The Masterbuilder - July 2012 - Concrete Special

MB Cover
Aquarius Engineers Pvt.Ltd
Aquarius Engineers Pvt.Ltd
Pidilite Industries Ltd.( Dr. Fixit)
Hess Concrete Machinery India (P) Ltd
Metecno India Pvt.Ltd
Associated Chemicals
EDITOR'S COMMENT
Your feedbacks are welcome and should be sent to: The Editor, The Masterbuilder, 102/11 (New No. 46/11), Tripti Apartments, Marshalls Road, Egmore, Chennai, India. Phone: +91 44 28555248 Telefax: +91 44 28586703
Editor-in-Chief K.P . Pradeep editor@masterbuilder.co.in Vice-Chairman K G K Moorthy moorthykgk@yahoo.co.in Director Editorial, Construction Chemicals Dr. Y P Kapoor Editor-in-Charge Ravi Damodaran Editor Nigel Narayan Associate Editors M.J. Krishna, M.K. Prabhakar, Sonjay Deb Head - Content Development CE, Infrastructure & Environment Sadagopan Seshadri Contributors Bhavani Balakrishna, Priya, Chaitanya Raj Goyal Vice President Marketing H. Usha Devi Head-New Media Initiative Pradeep Nair Credit Controller G.B. Muralidharan Finance R. Prema Manager Digital Production K. Sravanthi Kiran Manager Digital Media Lakshmi Creative Head S. Nithiyanandam Production Manager Caroline D'sylva Digital Production Assistant R. Anand, Sudhir Kumar Singh Subscription & Circulation Team Sateesh Kuniyil, S. Sasi Corporate Office MB Publishers Pvt. Limited 102/11 (New No. 46/11), Tripti Apartments, Marshalls Road, Egmore, Chennai - 600 008. Ph: 044-28555248 Telefax: 28586703. Subscription & Circulation subscription@masterbuilder.in Website www.masterbuilder.co.in Karnataka No.40, 2nd Floor, 7th "C" Cross, Ashwini Layout, Koramangala, Bangalore - 560047. Phone: 080 - 25701079 / 25705888 Mobile: 09343833191 Owned and Published by K.P . Pradeep 102/11 (New No. 46/11), Tripti Apartments, Marshalls Road, Egmore, Chennai - 600 008. Printed By Ashok Natarajan Times Printers & Publishers, New No. 57 (29), Dr. Besant Road, Ice House, Chennai - 600 014. Disclaimer All rights reserved. Reproduction, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, in whole or part without prior written permission is prohibited. All views expressed in this magazine are those of the authors and do not necessarily reflect those of the publisher, neither do the publishers endorse any of the claims made in the advertisements.
Changing the Composition

oncrete is the most preferred and valued construction material for its high compression strength, monolithic mass, resistance to harsh weather conditions, instant availability and low cost. Despite the fact that concrete's recipe has remained unaltered ever since John Smeaton made the first modern concrete; one cannot quite literally stop from being excited about the future composition of this truly captivating building material, explored and presented to us by researcher scholars recently. So what exactly is exciting us? To begin with, stakeholders across the globe are thrilled about the possibility of reduction in the quantity of Portland cement and replacing it with alternative eco-mixes. Green cement is one such emerging alternative that might eventually substitute Portland cement with reactive magnesia and industrial by-products, reducing the environmental impact of conventional cement. The temperature needed to produce green cement is almost half that of the standard, meaning renewable energy sources such as wind and solar power can be utilised, resulting in a product that can be almost 100% recycled. New technologies and techniques that can result in efficient and superior end products will find its way into the marketplace. Structural concrete building members will continue to increase in span with reduced thickness. Castable materials will have sufficient tensile and compressive properties, eliminating separate reinforcement. Concrete components will be more efficient and be much thinner leading to greatly reduced dead load of structures. Going forward, The use of by-products and recycled materials, generally sourced from demolition sites and abandoned buildings, will become popular within the construction industry. Foundations for new buildings will soon be formed from recycled materials, rather than tonnes of concrete being poured for the slab foundations. Crushed aggregate will be made from recycled concrete and used increasingly in the construction of roads, as well as the creation of new concrete. With so much said, the days are also not too far when a much greener concrete will take the centre stage during the construction of offices and homes, driven by a generation of civil engineers who have learned to differentiate between priorities and values. The materialistic values of our children would have changed dramatically, reducing demand for possessions. Our new-found wealth from reduced energy costs, infrastructure, and consumption will allow for focused spending on rebuilding a more compatible environment in this planet. The current edition of the Masterbuilder attempts to showcase some of the most important innovations and trends that are currently doing the rounds in the world of concrete. The edition also features well researched papers and in-house articles on Ready Mix Concrete, Cement, Manufactured Sand, Self Compacting Concrete, Self-Healing Concrete, Fly Ash Concrete, Concrete Equipments Crushing & Screening, Formwork, Admixtures, Non Destructive Testing, Corrosion, Repair & Rehabilitation, Composite Technology, Tall buildings, C&D Recycling, among others. We hope you enjoy the current edition and do send in your valuable feedback and suggestions.
K.P Pradeep, Editor-in-Chief

editor@masterbuilder.co.in
Marini India Pvt Ltd (Fayat India)
In Celebration of Concrete
Our July 2012 issue is a celebration of concrete- a much maligned, misunderstood, and yet ironically, among the most consumed material in the world. It won't be out of place to say that the last two centuries have been that of concrete and more concrete. What has undergone a sea change is the way in which concrete is produced, processed and placed, something that has a lot to do with the advent of specialized modern equipments. Speaking about change, The Masterbuilder is part of a few high profile and game changing events such as the sixteenth National Congress on Corrosion and its Control (NCCC), The Regional Conference of the International Network of Women Engineers & Scientists (INWES), Deep Foundation Technologies for Infrastructure Development in India, National Seminar on Modern Equipments for Concrete Construction, FICCI, IndiaChem 2012 and The National Colloquium on Concrete Construction for Coastal Conditions Causes, Concerns & Challenges (7-Cs) that is scheduled to take place in 2012. Stakeholders spanning across the spectrum of the construction industry will find the events extremely useful from the point of view of getting to know about the latest developments in their respective fields, apart from getting an opportunity to interact and network with fellow industry professionals. Another important event that is bound to have a significant impact and deserves a special mention is The Indian Concrete Institute's 20th Annual Awards 2012, to be held on 22nd September at Chennai. The ICI Annual Awards are in recognition of outstanding concrete structures as well as those engineers who have done exceptional and long standing contribution in the field of concrete/construction. Counted among the most prestigious events, the virtual who's who of the construction fraternity is expected to rub shoulders with each other on the occasion. Nominations for the awards close on July 31st, 2012. All those who have not sent in their nominations can go through the details provided in Page No. 271. It has been and will be our endeavor to bring to you the latest developments in the field of concrete. Connoisseurs of concrete will find going through this issue extremely interesting. Several leading luminaries have shared their words of wisdom as part of the concrete special. With this issue we hope to set the benchmark even higher, when it comes to covering core civil engineering topics. The issue also comes at a time when the country is poised to enter its crucial second phase of infrastructure development as part of the 12th Five Year Plan period. I am hopeful that the economy would bounce back by the end of the year and the bring in good news for the construction industry.
K.G.K.Moorthy | Vice-Chairman moorthykgk@yahoo.co.in
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The Masterbuilder - July 2011 www.masterbuilder.co.in
Gandhi Automations Pvt.Ltd
Contents
Trends in Concrete
20 Emerging Trends Shaping the World of Concrete
The Masterbuilder, Bureau Report
46
140
1 1
Editor's Comment.........................8 Vice Chairman Message..............10 Advertisers Index.......................20 Classification Index....................22 News & Events............................24 E-Scape.....................................302
58 66 70 78 82 86 92 102 110 132
RMC: Industry Analysis Ready Mix Concrete: Readies Itself toTake Over the Industry
Chaitanya Raj Goyal
RMC: Industry Evolution of RMC in India
Amir Hosein Bakhtiarain, 2Morteza Askari The Bsc. Student of Islamic Azad University, 2 The faculty member of Islamic Azad University
Form Work Pressure Effect of Concrete Temperature and Formwork Width on Variation Pressure Formwork of Self-compacting Concrete
Vijaykumar R Kulkarni, Member Managing Committee & Principal Consultant, RMCMA Immediate Past President, ICI
Cement: Industry Analysis Cementing Against Odds: The Indian Cement Industry
Bhavani Balakrishna
160 168
Concrete: Batching Plants Concrete Batching Plants: Set to Play a Crucial Role in Infrastructure Development Phase II
M.K. Prabhakar, Associate Editor
Crushing & Screening Equipment Nawa Engineers Acquires Global Manufacturing Rights of 'Duracone SRM Project Management Efficiency at Sites: The Prime Focus
Dr. R N Krishna, Ph.D (Civil Engg.) Concrete Technologist, Ex.Secretary General, Indian Concrete Institute, India. Proprietor, KC Contech Manufacturer of Rice Husk Ash
Concrete: Admixtures Rice Husk Ash An Ideal Admixture for Concrete in Aggressive Environments
E Ravishankar, Ph.D, Research Scholar, BITS-Pilani
Construction Chemicals: Analysis Construction Chemicals: Stakeholder Collaboration is the Need of the Hour
Bhavani Balakrishna
174 182 190 194
MB Bureau Report
Transit Mixers Concrete Transport Equipment: Small is the New Big
Dr. Y P Kapoor, Managing Director, Bang Associates & Director Editorial, The Masterbuilder
Concrete: Self Compacting Self Compacting Concrete: An Economical Approach
MB Bureau Report
Equipment: Concrete Placement Concrete Placing Equipment: When Newer Markets Beckon
Admixture: Metakaolin Metakaolin for High-Performance Concrete

Special Correspondent
Manufactured Sand Inspiring Saga of Challenge & Change Corrosion: Research Performance of Concrete Flexural Elements Reinforced with C-Bars
Concrete: Durability of Structures Durability of Concrete Bridges and Viaducts
Anil K Kar, B.Sc CE, MSCE, Ph.D, Engineering Services International, Salt Lake City, Kolkata
Dr. Anil K Kar1, Dr. M S Haji Sheik Mohammed2 Proprietor, Engineering Services International, Kolkata 2 Professor, Department of Civil Engineering
1
Formwork: Industry Analysis Formwork: Custom-Made Solutions Takes Center Stage

MB Bureau Report
Healing Concrete 202 Self Self-Healing Concrete
Sonjoy Deb, B.Tech,'Civil', Associate Editor
102 58
12 The Masterbuilder - July 2012 www.masterbuilder.co.in
160
70
Enviro Geosynthetics Pvt.Ltd
Contents
Concrete: Block Making Machinery 228 The Future Shines Bright for Concrete Block Making Machines
154 Benefit from Global Expertise in Concrete Forming 157 Plastic Shuttering: A Revolution in Construction Industry 208 Steel Fibre Reinforced Concrete (SFRC): Areas of Application 212 Energy Efficient Initiatives from The Supreme Industries 214 Proven and Reliable Lifting Solutions from Gandhi Automations 216 Innovations in Concrete and Epoxy Floorings 218 Turkish CE Major Spreads its Wings in India 220 World-Class Products Backed by Excellent After - Sales Service 222 Everest Equipments: Scaling New Heights
Recycling A Sustainable Community Development 244 C&D Approach
233
In Conversation Anand Sundaresan: The Man Who Saw Tomorrow

