s . R e i n fo r c e dc o n c re t e s t ru c t u r es i n c r i t i ca l p l ac e sl i ke n u c le a r p l an t s m ak e s t he m s oimportant that we have to be sure thatt he y a re in g oo d c on di ti on . T hi s i swhere structural health monitoring hasa r ol e t o pl a y. I t gi v e s a w a y t o o ve r -c o m e th e s e d ra w b a ck s w i t h m i n i ma ldamage and loss.

F i g 1 : M a j o r C i v i l S t r u ct u r e s i n w h i c h m o n i t o ri n g i sreq uired




S t e p s I n v o lv e d w i t h S H M

The following major steps are invol-v ed i n o v er al l pr oc es s of s tr uc tu ra lh e a l t h m o n i t o r i n g.- I de nt if y s tr uc tu re s ne ed in g mo ni to r-

ing- A cquire information on probable

degradation mechanisms and risksf r o m d es i g n e n g i n ee r s o r o w n e rs o fstructure.

- E st ab li sh e xp ec te d r es po ns es t odegradations.

- D es ig n S HM s ys te m t o d et ec t s uc hconditions and select appropriatesensors.

- I ns ta ll a nd c al ib ra te s y st em ( Fi g 2 ).- A cq ui re , an al ys e a nd ma nag e da ta.

F i g 2 : V a r io u s s e n s o rs i n s t a l l ed f o r a s s e ss i n g d a t a

This involves alarming the concernedp e o p l e w h e n e ve r t h e r e i s a n e m e r -g e n c y ( F i g 3) .

S ta t us o f S tr u ct u ra l H e al t h M o ni t or in g ,World

M a j o r d r i v e rs i n t h i s a re a h a v e b e e nt he o il i nd us t ry, o pe ra to rs o f l ar ge d am s

F i g 3 : D a t a a c q u is i t i o n f r o m v a r i ou s s e n s o rs w h i c ha r e l o g g e d f o r a n a l y s is .

a n d h i g h w ay s a g e n c i e s, w h o s e i n s t al -lations have received the greatest at-t en ti on a nd r es ea rc h e ff or t. A l so t hen e e d t o k e e p c u l t u ra l l y i m p o rt a n t s t r uc -t ur es i n g oo d he al th h as g iv en S HM

attention. A lthough worldwide SHM is a rela-

t i ve l y n e w t e rm i n c i vi l e n gi n ee r in g i n -d u s t r y, t h e u s e o f i n s t r um e n t s t o a s s e s st h e h ea l t h i s n o t n ew. B r i d g e fi e l d t es t -ing using various measuring instrumentsi s v er y o l d ac t iv i ty. T h e ob j ec t i ve s o fS H M a r e c o ns i s t e nt w i t h t h e o b j ec t i v e so f m an y o f t he s e lo ng s t an di ng p ra c-t i ce s . S H M i s i n f a ct a n a u gm e nt a ti o n o fcurrent practice.

A ccording to I nternational Societyo f S tr uc tu ra l He al th M on it or in g a nd

I ntelligent I nfrastructure (I SHMI I ) lot ofbridges and structures have beeni n s t a ll e d w i th s e n s o rs a n d ar e m o n i-t or ed fo r a ny d am ag e i n Eu ro pe an

[3 ]c o un t ri e s . T h is is p ri m ar i ly b e ca u se o ft h e E ur o p e an c u l t u re h a v in g i t s r o o tw a y b a ck i n t h e pa s t. T h is a l lo w s th e mt o r e t ai n a s t o c k o f o l d s t ru c t u r es , w h i c hh a v e t o b e m a i nt a i n ed i n g o o d c o n di -t i on t o r e pr e se n t t he i r c u l tu r e. T h is h a sd r i v e n t h e S H M o f t h e s e s t r u c tu r e s a n dm a d e t h e m p o pu l a r. I S H M II p r o v i d esr e f e re n c e o f m a n y b r i d ge s b e i n g m on i -

t o re d p r es e nt l y a l l o v e r E u ro p e. S o me A sian countries which have seen veryh i gh g r ow t h i n r e ce n t t i me s du e to t hem a n u fa c t u ri n g a n d t e c h n ol o g y r e v o l u-t i on , n a me l y C h i na , S i ng a po r e, J a pa n ,Ta i wa n , h a ve ma n y s t ru c tu r es un d ermonitoring and are doing well.

I n U SA th e n um be r i sn 't hi gh b uta pp re ci ab le w or k h as b ee n d on e. M an yu n i v e rs i t i e s h a v e b e e n i n v o l ve d w it hr e s e ar c h i n s t r u ct u r a l h e a l t h m o n i t or i n ga nd h av e a ls o i ns ta ll ed t he m o n b ri dg es

a n d b u il d in g s. T h er e a r e m a ny r e as o ns .F i rs t , u n li k e E u ro p e o r o u r c o u nt r y, t h eU S s tr uc tu re s a re f ai rl y y o un g ( l es s t ha n300 years, compared to several centu-r i es f o r u s ) . S e co n d, t h e s tr u ct u re s a r em ar ke d as h is to ri c b y t he U S r eg ul a-t i o n s , w h i c h a r e m a i n ta i n e d a n d c a n n otb e a l t er e d. T h e H i s to r ic A m er i ca n B u i l-d in gs S ur ve y ( HA BS ) a nd t he H is to ri c

A merican Engi-neering Record (HA ER)h a ve c o n s id e ra b le i n f or m at i o n o n t h e

[7 ]s u bj e c t a n d h a ve a n e x ce l le n t w e b s i te .

T h e i r c o l l e c ti o n s d oc u m e nt a c h i e-

v e me n ts i n a r ch i te c tu r e, e n gi n ee r in g ,a n d d es i g n i n t h e U n i te d S t a te s a n d i tst e r r it o r i e s t h r o ug h a c o m p re h e n s iv er a n ge o f b u i l di n g t y p e s a n d e n g in e e r -ing technologies including examples

a s d i ve r s e as t h e Pu e b l o o f A c o m a,h o u s e s, w i n d mi l l s , o n e - r oo m s c h o o ls ,t h e G o l de n G a t e B r id g e , a n d b ui l d i n gsd e s i g ne d b y F r a nk L l o y d W r i gh t . A d m i -

n i s t e re d s i n c e 1 9 3 3 t h r o ug h c o o p e ra -t i v e a g r e e m en t s w i t h t h e N a t i o n al P a r kS er vi ce , t he L ib ra ry o f C on gr es s , a ndt h e p r i v a t e s e c to r, o n g o i ng p r o g r a mso f t h e Na t io n al P ar k S er v ic e h av erecorded A merica's built environmenti n m u lt i -f o rm a t s u rv e ys c o mp r is i ngm o r e t h a n 5 5 6 , 9 00 m e as u r e d d r a w -i n gs , l a rg e -f o rm a t p h ot o gr a ph s , a n d

w ri tt en h is to ri es f or m or e t h an 3 8 ,6 0 0h i s to r ic s t ru c tu r es a n d s i t es d a t i ngfrom Pre-Columbian times to the twen-t i e t h c e n t u ry.

I n d i a h as m u c h m o r e t o d o p r o fe s -s i o na l ly. A l a c k o f g e ne r al a w a re n es sand reluctance towards trying new tech-n o l o g y a n d m et h o d s ma y h a v e k ep t u sb e hi n d o n t h is . T h er e a r e g o ve r nm e ntr e co r ds of m a ny h i st o ri c al bu i l di n gs ,w h i ch a r e n o t e a si l y a v ai l ab l e t o t h ep ub li c f or f ur th er p ro fe ss io na l st ud ya n d r e se a rc h . O n e c a n c a ll i t in a s im -p li s ti c m an ne r, R ep or t C a rd f o r I nf ra -s t r u c tu r e ( a s i n t h e U S ) i n a n a t i o na l p o l -i c y l ev el . I n i nd ia w e ca n l ea rn f ro m th eW e st f o r i m pr o vi n g o u r c o nd i ti o n s m u chf a st e r a s t h e i nf o rm a ti o n i s a v ai l ab l e,c o mm u ni c at i o n i s s i mp l er a n d t h e w o rl dh a s b e c o me m u c h s m a l l er t o w o r k .

S t a t us a n d n e e d o f S H M, I n d i a

Residential buildings and comme-r c i a l s t ru c t u r es i n I n d i a h av e r e c e i v edv e ry l e ss a lm o st i n e x is t en t fo c us o n

s t r u c tu r a l he a l t h m o n i to r i n g p r i m ar i l ydue to owners not knowing about itsa v a i l ab i l i t y a n d p o o r k n o w l ed g e a b o u tt he m. I n t he se ca se s S HM c an o nl y b emade possible andimplementedin thesestructures after some efforts have beenmade to make them aware and edu-c a t e th e m o r f o r c i ng t h e m i n t o it b yl e ga l ly m a ki n g r u le s . S o me i n s u ra n cep l a n s c a n a l s o b e w o r ke d o u t f o r t h e m .

D a m s ar e s t ru c t u r es o f g r e a t n a -

tional importance.Dams generally serve

t h e p r i m ar y p u r p o se o f r e t a i ni n g w a t e r,





while other structures such as floodgates

o r l ev ee s ( al so k n ow n a s di ke s ) ar e

u s e d t o ma n a ge o r p r e v e nt w at e r f l o w

i n to s p e ci f ic l a nd r e gi o ns . H y dr o - p ow e r

and pumped-storage hydroelectricity

a re o ft en u se d i n c o nj un ct io n w it h d am st o p r o v i d e g e n er a t e e l e c tr i c i t y. A d a m

c a n a l so b e u s e d to c o l le c t w at e r o r f o r

s to ra ge o f w at er w hi ch c an b e e ve nl y

distributed between locations.I n I n d i a da m s a r e ma j o r l y o w n e d b y

state government or the agencies gov-

e r n e d b y s t a t e g o ve r n m en t . A r e p o r t o n

d a m s a fe t y p r o c e du r e s h a s r e -v e a l e d

t h at o n t h e i n s tr u me n ta t io n s i de , w h ic h

i s v it a l fo r m o ni t o ri n g of d a m s a fe t y,

there appears to be a communication

g a p b e tw e en t h e o f fi c e r- i n- c ha r ge o f

d e si g n / c o ns t ru c ti o n a n d o ff i ce r s w ho[4 ]

t ak e o ve r m ai nt en an ce . T he re a re m an y

i n s t an c e s w h e r e t h e o f fi c e r s i n c h a r ge

o f m a in t en a nc e ar e no t aw a re o f t h e

i n st r um e nt a ti o n p r op o sa l t h at h a s g o ne

into the dam and there exist many miss-

i ng l i nk s. T he i n it ia l re ad in gs o f t he

i n st r um e nt a r e r ar e ly a v ai l ab l e fo r a n

i n s t ru m e n t e m b e dd e d i n t h e d a m , t h e

a bs en ce o f w hi ch h as m ad e s ub se -

quent analysis difficult.

Bridges are important lifeline struc-

t u re s , i t i s i mp o rt a nt f o r t h em t o h av eelaborate inspection and maintenance

p r og r am m es . S t at i c a n d D y na m ic L o ad

t e s t i n g' s a r e c a r r i ed o u t i n t o d a y 's b r i -

d g e s t o sa t i s f y t h e I S c o d e s an d s a fe t y

measures. These tests are carried only

d u r i n g m a j o r e v e n t s i n t h e b r i d ge l if e -

s pa n e s pe c ia ll y t he c o ns t ru ct io n t im e

a n d m a jo r r e pa i rs & r e tr o fi t ti n g. A p ar t

from this Permanent & Continuous mon-

i t o ri n g a r e r e qu i re d f o r m a jo r it y o f b r i-

d g e s t o pr e v e n t a n y h u m a n l o s s . T h e s e

c a n b e a l s o us e f u l t o a s s e s s th e d i s -

t r es s d u ri n g o r f o ll o w in g a n y m a jo r e v en t

l i k e e a r t h q u ak e , l a n d sl i d e s , s t o r m s e t c .

M o d a l A na l y s i s ha s c o me u p a s a

v e ry e f fe c t iv e w a y o f f i nd i ng da m ag e s

and overall health of bridges. Such global

m e t h o ds a r e v e r y i m p o r ta n t bu t c a n

o n l y d e t e c t o n l y g l o b al c h a n ge s s u c h

a s f o u n da t i o n s e t t l e me n t , b e a ri n g f a i l -

u re o r m aj or d ef ec ts , s uc h a s l os s of

m ai n c ab le te ns io n o r r up tu re of d ec k

e l e me n t . B u t a g ai n d o es n ot n ee d a

h ig h d en si ty o f s en so rs a nd c an be

d on e m in im um of o pt im al l y l oc at ed

sensors.S o m e w o r k o f i n s t al l i n g a d v a nc e

S t r u ct u r a l H e a l th M o n i t o ri n g h a s b e e n

d on e in i nd ia o n v er y f ew b ri dg es . O ne

o f t h e br i dg e i s Na i ni B r i dg e o ve r Yamuna River at A llahabad. This was

p ro ba bl y t he f ir st i ns ta ll at io n o f f ul ly

s t an d al o ne n ew g e ne r at i on G P S c o m-

b i n e d w i t h a d v a nc e p o s t p r o c es s i n g

s o ft w ar e t o c o nt i nu o us l y m o ni t or t h e

b r id g e f or v a ri o u s c ha n ge s i n c l im a te

a n d o p er a ti o ns w it h h i gh a c cu r ac y f o r

e x a m pl e 3 D a b s o l ut e d e f l ec t i o n s ca n[5 ]

b e m eas ure d u p t o m m ac cu rac y . T hi s

w o r k w as c a r r ie d o u t b y C O W I / D e v c o n

I n f ra s t r u ct u r e . B u t t h i s k i n d o f w o r k h a s

to be carried over all important bridges for

there better understanding and safety. A structurally deficient bridge is clo-

s e d o r r e s t r ic t e d t o l ig h t v e hi c l e s b e-

cause of its deteriorated structural com-

p o n e nt s . W h i l e no t n e ce s s a r il y u n s a fe ,

these bridges must have limits for

s p e e d a nd w e i g h t . A f u n c t i on a l l y o b s o -

l e te b r id g e ha s o l de r d e si g n f e at u re s

a n d, w h il e i t i s n o t un s af e f or a l l v eh i -

c le s, i t c an no t s af el y a cc o mm od at e

c ur re nt t ra ff ic v ol um es , a nd v eh ic le

s i ze s a n d w e i g h ts . T h es e r e st r ic t io n s n o t

o n ly c o nt r ib u te t o t r af f ic c o ng e st i o n,t h ey p o se s u ch m a jo r i n co n ve n ie n ce s

a s s c ho o l b us s es o r e m er g en c y v e hi -

cles taking lengthy detours.[6 ]

The A SCE I nfrastructure report card

w a s d e v is e d u n de r t h e l e ad e rs h i p o f

A merican Society of Civil Engi-neers

( AS CE ) i n 1 99 7, i n w hi ch t he s e- ni or

a ut ho r w as p er so na ll y i nv ol ve d. I t re -

veals some important facts about I n-

f r a s tr u c t ur e a n d a l s o g i v e s a l e s s o n i n

m ak in g u s, a s p ro fe ss i on al s , m or e

r e s p o ns i b l e f o r t h e n a t i on a l s t o c k . W e

a s p r of e s s i o n m u s t gu i d e a nd d i r e ct

s uc h a ct iv it y i n I nd ia t o m ak e p ub li c

a w ar e o f t h e f u t u re o f o u r i n f r as t ru c tu r es .

C o n c lu s i o n a n d F u t u re :

I n t h e pa p er m a ny a s pe c ts o f S t ru c -

t u r a l H e a l th M o n i t or i n g we r e c o ns i d -

ered.

- T he ne ed of SHM gives us some

s t r o n g r e a s o ns f o r i t t o b e co m e a

integral part of a structure- I ndi a as a de ve lo pi ng c oun tr y n ee ds

to be more aware and cautious

a b o u t i t s I n f ra s t r uc t u r e . A ma j o r

e v e n t c a n c a u s e i r r e ve r s i b le l o s s e s

and hence should be well informed

i n t i me .

- T he re a re m an y i mp or ta nt s tr uc -t u r e s w h e r e i n s t r u m e n t a t i o n i s

a l r e ad y b e i n g u s e d in I n d i a l i k e th e

d a m s , w h o s e v a r i o us p ar a m e te r s

h a v e t o b e l o o ke d u p o n , b u t t h e s e

arenot being done effectively andcan

b e b e t t e r w i t h n e w t e c h no l o g i e s.- L i fe l i ne s t ru c tu r es li k e h o s pi t al s a n d

i m p o r t a n t b r i d g e s a n d t u n n e l s

s h o u l d b e m a nd a t e d w i th m o n i to r -

i n g a s t h ei r f a il u re c a us e m o re l o ss e s

t h a n a n y o t h e r.- S tr uc tu ra l H ea lt h M on it or in g e co -

n o m i ca l l y i s a l s o li g h t a nd i s o n l y0 . 5 % t o 3 % o n e ti m e c o st o f t o t a l

structures cost and 2% to 5% for

monitoring structure over 10 years.- I t i s d o ne w it h s ome s tru ct ur es i n I nd ia

but have to be focused more on.

Structural Health Monitoring is rela-

t i v e l y n e w c o n c e pt w o rl d w i d e a n d ve r y

r e ce n t f o r I n di a . I t ha s pr o ve d to b e

e f f e c ti v e a n d fr u i t f ul i n m a n y c o u n t ri e s ,

n o w b e in g p ra c ti c es o f t en , a n d ha s a

great potential and usefulness for india

f o r g a i n i ng co n f i de n c e o v e r t h e s t r u c -tures we are making so that develop-

m e n t h a pp e n s f a s te r a n d w i t h a c c u ra t e

results

References

1 . B r an k o Gl i si c a n d Da n ie le I na u di , “ F i-b re o p ti c m e th o ds f o r s t ru c tu r al h e al t hmoni tori ng”, John Wil ey & Sons,Chi c he ster, 2007.

2 . G u i de l i ne s fo r S tr u c tu r a l H e a lt hMonitori ng, ISIS Canada.

3. In tern ati ona l S ociet y o f S tru ct ura l

h e a l t h M o n i t o r i n g a n d I n t e l l i g e n tInfrastruc ture, www.i shmi i .org

4 . “ R ep o rt o n D a m S a fe t y P ro c ed u re s” ,G over nmen t Of I ndi a, Min is try o fWate r Re sourc e s.

5 . J a co b E g ed e A n de rs o n, “ St r uc t ur a lH ea lt h M on it or in g S y st em s” , C ow i

A/S and Futurte c OY, 2006.6 . “ R e po r t c a r d f o r A m er i c a' s I n f ra s t ru c -

t u re ”, A me ri c an S o ci et y o f S t ru c tu r alEngi ne e rs,2005.

7 . h t t p :/ / m em o r y. l o c. g o v/ a m me m /c o ll e c ti ons/habs_hae r/




ll heritage buildings hav e theirunique historical significance.

T he i r c h ar ac te r d ef in in g e le me n ts Athat account for its heritage v alues v ary

f r o m s t r u ct u r e t o s t r u ct u r e . T h e m a s te rbuilders of the Middle Ages were able to

u s e ge o m e t r ic a l ru l e s , d e v e l op e d th -r ou gh c e nt ur ie s o f t ri al a nd e r ro r, t o b ui ld

structural elements at times when therew a s n o k no w l e d ge o f m a t e r ia l p r o p er -

ties or allowable stresses.T he p re se rv at io n a nd s tr en gt he ni ng

o f h er it ag e s tr uc tu re s i s t ri ck y, t he i nt en -d e d ch a ng e i n t h e us e o f s u ch b u il d in g

w i ll i n va r ia b ly c r e at e d i f fi c ul t ie s t o t a ck l e,

w hi ch i n t ur n w ou ld m ak e co m pl ia nc ew it h t he st at ut or y b ui ld in g s af e ty a nd

health requirements a challenge. Anotherbalance to be considered is the need for

p r es e rv a ti o n o f c h ar a ct e r- d ef i ni n g e l e-ments of the heritage buildings and the

n e e d t o c o mp l y w i t h t h e m i n im u m b u i ld -i n g s a f e t y a n d h e a l th s t a n da r d s .

R e p a ir a n d s t r e ng t h e n in g b y g r o u t -i n g o f b r ic k an d st o ne m as o nr y w a ll s

h as b e en l ar ge ly a pp li ed t h ro u gh ou tE u ro p e o n h i st o ri c b u il d in g s, n e ve r th e -

l es s n o g re at e ff or t w as d on e i n a dv an ceand during the time to test the effectiv e-

n e s s o f t h i s t e c h n iq u e .T h e s e is m ic r e si s ta n ce o f h i st o ri c

m as on ry b ui ld in gs i s a s pe ci al s ce na ri o

t o co n s i de r. T h e s e i s mi c a n a l ys i s o f u n -r e i n f o rc e d m a s o n r y s t r u ct u r e s i s a f i e l di n i t s i nf a nc y, w i th m o st e a r t hq u ak e e n -

g i n e e r s i n s is t i ng t h a t h i s t o r i c b u i l di n g sdo not hav e sufficient ductility to resist a

m aj or s ei sm ic e ve nt . M an y e ng in ee rswould propose that a structure need to

be strengthened to improv e its seismicr e si st an ce , b ut as a p ro f es si on , w e

s h ou l d c a u ti o n t h at o u r u n de r st a nd i ngo f t he s ei sm ic r es po ns e o f m as on ry

buildings is limited at present.M a ny r e as o ns a re p r es e nt f o r p r o -

p e r a t te n ti o n t o be g iv e n t o th e se h er i -t a g e / M a s o nr y s t r u ct u r e s . T h e f o l l o wi n g

a r e th e m aj o r r e a so n s fo r t h em t o u n-dergo rehabilitation, strengthening:

1 . Temperature changes and expo-sure to moisture and other env ironmen-

t a l f ac t o r s r e s u l t i n d e t e r io r a t i on , w e a k -e n i n g , f a t i gu e e f f e c t s , c h e m i c al a t t a c k s ,

weathering and inadequate maintenancea n d d i s t r es s o f m a s o nr y e l e m e nt s .

2 . O l d m a so n r y c o ns t ru c ti o n a s u n -r e i n f o rc e d s t r u c tu r e s i s e s p e ci a l l y v u l -

n e ra b le d u e t o m a ny e n vi r o nm e n ta lcalamities like:

s Earthquakes s Tsunamis s Excessiv e

rain s Soil pressure s Settlements due tounderground constructionsProblems due

to construction of newer structures around

a n d b e lo w.s

Vibrations induced due tov arious factors. s Fire also weakens thestructure and calls for rehabilitation.

3 . T h es e s tr u ct u re s a re o f te n o v er -

l o ad e d o v er t h e pe r i od o f t i me a s th er eq ui re m en t o f f lo o r s pa ce a nd s tr en gt h

h a s b e c o me h i gh w i th t h e t o d a y' s w o rl d .4 . T he us e o f m an y s tr uc tu re s h as

a l s o ch a n g e d m a n y t i m e s d u r i n g t h et im e . A s t he s tr uc tu re w e re n ot d es ig ne d

a n d m a d e f o r a l l k i n d s o f f u t u r e l o a d s, i ti s ve r y e v i d e nt t ha t th e s e st r u c t ur e s

need attention and strengthening.

T he re a re n um er ou s w ay s o f d oi ng t hestrengthening.

- Co nfinemen t: I t li t er a ll y m e an s to

impede the deformation.- Re inforceme nt: Ta k i n g u se o f n e w

materials and technology to build sec-tionsaroundto impartextra strength.

- Enl argemen t: W i d en i ng of t h e r e -s is ti ng s e ct io n w it h t he a d di ti on o f

n e w m a t e r ia l .- M at er ia l s ub st it ut io n: Remov al and

r e p l a ce m e n t o f d a m a ge d p ar t s o f a

s t r u c tu r e . T h e m a t e r ia l s u s e d i n t h er e c on s tr u c ti o n m a y b e s i m il a r t o t h e

o r i g i na l o ne s o r p o s s es s be t t e r m e -chanical properties.

- S tr uc tu ra l s ub st it ut io n: C re at io n o f

n ew l oa d b ea ri ng s tr uc tu re w it h m o-

d e r n m a t e r ia l s , w i t h o ut t h e d i s m a n-t l i n g o f t h e o l d o n e.

- Tying: B i nd i ng t o ge t he r d i ff e r en t e l e-

m e n ts o r d i ff e r en t p ar t s of a s i ng l eelement.

- Proppi ng: S u pp o rt i ng a pa r t o f a

s t r u c tu r e wi t h a d d i ti o n a l e l e m e n tsm ad e o f s te e l o r o th er n ew m at er ia ls .

T he m ai n d is ti nc ti on h as t o b e m ad eb e t w e en l a t e ra l p r o p p i n g ( s t r u t t in g )

and v ertical propping.

- Anchori ng: F a s te n i n g a n e l e m e nt o r

a p a r t of a s t r uc t u r e to a f i r m e r s o l i d .T he most diffuse form is an-choring

t o r o ck a n d s o i l . T h i s i n t e r ve n t i on i su s ed to im p r ov e t h e s t ab i li t y o f a

structure and to av oid its collapse inc a s e o f a s ei s m i c e v e n t.

- Prestressin g: Changing the stress

f ie l d i n a st ru ct ur e o r i n a n e le me ntu si ng e xt er na l l oa ds o r i nd uc e d c om -

p r e s si o n b e f o r e l o a d i n g .

- Isolation : Absorbing the seismic

forces and v ibrations in external de-v ic es u s ua ll y p la ce d b et we en t he

p r o p e r f o u n d at i o n a n d t h e m a s o nr ystructure.

- Soil stab ilization : I nt er ve nt io n f o-

c u s e d on t h e s oi l b e n ea t h t h e s tr u c -t u r e , a i m i n g a t a n i m p r o ve m e n t o f i t s

bearing capacity.

M os t of t he a bo ve t ec hn iq ue s an dm a t e r ia l s i n v o l v e t h e f o l l o w in g

- U se o f h ea vy m ate ri al s i n du ci ng d ea dload

- C ha ng in g t he or ig in al fl oo r s pa ce

a nd c r ea ti ng m o re s pa ce c o ns tr ai nt s

U se of FR P C om po si te s f or Re ha bi l it at io n o fHeritage Structures

188 T h e M a s t er b u i l de r - July 2013 Ÿ www.masterbuilder.co.in

D r. Go p a l R a iR & M I n t e rn a t i o n al Pv t . L t d .

R e p a i r a n d R eh a b



b y i n c r ea s i ng si z e a n d i n d u ci n gne w structural me mbe rs

- S em i- de st ru ct iv e p ra ct ic es i nv ol ve d,w h i c h a r e v e r y h a r m fu l a n d u n d e s i r -a b l e f or o l d s t r uc t u r es a s t h e y n e e d

to be conserv e d and some of the ma r e o f h i g h c u l t u ra l v a l u es

- C ha ng in g th e l oo k a nd a es th et i cs

o f t h e e x is t in g s t ru c tu r e a s i t i n vo l ve se re ct in g n ew m em be rs , e nl ar ge -

m en t of s iz e, u se o f d if fe re nt a ndne w mate rials e tc.

F i n a ll y, i t i s t h e r es p o ns i b i li t y t o u n -

d e r st a n d t h e p ro p e r r e q ui r e m en t o fthe se structure s as the y are not from

the mode rn world and hav e to be take nc a re w i th p r op e r e x pe r ti s e an d g ui d -

a nc e i .e . e rr or s i n a ny k in d o f r es to ra -t i o n a r e h i g h ly u n d e s ir a b l e.

F R P c o m p os i t es w h e n u s e d p r o p -e rl y o n t h es e s t ru c tu r es , t h ey a r e b e st

s u i t ed f o r t a c k li n g t h e se p r o b l em s o fm a s on r y s t r u ct u r es , w h i c h c a n b e u s e dt o ma k e t h e m d u r ab l e , d u c t i le a nd

s t r on g e r f o r t h e t i m e s a h e ad .

T h is p a pe r f u rt h er p r es e nt s s om eu s e o f F R P s t re n gt h en i ng t e c h ni q ue s

i n m a s on r y s t r u ct u r e s.

F RP U se i n S tr uc tu ra l R ep ai r a nd r e-

habilitationF R P c o mp o si t es h a ve b ee n l a te l y

v e r y p o p ul a r i n t h e f i e l d o f s t r u ct u r a l r e -

h a bi l it a ti o n. T h e u s e o f m a te r ia l s, l i kec a rb o n o r g l as s f i be r c o mp os i te s, h a s

c o n si d e r ab l y i n c r ea s e d i n t h e f i e l d o fre habilitation. RCC structure s that havebeen successfully rehabilitated and stren-

gthe ne d hav e conside rably incre ase d.

The FRPs present several well-knowna d v an t a g es , i n c l u di n g n e g l i g i b l e s p e -

c if ic w ei gh t, c or ro si on i mm un it y, a nd

high-te nsile strength.Fle xibility and e asya p p l ic a t i on a l s o a l l o w a w i de r a ng e of

application are as that is stre ngthe ninga n d r e st o ra t io n i n s ev er a l d a ma g in g

conditions.

M a so n r y s t r u ct u r es h a v e a l w ay sb e en u s e d s i n c e t h e d aw n o f c o n st r u c -t i o n , a n d n o w ad a y s, d u e t o ag i n g , m a -

t er ia l d e gr ad at io n, s et tl em en ts , a ndstructural alterations, usually some mem-

b er s n e ed s t re n gt h en i ng t o r e- e st a bl i sht h ei r p e rf or m an c e. I n t h is a s pe c t, F R Pcomposite s in the form of bonde d lami-

nate s applie d to the e xte rnal surface ofm a s on r y h a v e b e co m e a v i a b l e s ol u -

t i o n . T h e m o st i m p o r ta n t r e as o n i s t h a tt h ey c o mp l y w i th t h e c u lt u ra l v al u e o f

the building.

The re are nume rous possibilitie s inte rms of mate rial prope rtie s and appli-

c a t i on m e t ho d o l og y o f F R P m a t er i a l s i nold he ritage structure as it is importantto conse rv e the cultural significance

a nd a e st he ti c it y o f t he s t ru ct ur e. T hef o l l ow i n g i s t h e m aj o r a p p l i ca t i o ns o f

FRP composites in masonry structure s.T h er e a r e t w o t e ch n iq u es , w h ic h a r e

n o r ma l l y a d o pt e d f o r s t r en g t h en i n g o f

masonry syste ms.

- Single layers of composites andF R P w r a p : I n t h i s m et h o d , s e p ar a t em a t ri x a n d fi b e r a r e us e d , a n d t he yform the composite at the place of

a pp li ca ti on a ft er w et L ay -u p. I t i salso known as we t Layup syste m.

- C a rb o n C o mp o si t e L a mi n at e s: Inthis me thod pre -cure d carbon fibe rlaminate s/Plate s are use d, which are

b on d ed a d h es i ve l y w i th t h e s tr u c-tural member.

T h e g u i de l i n es a r e v e r y i m p or t a n tf o r a n y t e c h no l o gy / m e t ho d t o be c o m-m on ly a cc ep te d an d us ed . L ac k of

g u id e li n es f o r s t re n gt h en i ng o f m a so n rys tr uc t ur es wi th F RP h av e f or b ee n r e-

s i s ti n g t h e u s e of t h e s e ma t e r ia l s o nmasonry structure s. The te chnical com-mitte e of ACI 440 is working on bringing

t he c od e f or u se o f t he se m at er ia ls . U nt ilt h en t h e u s e o f F R P c o mp o si t es ha v eto be made aware by publications and

journals.F RP c an b e e ff ec ti ve ly u se d i n s tr en -

g th en in g on t he w al l s i n f le xu re b ya p p l yi n g p r o cu r e d l a mi n a t es o r r o d sm ad e of F RP i n t he v er ti ca l di re ct io n

(Fig 1).

S h ea r S t re n gt h en i ng c a n b e d o ne b yusing FRP Composite s and applying in

horizontal dire ctions as shown in Fig 1.S e i sm i c s t r en g t h en i n g : A s s h o w n i n

f i g t h e b eh a vi o r o f M as o nr y s t ru c tu r es

i n t h e e ff e c t of s e i sm i c f o r c es .The actual cracks de v e lope d afte r

a n e a r th q u a ke i s sh o w n i n F i g 3.

F i g 1 . F l e x ur e a n d s h ea r s t r e ng t h en i n g o f t h e w a ll s

u s i n g F R P C o m p os i t e s

( b ) R o c ki n g a n d s e i sm i c f o rc e s a c ti n g o n t h e s t r u ct u r e .

( a ) B a si c M a s o n ar y C o m p o ne n t s

M asonar y Bu i l di ng Components

P l i nt h L e v el

L i ntel L evel

R o o f L e v el

X C r a c k i ng o f

M asonary

Bu ilding

Com ponents

( a ) T he C r a c k s d e v e lo p e d b y t h e s e i s mi c f o r c es

F i g 2 : T h e s e i s mi c b e h a v io r o f t h e s t r u ct u r e

The stre ngthening of the se compo-ne nts is done by applying cross lami-

n a t es s o t h a t t h ey c a n r e s is t t h e m ov e -

S a n t a M o n i c a , N o r t hr i d g e E a r t hq u a k e , 1 9 9 4

F i g 3 : C r a c ks d e v e l o p ed i n t h e e a r th q u a ke .


189www.masterbuilder.co.in Ÿ T h e M a s t er b u i l de r - July 2013



me nt and de v e lopme nt of the se cracksi n t h e d i re c ti o n p er p en d ic u la r t o t h ei r

application.ExamplesareshowninFig4.

C as e S tu dy 1 : Re tr of it ti ng o f a O ldB u n g al o w i n A l i ba g

I n A li ba g, a n o ld b un ga lo w w as i nb a d c o nd i t i o n a s p e r s t r u ct u r a l p oi n t o f

v i e w. I t b e l on g e d t o a k no w n b u s i ne s sm an i n s ou th M um ba i. B un ga lo w i s a

load-be aring structure and numbe r of

f l oo r i s G +1 . I t w as f o un d t ha t s om ehorizontal crack ne ar first floor be am.

To protect the structure from anyfurthe r cracking and harm a structuralconsultant was appointe d, and he col-

laborate d with R&M Inte rnational to e xe-c ut e t he w or k. I t w as d ec i de d t o b e d on e

w i th t h e h e lp o f g l as s a n d c a rb o n f i be rf r o m b o t h t h e f ac e o f t h e wa l l . T h e Bu n -g a lo w a n d cr a ck s ar e sh o wn i n F i g 5, 6

and 7.R & M I n t er n a t io n a l w as a p p oi n t e d

f o r t h e e xe c u t io n o f t h e w or k . I t w as s u c -

F i g 4 : D i a g o na l B r a ci n g o f w a l l f or s t r en g t h en i n g

F i g 5 : F r o n t V i e w o f t h e S t r u ct u r e.

F i g 6 : H o r i z o nt a l C r a c k o n t h e S t r uc t u r e.

F i g 7 : H o r i z o n ta l C r a c k in t h e wa l l

C a se S tu d y 2: R ep a ir a n d S tr e ng t he -n i ng o f Se t tl e me n t af fe c te d o l d s t ru c -t u re i n D e lh i .

T h e U S I n d i a Fo u n d at i o n i s l o c at e d

in Caunaght place, New Delhi. The

B u i l di n g u n d er c o n si d e r at i o n w a s b ui l ti n 1 9 2 8. T h e s t ru c t u re i s a l o a d b e ar i n g

brick masonry G+1 structure.Due to ongoing tunne ling be low the

structure cracks we re de v e lope d in thebrick walls and the cracks we re se e n inthe right hand side block of the struc-

ture . As the clie nt wante d the structureto be safe and stre ngthe ning me asure s

to be unde rtake n.The following obse rv ations we re

done for the cracks de v e lope d.

- T he c ra ck s w er e p re se nt i n t he ri gh t

h a n d s i de o f t h e s t ru c t u r e an d i n t h emiddle portion.

- Th e c rac ks were u ni form ly p res en t i nallwallsandcolumnsofthe structure .

- Tw o m aj or c ra ck s w er e p re se nt , w h ic hc o u l d be s e en t o h a ve a c l e ar p r e s-e nce throughout the wall.

- T h e c r ac k s w er e p r es en t a t th e f i rs tfloor as we ll as the ground floor.

As the cracks we re pre se nt all ov e rt h e w a l l s i n t h e r i g h t h a n d s i d e o f t h e

structure , it be come s important to take

F i g 8: a ) Ve r ti c a l Ap p li c at i o n o f C - F R P w r ap a n d

h o r i zo n t a l a p p l i ca t i o n o f G - F R P.

F i g 8 ( b) : T h e B a ck s i d e vi e w o f t h e s tr u c t ur e .

c e ss f ul l y c o mp l et e d i n 2 01 2 . T h e f ol -lowing was use d to strengthe n the wall.

a. Carbon FRP: F ir st C a rb on f ib er i s

a p p l ie d o ve r t h e st r u c t ur e . T h e o r i -e nt at io n o f t he c ar bo n f ib er s he et

w a s v e rt i c a l a s s h o wn i n F i g 8 a .b . G la ss F ib er : Afte r curing pe riod of

c a r b on f i b er s h e et , h o r i zo n t a l s h e et

i s a p pl i e d a s p e r t h e d r aw i n g ass h ow n i n F i g. 8 b.

The same procedure was used to

re trofit the structure from inside .





F i g 9 : M a j o r c r a c k d e v e l op e d o n t h e 1 s t f l o o r a s

s e e n f r o m o u ts i d e

F i g 1 0: C r a c k s p r e s en t a s se e n i n s i d e o n t h e

c o l u mn s a n d o n t h e t o p .

- T he c ol um ns h av e to be i ns ta ll ed

w it h f ib er w ra p w it h l am in at es w he ret h e p l a ne i s c h a n g i ng a s s h o w n i nfigure 7.

F i g 1 1: R e p o i nt i n g Me t h o do l o g y i n t h e j oi n t s .

References:

1 . I sl am M d. R ,, I nv en to ry o f F RP s tr en gt h-

e n in g m e t h od s i n m a s on r y s t r uc t ur e s ,

Masters Thesi s, Erasmus Mundus.

2 . M ot av al li M ., G ui de f or t he d es ig n a nd

c o ns t ru c ti o n o f e x te r na l ly b o nd e d F RP

s y s te m s f o r s t re n gt h en i ng e x i s -t i ng

s t r uc t ur e s , C N R- D T 2 0 0/ 2 00 4 , R o me ,

I t a l y, 2 0 0 4 .

3 . M ar uc ci o C. , n um er ic al a na ly si s of f rp

s t r e n gt h e n ed Ma s o n r y s t r u c tu r e s , P h D

T h e s i s, D e c e m be r 2 0 1 0 .

F i b er B a n d sS ch eme of Fi ber Tr eatment f or S tr ength eni ng w al l s

F i g 1 2 : W r a p pi n g d e t a i ls a l o n g t h e W a l l s w h ic h w e r e

a f f ec t e d b y c r a c k s.

F i g 1 3 : T h e d e ta i l s o f c o n f i ne m e n t o f c o l u mn s w i t h

F R P a n d L a mi n a t e s

F i g 1 4: ( a ) C o l um n W r a p pi n g d o ne f o r c o n f i n em e n t

and streng th ening (b) Wraps done over th e cracks

f o r a r r e st i n g t h e m .

c a r e of t h e c r ac k s a nd t o g i v e ex t r as t r en g t h s o a s t o r em o v e an y c o n c er n ,

w h i c h m i g h t a r i s e i n f u t u re a n d m a k esthe structure stable .

R e p a ir M e t h od o l o g y

The following we re the ste ps inv ol-

v e d i n r e p ai r i n g a n d s t r en g t h en i n g o f

the structure .

- A ll t he ar ea wh er e c ra ck s h av eappe are d had to be cle ane d and all

t h e p l as t er a n d o t he r s u pe r fi c ia l a n dprotectiv e mate rialssuch as the gyp-s u m , e t c h a d t o be r e mo v e d wh e r e

the cracks had be e n notice d.- T he ar ea wh er e c ra ck h ad p ro pa -

gate d ne e de d to be cle ane d and

e xp os ed p ro pe rl y w it h t he h el p o fsand pape rs and le ss impact tools.

- T he c rac k pr op aga ti on c an b e of

t w o ty p es . T h ey c a n e i th e r b e on t h ej o in t w h ic h i s t h e m o r e l i ke l y o n e , a n d

i t c a n a l s o b e t hr o u g h t h e b r i ck s .- T he cr ac ke d m or ta r h as to be re -

m o ve d b y m e an s o f a t o ot h in g c h is el

o r a sp e c i al p oi n t e r' s gr i n d er, t o auniform de pth that is twice the joint

w id th o r u nt il so un d m or ta r i s r e-a c he d . C a re m u st b e t ak en n o t tod a m a ge t h e b r i c k e d g es . R e m ov e

all dust and de bris from the joint byb r us h in g , b l ow i ng w i th a i r o r r i ns i ngwith wate r.

- R ef il li ng or r ep oi nt in g mo rt ar s ho ul db e c ar e f ul l y s e l ec t e d an d f or m u -

l a t e d. I t i s a l w ay s a d v is e d t o p r o-duce be st re sults to fill the m with

t h e o r i g i n a l m o r t a r i t s e lf . O t h e rw i s e,

a m i x o f 1 p a rt Po r t l an d c em e n t , 4parts hydrate d lime and 11¼ to 15

parts fine sand is use d to fill there mov e d mortar space .

- T he r ep oi nt in g m or ta r s ho ul d b e

pre hydrate d to re duce e xce ssiv es h r i nk a g e. T h e p r o pe r p r e h yd r a t io n

p r o c es s i s a s fo l l o ws : A l l d r y i n g r e-die nts should be thoroughly mixe d.O n ly e n ou g h c l ea n w a te r s h ou l d b e

a d d e d t o th e d r y m i x t o p r od u c e ad a mp c o ns i st e nc y w h ic h w i ll r et a ini t s s h a pe w h e n f o r me d i n t o a b a ll .

The mortar should be mixe d to thisd am pe ne d c on di ti on 1 t o 1 ½ b ef or e

a dd in g w at er f or p la ce me nt . T hejoints to be re pointe d should bed a m p en e d , b u t t o e n su r e a g o od

b o n d, t h e b r i ck w or k m u s t a bs o r ball surface wate r be fore re pointing

m o rt a r i s p l ac e d. W at e r s h ou l d b eadde d to the pre -hydrate d mortarto bring it to a workable consiste ncy

( s o me w h at d r ie r t h a n c o n ve n t i on a lm o r ta r ) . T h e m o r ta r s h o ul d be pa -c k e d t ig h t l y i n t o t he j o i nt s i n t h i n l a y -

e rs (6.4 mm maximum), as showni n F i gu r e 5c . T h e jo i nt s sh o ul d b e

t o o l ed t o m a t c h t h e o r i g in a l p r o f il eafter the last layer of mortar is“ t hu m bp r in t ” h a rd , a s i n F i gu r e 5d .

As it may be difficult to de te rminew h i c h j o i n ts a l l o w m o i st u r e t o p e n e -t r at e , i t i s a d vi s ab l e t o r e po i nt a l l m or-

tar joints in the affe cte d wall are a.- Fo r c rac ks hai rl in e i n t he b ri cks . I f

t h e b ri c k s ar e ve r y m u c h d a m a ge di t c an b e r em ov ed a nd r ep la ce d o ne

a t a t im e . A s m al l p ar t o f t h e br i ckcould also be use d and re place d by

using the re pointing mix as de s-

cribe d abov e .- T he w ho le r ep ai re d su rf ac e wi l l be

t h en a p pl i ed w i th c a rb o n f i be r w r apa s p e r t h e F ig 6 . T h e f ul l d r aw i n g i se nclose d with the re port.

Fro nt Vie w

F i b e r W r a p A l l a r o u ndt he co lumn

Laminat e s t oco nfine t he

F i b e r W r a p

5 0 mm Gro o ve dinsid e fro mb e l o w a n d t o p

D e t ai l s o f W r a p pi n g a tC o l um n s a t U S I EF

c ) P a c k P o i nt i n g M o r t a r i n T h in L a ye r s

d ) To o l J o in t t o M a t chOrigin al Profil e

a ) D e t e r io r a t e dM o r t a r J o in t

b ) M o r ta r C ut b ac k to Un iform Depth





F R P C o m po s i t es


e c en t d e ve l op m en t s i n t h e fi e ld o f f i be r r e in f or c edc o m po s i t es h a v e r e s ul t e d i n t h e d e v el o p m en t o f

h i g h l y e f f i ci e n t c o n s tr u c t io n m a t er i a l s. N o w d a y s t h eRuse of fibe r re inforce d polyme r (FRP) composite s in civ il e ngi-

n e e ri n g a p p l i c at i o n s i s g a i n i n g h i g h i m p o rt a n c e. I n - si t u F R Pw a r p s y s te m h as w i de a c ce p t an c e an d n ow d a y s i t h a sbe come the common me thod of stre ngthe ning and/or re pair

of RCC structures. Taking into conside rations the limitationso f t h e i n- s it u F R P w r ap p in g , i t h a s b ee n c o ns t an t e n de av orb y S S S P L t o d ev e l op t h e i n n o va t i v e s y s te m in F R P c o m po s -

i te s it se lf . A s a p ar t of s uc h c on si st en t ef fo rt s, r ec en tl yS S S P L h a v e s u c c es s f ul l y d e l i ve r e d a p r o j e c t f o r s t r en g t h en -i n g of R C C s i lo s tr u ct u re a t Da l la , I n di a , u s in g sp e ci a ll y

d e s ig n e d p r e- f a br i c a t ed F R P s t i f fe n e rs . T h e b a si c p r o bl e mw i t h t h e RC C si l o st r u c t ur e wa s i ts f a ul t y c o n st r u c ti o n a n d

he nce , it had comple te ly lost the v e rticality. This re sulte d intoe c c en t r i c l o a di n g u n d er i t s o w n w e i gh t . A n d c o ns i d e ri n g t h ep r e ss u r e i mp o s ed b y t h e c on t e n t ul t i m a te l y r e s ul t e d i n to

undue moments at the diffe re nt le ve ls of the RCC wall of thes i l o s t r u ct u r e. T h e re f o re , i n o r d er t o i mp r o ve t h e l o a d c a r r y-

i n g c a pa c it y o f t h e s t ru c tu r e, s p ec i al l y d e si g ne d F R P p r e-f a b ri c a t ed s t i f fe n e rs w e r e us e d . T h e m ai n a d v an t a g es o fusing FRP pre -fabricate d stiffe ne rs are e xcelle nt quality and

e a se o f i n s t al l a t i on a t s i t eT h e r e p ai r o f t h e s t r u c tu r e s w i t h c o n ve n t i on a l m a t e r ia l s i s

o f t en d i f f ic u l t , e x p en s i v e, h a z ar d o us an d d i s r up t i v e t o t h e

ope rations of the e xisting structure s. The re mov al and trans-p o r ta t i o n o f l a r g e am o u n ts o f c o n c re t e a n d m as o n ry m a t er i -

a l s c a u s es c o n c e n t ra t i o ns o f w e i gh t , d u s t , e x c es s i ve n o i s e ,

and re quire s long pe riods of time to gain stre ngth be fore thes t ru c tu r e c a n b e r e -o p en e d f o r s er v ic e . O n t h e c o nt r ar y,

FRP, though originally de v e lope d for the ae rospace industry,a r e b e i n g c o n si d e r ed f or a p p l i ca t i o n t o th e st r e ng t h e n-i n g/ r ep a ir o f s t ru c tu r es . I t 's m a in l y d u e t o t h ei r l o w w ei g ht ,

e a se o f h a n d l in g a n d r ap i d i m p le m en t a t i on . A m a j or d e v el -opme nt e ffort is unde rway to adapt the se mate rials to the

s t re n gt h en i ng / re p ai r o f b u il d in g s a n d c i vi l st r uc t ur es . Appropriate configurations of fibe r and polyme r matrix hav eto be de v e lope d to re sist the comple x and multidire ctional

s t r es s f i el d s p r es e n t i n s t r u ct u r a l me m b er s . A t t h e s am et i m e, t h e l a r g e v o l um e s o f m a t er i a l r e q ui r e d f o r s t r uc t u r alstre ngthe ning/re pair and the low cost of the traditional build-

i n g m a t e ri a l s c r e at e a m a n d a t e f o r e c o no m y i n t h e s e l ec t i o n

of FRP mate rials for structural stre ngthe ning/repairs.I n s t r uc t u r al s t re n g th e n i ng / r ep a i r s a p p l ic a t i on s , i n - s it u

F R P w r a p s y s te m ha s no w d a y s g a i n ed w id e ac c e p ta n c e.

H o w ev e r, i t ' s b e i n g m o r e l a bo r o r i en t e d p r o ce s s ; t h e q u a l i tyo f t h e w o r k h i g h l y d e p en d s o n t h e s k i l l s e t o f t h e w o r km e n ,e nv ironme ntal conditions and e ase of acce ss at site . The par-

t i c u l ar s i l o s tr u c t u re i s l o c at e d a t v er y r e m ot e p l a ce i n N o r t hI n d i a. I t ' s di f f i c ul t t o w or k w i t h t h e p o ly m e r m a t r ix s y s te m a t

s u ch a l o w t e mp e ra t ur e en v ir o nm en t . A n d ac c es s t o th es t r u ct u r e w a s a l s o a n i s s ue . T h e re f o re , i t wa s d e c i de d t o

R ec en t A dv an ce s i n S tr uc tu ra l R et ro fi tt i ngU si ng P re cu re d FR P P ro fi l e

F i g u re 1 : M i s a l ig n m e nt i n t h e v e r t ic a l w a l l o f t h e s i l o s t r uc t u r e

D r. M a n g es h J o s h iM D, S a n r a ch n a , I n d i a



Jo int Jac ket in GR P

V e r t ic a l G R P S t i ff e n e r s

C i c u m fe r e n ti a l G R P s t i f fe n e r s

d e s ig n a n d d e v el o p t h e p r e - fa b r i ca t e d F R P s t r en g t h en i n gs ys t em , w h ic h c a n e as i ly b e i ns t al l ed a t s it e b y w ay o f a d he -siv e bonding as we ll as me chanical faste ning syste m with

the e xisting RCC structure . Since it's a pre -fabricate d syste mproduce d in the control e nv ironme nt at factory, the quality of

s u ch s y st e m i s m uc h b e tt e r t h an i n -s i tu s ys t em . B ei n g sp e -c i a l m o d ul a r d e s ig n , t h e m a s s p ro d u c ti o n w a s f e as i b l e w it hl i m i t ed n um b e rs of m o u l ds , w h i c h r e s ul t e d i n t o s i g n if i c a nt

p r o du c t c o st s a v in g . Tr a n sp o r ta t i o n a n d i n st a l l at i o n a t s i t ew a s v e r y e a s y d u e t o m od u l a r d e s ig n a n d li g h t- i n - w ei g h t o fthose stiffeners.

D e s ig n a n d A n a l ys i s

Proje ct: Stre ngthe ning of RCC silo structure - K5 Project,

a) FE M odel from level of 19. 373m to

6 8 m . E c c e n tr i c i t y i s mo d e l e d

b a s e d o n t h e i n p ut d a t a

b) FE Model sh owing FRP stif f ening

a r r a ng e m e nt . F o r c l a r i ty , i n t h e p r e s en t

v i e w o n l y p a r t i al s t i f f en e r s a r e s ho w n

f r o m e le v a t i on o f 1 9 . 3 73 m t o 3 7 m.

Su ch stif f ening arrang ement will be

p r ov i de d u p t o e l ev a ti o n o f 6 8 mF i g u re 2 : F E m o d el

S i z e o f t h e R C C s i l o s tr u c t ur e : 1 8 0 00 m m I D , t o t al e l e v a ti o n =68000 mm

The structure was out of the alignme nt throughout theh e i g ht a s p e r t h e i n i t i al s u r v e y r e p o r t a s s h o wn i n f i g u re - 1

D u e t o su c h l o s s o f v e r ti c a l al i g n m en t i n t h e ba s ic RCC

structure , the additional forces/mome nts impose d onto thestructure were calculated considering P- Δ analysis

F i g u r e 3 : S c h e ma t i c a r r a ng e m e nt o f F R P s t i f f en e r s

18.00 m

30.00 m

5 4 .0 0 m

60.00 m

V e rt i c a l F R P S t i ff n e r @1 0 0 0 m m c / c d i s t an c e

V e rt i c a l F RP S t i ff n e r @2 0 0 0 m m c / c d i s t an c e

V e rt i c a l F R P S t i f fn e r

@ 4 0 0 0 mm c / c

Horizontal FRPStiffe ne rs @2000mm spacing

Horizontal FRPStiffe ne rs @4 0 0 0 mm spacing

Horizontal FRPStiffe ne rs @6 0 0 0 mm spacing

F i g ur e 4 : Ty p i c a l s e c ti o n a l d e t a il s o f F R P s t i f fe n e r s

Fig u re 5: Typical inter-stif f ener joint details

x xN

Y

U.P. Cement Pr ojects (D.C.F.)P l u m b C h e c k i n g o f B l e n d in g S i l o ( K - 5 )

D u r i n g O p e r a t i o n o f S l ip F o r m

Date:-

KEY PLAN

Legent:-T = TopB = B ot t o m

Cross-Section of

F R P S t if f ne r

40 mm 60 mm 40 mm

50 mm

50 mm3 m m n o m i na lthicknes s

195www.masterbuilder.co.in · T h e M a s t e rb u i l de r - July 2013




ConstructionChemicals&Waterproofing

T o k no w m or e o n t he p ro du ct s , s ol ut io ns a nd s er vi ce s o ff er ed b y t he l ea di ng b ra nd s f ea tu re d a bo ve w r it e t o: [email protected]

A m i t T r ad i n g C o r p o r a t i onG l o b al e x p e rt s f o r d r a in a g esystem s

B A S F T h e C h e m i c al C o m p a n y3 0 B r a nd s B e c om e O n e : M a st e rBui l ders Sol uti ons

C e r a - C h em P r i v a te L t d .W h at e ve r y o u c h oo s e f r om o u r P la t te ri s H e at h y f o r y o ur B o dy, M in d &Busi ness

C i c o T e c hn o l o g i es L t d .T h e p r i d e t h a t i s I n d i a, r e s to r e d w i t hCico

Contech ChemicalsAcryl i c-Based El astom eri c WaterproofC o a t in g f o r R o o f & W a ll

F o s ro c C h e mi c al s ( I n di a ) P v t . L t d .Yo u w i l l s e e F o s ro c i n e v e r y i n f r as t r u ct u r eo r h i gh r is e b u il d in g p r oj e ct s

M a x C i v i C h em P v t . L td .Yo u w i l l s e e F o s ro c i n e v e ry i n f r as t r u ct u r eo r h i gh r i se b u il d in g p r oj e ct s

M C - B a u c he m i e ( I n d i a) P v t . L t d .C o n c re t e A d d it i v e B a s ed O n P o z zo l a n icA l u mi n o s il i c at e F o r H i g h P e r f or m a nc eConcrete

Multichem GroupU n iq u e s a fe l o ng t e rm p r ot e ct i onw i t h m u l ti c h em r a n g e o f pr o d u ct s

N u h a C o n s t r uc t i o n S o l u t i o nsSynkoFl ex the Dependabl ewaterstop

P e n e t r on I n d i a P v t . L t d .Advanci ng precast concreteprotecti on

C h e m b o n d Ch e m i c a ls L t d .F o r c o m pl e t e w a t e rp r o o fi n g s o l ut i o n s

Refer Page No.: 105 Ref er Page No.: 51 Refer Page No.: 63

Refer Page No.: 71 Ref er Page No.: 289 Refer Page No.: 85 Refer Page No.: 59

Refer Page No.: 59 Ref er Page No.: Flap Refer Page No.: 289 Refer Page No.: 91

R e fe r P a ge N o .: B a ck I n ne r

R

F i gu r e 6 : F EA R es u lt s : S t re ss e s i n F RP S t if f en e rs ( M ax i mu m s t re ss = 3 M Pa < a l lo w ab l e

s t re n gt h o f F RP a s p er E UR OC OM P D e si g n C o de ) _ S af e

In orde r to counteract those additional force s/moments,

FRP stiffe ning syste m was de signed conside ring the spe cialgeometrical form and reinforcements using glass fiber-e poxy syste m.

Owing to the comple x nature of the proble m and solutionsyste m, the structural analyses we re carrie d out using finite

e l e me n t t e c hn i q u es . F i g u re 2 b e l o w s h o ws F E M o d e l c o n -side re d in the analyses

Conclusion

As pe r the structural analyse s, the maximum stre sse sinduce d in the fibe r-reinforce d composite stiffe ne rs we re we ll

w i t h in t h e a l l ow a b l e l im i t . T h e a l l ow a b le l i m i t s w er e d e t er -m i ne d b as ed o n t h e s a fe t y f a ct o rs c a lc u la t ed a s pe r

E U R OC O M P D e si g n C o d e a n d H a n d b o o k1 . A c t u al l a m i n at et e s t re s u l ts 2 w er e o bt a i n ed d u r i ng d e si g n s t a g e i t s e lf t ode te rmine the me chanical prope rtie s (te nsile stre ngth and

m o d ul u s ) o f t h e l a mi n a t e. A n d h e nc e , t h e d es i g n w a s ba s e do n t h e r e a l is t i c m a t er i a l p r o p er t i e s. T h e p r o j ec t wa s c o m -p l e t ed i n S e p te m b er 2 0 11 w i th i n a c t u al e x ec u t i on t i m e s p a n

o f e i gh t we ek s . A n d s i nc e t he n t h e s y st e m h a s b e en s u c-ce ssfully pe rforming unde r se rv ice conditions.

Acknowledgements

We acknowle dge the e ntire te am of SSSPL inv olv e d in theproce ss of de sign, de v e lopment and installation this innov a-

tiv e FRP stre ngthe ning syste m.

References

- J oh n L . C la rk e, “ St ru ct ur al D es ig n o f P ol ym er C om po si t es -E U RO C OM P D es i gn C o de a n d H a nd b oo k ”, C h ap m ana n d H a l l, L o n do n , 1 9 96

- M ec ha ni ca l t es t re po rt s on F RP l am in at es- I np ut d at a l ik e s ur ve y r ep or ts , 2 D d ra wi ng s, e tc p ro vi de d

b y c l i e nt







.N.Engite ch De v e lope rs is one ofthe le ading solution prov ide rs for

i m p r ov e m en t / p r o te c t i on / r e p ai rSo f c o n c re t e s t r u ct u r es in t h e c o u n tr y.

T h e c o mp a ny p r ov i de s c o mp r eh e ns i vesolutions to the construction industry ind i ve r se a re a s. T h es e i nc l ud e , w at e r-

p r o of i n g s y s te m , r e p ai r / r eh a b i li t a t i on ,strengthening structures, expansion joints ys t em s, r eb a r f i xi n g, Tr i mi x f l oo r in g ,

core cutting and prote ctiv e coating.S . N . En g i t ec h h a s b e e n a s s oc i a t e d

with se v e ral landmark Civ il Engine e ringp r o je c t s a r ou n d I n d ia . I t s w i d e ar r a y o fproject expertise include hydro power,

industrial buildings, corporate house s,r e a l e s t at e , f a c t or y b u i l d in g s , f o o d p r o -ce ssing units, roads & runways, e tc. With

a t e am s t re n gt h o f o v er 4 0 , t h e c o mp a nyhas its corporate and re giste re d office

l o c a te d i n F a ri d a b ad a n d a b r an c ho f f ic e i n N e w D e l h i. T h e t e a m p r o vi d e si m me d ia t e a n d r e sp o ns i ve p r od u ct a n d

s a le s s u pp o rt v i a e m ai l , p h on e a n d V oI Pto customers around the country.

T h e c o mp a ny h a s b u il t u p c h er i sh e d

long-te rm rapport with se v e ral globallyr e n ow n e d n a me s . S o m e o f t h e t o p p l a y -

e r s w i t h w h o m S . N . En g i t ec h h a s pa r t -ne re d include , Se al Boss Corporation,U SA , B AS F In di a Li mi te d, C hr ys o,

G er m an y, a n d v ar i ou s o t he r n a ti o na la n d i n te r na t io n al l y w el l k n o wn p r in c i-ple s. The company is the sole technical

p a rt n e r, d i st r i bu t o rs a n d a p pr o ve d

a p p l ic a t o rs f or t h e en t i r e r a n g e o f t h e

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Factors Affecting the Selection,

Economics Involved in Formwork

Formwork is a die or a mould, including all supporting structures,

used to shape and support fresh concrete until it attains

sufficient strength to carry its own weight. It should be capable

of carrying all imposed dead and live loads apart from its own

weight.

A formwork system is defined as “the total system of support

for freshly placed concrete including the mould or sheathing

Sameer S. MalvankarDy. Manager - Engineering,

Gammon India Ltd.

Formwork

Appropriate selection of a formwork system is a crucial factor in successfully completing most building projects. However, in practice,

selection of an appropriate formwork system has traditionally depended mainly on the intuitive and subjective opinion of practitioners with

limited experience. This paper, discusses the guidelines on how to choose formwork, factors affecting the selection, economics involved in

formwork and the present scenario of formwork in India. This article can assist engineers to determine the appropriate formwork system at

the inception of future projects.

which contacts the concrete as well as supporting members,

hardware and necessary bracing”. However, “System” implies

a fully compatible arrangement of formwork with a minimum of

individual components with reusable elements intended to solve

each forming task thereby rationalizing the forming work.

Formwork system is among the key factors determining the

success of a construction project in terms of speed, quality,




A large proportion of the cost of formwork is related to formwork

labour cost. Significant cost savings could be achieved by

reducing labour cost. An exemplary comparison reveals that

the additional concrete use of up to 15% is economical than

the handling of angular forming areas, since their assembly is

rather time-consuming and the cost per square meter is higherthan that for a straight surface.

B) An Integrated Formwork/concrete Life Cycle

The process of providing formwork and concrete is highly

integrated. In the figure 2, the left circle represents the

formwork life cycle, while the right circle represents the

concrete construction life cycle. The two intersection points

represent the beginning and the end of concrete construction

life cycle. It should be noted that the phases ‘cure concrete’

and ‘stripping of formwork’ are interchangeable depending on

the type of structural element. For example, columns and walls

are cured after stripping the forms while slabs and beams are

cured before and then stripped.

C) Economy of Formwork and Significance

1. Economy in design of a concrete structure

The architect or design engineer can also contribute much to

reduce formwork cost by keeping the requirements of formwork

economy in mind when one is designing the structure. At the

time of design, consideration of the materials, methods that

will be required to make, erect and remove the formwork. Avoid

varying sizes in columns and beams; Usage of same sizes

to the possible extent economizes the design permitting the

reuse of formwork without alteration.

2. Economy in design, planning and building formwork

In designing, planning and building formwork, the contractor

should aim for maximum economy without sacrificing quality

and safety. Short cuts in design or construction th at endanger

quality or safety may be false economy. For example, if forms

do not produce the specific surface finish, much hand rubbing

of the concrete may be required; if forms deflect excessively,

bulges in the concrete may require expensive rectification

measures.

cost and safety of works. Nowadays, most projects are required

by the client to complete in the shortest time possible as a

means to minimise costs. For high-rise buildings, the most

effective way to speed up works is to achieve a very short floor

cycle — to have the structure of a typical floor completed inthe shortest time. On the other hand, aiming purely at speed

often contradicts the achievement of other quality standards.

Problems such as misalignment, misplacement, deflective

concrete or holding up other works causing serious interruption

can result.

The basic parameters of formwork are:

- Quality: in terms of strength, rigidity, position, and dimensions of

the forms

- Safety: of both workers and the concrete structure

- Efficiency: in operation, the ease of handling, erection and

dismantling, number of repetitions within the optimal limits- Economy: the least cost, consistent with quality and safety

A) share of Formwork Cost

In a typical multi-storey reinforced concrete building, formwork

cost is the largest cost component. Formwork cost accounts

for nearly 20-40% of cost of concrete and involves more than 60%

cost of time. Overall formwork related cost have significant

share ie.10% in the total construction cost.

Figure 3 - Categories of formwork classificationFigure 2 - Integrated formwork/concrete lifecycle

Figure 1 – Main cost type in a typical building project

Formwork




- Limit the size of formwork panels or systems to largest

possible that can be handled at site.

- Standardize formwork making, erection and stripping to

maximum possible extent

- Minimise the amount of components and accessories like

nut, bolts, nails etc. to avoid risk of losing- Create a material cost awareness cost of material con-

sciousness in the personnel

- Control reuse and repetitions. Specially plywood and timber

- Standardize various formwork systems

coordination and cooperation between engineers, contractors

are necessary to achieve the goals. Saving depends on

inventiveness and knowledge of the contractor. Judgment

in the selection of the materials and equipment, in planning,

fabrication and erection procedures, and in scheduling reuse

of formwork, will expedite the job and cut costs.

D) Various Formwork Systems

Formwork can be classified according to a variety of categories

as follows: (Refer Figure - 3)

Classification according to sizes

- Small-sized formwork

- Operation by workers manually Wooden and aluminium

formwork

- Large-sized formwork

- Crane facilities are required in the operation Reduce the

number of joints and to minimize the number of lift Stiffening

components -studs and soldier

Classification according to location of use

Various elements in the structure have specific design and

performance requirements in the use of formwork. Some systems

are more adaptive for specific location of use, such as

- Irregular frame structure – Conventional traditional timber form.

- Wall, Column – Girder form, Frame panel form, climb form

or jump form

- Slab – Conventional timber form, Modular slab formwork,

primary-and-secondary beam method, Panel form, Drop

head beam- panel system, table form

- Repeated regular section – tunnel form, modular aluminium

form

- Core walls, shells- Climbing formwork, Jump form and slip-form

- Precast structure- steel /aluminium mould forms

Classification according to materials of construction

- Timber: most popular formwork material -low initial cost

-high adaptability to complicated shape-labour intensive

and environmental unfriendly

- steel: hot-rolled or cold-formed sections heavy weight -

suitable for large-sized panels

Figure 4 - Parties involved in formwork selection process

- Aluminium: stiff and light weight-higher material and labour

cost-excellent finish

- Plastic: recyclable, tough, lighter weight

- Sacrificial concrete panels- Left in place formwork

Classification according to nature of operation- Crane independent- Manually handled formwork -Self-

climbing formwork

- Crane-dependent formwork

- Gantry, traveling and tunnel type formwork system

E) Evaluation / Selection Criteria for Formwork System

Earlier formwork was once built in-place, used once, and

subsequently wrecked. The trend today, however, is towards

increasing prefabrication, assembly in large units, erection by

mechanical means, and repetitive use of forms. These de-

velopments are in tune with the increasing mechanisation of

production in construction sites and other fields.

Formwork planning includes detailed layouts, cycle plans,

calculation of optimum amount of material for the site, observance

of fixed schedules and selection of the most appropriate and the

most economic formwork system to be used at the construction site.

Different Parties involved in formwork selection

The proper selection of the formwork systems to be used in

concrete structure is concern to all involved parties.

The following selection criteria have to be considered:

1) Geometry of building / structureInternal layout

Some buildings may have very simple layouts with few i n-situ

walls and floor plates framed with regularly spaced columns,

as seen in many commercial and office buildings. However,

some developments feature very complicated load bearing

internal walls that can make the casting process difficult.

Structural forms

Like internal layout, the structural form of buildings also affects

the formwork options. For example, buildings with a structural

core in the form of a vertical shaft limit the use of other formwork

Formwork




systems other than those of a self-climbing nature. Buildings

in flat slab design make table forms or flying forms the most

obvious choice. For buildings with regularly arranged shear

wall designs, the best selection is large-panel type steel forms

or other types of gang forms.

Consistency in building dimensions

Some buildings may have non-standardised dimensions

due to the architectural design and layout or to fulfill other

structural requirements. These include the reduction of sizes

for beams, columns and walls in high-rise buildings as the

structure ascends. Formwork systems like the climb-form or

steel form, may be quite difficult to use in such situations, due

to the frequent adjustments of the form to meet the changes in

dimensions may eventually incur extra cost and time.

Headroom

Higher headroom increases the amount (height) of staging

required and can also create accessibility and safety problems.

It can also make the erection of formwork, ensuring formwork

stability and the placing of concrete more difficult.

Building span

Large building spans also create problems similar to those with

high headroom situations. In addition, long-span structures

generally have larger beam sections, heavier reinforcement

provisions, or accompany post-tension works. This will further

complicate the formwork’s design and erection process.

Repetitive nature

High-rise block-shaped structures usually require highlyrepetitive cycles and this is favourable to the use of formwork.

However, the degree of repetition in building with very large

construction area like a podium or underground structures

such as basements is limited and the use of formwork, as an

expensive resource, becomes very critical.

2) Project Planning/speed of work

The over-all construction sequence must be planned to use

formwork in efficient manner and to permit the optimum

investment in formwork to meet schedule requirements.

Contractor should plan formwork and job sequence at the

time of making a bid. Project planning such as the phasing orsectioning arrangement, integration of the structure, site layout

and set-up arrangements or hoisting provisions and concrete

placing facilities are influencing factors when considering

formwork selection and application.

When working with buildings with large construction areas

and horizontal spread, projects can be expedited by the

introduction of additional sets of formwork, to create more

independent work fronts. This will, of course, increase the cost

of construction. For high-rise buildings, increasing the number

of formwork used cannot always expedite the project, for the

critical path still depends on the floor cycle. However, a properly

selected, designed and arranged formwork system will increase

work efficacy for each typical cycle. In some cases, adding

half or a full set of formwork, especially for the floor forms, may

help to speed up the cycle as the additional set can provide

more flexibility when the form is struck at an earlier time.

3) Construction process, methods

For selecting formwork one must know the sequence of con-

struction activities and methods to be followed. Construction

method will always give idea about inter dependency of the

activities, specifications and additional requirements in pour.

This will enable us to workout appropriate system which fulfils

the construction needs.

4) Site logistics

Exceptionally small or very large sites sloped or very crowded

sites, proximity to sensitive structures, sites where other major

activities are underway, or sites with many physical or con-

tractual restrictions will increase the difficulty of working withformwork. There is no specific solution to improve the situation

in general and problems are tackled according to individual

circumstances.

Accessibility to work during the course of construction,

accessibility problems may be created through segregation,

temporary discontinuation, or blocking of the layout by the

partially completed building or, in cases constructing a shaft-

type core wall is constructed in an advanced phase, the shaft

may stand independently for a long period of time before it

is connected to the horizontal elements. Proper access to

all components should be considered while planning a site

layout.

5) Climate condition

Formwork systems are sensitive to weather conditions. Typically, in

vertical forming systems, the newly placed concrete is supported

by the wall already cast below it. The lower wall section must

get the sufficient strength to support the fresh concrete above.

The rate of strength gain of lower wall is influenced by the

ambient temperature, moisture content, and the freezing and

thawing cycles.

Another factor that affects the economy of the selected system

is the effect of stopping formwork activity and concretingbecause of extreme weather conditions. In the case of a slip-

form, the work is usually continuous, 24hrs around the clock.

If the slip-form stops because of weather conditions, it may

impact structure as well as cost.

6) Labour efficiency

Considering the availability and qualification of the work force,

improving labour cost efficiency is a major factor, especially in

markets experiencing a building boom. Here, the qualification

of workers tends to be low in relation to ever higher demands

posed by construction methods.

Formwork




7) Cost of formwork system

This is a vital factor for deciding formwork system as one must

know the capital provision for formwork in the project. It is

always beneficial to work out these details at the time of bid.

Cost is influenced by three components;

Initial cost or make-up cost:

Includes cost of transportation, materials, assembly and erection.

Reuse cost of formwork system:

The formwork system cost goes on reducing as we increase

reuse of same. The re-use for traditional timber formwork is

usually limited due to the durability of the plywood sheathing.

The optimum number of uses for timber form usually ranges

from 12 to 14. Thus, it is still sufficiently economical to use timber

formwork for high-rise buildings at heights in accordance to the

multiple of the usual re-used times. Although the metal form

can be re-used many times, the high initial cost of providingthe form often discourages its selection, especially when there

is no need to reuse them too many times, for example in a

low-rise development. A careful balance between cost, speed,

performance and the quality of output should be properly con-

sidered when making the selection.

8) Maintenance & storage cost:

It includes cost of stripping, repair, storage, etc. Formwork

materials are a valuable asset of company, If proper care is

taken during handling and storage, much return is obtained

on the investment. Formwork needs to be handled correctly,

maintained, repaired if necessary and finally, cleaned regularly. Avoiding damage reduces costs incurred. Proper storage of

formwork materials gives easy reconciliation, faster retrieval of

material, better space management and avoid unnecessary

expenditures, improve safety at work place.

9) Availability of lifting devices (Crane time)

Many factors should be considered before employment of a

construction plan and the selection of the right formwork system.

These include considerations of whether there will be lifting

appliances provided for the erection of formwork; whether these

appliances will be able to access the work spot to assist in the

operation as the structural works proceed; whether any specialequipment will be required for striking the forms; and how the

removed formwork panels can be transported to other spot to

continue work.

Characteristic to high rise building sites is the confined and

congested space availability for working. Crane time and space

is regularly limited. In general, reinforcing (rebar) activities are

most critical, since lifting the reinforcement to building level is the

most crane- time consuming job of all. Thus, the capability of

formwork to rely less on or be used independently of crane time

is critical in high rise construction.

10) Simple logic of the system

Formwork system ought to be self-explanatory to use, this

automatically eases the usage for the engineers/supervisor and

also the labour who are end users of the system.

11) Working safety

Formwork should be self-securing with safe access and working

platforms. Thus, it is not left to the end user whether they takes

safety measures or not. Creating a safe work environment for

the entire work force involved in the construction process, has

become the pivotal issue in emerging construction markets.

12) Special requirements on Concrete surface/finish

Fair-faced concrete demands very high quality formwork in terms

of surface treatment of the panels, tightness of the formwork

joints and in dimensional accuracy. Requirements are slightly

relaxed where the concrete surface is to be finished at a later

stage.

13) Area or volume of cast per pour

The optimum volume of cast per pour depends on the types

of formwork used, the particular elements of structure to be

placed, the actual scale of work, and different levels of provisions

of plant facilities. Usually a volume of concrete ranging from 60-

200 cubic meters per pour can be comfortably handled in mostFigure 5 - Factors affecting selection of formwork system

Formwork




site environments. It also depends on whether the concrete to

be placed is for the vertical elements only or also includes the

beams and slabs, as a means of saving an additional phase

in the overall work cycle.

14) Involvement of other construction techniques

Tensioning and prefabrication activities are often involved in

construction. This may create certain impacts on the use of formwork,

especially where precast elements are to be incorporated

during the casting process. Provision should be made for

temporary supports or slot spaces and box out positions in

the formwork for the precast elements, or extra working space

for placing stressing tendons and onward jacking.

15) Provision of construction joints in structures

Many a times a large number of construction joints are inevitable

in a large structure because of the subdivision of works into

effectively workable sizes. The provision of construction joints

can challenge the output and affect the quality of the concrete.

Careful selection should be made to ensure a particular

formwork system can satisfactorily allow such arrangements.

16) Inventory- The fewer, the better

The most frequent time & cost consuming activity of formwork

assembly is the loose and small components/accessories.

The lesser inventories will help to reduce risk of losing parts

and provide ease in construction.

F) The Current Situation in India

In the past, India had been lagging behind over the other

advanced countries in applying advanced and safe conceptsfor formwork in reinforced concrete construction resulting in

a poor surface quality, wastage and low productivity of the

people involved in concrete construction. This unfortunate

situation continued for a long time because of availability and use

of very cheap unskilled labour and very few skilled personnel

who have had professional training for formwork jobs.

With increasing demand and competition and reducing project

completion times, there have been significant developments in

the construction industry in terms of experience and mastering

of the required managerial, construction or engineering skills

for handling very large and complex projects. At the same

time, the motivating factors highlighted above have createdan eagerness and readiness within the industry to advance.

From the building construction point of view, the use of better

formwork systems is no doubt a very direct way for introducing

innovative methods in the construction of buildings.

- Formwork labour cost is so immense that any innovative

system resulting in a labour cost reduction is highly lucrative.

- Fulfillment of fast track construction schedule provides

fewer choices, one of which is to adopt more innovative

formwork systems.

- Traditional systems can hardly satisfy the tight quality

standard that is required nowadays.

- Similarly, traditional systems can hardly satisfy current

safety and environmental standards.

- The accumulation of experienced crews makes the

application of more sophisticated formwork systems more

reliable and economical.

- Many developers view the application of innovative technologyin the construction process as a positive image-building factor.

G) Major Systems Dominate Today’s State of Art Formwork

Approach in High Rise Construction

- Slab edge protection by screens, providing a safe working

environment on the construction levels

- Modular slab formwork, operated independently of the

crane time, adapted flexibly to different building geometries

and floor layouts

- Undisturbed shoring for slab with drop beam systems

- Frame formwork for columns and walls

- Crane dependent climbing formwork for shear walls/mega

columns- Crane independent climbing formwork for core

H) The Potential and Limiting Factors of Innovative Technologies

in the Built Environment of India Potentials

- The public’s expectation (government, developers, building

users) are rising all the time.

- More stringent regulations have been imposed to control

the performance of the construction industries.

- Accidents are costly, especially where human casualties

are involved (both for the reasons of compensation, image

and government records).

- The development or importing of advanced technologyhave become more common and market affordable.

- The industry is gradually accepting the production of

higher performance buildings involving a more expensive

resource input.

Limitations

- Insufficient research and development in most contracting

firms or other supporting units.

- Lack of working space on construction sites (both on-site

and off-site work areas).

- Training opportunity (including on-the-job training) is still

limited for both the professionals and other workers.- No guarantee of a consistent market environment for

the development and continual application of innovative

technology in construction (learned skill and experience

will lose eventually).

- The extensive use of cross wall design especially in most

residential buildings and small-scaled projects makes the

use of more innovative formwork system less feasible.

- The exceptionally large scale and complex nature of projects

in terms of the site condition as well as structural and

building design confine the application of more advanced

and sophisticated formwork system.

Formwork




I) The Industry or Individual Corporations May Consider

for the Following Measures:

- Explore ways to streamline and re-engineer the work

structure at both industrial and corporate levels.

- Invest steadily in the human resources development andto train competent and high quality staff with the required

attitude and readiness to work in the new environment.

- Invest steadily in the research and development of

technologies that are particularly suitable for the built

environment of India

- Strengthen the linkages among government departments,

developers, consultants and contractor firms in the promotion,

development, cooperation and implementation of more

innovative projects.

- Government or other institutions may consider providing

funding to support research and development for the

exploration, recommendation or setting up of guidelinesand standards in the application of newer technology and

work systems in construction.

Conclusion

1. Selection of formwork system, is highly dependent on

individual site/project environment

2. Economy of formwork can be achieved with seamless

collaboration between owner, architect, designer teams

and contractor. And it can aid in the effective use of advance

formwork systems

3. The structural form of the building is one of the critical factors

to determine the choice of formwork

4. System products can contribute much in the success of

formwork application

Indian

IS 14687-1999 Falsework for concrete structure guidelines

IRC 87-1984 Guidelines for the design and erection of falsework for road

bridges

IS 2750-1964

(1995)

Specification for steel scaffoldings

International

ACI 347-04 Guide to formwork for concrete

ACI 347.2 R-05 Guide for shoring / reshoring of concrete multi-storybuildings

ACI SP-4 Formwork for concrete

BS 5975-2008 British standard code for practice for temporary worksprocedures and the permissible stress design of falsework

DIN 4420 & 4421 German standard for formworkDIN 18218 Pressure of fresh concrete on vertical formwork

CIRIA Report 108 Concrete pressure on formwork

Formwork Standards

References

1. ACI 347_04, “Guide to formwork for concrete”, Americanconcrete institute, 2005

2. Hanna A. S. & Sanvido V.E. , “ An interactive knowledge basedon formwork selection system for building”, Computer integratedconstruction, 1989

3. Hurd M. K. “Formwork for concrete”, American concrete institute,1915, 6th edition

4. Raymond W. W. M. , “Application of formwork for high rise andcomplex building structures-Hongkong cases”, Division ofbuilding science & technology, city university of Hongkong.

Formwork





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hav e e nte red the fray, the re are only fe wplaye rs who hav e be e n able to carv e a

n i ch e o f t h ei r o w n. T h e c u st o me r t o da ywants formwork systems that are easyt o u se , a ff or da bl e, a nd s co re h ig h w he n

i t c o m es t o s a f et y a n d q u al i t y. A n a m ethat imme diate ly come s to mind whe ny ou t hi nk a bo ut a ll t he se f ac to rs i s M ai ni

C on s tr u ct i on E q ui p me n ts . I t i s t h e n a met o wa t ch o u t f or i n t h e I n di a n f o rm w or k

industry.What make s Maini stand out from

the crowd is its commitme nt to quality,

s af e ty a n d s u st a in a bi l i ty. T h is I S O 9 0 01 -2008 ce rtifie d company, offe rs a widerange of aluminum formwork systems.

What se ts its se rv ice s apart is the com-p l e t e i n v o lv e m en t o f t h e t ea m i n e v e ry

s t a ge o f a p ro j e c t. R i g h t f r o m d e s ig n -i n g , t o t h e a c t u al er e c t io n , M a i n i p r o -v ide s comple te support with re gard to

formwork and scaffolding syste ms. Itsrangeof steel scaffoldingincludes cuploks y s te m s, p r o ps , s p a ns , m e t ri f o r m, w a l l

form and customize d syste ms.

A N a m e t o W at c h O u t F o r

A ke y asse t to Maini is a v astly e xpe -

r i e nc e d t op m a n ag e m en t t e am , w h i c h

f i r ml y b e l i ev e s i n u s i n g th e l a t es t t e c h-n o l og y, w h e n i t c o me s t o m an u f a ct u r -i ng , a nd c o ns ta nt u p gr ad at i on o f t he

s am e at r eg ul ar i nt er va ls o f t im e. I tss t a te - o f- t h e -a r t p r o d u c t i on f a c i l it i e s i nF a ri d a b ad , N C R a n d R u dr a p u r, U t t a ra -

k h a nd , a r e m a n n ed b y s o me o f t h e fi n -e s t t a l en t s i n t h e i n d us t r y. P e rh a p s t h e

b es t t es ti mo ni al fo r M ai ni is in i tsr e m ar k a b le gr o w th s t o ry, i n a r el a t i ve l ys h o rt s p a n o f t i m e . T h e e ve n t f ul j o u r n ey

s t a r te d i n 1 9 86 w h e n M a i n i S c af f o l di n gCompany was incorporate d. It was e ar-l i e r a d e al e r. B y 1 9 9 6, i t h a d e n t er e d t he

m a i n st r e am a n d m a d e de e p i n r o ad si n to t h e I nd i an m a rk e t. T h e co m pa n y

s t ar t ed a l um i nu m f o rm w or k i n 2 00 8 a n di s t o d a y c o n si d e r ed a p i o n ee r, w h i c ho f fe r s e n d- t o- e nd s o lu t io n s i n t h is h i gh l y

c o mp e ti t iv e i n du s tr y. T h e f a ct t h at i n j u stabout fiv e ye ars of time Maini has cre -a t e d s u ch a b r a n d r ec a l l s p ea k s v o l-

ume s about its commitme nt to supe riorquality and e xce llent te chnical support

s e rv i ce s. To d ay i t i s c o ns i de r ed t h e o n lyIndian company to manufacture all type sof syste m formworkunde r one umbrella.

B la zi ng a N ew Tr ai l i n F or mw or k S ys te ms





E co no mi ca l a nd E nv ir on me nt al S us -tainability

A pe nchant for be ing innov ativ eand unique has be e n the driv ing force

o f t h e c o mp a n y. A g o o d ex a m p le o f i t i sa v a il a b l e i n i t s u t i l i za t i o n o f s p e ci a l i ze dd e s ig n s o f tw a r e. M a i ni i s c o n s i d er e d a

trendse tte r with its 'Maini Software ', whichp r o vi d e s a 3 D p l a t fo r m fo r f a s t, p r o fe s -

sional planning of formwork and scaf-folding systems. From a simple base-me nt to a complicate d industrial build-

i n g , f r o m wa l l & s l a b fo r m wo r k t o p l a t -f o rm s ys t em s a n d s c af f ol d i ng - t h e m o stdiv e rse proble ms can be solv ed using

the software .

S u s ta i n a bi l i t y i s t h e b u z z wo r d i n t h e

c o ns t ru c ti o n i n du s tr y t h es e da y s, a n d

t h i s i s a no t h er a r e a wh e r e Ma i n i h a s

f o c us e d . I t s p an e l s ar e m a de o f 1 0 0 %

re cyclable aluminum. The se pane ls are

re cyclable unde r normal industrial pro-

c e s s. T h e se p a ne l s c an b e u se d b y u n -

s k i l le d w o r ke r s , s o t y p i ca l o f t h e I n d ia n

m a r ke t , w i t h ou t d i m e ns i o n s o r q u a l i ty

g e t t in g a f fe c t e d. I n c o m pa r i s on t o c on -

v e n ti o n a l w oo d e n f o r mw o r k, t h e se a r e

r e u sa b l e f o r m o r e t h a n 2 5 0 t i m e s a n d

are e nv ironmental-frie ndly. It sav e s the

s i t e fr o m wa s t ef u l i t em s , w h i l e a l s o

ke e ping the e nv ironme nt cle an for work-e rs. It also he lps to organize the ope ra-

t i o n l i n e u p m o r e e f f ic i e n tl y t o p r o du c e

e conomical construction. This e nsure s

b o t h e c o no m i c al a n d e n v ir o n me n t al

sustainability.

E x c e ll e n t t e c h ni c a l b a c k- u p s u p -port is anothe r are a whe re Maini is a

frontrunne r. Expe rie nce d Maini supe r-v isors are sent to site to train the supe r-v i s or y s t a f f a n d l ab o u r i n t h e p r o pe r h a n -

dling of the e quipment and to assist in

ge tting starte d, to establish the desire d

work cycle . This improv e d coordinationand construction manage me nt e nable s

the e quipme nt to be cycle d at optimum

spe e d and e nsure s that the re sults int e r m s o f s y s te m ef f i c i en c y a n d sp e e do f o u t p ut a r e o u t s ta n d i ng . N o wo n d er

Maini formwork systems have beenp a r t o f s e ve r a l k e y i n f r as t r u ct u r e p r o -

j e ct s , i n cl u di n g, b r id g es a t K ar n al t o Ambala Highway for NHAI, Allahabad-N a i n i B r i dg e , M u m ba i - P u ne E x p r e s s-

w a y, D e l hi M e t r o, D e l h i A ir p o rt , K o lk a t a Airport, e tc, to me ntion only a fe w.


M a i n i C o n s t ru c t i o nEquipments Pvt. Ltd.Ph: + 9 1 - 1 1 -4 9 6 8 6 80 0 ,

Em ail: info@m c epl.c omWeb: w w w.m ainiform work.c om





ConstructionChemicals&Waterproofing

Flooring


P e r m a C o n s t r u ct i o n

A i d s P v t . L td .C o mp l et e S o lu t io n f o r t h eConstructi on Industry

P i di l i te I n du s t ri e s L t d.W h a t ev e r t h e r o o f , w e ' llwaterproof i t.

PolyflexM o d if i e d h y b r id a c r yl i cpol ym er

S i k a I n di a P v t. L td .S i ka a d ds v a lu e t o y o ur c o nc r et e

B e k a e r t I n d u s t ri e s P v t . L t d .D r a mi x ® s t e e l f i b r es - L e a d e rs i nr e i n fo r c in g t u n n el s s i n ce 1 9 8 5 *

C i p y P o l y u r et h a n e s P v . L t d .S o l ut i o n s f o r y o u r c o a t in g n e e d s

I r o ni t e C o . o f I n di a L t d.To u g h f l o o rs . F o r a s m o ot h e r l i f e .

J B A s s oc i a te sB ri n gi n g l if e t o c o nc r et e

T h e S u pr e m e I n d us t ri e sT h e m o s t c o m pr e s si b l e f i l le r b o a r d f o rE x p an s i o n j o i n ts

T ra d e W i n dsH o u s e o f C o n st r u c ti o n C h e mi c a ls

R a z o n E n g i n ee r i n g C o m p a ny P v t . L t d .F o r c o m pl e t e w a t e rp r o o fi n g s o l ut i o n s

Refer Page No.: 279 Ref er Page No.: 6 Refer Page No.: 31

R ef er P ag e N o. : 9 7

Refer Page No.: 29 Ref er Page No.: 79 Refer Page No.: 191 Ref er Page No.: 183

Ref er Page No.: 45 Refer Page No.: 283

R e fe r P a ge N o .: 1 0 1

better together

harp Enginee rs, (Prop. M/s. SharpDe signe rs & Engine e rs India Pvt.Ltd.) offe rs worldclass productsS

and se rv ices in proje cts and e ngine e r-

ing solutions like acoustics e nclosure s,c o r e d ry i n g o ve n s , s t a i nl e s s s te e l &glass fit-outs/finishe s and aluminum

formwork syste ms. The company e sta-blishe d in 1987 has its state-of-the -art

manufacturing facility locate d in Chakan

n e a r P u n e . T h e pl a n t i s e qu i p p ed w i thm o d er n m a c h in e r y s u c h a s C N C t u r r etp u n c he s , C N C p re s s br a k es , l a s er c u t -t i n g m a c hi n e s , p a i n t i n g & p o w de r c o a t -

ing plants as we ll as NC controlle dshe aring facilitie s.

Sharp Engine e rs has e xtensiv e e x-p e r i en c e i n t h e f i el d o f g l a ss a n d s t a in -le ss ste e l inte riors. The company's abil-

i t y t o u nd e r st a n d e v e ry c l i e nt ' s u ni q u er e q ui r e m en t s a n d c o m e u p w i t h s t u n -n i n g d es i g n s, w h i l e al s o b e in g c o s t-

e ffe ctiv e has made it a pre fe rre d choicet o da y. A p ar t f r om i n t er i or s, t h e c om -

pany also cre ates customized de signsf o r s p i r al s ta i r c a s es , c a n op y, w a l l / c e i l-i n g c l a dd i n g , r a m ps , b r i d ge s , e t c .

S ha rp E ng in ee rs ' e as y t o u se a nde c o no m i c al l y v i a bl e a l um i n u m f o r m-work syste ms conforming to the late st

DIN18218 standards are aimed ata c h i ev i n g f a s te r f o r mi n g , d e - sh u t t er i n gandre ducing concre ting cycle time s,a p a r t f r o m g u a ra n t e ed s u p e r i or f i n i sh

a n d n e ar t o ta l s a vi n g o f p l as t er i ng w or k ,the re by making it a cost e ffe ctiv e solu-

t i on . H i gh l e ve l o f a c cu r ac y i s e ns u re df o r e v er y c l i e nt , r i g h t f r o m d e s ig n i n g t oo n s it e e r ec t i o n o f f o r mw o r k s y s te m s,

a n a pp ro ac h w hi ch h as be en b eh in dthe company's success story.

To p N o t ch E n gi n ee r in g S o l ut i on s

F o r f u rt h e r d e ta i ls :S h a r p E n g i ne e r sGat NO. 3 0 1 /2 , Nanekarw adi (CHAKAN)

Ta l . K h e d, D i s t. P u n e - 4 10 5 01 ,Ph: + 9 1 - 2 1 35 - 3 2 0 60 1

E- m ail: m arketing @sharp eng .c omWeb: w w w.sharp eng .com

CONCRETE SOLUTIONS

B rin gin g Life To Con cret e



216 ·T h e M a s t e rb u i l de r - July 2013 www.masterbuilder.co.in

C e l l ul a r C o n cr e t e

Bhavani Balakrishna

C EL LU LA R C ON CR ET E: An Alternative for Sustainable Design & Construction

o n c r e te i s o n e o f t h e m o s t w i -

d e ly u s e d c o n s t ru c ti o n m a te -Cr i a l s i n t h e wo r l d . T h e p ro d u c -

t i o n o f c o nc r et e , n o ta b ly i t 's mo s t i m -

p o rt an t i ng re di en t, c e me nt , p os es

s e ve r al s u st a in a bi l it y i s s ue s t h at n e ed

t o b e m a n a ge d . S i g n i fi c a n t a m o u nt s

o f c o al a r e us e d in t h e ki l ns t o m a ke

c li nk er, w hi ch i s t he m a jo r c om po -

n e nt i n c e me n t. E l ec t ri c it y i s ne e de d

t o r u n t h e m a ch i ne r y f o r g r in d in g a n d

b l e n d in g i n o r d e r t o m ak e t h e c l i n ke r

a n d t he n t o p r oc e ss i t w i t h o th er m a-

t er ia ls i nt o c em en t. T he w ho le p r o d u c -

t i o n p r o c e ss e m i t s l a rg e a m o u nt s o f

greenhouse gas (GHG) emissionsa n d t h e q u ar r yi n g o f r a w m a t e ri a ls p r o-

d u c e s lo c a l i mp a c t s su c h a s n o i se

and dust.

Because of limited natural resour-

c es , c on ce rn o ve r G HG s, i t i s n ec e-

s sa ry t o l oo k f or s us t ai na bl e s ol ut io ns

f o r f u t u r e c o n c r et e c o n s t ru c t i o n. T h e

f u tu r e vi a bi l it y o f t h e c on c re t e c om -

m u ni t y w i ll b e d e t e rm i ne d b y i t s r e s-

p o ns e t o t he g l ob a l is s ue o f s u s -

t ai na bi li ty. N ew r es ea rc h a nd t e ch -

n o lo g y, a nd t he r ap id d ev el op me nt o f

t he g re en b u i l d in g m o v em e n t c le a r l y

p o i n t o u t th a t c h an g e i n c u r r e nt l i f e

s t y l e s a r e e s s en t i a l i f w e a r e t o m a i n -

t ai n a nd im pr ov e o ur w ay o f l if e. O ne

o f t h e s e c h a ng e s i n c l u de s t h e u s e o f

materials that will extend the service

l i f e o f c o n c r et e a n d a d d i ti o n a l ly m a k e

c o n c r et e a c o n t r i bu t o r t o t h e m o r e

e ff ic ie nt u se o f e ne rg y a nd r aw m a-

terials.

A sustainable concrete structure

s ho ul d h av e a v er y l ow i nh er en t e ne rg y

r e qu i re m en t , b e p ro d u ce d w i th l i tt l e

w a s t e , p r o d u ce d u ra b l e s t r u c tu r e s ,

h a v e a v e ry h i g h t h e r m al m as s w hi l el e ad i ng to lo w er c a rb o n e m is s io n s.

O n e s u ch a l te r na t iv e t h at c o me s c l os e

t o t h e ab o v e d es c r i p ti o n i s c e l lu l a r

concrete.

C el lu la r c on cr et e, a ls o k n ow n b y

m an y o t he r n am es s uc h a s ae ra te d

c o n c r et e , a i r- c u r e d l i g ht w e i gh t c o n -

c r et e , a u to c l av e d c e l lu l ar c o nc r et e ,

cellular light weight concrete and cel-

l u la r l i gh t -w e ig h t, i s e n gi n ee r ed , l o w-

d e ns i ty c o nc r et e w i th v e rs a ti l e f e a-

t u re s t ha t c an s o l ve s e ve r al c o n-

s t r u c ti o n , m i n i ng , a n d m a n u f ac t u r i ng

challenges.

C e l l u la r c o n c r et e i s m o r e d u r a b l e

w h e n c o m p a re d t o t r a d i ti o n a l i n s u l a-

t i ng m a te r ia l s, e s pe c ia l ly w h en c o n-

s i d e r in g p o t e n t ia l c h e m i c al / f i r e e x-

p o su r e s u ch a s i n p r oc e ss f a c i li t ie s .

Compressive strengths are typically

g r ea t er t h an f o ur t i me s t h at of p l as t ic

f o a m . I t a l s o h a s f ir e p r o of i n g , i n s u l a-

t i on , s o u nd at t en u at i on a n d e n er g y

absorbing characteristics.