K.P. Pradeep, Editon-in-Chief
Non Destructive Testing 238 Concrete: Non Destructive Testing for Concrete: Advancing Equipments & Market
Chaitanya Raj Goyal
Corrosion 248 Concrete: Accelerated Short-Term Techniques to Evaluate Corrosion in Reinforced Concrete Structures
ASR 264 Concrete Alkali-Silica Reaction in Concrete
Ash Concrete 274 Fly Masonry Grout for Sustainable Development

Materials 286 Composite The Impact of Basaltic Fibre on Selected Physical and Mechanical Properties of Cement Mortar
Report 292 Site Putzmeister India's BSA 2110 HP D Pumps Concrete up to 200m at High-Rise Project in Mumbai
256 Crystalline Concrete Admixture

Construction Target New Heights in Indian Market with the 258 Case Launch of New Generation Steer Skid Loaders
Mumbai Bureau Report
294 300 98
Tall Buildings Extreme Engineering: World's Most Anticipated Skyscrapers

Chaitanya Raj Goyal
Realty The Big Squeeze: Mumbai Developers Battle Unsold Inventory Pile-up
the Block Making Market with Mr. Jayaram Ramesh 262 Exploring Managing Director, Sri Parijatha Machinery Works
270 Charting Out its Own Distinct Growth Path 280 Join the BIM Workflow with Your iPad or iPhone 282 Rising Dampness Compound 284 Record Number of Exhibitors at bauma China 2012
Communication Feature Nano Waterproofing for Increased Life-cycle in Structures
148 Home Grown Formwork Manufacturer Shining Bright 149 Reinventing the H-Beam
248 238
294
300
Garware Wall Ropes Ltd
Contents
Advertisers Index
1
20 Microns Limited 105 Gandhi Automations Pvt.Ltd Garware Wall Ropes Ltd GCI Wall Forms Pvt.Ltd
G
11 19 139 Razon Engineering Company Private Limited RD Mining Equipments Pvt. Ltd. RDC Concrete (India) Pvt Ltd Reliance Industries Ltd Relyon Facility Services Robo Silicon Pvt.Ltd Rockster Recycler India Ltd Roljack Industries ROTHO - Robert Thomas Metall- and Elektrowerke GmbH & Co. KG
R
197 129 63 231 282 187 205 241 261
A
Abcon Tech & Build Aids Pvt. Ltd. Action Construction Equipment Ltd Ajax Fiori Engineering (I) Pvt. Ltd. Akarsh Specialities Alpha High-Tech Polyurethanes Apollo Infratech Pvt.Ltd Aquarius Engineers Pvt.Ltd Associated Chemicals Atul Fastners Ltd 267 211 163 267 253 61 Gate Fold 7 243
H
H & K Rolling Mill Engineers Pvt.Ltd Hess Concrete Machinery India (P) Ltd Hitech Concrete Solutions Chennai Pvt. Ltd. 21 2nd wrapper 263 / 267
I
ICI - 2 days National Seminar on Modern Equipments for Concrete Construction 291 ICI- 20th Annual Awards-2012 Igloo Tiles INSTRUCT Ironite Co. of India Ltd 271 147 285 207 Schwing Stetter (India) Pvt. Ltd Sicoma Mixers India Pvt. Ltd Sika India Pvt.Ltd Silicone concepts Intl. Pvt. Ltd. Sri Parijatha Machinery Works Pvt. Ltd. STA Concrete Flooring Solutions STP Ltd Surie Polex
S
57/ 235 261 65 113 191 109 / 193 75 Back Inner
B
BASF India Limited BC India Bekaert Industries Pvt Ltd Bharat Road Development Combines Private Limited (BRDC) Brickwell Buildmat 2013 73 277 25 177 257 281
J
JBA Concrete Solutions Pvt.Ltd 201
C
Case New Holland Construction Equipment (India) Pvt.Ltd Cera Chem India Pvt.Ltd Chembond Chemicals Ltd Choksey Chemicals Pvt.Ltd CICO Technologies Ltd Cipy Polyurethanes Pvt. Ltd Civichem & Applications Private Limited CNS Infrastructure Ltd Columbia Pakona Engineering Pvt.Ltd Construction Risk Management (Marcus Evans) Cosmos Construction Machineries & Equipments Pvt.Ltd Cosmos Sales Corporation 37 53 27 85 77 99 23 107 165 273 219 223
K
Kalyan Industries Kumkangkind India 263 150 / 151
T
Tac System Formwork Sdn Bdh Tashi India Ltd Tech 9 Techny Chemy Tekla India Pvt.Ltd Texsa India Ltd The Masterbuilder Subscription Form The Supreme Industries Ltd Toshniwal Systems & Instruments Pvt.ltd 115 237 227 89 101 39 297 43 245
L
Lipi Polymers Pvt.Ltd Liugong India Pvt. Ltd 131 125
M
Macons Equipments Pvt. Ltd Mangalore Chemicals & Fertilizers Ltd Marini India Pvt Ltd (Fayat India) MC - Bauchemie (I) Pvt.Ltd Metecno India Pvt.Ltd MM Castings (P) Ltd Multichem Group 41 91 9 49 Front inner-2 145 119
U
Ulma Formwork Systems India Pvt. Ltd Ultratech Cement Ltd Unisteel Engineering Works United Steel & Structurals Pvt. Ltd Universal Construction Machinery & Equipment Ltd 135 Back Cover 181 185 159 / 179
D
DCS Trading & Services Pvt.Ltd Desire Construction Systems Doka India Pvt. Ltd 225 33 29
N
Nav Nirman Beam Technics Nawa Engineers & Consultants Pvt. Ltd. Neocrete Technologies Pvt.Ltd Nina Concrete Systems Pvt.Ltd Nuha Constructions Solutions 35 173 95 97 263 / 267
V
Venus Equipment and Tools Pvt. Ltd Vertical & Green Summit (Tavess) 167 / 171 269
E
Enviro Geosynthetics Pvt.Ltd Esquire - CMAC Pvt.Ltd Everest Equipments Pvt.Ltd 13 215 257
W
Waltar Enterprises Wendt India Ltd Wirtgen India Pvt.Ltd WISE India 250 / 251 251 121 283
P
Paschal Formwork (I) Pvt.Ltd Perma Construction Aids Pvt.Ltd Pidilite Industries Ltd.( Dr. Fixit) Pranav Construction Systems Pvt. Ltd 143 267 Front inner-1 31
F
Fine Equipment India Pvt. Ltd. Forensic Geotechnical Engineering Fosroc Chemicals (India) Pvt.Ltd 253 289 79
Z
Zydex Industries 69
20
H & K Rolling Mill Engineers Pvt.Ltd
Contents
Advertisers Index / Classification

Admixtures 20 Microns Limited 105 Cement UltraTech Cement Ltd. Back Cover CLC blocks Brickwell 257 Concrete Batching Plant Apollo Infratech Pvt. Ltd. 61 Macons Equipments Pvt. Ltd. 41 Schwing Stetter India Pvt. Ltd. 57 / 235 Universal Construction Machinery & Equipment Ltd. 159 / 179 Concrete Block Making Machinery Columbia Pakona Engineering Pvt. Ltd. 165 Hess Concrete Machinery India Pvt Ltd. 2nd Wrapper Concrete Demolishing Abcon Tech & Build Aids Pvt Ltd 267 Concrete Equipment Bharat Road Development Combines Private Limited 177 Everest Equipments Private Limited 257 Fine Equipment India Pvt. Ltd. 253 Sicoma Mixers India Pvt. Ltd. 261 Concrete flooring Machine Surie Polex Back Inner Concrete Machinery & Equipment Ajax Fiori Engineering (I) Pvt. Ltd. 163 Apollo Infratech Pvt. Ltd. 61 Aquarius Engineers Pvt. Ltd. Gatefold Schwing Stetter India pvt. Ltd. 57 / 235 Toshaniwal System & Instrument Pvt. Ltd. 245 Concrete Restoration Alpha High-Tech Polyurethanes 253 Concrete solutions Hitech Concrete Solutions Chennai Pvt. Ltd. 263 / 267 Concrete Tools Wendt (India) Ltd. 251 Construction Chemicals Associated Chemicals 7 BASF India Limited 73 Cera-Chem Pvt. Ltd. 53 Chembond Chemicals Limited 27 CICO Technologies Limited 77 Fosroc Chemicals India Pvt. Ltd. 79 MC - Bauchme (I) Pvt Ltd. 49 Multichem Goup 119 Nina Concrete Systems Pvt. Ltd. 97 Perma Construction Aids Pvt. Ltd. 263 Pidilite Industries Ltd.( Dr. Fixit) Front inner -1 Razon Engineering Company Private Limited 197 STP Ltd 75 Technychemy 89 Zydex Industries 69 Construction Equipment & Machinery Action Construction Equipment Ltd. 211 Ajax Fiori Engineering (I) Pvt. Ltd. 163 Apollo Infratech Pvt. Ltd. 61 Aquarius Engineers Pvt. Ltd. Gatefold Case New Holland Construction Equipments (India) Pvt. Ltd. 37 Cosmos Construction Machineries & Equipment (P) Ltd. 219 Esquire Cmac Pvt. Ltd. 215 Liugong India Pvt. Ltd. 125 Macons Equipments Pvt. Ltd. 41 Marini India 9 RD Mining Equipments Pvt. Ltd. 129 Schwing Stetter India Pvt. Ltd. Toshaniwal System & Instrument Pvt. Ltd. Unisteel Engineering Works Universal Construction Machinery & Equipment Ltd. Venus Equipment and Tools Pvt. Ltd. Wirtgen India Cranes Action Construction Equipment Ltd. DCS Trading & Services Pvt Ltd Crushing Nawa Engineers & Consultants Pvt. Ltd. RD Mining Equipments Pvt. Ltd. Roljack Industries Curing Compound Rotho - Robert Thomas Metall-und Elektrowerke GmbH & KG Concrete Demolition Machinery Rockster Recycler India Ltd Doors Automatic Gandhi Automation Pvt. Ltd. Facility Services Relyon Facility Services Pvt Ltd. Fibre Reinforced Concrete Bekaert Industries Pvt Ltd. Nina Concrete Systems Pvt. Ltd. Tashi Reinforcements LLP Flooring Bekaert Industries Pvt Ltd. Cipy Polyurethanes Pvt. Ltd. Ironite Company of India Ltd. JBA Concrete Solution Kalyan Industries Nina Concrete Systems Pvt. Ltd. Reliance Industries Ltd. Silicone concepts Intl. Pvt. Ltd. STA Concrete Flooring Solutions Tashi Reinforcements LLP Formwork Desire Construction System Doka India Pvt. Ltd. GCI Wall Forms Pvt. Ltd. Kumkangkind India Nav Nirman Beam Technics PASCHAL Formwork (India) Pvt. Ltd. Pranav Construction Systems Pvt. Ltd. Tac System Formwork Sdn Bdh Ulma Formwork Systems India Pvt. Ltd. Geosynthetics Enviro Geosynthetics P. Ltd. Metal Building Metecno India Pvt. Ltd. Microsilica Waltar Enterprises Mining Rockster Recycler India Ltd OEM Suppliers M M Casting (P) Ltd. Paving Machinery Venus Equipment and Tools Pvt. Ltd. Peb Metecno India Pvt. Ltd. Post Tensioning CNS Infrastructure Ltd Tech9 57 / 235 245 181 159 / 179 167 / 171 121 211 225 173 129 241 261 205 11 282 25 97 237 25 99 207 201 263 97 231 113 109 / 193 237 33 29 139 150 / 151 35 143 31 115 135 13 Front inner -2 250 / 251 205 145 167 / 171 Front inner -2 107 227 Precast concrete Pipe Columbia Pakona Engineering Pvt. Ltd. 165 Precast Concrete Products Sri Parijatha Machinery Works Pvt. Ltd. 191 Ready Mix concrete RDC Concrete (India) Pvt Ltd 63 Repair & Rehabilation Associated Chemicals 7 Cera-Chem Pvt. Ltd. 53 Chembond Chemicals Limited 27 Fosroc Chemicals India Pvt. Ltd. 79 MC - Bauchme (I) Pvt Ltd. 49 Multichem Goup 119 Nina Concrete Systems Pvt. Ltd. 97 Nuha Construction Solutions 263 / 267 Perma Construction Aids Pvt. Ltd. 263 Pidilite Industries Ltd.( Dr. Fixit) Front inner -1 Razon Engineering Company Private Limited 197 STP Ltd 75 Technychemy 89 Zydex Industries 69 Roofing Lipi Polymer Pvt Ltd 131 Texsa India Pvt. Ltd. 39 United Steel & Structurals Pvt. Ltd. 185 Roofing Fastners Atul Fastners Ltd. 243 Sand Manufacturers Robo Silicon Pvt. Ltd. 187 Scaffolding Cosmos Sales Corporation 223 Software Tekla India PVT LTD 101 Speciality chemicals Mangalore Chemicals & Fertilizers Ltd. 91 Tensile Membrane Garware Wall Ropes Ltd 19 Tiles Manufacturers Igloo Tiles 147 TMT-Technology Suppliers H & K Rolling Mills Engineering Pvt. Ltd. 21 Waterproofing Associated Chemicals 7 BASF India Limited 73 Cera-Chem Pvt. Ltd. 53 Chembond Chemicals Limited 27 Choksey Chemicals P. Ltd. 85 CICO Technologies Limited 77 Civichem & Applications Private Limited 23 Fosroc Chemicals India Pvt. Ltd. 79 Hitech Waterproofing Systems 263 / 267 MC - Bauchme (I) Pvt Ltd. 49 Multichem Goup 119 Nina Concrete Systems Pvt. Ltd. 97 Perma Construction Aids Pvt. Ltd. 263 Pidilite Industries Ltd.( Dr. Fixit) Front inner -1 Razon Engineering Company Private Limited 197 Sika India Pvt. Ltd. 65 STP Ltd 75 Technychemy 89 The Supreme Industries Ltd. 43 Waltar Enterprises 250 / 251 Zydex Industries 69 Waterproofing Membrane Texsa India Pvt. Ltd. 39
22
TM
Civichem & Applications Private Limited
Macro Synthetic Polypropylene Fibres
Macro Synthetic Polypropylene Fibre
Applications
Tunnelling Concrete Flooring Precast Concrete Mining Marine Structures
Key Benefit
Replaces steel mesh in concrete and shotcrete
100% Inert material and will never rust (Long Term Durability - Corrosion Free)
Cost Reduction vs. traditional steel reinforcement Significantly improves shrinkage and temperature crack control Eliminates bending, cutting and placing of steel mesh, increasing efficiency and productivity
Fibrillated Fibre
TM
Polyester Fibre
Tashi Reinforcements LLP (Formerly Tashi India Ltd)