What i s Cel l ul ar Concrete?

C e l l u la r c o n c r et e i s a l i g h t we i g h tc o n s t ru c t i o n m a t e r ia l c o n s i s ti n g o f

Portland cement, water, foaming agent,

and compressed air. The foam is for-

m u la t ed t o p r ov i de s t ab i li t y a n d i n hi b it

draining (bleeding) of water. Pozzolans,

s u ch a s f l y a s h, a n d f i be r s a r e o f te n

added to the mix to customize com-

p r e s s iv e a n d f l e x u ra l s t r e n g th s . C e l -

l u la r c o nc r et e t y pi c al l y c o nt a in s n o

sand or aggregate. By trap- ping air

b u bb l es w i t h in t h e c o nc r et e , a l i g ht -



C e l l ul a r C o n cr e t e

217www.masterbuilder.co.in · T h e M a s t er b u i l de r - J u ly 2 0 13

s he d ce ll ul ar c on cr et e, t hi s in t ur n

a f f e ct s s u c h p r o p e rt i e s as c o m p re -

ssive strength; shrink during setup and

c u r e , u n i f or m a g g r e g at e d i s p e r s i on ,

pumping stability, practical lift thick-

n e s s , a n d c o m p a ti b i l i ty w i t h a d m i xt u -r e s. A s th e de n si t y o f a l l l i gh t- w e ig h t

c o n c r et e i s r e d u c e d , i t b e c o m e s e v e r

more difficult to maintain the properties

noted above and the foaming agent

a n d f o a m g e n er a t i o n e q u i p me n t b e -

come increasingly important.

T he m ix d e si gn c ho s en f or t he p ro -

d u ct i on o f c e ll u la r c o nc r et e c a n h a ve

a g r e a t e f fe c t o n t h e p r o p e rt i e s a f t e r

c u r i n g as w e l l a s t h e ab i l i t y t o p l a c e

t h e m at er ia l. I n g e ne ra l, i f t he a pp li -

c a ti o n i s ge o te c hn i ca l or o t he r t y pe s

offill,themixdesigncanbequitesimple

and is not too difficult to develop.

H ow ev er, a s s o on a s t he re i s a ny s tr uc -

t u ra l e l em e nt r e qu i re m en t i n tr o d uc e d,

t h en m i x d es i gn c a n b e co m e c r it i ca l .

T h er e i s n ot a s in gl e “ be st ” m ix d es i gn

f o r p r od u ct i on o f c e ll u la r c o nc r et e a n d

t h e f i n a l d e s ig n i s a l s o d e p e n de n t o n

local materials, batching techniques,

foam mixing and placement methods.

Benefi ts of Cell ul ar Concrete

C e ll u la r c o nc r et e p r ov i de s u pe r io r

p e r f o rm a n c e, m o r e e f f i c i e n t c o n s t r u -

c t io n , a n d re d uc e d co s t wh e n c o m-

p a r e d t o a l t e r n a t i ve c o n s t r u c t i on a n d

manufacturing technologies because

o f i t s f o l l o w i n g p r o p er t i e s .

H ig h S tr en gt h/ Lo w D en si ty /L ig ht -

weight

Typical cast densities range from

2 5 t o 5 5 p er c ub ic fo ot , wi th c om -

p r e s s iv e s t r en g t h s o f 4 0 t o 7 5 0 p si ,

r e sp e ct i ve l y. W i t h i t s l o w d e ns i ty, c e l-

l u l a r c o n c r et e i m p o s e s l i t t l e v e r- t i c a l

s t r e s s o n t h e s u bs t r u c tu r e , a p a r ti c u -

l a rl y i m po r ta n t i ss u e i n a r ea s s e ns i -

t i v e to s e t tl e m e n t. D u e t o i t s l ow d e n -s i t y, c e l l u la r c o n c r et e i s a v i a b l e s o l u -

t i on f o r r e d u c in g l o ad i ng o n b u r- d e ne d

s o i l . A d d i t io n a l l y, c e l l u la r c o n - c re t e i s

less susceptible to differential settle-

m e n t . H e a v i e r d e n s i t y c e l l u l a r c o n -

c r e t e w it h h i g h er s t r e n gt h s i s p ro -

d uc ed a nd u s e d f or s pe ci al ty a pp li -

cations.

H i g h F l u id i t y

H i gh a i r c o nt e nt m a ke s i t e a sy t o

pump materials long distances at low

p r e s s u re s . T h e m a te r i a l is n a t u ra l l y

self-leveling and fills the smallest

v o i ds , c a vi t ie s , a n d s e am s . W h en p l a-

c i n g i n e x c a va t i o n s c e l l u l ar c o n c r et e

c o n fo r ms t o e v er y s u b g r a d e c o nt o u r.

R ap id I ns ta ll at io n a nd M in im al S it e

Disruption

High volume production and place-

m e n t ( v ia h o s e ) o f c e l l u la r c o n c r e te i s

a c o nt in uo us o pe ra ti on f ro m a m ob il ec e nt r al p la n t o n l o c at i o n. S i nc e th e

f oa m i s t he l ar ge st v ol um e c on tr ib ut or

i n c e l l u la r c o n c r et e , l i m i t ed d e l i v er i e s

o f t h e ra w m a te r ia l s a r e r e qu i re d , r e -

s u lt i ng in m i ni m al di s ru p ti o n t o t h e

c o n s t ru c t i o n s i t e .

W h e n u s e d as p a v e me n t u n de r-

l a y m e nt a nd r e ch a r g e b e d in p e r-

m e a b le p a v e m en t a p p l i c a t io n s , p e r-

v i ou s c e l l ul a r l i gh t we i gh t c o n c re t e

c a n r e d u c e th e a m o u nt o f e x c a va t i o n

r eq ui re d b y a s m uc h a s 5 0 %, m in i-

weight, insulating material is formed.

T he re a re t hr ee w ay s o f m ak in g t he

a i r a n d t h e v o id s n e e d e d f or a c e l l u la r

c o n c r et e . M a n y c o m p a ni e s s e l l r i c h ,

thick, long lasting foam that is added

t o c e m e n t s l ur r y. T h i s f o a m i s m ad eb y u s i n g s p e c i al fo a m g e n e r at o r s . A

s ec on d wa y t o ma ke c el lu la r c on -

crete is to use Expanded Polystrene

( EP S) fo r t he v oi ds . A t hi rd w ay t o

m a k e th e a i r b u b b l es n e e d ed f o r c e l -

l u l a r c o n c r et e i s t o u s e a n a l u m i -n u m

p o w d e r . T h e a l u m i n u m p o w d e r

r ea ct s wi th t he w at er i n t he m ix t ha t

c r ea t es ti n y h y dr o ge n b u bb l es t h at

cre ates the air void s. Water and

cement are mixed to form slurry.

T he n f oa m, E PS b ea ds , o r a lu mi nu mp o wd e r i s t h en i n tr o du c ed in t o t h e

m i x. F oa m i s t he m os t c om mo n a ge nt

u se d fo r t h e a ir b u b b le s . A n d i t i s a l so

the least expensive.

T h e r e a r e t w o p r i ma r y m e t h o ds o f

a d di n g t h e e x te r na l ly g e ne r at e d f o am

t o a s l u r r y m i x t o p r od u c e c e l lu l a r c o n -

c r e t e . T h e f i r s t i s t o a d d t h e f oa m t o a

b at ch m ix , s uc h a s a d ru m m ix er t ru ck

o r a s t at io na ry m ix er s uc h a s u se d i n

p re ca st p la nt s or o n- si te f or l ar ge

j o b s . T h e s e c o nd i s t o a d d t h e fo a m

“ i n - l in e ” t o a pi p e - l in e c a rr y i n g t h e

s l u rr y m i x o r i n to t he h op p e r o f a c on -

t i nu o u s m i xe r s u ch a s u s ed on v o lu -

m e t r i c t r u c k m i x e rs .

Concrete foaming agents used

f or t he p r od uc ti on o f t he e x te rn al ly

generated foam fall into two main cat-

e g o ri e s: T h e f i rs t i s p r o te i n b a se d ,

w h ic h u s ua l ly m e an s a n i ma l b y - pr o -

d u c ts . I n r e ce n t y e ar s , m o re f o a m in g

a g en t s a r e s y nt h et i c b a se d m a te r ia l s.Blended foam liquid concentrates

( bl en ds of p ro te in a nd sy nt he ti c i n-

g r e d i en t s ) w e r e i n t r o du c e d la t e r t o

t e c h n ic i a n s a dd i t i o na l t o o l s fo r p r o -

p o r t i o ni n g c e l l u l a r c o n c r et e m i x t u r e s

t o m e e t d e ma n d i n g pr o j e c t or p ro -

d uc t p er fo rm an ce r eq ui re me nt s. T h e

a d di t iv e c h em i ca l s a n d s t ru c tu r e u s ed

f o r t h e f o a m in g ag e n t c a n a f f e ct th e

bubble size, fo am life , and general

“ t ou g hn e ss ” o f t h e f o am . F o r t h e f i ni -

W etDens ity

3( kg /m )

400

450

500

550

600

2 8 - D a y C o m p r es s i v eS trength

(MPa)

0.71

0.84

1.14

1.51

1.98

ThermalC onductivity

(W /m/K)

0.075

0.080

0.086

0.092

0.97

R Valueper Inch

O 2( F ft h r/ Bt u)

2.0

1.8

1.7

1.6

1.5




t i cu l ar, c o nt r ac t or s a n d e n gi n ee r s

f re qu en tl y u se c el lu la r l ig ht we ig ht

concrete provide shock absorption in

earthquake zones.

W he n u se d i n r oo f d e ck , f lo o ri ng ,

i n- si tu a ff or da bl e h o u si ng , c as t- i n-p la ce w al ls , f lo o rs , o r r o of s, o r b l oc k

o r p r ef a br i ca t ed e l e me n t a pp l ic a -

tions, cellular concrete provides proven

d e fo r ma t io n r e si s ta n ce pr o pe r ti e s

a n d a n a b il i ty t o a b so r b l o ad s a n d

c r u s h i n a c o n tr o l l e d m a n n er. C e l l u la r

concrete is also fire resistant.

Recyclable

C e l l u la r c o n c r et e i s i n e r t a n d c a n

b e s a fe l y r e mo v ed a n d r e us e d. O n e

g re en u se o f r ec yc le d c e ll ul ar c o n-c r e t e i s a s a g g r eg a t e i n v e g e t at e d

r o o f c o n s t r uc t i o n ( g r e e n r o o f t op s ) .

Recycl ed Content

C e l l u la r c o n c r et e c a n i n c o r po r a t e

g r ou n d g r an u la t ed b l as t -f u rn a ce s l ag

or fly ash in the slurry or grout mix

d es ig n w it ho u t a dv er se ly a ff ec ti ng

c e ll u la r c o nc r et e p e rf o rm a nc e . T h e

u s e of t h es e p os t- i n du s tr i al b y p r o-

ducts eliminates the need to landfill

the materials and reduces the need

f o r v i rg i n m a te r ia l s i n c e ll u la r c o nc r et e

p r od u ct i on a n d t he e n v i ro n me n ta l

i m p a ct s f r o m t h e e x t r a ct i o n a n d p r o -

c e s s i ng o f t h e s e v i r gi n m a t e r ia l s .

R e du c e d C a r bo n F o o tp r i nt

C e l l u la r c o n c r e te i s p r o d uc e d o n

s i te i n m o st c o n s tr u ct i on a n d m a nu -

f a c t ur i n g a p p l i ca t i o n o r a t a p r e - c as t

f ac il it y w it hi n 2 0 0 m il es of t he co n-

s tr uc ti on s it e. L oc al p r od uc ti on r e-d u ce s s h ip p in g d i st a nc e s f o r b u il d in g

materials, minimizing fuel req uire-

ments for transportation and handling,

a n d as s o c i a te d e n e rg y a n d c ar b o n

dioxide emissions.

O n- s it e p ro d uc ti on o f c el lu la r c on -

crete in geotechnical applications re-

d u ce s a p r oj e ct ' s c a rb o n f o ot p ri n t s i g-

nificantly. Projects with volumes excee-

d i n g 1 0 , 0 0 0 c u b i c y a r d s o f g e o t e c h-

n ic al f il l u se a n o n- s it e b at ch p la nt t ha t

m i z i ng s it e d is r u p t io n , s a v i ng t im e

a n d m on e y, a n d r ed u c i n g t h e p r o-

j e c t ' s c a r b o n f o o t p ri n t .

More Fl exi bil i ty for Speci fic Construc-

ti on Chal l engesC e l l u la r c o n c r e te c an b e co n s t r u-

cted into various formations and pro-

f i le s . I t c an b e pr o du c ed a s a n on -

p e r m e ab l e o r a p e r m ea b l e m at e r i a l

c a p a bl e o f r e d u c in g l o a d s w i t h o ut

d i st u rb i ng o r r e -d i re c ti n g n a tu r al w a te r

f l ow. I t a l so f o r ms a r i g id , w e ll - bo n -

d ed b od y a ft er h yd ra ti ng ; t hu s, i t is

e f fe c ti v el y a f r ee s t an d in g s t ru c tu r e o n

i t s o w n a n d d o e s no t i m p o se l a t e r al

l o a d s o n a d j a ce n t s t r u c t u r es .

Pervi ous to Water

C e ll u la r c o nc r et e i s o p t i ma l f o r

applications where drainage is need-

e d . I t i s c a pa b le o f r e du c in g l o ad s

w i t h o ut d i s r u p ti n g o r r e d i r ec t i n g t h e

n a t u ra l f l o w o f w a t e r.

Reduced Sound Transmi ssi on

W he n u se d i n r oo f d ec k, f lo or in g,

c a st - in - pl a ce w a ll s , f l oo r s o r r o of s ,

b l o c k o r p e r- f a b r ic a t e d e l e m e nt s , f i r

o r p ar ti ti on w al l a pp li ca ti on s, o r a s

c a vi t y f i ll f o r v e hi c le s , t h e vo i d st r uc -

t u r e o f c e l l u la r c o n c r e te re d u c e s t h e

p a s s ag e o f s o u n d .

Thermal Insul ati on

C e l l u la r c o n c r et e p ro v i d e s g o o d

i n s u l at i n g q u a l it i e s . I t i s t h e r m a l l y e f f i -

c i e n t an d i s a n u n m o v in g i n s u la t i o n

m a t e ri a l w hi c h m a i n ta i n s lo n g t e rm

i n- pl ac e s t ab il it y f or a v a ri et y o f c on -

s t r u c ti o n a n d i n d u s t r i al a p p l i ca t i o n s.

C el lu la r c o nc re t e m ix es h ar de n t o

p r ov i de a m at e ri a l wi t h p r ov e n h i gh

temperature resistant characteristics

w h i c h p e r m i t i t t o b e u se d a s a f ir e

resistant material.

Provi desShock & Energy Absorption

U s ed b e ne a th r o ad w ay s , b r id g es ,

a nd r am ps , b ui ld in gs a nd o t he r s tr uc -

t u r e s , i t r e du c e s so i l l o ad i n g wh i l e

a d d i n g c o m p r e s s i v e a n d s h e a r

s t r e ng t h . A s c e l l ul a r c o n c r e te i s c o m -

p r e s s ed d u r i n g i m p a ct , r e s i s ta n c e

i n cr e as e s an d ki n et i c e n er g y i s ab -

s o rb e d. I n A m er i ca a n d Ja p an i n p a r-

C e l lu l a r C o n c re t e

H i g h a i r c o n t e n t m a k e s i t e a s y t o p u mp m a t e ri a l s l o n g d i s t an c e s a t lo w p r e s su r e s




produces and pumps cementitiouss l ur r y, w i th t r uc k in g n e ed e d o n ly f o r

t h e d e l i v e ry o f c e m e n t.

C e l lu l a r C o n cr e t e i n J o b si t e s

I t i s i mp o rt an t t o p ro c ur e a nd p la ce

cellular concrete from contractors who

h a v e e x t e n si v e e x p e r i en c e i n c e l l u la r

c o n c r et e i n s t a l l at i o n . Ty p i c a l e q u i p-

m en t u s ed f o r p ro du ct io n o f c el lu la r

c o n c r et e i n j o b s i t e s a r e f o am g e n e -

r a to r s m a de s p e c if i ca l ly f o r j o b s i te .

C o n t r ac t o r s a l s o w o r k w i t h p r o j e ct

engineers to ensure the wet density

o f t h e m at e r i al p r o d uc e d a t th e j o b

s i t e is w i th i n a s pe c i f i ed r a ng e o f t h e

d e si g ne d w e t- d en s it y p r oj e ct m i x a n d

meets project strength requirements.

C e l l u la r c o n c r et e i s m o s t t y p i c a ll y

p l a c e d by p u m p i ng . O w i n g t o it s h i g h

fluidity, cellular concrete is not affected

b y l o ng p um p r un s. T h ey h av e b ee n

s u cc e ss f ul l y p u mp e d b ey o nd 5 0 0

f e e t v e r ti c a l l y a n d 5 0 0 0 f e e t h o r iz o n -t al ly. C el lu la r c on cr et e c an a ls o b e

p lac ed b y o th er m et ho ds s uc h a s

bucket cranes, ready-mix truck chute

p l a c em e n t , w h e e l ba r r o w p l a c em e n t ,

a n d e v e n h a n d p l ac e m e n t f ro m c a r -

ried buckets.

Installation and finishing methods

d if fe r f or e ac h t yp e o f c e ll ul ar c on cr et e

applications. As most cellular concrete

i s c o ve re d b y a no th er m at er ia l, i t i s n ot

s ur fa ce f in is he d l ik e a t yp ic al c o nc r et e

logicandeconomicresultingcosts dur-

i n g t h e p h as e o f u t i l i za t i o n , a n d g u a r-

antees longterm building and living

q u a l i ty. C e l l u l ar c o n c r et e h a s a p r ac -

t ic al ly u nl im it e d se r vi c e li f e. D u e to

t h e e x t r e m e l y l o w t h e r m a l c o n -ductivity of up to l = 0 .0 6 W/ (m K),

c e ll u la r c o n c r et e i s a s u i t ab l e b u i l-

d in g m at er ia l f or u s e i n e ne rg y- s av in g

building projects.

C e l l u la r c o n c r et e d o e s n ' t c o n ta i n

a n y t o xi c s u bs t an c es o r r e le a se a n y.

T h i s a pp l i e s t o bo t h t h e p r o ce s s i n g

a nd t he e nt ir e l if e c yc le o f c el lu la r c o n-

c re te . E ve n i n t he ev en t o f a f ir e, n o

harmful gases are released.

T h e o u ts t an d in g b a la n ce o f s o u rc er e du c ti o n, e n er g y e f fi c ie n cy, l o w e m -

b od ie d e ne rg y, a bs en ce o f t o xi ns a nd

ozonedepletingsubstances,andnoise

r e du c ti o n m a ke c e ll u la r l i gh t we i gh t

c o n c r et e t h e u l t i m a t e g r ee n b u i l d in g

material.

Chal l enges & Future Outl ook

D e s p i te i t s v e r s a ti l i t y, c e l l u l ar c o n -

c r e t e h a s la g g e d i n p o p u l ar i t y d u e t o

a g e n er a l l ac k o f a w a r en e s s ab o u t

t h e b e n e fi t s o f t h i s c o n s t ru c t i o n m a -

t e r i al i n t h e c o n s t ru c t i o n c o m m u ni t y.

Again, while there are design specifi-

c a t i o ns a n d p r o t o co l s f o r t r a d i ti o n a l

m a te r ia l s, t h er e a r e v e ry f e w e d u ca -

t i o n al t o o l s t h at a r e a v ai l a b l e in t h e

i n du s t ry o r a k n o wl e dg e c o n so r ti u m

t h a t c o n s t ru c t i o n p r o f e ss i o n a ls c a n

resort to while implementing cellular

c o nc r et e s o l ut i on s . A l so , p a st po o r

e x p e ri e n c e w i t h f o a m l i q u id c o n c e n -

t r a t es , l a c k o f t e c h n ic a l s u p p o r t a n dp ro p er p ro d uc ti on a nd i ns ta ll at io n

guidance has discouraged the use of

c e ll u la r c o n cr e te s o l ut i o ns i n t h e i n-

d u s t r y. T h e r e a r e st i l l a f e w q u a l i fi e d

c o nt r ac t o rs i n t h e i nd u s tr y a n d c on -

s t r u c ti o n p r o f e ss i o n a ls w h o h a v e e x -

p e ri e nc e d t h e wo n de r s o f c e ll u la r

concrete and it is the true partnering

b et we en t h es e s ta ke h ol de rs o f t he

i nd us t ry c an l ea d t o t he a d op ti on o f

cellular concrete worldwide.

slab. Foam liquid concentrate manu-factures and distributors also provide

t r ai n in g a n d t e ch n ic a l s u pp o rt f o r c e l -

l u la r c o nc r et e u s ed i n p r e- c as t in g a n d

other manufacturing appli-cations.

Cel l ul ar Concrete & Sustai nabil i ty

C e l l u la r c o n c r et e d e l i v e r s a m o re

c o m p l et e s u s t a i n ab l e s o l u t i on b y s i g -

n i f i c an t l y r e d u c in g t h e am o u n t o f r a w

material needed and the energy

required to mold it into a shape for

construction

U p t o 5 m o f c el lu lar c onc re te c an3

b e ma d e fr o m 1 m o f s o l id r aw m a te -3

r i a l s . T h a n k s to t h i s e f fi c i e n t u se o f

r es ou rc es , c el lu la r c on cr et e a ct iv el y

contributes towards sustainable eco-

nomical methods of building.

T h e c e ll u la r c o nc r et e i n du s tr y

strives for as environmentally-friendly

p r od u ct i o n a s p o s s ib l e. P r oc e ss - re -

l a t e d e m i ss i o n s f r o m t h e u s e o f f u e l s

a r e c o n t i nu a l l y o p t i m iz e d , a n d r e d u -c ed t o a mi ni mu m. T he u se o f p ri -

m a r y e n e r g y d u r i n g t h e m a n u fa c t u r e

o f c e l l u la r c o n c r et e i s c o m p ar a t i v el y

l ow. T he p r od uc ti on o f c el lu la r c on -

c re te i s f re e o f w as te a nd w as te w at e r.

L ef t- ov er c el lu lar c on cr et e w hi ch

arises during the manufacturing phase

a n d on t h e co n st r uc t io n s i te a r e fe d

back into the production.

T h e h i gh q u al i ty o f t h e c e ll u la r c o n-

c r e t e p r o du c t s g u a ra n t e e s l o w e co -

Typical C ellular C oncrete Applications

Constructi on,Renovati on,

and

Rehabi li tati on

Geotechni cal

a n d M i ni n g

Manufacturi ng

• I nsulati ng cellular concrete roof decks wi th 2-hour fi re rati ngs ( UL-li sted)• I n s ul a t i ng r o o f d e c k f i l l s • Composi te i nsulated roof decks • F l o o r /c e i l in g f i l l

systems • Cast-i n-si tu affordable housi ng • Cast-i n-place walls, floors, and

roofs • Pre-cast, rei nforced-concrete wall, floor, and roof panels • Air-cured,c a st - in - si t u l i gh t we i gh t c o nc re t e b l oc k s a n d p re - f ab r ic a te d e l e me n t s • Permeablep a ve m e nt u n de r l ay m en t a n d r ec h ar ge b e d s • Firewalls • Slab-on-grade i nsulati on

a n d s u b b as e f i ll • U n d e rg r o un d t h e r m al c o n d ui t l i n i n g s • P ip e l i n e a n d c u l v er t

i nstallati on ( bedding and backfill) • Roadway rehabi li tati on • Retaini ng wall backfill

• Replacement of unstable soi ls • A nnular grouti ng • D e n s it y - c on t r ol l e d l o a d

relief • Load-reduci ng fi ll over structures • V oi d f i ll s • Structural fi lls • Permeable

fi lls / Stormwater runoff retenti on • Controlled, low strength materi al ( CLSM)

• Thermal i nsulati on for doors, safes, storage tanks, coolers, etc.

• Sound absorpti on for parti ti on walls • F i re p r oo f i n g p a n e ls

• A r ch i t e ct u r a l e l e m e nt s • C u l t u re d s t o n e

C e l lu l a r C o n c re t e



Flooring


K a s t u r i M e t al C o m p o s i t e s P v t . L t d .B u i l d s t r o n g, l a s t l o n g

S i l i c o ne C o n c e p ts I n t l . P v t . L t d .I n st a l li n g N e w F l o or s o r R e no v a ti n g e x is t i ngs u r f a c es ? H T S ha s t he r i g h t s i z e m a c h i nef or y ou a nd y ou r j ob

S TA C o n c r e te F l o o r i ng S o l ut i o n sW e D e l i v er F a s t e r, F l a t t e r, F l o o r s .

S t ew o l s I n di a P v t. L t d .G i ve y o ur c o nc r e te t h e s t r en g th o f s te e l.

N e o c r e te T ec h n o l o gi e s P v t . L t d .A p a t h e v e r y o ne w a n t s t o t r e a d , b u t do e s n ot k n o ww h er e t o g o …W e o f fe r t h e c o mp l et e s o lu t io n …

Recron 3SI t t a ke s a n y th i ng y o u c a n t h ro w a t i t . L ik e4 0 0 t o n s o f st e e l . 1 0 0 t i m e s a d a y

R e fe r P a ge N o .: 2 2 7

R ef er P ag e N o. : 8 3

Ref er Page No.: 159 & 193 Ref er Page No.: 279

Ref er Page No.: 135 Ref er Page No.: 243

Co n crete F lo o rin g So lu tio n s



y a n t ra i s a l e a d in g p r ov i d er o f f o a mc o n c re t e t e c h no l o gy i n t h e co u n t ry.

T h e c o mp a ny p r ov i de s p l an t , m a -Ic h in e ry, t e ch n ic a l k n ow l ed g e a n d a l l ie d

c h e mi c a l s f o r s e t t in g u p f o a m c o n c re t eplants of any capacity, for vari ousapplications across the world. The com-

p a n y' s m o d er n m a n u fa c t u ri n g f a c i l i t y i sl oc at ed in V is ha ka pa tn am , A nd hr aP ra de sh . S pr ea d o ve r a s pr aw li ng

4,800 sq.mts the plant is e quippe d withthe late st e quipme nt and appropriate

standards for manufacturing foam con-

c r e t e m a c h in e r y. A c om p e te n t an ds k i l le d 5 0 m e m be r s t r on g t e a m , t a k i ng

care of te chnical and non-te chnical as-p e c t s, i s a n o t h er a s s et f o r I y a nt r a .

Its range of machine s include s pop-

u l ar m o de l s s u ch a s, I F CS ( B AV ) , I F CS( S AV ) a nd I F C S ( FA V) . T h e co m pa n ymanufacture s specially de signe d foam

g e ne r at o r f o r f o am c o nc r et e p r od u c-t i o n . I y a nt r a ' s f o am g e n e r at o r s c o me

w i th c o rr os i on r es i st a nt c o at e d s t ee lb o dy a l on g w i th t i me r, a i r c o mp r es so ra n d l a nc e u n i ts . I y a nt r a ' s fo a m c on -

cre te mixers are unique ly de signe d tomix foam throughout the concre te in ane ve n m a nn er w i th o ut d e st r oy i ng t h e

f o a m, f o r a c c u ra t e d e n si t y a n d c o n t in u -ous production. The foam concre te mix-

e r s c o m e w i t h i n b u il t w a t e r d i s c ha r g i ngsyste m and digital we ighing scale sys-t em . T he mi xe r b od y i s b ui lt wi th h ig h

gauge stee l, while the shaft and othe rparts are made from alloy ste e l to be ar

h i gh i m pa c ts a n d l o ad s . S o me o th ero f f er i n g s o f I y a nt r a i n cl u d e , f o a m co n -

c re te p um ps , s cr ew c on ve yo rs , b el tc o n ve y o rs , s i l o s, s i l o a c c e ss o r i es , c e n -t r a l i ze d c on t r ol p a n el s , w i r e c u t t i ng

m a c h i n e r y , f o a m c o n c r e t e b l o c kmoulds, foam concrete conv e ying trol-le ys and othe r ancillary e quipme nt.

A prote in base d foaming age nt' C on l it e ' i s ye t an ot h er q u al i ty p r od u ct

o f I y a nt r a . ' C o nl i t e ' i s a 1 0 0 % b i o - d eg r a -d a b l e f o a m c o n c en t r a te , w h i c h f o r msv e r y s t a bl e b u b bl e s , w h i c h i m p a ct n e c -

e ss a ry p o ro si t y t o f o am c o n cr e te . T h ec o m p an y a l s o o f f e rs s y n t h e t i c- b a se d

f o a mi n g a g e nt , h a r d en e r s, p l a s ti c i z er sa n d o t h e r c o n st r u c t io n c h e m ic a l s u s e din foam concre te te chnology.

Pioneering Foam Concrete Technology

F o r f u rt h er d e ta i ls :

Iyantra3 - 2 - 6 11 / 2 , 1 s t F lo o r, K G N P la z a ,

O p p . H o wa r d P u b l ic S c ho o l,

H i m a y at N a g a r, H y d e r ab a d - 5 0 0 0 2 9

P h : + 9 1 - 40 - 2 7 6 30 6 6 6

E - m a il : v s i m ha 3 0 9 @ y ah o o . co mW e b : w w w. i y a nt r a . c om

Fo am Co ncrete m ixer Bri cks





itad el Eco-Build Pvt Ltd is the larg-

e s t s u p pl i er o f a e ra t e d a u t o cl a ve d

con crete (AAC) block s m an ufac-Ct u r e d b y B i l t ec h B u i l di n g E l e m e nt s L t d i n

I nd ia . T he c om pa ny h as a dd ed y et

a no th er f ea t he r t o it s ca p. I t ha s b ee n

r at ed b y t op r at in g a g en cy, C RI SI L , a s

t h e “ H ig h P e r fo r m a nc e a n d M o d e ra t e

F i n a nc i a l S t r e n g t h ” c o m p a ny. T h e r a t i n g

assures Citad el Eco-Build 's custom ers,

p r i n ci p a l s , i n v e st o r s a n d ba n k e rs t h a t

t he y c an b a nk o n a r el ia b le c om pa ny,

w h ic h m e an s b us i ne s s an d w hi c h v a l-ues an d follows ethical busin ess prac-

tices n o m atter what the circum stan ces.

I n a d di t io n t o s up p l yi n g qu a li t y A A C

b l o c ks , C i t a de l a r e a l s o m a n u f a ct u r e r s

o f G r ee c oB o nd - a r e ad y t o u s e, w e t m ix

m o r t a r, e s p e c ia l l y s u i t e d f o r A A C b l o c k s/

en gin eered block s an d G reecoPlast- a

r e ad y t o u se p l as t e r. T h e c o mp a n y h a s

b e en g r ow i ng b y l e ap s a n d b o u n ds u n de r

t he dy na mi c l ea de rs hi p o f i t s f ou nd er

Am ol Shitole.

C i t a de l G a l l er y

A stron g R & D focus has en abled Cit-

a d e l t o b ri n g t h e s e i n n o va t i v e , e c o -

f r ie n dl y n e w p r od u ct s t o c l i en t s- p r o d -

u c t s w h ic h s a v e t i m e a nd r e d u ce c o n -

s t r u ct i o n c o s t . C i t a d el h as a l wa y s b ee n

a tren d setter. It is also the first com pan y

t o co m e o u t w i t h a n e x c l us i v e g a l l e ry f o r

i t s c u s t o me r s a c r o s s t h e m e t r os , w h e r e

t h e r e a r e f a ci l i t ie s a v a i l a bl e f o r t e s t i ng

p r od u ct s a n d d i sp l a y o f p r od u ct s . T h is

g a l l e ry s e t u p i s av a i l a bl e in t h e fo l l o wi n g

c i t i es l i k e P u n e , M u m b a i, G o a , K o l ha p u r,

S o l a p ur, A u r a ng a b a d , H i n g o li , B a r a m at i

& K a r n at a k a .

I t h a s b e en t h e e n de a v or o f C i ta d elG r o u p, r i g h t f r o m t h e t i m e o f i t s i n c e p t io n

to provid e safer, m ore afford able perm a-

n e n t h o u si n g a n d s t r u c tu r e s . T h e c o m -

p a n y i s c o m m it t e d t o u t i l iz i n g e n v ir o n -

m e n t- f r i e nd l y ' G r e en ' b u i l di n g m a t e r ia l s

f o r c o n s t ru c t i on p u r p o se s .

Citad el is com m itted to provid in g the

i nd us tr y w it h p ro du ct s w hi ch h el p in

d esign in g structures that are hurrican e,

w i n d , p e s t an d fi r e re s i s t a nt , a p a r t fr o m

b e i n g e n v i ro n m e nt a l l y r e s p o ns i b l e. T h e

c om pa ny i s f or p r om ot io n o f h ou si ng t ha t

i s e ne r g y e f f i ci e n t a n d sa f e . I t a c hi e v e sthis by prom otin g build in g m aterials that

e l i m in a t e ma n y o f t h e d a ng e r o u s t o x i ns

a n d al l e r g en s , s o c o mm o n l y f o u n d w i t h

c o n v en t i o na l c o n st r u c t io n m e t h od s o f

today.

Citad el's q uest for the 'Perfect G reen

H ou se ' h as l ed i t t o c om bi ni ng t wo u ni qu e

a n d su p e r i or p r o d uc t s - Gr e e c oB o n d

an d G reecoPlast. Accord in g to the com -

p a ny b y i n co r p or a t in g t h es e t w o p ro d -

u ct s, w e c an m in im iz e o r e li mi na t e u ns a fe ,

toxic an d flam m able m aterials from buil-

d i n g s tr u c t u re s , a n d a t t h e s am e t i m e

d r a m at i c a l ly r e d u ce c o s t s . A s a r e s p on -

s i b l e c o r p o ra t i o n a n d on e o f t h e l a rg e s t

eco-frien d ly build in g prod ucts suppliers

i n I n d ia , C i t a de l h a s b e e n i n t h e f o r e f ro n t

i n e n d or s i n g su s t a i na b l e c on s t r uc t i o n

strategies.O n e o f t h e ke y r e as o ns f o r t h e co m -

p a n y ' s r a p i d g r o w t h h a s b ee n i t s ex c e l -

l e n t s u p p o r t s e r v i ce s . I t s t ea m o f q u a l i-

fied en gin eers helps clien ts to calculate

t h e e x ac t q u an t it y o f A A C m at e ri a ls r e -

q u i r ed f o r p r o j e ct s , t h e r eb y r e d u ci n g ex -

c e s s p r o cu r e m en t c o s t . T h e t e a m a ls o

p r o vi d es t e ch n ic a l k n ow - ho w a b o ut A A C

to proj ect m an agers an d site en gin eers.

Strict ad heren ce to q uality stan d ard s

i s a n o t h e r h a l l ma r k o f C i t a de l . Te s t c e r t i f -

icate an d weight slips are provid ed with

e v e r y d e l iv e r y b y t h e c o m p a ny. T h e c o m -pan y also m ak es sure that the m aterial is

d e l i ve r e d o n t i m e , e v e r y t i m e .

A rapid ly expan d in g clien t base of

o v e r 1 0 0 0 st a n d s te s t i mo n y t o t h e c o m -

pan y's rem ark able growth story.

A Testimony to Top Quality and Performance

F or f ur t he r d e ta i ls :

C i ta d el E c o- B ui l d P v t. L t d7 9 5/ 3 5 , S a m ad h a n A p t ., B h a nd a r ka r

Road, Pune - 4 1 1 0 0 4Ph: + 9 1 - 2 0- 2 5 6 5 6 5 7 5 , 6 5 2 8 9 6 7 2 ,

Web: w w w.c itadelec obuild.c om

OP EN APPLY FORGET



Adv e rtorial


h e In di an f or mw or k in du st ry i sp r e se n t l y g o i ng t h r o ug h a n e x c i t-

i n g p h a s e o f d e v e l o p m e n t .TSe v e ral innov ativ e te chnologie s arem a ki n g t h ei r w a y i n to t h e I n di a n m a r-

k e t . H i - L i te S ys t e ms , a g l ob a l pi o n ee rw h e n i t c o m es t o a l u m i nu m s y s te m sn o w o f f er s i ts q u al i t y r a n g e i n I n d i a. T h e

c o mp a ny, f o rm er l y k n ow n a s J a c ks onScaffolding, starte d its ev e ntful journey

i n 1 9 5 2. H i - L it e d e s i gn e d i t s f i r s t a l u mi -

n u m s h o ri n g sy s t em i n 1 9 7 4, t h e f i r s tc o mp a ny i n t h e w o rl d to do so . S i nc e

t h e n t h e r e h a s b e e n n o l oo k i n g b a c k .F a c to r s i n c l u di n g , r e d uc e d m a i n te -n a nc e , l o we r c o st s , l e ss h a nd l in g a n d

i n c r ed i b l e ve r s at i l i t y m a k e al u m i nu msyste ms from Hi-Lite the ide al choice

f or a v ar ie ty o f c on st ru ct io n p ro je ct s.Le t us take a close r look at the se alumi-num systems.

A l u m i n u m S h o r i n g S y s t e m s - F o rSpeed, Economy & Quality

H i - L it e S ys t e ms i s a p i o n ee r i n a l u -minum shoring syste ms. It is now offe r-

i n g i ts w i de r an g e in I n d i a, w h i c h i s i de -a l ly, s u it e d fo r b o th i n fr a st r uc t ur e an d

re al e state proje cts. Aluminum shoring frame s from Hi-

L i te a r e k n o wn f or t h ei r r e li a bi l i ty, d u ra -

b i l i t y a n d q u a l it y. T h e a v er a g e l i fe s p ano f t he se fr am es is ov er 2 0 y ea rs .

Additionally, with an amazing 70%

s cr ap v al ue , e ve n a ft er 2 0 y ea rs , t he ymake for e xce lle nt inv e stme nt. The fact

t h a t t h e y a r e m u c h m o r e d u r a bl e an do f f er a h i g h er s c r ap v a l u e, m a k es t h e mscore ov e r ste e l shoring frame s.

T h e d u ra b il i ty o f t h e s y st e ms h asb ee n c l ea r ly p r ov e d. A d r op t e st , w hi c h

w a s c o n du c t e d a t I IT, c o n c l us i v el yp r o ve d t h e f a c t . I n a f r ee f a l l t e s t o f a l u -

m in um f ra me fr om 2 0' h ei gh t in a lldire ctions and that too repe ate dly, thef r a me s s h o we d no d ef e c t s. I n o r d er t o

e ns ur e h ig he r s tr en gt h o f a lu mi nu m,the company use s pure bille ts and notscrap me tal. Te sts done at IIT show that

the frame s are 50% more stronge r thani n c a s es w he r e s c r ap m e t al h a s b e en

u s ed , w h il e al s o e n su r in g l on g er l i feand enhanced safety.

Anothe r major adv antage with the

aluminum shoring frame s from Hi-LiteS y st e ms i s th e fa c t th a t t h ey c a n b ee r ec t ed a m i nd - bo g gl i ng 1 0 t i me s f a st e r

t h a n s t e el f r a m es . T h e y a l s o sc o r e h ig hw h e n i t c o m es t o s a fe t y. T h e re a r e n o

loose parts and the y come inte grate dw i th c o up l er s a nd p i n s. T h is e n su r esthat the syste ms are v e ry safe for work-

e rs t o cl im b, e re ct t ow er, w it h n on -s l i p pe r y r u n g s.

T h e se q u a l i t y a l u m i nu m f o r mw o r k

syste ms are now be ing manufacture di n I n d i a. H i - L i te S ys t e ms a l so o ff e r s a

s l e w o f v a l u e- a d d ed s e r vi c e s i n c l u d i ngh e l p w i t h f i n a nc i n g . E x c el l e n t s it e – s u p -

port and te chnical back-up se rv ice s isa n o t he r a d v an t a g e t ha t i s o f f er e d b yH i - L i te S y s t em s . T h i s e n su r e s q u al i t y

a s su r an c e o n s i te , w h il e ad d it i on a ll ys p ee d in g u p c o ns t ru c ti o n w o rk , w i th o ut

a n y c o m p ro m i se o n t h e q u a li t y f r o nt .

A l um i nu m Te l es c op i c F l yi n g F o rm s -F o r I n c r ed i b l y F a s t C y c le T i me s

W it h a lu mi nu m t el es co pi c f ly in g

Versatile Aluminum Formwork SystemsS to rm I nd ia n M ar ke t

Gau m ont Disneyland – Paris

P r o j e ct 1 : H o g g s Ho l l o w B r i d ge i n To r o n t o - C on t r a ct o r

D u f f er i n C o n s tr u c t io n

P r o j e ct 2 : A t h a ba s c a R i v e r B r i d ge - L a r g e s t B r i d ge o f

A lberta - Size of Five Football Fields - Contractor:

F l a t i ro n C o n s t ru c t o rs



Adv e rtorial

225·T h e M a s t e rb u i l de r - July 2013 www.masterbuilder.co.in


H i - Li t e S y s te m s I n di a P v t . Lt d .V I R AG H B H AC H E CH( VP – S AL ES & E NG G)

5 B 1 , F i f t h F l o o r, J . P. To w e r - 7 / 2 ,

Nu ng ambakkam Hig h Road, Ch ennai - 600034.

M o b : 0 9 4 0 95 4 1 9 3 8 H . O . : To r o n t o C a n a d a ,

Tel No. : 001-647-880-4032

E-m ail: virag @ h i-lite-system s. com

forme s from Hi-Lite Syste ms, contrac-tors hav e be e n able to achie v e re mark-able cycle times of as le ss as 3 days.T h e a l um i n u m t el e s c op i c f l y i ng f o r m

syste ms from the company are ide allys u i t ed f or m u l t ip l e st o r i ed b u il d i n g sa n d i n fr a s tr u c t u re p r o je c t s. O n e o f t h e

m a j or a d v an t a g es i s i t s l i g h t we i g h twhich make s handling and asse mbling

e a s y. T h e m o d u la r c o m p on e n t s y st e me n s ur e s q u i c k er t u r n ar o u nd t i m e s . T h et el es co pi c d es ig n e ns ur es th at th e

m od ul ar c om po ne nt s y st em c a n b ea d j u st e d f o r d i f f er i n g f l oo r h e i g ht s a n df o r o t h er c o m pl e x c o n s tr u c t i on g e o me -

t r ie s. T h e sy s te m c an b e u se d o n t y pi -c a l f l oo r s an d n o n- t y p i ca l f l oo r t o o ,w h e re f l oo r h e i g ht s a re d i ff e r en t . I n t h i sc a s e ju s t b y p u l l i ng t h e p i n o u t , t h e t el e -

s c op i c s t ru t s ca n b e ex t en d ed , a s p ert he fl oor h ei gh t, bef or e t he p in i sadjuste d again.

The light weight of the system alsom e a ns r ed u c e d cr a n e t i m e or i n s o m e

i n s t an c e s, s u c h a s i n t h e c a s e o f l i g h t ersize d frame s, no require me nt of crane sat all. This is some thing that is just not

possible w ith either timber or steelf or ms . A no th er m aj or a dv an ta ge w it hthe aluminum tele scopic flying frame s

i s d ra st ic r ed uc ti on i n l ab or c os ts . T hestripping of the syste m is also not labor,

t im e o r c os t i nt en si ve . I n f ac t, i t c a n b ed on e b y a m in im um n um be r o f c on -struction worke rs.

These systems have enabled con-s t ru c ti o n c y cl e t i me s w h ic h w er e t i llnow conside re d practically impossible .

A good e xample is av ailable in the formo f C a s in o S t r u c t ur e s , l o c a te d i n A t l a nt i c

Ci ty, N ew J ers ey, US , wh er e Hi -Li teSyste ms has be e n able to achiev e ani n c r ed i b l e c yc l e t i m e of 3 d a y s u si n g

t h e a l u mi n u m t e l es c o pi c f l y i ng f o r m . I nIndia too the company has be e n able toachie v e a cycle time of 5 days for a pro-

j e ct of L & T.W i t h s o m a ny a d va n ta g es , i t is no t

surprising that aluminum te le scopicflying formwork from Hi-Lite Syste ms isf i n d in g a n i n c r ea s i n g n u m be r o f t a k er s

i n I nd ia . I n f ac t, t he c om pa ny h as s up -plie d its products to 60 construction

A lu m inu m Brackets In Gang Form

F e at u re o f A l um i nu m B r id g e O v er h an gBrackets:

r d- 1/3 The Weight of The Ste el

B r a ck e t = C a p ac i t y 8 0 00 K G w i t hs a f et y f a c t or 1 . 5 :1

- To p D ow n A dj uc tm en t – E xt re am lyS a f e F o r W o rk e r s – S a v es H u g e

L a b or C o st s

- C o nn e ct 5 To 6 B r ac k et s To g et h er –a n d F l y To g e th e r – s a ve s M a n H o u r s

And Labour Costs

Bracket - Connected to A bu tm ent Wall f or Bridg e Ref u rbish m ent

st1 P r oj e ct in G u ja r at (R E S & C O MM )

Telescopic Flying Form

s it es o f L & T I nd ia al on e, a fa ct th atspe aks volume s about the quality and

pe rformance of the syste ms.Hilite is trying to achie v e 3 days

cycle time for re side ntial and comme r-

cial proje cts in Mumbai and Pune.





r e a v e s c o n s t r u c t i o n e q u i p -me nt busine ss, part of Gre av e sC ot to n L im it ed , o ne o f I nd ia 'sG

l e a d in g en g i n ee r i n g c o m pa n i e s, r e -c e nt l y l a un c he d i ts h i gh c a pa c it y c o n-cre te pumps, with contemporary S Valv e

t e c h no l o gy. T h e Gr e a ve s S V a lv e s ta -

tionary concre te pumps are av ailable int hr ee m od el s: G CP 5 50 0, G CP 6 50 0a n d G CP 8 50 0 . D es i gn e d p ri m ar i ly f o rinfrastructure concre ting ope rations,

t h e se h i gh p e r fo r m an c e pu m p s a r eu s e d f o r h e a vy d u t y c o n st r u c ti o n a c t i vi -

tie s in high- rise comme rcial and re si-de ntial buildings and infrastructurew o r ks i t e s s u c h a s t u n n el s , d a m s , b r i d -

g e s , i r r i g a t i on e t c . All thre e mode ls of the stationary

c o n c re t e p u m ps a r e p o w er e d b y f u e l

e f f ic i e n t a nd e m i s si o n c o m p li a n t e n -

g i n e s a nd i n t e g r at e d w i t h c o n t em p o -rary hydraulic syste ms and compone ntst h a t a r e d e si g n e d t o d e l iv e r c o n c re t ep e r fo r m u n d er c h a l le n g i ng p u mp i n g

c o n d it i o n . G r e av e s Co n c re t e p um p se n s ur e t h e l o w es t c o s t p e r c u b i c m e t ero f c o nc r et e p u mp e d. A fu l ly e l ec t ri c al

c on tr ol p an el w it h r em ot e a s a s ta nd ar df e a t ur e c a n o p e ra t e b o t h o n t h e p i s t ona n d t h e r od s i d e . T h i s r es u l t s i n a m a x i -

m u m c o nc r e t e ou t p u t o f 5 0 - 80 c u b i cme tre s pe r hour, v arying from mode l tomode l.

The hard chrome platte d concre te

c yl in de r i n t he p u mp s o ff er e xt en de dse rv ice life against we ar and corrosion.The re place able hard rams are de signe dt o w it hs ta nd h ig h p re ss ur e a nd a re h i gh

w ea r r e si s ta n t. T h e in t er n al s a r e we l ld e si g ne d s o a s t o al l ow f o r m i ni m um

w ea r a n d t e ar, t h er e by m i ni m is i ng r e-place me nt and mainte nance costs.

S p e a k i n g a t t h e l a u n c h , S u n i l

P ah il aj an i, M D & C EO, s ai d, “ Be in g a ni n c r e a s i n g l y d e m a n d i n g b u s i n e s s ,t e ch n ol o gi c al l y s u pe r io r p r od u ct s a r e

t h e n e e d o f t h e h o u r. W i t h t h e l a u n c h o f

G r e av e s S v a l ve c o n c r e te p u m p s , c u s -t o me r s c a n b e a s su r ed o f r e li a bl e , b e st -i n - c l as s p r od u c t b a c ke d b y a s t r o ngafte r marke t support.”

“ T h e S v a l ve c o n c r et e p u m p s ad dt o o u r e x i st i n g r a ng e o f c o n c re t e o ff e r -ings making Gre av e s a compre he nsiv e

and total playe r in the infrastructure se g-m e nt . C u st o me rs c a n n o w a va i l t e ch -n o l og i c a l ly a d v an c e d S V a lv e c o n c r et e

p u mp s , w hi c h a r e d u ra b le , e c on o mi ca n d h i gh l y c o st -e f fi c ie n t. T h e i n te l li -ge ntly de signe d fe ature s prov ide func-

tional superiority and e ase of use ," said

R . N an da gop al , CE O, Co nst ru ct ionE q u i pm e n t Bu s i n es s . H e a d de d , “ O u re nde av our is to re spond to custome rre quire me nts and marke t de mands.

T h i s l a un c h i s a t e s ti m o n y t o o u r c o n t in -u o u s ef f o rt s i n i n n o va t i o n a n d p ro d u c t

de v elopment. Comple menting our wider a ng e o f p r od u ct s i s o u r c o un t ry wi d ee x te n si v e s e rv i ce n e tw or k , w hi c h c a te r s

to disce rning custome rs anytime , any-where.”

A b o u t C o n s tr u c t io n E q u i pm e n t B u s i -

nessP l a y in g a v i t a l r ol e i n I n d i a' s i n f r a-

s t r u ct u r e d e v el o p me n t , C o n st r u c t io n

Equipme nt Busine ss offers a wide rangeo f c o n c re t i n g a n d c o mp a c t i ng e q u i p -m e nt . P r od u ct s i n cl u de A u t om a te d

B a t c hi n g P l a n ts , n e w -g e n er a t i on c o n -c r e t e M i xe r s , C o n cr e t e p u m pi n g s y s -t e m s, S o i l c om p a c to r s a nd H e a vy a n d

Light Tande m Rolle rs. Gre av e s Cottonhas e stablishe d thre e de dicate d plants

n e ar C h en n ai , f o r t h e m a nu f ac t ur e o f

specialize d construction e quipme nt ands y s te m s. T h e m a n u fa c t u ri n g f a c i li t y i s

locate d at Gummudipoondi, Che nnai,TamilNadu.

Greaves Rolls Out High CapacityC on cr et e P um ps wi th S Val ve Tec hn ol ogyD e si g ne d fo r he a vy d u ty c o ns t ru c ti o n a c ti v it i es i nhigh-rise commercial, residential buildings and infrastructure worksites

F o r f u rt h er d et a il s :

M s . B h a v na S i n g hGeneral Manager- CorporateCommunications

G r e a ve s C o t t on L i mi t e dPh: + 9 1 - 2 2 - 2 4 3 9 7 6 26

E-mail: [email protected] C P 5 5 0 0 C o n c re t e P u m p





he battle for re taining and attract-

ing ne w tale nt occupie s a spe cialp o s it i o n w h e n i t co m e s t o s h a p -T

i n g t h e f u t u re h e al t h o f a n o r g an i z a ti o n .T h e s h o rt a g e o f r i g h t t a l en t , a c c e nt u -a t ed by e as y a c ce s s t h ro u gh i n te r ne t

s o u rc i n g , p u t s a ve r y h i g h p r e mi u m o na c q u ir i n g , r e t ai n i n g a n d d e v el o p i ng

t al en t f or m os t o rg an is at io ns . W i the ac h p as si ng y ea r, t he g ap b et we ens u p pl y a n d d e m an d i s o n l y i n c r ea s i ng ,

a n d t h e g a p b e t we e n a c a d em i c s a n d

practice is ev e r wide ning.I n t h is sc e na r io , t r ai n in g i n o rg a ni -

s a ti o ns , p h ys i ca l ly, s oc i al l y, i n te l le c tu -a l ly a n d me n ta l ly b ec o me s es se n ti a l

f o r n o t o nl y r e ta i ni n g a n d d ev el o pi n gtale nt but also to facilitate highe r le v e lso f p r od u ct i vi t y. H o we ve r, i t i s n o t j u st

the ore tical knowle dge , but e xpe rientialk n o wl e d g e th a t g r a nt t h e a b i l it y, t h es k i l l, t h e u nd e r st a n d i ng , a n d t he i n f or -

m a ti o n, w h ic h e ve r y i n di v id u al n e ed t oa c q u ir e i n o r d er t o b e a b l e to f u n ct i o n

e ffe ctiv e ly and pe rform e fficie ntly.

To da y, i t i s t he q ua li ty o f h um anr e s ou r c es , w h i c h i s th e pr i m e m o ve r i n

a n y o r g a n i z a t i o n ; h o w e v e r , w e l l -e n d ow e d i t m a y b e w i t h t h e m a ch i n e s,m a t er i a l s a n d e ve n m o n ey. Tr a i n in g i s

t h e m os t e f f ec t i v e t oo l i n s y st e m at i cd e v el o p me n t o f t h e k n o wl e d g e, s k i l ls

and attitude s re quired by e mploye e s top e rf o rm a d eq u at e ly o n a g i v en t a sk o rj ob . I t c an t ak e p la ce in a nu mb er o f

way s, on t he jo b or o ff t he job ; i n t heo rg a ni z at i on o r o u ts i de t h e o r ga n iz a-t i o n . S t a f f t r a i ni n g a n d d e v el o p m en t i s

a w o rk a c t i vi t y t h a t c an m a k e a s i g ni f i -c a n t i m pa c t o n t h e o v er a l l e ff e c t iv e -

n es s a nd p r of it ab il i ty o f a n o rg an iz a-t io n. H en ce , s ys te ma ti c a pp ro ac h t otraining encompassing holistic training

is e sse ntial in organizations.We have been of ten ask ed ; a re

i n v es t m en t s i n t h e a re a o f t r a i ni n g a n d

de v e lopme nt linke d to the bottom linew i t h in t h e b u s i n es s ? I n c r ea s i ng l y, h i g h

p e r fo r m in g o r g an i s a ti o n s t o d ay a r ere cognizing the ne e d to use the be sttraining and de v e lopme nt practice s

av ailable to e nhance their compe titiv e

adv antage . Training and de v e lopme nti s an e ss e nt i al e le me n t o f e ve ry b u si -

ne ss if the v alue and pote ntial of its pe o-ple are to be harnessed and grown.M a n y s t u d i es h a v e h i g h l ig h t ed th e

c l e a r l i n k s be t w ee n w e l l de s i g ne d a n dstrate gic training and de v e lopme nt ini-

t i a t i ve s a n d t h e b o t to m l i n e w i t hi n t h eb u s i ne s s. T h e i m a g e o f a n i n d u st r y a n do f i n d i vi d u a l e mp l o y er s i s a l so i n f l u -

e n c ed b y t h e e x t en t an d q ua l i t y o f s t a ff

training and de v e lopme nt.Pote ntial e mploye e s, with the ir

f o cu s o n c a re e r p r og r e ss i o n a n dd ev el op me nt , i n s uc h a n o pe n l ab ou r

marke t will asse ss the track re cord ofp r o sp e c t iv e e m p l oy e r s i n t h i s v i t a lare a. In today's busine ss climate whe re

all industrie s are e xpe rie ncing staff andskills shortage s, companie s are facedw i t h s t i f f i n t e rn a l a n d e x t er n a l c o mp e t i -

t i o n f o r q u a l i t y e m p l o y e e s . E a c he mp l oy er w h o i n ve st s se r io u sl y i n t h e

are a of Training and Dev e lopme nt will

r e ap t h e b en e fi t s o f a n e n ri c h ed w o rk -i n g e nv i ro n me n t wi t h h i gh e r l e ve l s of

staff re te ntion as well as incre ase d pro-ductiv ity and performance .

While the pe rce ntage and time

s p e nd o n t r a i ni n g s t af f m a y b e u se f u l i no rd er t o ge t an o ve rv ie w o f t he c om -

pany's commitme nt to training andd ev el op me nt , i t i s th e ma nn er, a p-p r o ac h a n d co n t en t o f t h e tr a i n in g i n i-

tiativ e s as we ll as the ir asse ssment andf ol lo w u p w hi ch d et er mi ne s u c ce ss . I ti s al l t oo e as y t o th r o w m o n ey a t a p e r -

formance proble m and assume that at r a i ni n g c o u rs e w i l l s or t i t o u t , w h e n t h i s

m a y w e l l be j u st p u t t in g a p la s t er o v era n o pe n w ou nd . Tr ai ni ng i ni ti at iv esne e d to be strategically aligne d to the

o ve r al l co mp a ny m i ss i on a n d g o al s .T h e y n e e d t o b e d es i g n ed a n d d e l i v -e re d w it h t he a im o f h el pi ng st af f

achie v e the ir de partme ntal as well asp e r s o n a l g o a l s , s o t h e t r e n d o f

incre ase d inv olv e me nt by line manag-e rs and e mploye e s is a positiv e de v e l-o pm en t i n t er ms of o wn er sh ip o f t he

t r ai n i ng a n d l e ar n in g p r og r am . B y a d op -t i ng a st r at e gi c a p pr o ac h t o tr a in i nga nd de ve lo pm en t r at he r t ha n a n u n-

p l a n ne d an d a d h o c o n e , t r a i ni n g a ndde v e lopme nt initiativ e s be come more

targe te d, me asurable and e ffe ctiv e .

I n o r de r t o re ma i n c o mp e ti t iv e an dto e nsure e xce llent staff are attracte d toa nd r e ma in w it hi n t he o rg an iz at i on ,

companie s ne e d to e nsure that thet r a i n i n g a n d d e v e l o p m e n t o f a l le m p l oy e es i s a n i s s ue wh i c h i s ta k e n

s er i ou s ly. B y i n ve st i ng i n t h e d e ve l op -me nt of the pe ople who are the face of

t he b us in es s, c om pa ni es c an g eta h e ad o f t h e c om p e ti t i o n a n d ex c e l i n

S t ay A h ea d o f th e C ur v e Vi a S tr a te g icTraining and Development

N ag es h R am mu rt hy i s a c e r ti fi ed

P roject Management P rofes s ional( P MP ) wi t h o v er 2 5 ye a rs o f e x pe r i-

e n ce i n t h e a r ea s o f p r oj e ct co n -

s t ru c ti o n s t ra t eg i es , c o nt r ol l i ng , d e li -

v e r y, c l o s i ng & h a n do v e r a n d l e a r n-i n g & d e v e lo p m e nt . H e g r a d ua t e d i n

Civil Engineering from Bangalore

Univer-sity in 1989 and currently

h o ld s t h e p o st i on o f D i r e ct o r, S c h o ol

o f C on st ru ct io n M an ag em en t E x-cellence, A N P rakas h Cons tr-uction

P roject Management Cons ultantsP vt. Ltd. (ANP CPMC). H e has worked

w i th C o n su l t a n ts , C o n s tr u c t or s , D e -

v e l o pe r s , a n d A r c h i te c t s i n v a r io u s

capacities and has pub lis hed s ev-e r a l r e s ea r c h p a p er s o n C o n st r u c -

tion P roject Management.

Nagesh Rammurthy

Project M anag em ent Prof essional A N Prakash Constru ction Project M anag em ent

C o n s ul t a n t s P v t . L t d



C o mm u n i c at i o n F e at u r e


F o r f u r th e r d e t ai l s:

A N P ra ka sh C PM C P vt .L td4 9 1, " V i sw a k ar m a ", E a s t e n d r o a d , 9 t h

Bloc k Jayanag ar, Bang alore 5 6 0 0 69 ,Ph: + 9 1 - 8 0- 2 6 6 3 97 8 0

Fax : + 9 1 - 8 0- 2 6 6 3 9 78 0E- m ail: bd@anp c pm c .c omWeb: w w w.anp c p mc .c om

w h at t he y d o . O n e o f t h e m os t im p or -tant aspe cts of managing pe ople lies in

h e l p i n g e m p l o y e e s b e c o m e m o r ee f f ec t i v e i n t h e i r j o b s an d b e i n g ab l e t o

a d ap t t o t h at jo b o r a n ot h er j o b a s

h e / sh e m a tu r e s wi t h i n t h e o rg a n i za -t i on . T h is r e qu i re s a hi g h l e ve l o f c o -

o r d i na t i o n b e t we e n e m p lo y e e t r a i ni n gand de v e lopme nt and the range ofot her p erso nn el fu nc ti on s, su ch a s

r e c r u i t m e n t a n d s e l e c t i o n , p e r f o r -mance appraisal, re ward syste ms and

e mp l oy e e r el a ti o ns . I d en t if i ca t io n o f acompany's training ne e ds, de signing ar e l ev a n t tr a i n in g p l an , s e l ec t i n g an d

imple me nting the re sulting training pro-gram and e v aluating its succe ss arethe re fore , inte gral e leme nts of the ov er-

all Human Re source De ve lopme nt pro-c es s. H ow ev er, f or a ny o f t he se f un c-

tions to be e ffe ctiv e, the training plansa n d p o li c ie s mu s t b e in l i ne w it h t h eo r g a n i s a t i o n ' s s t r a t e g i c o b j e c t i v e s .

Studie s hav e indicate d that most e ffe c-t i v e tr a i n in g a r e th o s e wh i c h i n c l u de

b ot h c o gn i ti v e tr a in i ng , i n te r pe r so n als k i l ls f ol l o we d by t h o se wh i c h i n c l u de

p s y ch o m ot o r s k i l ls o r t a s ks .

The training function is incre asingly

c o ns i de r ed t o b e a k ey p l ay e r i n h e lp -i n g t h e o r g a n iz a t i on a c h i ev e i t s g o a l st h r o ug h i t s p e op l e a s i t i s b ec o m i ng

more ge ne rally acce pte d that the re is as t ro n g c o rr el a ti o n b et w ee n o rg a ni z a-tional succe ss and inv e stment in train-

i n g an d de v e lo p m en t . T h e re i s n o w agrowing aware ne ss on the importance

o f a p l a nn e d ap p r oa c h t o t r ai n i n g a n dde v e lopme nt as a tool for compe titiv ea d v an t a g e, s t a ff r e c r ui t m en t , s e l ec t i o n,

r e t en t i o n a n d m o t i va t i o n. I n c re a s in g l y,organizations are turning to spe cialists,w i t h d e m on s t r at e d e x p er i e nt i a l s u c -

ce ss to work as coache s for ushe ringt he ir o rg an iz at io ns i n to s u ch a ct io n

le arning programs.W i t h t h e f o cu s o n e x pe r i en t i al

coaching and le arning, the Training pro-

grams re sult in improv e d performanceand othe r positiv e change s that se rv eas ante ce de nts to e xce lle nce in job pe r-

formance . The se practitione r-le d train-i n g pr o g ra m s w i t h i t s ac c e n t o n m u l t i -

ple de liv e ry me chanisms and focus on

t e c h no - m a na g e ri a l t r a i n i n g, i n c l u di n gr e g ul a r t r a i ni n g e f f e c ti v e ne s s s t u d ie s

a nd f in e- tu ni ng , h el p o rg an iz at io nsbring the ir e mploye e dev e lopme nt and

re te ntion aspirations to fruition.

F in al ly, m an y o rg an iz at io ns h av ere alize d that the y se rv e the ir custome rs

b es t, b y f oc us in g o n t he ir m os t v al u-a b l e a s se t s – t he i r h u m a n r e so u r c es ,f o r, h o n i ng th e s k i l ls of t h e se as s e ts

e n s ur e s n o t j us t c u s t om e r r e t en t i o n,but unle ashe s the innate innov ativ e -

ne ss in the se re source s to cre ate ev e rincreasing valuefor the customer. Soonert h a n l a t e r, t h i s i s go i n g t o b e c om e t h e

k e y d i f f er e n ti a t o r b e t we e n t h e s u c c es s -ful companie s and those that also ran.Wouldn't you want to be the forme r?

Steel Fiber Reinforced concrete

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T o k n o w m o r e o n t h e p ro d u ct s , s o lu t i on s a n d s e rv i c es o ff e r e d b y t he l e ad i n g b r a n ds f e a t ure d a b o v e w r i t e t o: [email protected]

B e k a e r t I n d u s t ri e s P v t . L t d .D r a mi x ® s t e e l f i b r es - L e a d e rs i nr e i n fo r c in g t u n n el s s i n ce 1 9 8 5 *

Kasturi Metal Composites

Pvt. Ltd.Bui l d strong, l ast l ong

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Te k l a I n d ia P v t . L td .

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D o w C o r n i ng I n d i a P v t . L t d .

A f i re r a te d j o in t s e al a nt t h a t n o o n e e l sec a n m a t ch !

W ac k e r C h e mi e I n di a P v t. L td .

Sustai nabl e sol uti ons for cem enti ti oust i l e a d h e si v e s

Z u a r i C e m e n t I t a l c e me n t i G r o u p

J u s t w h a t a g r e e n er w o r ld n e e d s. P u r el i g h t a n d a i r.

W a l t ar E n t e r p ri s e sL a r g es t M a n u fa c t u re r a n d e x p o rt e rof Li thi um Si l i cate

BrickwellN o p r e & p o s t w et t in g s a ve sN a t u ra l R e s o ur c e s, T i me & E n e r g y

Citadel Eco-Build SolutionsN o p r e & p o s t w et t in g s a ve sN a t u ra l R e s o ur c e s, T i me & E n e r g y

M e t h r a I n d u s t ri e sA G re e n R e vo l ut i on f o rF u t u re B u i ld i n g s

IyantraI n d i a' s n o . 1 c o m pa n y i n l i g h twei ght concrete technol ogy

Robo Silicon Pvt. Ltd.T h e E c o -F r i en d l y a l t e rn a t i ve t o r i v ersand

Ref er Pag e No.: 29 Ref er Page No.: 227 Ref er Pag e No .: 279

Ref er Pag e No.: 141 Ref er Pag e No.: 75 Ref er Page No.: 65 Ref er Page No.: 131

Ref er Pag e No.: 175 Ref er Pag e No.: 281 Ref er Pag e No.: 219 Ref er Pag e No.: 165R e fe r P a ge N o .: 2 1 5

R e fe r P a ge N o .: 1 2 5

better together

A utoc l av ed A erated Conc rete B l oc k s





e o c re t e s p e ci a l i ze s i n t r a ns -

f o r m i n g m u n d a n e c o n c r e t eNf l o or i n g i n to a w o rk o f a r t . T h e ir

p a s si o n i n t a k i ng u p c h a l l en g i n g as s i g -

n m en t c om b in e d w i th t h ei r q u es t fo r

i n n o va t i o n h a s r e s ul t e d i n t h e i r e x e cu t -

i n g a be a u t if u l f l oo r i n o n e of t h e p re s t i -

g i o u s t o w er s th a t h a s c o m e u p i n t h e

h e a rt o f M u m ba i . N e s tl e d i n L a m in g t o n

r oa d, t hi s t ow er p ro mo te d b y E ar thD e ve l o p er s b o a st s o f a n u m b e r o f f i r s ts

i n t h is a r ea . M u lt i - st o ry p a rk i ng a r ea s ,

a u t om a t i c s t a t e- o f -t h e - ar t l i f t s, P U c o a t -

i n g o f p a rk i ng d e ck s , s t am p ed c o nc r et e

in e ntrance portico and a de signer con-

c r e te i n g r o u nd a n d f i f t h f l o or a r e s o m e

o f t h e b o ld i n it i at i ve s ta k en b y t h e de -

veloper.

T h e s e q u e nc e o f e ve n t s i s as f o ll o w s :

Concrete is ground so as to remove

l a it a nc e ; l o os e p a rt i cl e s, e t c a n d p r o-v i d e a m e c ha n i c al k e y. I f t h e a re a h as

l ot o f u nd ul at io ns , i t i s n ec es sa ry t o l ev el

t h e f l o o r w i t h s e l f- l e v el i n g c e m e n t i ti o u s

u n d er l a y. I n t h i s c a se , w e l e ve l e d i t w it h

o u r p r o du c t N e o f l o r 3 0 10 .

P r e pa r e d e s i gn t e m p la t e s b a s ed

o n t h e d es i g n w h i c h s h o ul d b e ma d e t o

t h e e x a ct s c a l e . P o si t i o n t h e t e m pl a t e s

o ve r t h e a r ea a n d d r aw t h e pa t te r n o n

the floor.

M i cr o to p pi n g b y N e oc r et e

Our ce me ntitous micro-topping viz.

N e o fl o r 4 0 1 0 i s f o r mu l a t ed wi t h h i g h -

q u al i ty p o ly m er s & U V re si s ta n t p i g-

me nts and is de signe d to giv e an e xce l-

l e nt f l ow w i th t h e a d di t i on o f w at e r. M i x

the mate rial and pour into the re spe c-

tiv e re ce ptacle one -by-one .

P ou r v a ri o us c o lo u rs o n e a f te r

a n o th e r e n s ur i n g t h at t h i c k n es s o f o n e

pour doe s not e xce e d 5mm. Apply two coats of se ale r coats to

prov ide e nhanced prope rtie s of she e n,

ant-fungal and abrasion re sistance .The e nclose d photo speaks v olume s

a b ou t t h e c a pa b il i ty o f o u r m i cr o -t o p-

p in g t o p ro vi de a m os t a ma zi ng f lo or t ha tprov ide s be auty and e le gance unmat-

c h e d b y a n y o t h er p r o du c t .

B M N a ga r aj a n, Director, Neocrete Tech nolog ies Pvt. Ltd.


Neocret e Technologies Pvt Lt1 3 -A , S a t e ll i t e To w e r, F i l m C i t y R o a d,

Goreg aon(East), Mum bai - 40 0 0 6 3Ph: + 9 1 - 2 2- 3 2 9 3 79 8 1 ,Em ail: bm nag arajan@g m ail.c om

Web: www.neocrete.co.in/www.neocrete.in




The use of Steel and Synthetic Fibresin Concrete under Extreme Conditions

The use of fibres to enhance the properties of constructionmaterials can be traced back over 4000 years to the use of

straw in bricks and horse hair in plaster. Fibres can reduce

plastic cracking in fresh concrete and enhance the post-crack

ductility of hardened concrete. The elimination of reinforcement

fixing can have significant time, cost and safety benefits. Whilst

the random orientation and dispersal of fibres means they are

not as efficient as conventional reinforcement for dealing with

predictable stresses, they are able to resist crack propagation

under unforeseen stresses, particularly those arising close to the

surface of elements during construction and in service, such as

impact.

Fibres can be particularly beneficial under extreme environments,such as exposure to chlorides and fire. Fire and abrasion

resistance are enhanced and the discrete nature of fibres means

that the risk of corrosion and associated spalling is significantly

reduced.

The mining and tunnelling industry makes extensive use of fibres

in sprayed concrete linings for underground support. Fibres allow

the lining to retain ductility, even under high deformation, which is

critical for safety. Precast tunnel segments have utilised both steel

and synthetic fibres for handling and improved fire resistance

respectively (1). Marine works have used synthetic macro fibres

to eliminate corrosion risk under exposure to seawater (2).

This paper provides a review of structural and durability designapproaches based on published guidance. It should be noted

that performance is dependent on the particular fibre type,

including the manufacturer.

Fibre reinforced concrete

Fibre types

The principal fibre types in BS EN 14889 (3,4) are shown in

Figure 1. The shape and surface texture of the fibres is important

in determining their effect on concrete properties. Fibres should

fail by gradual pull-out after disbondment from the cement matrix

in order to provide ductility and features such as hooked ends,

Don Wimpenny1 , Wolfgang Angerer2 , Tony Cooper3 and Stefan Bernard4 1Principal Materials Engineer, Halcrow Pacific 2Senior Tunnel Engineer, Halcrow Pacific3Consultant Elasto Plastic Concrete 4Consultant, TSE

Concrete: Fibres

crimping, twisting and embossing are intended to promote frictionassociated with the pull-out mode of failure.

Table 2 summarises the characteristics of two widely used fibre

types and compares the attributes of concrete made with these

fibres to conventional concrete.

Short term laboratory and field studies on the durability of uncracked

steel fibre reinforced concrete (SFRC) indicate carbonation induced

corrosion is restricted to those fibres immediately below the

surface (5). Galvanic corrosion and spalling do not appear to

occur (6), but there is a potential for corrosion at cracks (7). This

is important, as it could ultimately lead to sudden failure of the

concrete due to fibre breakage rather than ductile failure by fibre

pull out (5). It is recommended that limiting crack width of 0.1 to0.2mm be adopted, depending on the service conditions.

Corrosion of steel fibres will cause staining and where this would

be unacceptable, galvanized steel is sometimes used (as the

solubility of zinc is increased when chloride ions are present,

stainless steel and synthetic macrofibres are more appropriate in

a chloride-rich environment).

Structural synthetic fibres are an alternative to steel fibres for

controlling handling damage and providing long-term ductility.

They are not significantly affected by exposure to seawater (8)

or sodium chloride at temperatures of 20-40°C (9). However, the

maximum service temperature should ideally be limited to 60°C

and exposure to some chemical agents, such as chlorine gas,

should be avoided.

Field examples

Evidence of satisfactory performance of fibres in concrete

elements is important in providing confidence to potential users.

Unfortunately, there is relatively limited information on long-term

durability of FRC in the field. For example, steel and synthetic

macrofibres have only been employed in sprayed concrete since

the 1970s and the 1990s respectively.

Table 3 summarises a selection of projects where the concrete is

exposed to extreme service conditions. Despite the many projects

The tunnelling and maritime environments can provide extreme conditions for reinforced concrete. Exposure to aggressive saline

water can be combined with design lives of 100 years or more. In recent years, traditional carbon steel reinforcement has been

substituted by the use of steel fibres and, more recently, by synthetic fibres for sprayed concrete and precast items, such as tunnel

segments. This paper describes some of the factors which have prompted the change from rebar to fibres and includes a detailed

consideration of the specific durability design aspects of fibre reinforced concrete use within desalination facilities.




utilising fibres, the duration in service is modest compared to the

design lives of 100 years, or more, which are increasingly required.

Structural design

Design methodology

The design of an FRC section follows the same approach used forthe design of reinforced concrete, with appropriate modifications

for material properties in the tension zones. In reinforced concrete the

properties of the concrete and reinforcement can be determined

separately. For FRC the properties of the composite of fibre and

concrete, such as tensile splitting strength, flexural strength at

first crack and residual flexural strength, should be determined

concurrently. These properties can utilised in standard equations,

which define the load capacity of the composite element.

Initial designs may use manufacturer’s data or data from previous

projects to estimate the material properties. However, it is important

that the validity of the data is checked and that the performance

of the material is demonstrated by testing in pre-production trials andby regularly sampling throughout production.

Figure 2 shows the stress-strain diagram adopted within the Rilem

design method. The values of stress and strain in the diagram

are defined in RILEM TC-162 TDF (10) and the design standards

using this approach such as Eurocode 2 (11) or NZS3101 (12).

Similar recommendations are given in guidance by the German

Characteristic Steel Fibres Synthetic micro-fibres Synthetic macro-fibres

Characteristic of Fibres

Shape/Texture Cold drawn hooked ends Straight smooth Continuously embossed

Collation Glued bundles Fibrillated UncollatedLength (mm) 60 12 48

Diameter (mm) 0.75 0.02-0.03 0.5-1

Tensile Strength (MPa) 1050 30 550

Elastic Modulus (GPa) >200 2 10

Dosage (kg/m3) 25-35 1-2 6-10

Service temperature (°C) 300 60 60

Melting point (°C) >800 150 150

Base material Carbon steel Polypropylene Polyolefin (polypropylene, polyethylene)

Comparison with conventional concrete (Unreinforced except where indicated by*)

Workability Reduced Slightly reduced Slightly reducedPlastic shrinkage cracking Unaffected Reduced Slightly reduced

Early-age thermal cracking Reduced Unaffected Reduced

Long-term shrinkage cracking Reduced Unaffected No data

Stray current corrosion Reduced Unaffected* Eliminated

Durability in chloride exposure* Increased Unaffected* Greatly Increased

Fire spalling resistance Slightly Increased Greatly Increased Increased

Compressive strength Unaffected Unaffected Unaffected

Residual flexural strength Increased Unaffected Increased

Impact strength Greatly Increased Unaffected Increased

Flexural toughness Increased Unaffected IncreasedAbrasion resistance Increased Slightly increased Slightly increased

Freeze-thaw resistance Slightly increased Increased Increased

Flexural energy absorption Greatly Increased Unaffected Greatly Increased

Concrete permeability Slightly increased Slightly increased Slightly increased

Pump wear Increased Reduced Reduced

Safety*Hazard from handling and protruding

fibresIncreased Increased

Finishing Extra care during floating Exposed fibres soon abradeFibres may float and protrude in poorly

designed mixes

Table 2. Comparison of steel and synthetic fibres

Concrete: Fibres




Concrete Association and in Concrete Society Technical Reports

63 and 65 (13, 14).

Although codes and recommendations mainly provide information

regarding steel fibre reinforced concrete, the design principles

apply equally to other structural fibres. Testing may be required to

confirm the validity of some of the design factors and allowance

should be made for the difference in stress-strain behaviour, long-

term performance and implications of exceptional load scenarios,

such as fire.

The properties determined from specific tests will differ from the

full-scale structure. The designer should verify that properties

are based on representative concrete samples and provideadequate allowances for the variability of the test method, the

pattern of loading and the difference in geometry between the

test specimen and the actual structure. Care should be taken in

the choice of test method (eg. beam or panel) and specified limit.

In particular, high residual flexural strength requirements at high

deflection values may have no relevance to the design and prove

unnecessarily difficult to achieve.

The full life of the structure should be considered in the structural

deign (5). For example, bursting performance of tunnel segments

during construction is based on tensile splitting and compressive

strength. Permanent loading for the serviceability limit state is

normally based on ensuring elastic un-cracked behaviour and as

such relies on the flexural strength at first crack. The ultimate limit

state allows for some plastic behaviour and utilizes the residual

flexural strength. However, fibres are generally not relied upon

as the primary reinforcement in plastic hinge regions. Structural

designs for serviceability generally incorporate limits on stress,

strain (eg. 10 microstrain in the tensile section) or crack width (eg.

3mm maximum for durable fibres).

Due to the random distribution of the fibres in a concrete matrix,

there is no recognised method to calculate crack widths in fibre

reinforced structures. A reliable first approximation of crack widths

can be estimated in members subject to axial and bending forcesby derivation of stress-strain diagrams in a linear elastic analysis.

Crack widths can be therefore be predicted according to the

Project Country Application Fibre typeDate

enteredservice

Halsney Tunnel Project Norway Sprayed concrete lining to a sub-sea tunnel Macro-synthetic 2005

Atlantic Ocean Tunnel

ProjectNorway non-corrodible reinforcement in a sub sea tunnel Macro-synthetic 2009

E18 Motorway Norway Sprayed concrete lining to tunnel close to waterfront Steel 2009

E18 Motorway Norway non-corrodible reinforcement in ground with high sulphide levels Macro-synthetic 2009

Sydney Northside

Storage TunnelAustralia sprayed concrete lining under chloride exposure Macro-synthetic 2003

Docklands Light Rail

ExtensionUnited Kingdom

track slab subject to stray currents and sulfate and chloride

exposureMacro-synthetic 2004

Quarry Bins United KingdomSprayed concrete repair to abrasion damaged aggregate storage

binsSteel 1998

Blackpool South Shore United Kingdom Precast revetment units subject to handling, abrasion and seawater Macro-synthet ic 2006

Channel tunnel rail link United Kingdom precast segments subject to fire loading Steel and micro-synthetic 2003

Gold Coast Desalination

ProjectAustralia Segmental lining for intake and discharge tunnels Steel 2008

Table 3. Examples of fibre reinforced concrete under extreme conditions.

Figure 2. Stress-strain diagram for fibre reinforced concrete

Figure 1. Fibre types to BS EN 14889

Concrete: Fibres




following equation:

w = b (h-x) (1)

where w is the crack width, b is the strain at the extreme

tension fibre, h is the section thickness and x is the depth of the

compression portion (Figure 3).However, the values obtained from such assessments are often

higher than the 0.1 to 0.2mm limit for steel fibres in extreme

exposure conditions (Section 2.1). Furthermore, the design

methods are not reliable enough to ensure these crack widths will

be consistently achieved. A prudent design approach for SFRC

exposed to chloride from seawater or de-icing salts is to prevent

the section from cracking during serviceability loading.

Long-term performance of FRC is heavily influenced by the

interaction between the fibres and the concrete matrix. Two aspects

are particularly important. Firstly, the aim of the addition of fibres is

to avoid the brittle failure associated with unreinforced concrete.

In FRC the development of excess strength and hardness inthe enveloping concrete matrix may result in a change from

ductile behaviour to brittle behaviour, as fibres fracture instead of

gradually pulling out of the matrix (15).

Secondly, the discontinuous nature of fibres means that they

may exhibit slip within cracked concrete leading to creep under

sustained loading. Recent research by Bernard on the creep

of cracked FRC (16) indicates that creep depends on the fibre

type, dosage and applied load (Figure 4). The results are specific

to the particular fibre types tested. The designer needs to verify

the influence of creep behaviour on the structure and provide

appropriate contingencies in the design, such as limiting the

tensile stresses.

Durability Design

Design Methodology

The durability design for steel fibre reinforced concrete involves

the prediction of carbonation and chloride ingress and the

associated corrosion. In conventionally reinforced concrete,

corrosion damage to the concrete, such as spalling or cracking,

would often be used as the serviceability limit state. In the case

of FRC, the loss of cross-sectional area of fibres by corrosion

determines the depth of concrete over which the contribution of

fibres to tensile and flexural strength should be ignored by the

structural designer. A limiting value of 20% loss is typically used.

The accuracy of the assumed exposure conditions is critical to

the validity of the predictions. In the case of a desalination facility,

conditions during construction and any maintenance outages

should be considered, as these may be more severe than those

in service. Table 4 indicates the input parameters defining the

service conditions and the characteristics of the concrete mix.

Figure 3. Calculation model for estimation of crack width in fibre reinforced

members subject to axial compression and bending

Figure 4. Relationship between creep deflection at 100 days and imposed load

for ASTM C1550 panel test (16).

The surface level of chloride will vary depending on the salinity

in the environment and amount of contact the concrete has with

the environment. For concrete in the marine environment the

surface chloride level will typically vary from 1-2% for submerged

and atmospheric exposure to 4% for wetting and drying. For

desalination schemes where the salinity can be 50% higher

than seawater surface chloride levels may be correspondingly

increased.

The carbonation and chloride models used in durability design

are discussed below.Carbonation Model

The carbonation model commonly used is based on work by the

Building Research Establishment (17) showing a good correlation

between the carbonation rate and oxygen permeability. The latter

is predicted based on the cement type, concrete strength and

duration of curing. Gas permeability or diffusion testing should be

carried out on proposed concrete mixes to validate the assumed

oxygen permeability value.

The modelling is normally deterministic rather than probabilistic,

General input parameter Specific input parameters

Relative humidity (%) Temperature

(°C) 28-day cube strength (MPa)

Cementitious content (kg/m3) Tri-

calcium aluminate level of cement

(%) Slag, fly ash or silica fume level

(%) Reinforcement diameter (mm)

Fibre thickness (microns) Cover

(mm) Allowable corrosion loss (%)

Service life (years)

Carbonation: Carbon Dioxide Level

(%) Intrinsic oxygen Permeability

(m2) Curing (days)

Chloride: Background and surface

chloride levels (%) Chloride diffu-

sion value (m2/s) and age (days)

Aging factor Exposure type (wetting/

drying, submerged, atmospheric)

Steel type (stainless, carbon)

Additional protective measures

(coatings, corrosion inhibitor)

Table 4. Input parameters to durability modelling

Concrete: Fibres




Concrete: Fibres

in that it adopts single values for each parameter rather than

allowing for variation and then predicting the likelihood of different

outcomes. The adopted values often reflect the worst likely

conditions for temperature and carbon dioxide levels. The carbon

dioxide level will typically lie between 0.04%, the average outdoor

value, and 0.1% for poorly ventilated spaces (17).Relative humidity is a key parameter affecting carbonation and a

sensitivity analysis should be carried out to encompass the range

of possible values during construction and in service.

Typical output from the model is shown in Figure 5.

Chloride Model

The chloride ingress by diffusion is predicted using a model based

on published research (18). The model uses Fick’s second law of

diffusion:

(1)where Dc is the diffusion coefficient (m2/s), Cx is the chloride

concentration at depth x (m) after exposure time t (s), Csn is the

notional surface chloride level (% by mass of binder) and erf is

the error function. The diffusion coefficient will increase withtemperature but reduce with age, dependent on the concrete mix

and the exposure conditions. The model allow for these effects,

as well for as the release of chlorides due to carbonation (18).

The chloride diffusion coefficients assumed in the design should

be verified by appropriate testing, such as the NTB 492 method

(19).

The chloride levels increase until the threshold chloride level is

surpassed and then corrosion is initiated. The threshold level

depends upon the cementitious type, service temperature,

presence of corrosion inhibitors and reinforcement type (eg.

carbon steel, stainless steel).

The rate of corrosion of steel is assumed to increase as the

chloride level in the concrete adjacent to the steel increases.

For example, the tidal and splash zone in marine conditions:

(3)

where CR is the corrosion rate (microns/year) and Cx is the

chloride concentration (% by mass of binder) at the depth of

the steel reinforcement. The corrosion rate will depend on the

temperature and relative humidity. An adjustment for temperature

can be made using Arrhenius law (18).

The model allows different corrosion mitigation measures to be

assessed, including: changes to the concrete mix and the useof protective coating, integral waterproofers, silane, controlled

permeability formwork and stainless steel reinforcement.

The cumulative corrosion from each stage of the structures life is

calculated and used to estimate a depth over which the effect of

the fibres should be ignored, in a similar way to the carbonation.

Figure 6 shows typical graphical output from the modelling.

Conclusions

Fibres provide significant advantages over reinforced and plain

concrete under extreme conditions, including exposure to fire,

abrasion and seawater. Steel fibres and synthetic macrofibres

Summary of Input

Parameter units value

relative humidity % 85

temperature °C 25

carbon dioxide level % 0.03

28-day cube strength MPa 50

cementitious content kg/m3 400

ggbs level % 0

pfa level % 30

minimum cover mm 30

bar diameter mm 16

fibre thickness micron 750

acceptable loss of section % 20

curing days 3

oxygen permeability 10-6m2 1

service life years 100

Summary of Output (rebar)

corrosion initiation 52years

propagation of 0.1mm cracks

propagation of 0.3mm cracks

3years

15years

service life to 0.1mm cracks

cover for service life

55years

41mm

service life to 0.3mm cracks

cover for service life

67years

37mm

Summary of Output (fibres)

depth of loss of section of 20% 32mm

(a) Summary of input and output

(b) Graphical output showing loss of fibres during construction period

Figure 5. Typical output from carbonation model




increase post-crack ductility. This is an important consideration

for use in ground support,

Steel fibres by virtue of their discrete nature and small diameter

appear to eliminate galvanic corrosion and associated spalling

damage compared to steel rebar and enhance resistance to

chloride and carbonation induced corrosion. However, maximum

crack width should be limited to 0.1-0.2mm depending on the

service life and exposure conditions. Synthetic macrofibres are

non-corrodible but will be affected by elevated temperature and

some chemical agents.

Structural design methods are available for fibre reinforced

concrete. These should use values of compressive, flexural and

tensile strength based on performance tests on the FRC andshould consider the whole life of the element. Serviceability limit

state design should generally be based on elastic behaviour of

an uncracked section using flexural strength to first crack data.

Ultimate limit state design can allow for some plastic behaviour

using residual flexural strength data.

The interaction between the concrete matrix and the discrete

fibre is critical. SFRC may lose ductility when the concrete matrix

becomes too strong leading to fracture rather than pull-out the

fibres. Creep due to slip and elongation of fibres is also an issue.

Deformation and creep in cracked FRC depends on fibre type,

dosage and loading.

Durability design of facilities, such as desalination schemes,should assess the conditions during construction, operation and

at times of outages. Carbonation and chloride ingress can be

predicted from models based on published research. The loss

of cross-section of fibres by corrosion can be used to estimate

the depth of concrete over which any effect of fibres on flexural or

tensile strength should be ignored.

References

1. Greenhalgh J., “Segmental linings – the future is steel-fibre-reinforced”,

Concrete Magazine, October 2003, pp 19-20.

2. Perry B., “Synthetic macrofibres storm to the front of coastal defenceinnovation”, Concrete Magazine, November 2006, pp 72-73.

3. British Standards Institute, “BS EN 14889-1 Fibres for concrete, Part 1:

Steel fibres- definition, specifications and conformity”, BSI, London, 2006.4. British Standards Institute, “BS EN 14889-2 Fibres for concrete, Part 2:

Polymer fibres- definition, specifications and conformity”, BSI, London,2006.

5. King M. R., and Alder A. J.,”The practical specification of steel fibre

reinforced concrete (SFRC) for tunnel linings”, Proceedings ofUnderground Construction 2007 Conference, London, Brintex Ltd.

6. American Concrete Institute, “ACI 544.4R Design considerations for steel

fibre reinforced concrete”, 1996

7. Bernard E. S., “Durability of cracked fibre reinforced shotcrete”, 2nd

International Conference on Engineering Developments in Shotcrete,

Cairns, Australia, October 2004, In Shotcrete: More EngineeringDevelopments (Bernard E S ed) Taylor and Francis, London, 204, pp

67-80

8. Hannant D. J., “The effects of age up to 18 years under various exposure

conditions on the tensile properties of polypropylene fibre reinforcedcement composite”, Materials and Structures, Vol 32, No 216, March

1999, pp 83-88.

9. Basell, “Prof-fax and Moplen Polyproplene Chemical Resistance”, Data

sheet 08/02, 2002.

10. Rilem, “Final recommendations of TC162-TDF, Test and design methodsfor steel fibre reinforced concrete, design method”, Materials and

Structures, Vol 36, 2003, pp 560-565.

11. British Standards Institution, “BS EN 1992, Eurocode 2, Design of concrete

structures, Part 1-1, General rules for buildings”, BSI, London, 1994

12. NZS 3101, Concrete Structures, “Part 2- Commentary on the Design ofconcrete structures, Appendix C5A, Test and design methods for steel

fibre reinforced concrete subject to montonic load”, 2006, pp 7-13

13. Concrete Society, “Guidance for the Design of Steel-Fibre-Reinforced

Concrete”, Technical Report 63, 2007.

14. Concrete Society, “Guidance on the use of Macro-synthetic-fibre-reinforced Concrete”, Technical Report 65, 2007.

15. Bernard, E.S. 2008. “Embrittlement of Fibre Reinforced Shotcrete”,

Shotcrete, ACI, Summer edition, pp 16-21.

16. Bernard E. S., “Creep deformation of cracked fibre reinforced shotcrete

panels for Elasto-plastic concrete”, TSE Report Number 189, March2008.

17. Quillin K. ”Modelling degradation process affecting concrete”, CRC Ltd,

2001.

18. Bamforth P. B., “Enhancing reinforced concrete durability, Guidance on

selecting measures for minimising the risk of corrosion of reinforcement inconcrete”, Technical Report 61, 2004.

19. NTB 492, “Concrete, mortar and cement based repair materials: chloride

migration coefficient from non-steady migration experiments”, Nordtest

method, 1999.

(a) chloride ingress 50mm depth (b) loss of section of fibres for outages of

Figure 6. Output from chloride model

Concrete: Fibres





asturi Me tal Composite (P) Ltdi s a l e ad i n g m an u f ac t u r er a n de xporte r of a wide assortme nt ofK

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T h e c o m pa n y h a s a d yn a m i c t e a m

o f p r o fe s si o n a ls a t t h e he l m o f a f f ai r s .M r . S a m i t S i n g h a i i s t h e D i r e c t o r -Te chnical of the company. A te chnocratw i th w i de r a ng i ng ex p er i en c e i n t h e

f i el d o f s t ee l f i be r s, M r. S in g ha i h a sb e en o n e of t h e ke y p l ay e rs r e sp o ns i -b l e fo r t h e re m ar k ab l e gr o wt h s t or y o f

the company.C em en t C on cr et e, w he th er c on -

t a i n i ng n a t u r a l o r w a s te g l a s s a gg r e -g a t e i s r el a t i ve l y b r i t t le , a n d it s t en s i l es tr en gt h i s t yp ic al ly o nl y a bo ut on e

t e n t hs of i t s co m p re s si v e s t r en g t h .C on c re t e b y i t se l f i s na t ur a ll y v er y b r it -t le , l ac ki ng d uc ti li ty w he n t en si on o r

i m p a ct l o a d s ar e i m p os e d . W h e n s u b -j e ct e d t o t e ns i le s t re ss ed , u n -r e in f or c ed

concre te will crack and fail.Traditionally concre te has be e n suc-

c es sf ul ly r ei nf or ce d wi th s te el b ar s

a n d / or w e l de d wi r e f a b ri c s e t i n t o t h econcre te whe re analysis indicate s hight e ns i le st r es s o r h i gh i m pa c t l o ad s .

H ow ev er e ve n w el l d es ig ne d b ar-re inforce d concre te syste ms will mani-

fe st cracking ov e r time .F o r m a n y a p p l i ca t i o ns , i t i s b e c om -i n g i n cr ea s in g ly p o pu l ar t o re i nf o rc e

t h e c on c re t e w it h s ma l l, r a nd o ml y d i s-t r i b ut e d f i be r s . T h e ir m a i n p u r p os e i s t oi n c r ea s e t h e e n e r g y a b s or p t i on c a p a c-

i t y a n d t o u gh n e ss o f t h e m a t er i a l a l on gw i t h s u p er i o r c r a c k r e s is t a nc e .

The conce pt of fibe r-re inforce d con-cre te is not ne w, rathe r from a historicalpe rspe ctiv e it appe ars much like a con-

t emp or ary vers ion of a n ol d t heme.Historical re cords dating back to bibli-

Fiber Reinforced Concrete & Its Advantages

SFRC (Steel Fiber Reinf orced Concrete) Indu strial Flooring -A Su per Crack Resistance concrete

Samit SinghaiDirector- Tech nical, Kastu ri M etal Com posites (P) Ltd.




241www.masterbuilder.co.in · T h e M a s t er b u i l de r - July 2013

cal time s cle arly atte st to the practice ofu s i n g " s t r aw " i n b u i l d in g b l o c ks . E v e n

Roman building practice incorporate da ty p e o f " f i b er " - h or s e ha i r, w h i c h w a s

w i d el y u s e d i n t h e c o n st r u c t io n o f m a n y

i m p o s i n g s t r u c t u r e s n o t a b l y t h eC ol l os eu m . T h ro u gh t h e a g es t he r e-

f o r e, t h e u s e o f f i b er s h a s be e n a r e c u r-r i ng t h em e f ro m st r aw i n a d ob e, h a ir o fw i l d a n i ma l s t o t h e h o st o f m o d er n s y n -

t h e t ic f i b er s .Ste e l-fibe r-re inforce d concre te is a

s t a t e - o f - t h e - a r t c o m p o s i t e m a t e r i a lm ad e o f h yd ra ul ic c em en ts , f in e o rc o a rs e a g g re g a t e, a n d a d i s p e rs i o n o f

d i s c on t i n u ou s s t ee l f i b er s . I t m a y c o n -t a i n p o z zo l a n s a n d a d d i t iv e s c o m -m on ly u se d w it h c on ve nt io na l c on -

c r et e . T h e a m ou n t o f f i be r i n c o nc r et emixe s typically range s from 0.5 pe rce nt

t o 2 .0 p er c en t b y v o lu m e, a l th o ug hs m a ll e r a m o un t s h a ve b e en u s e d su c -c es sf ul ly i n r ed uc ti on o f p la st ic - a nd

d r y i ng - s h ri n k a ge c r a c ki n g . A c c o rd i n gto the Portland Ce me nt Association,

s t e el f i b e r c o n t en t s g r e a te r t h a n 2 . 0 p e r -c e n t r e s ul t i n p o o r w o rk a b i li t y a n d fi b e rdispe rsion within the concre te mix.