Imambada Road, Nagpur - 440018 (M.S) India Tel : 91 - 712 - 2720071~80, Fax : 91 - 712 - 2723068 / 8050, Mob. : +91 9325132303, 9370319954, 9823185510, 9370319951 email :plastfibre@bajajngp.com, Web : www.tashiindialtd.com
News & Events
CONSTRUCTION EQUIPMENT
Metro Projects to the Rescue of Concreting Equipment Suppliers

While leading construction equipment manufacturers could have been worried over the recent recessionary trends prevalent in the Indian market, those manufacturing concreting equipment may not have felt that kind of a pressure, thanks to the various metro projects around the country. Work has been going on in many parts of the country, either to add new lines as in the case of the National Capital Region (NCR) or Kolkatta, or the development of new metro projects, as in Chennai, Bengaluru, Hyderabad, and Jaipur has meant that at least there is some good news for manufacturers of concreting equipment.
Concrete pumps are a good example for concreting equipment that is often used for metro projects. Similarly, shotcreting machines, boom pumps, boom placers and transit mixers are other examples of machinery that is in demand due to metro projects.
India, Apollo Infratech, REL, Sany, etc, to mention only some, offer models that caters to this rising market. With the economy expected to turn around and give the much needed push to the realty sector by the end of the year, there are good times awaiting concrete pump manufacturers in the near future.
Irrigation Projects Prove a Boon to Canal Paver Suppliers
water and irrigation projects in the pipeline during the 12th Five Year Plan Period (2012-17), this is a market segment that is expected to grow substantially in the next few years. Manufacturers of concrete pavers have been focusing on tailoring their products to suit Indian working conditions.
Construction Equipment Financing; A Growing Business in India
High-Rise Projects Propel Demand for Concrete Pumps

India is a country that is fortunate enough to have been blessed with countless water bodies. In fact, there is perhaps no state in the country where a major river does not flow. State governments and the Centre have been giving thrust to development of canals in various places across the country, something that has come as good news to canal paver suppliers. In fact, several leading global players are in fray today in the Indian market. Many models have been specifically launched in recent times to cater to this growing segment. With several drinking With property prices going through the roof quite literally, it was only time before several cities in the country went vertical, as it is happening today. With the skyscraper capital of India, Mumbai, showing the way, several ambitious high-rise projects are being planned around the country. The spurt in high-rise projects has come as good news to manufacturers of concrete pumps and boom placers. Today these two pieces of equipment have become omnipresent at high-rise construction project sites. Almost every major player in the fray including, Putzmeister India, SchwingStetter
The growth of the construction equipment industry has meant a direct impact on several other industry verticals. For example, the equipment finance segment has received a big boost because of the rising popularity of construction equipment. Apart from several companies, who are specialized in financing capital inten-
24
Bekaert Industries Pvt Ltd
News & Events
CONSTRUCTION EQUIPMENT
sive heavy industry machinery, there are also instances of construction equipment manufacturers getting into tie-ups with leading finance companies for facilitating financing options for their customers. A good example is the recent Private Label Agreement between L & T Finance Ltd and Sany Heavy Industry India Pvt Ltd, which was signed recently for offering financial assistance to Sany's customers, according to a recent news release from the company. The latter's product lineup in India includes excavators, crawler cranes, truck cranes, motor graders, drilling rigs, port machines, and asphalt pavers. Similarly, several other leading companies are also expected to follow suit soon, in this financial year. For construction equipment manufacturers too, with the market being hit hard by recessionary trends, these tie-ups offer a way out and give push to sales.
JCB India Launches All New JCB 3DX Backhoe Loader
Used Equipment Market Growing at a Consistent Pace

The Indian construction equipment industry is showing a good pace of growth. The trends being witnessed in India mimic those that were earlier seen in developed countries. The rising level of awareness has meant that no longer are used equipment seen as a poor substitute for new ones. With contractors realizing the importance of timely maintenance of construction equipment, the market for used construction equipment has been growing consistently. Road building machinery for example is one of the key market segments. In road building machinery, equipment that are used for compaction or paving can now be sourced from the used equipment market in India. One of the contributory factors for this trend has been equipment auctions, a concept that is no longer alien to the Indian market.
JCB India, considered the trendsetter which introduced the backhoe loader in India way back in 1980, has launched its all new JCB 3DX backhoe loader on June 20, 2012. The new model would radically change the landscape of the construction industry in the country, according to the company. JCB India, which is the fully owned subsidiary of JC Bamford Excavators Limited, UK, plans to strengthen its share of the backhoe loader market in India and extend its reach even further to the developing rural markets, with the new launch. The company has invested heavily in upgrading its manufacturing facilities and research and development keeping it at the cutting edge of innovation. According to the company the benefits that this new generation machine provides to its customers are immense with 20% lower fuel consumption in excavation which will result in fuel savings worth ` 2.25 lacs per year at current diesel prices, with what it claims to be the best engine in the construction equipment industry and a spacious, comfortable and livable cabin because a comfortable operator is a productive operator.
The new backhoe loader model is powered by the JCB ecoMAX engine which is a purpose built in house 76 hp engine which is big on fuel savings and high on performance with 16 valve effort; has a twin ram steering for easy steer ability. It has also been provided with new brake linkage to ease the braking effort by the operator and which ultimately leads to effective braking & reduced fatigue while braking. The machine has been strengthened and a more reliable rear axle gives trouble free life. The machine has robust king pin design and has a new JCB transmission for better dozing. It has been ergonomically designed with 20% more cabin space keeping in mind the requirement of the operator. The new bonnet with better service access enables the operator to easily carry out daily maintenance checks. JCB India Limited has an extensive network of 57 dealers and over 430 outlets throughout the country, along with a world-class customer service network support. JCB also runs Operator Training Schools and has trained over 18000 young men to be operators till date.
26
Chembond Chemicals Ltd
News & Events
INFRASTRUCTURE
First phase of Jaipur metro project to be completed by June 2013
programs, then it must be Greater Noida. There are plans ranging from the construction of expressways to a rapid rail transport line to make the city a truly world-class hub. Amendments to its master plan are on the anvil in order to come out with the expressways and rapid rail transport line projects in the city. The city could in fact become the first in the NCR to make provisions for future transport requirements. Details of the changes to the master plan suggest that the city has learnt from the mistakes that were committed during the haphazard development of another prominent part of the NCR- Gurgaon. Among the plans is an expressway from Ghaziabad to Dadri, a regional rapid transport system from Greater Noida to Khurja and another link to Jewar. These projects are apart from the metro line. The different versions of declining growth forecasts has come as ammunition for the opposition which is gunning for the government and accused it of policy paralysis. The government finds itself on a sticky wicket since it is not able to push forward reforms to rejuvenate the economy, given the compulsions of coalition politics.
Opening of Country's First Mega Food Park ushers in a New Era
Jaipur metro project (Phase I) is half way through and is expected to be fully operational by June next year. According to Rajasthan government sources the remaining work is expected to be completed by June 2013. Under Phase I three underground and 8 elevated stations is constructed at a cost ` 3149 crore and will run between Mansarovar and Chandpole covering a distance of 9.718 km. In Phase II of the Jaipur metro project will run between Chandpole to Bari Chaupar covering a distance of 2.349 km with 5 underground and 15 elevated stations.
India's Growth Rate Cut to 6.5 % in FY 12 by ADB
The inauguration of the country's first mega food park by the Union Minister for Agriculture and Food Processing Industries, Mr.Sharad Pawar, earlier this week has provided the much needed boost to the industry. The Srini mega food park in Chittoor in Andhra Pradesh and located a few hours away from Chennai, is expected to set a precedent for similar such ventures elsewhere in the country. From seed to shelf, Srini Food Park facilitates end-to-end food processing with beneficial forward and backward linkages. On par with software parks, this new-age facility is equipped with Central Processing Centre and Primary Processing Centres. It aims at becoming a pioneering infrastructure enabler and facilitator for the food processing industry, according to an official government statement. As a model `Mega Food Park` and the first of its kind in India, Srini provides state-of-the-art food processing infrastructure designed as per global standards and develops a veritable market place with common facilities on the lines of a software park or a textile park.
Greater Noida's Transport Infrastructure Poised for Growth
After the different rating agencies, it is now the turn of the Asian Development Bank (ADB) to cut down the FY 2012 growth forecast for India. The top bank has forecast that the country's economy will grow by 6.5% in 2012. It is down from the earlier forecast of 7.0%. Similarly the forecast for 2013 is 7.3%, which is less than the previously forecast 7.5%. The growth forecast has been cut down based on factors such as poor demand and high inflation. The news comes at a time when other rating agencies too have predicted something on similar lines.
If there is one city in the country which is almost constantly in the news for its various infrastructure development
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Doka India Pvt. Ltd
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The statement further added that the mega food park is promoted by experienced professionals and supported by the government (the Ministry of Food Processing Industries and the Andhra Pradesh Infrastructure Investment Corporation) and is intended to benefit all components of the value chain. A substantial increase in air traffic would mean that there could be second airports being built in five major metros, and a third in Mumbai, over the next decade, according to an aviation consultancy firm. The cities of Bangalore, Chennai, Delhi, Hyderabad, and Kolkata are the ones that would need a provision for a second airport over the next decade, while Mumbai would need a third one, according to the Centre for Asia Pacific Aviation (CAPA). The consultancy firm has said that an estimated US$ 30 billion would need to be invested in these projects. The study also noted that several nonmetro airports having already outgrown their existing infrastructure. The study also pointed out that there is also a possibility for the construction of a second airport in Ahmedabad too.
DMIC among 100 Innovative Global Projects
of major debate in recent times. A recent parliamentary standing committee report had left the UPA government red-faced after it said that the governments should not have a role to play in acquiring land for private players. A vast majority of those in the industry felt that such a provision could prove detrimental at a time when the country is trying to woo investments in various sectors and critically in infrastructure development. However, the Rural Development Ministry subsequent rejection of the panel's report forms the basis for the reworked land acquisition bill which could be presented in the Parliament during the monsoon session. The draft of the reworked bill gives freedom to the states to decide on the threshold limit for acquisition of fertile land and the settlement and rehabilitation provisions in deals where private players are involved.
The ambitious and much hyped Delhi-Mumbai Industrial Corridor (DMIC) project has been included amongst the 100 most innovative infrastructure projects in the world.The project finds place among in a long and prestigious list of inspiring infrastructure projects compiled by leading consultancy firm, KPMG. The company said in a recent statement that a profile of the project is featured in its second edition of Infrastructure 100: World Cities Edition. The project along the DelhiMumbai Rail Freight Corridor is the most ambitious kind of its project that has been ever undertaken in India. Estimated to cost US$90 billion the project is expected to dramatically change the face of the region and spur massive economic growth.
New Look Kolkata Airport Integrated Terminal Ready
AIR PORTS
Second Airport in Five Major Metros Over the Next Decade
The new integrated terminal at the Kolkata Airport is all set for welcoming guests from around the world. The trail run of the new lounge is expected to begin from July 15th, marking yet another memorable occasion in the long history of the airport. A trial run of the arrival lounge of the integrated terminal has been planned by the authorities. With traffic increasing manifold at the airport, a modern, integrated, terminal building has been one of the long pending demands for the airport.The airport will also get about 18 aerobridges in the near future. Also in the pipeline are 10 new baggage carousels. The parking facilities at the airport are also being spruced up.
State Governments will play a Part in Land Acquisition