H o w ev e r, t h e m a i n e f f ec t o f a d d i ngs t e el f i b e rs i n c o n c re t e , t h a t i s a ls o t h em a i n a d v an t a g e of S F R C a n d t h e mo s t

u s e fu l r e ga r d i ng d e si g n o f h y p er s t a ti cc o n st r u c ti o n ( l i k e sl a b o n g r o u nd ) , i s i t s

p o st - cr a ck b e ha v io r o r t o ug h ne ss o fSFRC. Ste e l fibe rs in concre te start act-i n g w h en t h e f i r st c r a c k a p p ea r s a n d

hav e the ability to absorb and re distrib-u t e t h e l o a d s ( o r e n e rg y ) , s o t h a t t h eS F R C wi l l s t i l l be a b l e t o b e a r l o a d s

e ve n a ft er t he f or ma ti on o f c ra ck s. I nf a ct , S F RC h a s a d u ct i le b eh a vi o r o r

toughne ss and the re fore , that surpluso f f l ex u ra l c a pa c it y f r om t h e p l as t icp h a se (p o s t- c r a ck d uc t i l i ty ) c a n b e

u sed for d esi gn of st ru ct ur e wh end e f or m a t io n m u s t be c o nt r o l l ed l i k es l a bs o r f o r s t r u ct u r e s w he r e d e fo r m a-

tions controlle d the de sign like unde r-g r o un d l i ni n g s . I t i s t h e re a so n w h y, f o r

t h e s a me t h i c k ne s s, a S F R C s l ab o n

g r o un d c a n s u p p or t h i gh e r l o a d s t h a na conv e ntional concre te slab.

T h e ad d it i on o f t h es e f i be rs p r o vi d esimprov e me nts of the e ngine e ring prop-

e r t i es o f t h e co n c re t e s u c h a s Im p a ct

stre ngth, toughne ss (post-crack ductil-i t y ) , a b i l it y t o r e si s t c r a ck i n g a n d m at e -

r i a l d i si n t e gr a t i on , a s w el l a s f a ti g u er e s i s t a n c e . T h e e x a c t a m o u n t o fi n c r ea s ed st r e ng t h d e p en d s o n m a n y

v a r ia b l e s, e s p ec i a l l y f i b e r c o n t en t . W i t hf i b er c o n t en t s o f 1 . 5 p e r ce n t t o 2 . 0 p e r -

c e n t by v o l um e , d i r ec t t e n si l e s tr e n gt hwill incre ase 30 to 40 pe rce nt, and fle x-ural stre ngth (first crack) will increase

50 to 150 percent.

Benefits of Duraflex SFRC Floors Tot h e O w n er

- L es s Co st , H i gh Q ua li ty, L on ge r L i feo f F l o or s

- R es i st a nc e t o m i cr o c r ac k s p r op o -

gating into macro cracks- P ro vi de s h ig h i mp ac t r es is ta nc e

- Excell ent surface finish can beachie v e d

- E l im i na t es s p al l in g d u e t o c o rr od -ing re inforce me nt

- R ei n fo r ce s t h e e d ge he l pi n g t o p r e-

v e nt joint failure

To t h e C o n s ul t a n t

- C us om iz ed De si gn S up po rt- S ui ta bl e f or w id e r an ge of a pp li ca -

tions

- E as e i n d es ig ni ng fo r c om pl et e l if es p a n o f C o n cr e t e F l oo r s

- E ns ur es Op ti mu m u se of m at er ia l

and Technology.- R ed uc e s te el r ei nf or ce me nt r eq ui re -

me nts

To t h e C o n t ra c t o r

- Fast er c on st ru ct ion

- Reduced l abor cost- Ea sy t o ha nd le, mi x, p lac e an d fi n-

i s h v a r i et y o f F l o o rs s u r f ac e s .- E nv ir on me nt al ly f ri en dl yDISCRETE REINFORCEMENT

C ON TIN U OUS REIN FORC EM EN T

M i cro cracks

M icr o cr acks

Fibres

W i th ou t Fi bers

B RITTLE

W i t h F i b e r s

DUCTILE

- C om pa ti bl e wi th a ll s ur fa ce f in is hand coating te chnique s.

TMD U RA F LE X S t ee l F i b er s a n d

TMD UR OC RE TE P P F ib er s a re hi ghs t re n gt h f i be rs , w i th f a vo r ab l e s h ap e ,

orie ntation, and stre ngth. The stee l fibe rsare known to hav e posse ssed high te n-sile stre ngth and ductility. The most sig-

n i f i c an t f a c t or a f f ec t i n g r e si s t a nc e t oc r ac k p r op a ga t io n a n d s tr e ng t h o f t h efibrous concre te and mortar are

- S hap e a nd b on d a t fi ber ma tr ix i nt er-face

- Vo lu me f ra ct io n o f f i be rs- F ib er a sp ec t ra ti o an d Or ie nt at io n

o f f i b e rs- w or ka bi li ty a nd C om pa ct io n of

Concre te- S iz e o f C oa rs e A gg re ga te- Mixing

P er f o rm a n c e o f c o n ve n t i on a l c o n -c r et e i s e n ha n ce d b y t h e ad d it i on o f

f i be r s i n c o nc r et e . T h e b r it t le n es s i n c o n-cre te is re duce d and the ade quate duc-t i l i t y o f c o n c re t e i s e n s ur e d b y t h e a dd i -

t i o n o f F i b e rs i n c o n c re t e . T h e m a i n r e a -sons for adding ste e l fibers to concre tematrix is to improv e the post-cracking

r e sp o ns e o f t h e c o nc r et e i , e. , t o i m pr o veits e nergy absorption capacity and appa-

r e nt d u ct i li t y, a n d t o p r ov i de c r ac k r e si s -tance and crack control.

F ib er B le n ds fo r v ar io us FR C (F ib er r ei nf or ce d

Concrete) applications – WA Y TO LOOK FORWA RD!





Fibe r Ble nds – Concre te can be re in-f o r c ed b l e n d s o f s t e el a n d / o r s y n th e t i c

a n d/ o r c e ll u lo s e f i be r s. T h e r e as on f oru s i n g fi b e r b l e n ds i s t o e nh a n c e th e

p r o p er t i e s of c o n c re t e b y c o m b in g t h e

b e ne fi t s t h at e a c h p a rt i cu l ar f i be r t y pec a n i m p a rt .

T h er e i s no f i be r t y pe t h at c a ne ncompass all the de sire d prope rtie so f f re sh a nd ha rd en ed co nc re te in

t e rm s o f, f o r e x am p le , p r ov i di n g l o adbe aring capacity at cracke d se ctions,

c r a c k c o n t ro l , s p a ll i n g r es i s ta n c e a te le v ate d te mpe rature s, improv e d abra-s i on , i m pa c t a nd f r os t r es i st a nc e .

H o w ev e r, a p p ro p r i at e b l e n d s o f f i b er s ,w i th o r w i th o ut , t r ad i ti o na l r e in f or c in gb a r s c a n l e a d t o sy n e rg e t i c e f f ec t s , i . e .

c o mb i na t io n s o f d i ff e re n t f i be r t y pe sc a n e n h an c e c o n c re t e i n b o t h i t s f r e sh

and harde ne d state s.

L ar ge f i ber sP

P

Microfibe rs

Microcracks

Short microfibe rs

L ar ge f i ber s

Plain matrix

Strain

Stress

Properties of Fiber Blends ReinforcedConcrete

S t e e l/ S t ee l F i b e r B l e n ds

Small ste e l wire fibe rs are e ffe ctiv e

i n m i c r o- c r a c k b r i d gi n g , l e a d in g t o anincre ase d fractural e ne rgy and highe r

flexural strength.Their use,when blendedw it h l ar ge r s te el wi re Fi be rs , c an d ra -m a t i ca l l y i n c r ea s e t h e p ea k l o a d a n d

post-cracking pe rformance of concre te .In other words, by combining s teelf i b er s t ha t a re e ff e c t iv e in b o t h m i c r o-

cracking and in macro-crack bridging,s y n er g e ti c e f f ec t s w i l l i n c r ea s e t h e

f r ac t ur a l e n er g y a b so r pt i on c a pa c it yand toughne ss of the concre te .

S t e e l/ M i cr o S y n th e t i c F i b e r B l e n ds

Ste e l Fibe rs do not contribute sig-n i f i ca n t l y t o t h e p er f o rm a n c e of p l a s ti c

c o nc r et e , b e ca u se t h ei r s t re ng t h a n dstiffne ss diffe rs too much from the prop-

e r t i es o f c o n c re t e a t an e a r ly a g e . M i c r opolypropyle ne fibe rs are be tte r suite dt o t a ke u p s t re s se s i n p l as t ic c o nc r et ed u e t o t h e i r l o we r e l as t ic m o du l us . F u r-

t h er m or e , t h ei r a b il i t y t o i n te rf e re w i th t h ec a pi l l ar y f o rc e s b y w h ic h w a te r b l ee d s

to the surface of concre te re duces ther i s k o f p l a s ti c s e t t le m en t d u e t o wa t e re v a po r a t io n . C o n se q u en t l y, a b l e n d o f

large ste e l fibe rs and micro polypropy-le ne fibe rs can combine structural rein-f o rc e me n t w i th p l as t ic c r ac k co n tr ol .

T h e m i c r o s y n t he t i c f i b er s in t h e c o n -cre te also incre ase its re sistance to

spalling in fire situations.

Synthetic/Synthetic Blends

As pre v iously me ntione d, micro syn-

t h et i c f i be r s h a ve b ee n u s ed f o r m a nyye ars to e ffectiv e ly control plastic shrin-

kage cracking as we ll as plastic se ttle -m e n t c r ac k i n g i n c o n cr e t e f l oo r s a n dslabs. Howe v e r, once the concre te has

s et an d b e gu n t o g a in s t re n gt h , t h er ea r e n o b e ne f i t s wi t h r e s pe c t t o c r a c k

c on tr ol . M ac ro s yn th et ic f ib er s a red i me n si o na l ly m u ch b i gg e r t h an m i cr os y n th e t i c f i b e rs a n d t h e r e f or e t h e y p r o -

v i d e v er y f e w b e n ef i t s t o t h e p l a st i c c o n -c r e t e (a l t h ou g h t h e r e a re s o m e c o m-mercially available macro synthetic fibers

that are claime d to pe rform a similarrole to that of micro synthetic fibe rs).

T h e m a i n r o l e o f s y n th e t i c/ s y nt h e t ic

ble nds is to control plastic cracking (inf r e sh c o n c re t e ) a nd d r y i n g s h r in k a g e

c r a c ki n g ( i n h a r d en e d c o n c re t e ), a n dto improv e post-cracking toughne ss,


K a s t ur i M e t a l C o m p os i t e s P v t L t dReg us, Level 1 3, Platnm Tec ho Park,P l o t n o 17 & 1 8 , S e c t 3 0 A , V a sh i ,Navi Mumbai - 400705

Ph: + 9 1 - 7 21 - 2 5 9 0 29 3 /9 5E- m ail: [email protected]

Web: w w w.steelfiberindia.in

s u b je c t t o th e p r ev i o us l y m e n ti o n edprov isos on the long-te rm prope rtie s ofm a c ro s y n t h e ti c f i b e rs . M i c r o s y nt h e t ic

fibe rs also incre ase re sistance tospalling in fire situations.

Steel/Synthetic Blends

A more re ce nt de v e lopme nt in fibe rre inforce d ce me nt-base d composite s

c o n ce r n s t he u s e o f h y b ri d b l e n d ofS t e el a n d S y n t h et i c P P F i b er s . T h e c o n-

c r e t e t ou g h n es s c a n b e o p t i mi z e d b yusing ste e l fibe rs that will affe ct thecracking proce ss during differe nt stages

o f l o a d in g a n d m i c r o- f i b er s i m pr o v ec o m p os i t e s t re n g t h b y b r i d gi n g m i c r o-c ra ck s an d, t he re fo re , d el ay in g th e

coale sce nce of these cracks into macro-c ra ck s. O n t h e o t he r h a nd , m a cr o- f ib e rs

a r e m or e e f f ec t i v e i n b r i d gi n g l a r ge rc r a c k o p e ni n g s . T h e re f o re , b l e nd c anbe conside re d a multifunctional mate -

rial that is able to achie v e a se t ofd e s i re d p e rf o r ma n c e s by t h e u s e ofdiffe re nt Fiber type s; as a se cond exam-

p l e , t o u gh n e ss a n d d u c t i li t y c a n b e p r o -v i d e d b y h i g h -m o d u lu s f i b e rs , s h r i nk -

a g e c r a c ki n g c o n t ro l b y l o w -m o d u lu sf i b e rs , c o n d uc t i v it y b y c a r b on f i b e rs .



to e nsure that the y prov ide all this at a

f ai r p ri ce , p ar ti cu la rl y i n t he c o nt ex t o f

the price-se nsitive Indian marke t. Things

have however, taken a turn in recent times,

w i th c o nt r ac t or s u n de r st a nd i ng t h at t h e

l o ng t e rm g a in s w ou l d a l wa y s o f fs et a n y

h i gh e r i n it i al i n ve st m en t . W i th t h e m a r-

ke t ge tting se gre gate d along ce rtain

s p e ci f i c l i n e s, t h e j o b o f m a n uf a c t ur e r s

h as b ec om e i n a w ay a l ot e as ie r. F or t he

l a r g e s c a l e pr o j ec t s t h ey o f f er t h e b i g-

g e r m a ch i ne s, w h il e f o r t h e r ea l e s ta t e

s e c to r a n d sm a l l er p r o j ec t s th e r e i s a

v ast range of compact batching plants

av ailable in India today.

T h e I n di a n c o ns t ru c ti o n i n du s tr y h a ss ee n t he st ea dy g ro wt h o f r ea dy -m ix-

c on cr et e ( RM C) s ec to r o ve r t he l as t t wo

d e c ad e s . W i t h t h e i n c r ea s ed de m a nd

f o r s p e ci a l i ze d c on c r e te s uc h a s se l f -

compacting concre te , fibe r-re inforce d

concre te , te mpe rature -controlle d con-

c r e t e, e t c , c o n t ra c t o rs ha v e f o u n d a n

able ally in the late st ge ne ration concrete

b a t c hi n g p l a n ts . S t r i c te r s p e c if i c a ti o n s

a n d s t ri n g e nt q u a l i t y s t a n da r d s h av e

m a d e t h e u se o f c o n c re t e ba t c h in g

h e I n di a n c o ns t ru c ti o n i n du s tr y

h a s h a d a fa i ry t a le ru n o ve r t h e

Tpast two decades or so. It all started

w i th t h e o p en i ng u p o f t h e e c on o my i n

the e arly 1990s and the e nsuing boom

i n c o n st r u c ti o n . T h e en t r y o f g l o ba l p l ay -

e rs brought with it se ve ral ne w te chnol-

o g i es an d a g r e at e r f o c u s o n q u a l i ty.

T h e w ay c o nc r et e wa s pr o du c ed

unde rwe nt a se a change . Le ading this

r e vo l ut i on w er e t h e m od e rn c o nc r et e

b a tc h in g p l an t m od e ls . B y t h e t u rn o f

t h e c e n t ur y, I n di a h a d b e c o me o n e o f t h e

k e y m a r k et s f o r c o n c re t e b a t c h p l a n ts .

It is one marke t se gme nt that has be e n

m a i n ta i n i ng a st e a d y p a c e o f g r o wt h o faround 20% consiste ntly from the e arly

2 00 0s , w ha te ve r m ay b e t he s ta te o f t he

economy.D ic t at in g t he t re nd s h as b ee n a n e ve r

- e v olv ing custome r, who today wants a

concre te batching plant that should

o ff e r o p ti m um p e r fo r ma n ce , f u el e f f i -

c i e n cy, i s e n v ir o n me n t- f r i en d l y, s h o ul d

b e e as y t o i n s ta l l a n d if n e c es s a ry m u s t

be portable e nough to shift to anothe r

location. Manufacture rs on their part had


plants almost impe rative . Following the

p a t t er n s i n t h e d ev e l op e d wo r l d , R M C

c o u l d s o o n o v e r t a k e s i t e - m i x e d -

concrete (SMC) in popularity stakes here.

All the se factors hav e be e n fue lling the

growth rate of concre te batching plants

i n t he c ou nt ry. T he g ro wt h r at e i s p oi se d

to incre ase rapidly, giv e n the increase d

a d ap t io n o f R M C b ot h i n t h e i nf r as t ru c -

ture and re al e state se ctors.

Tough Competition

As me ntione d e arlie r, le ading play-

e rs are focusing across a range of

capacitie s, cate ring to diffe re nt marke t

s eg me nt s. A l ot o f R & D i s a l s o g o in g i nt ocoming out with product innov ations to

s u i t th e n ee d s of t h e In d i a n m a r ke t . F o r

ex am pl e, wi th l abou r c ost s get ti ng

st eep er b y t he d ay a nd l ab ou r al so

b e c om i n g d i f fi c u l t t o f i n d , c o m pa n i e s

a r e f oc u s i ng o n s e l f- l o a di n g m e ch a -

n i sm s i n c o nc r et e b at c hi n g pl a nt s . A

good example for this is av ailable in the

f o r m o f t h e po p u l ar C P 3 0 m o d el f r om

S c hw i ng S t et t er I n di a . T h e pl a nt w i t h

p la ne ta ry m ix er c om es i n t hr ee v er -

Equipme nt: Concre te Batching Plants

M.K. Prabhakar, Associate Editor

Concrete Batching Plants:Concrete Batching Plants:E mp ha si s o n Q ua l it y a nd Va ri et y o f C on cr et eDrives Continual Demand

E mp ha si s o n Q ua li t y a nd Va ri e ty o f C on cr et eDrives Continual Demand



sions, star, compartment and inline. CP30

i n li n e v er s io n w i th s k id a n d c o nv e yo r

c a n h e l p c o nt r ac t or s c u t d o wn o n l a bo u r

c o s ts . T h e c o m p an y h a d al s o i n r e c en t

time s come out with the late st v e rsion

o f H N 1 h o r i zo n t al b a tc h i n g p l a n t , f e a -turing plane tary mixe r with twin discharge

and incline d be lt conv e yor syste m, ide -

a ll y s ui te d f or p re ca st a pp li ca ti on .

Schwing Ste tter India also offe rs othe r

p o pu l ar m o de l s su c h a s t he M 2. 5 , t h e

largest foundationless concrete batching

p l a n t i n t h e c o u n tr y, a c c o rd i n g t o th e

company, and the CP18.L in nh of f I nd ia i s a n ot he r l ea di ng

p la ye r t ha t h as m ad e m aj or i nr oa ds i nt o

t h e I n d ia n m a r ke t w i t h i t s w i d e r a ng e o f

concre te batching plants. The 'Eurote c'S er i es o f c o nc r et e b a tc h in g p l an t s f r om

t h e c om p an y h a ve p r ov en t h ei r m et t le

i n s e ve r a l p a r t s o f t h e wo r l d. A m o ng i t s

spe cialtie s is the 'Eurote c Control Sys-

t em' (E CS) , wh ic h ens ures op ti mal

h o m og e n ou s m i x . G o i n g i nt o d e t ai l s

be hind the syste m, Mr.Ashok Tanna,

M an ag in g D ir ec to r o f t he co mp an y

e xp la in ed , “ Th e E CS i s a b at ch in g s o f t-

ware for full use of the plant automation

t hr ou gh a u se r- f ri en dl y w in do ws i nt er -

face.The systemis easy tolearnand offers

s e c u ri t y f e a tu r e s t o p r ot e c t s e ns i t i ve

d a t a a n d i np u t . P l a n t c on t r ol s c a n e a s -

i l y b e s wi t c he d b et w ee n f u ll y a u to m at e d

and total manual control giv ing full fle xi-

b i l i t y t o t h e p l a n t o p e ra t o rs . S o f tw a r e

o p ti o ns a l lo w t h e s y st e m t o b e a c c e ss ed

re mote ly v ia mode m giving he ad office

the choice to monitor plant production

and material consumptions. Data down-

loade d from the control syste m can be

r e ad i l y u t il i ze d i n M i cr os o ft W i n do ws

software allowing office staff to incor-

porate the data into v arious accountingpackage s. “Additional options for e xtra

a g gr e ga t es , s i lo s a nd e v en m oi s tu r e

c o n t ro l s e n so r s t o o c a n b e e a s il y i n t e r-

face d with the software syste m. Anothe r le ading playe r which has

b e e n f o c u si n g o n u n i q u e t e c h no l o gy t o

c a t e r t o a di s c e rn i n g c u s t om e r i s A j ax

F i o r i. T h e c o m pa n y ' s ' Ra d i u s L i ft A r m

B a t c hi n g P l a n ts ' r a n gi n g i n c a p ac i t i e s

o f 2 0 c u .m p er h ou r t o 3 0 c u .m p er h ou r,

fe ature the unique 'Swinging Radius Lift


which include the dragline type and the

c o mp a rt m en t b in t y pe w i th p l an e ta r y

m i xe r i n t h e 30 c u .m p e r h o ur c a pa c it y.

The plane tary mixe rs are manufactured

i n - h ou s e i n c o l l a bo r a ti o n w i t h E u r os t a r,

I t al y. T h e c o mp a ny a l so o f fe r s t h e ' i nl i n eb i n ' t y p e b a tc h i n g p l a nt s i n t h e c a p a ci t y

r an ge o f 3 0 c u. m p er h ou r t o 1 80 .c u. P er

hour.

Supplie rs are conce ntrating on

m od e ls w i th m o du l ar d e si g n t o e n a bl e

e a si e r i n s t al l a t i on . A q u ar i u s E n g i n ee r s

f o r e x a mp l e , o f f er s s t a t io n a ry c o n c re t e

batching plants featuring modular design

u n d er i t s ' S P ' s e r i es . T h e c o m p an y a l s o

o ff er s t wo m ob il e p la nt s, M P 2 1 a nd M P

2 4, w hi c h c an b e m ou nt ed o n r e- us ab le

p r e c as t f o u nd a t i on s . T h e c om p a n y' srange of concre te batching plants fe a-

ture control syste m base d on re quire -

m e n t o r a p p l i ca t i o n. E x p l ai n i n g t h e to p

f e a t u r e s o f t h e c o n t r o l s y s t e m ,

Mr. Sudhakar Waggh, Country Manage r

( S er v ic e ) o f t h e c om p an y s t at e d, “ O ur

batch control syste m is use r-friendly and

c a p a bl e o f p r o vi d i n g d a t a i n C S V fo r -

m at , d el i ve ri ng c on cr et e wi th 1 00 %

a c cu r ac y f o r c e me n t a n d a d di t i ve s, a n d

a l lo ws r em o te a c ce ss f or a f te r s a le s

s e rv i ce & t r ou b le sh o ot i ng . ” O t he r t o p

f e a tu r e s i n c l u d e G S M /I S M s y n c hr o n i -

z a t i on f o r d e l i ve r i ng o n l i n e r ep o r ts a n d

m e ss a ge s o n p h on e a nd m a il s , c o n-

Arm' te chnology. Se lf-loading of aggre -

gate s and sand with minimum wastage

i s e n su r ed d u e t o t h e t w o r a di u s l i f t a r ms ,

s wi n gi n g a l mo s t 1 80 d e gr e es . T h e p l an t

also e liminate s the ne e d for bins /parti-

tions like traditional syste ms as the radius

lift arms pick up mate rial from the ground.

It also offe rs compact batching plants,


“ Th e E CS i s a b at ch in g s of t-w ar e f or f ul l u se of th e pl an ta ut om at io n t hr ou gh a u se r-friendly windows interface. Thes ys te m i s e as y t o l ea rn a ndo f f er s s e c u r i ty f e a t u r es t o p r o -t ec t s en si ti ve d at a a nd i np ut .P l a n t co n t r ol s c a n e a s i ly b es w it c he d b e tw e en f u ll y a u t o -m at ed a nd t ot al m an ua l c on tr olg iv in g f ul l f le xi bi li ty t o t he p la ntoperators".

Ashok TannaM a n a gi n g D i r e c t o r, L i n n h o ff I n d i a

P l a n t s th a t a r e ea s y t o s e t u p a n d r e q ui r e l e s s la b o u r t o o p e r at e a r e i n d e m a nd



246 ·Th e M asterbu ilder - www. masterbu ilder. co. inJuly 2013

c r et e s l um p i n di c at i on , c o nt i nu o us l e ve l

i nd ic at or f or c em en t, a nd a ' mi xe r m in d'

fe ature for be tte r pe rformance of mixe r.W i t h c o m pe t i t io n i n t e ns i f y in g , m a n -

ufacture rs are also focusing the ir R&D

o n m a ki n g p l an t s ' g re en e r' . A g o od c a se

i n p o in t i s a v ai l ab l e i n t h e f o rm of t h e

range offe re d by Univ e rsal Construc-

t i o n M a c h in e r y & E q u i pm e n t . T h e c o m -

pany offe rs concrete batching and mix-

i n g p la n ts w h i ch a r e en v ir o nm en t -

f r ie n dl y d u e t o t he a d op t io n o f e l ec t ri c

d r i ve s , w h i c h d o n o t e m it a n y p o l l ut a n t s

and also ensure low noise . Highlighting

t h e o t h er s a l i en t fe a t u re s o f t h e t e c h-

n o l o g y , M r . R a j e s h K a w o o r , V i c e -

P r e si d e n t ( C on c r et e B u s i n es s ) o f t h e

company explai ned, “Our batching

p l an t s a r e a l s o e q ui p pe d w i th d u st f i lt e rs

a n d d u st c ol l ec t or s , w h ic h l i mi t d us t

p o ll u ti o n t o a g r ea t e x te n t. T h e l at e st

batching plants offe re d by us are fitte d

with adv ance d control syste ms which

e n su r e o p ti m iz a ti o n o f e n er g y d u e t o

supe rior ope rating e fficie ncy. “

Anothe r popular playe r that offe rs a

wide range is Apollo Infrate ch. The com-

p an y o ff er s p op ul ar m od el s s uc h a s

ATP 20, ATP 30, ATP 45/ATP 60 and

ATP 90/ATP 120. It also offe rs mode ls

su ch a s AT P 21, ATP 3 1, an d ATP 6 1

u nd er i ts c o mp ac t s e ri es . S im il ar ly,

Speedcrafts is one more name that

offe rs a wide range of concre te batch

mix plants which include s mode ls SCP-

30, SCP-45, SCP-60 and SCP-90 rang-

i n g i n c a p a ci t i e s f ro m 3 0 c u . m p er h o u r

to 90 cu.m pe r hour. It also offe rs com-

p a c t , m o b il e c o n c r et e b a t c h m i x p l a n t s

i n t h e 2 0 c u. m p e r h o ur c a pa c it y r a ng e .

Spe edcrafts also offers mobile concre te

batching plants with output ranging up

to 30 cu.m pe r hour capacity.C on m at , a n ot h er l e ad i ng b r a nd i n

c o ns t ru c ti o n e q ui p me n t m a rk e t, a l so

T h e r e a l e s t at e s e c t o r h a s b e e n h e l p in g s u s t a in d e m a nd f o r c o n c r et e b a t c h i ng p l a n t s

“ Ou r b at ch c on tr ol s ys te m i su s e r -f r i e nd l y a n d c a p ab l e o f p r o -v id in g d at a i n C SV fo rm at ,d el iv er i ng c on cr et e w it h 1 00 %a c cu r ac y f o r c e me n t a nd a d di -t i ve s , a n d a l lo w s r e mo t e a c ce s sf o r a f te r s a le s s e rv i ce & t r ou b le -shooting”

S u d ha k a r W a g ghC o u n tr y M a n a ge r ( S e r v ic e ) , A q u ar i u s E n gi n e e r s


A qu ariu s Eng ineer' s concrete batch ing plant M obile plants are doing well in sm aller towns and cities



o ff er s a w id e ar ra y o f f ul l y a ut om at ic

mobile concre te batching plants in the

2 0 , 2 5 a n d 3 5 c u .m pe r h o ur c a pa c it y

r a ng e . M a co n s , a f am i li a r n a me i n t h e

c o ns t ru c ti o n e q ui p me n t i n du s tr y, o f fe r s

bin typeplants underthe 'MCP'series,and

compact plants unde r 'MAC' series. Sany

I nd ia i s y et a no th er t op b ra nd t ha t o ff er sconcre te batching plants, consisting of

models SPB05 and SBP10.

With the gradual pe ne tration of RMC,

d e ep i n to th e ru r al p ar t s o f I n di a , a n d

the continue d thrust be ing prov ide d to

i n f r as t r u ct u r e d e v el o p me n t u n d e r t h e

XIIFiv e Ye arPlan, sev eral ne wplayers are

e xpe cte d to e nte r this lucrativ e marke t.

Positive Signals Emanate

The re are se v e ral se ctors which are

d r i v in g d e m an d fo r c o n c re t e b a t c hp l a nt s , n o tw i t hs t a nd i n g t h e r e ce n t

re cessionary tre nds. The transportation

s ec t or, f or e x am p le , h a s b ee n o n e, w ha t

withseveral highwayprojects,many of them

inv olv ing tunne ling , along with railways

announcing ke y proje cts offe rs immense

s c op e . T h e r e al t y s ec t or, e s pe c ia l ly i n

smalle r towns and citie s, is another mar-

k et t ha t i s d ri vi ng d em an d, e s p ec i a l l y f o r

compact sized plants. Manufacturers too

h a ve t a ke n n o te o f t hi s t re nd a nd c om e

out with models that offe r mobility.The re ce nt announce me nt from the

P r im e M i ni s te r, D r. Ma n mo h an S i ng h

a b ou t r a mp i ng u p m ea s ur e s t o i m pr o ve

i n fr a st r uc t ur e c o me s a s a s h ot i n t h e a r m

for the concrete batching plant manu-

facture rs. The Prime Ministe r has se t an

ambitious inv e stme nt targe t of ` 1.15

l a k h c r o re i n P P P p r o je c t s a c r os s c o r e

infrastructure se ctors such as rail, power

a n d p o rt i n t h e n e xt s i x m o nt h s, a t a

m e et i n g c o nv e n ed w i t h k e y i n f r as t r uc -

ture ministrie s re cently. The announce -

m en t i s ye t an o th e r t e st i mo n y t o t he

continue d thrust be ing prov ide d to

i n f r as t r u ct u r e d e ve l o pm e n t. A l l t h e s e

de v e lopme nts translate into a pe riod of

sustaine d de mand for concrete batching

p l a n ts i n t h e n e ar f u t u re .

“ O ur b a tc h in g p l an t s a r e e q ui p -p ed w it h d us t f il te rs a n d d us tc o l l ec t o r s, w h i c h l i m i t d u st p o l -l ut io n t o a g re at e xt en t. T he l at -e st b at ch in g p la nt s o ff er ed b y u sa re f it te d w it h a dv an ce d c on tr ols y st e ms w h i c h e n su r e o p ti m i-z a ti o n o f e n er g y d u e t o s u pe r io ro p e r at i n g e f fi c i e nc y “

Rajesh KawoorVice-President (Concrete Bu siness), Universal

C o n s t ru c t i o n M a c h in e r y & E q u i pm e n t


248 ·Th e M asterbu ilder - www. masterbu ilder. co. inJuly 2013

BlockMakingMachinery

ConcreteProducts

ConcreteTestingEquipments Concrete Testing Equipments

ConcreteCuttingMachine ConcreteCuttingSpecialist CuringCompounds

ConcreteTestingEquipment

T o k no w m or e o n t he p ro du ct s, s ol ut io ns a nd s e rv ic es o ff er ed b y t he l ea di ng b ra nd s f ea tu re d a bo ve w ri te t o: [email protected]

C o l u m b ia P a k o n aEngineering Pvt. Ltd.E c o no m i ca l l a r g e p a l l et s o l u ti o n sf r o m C o l u mb i a

H e s s C o nc r e te M a c hi n e ryI n d i a P v t . L t d .S u c ce s s t h r o u gh i n n o va t i o n &technol ogy!!!

S r i P a r i j at h a M a c h i n er yW o r k s P v t . L t d .Leadi ng M anufacturers and Exporters ofConcrete Bl ocks, Interl ock Pavi ng Bl ocks& Terrazzo Ti l es M achi nery i n Indi a

B u i l d te c h I n d i a C o r p o r at i o nM anufacturers & Suppl i ers of PrecastC o n cr e t e P r o du c t s

P r i m e T e ch n o l o g ie sH u s q va r n a c o n st r u c ti o n p r o d uc t s a n dc o n c re t e c u t t in g m a c hi n e s

A b c on Te c h & B u i ld A i ds P v t L t dC o n c re t e S a w in g & D r i l l in g , R e t r o f it t i n g &R e s t or a t i on w o r ks

R o t h o R o b e r t T h o m a sN u mb e r o n e i n c u ri n g f a ci l it i esA d v an c e d G e r ma n Te c h n ol o g y

H i t e c h C o n c re t e S o l u t i on sChennai Pvt. Ltd.S p ec ia l iz e d i n p r ov id i ng s o lu t io n s t o t h evari ous concreti ng i ssues through i n-si tuand l aboratory testi ng

R & M I nt e rn at io n alS o l u ti o n s i n f i b r e w r a p pi n g ,c a r b on c o m po s i te s t r en g t h e ni n g ,m i cro concreti ng, structural steel ,d e s i gn a n d t u r n ke y p r o j e ct s .

S.N. EngitechD e v e l o pe r s P v t . L td .Concrete Repair, Inj ecti on, Coati ngSystem Sol uti ons & Equi pm entConsul ti ng & Speci fi cati ons.

S t r u c tw e l D e s i gn e r s &C o n s u l ta n t s P v t . L td .E x cl u si v e & i n n o va t i ve R e p a ir s o l u ti o n s,G r e en / B r o wn f i e ld i n d u st r i al / Wa r e h ou s i ngproj ects wi th tank farm s etc

T e ch n i c a l & S c i e n t if i c S a l e s ( TA S S )I n t r o du c i ng s t a t e o f t h e a r t c o n c re t e p a nm i xer of i nternati onal qual i ty, Concretetesti ng equi pm ent/ Soi l i nvesti gati onequi pm ent

R e fe r P a ge N o .: 2 5 5 R e fe r P a ge N o .: G a te F ol d R e fe r P a ge N o .: 2 6 5

Ref er Page No.: 277 Refer P age No.: 121 Ref er Page No.: 289 Ref er Page No.: 277

Ref er Page No.: 287 Refer Page No.: 185 Ref er Page No.: 199 Ref er Page No.: 177 & 179

R ef er P ag e N o. : 1 77 & 1 79

PARIJATHA MACHINERYA R I J A T H A M A C H I N E R Y




he ways and means to convey

and place concre te hav e unde r-Tgone a se a change ov e r the last

t hr ee d ec ad es a nd i n a w ay h av e p l a ye d

a bi g ro l e i n t h e p r ol i fe ra t io n o f m e ga

p r o j ec t s , w h i c h w e r e e a r l i e r c o n si d e r ed

i m po ss i bl e . W h et h er i t i s t h e t a ll e st

b u i l d in g o r t h e l on g e st t u n n el , i f t h e re i s

o n e t hi n g c om m o n a m o ng a l l m aj o r

proje cts, it hasto be the e quipme nt being

u s e d f or c o n ve y i ng a n d p l a c i n g c on -

c r e t e. F r om s et t i n g n e w r e c or d s in v e r -

tical concre te pumping to pumping

concre te ov er re cord distance horizon-

tally, it is one market se gme nt that has

g ro wn s te ad il y i n I nd ia . A cc or di ng t o

i n d u st r y e s t i ma t e s a r ou n d 2 5 0 0 u n i t s

o f c o n c re t e p u mp s a r e b ei n g s o l d i n

t h e c o un t ry o n a n a v er a ge e ve r y y ea r.

G i v en t h e c on s i st e n t th r u s t t o i n fr a -

s t r u ct u r e d e v el o p m en t a nd w i t h t h e

s c al e o f p r oj e ct s g et t i ng b i g ge r b y t h e

d a y, t h e se n u m be r s c ou l d g r ow e x p o-

n e n t ia l l y i n t h e c o m i ng f u t u r e .

Among concre te pumps, stationaryconcrete pumps are the prefe rred choicef o ll o we d b y b o om pu m ps . C o nc r et epumps is a marke t se gme nt which has

s ee n i nt en si fy in g c o mp et it io n, w it hm a nu f ac t ur e rs f i gh t in g i t o u t o n a s m u cho n t he pl an k o f t ec hn ol og y a s p ri ce .

Le ading players have also be en rampingup the ir e xisting manufacturing and se r-

v ice ne tworks in a growling marke t.

H i g h er & L o n g e r

C o n c r e t e p u m p s h a v e a l w a y s

e njoye d consiste nt de mand in the Indian

m ar ke t o ve r t he p as t t wo d ec ad es . W i th

t h e n ee d t o p um p c o n c re t e h i gh e r a n d

longe r, while also not compromising on

t he e nd -q ua li ty o f c on cr et e, i t is o ne

p r o d uc t c a t e go r y, w h o se u s a g e h as

be come almost impe rativ e for contrac-t o r s. T h e m a rk e t f o r c o n c re t e p u m ps i n

I n d i a i s p a s si n g t h r o ug h o n e i t s m o st

c r u c i al p ha s e s. I t is a p h a s e w h i c h i s

w i t n es s i n g c o n s ol i d a t io n b y b i g n a m e s

a n d e n t h us i a st i c c o m p et i t i on f r o m t h e

n o t -s o - bi g o n e s . T h e m a r k et w h i c h h a s

m a in t ai n ed a h e al t hy g r ow t h r a te of

2 0 %- 3 0% c o ns i st e nt l y o ve r t h e p a st

d e ca d e c o u l d g r ow a t a q u ic k en e d p a c e

i n t h e n e a r f u t u re , w h a t w i t h t h e p o s it i v e

fore casts for the e conomy. It is also one

E q u i pm e n t: C o n c re t e P l a c em e n t

Concrete Placing Equipment: Application Requirements Dictate Market TrendsM. K. Prabhakar, Associate Editor



marke t se gme nt among concre ting

e quipme nt which is se t to witne ss inte nse

c o m pe t i t i on i n t h e ne a r f u t u re .

The de mand for boom pumps has

hit the upward curv e ov er the past five

ye ars. Pushing the de mand has be e nthe spurt in infrastructure projects.A good

c as e i n p oi nt i s th e nu mb er o f m et ro

p r o j ec t s a r o u nd t he c ou n t r y. F r om

building e le v ate d v iaducts and stations

to underground construction, where boom

p u m p s p la y a k e y r o l e i n a r e as l i k e s i d e-

w a l l c o n st r u c t io n , t h e y a r e n o w a m u ch

s ou g ht a f te r t y pe o f e q ui p me n t f o r m e t r o

proje cts. Manufacture rs hav e spotte d

the rising opportunitie s and come out

w i th r a ng e o f c a pa c it i es s p ec i fi c al l y

tailore d to me e t the de mands in India.H o r s es f o r C o u r se s

As me ntione d e arlie r, application

has be en driv ing de mand patte rns for

c o nc r et e p u mp s i n t h e c o un t ry. I n cr e as -

i ng h i gh - ri s e c o ns t ru c ti o n i n m e tr o s

a n d b o o mi n g m i d - r i se c o n s t r uc t i o n i n

s ma l le r c i ti e s, f o r e x am p le , h a s n ec e s-

s i ta t ed p u m p m o de l s sp e ci f ic a ll y t a i-

l o re d f o r t h e n e ed . T h er e fo r e, v er t ic a l

p u mp i ng c a pa b il i t ie s h a ve b e en a n a r ea

o f f o c us a m o n g c on c r e te p u m p m a n u -

f a c t ur e r s i n r e c en t t i me s . S e v er a l ne wm od e ls c a te r in g t o t h is m a rk et s e gm e nt

h a v e b e e n l a u n c he d i n r e c en t t i m e s. A

good e xample can be found in the form

of the SP1600 model unveiled by Schwing

S t et t er I n di a r ec e nt l y. I t h a d e a rl i er

launche d the SP1400 and SP1800

m o d e l s f o r h i g h - r i s e c o n s t r u c t i o n .

S c hw i ng S te t te r I n di a al s o h a s i n i t s

r a ng e , t h e po we r fu l S P3 6 00 , w i th t w in

c i r c u it 1 60 ba r p r e ss u r e v a l ve , i d e a ll y

s u i t ab l e f o r c o n c re t i n g b e y on d 20 0

m et re s h ei gh t, a nd c o me s i n a n a es -

t h et i c a e ro d yn a mi c d e si g n. T h e c o m-

pany's othe r trailer pump mode lsinclude ,

S P1 00 0, B P3 50 , S P1 20 0, S P2 80 0, S P

4800 and SP8800. Aquarius Engine e rs is anothe r le ad-

ing name that is cate ring to the high-

r i se p r oj e ct s eg m en t . I t s 7 0 0, 1 0 00 , 1 4 00

a n d 2 1 0 0 s e ri e s o f h i g h p e r fo r m an c e

pumps are use d for high-rise and long

distance conv e ying. A unique fe ature

of all Aquarius concre te pumps is the

w a t er c l e an i n g s ys t e m an d e f f ec t i v e

r e ve r s e p u m p in g o f c o n c re t e . A p u m p

re gulator prote cts the hydraulic syste m

from ov e rhe ating and the e ngine from

o ve r lo a di n g. A q ua r iu s E n gi n ee r s r a ng e

include s its late st ne w look mode ls 703D,

1004D and 1405D.The se mode ls fe ature

a c a no p y w h i c h h e l p s b r i n g d o w n s o un d

le v e ls of the pumps drastically, a factor

s o c r uc i al , e s pe c ia l ly i n u r ba n e n vi r on s .Global playe rs hav e be e n e nte ring

t h e I n d ia n m a r ke t i n r e c en t t i m e s, e i t h er

b y s et ti ng u p t he ir o wn m an uf ac tu ri ng

u n i t s o r w i t h t i e - up s w i t h d o m es t i c p l a y -

e r s . U n i ve r s al C o n st r u c t io n M a c hi n e r y

& E q u i pm e n t L t d f o r e x a mp l e h a s n o w

t ie d u p w it h Z oo ml io n f or d is tr ib ut io n,

m a r k et i n g a n d s e r vi c e o f i t s c o n c re t e

p u mp s i n I n di a . G oi n g i nt o d e ta i ls o n

what giv e s the range the e dge ov e r

c o mp e ti t io n , M r. R aj e sh K a wo or, V i ce -P r e si d e n t ( C on c r e te B u s i n es s ) o f t h e

c o m p an y e x p l ai n e d, “A l l t h e c o n c re t e

and truck mounte d boom pumps man-

u f a c tu r e d b y Z o o ml i o n a n d of f e re d b y

U n iv er s al a r e e q ui p pe d w i th a n a u to -

m at ic c en tr al i ze d l ub ri ca ti on s ys te m

w h ic h e n su r es p r o p er a n d t i m el y l u br i -

cation. The mode ls are also e quippe d

with hydraulic accumulator which av oids

ov e rloading on the hydraulic syste ms,”

fe ature s that be come ne cessary in order


N o t h i ng i s i m p o s s i b l e : T h a n k s t o p o w e rf u l c o n c r e te p u m p i n g m a ch i n e s , t h e re h a s b e e n a s p u r t i n m e g a

inf rastru ctu re projects in recent tim es

C o n c r et e p u m p s p la y a k e y r o l e i n a d h e ri n g t o s t r i c t p r oj e c t d e a dl i n e s

E q u i pm e n t : C o n c re t e P l a c em e n t



t o t ak e o n t he r ou gh a nd t um bl e o f I nd ia n

working conditions.

S u pp l i er s a r e f o cu s in g t h ei r R & D

efforts towardscoming out with machines

that are re ady to me e t the e v olv ing chal-

l e ng e s s u c h a s l a rg e r s c al e s o f p r oj e ct s .P u t z me i s t er I n d i a f o r e x a mp l e h a s i t s

B S A s e ri e s o f t r ai l er p u mp s wi t h f r ee -

flow hydraulics me chanism that helps

i n p u mp i ng l a rg e q u an t it i es o f c o nc r et e .

S o me o f i t s po p ul a r m o de l s i n cl u de ,

702D, 1403HE, 1404HD, 1405D, 1406E,

1407D, 1408D and 1409D. Apollo Infrate ch is one more top

n a m e wh i c h o f f er s a r a n g e o f c o n c re t e

p u m p m o d el s s uc h a s t he S AP - 5 0 an d

S A P- 2 0 . T h e c o mp a n i es r a n g e o f c o n -

c r e t e pu m p s h a ve b e e n p a r t o f v a r i ou st h e rm a l p o we r a n d c a n al p r o j e ct s i n

M ad hy a P ra de sh , C ha tt is ga rh a nd

J h a rk h a n d, a p a rt f r o m , h i g h - ri s e b u i l d-

i n g p r oj e c t s i n M u m ba i a n d ot h e r m e t -

r o s . O n e m o re l e a d i ng n a m e i n t h e f r a y

is REL- Construction Equipme nt Div i-

s i on , w i th i t s R e va t hi W ai t zi n ge r m o d-

e ls - T HP 4 5D, T HP 50 D a nd T H P6 0D,

w h i c h a r e d e s ig n e d f o r l o n g d i s t an c e

conv e ying.

s p ur t i n r e al e s ta t e, a s we l l as i n fr a -

s t r uc t u r e p r o j ec t s . M a n uf a c t ur e r s a r e

k e ep i n g a c l o se w a t c h o n t h e d e ve l o p-

me nts and strengthe ning the ir se rv ice

n et wo rk r ea ch i n o rd er t o ta p i nt o th is

p ot en ti al ly h ug e m ar ke t f or t ra il er

mounte d concre te pumps.

T h e B o o m C o n t in u e s

Boom pumps are gradually making

t h ei r p r es en c e f el t i n I n di a . T h ei r s a le s

figure s, hov e ring around the 150 units

a y ea r t i l l r ec e n t ly, i s b ou n d t o r i s e, f o l -

l o w in g t h e s p ur t i n m e t ro a n d f l y ov e r

p r o je c t s. M a n uf a c t ur e r s h a v e b e e n

banking on innov ativ e product design

a n d a v ar i e d c ap a c i t y r a n ge t o c a t er t o

T h e GC P 3 5 0 D / E De l u x e m o d el

from Gre av e s Cotton is anothe r powe r-

f u l c on c re t e pu m p t h at c a n g e ne r at e

h ig h p re ss ur e, u p t o 8 6 b ar s w it h t he

ability to placing concre te at distance s

o f o v er 4 0 0 m et r e s h or i z on t a l l y a n d 1 0 0

m e tr e s v er t ic a ll y. A n ot h er t o p b r an d i s

S an y, w hi ch o ff er s s ta ti on ar y p um p

m o d el s i n c l u d i n g, H B T 30 C - 1 0 0 6 D Y,

H B T 40 C - 1 40 8 D II Y, H B T 50 C - 1 41 0 D II Y

a n d H B T 6 0C - 1 4 13 D Y, t o m e n t i on o n l ya fe w among its e xte nsiv e range .W i t h c o m p et i t i on g e t t in g i n t e n se b y

t he d ay i n t he s ta ti on ar y c on cr et e p um p

marke t se gme nt. Ne we r marke t oppor-

tunitie s are also e me rging in the form of

hinte rlands that are now witne ssing a


Increase in core inf rastru ctu re projects like tu nneling is keeping demand consistent f or concrete pu m ps

A qu ariu s Eng ineers' 43 m boom pu m p m odel

“ Al l t he c on cr et e a nd t ru ckm o un t ed b o om p u mp s ma n u-f a ct u re d b y Z o om l io n a n do ff e re d b y U n iv e rs a l a r ee q ui p pe d w i th a n a u to m at i c c e n-t r al i ze d l u br i ca t io n s y st e mw h ic h e n su r es pr o pe r a n dt i m e ly l u b r i c a ti o n . T h e m o d el sa re a ls o e qu ip pe d w it h h yd ra u-l i c a c cu m ul a to r w h ic h a v oi d so ve rl oa di ng o n t he h yd ra ul icsystems”

Rajesh KawoorVice-President, Universal Constru ction

M a c h in e r y & E q u i pm e n t P vt L t d .