The question of whether or not states will have a role to play in helping private players acquire land has been an issue
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Pranav Construction Systems Pvt. Ltd
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The Union Minister for Road Transport & Highways , Dr.C.P .Joshi held a meeting with concessionaires, financial institutions, banks, consulting engineering firms on the issues related to the road sector in general and NHAI in particular in the capital. An official statement from the ministry on the occasion said that the minister said that despite ups and downs in other sectors, road sector had held on to its own momentum and has been performing much better. Huge resources are required to complete very ambitious task at hand and the same have to be mobilized fast. The ministry looks up to lenders and financial institutions for their continued support and enhanced funding commensurate with its targets. Dr. Joshi, who chaired the meeting, stated that this meeting has been convened for an open dialogue with financial institutions and concessionaires to understand the current scenario and if there are any reasons for drop in sentiment. The Ministry wants to understand what are the concerns of the lenders, concessionaires, and developers? Is there something which Ministry needs to do further? What more remedial steps Government need to take so that the planned targets could be met? He said that his Ministry's role is that of a facilitator and sought cooperation of all concerned in achieving set targets in road sector. He assured the participants that such meetings will be held more frequently. The Minister informed the participants that the financial year 2011-12 has been an outstanding year for the Indian Road Sector. A record length of 7957 Kms of roads was awarded for strengthening/ up gradation and improvement and over 2200 Kms were completed during the year 2011-12. This has been the highest ever achievement so far and the Ministry compliment the role played by infrastructure Industry. Buoyed by the success achieved in the year 20012-13, the Ministry has pegged the targets for the road sector, to achieve 9500 Kms of award and 3500 Kms of completion. The minister expressed his concern that
ROADS
` 20k Cr Push to Road Projects among Centre's Plans
Building road infrastructure has been one of the priority areas for governments over the last decade and it is no different in the case of UPA II. It is reportedly planning to roll out 30004000 km of highway projects with 100% financial support. An outlay of `15, 000-20,000 Cr is likely to be spent on these stretches that are being identified by the NHAI. The economic slowdown has meant that the process of awarding highway projects has again slowed down in recent times. The government had announced plans
for awarding about 9500 km of road projects during the year, a target which looks like a distant dream now because of the prevailing negative market sentiments.
Two-Laning Project on NH 231 Approved
concession period will be 17 years including the construction period of 24 months. The main object of the project is to expedite the improvement of infrastructure in the state of Uttar Pradesh and also in reducing the time and cost of travel for traffic, particularly heavy traffic, playing between Raibareilly Jaunpur. It will also increase the employment potential for the local labourers for the project activities. The project will benefit the districts of Raebareilly, CSM Nagar, Pratapgarh, and Jaunpur in Uttarpradesh.
The Cabinet Committee on Infrastructure (CCI) has approved the proposal for the development of the two laning with paved shoulders of 'Raibarelly Jaunpur' section on NH - 231 in Uttar Pradesh under NHDP Phase IV on DBFOT basis in BOT (Annuity) mode of delivery, according to an official statement released on the occasion. The total cost estimated of the project will be `647 .98 crore out of which `78.62 crore will be for land acquisition, resettlement and rehabilitation and preconstruction and ` 569.36 crore will be for construction.The total length of the project will be 166.40 km and the
Key Meeting between Stakeholders on Issues Related to Road Sector and NHAI
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Desire Construction Systems
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INFRASTRUCTURE
the performance of road sector during first quarter has not been quite up to the mark. Projects bid out in the first quarter have not received the kind of response the Ministry had last year, with some getting no bidders at all. Feedback received indicates that one of the reasons may be the tightening of the purse-strings from the lenders for funding of road projects. Also present in the meeting were Dr.Montek Singh Ahluwalia, Deputy Chairman of the Planning Commission, Mr.Jitin Prasada, the Minister of State for Road Transport & Highways, the NHAI Chairman, Mr.R.P .Singh and the Secretary, Ministry of Road Transport & Highways, Mr.A.K.Upadhyaya. widely-recognized best practices in engineering design, pre-construction activities and project management. The statement added that the 1st tranche, which was signed, will improve around 200 kilometers of road in the isolated states of Assam, Meghalaya, and Sikkim. Improvements will include widening of existing sections of roads, strengthening pavements, raising embankments, and providing permanent structures at river crossings.
RAILWAYS
ADB Loan for Better Road Connectivity in North Eastern Region
Western Dedicated Freight Corridor Project Reviewed

The ambitious Western Dedicated Freight Corridor's second phase has been reviewed by a Japanese team. The project's second phase from Vadodara to Jawaharlal Nehru Port Trust and Rewari to Dadri was reviewed by a team from the Japan International Corporation Agency (JICA). The six-member team from Japan
visited the project sites which extends over 550 route kms. The project is being considered as one of the most crucial infrastructure development initiatives in the country. They reviewed project aspects including bridges, tunnels, and rock cutting. The dedicated freight corridor project if successful could set the trend for similar projects elsewhere in the country. With the western region being one of the most industrialized in the country, the completion of the project is being eagerly awaited as it could further speed up the economic growth of the region.
Experts say No to PRTS Project in Amritsar

The Asian Development Bank (ADB) and the Government of India have signed a US$74.8 million loan to improve connectivity with the north eastern region of the country. The loan constitutes the first tranche of the North Eastern State Roads Investment Program, a $200 million multitranche finance facility (MFF), expected to be executed in two tranches. Under the facility, a total of 433.7 km roads would be improved/upgraded/ constructed in six states- Assam, Manipur, Meghalaya, Mizoram, Sikkim, and Tripura, according to a recent government official statement. This will be ADB's first transport sector project in NE region to develop and implement road investments that follow Several leading experts have said a strict no, no to the proposed PRTS (Personal Rapid Transport System) in the city of Amritsar. They feel that the project could mar the view of the city's major landmarks including the world famous Golden Temple. Architecture experts have warned that the proposed project could adversely affect the heritage character of the walled city besides blocking views of iconic landmarks including, the Jallianwala Bagh, Town Hall and Hall Gate, apart from the Golden Temple. According to many of the experts, the project would not only mar the views but also create traffic snarls in the
walled city, since the pillars that would be used for constructing the overhead PRTS system could obstruct free movement of vehicles and pedestrians, apart from affecting traders who own businesses in the area.
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Nav Nirman Beam Technics
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POLICY & NEWS MAKERS

of the parliament, which is due to start soon. The government has already rejected an idea from a parliamentary panel that the state should not have a role to play in the land acquisition process for private parties earlier. It remains to be seen as to what would be the reaction of the opposition parties for the proposed changes in the bill.
New Regulatory Authority Planned to Check Errant Builders in Maharashtra
Institutional Mechanism for Monitoring of PPP Projects
There is at last some good news for buyers in Maharashtra who have been troubled by errant builders. A housing appellate tribunal and a housing regulatory authority are in the pipeline and could come into existence within a year. The presence of these bodies could mean that buyers can approach them in case of any dispute. The laws are also expected to be stringent with provisions even for putting developers behind the bars for up to three years for not complying with the dictates of the tribunal. A 19 member joint select committee
of the Maharashtra state assembly has recommended imprisonment of developers along with a penalty of `10 lakh for errant builders, in what is being considered a major amendment to the Maharashtra Housing (Regulation and Development) Bill 2012. The committee has also said that open spaces should not be used as parking lot and that they should be mandatory. Another key amendment that has been made is that a developer cannot alter a flat once it is sold and that they cannot add a wing or a floor without the consent of the flat owners.
Land Acquisition Deals to Become Friendlier to those Displaced

Land acquisition is an issue that the centre has been grappling with in several parts of the country in the recent past. There are countless instances of major infrastructure projects getting stalled, delayed, or altogether cancelled because of the issue. The government is now planning to pay an extra 12% of the cost of the land every year, to all those displaced due to land acquisition. The move is being seen as one that will try to make land
The Cabinet Committee on Infrastructure (CCI) has approved a proposal from the Planning Commission to set up an Institutional Mechanism for monitoring and enforcement of provisions in PPP projects. With an increasing reliance being placed on PPP projects across many wings of the government, it has become necessary to adopt a well-defined institutional structure for overseeing contract performance effectively, said an official statement on the occasion, which further said that this is all the more necessary as concessionaires will have an incentive to cut corners whereas the criticism would be faced by government. The institutional framework requires project authorities to create a two-tier mechanism for monitoring the performance of PPP projects, including a PPP Projects Monitoring Unit (PMU) at the project authority level and a PPP Performance Review Unit (PRU) at the Ministry or state government level, as the case may be. Going into the details of the mechanism, the statement said that the PMU is to prepare a report to be submitted to
acquisition deals friendlier to the displaced lot. The proposed changes to the Land Acquisition Bill are being eagerly watched by those in the industry, since there is a lot riding on them. The redrafted bill is in all probability likely to come up during the monsoon session
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Case New Holland Construction Equipment (India) Pvt.Ltd
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POLICY & NEWS MAKERS

PRU within 15 days of the close of the relevant month. The report is to cover compliance of conditions, adherence to time lines, assessment of performance, remedial measures, imposition of penalties, etc. The PRU is to review the reports submitted by the different PMUs and oversee or initiate action for rectifying any defaults or lapses. The statement added that in addition to following the guidelines for the mechanism, the respective Ministries will send a quarterly compliance report to the Planning Commission with a copy to the Ministry of Finance. Planning Commission, in consultation with the Ministry of Finance, will prepare a summary of these reports along with the recommendations relating to further action/ improvements which would be placed before CCI once every quarter for the next two years. Based on the experience gained any necessary modifications would be made in the Guidelines. The measures are expected to ensure good governance, accountability, efficiency, and economy in spending. It will also mean that the Planning Commission will have a central role to play in ensuring high quality monitoring. Moreover, the cabinet will also have a chance to monitor projects every quarter. support setting up of both Greenfield and Brownfield EMCs. The proposed scheme is expected to help flow of investment for the development of world-class infrastructure specifically targeted towards attracting investment in the ESDM sector. Nearly 28 million persons are expected to be employed, directly or indirectly for the ESDM turnover to reach USD 400 billion. The statement further added that the policy covers all states and districts and provides them an opportunity to attract investments in electronics manufacturing.
loan of `15 lakh and `9925 for a loan of `10 lakh. The extended scheme will benefit all house loans availed in FY 2012-13. The extension is expected to bring in some good news for the realty sector, which has been struggling over the past year.
New NHAI Head has his Task Cut Out
Scheme for Attracting Investments for Electronic Manufacturing Clusters Approved

At last the Government has appointed a new chairman for the National Highways Authority of India (NHAI), an organization which has been headless for almost two years now.Mr.Rajinder Pal Singh, a 1976 batch retired IAS officer had been appointed to the position recently. The Union Cabinet has approved the proposal for offering financial support for the development of Electronics Manufacturing Clusters (EMCs). The EMCs are expected to aid the growth of the Electronics Systems Design and Manufacturing (ESDM) sector, along with helping the development of entrepreneurial ecosystem, drive innovation and catalyze the overall economic growth of the region by increasing employment opportunities and tax revenues, said a recent government official statement. The proposed EMCs scheme would The new chairman has his task cut out with the NHAI managing over 75,000 km of highways across the country. The Prime Minister had also recently set a target of building over 9,500 km of road in FY 2012-13. With several factors such as clearances and land acquisition stalling key highway projects, the new chairman has quite a task at hand. Mr. Singh will hold office for three years or till the age of 65 or until further orders, whichever is the earliest.
Interest Subvention of 1 % Brings Some Cheer to Struggling Realty Sector

The Union Cabinet has recently approved the proposal for extending the scheme of interest subvention of 1% on housing loans up to `15 lakh where the cost of the house does not exceed `25 lakh for the year 2012-13 and to amend the operational part of guidelines for release of funds. A budgetary provision of `400 crore has been made for FY 2012-13 for implementing the scheme, said a government statement on the occasion. Consequent upon the extension of scheme, the limit of subsidy for an individual borrower would be `14, 912 for a
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Texsa India Ltd
News & Events
CORPORATE
Essar Projects completes ONGC's D1 field project
value our partnership with ONGC. The Offshore & Subsea Long-term business partnerships are key to our performance. Having completed this project it showcases our ability to deliver and our ambition in furthering our lead in the Oil and Gas market space. By completing this large offshore project, Essar sends the signal that it is our intent to develop long-term collaboration with major Indian and global oil and gas market players. Each platform has two main parts the jacket and the deck. The jackets for each of the three platforms were fabric a t e d a t t h e C U E L Ya r d i n LaemChabang, Thailand. The three decks were fabricated at the Profab yard in Batam, Indonesia. The Platforms in the D1 Project region are heavier than their counterparts in the Indian offshore. This is because the water depth in the field being deeper by about 90 metres. Some of the technological achievements of the project included transporting nearly 17,000 tonnes of steel for fabrication of jackets and decks across 2,000 nautical miles to reach Bombay High. The jackets are driven into the sea bed at a depth of over 100 metres and the decks are installed on the jacket to complete the platform. All the jackets, decks and the associated pipelines, bridges and PLEM have been successfully installed and handed over to ONGC. Power Tools India. The unveiling was followed by a live demonstration of the HPW range by PrateikBabbar at Taj West End, Bangalore. Speaking on the occasion Mr. Vijay Pandey, Vice President, Bosch Power Tools said These tools will further strengthen our innovative edge in India and are designed to cater to the ever growing construction, public transport, commercial vehicle, automotive, public area and service and repair industry. Speaking on the development of Bosch Lawn and Garden, Mr. Graeme Stokoe, Head of Business Development, OCE said, This is the first Professional High Pressure Washer Range introduced by Bosch. The emerging market growth in Asia Pacific provides ample opportunity for this range. This range has been designed specifically to cater for the requirements of heavy duty user in the toughest Indian terrain. He added, Bosch is a leading provider of technology and services, which develops and manufactures lawn and garden products across a worldwide platform. We are continuing to expand the product range and introduce more technically advanced products globally. Bosch is the world leader in the power tools segment. In India, the company plans to introduce the new products in a phased manner, which will be made available through a network of more than 600 Bosch authorized dealers and channel partners across 150 cities. The range will be available across India and priced at INR 40000/- to INR 100000/-.
Essar Projects Limited, one of the leading EPC contractors in the country has announced the completion and handing over of the Rs 1,064-crore D1 development project, 200 kms off Mumbai, to ONGC, facilitating the scaling up of the D1 field production to 35,000 BOPD (barrels of oil per day). The largest offshore project executed by Essar Projects Limited envisaged the installation of three offshore platforms, the laying of subsea pipelines to connect the three platforms to the floating production, storage, and offloading (FPSO) through a Pipeline End Manifold (PLEM). All new platforms, the PLEM and the existing D1 Platform will be connected with a network of subsea rigid and flexible pipelines and composite cables totaling about 14.5 kms. Commenting on the project, Mr. Alwyn Bowden, President & CEO of Essar Projects said: Executing the prestigious ONGC project on schedule was a strategic objective for Essar Projects Limited. The company has demonstrated its ability to conclude such a challenging project on time and is poised to execute projects of similar kinds worldwide. Sharing similar sentiments Mr. PCB Nair, CEO & MD, Essar Offshore & Subsea Limited, a strategic Business unit of Essar Projects Limited, said We
Bosch Power Tools Launches Professional High Pressure Washer in India

Bosch Power Tools, an industry leader in power tools has announced the launch of their powerful and high performance range of professional High Pressure Washers (HPW) in India. Bollywood Actor PrateikBabbar unveiled the High Pressure Washer along with Mr. Graeme Stokoe, Head of Business Development, Outdoor Cleaning Equipment and Mr. Vijay Pandey, Vice President, Bosch
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Macons Equipments Pvt. Ltd
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INTERNATIONAL
too. The market has record a substantial 27.8% drop in construction in the first half of 2012 from the corresponding period of the year in 2011, according to Vedomosti. Several other key markets in the European continent have been hit hard by the recessionary trends. UK is another major market where construction has reported a downfall in the recent past. The progress of Moscow's realty market is being witnessed with interest globally, since it had emerged as a key market in recent times, especially with respect to construction of high-rise projects.
New York: The capital of roof gardens
Shard is Now Europe's Tallest Building

New York City is fast emerging as the capital of roof gardens. Everything from vegetables to even trees are being grown in a city where land is available at a premium. The city which is famous for its skyscrapers has been grappling with the issue of increasing its green cover and seems to have found a novel way of doing it. With an increasing number of buildings having roof top gardens and farms, the very meaning of the word 'farm living ' or 'farm houses' is assuming a new meaning in the 'always' city. Organic farming seems to be the order of the day as residents of the city are experimenting with a variety of greens. The rooftops of the city are now getting a greenish tinge and offer a commercial, as well as healthier alternative for the inhabitants of the buildings. According to Joe Nasr, co-author of Carrot City: Creating Places for Urban Agriculture, New York City has emerged as the undisputed capital of rooftop farms. He also expects the trend to increase more rapidly in the near future. Apart from the obvious commercial agriculture benefits, another benefit has been observed in the city due to the rooftop farms. These farms have been able to capture millions of gallons of storm water and divert them into the sewer system in a systematic manner, an avowed goal of the city's Mayor, Michael R.Bloomberg.
London has added one more landmark to its rapidly rising skyline. The Shard has been officially unveiled in Central London. The building is the tallest in Europe and would become yet another iconic landmark in the city as it rises 1,000 ft into the skyline. Designed by Italian architect Renzo Piano, this mixed developed has restaurants, a luxury hotel, and plush luxury residencies. However, the tower's reign as the tallest building in Europe is likely to be shortlived. The rapidly rising 332 metre Mercury City Tower in Moscow could soon be holding that coveted status. The skyscraper in Russia is most likely to upsurp the title by the end of 2012.
Moscow Residential Housing Market Records 28% Drop