Bhavani Balakrishna with inputs from Knight Frank Research




the e v olv ing marke t dynamics. Pointing

out the de mand driv ers for boom pumps,

Mr.Sudhakar Waggh, Country Manage r

(Service), Aquarius Engineersobserved,”

H i gh v ol u me c o nc r et e w o rk i n m i ni m um

t im e a nd h ig h m ob il i ty m ak e bo omp u m p s pr e f er r e d e qu i p m en t f o r p r o -

je cts such as mass housing proje cts,

s l u m r e h ab i l i t at i o n p r o je c t s , i n d u st r i a l

projects, bridge projects, metro projects,

r o a d p r o je c t s , R M C b u s i ne s s, e t c . A d d i -

tionally, the de mand for stationary boom

place rs is picking up for high-rise build-

i n g p r oj e ct s i n c i ti e s l i ke M u mb a i, N o id a ,

B e n ga l u r u , P u n e , e t c . ”

W h i l e ea r l i er t h e r e wa s a l o t o f h y p e

a b ou t l o ng er r ea c h b o om s , t o da y y o u

have a scenario where there are boompumps ranging from 20m to the ove r 40

m r a n g e , h a v i ng c r e a t ed t h e i r o w n m a r -

ke tniche in India.Re ce nt time shav e se en

i n t e ns e c o mp e t i ti o n i n t h e 2 0 m he i g h t

r a n ge , s i n c e t h es e b o o m p u mp s w i t h a

s h o rt e r u n f ol d i n g he i g h ts a n d wh i c h

c o u l d b e d r i v en t h r ou g h n a r r ow r o a ds ,

a r e i d ea l ly s u it e d f o r u r ba n c e nt r es o f

I nd ia . T he 2 0 m b oo m p um ps h av e c o m e

a s t h e i d ea l s t ar t er b oo m p u mp s f o r r o a d

contractors, metro contractors and RMC

companie s that want a price -compe titiv e

machine that performs efficiently.

W i th c l ea r m ar ke t di ff er en ti at io n,

c o m p an i e s ar e f oc u s i ng o n o f f er i n gspecific solutions, as far as boom pumps

are conce rned. Aquarius Engine ers fori n s t an c e , o f f er s a 2 0 m b o o m p um p ,

a p a r t f ro m 3 2 , 3 6 a n d i t s r e ce n t l y i n t r o-d uc ed 4 3 m m od el , w it h a 5 -s ec ti on , ' RZ 'f o ld i ng b oo m . S c hw i ng S t et t er I n di aalso offe rs a wide range that include s

m od el s- S4 3, S 36 , S 20 a nd S1 7,d e s i gn e d fo r i n f r as t r u ct u r e p r o je c t s .

U ni ve rs al C on st ru ct io n M ac hi ne ry &Equipme nt offe rs boom pumps ofZ o o ml i o n w i t h b o o m v e rt i c a l an d h or i -

z on ta l r ea ch r an ge o f 3 5. 6 x 3 1. 6 m et re sand 18.2 x 21.6 me tres. The Zoomlionb o o m p um p s a r e eq u i p pe d w i t h t w i n

h y d r au l i c p u m p s fo r p u m p in g a n d a gi -

t a t i n g, e n s ur i n g h i g h r e l i ab i l i t y. A n o th e rs al ie nt f ea tu re i s t he q ui ck p is to n c ha ng ete chnology. The boom pumps also fe a-t u r e P L C t e c h no l o gy w h i c h a c c o rd i n g

t o t h e c o m p a ny e n s ur e s o p t i mi z a t io no f t h e h y dr a ul i c s y st e m r e s u lt i ng i n l o we r

fue l consumption. An e xte nsiv e range of boom pumps

i s a ls o of f er e d by S a ny I n di a u nd e r i t s

' S Y' a n d ' S YG ' s er i es . O n e m or e na m e

t ha t o ff er s m od el s i n v ar ie d b oo m r ea ch

c a p a ci t i e s i s P ut z m ei s t e r I n d i a w i t h i t s

B S F M 2 0 - 3, B S F M3 2 - 4 a n d B SF M 4 6-

5 models.

Discerning Customer

The Indian market for concrete pumpsi s e nt e r i ng a r a pi d g r o wt h p h a se . W i t hd e m an d e x p ec t e d t o pi c k u p f u r t he r, i t

is also a marke t whe re the compe titionis also ge tting more inte nse by the day.

While sev eral le ading global players havea l r e ad y s e t u p s h o p h e r e, t h e r e a r e se v -e r a l o th e r s, w h o a re w a i t in g t o g e t a

f o o th o l d i n t h i s lu c r a ti v e ma r k et . A p a rtf r o m k e y i n f r as t r uc t u r e p r oj e c t s s uc ha s m et r os , w h ic h h a ve a l wa y s b e en

d r i v in g d e m a nd f o r c o n c re t e p u m ps ,e ncouraging ne ws is also coming from

t h e r e a li t y m a r ke t , w h i c h i s e x p an d i n g,

i n t h e t ru e s e ns e o f t h e w or d . T h e re a l t yb o om w h i ch w as e a rl i er w i tn e ss e d i n

the me tros has spre ad to the de e p hin-te rlands. Infrastructure projects are alsoc o mi n g up i n r em o te a re a s. S u pp l ie r s

the re fore face challe nge s in the form oflogistics and se rv ice ne twork. Proje ct

assistance and prompt te chnical sup-p o rt s er v ic e s a r e a m on g v al u e a d di t io n sthat customershave takenas given, given

t h e h ig h l y c o m p et i t i ve s c en a r i o. I n h o wwell they serv e this de manding custome r

lie sthe ke yforthe succe ssofsupplie rs.W i t h p r o j ec t s c a l e s ge t t i n g b ig g e r, h i g he r c a p a c it y s t a t io n a r y a n d b o o m p u mp s c o u l d b e i n

d e m a nd i n t h e n e a r f u t ur e

” Hi gh v o lu me c on cr e te w or k inm in im um t im e a nd h ig h m ob il it ym a ke b o o m p u m ps p r ef e r re de q u ip m e nt f o r p r o je c ts s u ch a sm a s s h ou s i n g p r o j e c ts , s l u m

r e h a b i l it a t i o n p r o j e c ts , i n d u s t r i a lp r o j e c ts , b r i d g e p r o j e c ts , m e t r op r o je c ts , r o a d p r o je c ts , R M C b u s i-ness, etc. Additionally, thed e ma n d f or s ta ti o na r y b o om p l ac -e rs i s pi ck in g u p f or h ig h -r is eb u i ld i n g p r o je c ts i n c i ti e s l ik eMumbai, Noida, Bengaluru,Pune, etc”

S u d ha k a r W a g ghC o u n tr y M a n a ge r ( S e r v ic e ) ,

A qu ariu s Eng ineers






M.K. Prabhakar, As s o cia te Ed ito r

Concrete TransportationEquipment: On the Move

D e f fo r ts i n c o mi n g o u t w it h d e si g n a n d

fe ature s that suit the unique applica-

t i o n r e q ui r e m en t s o f t h e I n d i an m a r ke t .

P er h ap s t h e ri s in g p op u la r it y o f s e lf -

loading concre te mixe rs is the be st

e xample for applications dictating prod-

u c t d e s i g n a n d p o p u l ar i t y. T h e m a n eu -

v e r ab i l i t y o f t h e se m a c h i n e s, e s p ec i a l l y

o n si t e, a n d th e ir a b il i ty t o d ou b le u p a s

a mini batching plant has made the m

e x t re m e ly p o p u la r i n r e c en t t i m e s .

Innovative Strategies

I n a r a p i dl y e v ol v i n g m a r ke t , m a n u -

f a c t ur e r s ha v e b ee n f o c u si n g o n i n n o -

v ation in de sign and incorporation of ne w

te chnologie s in order to woo a custome r,

w ho i s n o l on ge r d ri ve n o nl y b y p ri c e b u t

he market for concre te transport

e quipme nt has be e n maintainingTa h ea lt hy g ro wt h r at e o f 2 5% - 30 %

i n r e c en t t i m e s , t h e r e c e ss i o na r y t r e nd s

notwithstanding. The increase d use of

transit mixe rs has ke pt manufacture rs

o n t he ir t oe s. C us to me rs ' p re fe re nc es

hav e force d product innov ations. Man-

u f a c tu r e rs h a v e b ee n f o c us i n g t h ei r R &

Equipme nt: Concre te Transportation



257www.masterbuilder.co.in · T h e M a s t er b u i l de r - J u ly 2 0 13

is looking for adde d v alue . Manufactur-

e r s h a ve b e e n c o n st a n t ly g e t ti n g f e e d-

back from e nd-use rs and incorporat-

i n g c h a n ge s i n t h e i r t r a n si t m i x er m o d -

e ls to maintain that compe titiv e edge . It

i s n o d i f f er e n t i n t h e c a se o f t r a n si t m i x -e rs. Manufacture rs ke e p talking to e nd-

u s e rs t o k ee p c o m i ng o u t wi t h i n n o va -

t i v e f e at u r e s. A g o o d e x a mp l e f o r i n n o -

v a ti o n c a n b e f ou n d in t h e fo r m of t h e 7

c ub ic m et re t ra ns it m ix er o f S ch wi ng

S t et t er I n di a , w h ic h c o me s w i th o p ti o na l

a c ce s so r y o f a d m i x er d o si n g s ys t em ,

a n a d di t io n w h ic h i s i d ea l ly s u it e d f or a

c o u n tr y l i k e I n d i a, w h e re q u a l i ty a s s ur -

a n c e o n s i te i s a m a j or i s s u e. S c h wi n g

Ste tte r offe rs a wide range of transit mix-

er s u nd er i ts 6, 7, 8, 9 , an d 10 cu bi cm e t re s e r ie s . O f f -e re d i n t hr ee d if fe re nt

v er si on s, i .e ., m ix er w i th s l av e e ng i ne ,

m ix er w it h P TO d ri ve an d m ix er m ou n-

t ed o n t ra il er, t he y c om e w i th a h o st o f

a d v an c e d fe a t u re s i n cl u d i ng , p l a s ti c

e x t en s i on c h u t e, w a t er m e t re , h y d r au l i c

chute adjustme nt me chanism and ¾ flap

drum cove r. The company has also se t

a ne w t rend wi th t he lau nc h o f i ts 3

c ub ic m et re c ap ac it y ' Ni mo' . W it h t he

common 6 cu.m class transit mixe rs not

be ing allowe d inside citie s during pe ak

t r af f ic h o ur s, i t m ea n t th a t th e re w as

o n l y a s m al l w i n do w, a v a il a b l e f o r R M C

d e l i ve r y a t s it e s . T h e Ni m o i s t h e on l y

transit mixer can be de liv ering RMC dur-

i n g d ay t i m e, a c c or d i n g to t h e c o m -

p a n y. A n o th e r a d v an t a g e o f t h e m o d el

is the facts that it can be mane uve re d

e as il y t hr ow n ar ro w r oa ds , a n a sp ec t

t h at i s c om m on t o m os t I nd i an c i ti e s

a n d t o w ns . S i m i la r l y, t h e s m a l le r c a pa c -

i ty a ls o m ea ns a m or e ec o no m ic a l op -

t i on f o r s i te s wh e re i t d oe s n ot m a ke

s e n se t o s e nd a l a r g er t r a n si t m i x e r f o rthe contractor.

One more name that offe rs both

s m a ll e r a n d h i g h er c a p a ci t y t r a n si t m i x -

e rs is Ajax Fiori. Its range includes the

X V J 4 0 01 , a n d th e XC 6 00 0 mo d el s ,

w i t h d r u m c a p a ci t i e s o f 4 cu b i c m e t re s

and 6 cubic me tre s re spe ctive ly. Transit

m i x er s f r om A j a x F io r i c om e s w it h a

h o s t o f f e a tu r e s s uc h a s a u n i q u e dr u m

d es ig n m ad e of h i gh ly d ur ab le s t ee l,

optimize d positione d spirals with anti-

we ar prote ction, e fficie nt hydraulics with

p l a n et a r y d r i v e, r u g g ed & c o m pa c t m i x -

i n g u n i ts , w a t er t a n k a nd p u m p a n d s p e-

c i al l o a di n g h op p er a n d u nl o ad i ng

chute , among othe rs.I n a m ar ke t l ik e t ha t o f I nd ia , i t m ak es

se nse for manufacture rs to offe r a cho-

i c e, a s w id e a s p os si b le , b e ca u se o f

t h e v a ri a ti o n i n p r oj e ct s c al e s. A p ol l o

I nf ra te ch , f or e xa mp le , o ff er s AT M2 ,

ATM 4 and ATM6 mode ls, in the 2 cubic

me tre , 4 cubic me tre and me tre capaci-

t i e s, r e s pe c t i ve l y. T h e se t r a n s it m i x e r s

fe ature long life mixing drum and spi-

rals made of ST-52 mate rials. Similarly,

G r e av e s C ot t o n o f f er s t h e G C M 4 5 X L ,

w i th 4 c ub i c m e tr e ca p ac i ty f o r s m al l er

p o u rs a n d t h e l a r g er G C M6 5 X L m o d el

f or b i gg e r p ou r s. Tr a ns i t m i xe r s f r om

t h e c o m pa n y f e a tu r e l o w c e n t re o f g r a v-

i t y w h ic h c r ea t es a n i d ea l b a la n ce d l o ad

d is tr ib ut io n, o bt ai ni ng b et te r d ri vi ng


A pollo Inf ratech of f ers transit m ixers in th e 2, 4 and 6 cu bic m etres capacities

S m a l le r c a p a c it y t r a n si t m i xe r s l ik e N i m o a r e i de a l l y s u i t ab l e f o r s m a l l er p o u rs i n c r a m pe d u rb a n c e n t r es




p o s it i o n a n d p e r fe c t s t a b il i t y, p a r t ic u -

l a rl y i n n a rr o w b e nd s , t r ai t s t h at a re so

c r u c i al f o r s a f e d r i vi n g i n I n d i a.W i t h I n d i a c o n t in u i n g to b e a ke y

m a r ke t f or t r a n si t m i x er s , i t i s no t s ur -

prising that many ov e rse as playe rs are

l oo ki ng t o e nt er t he m ar ke t. KY B, f ori n st a nc e , w h ic h i s th e la r ge s t t r an s it

m ix er p ro du ce r i n J ap an , h as r ec en tl y

e nt e re d i n to a s t ra t eg i c p a rt n er s hi p w i th

C on ma t I nd ia . W i th r ec es si on h it ti ng

E ur op ea n m ar ke ts h a rd , t he re h a ve

b e en i n d i c at i o n s t h a t m an y b i g n a me s

from Europe are e ye ing the Indian tran-

s i t m i xe r m a rk e t. S i mi l ar l y, S a ny, a g l ob a ll ea de r i n c on st ru ct io n e qu ip me nt a n-

nounced production of truck mixe rs from

i t s pr od u ct i on u n it i n P u ne a f e w y e ar s

ago. Truck mixe r mode ls from the com-

p an y i nc lu de , T M0601 , TM002 an d

TM0603.

A G l u t o f Ne w M a c h in e s

C on v er g en c e s ee m s t o b e t h e n a me

o f t h e g a me , w h e th e r i t i s e l ec t r on i c s o r

e ve n i n t h e c a se o f c o ns t ru c ti o n e q ui p -

me nt. A single machine that doe s mul-

tiple jobs is what the typical Indian con-

t r a c to r i s l oo k i n g f o r, a n d th a t i s w h a t

the y ge t with se lf-loading concre te mix-

e r s . T h e se m e a n m a c h in e s a r e m o b i l e,

t h ey m i x co nc r et e a nd h el p i n l a yi n g it

t o o, m a ki n g it a n a l l- r ou n de r, t h at h a s

be come impe rativ e construction site s.T h e ir s e l f- l o a di n g n a t u r e m ea n s s a v -

i n g s o n l a b ou r c o s t s t o o . T h e se m ix e r s

hav e be come the staple whe ne v er the

re quire me nt is small to me dium con-

c r e t in g j o b s a t s e mi - u r ba n a r e as a n d

r e mo t e p ro j ec t s i t es . T h ey o f fe r e x ce l -

l e n t m o bi l i t y o n s i te . W i t h a l m os t a l l m o d -

e ls fe aturing 4 whe e l driv e s and supe rb

m a n eu v e ra b i l i ty, t h e y a r e c u t o u t f o r t h e

r o ug h a n d t u mb l e o f I n di a n c o ns t ru c -

t i o n s i t es , w h e re s l u s hy c o n di t i o n s a r e

c o mm on . T h ey a l so c o mp l em e nt l a rg e rcapacity concre te batching plants and

t r a n si t m i x er s a t m aj o r i n f r as t r u ct u r e

proje cts too, adding to the ir v e rsatility.W i t h t h ei r p o pu l ar i ty p i ck i ng u p , i t i s

no wonde r that compe tition is intensify-

i n g i n t h i s ma r ke t s eg m en t . O n e of t h e

f i r st n a me s t o e n t er t h e fr a y w a s A j a x

F i o r i, w i t h i t s s u cc e s sf u l ' A rg o ' S e r i es o f

se lf-loading mobile concre te mixe rs-

Argo 1000 (1 cu.m), Argo 2000 (2 cu.m)

a n d A r go 4 00 0 ( 4 c u .m ) v e rs i on s . T h es e

mixe rs fe ature the indige nously de v e l-

o p ed ' C on c re t e B a tc h C on t ro l le r ' ( CB C )

w i t h p r i n t fa c i l i ty, s o t h at r e p or t s c an b e

ge ne rate d right on the side. The close d

c a b i n o f f er s su p e ri o r p r o t ec t i o n, s a f et y

and comfort to the operator.W i t h I n d i a e me r g i ng a s a l u c r a t iv e

m a rk e t f o r s e lf - lo ad i ng m o bi l e c o nc r et e

mixers, se v eral global majors hav e be e n

a n n ou n c i ng s t ra t e g ic t i e - up s i n r e c en t

t i m es . A p o l lo I n f r at e c h f o r e x a mp l e , e a -

r l ie r a n no u nc e d s t r at e gi c p a rt n er s hi p

w i th C a rm i x, I t al y. T h e c o mp a ny o f fe rs

Tw e a k s i n t r a f fi c r u l e s c a n f u r th e r b o o s t s a l e s o f h i g h er c a p a ci t y t r a n s it mi x e r s i n I n d i a

A jax Fiori self -loading concrete m ixer at a constru ction site.

It is dif f icu lt to im ag ine inf rastru ctu re projects with ou t self -loading m obile concrete m ixers th ese days





a w i d e r an g e o f s e l f- l o a di n g m i x er s ,

i n cl u di n g m o de l s s u ch a s 5 . 8 X L , 3 . 5T T,

2.5TT, 25FX and One .S im il ar ly, a no th er l ea di ng n am e

w ho h as e nt er ed t he f ra y i n r ec en t

time s is Spe e dcrafts. It has e nte re d into

c ol la bo ra ti on w it h D mi x S RL o f I ta ly t o

s t ar t pr od u ct i on o f s el f- l oa d in g co n -

c r et e m i xe rs i n t h ei r m a nu f ac t ur i ng f a ci l -

i t y a t H a r- d w ar. T h e co m p an y ' s r a n g e

i n c l u de s m o de l s - D S 1 0 00 ( 1 c u . m ),

D S 2 50 0 (2 .5 c u. m ) a n d D S 4 0 00 ( 4

c u . m ). S o m e o f t h e sa l i e nt f e a tu r e s o f

t h e se m o d e ls i n c l u d e a n o p t i ma l m i x

due to spe cial drum configuration, e le c-

t ro ni c b at ch in g sy st em , h ig h m an eu -

v e r ab i l i t y a n d e x ce l l e nt r o a d h o ld i n g

capability, among othe rs.One more le ading name that offe rs

se lf-loading mobile concre te mixe rs is

M ac o n. T h e c o mp a ny o f fe r s m od e ls

a va i la b le in t h e 1 , 1 . 2, 2 , 2 . 5, 3 . 5 a n d 4

c u .m c a pa c it i es . S o me o t he r t o p f e a-

t u re s i n cl u de , 3 5 % g r ad e ab i li t y, 1 80

de gre e s re v e rsible driv ing post and

e l e ct r o n ic w e i gh b a t c hi n g u n i t . Apart from the infrastructure se ctor,

t h e r e al t y s ec t or i s a n ot h er k e y m a rk e t

s e g me n t t h a t h a s b e e n d r i v in g d e-

mand for se lf-loading concre te mixe rs.W i th t he f oc us n ow a ls o sh if ti ng t o

smalle r tie r-II and tie r-III towns and cit-

ie s, as far as re al e state de v e lopme nt is

c o n c er n e d , d e m an d h a s b e e n s p u r re d

o n b y p r oj e ct s i n I n di a 's h i nt e rl a nd . T h ei r

ability to offer a short turning radius and

n e g ot i a t e s l u s hy c o n di t i o n s, w h i c h a r e

c o mm on p la c e i n I n di a n c o ns t ru c ti o n

s i t e s, e s p ec i a l l y i n c r a m pe d u r b a n c e n -

tre s, hav e made the m a fav ourite with

c o nt r ac t or s . W h en i t c om es t o i n fr a -

structure projects, the se machines are

i de al ly s ui te d f or a va ri et y o f p ro je ct s

s u ch a s c o nc r et e p a ve m en t s, a i rp or t

r u nw a ys , i r ri g at i on c a na l s, d r ai n s, c u l-

v e r ts , e t c ., t o m e n ti o n o n l y s o m e.

Upwardly Mobile

The marke t for concre te transporta-

tion e quipme nt is not going to plate au

d ow n a ny ti me s oo n. W i th t he k in d of

infrastructure projects e nv isage d unde r

t h e 12 t h F i ve -Ye a r P l an P er i od ( 2 01 2 -

1 7 ) , t h e d e ma n d f o r t h e se m a c h i ne s i s

only e xpe cte d to incre ase . The next de -

cade could se e a rapid growth phase

f or t he se m ea n m ac hi ne s. T he r ea lt ys e c to r h a s a l so e m e rg e d a s o ne o f t h e

ke y market se gme ntsfor concre te trans-

p o rt a ti o n e q ui p me n t. S u pp l ie r s h a ve

t a k en n o t e of t h e t r en d s a nd a r e t r yi n g

t h ei r b e st t o c om e ou t w it h p r od u ct s

tailore d to suit the unique re quire me nts

o f t h e I nd i a n m a r k et .

Global playe rs hav e be e n ke e ping

a k ee n e ye o n t he I nd ia n m ar ke t. W i th

the pace of award of infrastructure pro-

je cts e xpe cted to pick up ste am soon,

i t w on ' t c om e a s a s u rp r i s e i f m a n y o fthe m jump into the concre te transpor-

t a t i on e q u i pm e n t b a n d wa g o n. W h a t i s

re quire d is furthe r push to the RMC sec-

t or. A rc ha ic t ra ff ic r ul es p re va le nt in

ma ny of ou r c it ies too need to be

l o ok e d i nt o , f o r t h ey h a ve l o n g b ee n a n

u n n ec e s sa r y h i n d ra n c e t o t h e g r o w t h

o f t h e t r an s i t m ix e r m a r k et . O n c e t hi n g s

a r e s e t r i g ht , c o n c re t e t r a ns p o rt a t i on

e quipme nt is one marke t se gme nt that

could grow by le aps and bounds.

G r o w in g R M C m a r k et p e n e t ra t i o n i n I n d i a i s g o o d n ew s f o r t r u c k m ix e r s u p pl i e r s





M.K. Prabhakar, Associ ate Edi tor

C on cr e te Pr o du ct M ac h in er y:Shaping Up Well

the transition was the f act that today's

c o n tr a c t or i s u n d e r m o r e p r es s u r e t h an

everbef ore to deliver quality, on-time and

w i t hi n b u d ge t .T h e I n di a n m a r k et w a s e a r l ie r b e i n g

d o mi n at e d b y t h e s m a ll e r, s e mi - au t o-

m a t e d o r m a n u al l y o p e r at e d m a c h i n es .

Several Chinese machines were also

d oi ng t he r ou nd s o f t he m ar ke t. T he y s ti ll

d o, b ut a re n o l on ge r t he s ta pl e. T he e nt ry

o f g l o b al p l a y er s i n t h e fi e l d ha s c h an -

g e d m a rk e t e q ua t io n s. T h e m o re ' a wa r e'

c u s t om e r o f t o d a y d e m a nd s ma c h i ne s ,

w i th l a rg e r c a p a ci t ie s , w h i c h a r e e a sy t o

s e t u p a n d w h ic h a l so f ea t ur e gr e en

technologies.

Consistent Demand

T h e r e c e nt r e c e s s io n a r y t r e nd s d o

n o t se e m to h a ve m u ch o f a n i m p a ct o n

concrete product machinery manuf ac-

t u r er s . W i t h c o n tr a c t or s u n de r p r e ss u r e

t o s t ic k t o o r c u t do w n o n p r o je c t c os t s ,

concrete block s have come as a boon.

n a v a st m aj or it y o f t he c a se o f m id -

s i z e d c o ns t r uc t i o n e q u ip m e n t, t h e reIh a s b ee n a n i n t er e s t in g t r en d w i tn e -

s s ed o v er t h e la s t de c ad e o r s o . T h er e

h a s b ee n a g r a du a l t ra n s i ti o n f r o m t h e

d o mi n an c e o f t h e u n or g an i ze d s e ct o r t o

t ha t o f a n o rg an iz ed o ne . P er ha ps , n ow -

h e r e is i t m o r e ev i d e nt t h a n i n t h e c a se

o f c o n cr e t e p r od u c t m a c hi n e ry. A l o t o f

i t h a s g o t t o d o w i th e n t r y o f g l o b al p l a y -

ers and increasing awareness levels

a b o u t la t e s t te c h no l o g ie s . A d d i ng t o

Concre te : Block Machine ry



“ A s a G e r m an y c o m pa n y w eh av e t he t ru st a n d g oo dw il l i nt he m ar ke t a nd w e c on si de r

I nd ia a s a m aj or m ar ke t w it hh u ge p o te n ti a l. F o r t h is r e a s onwe have taken a strong step top ro ce ed w it h t he e xp an si on o fo ur I nd ia n b as e. T hi s h as h el pe du s t o d o m or e e ng in ee ri ng i nI nd ia , b y r ed uc in g t he c os t o f t hematerials without compromisingo n q u al i ty. D e ci s io n t o s o ur c el o ca l ly h a s gi v en H e ss I n di a agreater edge over the competition”

Manoj KumarM anag ing Director, Hess India

263www.masterbuilder.co.in · T h e M a s t er b u i l de r - J u l y 2 0 13

According to industry estimates, the

m a r k et f o r c o n c re t e b lo c k m ac h i ne s

has clock ed a healthy 25% -30% growth

r a t e i n t h e r e c e nt p a s t , t h e r e c e ss i o na r y

trends notwithstanding. What is also in

f a vo r o f c o nc r et e p r od u ct m a ch i ne r ie s i sthe f act that concrete block s and other

p r o du c t s a r e be i n g u s e d i n b o t h i n f ra -

s t r uc t u r e a n d r ea l e s t a t e s e c to r s . T h e

d e m a nd t h e r ef o r e i s s us t a i ne d . I f t h e r e

i s a l u l l in i n f ra s t r uc t u r e p r o j ec t s , i t c a n

b e o ff s e t by t h e re a l e st a t e se c t o r a n d

vice-versa.

Evolving Market Trends

T h e c o nt i nu e d t h ru s t b e in g p r ov i de d

to inf rastructure development and the

growth of the real estate sector has meantthat India has emerged as a k ey mark et

f o r c o n c re t e b l oc k m a ki n g m a ch i n e s

o v er t h e pa s t d ec a de . G l ob a l p la y er s

are entering the f ray and consolidating

t h ei r p r es e nc e . T h e f o cu s i s o n b e in g

c l o s er t o t h e m a r k et , b y s e t t in g u p m a n -

u f a ct u r i ng f a c i l i t i es i n I n d i a. H e s s I n d ia ,

t h e I n d i an a r m o f a g lo b a l l e a d er i n c o n -

c r e te p r od u c t ma c h i ne r y, h a s m a de

s t ea d y p r og r es s i n r e ce n t t i me s . W h en

queried upon the logic behind the com-

pany starting manuf acturing f acilities in

India, when others have adopted a cau-

tious stand due to the economic uphea-

v a ls o f t h e r e ce n t p a st , M a no j K um a r,

M a n a gi n g D i r e ct o r o f t h e c o m pa n y o b -

served, “A plus point f or Hess in starting

l o c a l f ac i l i t ie s i n p l a c es l i k e I n d ia a n d

B r a z il , w h i ch h a v e hi g h er i m p o rt d u t ie s ,

is that we were able to support the cus-

t om er i n s av in g t he i mp or t d ut y a nd

f re ig ht c os t. F ur th er b y o ff er in g lo ca l

support and service, the customers are

able to get real conf idence while invest-

i n g. A s a G e rm a ny c o mp a ny, w e ha v ethe trust and goodwill in the mark et, and

w e co n si d er I n di a a s a m a jo r m a rk e t

w i th h u ge p o t e nt i al . F or t h is r e as o n, w e

h a ve t a ke n a s t ro n g s t ep t o pr o ce e d

w it h t he e xp an si on o f o ur I nd ia n b as e.

This has helped us to do more engi-

n e e ri n g i n I n d i a, b y r e d uc i n g t h e c os t o f

the materials without compromising on

q u al i ty. D e ci s io n t o so u rc e lo c al l y h a s

g i ve n H e ss I n d ia a g r e at e r e d ge o v er

t he c om pe ti ti on ,” w or ds t ha t s um u p t he

sound reasoning f or global players try-

ing to set up manuf acturing base here.H e ss I nd i a o f fe r s a v a ri e ty o f m a -

c h i ne r y i n c l ud i n g, c o n cr e t e b l o c k m a -

c h in e s, h a nd l in g s y st e ms , a u to c la v ed

aerated block machines, concrete pipe

m a c h in e s a n d pr e s s m a ch i n es . H e s s

I n d i a h a s a l s o s t a rt e d p r o du c t i on o f w e t

cast press machines in India together

w it h f or es t P re ss f ro m U K . T he c om pa ny

t h a t o f fe r s a r a n g e o f m o d el s g l o b a l ly

including Multimat RH 2000-3, Multimat

1 50 0- 3, M ul ti ma t 7 60 , M ul ti ma t 6 0 0- 2

and Multimat RH -500 has been f ocus-

i n g o n c o m i ng o ut w it h m a c h in e s t h a ta r e i d e a ll y s u i t ed f o r t h e I n d i an m a r k et .

W i t h c o m p et i t i o n i n t e ns i f y i ng c o m -

p a n ie s a r e fo c u s in g o n v a l u e ad d e d

services. Prompt technical support ser-

v i ce , i s s om e th i ng t h at i s c ru c ia l o f i t

h e l ps i n a v o i di n g m a c h in e d o w n ti m e .

C o l u mb i a P a k o n a E n g in e e ri n g , w h i c h

i s th e I nd i a n j o i n t v e n tu r e c o m p an y o f

C o lu m bi a M a ch i ne I n c U S A f o r i n st a nc e ,

has a strong thrust on of f ering technical

support services. Highlighting this point,

T. P. S o ji , S e n io r M a n a ge r M a r ke t i n g, o f

t h e c o mp a ny e x pl a i ne d ,” W e h a ve a

s t r o ng , w e l l e x p e ri e n c ed c u s t o m er s e r -

v ic e te am b as ed o ut o f o ur f ac to ry a t

V a do d a ra . T h i s s e r vi c e s u p po r t a l o n g

w i t h l o c a l a v a i l ab i l i t y o f a l l sp a r e s f o r o u r

e q u i pm e n t h a s gi v e n u s an e d g e o v e r

o u r c o m p et i t o rs w h o a re p l a n ni n g t o

s t ar t su c h f a ci l it i es i n I n di a . “ T h e c o m-

p a ny h a s b e en m a nu f ac t ur i ng c o mp l et e

block machinery plants including aggre-

g a t e / c e m e n t s t o r a g e , b a t c h - m i x i n g

p l a n ts , b l o c k m a ch i n es , p a l l et a n d p r o -

Concre te : Block Machine ry

G l o b a l p l a ye r s a r e e n t e ri n g t h e f r a y a n d c o n s o l id a t i n g t he i r p r e s en c e i n I n d i a



” We h av e a s tr on g, w el l

e x pe r ie n ce d c u st o me r s e rv i cet ea m b as ed o ut o f o ur f ac to ry a tVadodara. This service supporta l on g w i th l o ca l a v ai l ab i li t y o f a l ls p ar e s fo r o u r e q ui p me n t ha sgi ve n us a n ed ge o ver o urc o mp e ti t or s w h o a r e p l an n in gt o s ta rt su ch f ac il it ie s i n I nd ia “

T.P. SojiS e n i o r M a n a ge r - Ma r k e t in g ,

Colu m bia Pakona Eng ineering Pvt Ltd

Rapid u rbanization h as m ade scenes like th is com monplace in India


d u ct i on h a nd l in g e q ui p me n t, m o ul d s,

e t c f o r i t s c us t om e rs i n I n di a f o r o v er t e n

y e a r s. T h e c o m p an y p r o vi d e s a r a ng e

o f c o n c re t e b l o ck m a c h i ne s f r o m t he

economical 2-Block machine model

SPM20 to the 12-Block machine modelS HP 5 0 00 C . I n a d di t io n t o t h ei r v e rs a ti l -

i t y i n m a nu f ac t ur i ng a wi d e r a ng e of

p r o du c t s, t h e s e m a c hi n e s f e a t ur e t h e

unique vertical vibration technology. This

r e s ul t s i n s u p er i o r p r o du c t q u a l it y a r i s -

i n g f r o m u n i fo r m d e n s it y, t h r o ug h o ut

t h e h e i g ht o f t h e p r o d uc t , b e t w ee n p r o d-

u c t s w i t h in a s i n gl e p al l e t or c y c l e a n d

b e t w ee n p r o du c t s of v a r i ou s p a ll e t s or

t o w at c h o u t fo r w h en i t c om e s to c o n-

c r et e p i pe m a ki n g m a ch i ne s . G o in g i n to

d e t a il s o n t h e o p p or t u ni t i e s a v a i la b l e ,

M r. M a no j K u m a r o f H e s s I n d i a p o i n te d

out that the pipe industry is completely

d e p en d e nt o n g o v er n m e nt a l p o li c i e s

a n d d ec i si o ns . H e f u rt h er a d de d , “ T he

mark et potential really huge in India and

s u b s ta n t i al p a r t o f i t s d e v el o p m en t i s

p o is e d f o r g r ow t h o n a c co u nt o f i n du s -

t r i a li z a t i on , u r b a ni z a t i on , e c o n om i c d e -

velopment and people's rising expecta-

t i on s f o r i m pr o ve d q u a li t y o f l i vi n g. C e r-

t a in s t at e s l i ke G uj a ra t , H a ry a na a n d

Ta m il N a du a l re a dy p r ep a re d a l o ng t e rm

p la n. T hi s ma y b e in t he f or m of c on -

n e c ti n g t h e r i v e rs b y c a n a ls o r p u m pi n g

w a te r t h ro u gh p i pe l i ne s e it h er f o r a g ri -

c u l t ur e , i n d u st r i a l o r d o m e st i c u s a ge s . ”

Not surprisingly several global ma-

j o r s a r e e y ei n g t h e I n di a n m a r ke t . I t w a s

only sometime ago that companies lik e

C o n c r et e p i p e m a k i n g m ac h i n e ry h a s g o t a f i l l i p d u e t o d e m a n d f o r p i p e s f ro m c i v i c a u t h or i t i e s

cycles. According to the company, pro-

ducts manuf actured using its equip-

ment have lower material costs arising

f r om r e du c ed c e me n t c o ns u mp t io n a n d

s up er io r h ei gh t co nt ro l wi th a n a cc u-

r a c y o f + / - 0 . 5m m .

S e ve r al o t he r g l ob a l co m pa n ie s

could be f ollowing suit soon and setting

u p b a se in I n di a i n t h e n e ar f u tu re , c o n-

sidering the encouraging mark et trends.

N o L o n ge r a P ip e D re am

W i t h w a te r s u pp l y p r oj e ct s be c om -

i n g a m a j o r f o c us a m o ng c i v ic a u t h or i -

ties, India has emerged as the mark et

C o n cr e t e: B l o ck M a c h in e r y



Th e M 1600 m odel f rom Colu m bia Pakona Eng ineering


Hawk eyePedershaab, considered a

g l ob a l l e ad e r i n t h e f ie l d, h a ve e n t er e d

t h e f r a y. A j o i n t v e n tu r e b e t we e n A p o l lo

I n fr a t ec h a n d H a wk e y eP ed e r sh a a b,

of f ers concrete pipe mak ing machines

of various capacities. The JV of f ers mod-e l s C A P - 1 5 0 , C A P - 2 0 0 a n d V I H Y

M a s t er f l ex S C6 0 . T h e CA P- 1 5 0 a n d

C A P- 2 0 0 m a c hi n e s a r e u s ed f o r p r o -

d u c in g c o n c re t e p i p es , m a n h ol e s y s -

t e m s , b o x c u l v er t s , l i n e d p i p es , j a c k in g

p i p es , e t c . W h i l e t h e pi p e ma n u fa c t u r-

i n g c a p a ci t y o f C A P- 1 5 0 i s 3 0 0 m m t o

1500 mm diameter, it is 300 mm to 2000

m m d i am e te r i n t h e c a se of C A P- 2 00 .

The VIHY Masterf lex SC 60 is used f or

mass production of small-diameter, non-

r e i nf o r ce d c o nc r e t e p i p es . I t i s a ls o

capable of producing branch pipes and

g u l le y p o t s.

U s e o f I n d us t r i a l W a st e

The rising emphasis on environment-

f riendly building strategies has also been

one of the k ey reasons behind the grow-

i n g m a r ke t f o r c o n cr e t e b l o ck m a k i n g

machinery. Manuf acturers are f ocusing

o n m a c h in e m o d e ls t h a t u t i l iz e i n d u s-

t r ia l b y -p r od uc t s s uc h a s f l y a s h i n a b i g

w a y. H e s s In d i a f o r e x a m pl e h as b e e n

d o in g l o ts of R &D i n c o nc r et e a n d f l y

a s h r e l a te d p r od u c ts a n d d e ve l o pe d

s y s t em s . A c c o rd i n g t o M a n o j K u m a r, i t

has installed plants with leading names

l i ke J in d al a nd K JS i n I n di a . I n t h e c a se

w i t h t h e p l a nt w i t h J i n d al , t r a ns p o rt a t i o n

and manual interf erence were avoided,

w it h t he a sh r ea ch in g t he H es s m ac hi ne

d i r e ct l y t h r ou g h a c l o s ed c o n ve y o r. H e

f u rt h er a d de d t h a t o t h e r t h a n f l y a s h, t h e

company also of f ers machines that are

able to use GGBS (Ground-granulated

b l a s t- f u rn a c e s l a g) a n d e v e n P u m i ce . I t

h a s a l s o s u p pl i e d s i m i la r m a c h in e s t o

steelcompanieslike Tiscon, Ruuki, SSAB,

R o c kw o o l a nd K u tt n e r f o r s t e e l br i q ue -

tting.S i m i la r l y, C o l u mb i a P ak o n a En g i -

neering of fers the SPM20 model, capa-

b le o f m an uf ac tu ri ng 8 00 0 t o 1 60 00 n um -

b e rs o f h o ll o w/ s ol i d b l oc k s o r 5 0 00 0n um be rs o f f ly a sh b ri ck s in a d ay. I t' s

S P M 26 m o d e l i s c a p ab l e o f m a n u fa c -

t u ri n g 8 0 00 0 f ly a s h b r ic k s or 1 5 00 0 t o

2 5 0 0 0 h o l l ow / s o l id b lo c k s i n a d ay. I n

a d d i ti o n , t h e c o m pa n y a l s o o f f er s t h e

1 6 0 0 m od e l w hi c h i s c a pa b l e o f m a n u -

f a c t ur i n g 20 0 0 0 t o 3 5 0 0 0 h o l l ow / s o l i d

b l oc k s o r 1 2 50 0 0 fl y a s h b r ic k s in a d a y

a n d m o d el S HP 5 0 0 0 C P RO , w h i c h i s

c a p a bl e of m a n u fa c t u ri n g 4 0 0 0 0 t o

75000 hollow/solid block s or 150000 f ly

a sh b ri ck s i n a d ay. “ Ma ny o f o ur c us -

tomers have started using slag f rom

steel plant as a replacement f or aggre-

g a t e s f o r t h e m a n uf a c t ur e o f b r i c ks a n d

b l o c ks , ” s a i d T. P. S o ji , S e n io r M a n a ge r-

Mark eting of the company, highlighting

the increasing awareness levels about

u s i ng e n v i ro n m e nt - f ri e n dl y t e c hn o l o -

giesand construction strategies in India.

Dynamic Market

The concrete product machinery

m a r ke t i s e n t e ri n g a n e x c i ti n g p h as e .

There are several international playersq u e ui n g u p t o t a k e a dv a n t ag e o f a l u c -

r a ti v e m a rk e t. M a ny o f t h em a re e it h er

s e t t in g u p m a n u fa c t u ri n g u ni t s o r l o o k -

i n g t o t i e- u p w i th d o me s ti c p l ay e rs t o

e st ab li sh t he ir b ra nd s in I nd ia . A ll t hi s

s p e l ls g o o d n e w s u l t im a t e ly f o r t h e c u s -

t o me r, w h o n o w h a s a w i de r c h oi c e t o

choose f rom.

H ow ev er, c ha ll en ge s re ma in f or

m a n u fa c t u re r s . F o r o n e , t h e r i s i ng i n p u t

c o st s a re o n e f ac t or f o r w h ic h t h ey l o ok

t o w a rd s th e g o v er n m e nt fo r h e l p. T h e

authorities concerned should come out

with plans to encourage increased use

o f c o nc r et e p r od u ct s . F or t un a te l y, f o r

the manuf acturers the signals towards

t h i s e n d a r e al r e a dy v i s i b le . T h e re h a s

b e e n r i s i ng e m p h as i s o n u s i ng p r e c as t

components. The increased use of con-

c r e te b l o ck s a n d p r o du c t s i n l a r g e-

scale projects such as integrated realty

t o w ns h i p s, h i g h -r i s e p ro j e ct s , h i g hw a y

projects and SE Zs has also come as

good news f or manuf acturers.Concrete blocks are h ere to stay

C o n cr e t e: B l o ck M a c h in e r y





u i l d t ec h I n d i a C o r p or a t i on ( B I C)

i s a l e a di n g pr o d uc e r o f a w id er a ng e o f c e me n t p av e r b l oc k s,B

d e si g ne r t i l es , s h ot b l as t ed p a ve r s, k e rbs t on e s a n d c o nc r et e b l oc k s. A p ar t f r ommanufacturing, as a se rvice provide r, the

company also unde rtake s laying con-t r a c ts f o r p a v in g b l o c ks a n d e x t er i o rtiles. Its commitment to high quality, along

with cost-e ffe ctive and sustainable solu-

tions has made BIC a pre fe rre d choices i n c e i t s i n ce p t i on i n 2 0 0 8.

T h e v e r s a t i l e p r o d u c e r a n g eo f f er e d b y B u i l dt e c h f i n d s v ar i e d a p p li -

c a t i on s . T h e c e m en t p a v e r b l o c ks f r o mB u il d te c h a r e i d ea l f o r b o th d o me st i cand comme rcial pathways and driv e -

w ay s . T h ey a r e s t ur d y, d o n o t b r ea k ,e n h an c e t h e a e st h e t ic v a l u e o f d r i ve -

ways and pathways, while also be inge a sy t o m a i nt a i n . C e m en t p a v er b l o c ksu s ed f or e x te rn a l f l oo r s a r e i n g r ea t

de mand owing the ir unbe atable com-b in at io n o f a es th et ic s, d ur ab il it y a ndeconomy.

T h e c o m pa n y a l s o m a n u fa c t u re sd es ig ne r p av er bl oc ks , w hi ch ar e

m ad e i n a dd it io n w it h w hi te ce me nt .T h e d e s i gn e r p a v er b l o c ks a dd t o t h e

l o ok s o f b u il d i ng s , w h il e a l so be i ngd u r a bl e a nd l o ng l a st i n g . S o m e o f t h e

p a v er b l o c k t y pe s / sh a p es o f f e r ed b yB I C i n cl u d e , Tr i h ex , D u m b le ( I s h a pe ) ,

B a r b e q u e , U n i p a v e r ( z i g z a g ) a n dH e x ag o n . T h e se p a v er b l o c ks c o m e i nv arious size s including (a) Light Use -4 0 m m w i d t h, w h i c h a r e u s e d a s si d e -

w a l k p a v e rs , g a r d en w a l k p a v e rs , s w i m-m i n g p o ol s i d e w al k s , f o o tp a t h s, c y c l e

p at h, e tc , ( b) M ed iu m u se - 6 0m mw i d t h- u s e d t y pi c a l l y i n o p e n r e s ta u r an tare a, hote l driv e are a, farm house driv e

r o a d, s h o pp i n g m al l s , p a r k in g l o t s, r a i l -w ay s ta ti on s, e tc , a nd ( c) H ea vy U se -

8 0 m m w i dt h , u s ed fo r a p pl i ca t io n ss uc h a s f ac to ry c om po un ds , p et ro l

p u m p s, i n d u st r i a l f l o or s , b u s te r m in a l ,ware house s, e tc.

Buildte ch's shot blaste d pav e rs arethe pre ferre d choice for se v e ral appli-cations. Use of high quality mate rials pro-v ide s the shot blasted pav e rs with opti-

m a l l e ve l o f d u r a bi l i t y a n d m a ke s t h e ml a st l o ng . A p pl i ca t io n a r ea s o f s h ot b l as -

te d pav e rs include , e xte riors and ope nspaces like foot-paths, side-ways, garage,parking, open areas, promen ad es,

s w i mm i n g p o o l d e c ks , b u i l di ng c om -pounds, v e randah,e tc, to mention only af e w, w h e re g o o d f i n i s h, a n t i -s k i d p r o p-

e rtie s or te xture d look is de sire d.BIC also offers a range of ke rb sto-

n e s , k n o wn f o r t h e i r s t u r dy c o n st r u c t io na nd e nd ur an ce , w hi ch a re u se d a s k er be le me nts to de marcate roadway e dges,

p e d es t r i an p a v em e n ts , f o o tp a t h s a n dt h e l i ke s . T h e y a r e a ls o u s ed f o r a d d i ngstyle and grace to the floors as we ll as

the pav e me nt are as buildings or a con-fine d are a.

BIC is also one of the le ading manu-f a ct u re rs o f c o nc r et e b l oc k s, h o ll o w b l o-cks and solid blocks. Env ironme nt-fri-

e n d l y i n n a t u re , t h e se b l o c k s a re i d e a l lys u i t ed f or t h e c o n st r u c t io n o f b o t h c o m -

me rcial and re side ntial buildings.

B ui ld in g Tr us t t hr oug h Qu al it y F oc us

For further details:

Buildtech India CorporationN o . 8 / 1 6, 2 n d Fl o o r, R o u nd B u i l di n g ,

Anna Nag ar West Extension,Chennai - 600101,

Mob: + 9 1 - 9 84 0 0 8 4 68 7E- m ail: info@buildtechc orp .in

Web: w w w.buildtec hc orp.in

Sh ot Blasted PaverCem ent Paver

Kerb Stones

D e s i gn e r T i l e s

D e s i gn e r P a v er s



C o m m un i c a t io n F e a tu r e


n e x p a ns i o n j o i n t i s a n a s s e m bl yd e s i g n e d i n - o r d e r t o s a f e l yabsorb the heat-induced expan- A

s io n a nd c o nt ra ct i on o f v ar io us c on -s t r u c ti o n m a t e ri a l s , t o a b s o r b v i b r a t i o n ,t o ho ld c er ta in p ar ts t og et he r, o r t oa l l o w m o v e me n t d u e t o g r o u n d s e t tl e -m e n t o r e a r t h qu a k e s .