The after effects of the European debt crisis are being felt in almost every major market in the region. One of the key real estate markets that have been emerging in recent times has been that of Moscow. However, things seem to have gone from bad to worse in Moscow's case
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The Supreme Industries Ltd
Trends in Concrete
20 TRENDS
SHAPING THE WORLD OF CONCRETE
The Masterbuilder, Bureau Report
EMERGING
he need for innovation in the construction industry has long been stressed from both within and outside the industry. Changes in global markets, increased customer expectations, and government pressure have all led to innovation becoming a key focus for the construction sector. There is increasing pressure on the construction industry to become more environmentally sustainable. As the construction industry is a major energy user as well as contributer to the greenhouse gas emissions and waste levels, the
government is pushing hard to the construction sector to come up with more and more innovative technologies in concrete since concrete is the mother constituent of any construction. Developing and maintaining world's infrastructure to meet the future demands of industrialized and developing countries has become necessary to economically grow and improve the quality of life. The quality and performance of concrete plays a key role for most of the infrastructure including commercial, industrial, residential and military struc-
tures, dams, power plants and transportation systems. Concrete is the single largest manufactured material in the world and accounts for more than 6 billion metric tons of materials annually. In United States, federal, state, and local governments have nearly $1.5 trillion dollars in investment in the U.S. civil infrastructure. The worldwide use of concrete materials accounts for nearly $780 billion in annual spending. The industrialized and developing world is facing the issues related to new construction as well as repair and reha-
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Trends in Concrete
bilitation of existing facilities. Rapid construction and long term durability are requirements on most projects. Initial and life-cycle costs play a major role in today's infrastructure development. There have been number of notable advancements made in concrete technology in the last fifty years. Some of these advances have been incorporated in routine practices. But, in general, the state-of-practice has lagged far behind the state-of-art. This is particularly true for public sector projects. There is an increasing concern in most parts of the world that it takes unduly long time for successful concrete research products to be utilized in practice. Even though some advances have been made in quick implementation of new concrete technology, significant barriers to innovation and implementation remain. Continued coordination of ongoing international research and educational programs is needed. Numerous advances have been made in all areas of concrete technology including materials, mixture proportioning, recycling, structural design, durability requirements, testing and specifications. Throughout the world some progress has been achieved in utilizing these innovations but largely these remain outside routine practice. The high performance concrete (HPC) for transportation structures, e.g., bridges and pavements, are gaining wider acceptability in routine practice. HPC provides enhanced strength and durability properties and contributes towards long lasting structures and pavements. The constructability can also be enhanced by proper mixture proportioning and testing. Most HPC mixture include recycled materials e.g. fly ash, ground granulated blast furnace slag (GGBFS), Metakaolin (MK) or silica fume. The use of recycled materials in construction is an issue of great importance in this century. Utilization of fly ash and GGBFS in concrete addresses this issue. The replacement of Portland cement by fly ash or GGBFS reduces the volumes of Portland cement used is a major benefit. The reduction of Portland cement pro-
duction will reduce carbon dioxide (CO2) emissions, reduce energy consumption and reduce the rate of global warming. Utilization of fly ash and GGBFS usually provides cost savings as well as improved concrete properties. The case histories discussed demonstrate the practical uses of supplementary cementitious materials. fly ash, GGBFS and silica fume for various types of bridges and pavements in wide ranging environmental conditions. The successful utilization of supplementary cementitious materials requires proper mixture proportioning, testing, placement and curing. Lack of widespread transfer of developed and available new concrete technology is a major problem in most countries. The practicing engineer's (user) involvement through re-search, development and technology transfer stages is a key to successful application of new concrete technology in routine design and practice. The past experience has shown that successful technology transfer occurs when there is a pressing national need, champions of technology are created, champion and organizations involved persist, practical demonstrations of technology are conducted to demonstrate benefits, and regulatory requirements are implemented. The new concrete technology must fulfill a need to be successful. The user's (owner/designer/construction
engineer) involvement is vital to success. The user starts and ends the technology process. Examples of successful concrete technology transfer efforts are discussed. Some Emerging Trends and Innovations in Concrete Green Cements Blended Cements High Performance Concrete (HPC) Smart Concrete Self-Consolidating Concrete (SCC) Use of Recycled Tire Rubber in Concrete 7. Smog Eating Concrete 8. Reactive Powder Concrete (RPC) 9. Translucent Concrete 10. Pervious Concrete 11. Low Temp. Concrete Admixture 12. Prepacked Shotcrete Admixture 13. Steel-Free Concrete Bridge Deck 14. Pavemend - Rapid Repair Products 15. Suntreat - Concrete Restoration & Protection System 16. Precast Inverted T Beam 17. Conductive Concrete 18. Corrosion Inhibitors for Reinforced Concrete 19. Shrinkage Reducing Admixture for Concrete 20. Mellose non-dispersible Underwater Concrete Admixture Green Cements Research has been carried out to 1. 2. 3. 4. 5. 6.
Precast sea wall using eco cement
www.masterbuilder.co.in The Masterbuilder - July 2012
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Trends in Concrete
The making of green cement

Stanfort Professor Brent Constantz has developed a process for making cement that produces no carbon dioxide, and he is using the method to make small batches at his pilot factory in moss Landing. Eventually, Constantz hopes to persuade Caltrans to use the cement in the construction of roads and bridges. Flue gas
From factories' smokestacks; contains carbon dioxide
The Calera Process

Carbon dioxide from industrial pollution is bubbled through seawater. In a process similar to how coral reefs form, minerals in the seawater are combined to make carbonates. Seawater
Containing calcium and magnesium
The process sequesters the carbon dioxide into cement, with only clean water and air as by-products, Constantz says. The preceise details are secrete pending publication of his patent.
Cement
Clean water
Clean air
Figure 1: Making of Green Cement
conditions. By increasing concrete strength and performance, the required thickness of concrete members and the cost of concrete structures can both be reduced. In the U.S., a major move toward HPC is underway, especially in the manufacturing environment of precast concrete. A major demonstration precast concrete bridge is under construction in Texas. High Performance Concrete (HPC) is the latest development in concrete. It is not just HighStrength Concrete (HSC) and has replaced HSC developed in the early 1980's. HPC can be defined as a concrete made with appropriate materials (superplasticizer, retarder, fly ash, blast furnace slag and silica fume) combined according to a selected mix design and properly mixed, transported, placed, consolidated, and cured to give excellent performance in some properties of concrete, such as high compressive strength, high density, low permeability and good resistance to certain forms of attack. Smart Concrete Concrete has been widely used for many years as a composite material for various types of structures. One of the weaknesses of concrete is that it cannot withstand tension which can cause cracks easily. There has been a huge demand to monitor concrete structures cracking and preventing them from propagating further. These efforts are important for timely repair, safety and long-term durability of critical structures. Non-destructive evaluations, such as attaching or embedding sensors into structures, have been used in many ways to accommodate the demand, yet the tests are considered expensive. Smart concrete was developed by Dr. Deborah D.L. Chung from State University of New York at Buffalo. Smart concrete is reinforced by carbon fiber as much as 0.2% to 0.5% of volume to increase its sense ability to strain or stress while still has good mechanical properties. By adding small amount of short carbon fiber into concrete with a conventional
Figure 2: Blended Cement
develop non-clinker green cement using two industry wastes: cement kiln dust (CKD) and fly ash (FA). CKD contains partially calcined materials with some hydraulic and cementitious properties. It also has high alkali, chloride, and sulfate content, which may cause problems in cement performance. Blended Cements An important concept of concrete technology innovation is blended cements. It makes use of industry by products like fly ash and blast furnace slag, which otherwise would have required
land for its disposal. The concept also gives lesser natural lime stone and lesser emission of CO2 to atmosphere. Common ternary blends includes, 50% Portland cement + 30% slag cement + 20% fly ash, to improve concrete performance, qualify for tax credits with recycled content. High Performance Concrete (HPC) Normal Strength Concrete (NSC) is heavy and lacks the required workability in some large concrete structures, such as high-rise buildings, bridges, and structures under severe exposure
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Trends in Concrete
Figure 3: Self Consolidating Concrete
concrete mixer, the electrical resistance of concrete increases in response to strain or stress. As the concrete is deformed or stressed, the contact between the fiber and cement matrix is affected, thereby affecting the volume electrical resistivity of the concrete. Strain is detected through measurement of the electrical resistance. So, the smart concrete has the ability to sense tiny structural flaws before they become significant, which could be used in monitoring the internal condition of structures and following an earthquake. Self-Consolidating Concrete (SCC) It has brought about Revolution in the precast industry. No compaction required in SCC still it results in no segregation and shows excellent flowability. It eliminates vibration and yields smooth surface finish with no voids. Use of Recycled Tire Rubber in Concrete More than 250 million scrap tires
weighing more than 3 million tons are generated each year in the United States (Naik and Siddique 2002). This is considered as one of the major environmental challenges facing municipalities around the world because waste rubber is not easily biodegradable even after a long period of landfill treatment. One of the solutions suggested is the use of tire rubber particles as additives in cement-based materials. Smog Eating Concrete Cement treated with titanium oxide. Photocatalytic reaction with UV light takes place, it accelerates natural oxidation process and decomposes pollutants to clear air. The reaction prevents bacteria and dirt from accumulating on a surface. It is easily removed with water or rain and keep concrete clean and white. Reactive Powder Concrete (RPC) Reactive Powder Concrete is an ultra high-strength and high ductility
composite material with advanced mechanical properties. Developed in the 1990s by Bouygues' Laboratory in France. It consists of a special concrete where its micro structure is optimized by precise gradation of all particles in the mix to yield maximum density. It uses extensively the pozzolanic properties of highly refined silica fume and optimization of the Portland cement chemistry to produce the highest strength hydrates. RPC represents a new class of Portland cement-based material with compressive strengths in excess of 200 MPa range. By introducing fine steel fibers, RPC can achieve remarkable flexural strength up to 50 MPa. The material exhibits high ductility with typical values for energy absorption approaching those reserved for metals. Translucent Concrete It changes the perception of concrete's opaque mass, it is prepared with optical glass fibers.
Figure 4: Smog Eating Concrete
Figure 5: Application of Reactive Powder Concrete
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Trends in Concrete
Figure 6: Translucent Concrete
(a)
Performance Characteristics
MIX DATA Type II cement, Ib/yd3 (kg/m ) Slump, in. (mm) Air Content % Concrete Temperature
3
required to prevent damage due to inappropriate weather environment. Concrete admixtures, mostly chemically, interact with the constituents of concrete and affect the properties and characteristics of the fresh and hardened concrete and its durability. The purposes of the admixtures include water reduction, high strength, corrosion protection, crack control, finish enhancement, flowability, etc. One of the interesting and useful purposes is protection against freeze. Accelerating admixture is to increase the rate of early strength development or to shorten the time of setting, or both. Some of these accelerating materials have properties effective to avoid freezing. Pozzutec 20+ developed by Master Builders, Inc. is a multi-component, non-chloride, water reducing and accelerating admixture formulated to accelerate concrete setting time and increase early and ultimate strengths across a wide range of ambient temperatures. Prepacked Shotcrete Admixture Over the past 10 years, the wet shotcrete method has become increasingly used in the repair of vertical and over-head concrete surfaces. This is due, in part, to advances in materials such as the introduction of silica fume (microsilica), fibers and superplasticizers, which not only make shotcrete easier to place, but also improve its durability. Batching all these materials in the right proportions with sand and cement can be difficult, so many manufacturers have developed pre-packed shotcrete repair mortars to which contractors add only water. The prepacked materials simplify batching and provide more consistent quality. But packaging all the dry materials increases their cost. Gemite Products Inc. Amherst, NY developed pre-packed products (called "concentrates"), which include all the admixtures but require contractors to provide their own sand and cement. The material costs of concentrates mixed with sand and cement are considerably lower when compared with complete packaged systems, while maintaining the same quality.
51
600 (356) 4 1 (100 25) Non-air-entrained concrete 55 0f (12 0C)
Mild Weather
Setting Time Ambient Temperature: 70 0f(21 0c) Mix Plain Pozzutec 20+ admixture @ 10 fl oz/cwt (650 ml / 100 kg) Intial Set H:min 4:30 3: 18 Time of Set Comparison H: Min REF -1:12
Cold Weather
Setting Time Ambient Temperature: 50 0f(10 0c) Mix Plain Pozzutec 20+ admixture @ 20 fl oz/cwt (1,300 ml/100 kg) Intial Set H:min 5:48 4:00 Time of Set Comparison H: Min Ref -1:48
Figure 8: Scrap tire, a major environmental challenge
Pervious Concrete It possesses little or no sands and has open pore structure. It Reduces storm water run-off. Low Temperature Concrete Admixture Performing construction processes under the cold weather condition requires construction engineers to plan operations considering low temperature condition. Especially, since the quality of concrete is sensitive to temperature, costly cold weather protection has been
Subfreezing Weather
Setting Time 0 0 Ambient Temperature: 50 f(10 c) Mix Plain Intial Set H:min 5:48 Time of Set Comparison H: Min Ref -8:18 -9:48
Pozzutec 20+ admixture @ 60 fl oz/cwt (3,910 ml/100 kg) 3:54 90 fl oz/cwt (5,850 ml/100 kg) 2:24
(b) Figure 7: (a) Concrete pouring in the low temperature, (b) Performance data of Pozzutec 20+ developed by Master Builders
Trends in Concrete
reinforcing steel. The external steel straps can be inspected and maintained in a similar fashion to steel girders. Status: Two versions are available: 1. The cast-in-place version 2. The pre-cast Arch Panel version. The cast-in-place deck slab is now in the Canadian Highway Bridge Design Code (CHBDC), currently in the press. Japan is reviewing the technology. Meeting with American Association State Highway Transportation Officials (AASHTO) Code Committee is in pro-gress. Pavemend - Rapid Repair Products Repair of concrete continues to be a major maintenance item in the budget of many agencies. There are many circumstances in which a rapid repair is highly desirable. Ceracrete Technologies, Inc. (CTI) is a Richmond, Virginiabased small business. CTI focuses on the manufacture of commercial products for construction applications using nonhazardous inorganic recovered raw materials to replace conventional virgin raw materials. Ceracrete technology is a chemical bonding process that uses very high percentages of coal ash, municipal solid waste ash, foundry sand residue, dredge material, flue gas desulferization by-products, etc. to create rapid concrete repair products. The initial Ceracrete rapid concrete
Figure 9: Pervious Concrete
Steel-Free Concrete Bridge Deck Steel-free concrete replaces reinforced concrete in bridge decks and similar structures in marine environments and in northern climates having snow and ice. It is to eliminate the source of deterioration, the steel reinforcing bars in slabs exposed to deicing salts. Eliminating corrosion makes concrete deck slabs virtually maintenancefree, which makes life cycle costs of steelfree concrete decks much lower than reinforced concrete decks. Shear connectors make the steelfree concrete deck composite with the steel girders
that support it. Top flanges of girders attempt to displace outward when a truck drives across the deck. External transverse steel straps below the bridge deck and between the bridge girders prevent this outward displacement by providing a lateral restraining force to the girder and concrete deck. In response, compressive membrane forces develop in the concrete deck. Ultimate load can be greater than the load at which the same deck would fail if it were reinforced conventionally. In fact, the tension capacity of the steel straps in the steel-free deck replaces conventional
0.75-inch diam, DoubleHeaded Stainless Steel Bar @ 12 inches 14 inches 3.4 feet 3 - 0.87 --inch diam. Studs on straps 7.3 inches GFRP Bars GFRP Bars 5.1 inches
2 x 0.8-inch Steel Strap @ 3.9 feet 6.6 feet