T h r o u g h o u t t h e y e a r , b u i l d i n gf a c e s, c o n c re t e sl a b s a n d p i p e l in e sexpand and contract due to the warm-

ing and cooling through seasonal vari-a ti o n, o r d ue to ot he r h ea t s ou rc e s. I fe x p a n s i o n j o i n t s w e r e n o t i m p l e -m e nt e d i n b r id g es , b u il d in g , h i gh w ay se tc . t he i n te ns e h ea t i n t he s u mm erw o ul d e x pa n d t he m e t al , b r ic k , o r c o n-c r e t e m a te r i a l s i n a s t r u c t u re r e s u l t i n gi n d e v e l o pi n g cr a c k s a n d m a y e v e n t u-a l l y e n d u p b r e ak i n g .

F u rt h e r m or e , i n t h e w i n t e r, t h e h a r s hcold temperatures would make them a te r ia l s co n tr a ct i n n a tu r e, a n d th i sw o u l d a l s o r e s u lt i n d i s a s tr o u s c i r c u m-

stances.' D U R A b o a r d H D 1 0 0 ' ( f o r m e r l y

S I L f le x / C ap e l l H D 10 0 ) i s a n e x c l u si v ecompressible filler board speciallydesigned to be used as expansion jointf i ll e r i n c o nc r et e b ri c k, b l oc k w or k a ndi so la ti on j oi nt , w he re i s r ea di l y c om -p r es s i bl e l o w l o ad t r a ns f er j o i nt f i l le r i sr e qu i re d . I t s ex c el l en t r ec o v er y p r op -erty makes it the most suitable productf o r t h i s a p p l i c a t io n .

' D UR A bo a rd H D1 0 0' i s a h i gh p e r-f o r ma n c e , p r e - mo u l d e d c o m p r e s s i bl e

f i l l e r b o a r d, c l o s e d -c e l l j o i n t f i l l e r m a t e -r i al av a il a bl e i n t h e b o ar d o r s h ee t sf o r m . I t is v e ry l i g h t w e i g h t. T h i s m a k e si t ve r y e a s y t o ha n d l e a n d i n s t a ll . B e i n gp o ly m er b a se d , i t i s r ot p r oo f a n d ba c -teria resistant.

T h e s t ri k in g f e at u re s o f ' DU R Ab o a rdH D 1 0 0 ' a r e :

- B it ume n f re e - ca n b e c ut in to an ys i z e w i t h a n o r m al k n i f e

- Excell ent recovery of 9 5 percenta f t e r c o m p re s s i o n u p t o 5 0 p e r c e nt

- Po l ym er b as ed – h en ce it wo n' t d et e-riorate also over a long period

- R es i li en t an d do es n ot d is to rt u nd ernormal load from wet concrete

- Non- staining

' D U RA b o a rd H D 1 00 ' c a n b e u s e d i n :

- Expansi on joi nts i n building, con-crete structure

- E xp an si on j oi nt s in c on cr et e ro ad s,parking areas,industrial flooring etc.

- Joints in bridges, de cks , wate r re-t a i n i ng a n d w a t er e x c l u di n g s t r u c-tures etc.

DURAboardHD100:B itu men Fr ee J oi nt F il ler

- I so la ti on j oi nt s i n m ac hi ne fo un da -tion.

T he c on st ru ct io n i nd us tr y a cr os st h e w o r l d, i s w i t n e s s in g a t r e m e n do u sb o om . A n d In d ia i s n o ex c ep t io n !Government polices and expenses oninfrastructure have helped the sectorg ro w a t h i gh er l ev el s , a nd t he s am ep a ce i s li k el y t o be s ee n i n t h e co m in gy e ar s t o o. T h is i n du s tr y c o mp r is e s o fma ny c om po ne nt s, i nc lu di ng c on -

s t r u ct i o n o f h e a v y a n d c i v i l e n g i ne e r i n g( h ig h wa y s , b r id g es , r a il w ay t r ac k s, a i r-p o r t s, e t c . ) , r e a l e st a t e ( bo t h r e s i d en t i a las well as commercial) development,and specialized construction products( s u c h a s a r c h i t e c tu r a l p r o d u c t s, e l e c t ri -cal connections,decorativeitems, etc.)

T h e 1 2t h p la n ( 2 01 2- 2 01 7) e n v is -a g e s a ma s s i v e $ o n e t r il l i o n i n v e s t-ment into infrastructure developmentt h e r e by, p r o v i di n g a m aj o r b o o s t f or t h ec i v i l c o n s t ru c t i o n i n d u s tr y. T h e i m p o r-t a nc e o f c i vi l c o n s tr u ct i on i n du s tr y c a nbe gauged from the fact that it is thes e c o n d l a r g es t e c o n o mi c a c t i vi t y a f t e ra g r i c ul t u r e . W i t h e s t i ma t e d i n v e s t me n t

D U R A b oa r d H D1 0 0 i n C o l u m n s

Ajay MohtaGeneral Manag er, Construction A ccessories Division,The Sup reme Ind ustries Ltd



C o m m un i c a ti o n F e a tu r e

271www. masterbuild er. co. in · T h e M a s t er b u i l de r - July 2013


T h e S u pr e me I n du s tr i esM o b i le N o . : 0 9 8 3 1 0 20 8 0 8E- ma il: dura @supreme.co.inWeb: www.supreme.co.in

i n c o n s t ru c t i o n p e g g e d at 1 1 p e r c e n t o fI ndia's Gross D omestic Product (GD P)– it holds huge untapped potential.

Around Rs. 15,099.84 billion is likely tobe invested into the infrastructure sec-t o r o v e r t h e ne x t fi v e t o te n y e ar s i n s e g-m e nt s s u ch a s p ow e r, r o ad s , b r id g es ,c i ty i n fr a st r uc t ur e , p o rt s , a i rp o rt s , t e le -communications – this is expected togive impetus to the construction indus-t r y n a t i on w i d e .

T h e r o l e o f o r g a n i z a t i o n s l i k eS u p r em e I n d u st r i e s i n s u p p o rt i n g t h ec o n s t ru c t i o n i n d u st r y h a s b e c o me p r o -m i n e nt a n d c r i t i c a l . E x p o su r e t o w o r l d -c l a s s e xp e r t is e a n d a dv e n t o f g l o b alp l a y e rs h a s l e d t o i n f us i o n o f n e w m a t e -

r i a l s , e q u i p me n t a nd t e c h no l o g i es i nt he co ns tr uc ti on p ra ct ic es in I nd ia .H o w e v er, q u a l i ty a l o n g w i t h c o s t -e f f e c -tiveness remains a serious challenge.M or eo ve r, t he g ap b et we en t he r e-q u i r em e n t s o f t h e c o n s t r u ct i o n i n d u s tr yand solutions available remains unful-filled.

T h e S u p re m e I n d us t r i e s L t d, f o u n -d ed i n 1 94 2, p io ne er ed m an y p at h-b r ea k in g p r od u ct s i n t h e c ou n tr y a n db e ca m e t r en d se t te r s i n p l as t ic p r od -u ct s b y i nt ro du ci ng m a ny a dv an ce d

s o l u t i on s f o r v a r i o us a p p l i c at i o n s a n dindustries. Ajay Mohta, General Manager,C o n s t ru c t i o n A c c e s so r i e s D i v i s io n , t h eSupreme I ndustries Ltd, talks about thec om pa ny 's s ta r b ra nd , ' DU RA bo ar dHD 100'.

T he c o ns tr uc ti on a cc es so ry d iv i-s i on o f S u pr e me h a s d e ve l op e d cu s -t om iz ed s ol ut io ns , s pe ci fi ca ll y f or t hec o ns t ru c ti o n r e qu i re m en t s o f v a ri o uss e g m en t s . “A l l o u r p r o d uc t s h a v e b e e nd e v e l op e d af t e r c o n t i nu o u s re s e a rc ha n d u nd e r s ta n d i ng t h e n ee d s o f t h ec h a n gi n g d e m an d s o f t h e n e w - ge n e -ration constructio ns . Many of thesep r od u ct s h av e be e n p i on e er e d b yS u pr e me , ” h e s a id . H e f u rt h er e x pl a in e d,

“A c as e i n p o i n t i s t h e c r e a t io n o f a l o wc o m p r e s s i o n s e t f i l l e r b o a r d' D U R A b o a r d H D 1 0 0 ' e s p e c i a l l y f o re x p a ns i o n j o i n t s a p p l i ca t i o n, t o r e p l a c el e s s e f f e c ti v e b i t u me n b o a r d b a s e dsolutions.

“ T h e d i v i s i on o f f e rs n e w g e n e ra t i o n ,b e t t er a l t e r na t i v e p r o du c t s t o c o n v e n-tional materials like rubber, metals, andw o od , t h us b ei n g c o s t e f fe c ti v e. T h e' D UR A ' r a ng e s o f p r od u ct s a r e m an u -f a ct u re d f r om v i r gi n r a w m a te r ia l a ndw e d o no t u s e a n y C F C / H C F C ga s e s .

At every stage of the manufacturing pro-c e s s , a s t r i n g e nt q u a l i t y c h e c k m e t ho d -o l o g y a s s u r es t h e re l i a b il i t y o f t h e p ro d -u c t s ,” h e a d d e d .

H ow ev er, A ja y M oh ta , r ai se d h isc o n c e rn s o ve r u s e of o l d s pe c i f i ca t i o no f b i tu m en b y s o me g o v e rn m en t o r ga -n i z a ti o n s . “ T h e y s t i l l h e s i ta t e t o u s e n e wg en er at io n p ro du ct s, ” s ai d w or ri edM o ht a . U s in g bi t um e n b a se d bo a rd sa nd c o rk s h ee ts , w hi ch d is in te gr at eo ve r a pe ri od of t im e, a bs or bs w at er

a n d h a r d l y r e c o v er s o n c e c o m p re s s e d- i t d e f e a t s t h e p u r po s e o f a p p l ic a t i o n. I ta b so r bs w a te r a n d oo z e s b i tu m enthereby staining the structure.

S u p r e me h a s a n u mb e r o f s a t i s fi e d

c u s to m er s ( g o v er n me n t, s e mi - g o v -e r n m e n t a n d p r i v a t e ) w h o h a v estopped using and recommending bitu-m e n b o ar d s/ c o rk s s h e e ts a f t e r u n de r -s t a n d in g t h e b en e f i t s of ' D U R Ab o a r dH D 1 0 0 ' c o n c l u de s A j a y M o h t a.

D U R A b oa r d H D1 0 0 i n R o a d s





The worldwide reference forc a l c ium a l um i na t e t e c h no l o g yin drymix mortars

www.kerneos.com

K e y P e r f or m a n c e:

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R e t ur n t o S e r v ic e Ÿ Crack free Application

Example of Applications:

Ÿ Precision Grout Ÿ Concrete Repair MortarŸ Road Repair Mortar Ÿ Tile Adhesive and GroutŸ Waterproofing Mortar Ÿ WaterstopŸ Self-leveling Flooring

T h e W a it i s f i na l l y o v er K e r n eo s i s t h e O N LY BI S c e r t i f ie d c o m pa n y f o r S a l es & Pr o m ot i o n o f C a l c iu m A l u m in a t e C e m e nt i n I n d i a.

s a principle , the grouting inje c-

t i o n s s y s t e m s s h o u l d b es e l ec t e d b a se d o n t h e c r a c k o r A

c a vi t y w i dt h . T h e f o ll o wi n g m a te r ia l s

c a n b e s e l e c t e d f r o m t h e M C -Bauche mie Range :

a ) F or c ra ck s ≥ 2 mm w id th C en tr ic re teb ) F or c ra ck s > 0. 2 t o 2 mm wi dt h

M C - D UR 1 2 64 E p o x y S y s te m

C en t ic r et e i s a r ea d y t o u se , H y-

d ra ul ic al ly S et ti ng , P ol ym er M od if ie dW a t er p r oo f g r o ut f o r i n j e ct i o n a n d f i l l i n go f c ra ck s a nd c av it ie s. C en tr ic re te

i n j e ct i o n g r o ut i s p r o du c e d w i t h c a r e-f u l l y s e l ec t e d w a te r r e p el l e n t a n d s i li c i -fying che mical compounds and ine rt

fille rs to achie v e v arie d characte risticslike water impermeability, non-shrinkage,f r ee f l o w, e t c. C e nt r ic r et e c r ea t es a n

i n te g ra l w at e rp r oo f b a rr i er a n d p r ev en t sw at er p en et ra ti on a nd r i si ng d a mp -

n e s s. C e n t ic r e te i n j e c ti o n g r o ut i s s u i t -a b le fo r g r av i ty a s w el l as pr e ss u re

grouting. This grout is pumpable whenthe wate r-powde r ratio is about 0.45 to0 . 5 0 i . e . f o r 3 0 Kg s Ce n t r ic r e t e, 1 3 . 5 t o15 litre of wate r.

MC-DUR 1264 is a two compone nt,l ow v is co si ty E po xy i nj ec ti on r es in f or

s t r u ct u r a l r ep a i r o f c r a c ks . T h i s m et h o d

o f a p p l ic a t i on v a r i es f r o m s i m p l e b r u s htre atme nt to sophisticate d two compo-

n e n t p re s su r e i n je c t i on m a c h in e s . T h ea p pl i ca t io n t i me of M C - DU R 1 26 4 d e -

p en ds o n t he a mo un t o f r es in m ix ed a ndt h e a m b i en t t e m p er a t u re . T h e m i x i ngr a ti o o f R e s i n t o H a rd e ne r i s 1 00 : 18 P b w.

M C - Ba u ch e mi e ( In d ia ) P vt . L t d.

manufacture s the se productsalong witha h o s t o f o t h er C o n st r u c t io n C h e mi c a l s

in te chnical and financial collaboration

w it h M C- Ba uc he mi e, G er ma ny. M C-B a uc h em i e ( I nd i a) P vt . L t d. i s a n I S O

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F o r f u rt h er d e ta i ls :M C – B au ch em ie ( In di a) P vt . L t d.4 1 1 , A r e n ja C o r n e r, S e c t o r 1 7 , V a s hi ,

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A Unique Dry PowderMixer from Toshniwal

r y p o w de r b l e n di n g i s a t t he h ea r t o f m a n y p r o ce s s in g

industrie s today. Howe v e r, it still re mains to be the le astDu n d e rs t o od o f a l l t h e p r o ce s se s . M i x i ng a n d b l e n di n g o f d r y

ingre die nts occurs fre que ntly in building mate rials such as:

- Dry Mortar

- C on st ru ct io n C he mi ca ls

- Renders

- Wal l Plasters

- Wal l Putty ( Dry)

- Floor S creeds

- Skim Coats

- Blended Cement

H o we ve r, t h e u n iq u en es s of e ac h i n di v id u al p ro d uc tf o r mu l a t i on , u s u a ll y m e a n t h a t n o t w o b le n d i ng p r o c es s esare e v er the same .

F r om t h e ba s i c b l e nd i n g of t w o si m i l a r m a t er i a l s t o t h eble nding of many diffe re nt ingre die nts with diffe re nt charac-

t e ri s ti c s, t o da y 's m i xe rs h a ve a w id e va r ie t y o f p o ss i bl ea p pl i c at i on s . A l th o ug h m i xi n g a n d b l en d in g t e ch n ol o gy h a s

g r e at l y i m p r ov e d o v e r t h e ye a r s w i t h t h e ad v e nt o f m o d er nb l en d er s t ha t a re n ow c a pa b le o f m i xi n g of a l l ki n ds o f

powde rs the proce ss of se le cting the be st ble nde r and thec o r re c t o v er a l l s ys t e m d es i g n o f a s p e c if i c a p p l i ca t i o n, s t i l lre mains an art form owing to the many v ariable s inv olv e d.

G i v en t o d a y' s “ L e a n M a n uf a c t u ri n g “ e n v ir o n me n t , i t h a sb e c om e i m p er a t i ve f o r o n e t o c a r ef u l l y c o n si d e r b l e n di n g

t i m e s , e q u i p m e n t f l e x i b i l i t y , P r o d u c t s e g r e g a t i o n i . ede mixing of the ble nded product in post blending.

To sh n iwa l Mixe r

Toshniwal offers thei n n o v a t i v e N o r w e g i a n

t e ch n ol o gy m i xe r w h ic hi s a n a b s ol u t e t es t p r o-

v e n m i x i n g e f f ic i e n cy f o rmanufacturing the buil-ding mate rial product.

T he mi xi ng qu al it y i se xtre me ly good, and

m i x i n g t i m e fo r m o s t ap p l i c at i o n s i s v er y s h o rt a b ou t 3 0s e c on d s . D u e t o t h e v e ry s h o rt m i x i n g t i m e h i gh t h r ou g h p ut

c a n b e a c h i ev e d , t h e i n f l ue n c e o f s h e ar i s n e g l i gi b l e .

M/s. Toshniwal Systems & Instruments Pvt. Ltd.,2 6 7 , K i l p a u k G ar d e n R o a d, C h e nn a i - 6 00 0 1 0, I n d i aPhone No: 91-44-26445626 / 26448983Email: sale [email protected] t / We b : www.toshniwal.ne t

273www.masterbuilder.co.in · T h e M a s t er b u i l de r - July 2013

C o m mu n i c at i o n F e at u r e





i nc e th e in ce pt io n i n 1 98 2, t hec o m pa n y h a s b ee n i n s t ru m e nt a l

i n t he av ia ti on s ec to r. T he ve rySf i r st p r o j e ct f o r I n t er a r c h w a s t h e I GI T 2

i n N ew D el hi . I nt er ar ch w as t he f ir stc o mp a ny t o i n t ro d uc e w i n do w c o ve r -i n gs t h r ou g h t h ei r p r od u ct T R AC a n d

first one to introduce e ngine e re d me talroofing and cladding syste ms. Interarch

e nte re d into infrastructure proje cts as it

b a gg ed t h e l ar g es t o rd e r f o r t u rn k eys up pl y o f o ne -o f- it s- ki nd c o mp os it e

roofing syste m and pre e ngine e re dr o of s t ru c tu r al sy s te m f o r t h e I n di r aGandhi International Airport Terminal-

3 , N e w D e lh i wh i ch w as co m pl e te d i n2010.

F or a i rp or t s, t h e p r im e c o nc e rn s ,f u n c ti o n a ll y a n d a e s t he t i c al l y, a r e u s u -a l l y t h e l ar g e cl e a r s s p a n f r a mi n g c an

b e e a si l y m a de i n s t ee l . S t ee l i s a l sof a st e r i n c o ns t ru c ti o n i n c o mp a ri s on t oothe r mate rials and le ss disturbance at

s i te , w h ic h f u rt h er r e su l ts i n f a st e r c o n-s t r uc t i o n r e s ul t i n g i n e a r l y o c c u p a n c y &

ear ly re tur n on i nv est men t. For l ar ges t or a ge o f c a rg o s, v er t ic a l m u lt i st o ryste e l buildings and re trie v al syste m,

s t e el h e l p s i n f a s t er s t o ra g e a nd d e l i v -e ry. Ste e l can offe r highe st archite cturalf l e xi b i l i t y i n d e s ig n a n d f a b r i ca t i o n.

The product has be e n succe ssfullya p p l ie d fo r v a r io u s s t e el s tr u c t u re s

u n d er t h i s se c t or, l i k e Ai r p o rt t e r mi n a l

b ui ld in gs , A ir p la ne h an ga rs , C ar goa n d f r e i gh t s t a t io n s , w a r eh o u se s , f i r estation buildings and roof and ce iling of

buildings.

S o me o f t h e N i tt y- g ri t ty ' s t h at w o rk e di n f a v or o f t h e a p p l ic a t i on i n s t e el w e re ,

S m a ll e r m a n a ge a b l e p a r t s n o m a t -t er h ow l ar ge t he f in al s tr uc tu re - He lpslogistics and re duce s transport costs

B o l t- O n a s s e m bl y - All se ctions ared es ig ne d to a li gn p er fe ct ly d ur in gassembly

Re ad y to b uil d - S h ap ed , w el d eda n d t e st e d f o r d e s ig n e d l oa d c o n d i-tions

I nt er ar ch 's C on tr ib ut io n t o

Aviation Sector in India and Abroad

Project Snapsh ot: Delh i Carg o Services Centre



A ir Deccan Hang er

DA IL IGI T3 Term inal

B u i l di n g L oc a t i on

B u i l di n g U s a g e

Area

Length i n meters

Wi dth i n meters

Hei ght i n meters

K e y F e a t u re s

I ndra Gandhi I nternati onal A i rport, New Delhi

C a r go W a re h o u s e- g r ou n d + 2 m u l t i st o r y b u i l di n g

25000sqm

366m

102m

22m

Ÿ 2 2 m h e ig h t

Ÿ 3 l e ve l m u l t i s t o re y w a r eh o u s in g b u i l t e n t i re l y i n pr e - e ng i n e e re d s t e e l

Ÿ 1 : 4 0 r o of s l o p e w i t h Tr a c d e k S t a n di n g S e a m r o o f sy s t e m ( vi r t u a ll y f l a t r o o f)

Ÿ E a c h f l o o r d e s i gn e d f o r 15 0 MT / S q M D L + L L a nd f o r fo r k l i ft m o ve m e n t



C o m mu n i c at i o n F e at u r e


M a j o r P r o j ec t s E x e c u t e d

Taj Flig h t Kitch en

H A J Te r m i na l


I n t e r a rc h B u i l di n g P r o d u ct s P v t L t dE- m ail: info@interarc hbuilding s.c omWeb: w w w.interarc hbuilding s.c om

M a nu f ac t ur e d t o e n d ur e - Spe ciali-

ze d coatings and tre atme nt av ailablef o r l o n g ev i t y

S h ip p ed s m ar t - S m ar t l o gi s ti c s a n d

shipme nt synchronize d with construc-tion re quire me nts at proje ct site .

Indian Airlines

Jet Airways

Spice j et

D e l h i C a rg o S e r v ic e

Air Deccan

Shri Mata Vaishno Devi Shrine Board

Star Track Terminals

D e l h i C a r go Te r m i na l 3

Airport Haj Terminal

Nagpur Airport

H y d e ra b a d I n t e rn a t i o na l A i r p or t

Delhi Airport

Bagdogra Airport

Mumbai Airport

Bangalore Airport

Chennai Airport

Guwahati Airport

B h o p al A i r p or t

Raipur Airport

Lilabari Airport

Agartala Airport

A i r C a r g o W a re h o u se



Warehouse

Aircraft Hangar

Helicopter Hanger

Warehouse


Haj Terminal Building

Roofing

Roofing&False Ceiling System

F a l s e C ei l i n g S y s t em














andhi Automations Pv t Ltd isc o ns i de r ed a n i n du s tr y l e ad e r

i n t h e f i el d o f e n t r an c e a u t om a -Gt i on s y st e ms a n d l oa d in g b ay e q ui p -m en t in t he c ou nt ry. T he c om pa ny

o f f er s a w i d e ra n g e of p r o d uc t s t h a ti n c l u de s , h i g h s p e ed i n du s t r ia l d oo r s ,

se ctional ov e rhe ad doors, dock le ve l-e r s & d o ck sh e lt e rs , a i rc r af t h a ng a rdoors & shipyard doors, motorize d roll-

i n g s h u t te r s , t a i l l i f t s & s c i s so r l i f t s a n db o om b ar r ie rs & g a te s. O n e i f i t s sp e -c i a l t ie s a r e a u t om a t i c i n d u st r i a l o v er -

h ea d do or s, t he i de al s ol ut io n f or a lli n d u st r i a l n e e d s. T h e w e a t h er r e s is t a n t

industrial doors offe r maximum safe tyand be st use of transit ope nings.

The compact size of the automatic

industrial ov e rhe ad doors le av e s morea v a il a b l e s pa c e b o th i n s i de a n d o u t -

s i d e th e p r em i s es . T h e se o v er h e add o or s e n su r e a be t te r u s e o f i n si d e

space as the side runne rs v e rtically

mov e the door along the wall and paral-le l to the ce iling. The doors are installe d

a b o ve t h e op e n i ng , t h u s en s u ri n g abe tte r use of the transit ope ning.

O t h e r t o p f e a tu r e s o f t h e a u t om a t i cindustrial ov e rhe ad doors from Gandhi

Automations include :

- Easy and practical to open andope rate : As the se doors slide ve rti-

c al l y, s to pp in g i n t he pr ox im it y o ft he c ei li ng , t he y b le nd i n w it h t hea r c h it e c t ur a l f e a t ur e s o f t h e b u i l d -

i ng . T he ir c om pa ct s iz e e ns ur esm o r e av a i l ab l e s p ac e b o t h i n s i de

a n d o u ts i de o f t h e p r em i se s. T h edoors are also e asy and practical tou s e, e sp e ci a ll y i f t h e o ri g in a l D i te c

motors are used.- M or e en vi ro nm en ta l co nt ro l: H ea t

i n s u l a t i o n a n d s o u n d p r o o f i n ge n s ur e d b y h e a t- i n s ul a t e d p an e l s

improv e working conditions on the

p r e mi s e s a n d e ns u r e e n er g y s a v -ings.

- L ig ht a nd a es th et ic al ly p le as in ge n v i ro n m en t s : T h e p an e l s c an a l s o

b e m a n u fa c t u re d w i t h t h e a d d i ti o no f p r ac t ic a l p o rt h ol e s o r f u ll a l u-minium se ctions fe aturing polycar-

b o n at e o r u n b r ea k a b le g l a s s p a n -e l s , w i r e me s h in g o r a i r g r i l l es .

- T he y a dd va lu e t o t he pr em is es an d

m e e t a l l r e q u i r em e n ts : T h e d e s i gna n d d i f f e r e n t s o l u t i o n s o f f e r e d

e nsure the door to be ae sthe ticallyp l e a si n g a n d p e r fe c t l y s u i t ed i n a n yarchite ctural e nv ironme nt – from

m o d er n a n d t r a d it i o n al i nd u s tr i a lbuildings to fine comme rcial build-

i ng s. T he d oo rs c an m ee t a nyindustrial and comme rcial re quire -me nt and add v alue to the building

t h e y a r e i n s t al l e d o n . T h e se do o r sare built to e nsure the highe st e asea nd f le xi bi l it y o f u se w hi c h, i n t ur n

e n s ur e s a qu i c k , h a s sl e f r ee a n daccurate re place ment of old doors.

- R el ia bi li t y: A ll pr od uc ts ar e a ff ix edw i t h a C E m a r k.

Industrial Overhead Doors:M ak in g t he Ri gh t C ho ic e


Gandhi A utomations P vt Ltd

2 nd Floor, Chaw da Com m ercial CentreLink Road, Malad (W,) Mum bai – 4 0 0 0 6 4

Ph: + 9 1 - 22 - 6 6 7 2 02 0 0 , F a x : + 9 1 - 22 - 6 6 72 0 2 0 1 ,

E- m ail: sales@g eapl.c o.in

Web: w w w.g eap l.c o.inSectional Overh ead Doors

Sectional Overh ead Doors



Events


Aptly, the show focuses on “build-

ing products and construction technol-

o gi e s. " A s i n o t he r i nd us tr ie s, w id e-

s p r e a d d e p l oy m e n t o f a d v a nc e d t e c h -

n o l o g y p r o d uc t s i s h e l p i ng t h e c o n -

s t ru c ti o n i n du s tr y t o im p ro v e q u al i ty,

t i m e l i ne s s o f p r o j e ct de l i v e r y a n d p e r -

formance as well as to address long

t e r m s u s t ai n a b i li t y a n d e n v i r on m e n trelated concerns.

T h e B i g 5 C o n s t ru c t I n d i a s ho w w i l l

feature a staggering range of the latest

local and international building mate-

r i a l a n d c o n s t ru c t i o n p r o d uc t s w i t h s e v -

e r a l c o mp a n i e s ex h i b i ti n g t h ei r p r o d -

u ct s fo r t he f ir st t im e in I nd ia . T he se

products include innovative technolog-

ically advanced polyurethane products

f o r w a t e r p r o o fi n g , f l o o ri n g a n d r o o f i ng ;

t he s up er s tr et ch a nd w ra p u lt im at e

multipurpose rescue tape that could beu s e d t o f i x v i r t u al l y a n y t h in g ; a n d s e a m-

less sculptural wall surface designs,

s e a m l es s c o n t e mp o r a ry r e s i n f l o o ri n g s

and decorative resin wall panels.

“ W e h a v e p a r t i ci p a t ed i n o t h e r e d i -

t io ns o f T he B ig 5 in o t he r p ar ts o f t he

w o r l d a n d t h e y a l l of f e r ed u s m a n y

o p p o r tu n i t i es t o s h ow c a s e o u r p r o d -

u c ts a nd p ro m ot e o ur b u si n es s . T h is

t i me t o o w e pl a n t o e xh i bi t o u r r a ng e ,

including rebar, wire rod and heavy sec-

tions. We believe that this event will beg o od f or o u r b u si n es s , k n ow i ng t ha t it

is taking place in a market that is grow-

i ng e ve ry y e ar a nd p oi s ed f or e xc ep -

t i o n a l g r o w t h. O t h e r b e n e fi t s o f b e i n g at

the show include making direct contact

w i th o u r e n d c us t om e rs a n d n e tw o rk -

i ng w it h n ew o ne s, ” s ai d M r. M oh am -

m e d A l A f a r i , A V P E m i r at e s S t e e l .

“ C o ns t ru c ti o n i n I n di a o ff e rs h u ge

potential to those looking to develop

a n d e x pa n d t h ei r b u si n es s , a n d T h e

p ur re d o n b y t he b oo m i n t he r ea l

e s t a t e s e g me n t w h i c h a c c o u nt sSf or n ea rl y 4 3 % o f t he co ns tr uc -

t i on s p en d , I n di a 's g r o wi n g c on s tr u c-

t i o n i n d u st r y i s a t tr a c t in g a l a r g e n u m -

b er o f g lo ba l pl ay er s. A cc or di ng t o a

PwC report prepared for the organizers

o f T h e B ig 5 C o ns t ru c t In d ia , t h e re a l

e s t a t e se c t o r i s f o r e ca s t e d to g r o w a t aC AG R o f 3 .6 % du ri ng 2 0 12 t o 2 01 6,

w i t h a t o t a l m a rk e t f o r t h i s s e g me n t d u r -

ing this period estimated to be U S$ 380

b i l l i on ( a p p ro x . ` 22,800 crore)

To provide a platform to the large

n u m be r o f i n t e r na t i o n al m a n uf a c t ur e r s

k e en o n e n te r in g t h e I n di a n c o ns t ru c -

t io n m ar ke t, F IC C I ( Fe de ra ti o n o f I nd ia n

Chambers of Commerce and I ndustry),

t h e M i n i s tr y o f U r ba n D e ve l op m en t , G o v -

e rn me nt o f I nd ia ( M UD ), a nd d mg e v en ts

are organizing a mega building & con-s t ru c ti o n s h ow i n M u mb a i f r om 2 nd t o

4 t h S e p t e mb e r t h i s y e a r a t t h e B o m b ay

E x hi b it i on C e nt r e. T h e s h ow h a s e v ok e d

overwhelmingresponse andhas received

c o nf i rm at i on s f ro m 1 0 i n t e rn a t io n a l

c o u n tr y p a v i l io n s , i n c l u di n g G e r m an y,

I ta ly, S pa in , Tu rk ey, U K, I ra n, G re ec e,

Ta i w a n, K o r e a & C h i n a. I n a d di t i on , l e ad -

ing companies from countries like I ndia,

T h a i l an d , J a p an , U A E , O ma n, V ie tn am ,

S in ga po re , F ra nc e, A us tr al ia , e t c h a ve

confirmed their participation.E m er g in g t e ch n ol o gy t r en d s a re

r e d e f i n i n g t h e I n d i a n c o n s t r u c t i o n

i n d u s tr y a n d t a ki n g i t t o t h e n e x t l ev e l

g l o b a ll y. Te c h n o lo g y i s e m e rg i n g a s a

c a t a l ys t o f c h a n ge a s t h e i n d u st r y g r a p -

ples with challenges like escalating pro-

ject costs and prolonged construction

p e ri o ds . Te c hn o lo g y h o ld s t h e k e y t o

address these issues and enables the

sector to react to changing market con-

ditions effectively and efficiently.

Big 5 Construct India Show is a perfect

p l a c e t o c u l t i va t e n e w o p p o rt u n i t ie s i n

t h e r e g i o n” , s a i d M u h a mm e d K a z i , P r o -j e ct M a na g er, T h e B i g 5 C o ns t ru c t I n d i a.

A series of free seminars and panel

discussions will complement the show

f l o o r a c t i v it y p r o v i di n g p a r t i ci p a n t s w i t h

u p - t o -t h e - mi n u t e i n f o r ma t i o n , t r e n d s

analysis and best practice case stud-

ies to improve the decision making pro-

c e s s a n d e nc o u r a ge i n v e s t me n t . T h e

B i g 5 C o n s t r u ct I n d i a s h o w w i l l b e h e l d

a t th e B o mb a y E x h i bi t i o n C e n t r e, G o r e -

g a on , M u mb a i f r om 2 nd to 4 th S e p-

t e m b er 2 0 1 3 .

The leading names supporting the

event are as follows: Platinum Partner:

Emirates Steel; Associate Partner:

ARC; Seminar Partner: Tekla Stone;

Pavilion Partner:CDOS; Knowle dge Part-

n e r: P w C.

F o r m o r e i n f o rm a t i on c o n t ac t

Angelique Botes,

Marketing Manager, D MG EventsTe l : + 9 7 1 4 4 4 5 3 7 70Email: [email protected]

Unprecedented international & local response for mega building & construction

s ho w o rg an iz ed b y F IC CI , Mi ni st ry o f U rb an D ev el op me nt a nd D MG e ve nt s

Growing Opportunity in India'sC o nst ructio n S e cto r Dra w s Glo ba l At t e nt io n

Muhammed KaziProject Manag ar, The Big 5 Construct Ind ia

“ Co ns tr uc ti on i n I nd ia o ff er s

h ug e p ot en ti al t o t ho se l oo ki ng

t o d ev el op a nd e xp an d t he irb us in es s, an d T he B ig 5 C on -

s tr uc t In di a S ho w i s a p er fe ct




s t r uc t i v e t e st i n g t e c hn i q u e s, a s w e l l a s

c o nc r et e t e ch n ol o gy. T h e c o mp a ny w h ic h

o f f e rs s ol u t i o ns i n t h e ar e a s o f c o n c re t e

t e c h no l o g y a n d n o n - de s t ru c t i v e t e s ti n g

( N DT ) f o r q u al i t y r e la t ed i s s ue s h as i t s

s tate-of-the-art lab oratory located in

Chennai.

Focus Areas

F o r me r l y k n o w n a s N D T C o n s ul t a n cy

& S e rv i ce s , m o st of t h e e q ui p me n t w a s

a lr ea dy i n p la ce w he n H it ec h C on cr et e

S o l u ti o n s wa s f or m e d . “A f t e r t h e f or m a -t i o n o f H i t e c h C o n c re t e S o l u ti o n s , a n u m -

b er o f e qu ip me nt s f or N AB L c on fo rm it y

w e r e a c q ui r e d b y u s , ” p o i n te d ou t D r. K .

B a l a su b r am a n i an , M a n ag i n g D i r e c to r o f

the company. According to him, the com-

p a n y' s ma i n f o c u s a r e a h a s b e e n N D T.

H i t e ch C o n c re t e S o lu t i o n s i s a l s o in t o

s ugges ting appropriate repair methodol-

o gy wi th B OQ bas ed o n ND T. M at er ial

tes ting and concrete des ign mixes are its

o t h e r a r e as o f c o n c e nt r a t io n . H i t e ch C o n -

crete Solutions is als o into training of s ite

e n g i ne e r s in t h e a re a s of c o n c re t e t e ch -n o lo g y a n d w a te r pr o of i ng . G o in g i n to

details b ehind the training initiative,

B a l a s u b r a m a n i a n e x p l a i n e d , “ I n i t i a l l y

h a n ge i s t h e o n l y c o n s ta n t g o e s

a n o l d a da g e a nd n o w he r e i s itCm o r e a p p l ic a b l e t h a n i n t h e c a s e

o f c o nc r et e . T h e c o nc r et e o f t o da y i s n o

l on ge r j us t a c om bi na ti on o f w at er, c e-

ment and aggregates . While the produc-

t i on f o rm u la m a y b e s t il l s i mp l e, t h e p ro -

d u c t i on p r o c es s h a s un d e r go n e a s e a

c h an g e, w h at w i th t h e i n cr e as e i n d e ma n d

f o r s p ec i al i ze d co n cr e te su c h a s s e lf -

compacting concrete, temperature con-

t r o l l ed c o n c re t e , f i b re - r e i nf o r c ed c o n -

c r e t e, e t c . S t r i ng e n t q u al i t y s t a nd a r ds a r e

a l s o d i ct a t i ng t h e w a y c o n c re t e i s p r o-

d u ce d a n d u s ed . Te s ti n g o f c o nc r et e

t h e r ef o r e , h a s e me r g ed a s a k ey a r e a in

t h e c o n s t r uc t i o n i n d u st r y g l o b al l y. I n d i a i s

n o d i ff e re n t. A s t h e c o un t ry b u il d s i t s

infras tructure, concrete tes ting is a field

that has now gained importance.

O n e n a me t h at h a s m a de r a pi d s t ri d es

i n t h e f i e l d i s Hi t e c h C o n c re t e So l u t i o ns

C h e n na i P v t L t d , a n N A B L a c c r e d i t e d L a b-

o ra to ry i n C he nn ai . A co ns ul ti ng co m-

p a n y, i t s p e c i a l i ze s i n p r o vi d i n g s o l u t i on s

t o v a r i o u s c o n c re t i n g i s s u es t h r o u g h i n -

s i tu a n d l a bo r at o ry t e st i ng . I t s f o un d er s

a r e s t r u ct u r al e n g i n e e r s w i t h o v e r t w o d e -

c a d e s o f e x p e ri e n c e i n v a r i ou s n o n - de -

w h e n w e s t ar t e d , w e d i d n' t w a nt t o e n t er

i n t o a ny r a t r ac e w i t h o t h e rs . S i n c e I ha d a

s t r o ng e x p o su r e t o t h e p ow e r s e c t or,what I s tarted to do was to go into the s ec-

t o r a n d o f fe r t r ai n in g t o t h ei r s i te en g i-

n ee rs . T hi s h el pe d i n b ei ng s om e k in d o f a

s t ep p in g s t on e ”. T h e c o mp a ny a l so a l lo w s

s tudents on a s elective bas is to us e the

lab facilities for theirP os t Graduate thes is .

I n a d d i ti o n t o t hi s , i t e nc o u r ag e s c o n -

s t r uc t i o n c h e m i ca l c o m p a ni e s t o u s e i t s

l a b f a c i l i ty a n d B a l a su b r am a n i an f u r t he r

addedthatBASFis oneofits regularclients .H i te c h C o nc r et e S o lu t io n s g ot i t s

N A BL a c cr e di t at i on r e ce n tl y i n A p ri l , 2 0 1 3

i n t h e a r ea s o f N D T a n d M ec h a n ic a l t e s t-ing(tes ting of cons truction materials

including b ricks and b locks and s teel re-

b a r s) . O t h e r s i g n if i c a nt m i l e st o n e s a c h i -

e v e d by t h e c om p a ny i n c l u de s i g ni n g o f

an MO U wi th C SI R- SERC fo r p oss ibl e

o u t s ou r c i ng of c o n s ul t a n cy, w h i c h w o u l d

h e lp i t un d er t ak e mo r e R & D a n d S & T

related initiatives .

Infrastructure

Sound infrastructure has b een a cor-

n e rs t on e o f H i te c h C o nc r et e S ol u t io n 's

H i te c h C o nc r et e So l ut i o ns C h en n ai : A State-of-the-art Concrete Testing Center

We have signed an MOUw it h C SI R- SE RC f or p os si bl eo u t - so u r c in g o f c o n s ul t a n cy.T hi s w il l a ls o h el p i n u nd er -t aki ng mo re R &D a nd S&T-r el at ed r el at ed i ni ti at iv es f ort h e i n du s tr y.

Dr. K. BalasubramanianM anag ing Director

H i t e c h C o n c r et e S o l u t io n s C h e n n a i P v t. L t d .


A h ost of non-destru ctive and partially destru ctive testing equ ipm ents are available at

Hitech Concrete Solu tionsCh ennai



s ucces s s tory. The company's premis e in

Chennai has a cement lab, concrete lab ,

c h e m ic a l l a b a nd N D T l a b. A h o s t o f n o n -

des tructive and partially des tructive test-

ing equipments can b e found in the lab s .

The cement lab is temperature and

humidity controlled for conducting various

t e st s o n c e me n t a s pe r r e le v an t I n di a n

Standards . The concrete lab is equipped

w it h p an m ix e r, v ib ra ti ng t ab le , v ar io us

workab ility meas urement devices and an

accelerated concrete tes ting chamb er. A

3 0 0 0 k N c u b e C o m p re s s i on Te s t i ng

Machine (CTM) and a 1000 kN Univers al

Tes ting Machine (UTM) for the tes ting of

cub es and s teel rods can als o b e found in

the concrete lab . The concrete lab is als o

h a v i ng f a c i li t i e s f or t e s t i ng o f t h e v ar i o u s

c o ns t it u en t ma t er i al s o f c o nc r et e , v i z. ,

fine and coars e aggregate. The lab can

g i v e e c o n o mi c a l c o n c r et e d e s i g n m i x e s

b as ed o n t ri al m ix es f or t he v ar io us

grades and us ing mineral admixtures .

The chemical lab is equipped with

s tate-of-the-art facilities with Fume Cup-

b oard to evaluate the chemical compos i-

t i o n o f r e i n fo r c i ng s t ee l r o ds a n d w a t er.

For non-des tructive and partially-des truc-

t i ve t e st i ng , H i te c h C o nc r et e So l u ti o ns

has equipments s uch as Ultras onic P uls eVelocity (UP V) Tes ter, R eb ound H ammer,

P rofometer, H alf Cell Potential Meas uring

D e v i c e , R a p i d C h l o r i d e P e n e t r a t i o n

Tes ter (R CP T) and P ile Integrity Tes ter.

T h e c o m pa n y c a t e rs t o s e v e r al s e c -

tors s uch as power, ins titutional buildings

& f a ct o ri e s, i n fr a st r uc t ur e p r oj e c ts a n d

m a r in e s tr u c t ur e s . S o m e o f i t s to p c l i e n t s

i n c l u de na m e s s u c h a s L a r se n & To u b r o

L i mi t ed , G a mm o n I n di a , R e li a nc e I n fr a -

s t r uc t u r e , L a n co I n f r at e c h , J M C P r o j e c t s ,

IT D C eme nt at io n, NCC Li mi te d, B GR

E ne rg y S ys te ms , B ri dg e & R oo f, C CC L ,S o m a I n f ra t r u ct u r e , A f c o ns , P a nd u r ag a

Energy, Coas tal Energen P ower Corpora-

t io n, K SK M ah an ad i Po we r C om pa ny

L i m i t, S t e r li n g R e s or t s , N A B A RD , O r c h id

C h e m ic a l s , L a f ar g e C o n c re t e , U l t r at e c h

C on cr et e, M ar g e tc . t o m en ti on o nl y a f ew.

S o me o f t h e ma j or p r oj e c ts w hi c h i t h as

b een as s ociatedwith include, Amarkantak

P o we r P r o j ec t a t K o r b a , S a s an U l t r a T h e r-

mal Po we r Pr oj ec t, C MRL , Vi zh in jam

P o rt , D G N P, V i z ag t o m e n t io n o n l y s o m e.

As part of its future plans , H itech Con-

crete Solutions has lined up s ome inter-es ting initiatives . Going into details ab out

t h e m , B a l a s u b ra m a ni a n s a i d , “ O n e o f t h e

e m e rg i n g o p p or t u n it i e s i s i n t h e f i e l d o f

t e s t in g o f e p o x i es an d o t h e r t e s t i ng re -

quirements of cons truction chemical com-

p a ni e s. L o ng t e rm m o ni t o ri n g of i n fr a -

s tructure like bridges in collab oration with

S E RC a n d II T i s an o t h e r d o m a in t h a t we

a r e l o ok i n g at f o r t h e f u tu r e ” . T h i r d pa r t y

auditing of quality s tructures and s oil tes t-

i n g ar e t he o t h er a r e a s w h i c h a r e hi g h o n

its agenda for the future.


T h e c o m p a ny c a t e rs t o s e v e ra l s e c t o r s s u c h a s p o w e r, i n s t i tu t i o n al b u i l d i n g s & f a c t or i e s , i n f r a st r u c tu r e

projects and m arine stru ctu res.

Th e cem ent lab is temperatu re and h u m idity controlled f or condu cting variou s tests on cem ent

a s p e r r e l e v an t I n d i a n S t a n d ar d s .

F o r F u rt h er d e ta i ls

H i te c h C o nc r et e S o lu t io n sC h e n na i P v t . L t d . ,( N A B L A c c r e di t e d L a b o r a to r y a s pe r

I S O / IE C 1 7 0 25 : 2 0 0 5 )

# 64 , G al ax y R oa d ,

P o nn i y a m ma n N a g a r,

Ayanambakkam, Chennai - 600 095.

M o b i le : + 9 1 9 9 4 0 4 5 55 3 0 /

+ 91 9 94 03 8 85 56 / + 91 4 4 2 65 3 0 06 0

Web: www.hi techconcrete. i n





M.K. Prabhakar, Associ ate Edi tor

T he I nd ia n C on st ru ct io n C he mi ca ls M ar ke t:Building a Sustainable Future

ture s. Howe v e r, the construction che m-

i c a l s i nd u s t ry i n I n d i a is s t i l l in a n a s c en t

s t a t e w i t h t h e p e r c a p i ta c on s u m pt i o n

o f c o n st r u c ti o n c h e m ic a l s b e i ng l o w i n

comparison to countries from Europe ,

North America, and e v en Southeast Asia.

India's pe ne tration le v e ls are 50% lowe r

t h an C h in a 's p en e tr a ti o n a n d 7 0% l o we r

than the de v e lope d world.

Market Drivers According to a re port by FICCI, the

construction che micals marke t has in-

creased from ` 1,400 crore s in 2007 to

` 3 , 1 00 c r or e s in 2 0 12 . T h e In d i a n c o n -

struction che micals marke t has shown

a s t ro n g g ro w t h r a t e o f 1 7 % pe r a n n um

historically and is e xpe cte d to grow at a

C A G R o f 1 9 . 49 p e rc e n t ov e r t h e p er i o d

o n st r uc t io n c h em i ca l s i n I n di a

a r e a s s um i n g g r e at e r s i g n if i -Cc a n c e w i th t h e s u r ge i n r e si d e n -

t i a l a n d c o m m er c i a l c o n st r u c ti o n d u e

t o u r b a ni z a t io n a n d e m p ha s i s o n i n f r a-

s t r u ct u r e . T h e I n d i an c o n s tr u c t io n c o m -

m u n i t y i s g r a d u al l y r e a l iz i n g t h e i m po r -

t a n c e o f e n h an c i n g t h e pe r f or m a nc e

a n d d ur a bi l i ty o f b u il d in g s an d s t ru c -

C o n st r u c ti o n C h e mi c a l s: I n d u st r y A n a l ys i s



"In Inida it is necessary to makeproducts that are suitable to thel o c a l c o n di t i o ns b e c a u s e t h eneeds are extremely specific"

Thier r y Ber nar dG l o b a l C E O, C h r y so

A ccording to a report, th e Indian constru ction ch em icals m arket is f orecasted to witness exponential g rowth ,

e s p e ci a l l y i n i t s a d m ix t u r es s e g m en t i n t h e n e x t f i ve y e a r s


2 0 1 2- 2 0 16 . T h e m a r k et r e v e n u e f o r t h e

I n d i an c o n st r u c t io n c h e mi c a l ' s m a r ke t

i s ex pe ct ed t o r ea ch u p t o US D 1 .1 3

B i l l i on b y t h e e n d o f 2 0 1 8. A large part of this numbe r is attrib-

ute d to the growing aware ne ss amongstthe community archite cts, builders, con-

tractors and owne rs - that construction

c h e m ic a l s h e l p i n i m p r ov i n g t h e q u a li t y

a n d pe r f or m a nc e o f c o n st r u c t io n o v e r

a l o n g e r p e r io d . A r c h it e c t s a n d c o n su l -

tants hav e re alize d the importance of

quality construction che micals, and the y

g e ne r al l y t e nd t o s p ec i fy t r us t ed b r an d s

o f c o n st r u c ti o n c h e m ic a l s .

T he e nt ry o f f or ei gn p la ye rs i n t he

construction che micals se ctor has also

acce le rate d the growth of the construc-t i o n c h e mi c a l s s e ct o r s. B i g p l a y er s a r e

inv e sting efforts and manpower on e du-

cating contractors and builde rs on the

significance of construction che micals.

L o ca l R& D l a bs h av e b e en w i th a n a i m

to manufacture products suitable for

local conditions at affordable price s.

This has le d to a subtle shift in the con-

tractors from be ing price conscious to

q u a l i ty c o n sc i o u s w i t h r e s pe c t t o c o n -

s t ru c ti o n c h em i ca l s. A n d w i th i n cr ea s ed

e mphasis on ne e d for affordable hous-

ing, urbanization and he ighte ned inv est-

m e n ts i n i n f r as t r u ct u r e b y t h e g o v er n -

m e nt , t h e d e ma n d f o r c o ns t ru c ti o n c h e-

micalsin the future onlyse e ms brighte r.

Market Split

C on st ru ct io n c he mi ca ls c an b e

classifie d into product cate gorie s ad-

m i x t ur e s , w a t er p r oo f i n g s y s te m s , s e a l-

a n ts , f l oo r in g , t i li n g a n d r e pa i r & r eh a -

b i l i t at i o n e t c . T h e re ar e a l s o o t h er m i s -

ce llane ous construction che micals,

w h ic h c a n b e u s ed t o e n ha n ce c on -struction activ itie s.

According to a re port, the Indian

construction che micals marke t is fore -

caste d to witne ss e xpone ntial growth,

e s p ec i a l l y i n i t s a d m i xt u r es s e g m en t i n

t h e n e x t f i v e y e a rs . I n 2 0 1 2, t h e a d m i x-

ture s and wate rproofing syste ms con-

s t i t ut e d m o r e t h a n 6 0 % o f t h e o v e ra l l

c o n st r u c t io n c h e m ic a l s m ar k e t r ev e -

nue s. Concre te admixture s accounte d

f o r 4 2 % o f t h e t ot a l c o ns t r u ct i o n c h e m i-

cals market, while flooring and wate r-

proofing che micals had a share of

1 4 %e a ch . O t he r s eg m en t s i n cl u de s ea -

l a nt s , g r ou t s a n d a d he si v es , w h ic h t o -g e t h er a c c o un t f o r 1 8 % o f t h e t o ta l c o n -

s t r u ct i o n c h e m ic a l s m ar k e t. T h e s ha r e

o f f l oo r in g i s h i gh i n t h e I n di a n m a rk e t

as compare d to the de v e lope d world

w h i l e t h e c ou n t r y h a s a lo w e r s h a re o f

t i l in g , s ea l an t s a n d w at e rp r oo fi n g. M or e

t h an 8 0% o f t h e c o ns t ru c ti o n b u si n es s

is from ne w built structure s & buildings.

Market Players

The construction che micals marke t

i s f a i r ly c o n so l i d at e d w i t h t h e t o p p l a y-

e r s a c co u nt i ng fo r m or e t h an 5 0% -

6 0 % o f t h e m a rk e t . 7 0 % m ar k e t i s co n -

t r ol l ed b y o rg a ni z ed s e c to r. T h e r es t

c o m pr i s e s of s m a ll a n d u n o r g an i z ed

playe rs. 300 companie s are estimate d

t o b e o p e ra t i n g in t h i s se g m en t . H o w -

e v e r, the re is considerable fragme nta-

t i o n o f i n d i vi d u a l p r o du c t s a n d a p p l i c a-

t i on a r ea s . I n di a 's c o ns t ru c ti o n c h em i -c a l s m a r ke t i s h i g h l y c o m pe t i t iv e w i t h

just top fiv e companies accounting for

almost 50% marke t rev e nue s in 2012.

T h e ke y v e n do r s do m i n at i n g t hi s

marke t space are BASF, Fosroc, Pidilite ,

S WC -C hr ys o, S ik a, C IC O, Pe ne tr on ,

Vandex, Techny Chemy, MC-Bauchemie,

Ce ra Che m and STP. Se v e ral inte rna-

tional playe rs hav e e nte re d the Indian

c o n st r u c t io n c h e m ic a l s m a r ke t a n d

i n ve st i ng h e a vi l y i n l o ca l R & D i n du s tr y

a s ev en t h ou g h t h e ma r ke t d oe s no t

m a k e e x t e ns i v e u s e of c o n st r u c t io nc h e mi c a l s a t p r es e n t, t h e s h ee r s i z e of

its pote ntial and ongoing urbanization

make s it attractiv e .

C o n st r u c t io n C h e mi c a l s: I n d u st r y A n a l ys i s

S p e n d in g o n C o n c r et eA d m i xt u r e s ( $ / m 3)

India China USA



"Manufacturers have theresponsibility of incresing theawarness level on the benefitsof using construction chemicalsf r o m an o v e ra l l l i f e c yc l eperspective. This is a challengethe industry has to face boldly

in its own interest.”

Subu Venkat r amanM D , S i k a I n d i a P v t . L t d .

T h e m a j o r i n d u st r y p l a y e rs a re i n -v e s t in g a l o t in R & D a c t i v it i e s i n o r d e r t o de v e l o p h i g h

v a l u e a n d l o w c o s t p r o du c t s t o c a t e r t o t h e p r i c e s e n si t i v e I n d ia n m a r k et .Environm ent f riendly m aterials su ch as water-based coating s, g reen coating s,

and insulation coating s are required f or th e constru cting of g reen bu ildings


R & D a n d I n n o v at i o n

T h e ma j or i n du s tr y p l ay e rs a r e i n-

v e st i n g a l o t i n R & D a c t i vi t i e s i n o r d er t o

d e ve l op h i gh v a lu e a n d l o w c o st p r o d-

u ct s t o c at er t o t he p ri ce s en si ti ve I nd i an

marke t. Curre nt and prospe ctiv e re gu-

latory guide line s ince ntiv izing e ne rgy-

e fficie nt and gre en buildings will driv e

de mand for suitable , innov ativ e prote c-

tiv e coatings and safe chemicals. As a

re sult of the incre asing focus on e ne rgy

c o n se r v at i o n a n d e c o - f ri e n d li n e s s, t h e

n e ed fo r g r ee n b u il d i ng s a n d g r ee nproducts has incre ase d across indus-

t r i e s i n I n d i a. E n v ir o n me n t f r i e n d ly m a t e-

r i a l s su c h a s w a te r- b a se d c o at i n g s,

g re en c oa ti ng s, a nd i ns ul at io n c oa t-

ings are re quire d for the constructing of

g re en b ui ld in gs . F or i ns ta nc e, i ns ul a-

t i on c o at i ng on t h e r o of a n d w al l s o f a

building act as an insulator, prov iding a

c o ol i ng e f f ec t , w h ic h r e du c es e n e rg y

c o n su m p t io n a n d t h e lo a d o n a i r c o n di -

t i o n er s . T h e e m e r g en c e o f e c o -f r i e nd l y

c o ns t ru c ti o n c h em i ca l s is o ne o f t h e

e m er g i n g tr e n ds i n t h e c on s t r uc t i o n

c h em i ca l s m a rk e t i n I n di a . S i li c on e -

b a s ed b a s e d c o n s tr u c t io n c h e m ic a l s

are also gaining rapid popularity.C h r ys o , a k e y i n t e rn a t i on a l F r en c h

s p ec i al i st i n c o ns t ru c ti o n s ys t em s , r e -

c e nt l y s et u p i t s c e nt e r i n I n di a , s p re a d

o ve r a p pr ox i ma t el y 5 0 00 s q u ar e f e et

n ow, w it h a p ro vi si on f or e xt en si on a c-

ross the total are a of 10000 square fee t

i n t h e f u tu r e. T h e R & D c e nt e r i s a i me d

a t c u s t o mi z a t io n o f p r o d uc t s s p e c if i c t o

Indian conditions. The R & D center

boasts of late st pie ces of e quipme nt on

t h e cu t t i n g- e d g e o f t e c h no l o gy. S o m e

of the re pe rtoire include s instrume nts

f or t es ti ng of c on cr et e a dm ix tu re s,

w a t er p r oo f e rs , t e c h ni c a l m o r ta r s , a n d

c e m en t a d d i t iv e s . C o n cr e t e m i xe r w i t h

spe e d controlle r to re plicate the spe e d

o f a t ra ns it m ix er i s k ey e qu ip me nt .

O t h er i n s t ru m e n ts a n d f a c i l it i e s i n t h e

l ab or at or y i nc lu de m oi st er a na ly ze r,

digital v iscome te r, pullout bond te ste r,

c o lo u r c o mp a ra t or, h a rd n es s t e st e r,

h um id it y c ha mb er s, e po xy / p re -p ai ntd i s p en s e r, s p e ct r o p ho t o me t e r, F T I R t o

m en t io n o n ly s o me . O n e o f t h e p ri m ar y

a re as of f oc us in t he ce nt er w il l b e

d e v el o p m en t a n d u p g r ad a t i on o f c o n -

c r e t e a d m i xt u r e f o r u l t r a- h i g h s t r en g t h

concre te M80 and abov e , using poly-

c a rb o xy l at e t e ch n ol o gy. A n ot h er k e y

a r e a o f c o n c en t r a ti o n w i l l be d e ve l o p-

ing concre te admixture s to e ncounte r

t h ix o tr o ph i c n a tu r e. S o me o f t h e ot h er

focus are as include de v e lopme nt of

ae sthetic concrete , wate r proofing mem-

br anes , P U & E pox y b ase, f loor in g &

coatings and te chnical mortars, e tc.

Pidilite 's construction che micals di-

v ision has introduce d se v e ral innov a-

t i v e p ro d u c ts u n d e r t h e D r. F i x i t b ra n d

d u ri n g t h e y ea r - D r. F i xi t Lo w E n er g y

C on s um p ti o n ( L EC ) s y st e ms f o r h i gh

e nd wate rproofing couple d with insula-

t ion f or t er ra ces an d wa ll s, D r. F ix it

E xt en sa , a h i g h e nd p u n ct ur e- pr oo f

w at er pr oo f c oa ti ng f or r oo fs & b as e-

me nts and Dr. Fixit Bathse al Kit, a solu-

t i o n f o r c o m pr e h en s i ve a nd l on g l as t -

ing waterproofing for bathrooms. Pidilite

h a s a n i n no va t io n c e nt e r i n S i ng a po r e,

w hi ch f oc us es e xc lu si ve ly o n g re en

c o at i ng s t ha t c an l e ad t o l ow er c o n-

s um pt io n o f e le ct ri ci ty a nd t he re fo re ,

e v en t u a ll y l e a di n g t o a n i m p or t a n t c o n -

tribution to gre en buildings. Building can

u s e h e a t i n su l at i on c o at i ng s o n t h e r o of s

o r t h e w al l s. C o at i ng s , s u ch a s D r. F i xi t

H e at s hi e ld , p r ov i de a c o ol i n g e ff e ct a n d

a c t s a s an i n s u la t o r, r e s ul t i n g i n t h e re -

d uc ti on o f a ir c on di ti on in g l oa ds . T hi s

n a tu r al l y h a s a n i m pa c t on t h e e n er g y

conse rv ation and e co-frie ndline ss.




“Our Building Codes by the BISare primitive and there aren e it h er c o de s n o r co d es o f practice for waterproofing,repairs, flooring, structuralrehabilitation etc. Our civilengineering curriculum in theengineering colleges is alsov e r y o l d a n d ob s o l et e . ”

M.A. WaheedP e r ma C o n s t r uc t i o n A i d s P v t. L t d

It calls for collaborated effortsi n v ol v i n g a l l s t a ke h o l de r s t h eindustry, the end users, theconcerned ministry, concernedapproved organization inchemicals like FICCI, codalorganizers like BIS, universitys y l l ab i c o m mi t t e es a n d e v e nPlanning Commission tocollaborate and recognize theimportance of this industry.

S a m ir S u r l ak e rM a n a gi n g D i r e c t o r, M C - B a uc h e m ie ( I ) P v t . L t d


Vande x offe rs a we ll-rounde d port-

folio of coatings for protecting structure sf r om w a t er p e ne t ra t io n s u ch a s d i a ph -

r ag m w al l s or e le va to r s ha ft s, u nd er -

g r o un d g a r a ge s o r s w i mm i n g p o ol s .

Vande x ceme ntitious products for drin-

king water re taining structure s are de -

signe d to prov ide a se a of application,

e xce ptional re sistance to le aching, pro-

t e c t io n f r o m c o n ta m i n at i o n a n d e a s y-

to-cle an surface s.

As part of its marke ting initiativ e s,

BASF has rolle d out its Maste r Builde rs

S o l u ti o n s b ra n d i n I n d i a - a c o mp r e -

h e n si v e p or t f ol i o o f v a r i ed s p ec i a l t yB A S F b r a nd s t o c o n s t r uc t i o n i n d u st r y

m aj or s, a ll u nd er o ne u mb re ll a. T he

portfolio of products and se rv ices mar-

k e t ed u n d er t h e Ma s t er B u i l de r s so l u -

tions brand e mbrace s che mical solu-

tions for ne w construction, maintenance ,

r e pa i r a n d r e no va t io n o f b u il d in g s a n d

infrastructure : concrete admixture s, ce -

me nt additiv e s, che mical solutions for

m i n i ng a n d t u n n e l in g , w a t er p r oo f i n g,

c o nc r et e p ro t ec t io n a n d re pa i r p r od -

ucts, grouts and high-pe rformance flo-oring products. This is expe cte d to fa-

cilitate be tte r acce ss to the marke t and

s t r en g t h en t h e aw a r en e s s o f t h e c o n -

s t ru c ti o n i n du s tr y o n o u r e x is t in g r a ng e

o f p r od u ct s a nd o f fe r in g s. T h e i n tr o -

d u ct i on o f G l en i um t e ch n ol o gy b y B AS F

I n d i a i n t h e a d m i xt u r es s eg m e nt i s

e xpe cte d to driv e its marke t share in

the ne xt fiv e ye ars.

In orde rto further stre ngthen itsstrong

c u s t om e r- o r i en t a t io n a n d d e v e l o p a n d

o f f er i n n ov a t i ve s o l u t io n s t o t h e c o n -s t ru c ti o n i n du s tr y c u st o me r s i n S o ut h

Asia, BASF re ce ntly announce d the

o p en i ng o f a n e w C on s tr u ct i on Te c h-

n ol og y Cen ter i n Mu mb ai , In di a. Th e

n e w c e n te r w i l l s u p p or t j oi n t de v e lo p -

m e nt wi t h c u st o me r s f o r n e w p r od u ct

applications and formulations, prov id-

ing an e xce lle nt ve nue for e nte rprise s in

t h e s u b- r eg i on t o e mb r ac e w or l d- c la s s,

c u t t i ng - e dg e t e c h n o l og i e s i n p a r t ne r -

shipwithBASF'stechnicalprofessionals.

Challenges

D e s pi t e s ev e r al p l a y er s i n t h e i n -

d u s t ry, t h e e nd u s e r m a r ke t i s s t il l s u f -

f e r s f r o m l o w a w a re n e ss l e ve l s on t h e

a p pl i ca t io n a n d b en e fi t s o f c o ns t ru c -

t i on c h em i ca l s. L ow a w ar e ne ss l ev e ls

among contractors about the te chnol-

o gy a nd a pp li ca ti on o f c on st ru ct io n

c h e mi c a l s h a m pe r s t h e g r o wt h o f t h e

industry.

W h i l e m a j or p l a y er s of t h e in d u s tr y

i m p r es s u p o n t h e n e ed f o r t h e s k i ll a n d

k n o w- h o w t o t h e e n d - us e r a n d a r e w i l l-

ing to prov ide the ir te ams for guidance ,

training and support, the re is a de arth

of skille d worke rs and technical e xpe r-

tise in the industry. It also doe s not he lp

that the curre nt civ il e ngine e ring curric-ulum and syllabus in colle ge s and uni-

v e rsitie s do not dev ote much atte ntion

t o t h e s ig n if i ca n ce o f c o ns t ru c ti o n

che micals on the structure and pe rfor-

mance of buildings.T h e I n d i an c o n st r u c t io n c h e m ic a l s

m a rk et i s h i g hl y c o st - co n sc i ou s . T h e

custome rs de mand the be st quality at

v er y l o w p r ic e s a n d s om et i me s u s e

low-cost substitute s that may not pe r-

form unde r sev ere conditions. Decisions

are take n base d on imme diate cost noto n o v e ra l l c o s t o f o w n er s h i p ( l i f e- c y c l e

P r od u ct C a te g or i es M a rk e t S p li t

42%

14%

14%

12%

18%

Admixtu res

F loorin g

Waterproofin g

R e p a i r & R e ha b i l i t at i o n

Miscellan eou s




D e s p it e s e v e r al p l a y e r s i n t h e i n - d us t r y, t h e e n d u s e r m a r k e t i s s t i ll s u f f e rs f r o m l o w a w a r en e s s l e v e ls o n t h e

a p p l ic a t i o n a n d b e n ef i t s o f c o n s t ru c t i on c h e mi c a l s

cost) basis. Margins are lower be cause

most contractors prefe r low-cost che m-

icals to re duce the ov e rall construction

c o s t. H i g h v a l ue p r o d uc t s h a ve l i m i t ed

de mand and are use d only by pre mium

construction house s.

The re are no e stablishe d standards

f o r c o n s tr u c t io n c h e m ic a l s u n l i k e o t h er

countrie s whe re guide line s about prod-

u c t p e r fo r m an c e a r e c l ea r l y l a i d o u t.

F u r th e r mo r e , d u e t o l a c k of s t a n da r d s

a n d l o w e n tr y b a rr i er s , s e ve ra l l o w v a lu e

products are be ing sold in the marke t,

thus hindering the growth of the industry.

F u t u r e O u t lo o k

T h e I n d i an c o n st r u c ti o n c h e mi c a l smarke t has be e n te rme d as the “sun-

rise industry” and the term se e ms ap-

p r o p ri a t e a t t h is j u n c t ur e . T h e I nd i a n

c o ns t ru c ti o n i n du s tr y i s e x pe c te d t o

witne ss a surge in the ne xt de cade and

with increasing levels of awareness about

t h e r o l e a n d s i g ni f i c a nc e o f c o n s tr u c -

t i o n c h e m ic a l s i n b u i l di n g s u st a i n ab l e ,

d u ra b le a n d e c o- f ri e nd l y s t ru c tu r es , t h e

g r o wt h o f t h e I n d i an c o n st r u c t io n c h e m-

ical industry se e ms ine v itable .


Industry Initiatives: CCMA

I n 2 0 12 , t he m an uf ac t ur er s fo r

c o ns t r uc t i on c h em i c al s i n I n di a c a me

t o - g e t he r t o f o rm t h e C o n s tr u c t i o n

C hemica ls Ma nufa cturers As s ocia -t i o n ( C CM A ) i n 2 0 1 2 w i t h t h e a i m o f

p r o m o t i n g a n d a c c e l e r a t i n g t h e

g r ow t h o f c o n st r uc t i on c h em i ca l s i n

India a nd a ct a s a forum to communi-

c a t e w i t h t h e go v e r n me n t b o- d i e s ,

a s sociations , cha mbers of commerce

a n d o t h e r c o m m e r ci a l i n d u s t r ia l a n d

p u b l i c b o d i e s w i t h i n o r o u t s i de I n d i a .

C C MA ha s a ls o urg ed C ons truction

In-dustry Development Council( CIDC)

t o w o rk w i t h C C M A o n s k i l l d e v e l op -

m en t of c ra ft sm an i nv ol ve d in t he

a pp li ca ti on o f c on st ru ct io n c he mi -ca ls a cros s India , improving s pecifi-

ca tions a nd crea ting a wa renes s a t

f r o n t- l i n e e n g i n ee r s , j o i n t ly o r g a ni z e

C C a wa renes s works hops a cros s

I n d i a fo r a l l e n d u se r s a n d in f l u e n-

c e r s , a s s i st a n d g u i d e C C M A t o d e -

v el op a s yl la bu s on b as ic u sa ge o f

c o n s t ru c t i o n c h e m i ca l s a n d t a k e u p

a n d a dd r e s s t he i s s u e o f i m p o rt e d

r a w m a t e r ia l s a t t h e c h e m i c a l i n d us -

t r y f o r u m .

The ma rket pla yers ha ve rea lized

tha t continuous tra ining a nd educa -

t i on a b ou t ne w t e c hn o lo g ie s in c o n-

s tr uc t io n c h em ic al s i s t h e n ee d. M os t

o f t h e m a r e i n di v id u al l y o r ga n iz i ng

m e e t s a n d w o r k s ho p s f or t h e i r d e a l -

e r s , d i s t r ib u t o r s a n d o t h e r s t a k e ho l -

d e r s . T h e s e w o r ks h o p s i nc l u d e o n -

s ite tra ining to educa te cons truction

contra ctors a bout the benefits of

u s in g su p er i or c o ns t ru c t io n c h em i -

c al s, i n t e rm s o f l ow er p ro je ct co m-

p l et i on t i m e an d e a se o f u s ag e , p r o-

viding technica l tra i-ning to workers

a b o u t a p p r op r i a t e u s a ge o f t h e s e

c h e m i ca l s i n c o n s t ru c t i o n w i l l e n s u rec o r r e ct ap p l i ca t i o n a n d b e t t e r r e s u l t

a n d co r re c t u sa g e o f c h em i ca l s.

M a ny o f t h e b ig p l ay e rs h a ve d e di -

c at e d a pp li ca to r c ar e c el l, w hi c h

helps them in providing the rig ht kind

o f s o lu t i on s f o r t h e ir p r ob l e ms . P i di l i te

ha s set up a not-for-profit org a niza -

t io n c al le d Dr. F ix i t In st i tu te , w hi c h

impa rts tra ining to contra ctors , a ppli-

c a t o r s, e n g i ne e r s an d s t ud e n t s o n a

continuous ba s is .




t h a s be e n r e p o rt e d t h at h e a vy r a i n sa n d a bu r st g e y se r o r w a te r p i pe a r eone of the most damaging disastersI

to a building. Waterproofing a buildingp l a y s a p i v o ta l r o l e i n p r e v e nt a t i v e r i skm a na g em e nt . I t i s ch e ap e r t o ou t la ym o n e y b e f o re d a m ag e i s ca u s e d a so p p o s ed t o o u t l ay i n g m o n e y a f t e r d a m -a g e h a s b e e n c a u s ed .

The waterproofing should be made

m a n d at o r y f o r a l l s t r u c t ur e s a n d s h o u l dn o t a n o p ti o na l o n e. T h e a p pr o ac h t owaterproofing problem must be con-c e p t u al an d t h e s e l e c t io n o f a p p r op r i -a te m at er ia l a nd p ro pe r d ia gn os is o f t heproblem and employ ing the right appli-c a to r f o r e x e cu t in g th e j ob i s e qu a ll yimportant.

Waterproofing is as important asa n y o t he r p a ra m et e r i n v ol v ed i n d e si g n -i n g a s t r u c tu r e . I t i s be c a u s e w a t e r -proofing also play s a vital role towardst h e d u ra b i l i ty c o n c r et e a s w e l l as t h esafety o the structure.

Waterproofing MethodsW a t er i s m o s t d e s t r u c ti v e w e a t h e r-

ing element of concrete structures; waterc o n t i nu e s t o d a m a ge o r c o m p le t e l yd e s t r oy m o r e b u i l d in g s a n d s t r u c t u re st h an n a tu r al d i s a s te r s. W at e rp r oo f in gtechniques preserve a structures integ-r i ty a n d u s ef u ln e ss th r ou g h a n u n de r -s ta nd in g o f n at ur al f or ce s a nd t he i r e ff ec tduring life cy cle.What is Waterproofing?

“ I s th e fo rm at io n o f a n i nt er na l or

e x t e r na l m e m b ra n e w h i c h i s d e s i g n e dt o p re v e nt w at e r f r om e nt e ri n g ore s c a p in g t h e c o n c r e te . I n t e rn a l m e m -b r a n es a r e c r e a te d w i t h w a t e rp r o o f in ga d m i xt u r e . E x t e rn a l m e m br a n e s a r ea p p l i ed t o t h e s u r f a ce o f t h e c o n c re t en e a r ly a l w a ys o n t h e p o s i t iv e s i d e . ”

External membrane is divided intotwo sub categories: fluid applied mem-branes and sheet applied membranes.

T he re a re f ew t yp es o f t he m os t c om -m o nl y u s e s y st e m o f w a te r pr o of i ng i nconstruction industry.- C em en ti ti ou s w at er p ro of in g- L i qu id w at er pr oo fi ng me mb ra ne- B it um in ou s c oat ing- B it um in ou s me mbr an e- P ol yu re th an e li qu id me mb ra ne

C e m e n t i t i o u s w a t e r p r o o f i n g : C ementitious waterproofing is oftenu s e d in t h e i nt e r n al w e t a r e as s u c h a st oi l et s. M os t o f t he t i me t he t yp e o fcementitious waterproofing is semi-f l e x i bl e , s o m e ev e n t o w a rd r i g id t y pe . I tis still good to use because internal toi-lets are not exposed to sunlight andweathering and so it do not go throught h e c o n t r a ct i o n a n d e x p a n si o n p r o c e sscontinuously

L iq ui d w at er pr oo fi ng m em br an e:L i q ui d m e mb r an e i s a t h in c o at i ngw h ic h c o ns i st s o f u s ua l ly a p ri m er c o ata nd tw o c oa ts of t op c o at s. I t o ff er sm o re f le x ib i li t y t h an t h e c e me n ti t io u st y p e s o f w a t e rp r o o fi n g . T h e e l o n g at i o n

p r op e rt i es o f t h e co a ti n g ca n r e ac h a sh i gh a s 1 0 00 % . B u t th e d ur a bi l it y o f t h ewaterproofing coating also depend onw h a t t yp e o f p o l y me r t h e m a nu f a c tu r e ru s e fo r t h e ma k i n g o f t h e li q u i d w a t e r-proofing.

Bituminous coating: Bituminouswaterproofing coating is made of bitu-m e n b a s e d m at e r i al s a n d i t i s n o t s u i t -a b l e f or e x p o s e to s u n l i gh t . I t b e c om e sv e r y b r i t tl e a n d f ra g i l e wh e n l o n g e xp o -sure to the sunlight unless it is modifiedw i t h m o r e f l e x ib l e m a t e ri a l s u c h a s p o l y -

Advanced Multipurpose WaterproofingCoatings

278 · T h e M a s t er b u i l d er - July 2013 www. m asterbuild er. co. in

S a m ee r R . B ho r e , P r o j e ct M a n a g e r, M u l t i c h em G r o u p , M u m b a i

F i g . 1 : A L ea k i n g B a s e me n t

u r et h an e o r a c ry l ic b a se d p o ly m er s .T h e f l ex i bi l it y o f t h e f i ni s he d p r o du c tsalway s depends on the solid content ofthe poly mer added to the bitumen.

B i t u m i n o u s m e m b r a n e : Bituminous waterproofing membraneh a v e t or c h o n m e m b ra n e a n d s e l f a d h e -

s i v e m e mb r a n e. To r c h o n m e m br a n e i sthe more preferred one use because ofi t s s h el f l i fe an d e a se of u s e d u ri n g

application.T h e s e l f a d h e si v e t y p e m u s t b e u s e

f a s t a s t he b o n d i ng p r o p e rt i e s o f t h em e m b ra n e i s r e d u c in g t h ro u g h t i m e .V e ry o f t e n a p p l ic a t o r s fi n d t h e s e l f a d h e -s i o n m e m b ra n e a l r e ad y l o s e i t s bo n d -i n g p r o p e rt i e s w h e n t h e y w a n t t o a p p l y.T h e re f or e , t h ey h a ve t o u s e o n e ad d i-tional primer to prevent the debondingp r o b l em i n t h e n e ar f u t u re .

To r c h o n m e m br a n e h av e e x p os e da n d c ov e re d t y pe s . E x po s e d me m -b r a n e o f t e n h a s m i n e r a l g r a n u l a ra g g r eg a t e t o w i th s t a n d th e w e a r a n dt e ar o f t h e w e at h er i ng an d t h e o t he rt y p e s o f m e m br a n e , c o n t r ac t o r n e e d t oapply one protective screed to preventthe puncture of the membrane.

B u t o n e h a s t o b e v e r y c a r e fu l w h e napply ing the protective screed which iso f t e n c e m e nt m o r t ar. T h e c e me n t r a ti ohas to be high and the mixing has to bet ho ro ug h t hr ou gh o ut t he p ro ce ss .There is premixed ty pe of cement mor-t ar i n t he m ar ke t av ai la bl e f or u se f or

b e t t e r q u a l i ty a n d co n s i s te n c y. S i t e m i xu s ua l ly w i ll c o m p en s at e t h e q u al i t y o ft h e f i n is h w o r k b ut t h e c o s t i s a lw a y sc h e a p er c o m p ar e d t o p re m i x e d mo r -tar.

P ol yu re th an e l iq ui d m em br an e:Poly urethane is also use for the flat roofarea and exposed to weathering but iti s e xp e ns i v e. I t c an o f fe r h i gh e r f l ex i bi l -i t y. P ol y ur e th a ne i s v e ry s e ns i ti v e t om o is t ur e c o n t en t p r e se n t, t h er e fo r eb e f o re a p p l i c at i o n ; o n e h a s t o b e v e r ycareful evaluating the moisture content

Waterproofing



o f t h e c o n c r et e s l a b . O t h e rw i s e p e e l i ngo r d eb on di ng ea si ly o bs er ve d a ft ersome time.Waterproofing Technology

H y d r o p h i l i c v s . H y d r o p h o b i c :

H yd ro ph o bi c o r w at er r ep el l en t p r od -u ct s r ep el t he w at er b y i nc re as in gh y d r op h o b il i t y. t h e y r e d u ce a b s o rp t i o nbut are not enough to resist significanto f w a t e r p r e s s ur e .

F i g. 2 : H y dr o ph o b ic

H y d r op h i l i c c h e m i ca l s a b s o rb a n du t i l i z e w at e r t o c a t a l yz e a n d r e a c t w i thcement particles to produce elongatedc r y s ta l l i n e s t r u c tu r e r s. t h e y p h y s i ca l l yb l oc k po r es , c r ac k s an d IT Z t o s uf f i-c ie nt ly r es is t t h e p en et ra ti on o f w at eru n d e r p r e s s ur e .

F i g 3 : H y d r o ph i l i c

S u ch t y pe of w a te r pr o of i ng p r od -ucts is commonly called cataly ticw a te r pr o of i ng b y c r ys t al l iz a ti o n, e . g.H y d r on i l r a n g e o f p r o d u ct s , m a n u fa c -t u r e d b y M u l t i ch e m .P o s i t i v e a n d N e g a t i v e - s i d eWaterproofing

P o s it i v e s i d e w a t e rp r o o fi n g : Whenr e f e rr i n g t o t h e p o s it i v e s i d e o f w a t e r-

p r o o fi n g ap p l i c at i o n . W e ar e t a lk i n ga b o u t th e s i d e w h e re t h e w a t e r w i l l b ec o mi n g i n c o nt a ct w i th t h e c o nc r et e .T h e o p p o rt u n i ty t o w a t e r pr o o f t h e p o s i -t i v e s i d e i s m o s t ly t h e r e o n l y d u r i n g c o n -

struction.

F i g . 4 : P o s i ti v e S i d e W at e r p ro o f i n g

N e g a t i v e s i d e W a t e r p r o o f i n g : Negative side waterproofing is appliedto the inside (dry ) face of a structure (oro ut si de o f r es er vo ir ); E as y a cc es s tot h e dr y s i de m ak e s ne g at i ve s i dewaterproofing the first choice for reme-dial projects.

M u l t i c h e m G r o u p P r o v i d e s Y o uA d v a nc e d W at e r p ro o f i ng C o a t in g s

M ULT IG UA RD I W+ : a n i nt eg ralwaterproofing product - I t is alway sb e t t e r t o a d d w a t e r p r oo f i n g a d d i ti v e i nf r e s h / g r e e n c o n c r e t e a n d p l a s t e r

b e fo r e t he y a r e c as t ed / ap p li e d. S u chadditives give excellent waterproofingp r o p er t i e s i ns i d e t h e bo d y o f t h e m a ss ,b ec au se o f c re at io n o f c oh es i ve m ixa n d i n t e r n a l w a t e r p r o o f i n g b a r r i e r .S u ch a d di t iv e s ar e c al l ed I n te g ra lwaterproofing compounds. MultiguardI W+ falls into this category and impartc o rr o si o n p r ot e ct i on t o r e ba r s a l on gwith leakage protection.

LeakShield: LeakShield is a singlec o m p o n e n t p o l y m e r m o d i f i e dc e m e nt i t i o u s h i g h p e r f or m a nc e w a t e r -

F i g . 5 : N e g a t iv e S i d e W a te r p r oo f i n g

p r o o fi n g c o a ti n g f o r c o n c re t e p r o t ec -t i o n . L e a k Sh i e l d fo r m s a de n s e , w a t e r-p ro of s ur fa ce b ar ri e r. I t c on si st s o fP o rt l a n d c e m e nt , w e l l - gr a d e d q u a r tzs a n d a n d a c t i v e p o l y me r e n h a nc e d

s p e c i a l c h e m i c a l i n g r e d i e n t s ( w i t hn a n o t e c h no l o g y ), m a k i ng a h a r d a n dflexible membrane.

L e ak Sh ie ld c a n b e u se d f or r ig idw at er pr oo fi ng o f w at er t an ks , s e al i ngi n te r na l b as e me n t an d c e ll a r w a ll sa g a i ns t d a m p ne s s , w a t e r l e a k ag e , p r o -t e c t i o n o f c o n c r et e s t r u c tu r e s i n m a r i nee n v i r on m e n ts , e x t e r na l t an k i n g o f s u b -structure concrete such as foundationsa n d b as e me n t w a ll s i n n e w b u il d in g s.T h e p r od u ct c a n w i th s ta n d p os i t iv es i d e w a te r p r es s ur e up t o 8 b a r/ a tm

w at er p re ss ur e. F or t er ra ce o r e xt er io rw a t e r p r o o f i n g p r o t e c t i o n , p r o d u c tc o me s i n w hi te , g ra y, a nd m u lt ip le o fcolours.

Hydronil: W at er pr oo fi ng o f c on -c r e t e s t r u c t u r e b y C a t a l y t i cC ry stallization

W a t er p r o of i n g o f r i g i d s t r u c tu r e ss u c h a s b a se m en t , w a te r t a nk s , s w im -m i n g p o o l s , c a n b e b e s t p r o t ec t e d b yc a ta l yt i c c r ys t al l iz a ti o n b a se d w a te r -p r o o f in g p r o du c t s . H y d r on i l r a ng e o fp r o d u ct s , g i v e ne a r t o p e rm a n en t p ro -

t e c t i o n t o t h e l i f e t im e o f s t r u ct u r e . T h e ybecome part o f body of concrete,h e nc e ab s ol u te l y n o c ha n ce o f d a m-a g e b y e x te r na l a c ti v i ti e s. S t ru c tu r esw a t e r pr o o f e d w i t h H y d ro n i l p r o d u ct sc a n w i t h s t an d 1 7 a t m w a te r h e a d .

R a i n S H I E L D ™ : E l a s t o m e r i cWaterproofing coating - RainSHI ELD™i s w a te r b a se d h i gh s o li d e l as t om e ri ccoating utilizing the latest advances ina c r y li c a n d p o l y ur e t h an e t e c h n o l og y.H i g h e st q u a li t y r e s i n s a r e co m b i ne dw i th r ei nf or ci ng l am in ar p ig me nt s, a neffective biocide packages and non-m i g r at i n g f i r e r e t a rd a n t , r e s u l ti n g ins up er io r d ur ab il it y, w ea th er pr oo fi ng ,u l t r av i o l e t r e s i st a n ce , a l g ae / mi l d e wr e s i s t a n c e a n d f i r e r e t a r d a n c y .R a i n SH I E L D™ i s h i g h ly r e f l e ct i v e , t h e r -m al i ns ul at in g, p er ma ne nt l y f le xi bl e,b r e a th i n g me m b r an e , a l l o w in g m oi s -t u r e v a po u r f r o m t h e s u bs t r a t e o r b u i l d -i n g i n t e ri o r t o e s c a p e w hi l e r e m ai n i n gi m p e rv i o u s t o m a s s w a t e r p e n e t ra t i o nform the exterior.

Waterproofing




U n i q ue F e a t u re s :- Su pe ri or F le xi bi li ty, H ard ne ss an d

Solvent Resistance.- B ri dg es su bs tr at e c ra ck up t o 2 mm .- L on g t er m c ra ck r es is ta nc e.

- S up er io r f r e ez e/ th aw r es i st an ce .- Sel f c uri ng.- Very l ow shrinkage.- N o n - t o x i c a n d e n v i r o n m e n t a l

f r i e nd l y p r o d uc t .- U ni qu e an ti -f un gu s a nd a nt i- al ga e

properties- Su pe ri or e xt er io r d ur abi li ty an d UV

light resistance.- H ig h t e m pe ra tu re s ta bi l it y.- L ow t em pe ra tu re f l ex ibi li ty d ow n t o

–15˚c.- D ir t p ic k- up r es is ta nc e.

- E xc el l en t a dh es io n t o p ol yu re th an ef o a m a n d m a ny o t h e r s u b s t ra t e s .

- H ig h r ef le ct iv it y w hi ch r ed uc es w al ls u r f ac e te m p e ra t u r es , t h e r e by p r o -longing wall life and reducing inte-r i o r t e m p er a t u re s .

- E as y a p pl ic at io n b y s pr ay, b ru sh , o rr o l l e r - t h u s l o w e r i n g a p p l i c a t i o ncosts.

- L ow t ox ic it y a nd or de r.- S im pl e w at er c le an up f or ma nu fa c-

turers and contractors. ®

R O O F S H I E L D : E l a s t o m e r i c

Waterproofing coating®R O OF S HI E LD i s w a te r b a se d h i gh

s o l i d e l a s t om e r i c c o a t i ng s u t i l i z i n g t h el a t e s t a d v a nc e s i n a c r yl i c a n d p o ly u r e -

t h a n e t e c h no l o g y. H i g h e st q u al i t y r e s -ins are combined with reinforcing lami-n ar pi gm en ts , a n e ffe ct iv e b io ci depackages and non-migrating fire retar-d an t, r es ul ti ng i n s up er io r d ur ab il it y,weatherproofing, ultraviolet resistance,a l g a e / m i l d e w r e s i s t a n c e a n d f i r e

®r e ta r da n cy. R O OF S HI E LD i s h i gh l yr e fl e ct i ve , t h er m al i n su l at i ng , p e rm a -n e nt l y f l ex i bl e , b r ea t hi n g m e mb r an e ,

allowing moisture vapour from the sub-s tr at e o r b ui l di ng i n te ri or t o e sc ap ewhile remaining impervious to massw a t e r p e n e t ra t i o n f o r m t h e ex t e r i or. I t i s

a va il ab le i n h ig h t en si le s t re ng th v e r-s io n f or r oo f a re as s ub je ct t o he av ym a i nt e n a n ce t r a f fi c , s e v e r e w e a t h erconditions, chemical fallout etc.Uses:- C ur ed c on cr et e su bs tr at e (F la t or

sloping)- All metal roofs- Po ly ur et ha ne fo am , A sp ha lt sh in -

g l es , E P DM , H y pa l on , b i tu m en e t c.

- Woo d- Old buil di ngsConclusion:

W at e rp r oo f in g o f s t ru c tu r e i s a si mp or ta nt a s a n y o th er c o ns t ru ct io n

r e la t ed a c t iv i t ie s o f t h e p ro j ec t . I n f a ct ,waterproofing will make structure mored u r a bl e a nd l o ng l as t i n g . I t is a l soe q u a l ly i m p o rt a n t t h at d i f f e r en t p r o d -u ct s sh ou ld b e c ho se n a s pe r t hew a t e r p r o o f i n g r e q u i r e m e n t , e . g .Basement is best protected by cry stal-l i n e b as e d t e c hn o l o g y a n d r oo f s a rep r o t e ct e d f r o m w a t er a n d h e a t b y u s i n ge l as t o me r ic c o at i ng s . T h es e c o at i ng sc a n l a s t f o r m o r e t h a n 1 5 y ea r s .

Fig 7

F or f ur t he r d e ta i ls :

M u l t ic h e m G r o u p1 , M a ha v ir G a ur a v B ui l di n g, M . D. K i niM a rg , B h an d up V i ll a ge , B h an d up ( E ),Mumbai - 42Ph: + 9 1 - 2 2- 2 5 6 69 1 3 7 , M o b : + 9 1 - 9 32 3 8 9 01 9 5 ,

E-mail: in f o@multichemgroup. n etW eb: www. multichemgroup. n et

Fig 6:


Waterproofing



T P L i m i te d i s on e o f t h e l e a di n gn a m es i n t h e I n d i an w a t er p r oo f -ing and prote ctiv e coatings mar-S

k e t. T h e c o mp a ny h a s a w i de sp r ea dd e a le r n e t wo r k sp a n n in g t h e l e n g th

a nd b re ad th o f t he c ou nt ry. S TP h adr e ce n tl y o r ga n iz ed i t s a n nu a l N o rt h I n di aRe gional Associate s Me e t. The me e t,

h e l d a t t h e T i v ol i G a rd e n H o t el i n N e wD el hi , s aw t he e nt hu si as ti c p ar ti ci pa -t i o n o f 2 0 0 l ea d i n g Po i n t o f S a l es ( P O S)

de ale rs from North India.The company has always focuse d

on re ce iv ing fe e dbacks from its associ-a t e n e t wo r k , c o n si s t i ng o f d i s t ri b u t or s ,d e al e rs o r a p pl i c at o rs , i n a b i d t o c on -

stantly improv e upon its product range .S TP h as be en a n R & D l ed in no va ti vec o m pa n y e n d ea v o ri n g t o d el i v e r v a l u e

f or m on e y t o it s cu s to m er s . T h e m e ets aw S T P l a un c h i t s ' Li q ui d M em b ra n e'

series. An inte ractive -session, during which

t h er e wa s a de mo n st r at i on o f o n si t e

a p p l ic a t i on o f t h e pr o d u ct s , w a s on e o fthe highlights of the me e t.

Addre ssing the associate during

the me e t , Mr.K.P.Shri v astav , Chie fE xe cu ti ve O ff ic er o f t he c om pa ny

r em a rk e d, “ I n o u r e n de a vo r t o e st a bl i shSTP as the most prefe rre d brand andd e l i ve r i n g v al u e t o o u r c u s t om e r s, S T P

s h al l c on t in u e to i n ve st i n c o re R & D t om a in t ai n i t s l e a de r sh i p p o si t io n a n d t od e l i ve r q u a l i ty p r o du c t s a t c om p e ti t i v e

price s."The following are the products

l au nc he d b y t he c om pa ny u nd er t heLiquid Me mbrane se rie s during theoccasion:-

Ta r F e lt L M - W a te r B a s ed B i t u m i n ou s

Liquid Me mbrane TarFe lt LM is a single compone nt;

w a t er b a s ed e l a st o m er i c p o l ym e r i ze d

b it um in ou s e mu ls io n w it h s el ec te dgrade d fine fille rs and some additiv e s.Ta rF el t L M i s a pp li ed b y b ru sh / r ol le r

w i th o ut a n y u s e o f h e at . Ta r Fe l t L M f o rm s

a t o u g h, e l a st o m er i c , m o n ol i t h i c, s e am -le ss wate r proofing me mbrane.

ShaliUrethane LHM - SingleComponent

E l a s t o m e r i c M o d i f i e d P o l y u r e t h a n eWaterproofing Membrane

ShaliUre thane LHM is a single com-

ponent modified polyurethane elastomericliquid applied waterproofing me mbrane

c o a ti n g . I t f o rm s a s ea m l e ss w a t er -p r oo f in g me mb r an e by r e ac t io n w i thatmosphe ric moisture . This confirms to

ASTMC-898-2009, C-836-2012 code s.

S ha li Cr yl RW P - UV Re sistant He av yD u t y L i q u i d A c r y l i c R o o f W a t e r p ro o f in g

ShaliCrylRWPisanuniqueelastomeric

he av y duty te rrace wate rproofing liquidme mbrane syste m compose d of spe -c ial ly d evel oped h ig hl y el ast ic an d

r es il ie nt a c ry li c p ol ym er s, p ro pe rl yse le cte d and grade d fille rs, light fasta n d w e a t h e r d u r a b l e p i g m e n t s ,

microfibe rs, additiv e s and be st qualityf u ng i ci d al i n w a te r m e di u m. I t is us e d

as liquid applie d wate rproofing me m-

b r a ne f or a l l t yp e of b u i l d in g t er r a c es .

Hav ing a unique UV cross-link curingm e ch a ni s m, S h al i Cr y l R W P b ec o me smore durable with age .

ShaliUrethane BTD - Single Component

E l a s to m er i c B i t u mi n o u s P o l y u re t h an eLiquid Me mbrane

S h al i Ur e th a ne B T D i s h i gh p e rf or -

m a nc e w at e r b a se d c o ld ap p li e de lastome ric coating. This unique singlec o m p on e n t s y s te m i s r e a dy t o u se

m a te r ia l b a se d o n P U m o di f ie d b i tu m en

e mulsion.

S ha li Cr yl 2 15 - Single Compone nt UVRe sistant Elastome ric Exte rior Coating

S h al i Cr y l 2 1 5 i s a u n iq u e e l a s to m er i ch i g h b u i l d c o a t in g ba s e d o n a r ev o l u-t io na ry a cr yl ic p ol ym er w it h q ui c k- se t

capabilitie s to re sist pre mature mois-ture attack. ShaliCryl 215 provide s dura-

b i l i t y, f l e x ib i l i t y, a n d ex c e l le n t we a t he rresistance. Because of a unique UV cross-l i n k c u r i n g m e c h a n i s m , S h a l i C r y l

b e c om e s m o r e d u r a bl e wi t h a g e . I t i s

e a sy t o a pp l y a n d is e n vi r on m en t al l ys a f e a n d n o n- p o l lu t i n g . S h a l iC r y l 2 1 5

has inhe re nt wate rproofing qualitie s aswe ll.

ShaliBond APP - Cold Applied Adhesive APP Me mbrane

ShaliBond APP is pre ssure applie d,s yn t he t ic r u bb er i ze d a d h es i ve w i t hbonding stre ngth de signe d spe cifically

f or c ol d ap pl ic at io n o f m od if ie d bi tu -m e n m e m b r a n e s . S h a l i B o n d A P P

m e m b r a n e a d h e s i v e h a s s u p e r i o rb o nd i ng s t r e ng t h a n d h i g h f l ex i bi l it y t oaccommodate te mpe rature re late d

e xpansion and contraction.S T P a l s o i n t ro d u c ed a v i r tu a l s e l f-

a d h es i v e - Ta r Fe l t A P P i n c o m bi n a t i on

with ShaliBond APP, on the occasion.

H i gh P e rf o rm a nc e L i qu i d M em b ra n e S er i esLaunched

278 · T h e M a s t er b u i l de r - July 2013 www.masterbuilder.co.in


S T P L i m i te d7 0 7 C h i r an j i v To w e r 4 3 N e h r u P l a c e ,

N e w D e l h i - 1 1 0 0 1 9

P h : + 9 1 - 11 - 4 6 56 1 3 5 9 , F a x : + 9 1 - 11 - 4 6 56 1 3 5 8

E-m ail: inf o@ stpltd. com

Web: www.stpltd. comM r. K .P. Sh ri va st av a Ad dr es si ng to t he G at he ri ng N ew P ro du ct L au nc h

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