Figure 10: Steel-Free Concrete Bridge Deck
6.6 feet
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Cera Chem India Pvt. Ltd
Trends in Concrete
(a)
(b)
Figure 11: (a) Surtreat application, (b) Untreated lanes (left) vs Treated lanes (right)
repair product, PaveMend, reaches 3670 psi at one hour and 4400 psi at three hours, easily qualifying it as a very rapid pavement repair material. The twenty eight day comprehensive strength levels operate at around 6,000psi. This generally means that field users can mix, pour/place and open the area to traffic quickly without special curing or protection measures. Suntreat - Concrete Restoration & Protection System Reinforcing steel corrosion is the most common cause of failure of concrete structures. Once started, rebar corrosion cannot be stopped by simply
waterproofing the surface of the concrete. The corrosion process is influenced and promoted by penetration of air, water, chloride and an acid environment. Surtreat can be used to prevent contamination and decomposition of concrete surfaces in hostile, chloride and acid containing environments. Surtreat is a proprietary concrete restoration and protection system. The system includes sequential application of chemical treatments to improve the properties of the deteriorating concrete and protect new structures. Surtreat proprietary chemical formulations penetrate into the concrete microstructure in liquid and vapor state to combine with the cement
phase of concrete and deposit on steel components. Surtreat increases the ability of concrete to resist deterioration by increasing compressive strength, reducing permeability, inhibiting corrosion of the reinforcing steel components and improving concrete's resistance to acid attack. Surtreat is used in the widest variety of applications and every owner /manager/operator of structures that include concrete components can benefit from the installation of Surtreat. All tests were conducted at the NASA Kennedy Space Center laboratories and in compliance with applicable ASTM Standard Test Methods. The evaluation methods employed by NASA specialists included measurement of halfcell potential, corrosion current and polarization resistance. The most direct measure of the corrosion rate, polarization resistance was increased by 300% after application of Surtreat. Halfcell potential and corrosion current measurements also reflect a significant decline in corrosion rates after application of surtreat corrosion inhibitors. Precast Inverted T Beam:
Figure 12: Shotcreting process
Figure 13: Developed in Nebraska, a precast inverted T-beam saves up to 20% in weight off standard I-beams
Current systems are either costly or time consuming to erect and have limitations. Cast-in-place slabs have become too expensive and time-consuming due to extensive field formwork. Precast solid slabs aren't economical for spans longer than 9 meters. I-girders with concrete deck slab topping can span longer than other systems, but require field formwork and significantly higher clearance. The new precast concrete product for short to medium span
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Trends in Concrete
(a) (b) Figure 14: (a) Concrete particles without Mellose (water pictured as black dots), (b) Concrete particles adding Mellose under water (water pictured as black dots)
bridges was developed by the University of Nebraska. The Nebraska Inverted Tee (IT) can span up to 26 meters with a total structural depth of 725 mm. Most U.S. highway bridges have short to medium span lengths. And most bridges needing rehabilitation or replacement are short-span. A recently developed type of pre-stressed concrete beam is helping slash 20% off the weight of a bridge being built in Florida between the cities of Boynton Beach and Ocean Ridge. Conductive Concrete: Concrete has been used for many years as a composite material that has excellent mechanical properties and durability for construction. However, concrete is a poor electrical conductor, especially under dry conditions. Concrete that is excellent in both mechanical and electrical conductivity properties may have important applications in the electrical, electronic, military and construction industry (e.g. for deicing road from snow). Traditional methods can
warm roads, but installation cost is high and the procedure is complicated. The principle behind it is the use of cement to bind together electrically conductive materials such as carbon fiber, graphite and 'coke breeze' - a cheap byproduct of steel production - to make a continuous network of conducting pathway. The design formulation is based on the 'electrical percolation' principle by which the composite conductivity increases dramatically by several orders of magnitude when the content of the conductive phase reaches a critical 'threshold' value. Further increases in the conductive phase content boost composite conductivity only slightly. The design specifies an amount just over the threshold content, assuring high conductivity and mechanical strength as well as good mixing conditions. Corrosion Inhibitors for Reinforced Concrete Steel corrosion in reinforced concrete structures has been a major problem across World today. Steel-rein-
forced concrete structures are continually subject to attack by corrosion brought on by naturally occurring environmental conditions such as carbonation and the introduction of chlorides from sources such as salt water, deicing salts, and accelerating admixtures. Corrosion inhibitors available in the market can be mixed with ready mixed concrete or applied over the old concrete greatly reduces the overall corrosion activity (up to 65% reduction). Such products normally do not affect the properties of hardened concrete, such as compressive strengths, permeability, etc. One demerit of such products are that it reduces corrosion but cannot stop it. A combination of this product with other protective systems is required if the level of durability of the concrete structure needs to more than double. Shrinkage Reducing Admixture for Concrete Concrete shrinkage cracking is a common problem in all types of concrete structures, especially for structures and environments where the cracks are prevalent and the repercussions are most severe. Examples of these are bridge decks, parking garages, marine structures, containment structures, and high performance floors. A liquid shrinkage reducing admixture for concrete, developed by Grace Construction Products and Arco Chemical Company, that reduces significantly the shrinkage during concrete drying and potentially reduces overall cracking over time. The product can be easily dissolved in concrete mix water or dispersed in concrete during mixing. The admixture
High Performance concrete for transportation structure are gaining wide acceptance
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Trends in Concrete
works by reducing the surface tension of the water, decreasing the force pulling in on the walls of the pores, resulting in a reduction of the shrinkage strain. Mellose Non-dispersible Underwater Concrete Admixture Many under-water civil engineering structures are affected not only by the presence of water or salt but also by water pressure; flow of water, and by the different material's density. These factors could cause cracks, corrosion, and dispersion of concrete particles. Mellose is a viscose agent based on under water Cellulose (Hydroxy Propyl Methyl Cellulose). It is commonly referred to as a self-leveling agent that increases viscosity when is dissolved in water. It can be also described as an anti-washout concrete or non-dispersible concrete mixture. When Mellose is added, it prevents the loss of cement in the mortar and the separation of the concrete particles due to its increased viscosity. It combines first with the water than with the cement and the other concrete particles. Benefits include: Mellose increases the viscosity of suspended concrete but decreases the viscosity of flowing concrete. Therefore, it increases the workability of the concrete, while there is no separation of its aggregates. It prevents the segregation of aggregates as well
Figure 16: Corrosion inhibitor
as the bleeding when used for under water construction. The product comes in the form of a powder that is added as a concrete admixture. Barriers are: Mellosecan not be used with Naphtalene Sulphonate because of chemical reactions. Conclusion The cement and concrete industry has some inherent problems that restrict the rate of adoption of new technologies to meet these challenges. These include: Expensive manufacturing infrastructure Low margin product Proliferation of formula based technical standards Industry culture tied to the orthodox belief that "it has always been done this way"
Figure 15: Conductive Concrete
These excuses will not impress an institutional investor that has a myriad of investing opportunities to choose from and is ready to move millions of dollars of capital to anywhere in the world at the press of a button. Neither is a user trying to overcome a problem such as cement shrinkage or corrosion or a politician who is being pressured by community concern over environmental degradation going to be Interested in the problems of the industry.
Cement manufacturers need to ask themselves the same questions. Cements and concretes are changing to better meet the needs of customers ahead of the competition. The construction industry is conservative and the changes have been slow, such as the increase in thealite/belite ratio over the last twenty years and the incorporation of supplementary cementitious materials and various fibres. Cements and concretes probably need to change much more quickly to meet the challenges of the future. Challenging the traditional construction paradigm is robotics. In the USA and elsewhere in the world researchers are looking at using robots to literally print buildings. It is all quite simple from a software, computer hardware and mechanical engineering point of view. The difficulty is in developing new construction materials with the right Bingham plastic rheology so they can be squeezed out like toothpaste; yet retain their shape until hardened. The main inhibiters to evolution in the industry are the formula-based approach to standards which grew out of the industrial environment of the early twentieth century. Standards are important for society's protection, but to allow creativity and innovation, standards would be a much better servant to society if they were performance-based rather than formula-based.
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Schwing Stetter (India) Pvt. Ltd
RMC Industry Analysis
READY MIX CONCRETE:

Readies Itself to Take Over the Industry
Chaitanya Raj Goyal
58
oncrete is truly an amazing building material. There aren't a lot of materials that have persisted for millennia while hunger for this commodity has only become more ravenous. We're completely surrounded by concrete today. The world is practically wrapped in it. However, the Ready mix concrete business in India is still in its infancy. The Ready Mix Concrete industry is perhaps among the fastest growing sector in India. In the coming years the country will witness increased construction activity with faster development in our cities and infrastructure. RMC is expected to play a very important role in the scenario. As India builds its infrastructure, the RMC industry is steadily gaining pace as the most viable option to speed up construction. Over the next 5 years, the size of the RMC industry is estimated to grow from INR 155-160 billion in 2009-10 to ` 395400 billion in 2014-15. Though the penetration of RMC is higher in the metropolitan cities as compared to all India average, there is scope for further penetration of RMC in these cities with higher verticalisation and expected infrastructure development. Witnessing a decade of rapid growth In early 70s both pricing and distribution of cement were controlled due to shortage of supply, Ready mix concrete technology could not be implemented as investors felt that RMC plant will starve due to non-availability of cement. The levy of additional taxes & duties on RMC, entry tax, excise duty also contributed to the slow development of the concept. In the late 80s, after cement was fully de-controlled, RMC was manufactured on a commercial basis. RMC industry has been on a continual growth path ever since the first commercial RMC plant was established in Pune in the year 1991. The year 1993 saw the entry of two corporate companies, ACC Cements and Unitech construction starting their commercial RMC plants in Mumbai to commercially exploit the potential of this sunrise industry. Ever
It is safe to conclude that we have not achieved as much as we should have. Because of added component of transportation cost, RMC will always be costlier than sitemixed concrete of identical mix proportions. Once the owners of construction projects are ready to pay the extra cost to ensure quality, speed of construction, lower the lifecycle cost and reduce C&D wastes, RMC will have its rightful place in the construction sector.
metros, tier 2 cities and even tier 3 cities as real estate and infrastructure projects line up in developing urban regions. Today commercial RMC plants are present in more than 90 cities and towns across India and there are numbering more than 2500 RMC plants in operation in cities, and various projects locations across the country. Production & trade: Current market statistics The production capacity of a readymix concrete plant depends on the capacity of the batching plant. An average plant has a production capacity of 30 cubic meters per hour. The plant will be able to produce about 90,000 cubic meters a year. But the ready mix concrete (RMC) business in India has been facing continued hiccups over some time now. Established players have to take on intense competition from smaller region-specific companies. Major RMC companies are thus reworking strategies. The current slowdown has started slowly affecting the RMC industry in terms of reduced production volumes and cash flows. The main raw material being cement, the periodic fluctuations in cement prices and higher transportation costs due to fuel price rises have also affected the price realization for
Dr. A. K. Mullick, Former Director General,

National Council for Cement and Building Materials
since, the industry has grown leafs and bounds and as we see today the industry is growing and geographically spreading to all the corners of India covering,
RMC Unit established by Madras Cements in 1998 has been producing concrete customized to the unique requirements of its customers
59
Ready Mix Concrete plant from ACC
the industry. remarked Dr. Aswath, Technical Advisor RMCMA-Karnataka. In India, ready-mix concrete accounts for 4-7 per cent of the cement consumption as the economy fluctuates. In contrast, 70 per cent of the cement produced in a developed country such as Japan is used by the ready-mix concrete business. Currently RMC conversion ratio of Europe is 65%, of USA is 75% and that of UAE is 90% of cement. The growth of ready-mix concrete business in India is predominantly driven by demand from metros and Tier-2 cities. But now, since the focus has shifted to Tier-3 and-4 cities, the demand for it has shown a steady increase. The total concrete market in India is estimated at 300 million cubic meters per annum of which the plant produced share is less than 35 million. Its share is expected to go up gradually from the present level of less than 6 per cent of the total cement production to the global average of 70 per cent, industry players say. RMC is my undoubted preference. Besides savings in cement, there is a full control on the quality of the concrete without sacrificing the speed while site mixed concrete is the slave of the labor availability and end results on large volumes are not encouraging said Mr. Ashok Dalwani, COO- City Head, Nirmal Lifestyle Ltd.
Major obstacles hindering the growth Despite the growing acclamation there are many hurdles in the healthy growth of this industry. A RMC plant
Two Indian experts have tried to estimate the future growth potential of RMC industry in the country. Basing their estimate on the cement consumed through RMC route, they postulate that the percentage of cement consumption through RMC may reach the 10% mark by 2013-14. Thereafter, the growth may be faster and the cement consumption through RMC may reach the 25% mark by 2022, when the total number of commercial RMC plants in the country will reach 1,516.
has to be located in an area where Concrete consumptions are there, as the concrete has to be transported. Also good water source at the plant site is a prime requirement because in case of non-availability of potable water in and around the location of plant, water has to be transported from distant location. In Mumbai, growth of Ready Mix Concrete is slow as compared to Bangalore and other cities as its use has been made compulsory by their government. RMC also attracts sales tax of 15.8 per cent. Soon, more states will start levying sales tax on RMC. For example, today, Delhi charges 10 per cent sales tax on RMC whereas in Karnataka it is 12 per cent. Government help is extremely necessary for the growth of this sector and Government specifications for CPWD and PWD jobs should include Ready mix concrete as a mandatory item. Moreover, Tax breaks are required for the growth of RMC. Also, developers /contractors should be discouraged from piling up materials like metal, sand etc. on roads/foot paths. Government bodies, private builders, architects/engineers, contractors, and individuals should be made fully aware about the advantages of using ready mix concrete. Said Mr. Vijaykumar Kulkarni, Principal Consultant, RMCMA, Two Indian experts have tried to estimate the future growth potential of RMC industry in the country. Basing their estimate on the cement consumed through RMC route, they postulate that the percentage of cement consumption through RMC may reach the 10% mark by 2013-14. Thereafter, the growth may be faster and the cement consumption through RMC may reach the 25% mark by 2022, when the total number of commercial RMC plants in the country will reach 1,516. RMC sector: Key players target fasttrack growth
Vijaykumar R.Kulkarni
Member Managing Committee & Principal Consultant, RMCMA Immediate Past President, ICI
Today's fast-paced construction industry demands top quality products, delivered efficiently and on time. Many project managers prefer ready-mix con-
60
Apollo Infratech Pvt. Ltd
The current slowdown has started slowly affecting the RMC industry in terms of reduced production volumes and cash flows. The main raw material being cement, the periodic fluctuations in cement prices and higher transportation costs due to fuel price rises have also affected the price realization for the industry.
Dr. Aswath
Technical Advisor RMCMA-Karnataka
crete to on-site mixing, as the product is made with more precision. Anticipating a huge potential for the product, several major manufacturers of cement have launched ready-mix concrete. The Indian market for Ready Mix Concrete has been showing a consistent positive growth, year after year, in spite of a few policy hurdles on the way. With the big infrastructure projects slowly turning to RMC, experts in this
segment predict a business growth rate of 25% in India. The increased use of RMC, as against the sluggish cement market, has made local producers as well as a host of major international players focused on the RMC business; Holcim, Lafarge, Heidelberg, etc. to name a few. With major investments flooding into this segment, the focus has now shifted to increasing the brand presence in the shortest possible time. The strategy is to have a well spread network of RMC plants, through timely execution of greenfield projects across the country. Holcim, a major player in this segment, through its local associates ACC and Ambuja Cements, has already taken dynamic steps to revolutionize this industry. Other big players that dominate the Indian market are Ultratech, RMC India (Prism cements), Godrej and Boyce, India cements, Madras cements, Lafarge (which overtook the L&T RMC business last year for INR 1450 crore), RDC concrete, Ahlcon RMC, IJM concrete, Bharath cement products RMC and CI concrete India. The National Ready Mixed Concrete Association (NRMCA) had launched certifications for both ready mixed concrete industry facilities and professionals involved. These certifications have provided a competitive edge in the industry, showing customers and regula-
Lafarge RMC plant at Thane, Mumbai
tory agencies that certified producers have an understanding of and support measures to provide the highest quality RMC in the safest and most efficient ways possible. There are about 260 RMC plants that have been certified by the association. RMCMA has taken enormous efforts in evolving a quality scheme for RMC and implementing the same in different parts of the country. Two of the world's leading organizations dealing with readymixed concrete, namely the NRMCA, USA and ERMCO, Europe, have highly appreciated the work done by the RMCMA. said Dr. Aswath, Technical Advisor RMCMA-Karnataka. Innovation and technology trends Today the entire RMC process is fully computerized, leaving no scope for human errors. All the control systems are Windows based. Cement and other raw material are checked as per the quality plans of the companies. All the raw materials are stacked in separate bins and are stored under cover so that aggregates are not exposed to direct sunlight and environment pollution. Cement, Fly ash, Slag etc. are stored in separate silos for better control on recipe and handling of fly ash and slag are done from closed bunkers to silos directly. Also, separate weigh-batchers are provided for each ingredient like cement, water, admixtures and aggregates. The weighing is done on sophis-
Location of plants play vital roles in overall project costs.
62
RDC Concrete (India) Pvt Ltd
ticated electronic weigh batchers. Precise weighing of all materials is done through electronic load cells made up of special alloys. Moreover, homogeneous mixing of concrete is ensured by use of special high-efficiency mixers like pan-type or turbo-twin shaft mixers and a fully equipped onsite plant laboratory is available at each plant. A Sprinkler system is installed to ensure temperature control of aggregates in hot weather. In line with NRMCA's focus towards environment and eco-friendliness all member silos are installed with bag filters and level indicators to avoid any kind of pollution and processes are in place for effective and periodic maintenance and calibration of all critical components. Also, laser sensor and moisture control are used for a stringent quality assurance while well trained and experienced engineers are available at every plant to take care of the quality of concrete. Recently ACC Concrete introduced an innovative concrete solution M100 grade for construction of high intensity towers. It is for the first time in the world that M100 was manufactured without natural sand but by using fine aggregates. With this innovation ACC Con-
RMC plants today, are mostly if not fully automated. This helps in the timely and speedy delivery of goods.
crete has become the only ready mix concrete company in India to offer specia lized solutions for high intensity towers. Future: Cementing the growth If you've noticed a gang of laborers reminding you of the past century, standing in line and passing head-loads of concrete mixture up a stairway at a construction site, no proof is required to underline the rudimentary systems that continue to prevail in a nation's infrastructure sector. With the concern over liquidity there has been a general slowdown in both real estate and infrastructure projects. Many of the high-end residential projects, especially in metro cities, have been delayed. Unfortunately, only these projects depend on RMC as these buildings come up generally in congested residential areas. While China has embarked on a furious pace of construction building express highways and high-rises galore, India seems to lag. For a country focused on development, it is imperative to mechanize its infrastructure creation. Most countries of the world have banned head-load supplies of concrete at construction sites and insist on pumped concrete. The concept of using site-mix concrete is thus slowly fading away across the world. With RMC you can achieve almost 15.5% savings in construction costs in terms of factors such as quality and
RMC is my undoubted preference. Besides savings in cement, there is a full control on the quality of the concrete without sacrificing the speed while site mixed concrete is the slave of the labor availability and end results on large volumes are not encouraging.
wastage-avoidance. One reason why India is beginning to shed its dependence on manual concrete mixing is the penalties now associated with infrastructure projects. Delays cost the builder now, in contrast to even a few years ago when the builder would pass on cost escalation to the buyer in case of a delay in the project. It is safe to conclude that we have not achieved as much as we should have. Because of added component of transportation cost, RMC will always be costlier than site-mixed concrete of identical mix proportions. Once the owners of construction projects are ready to pay the extra cost to ensure quality, speed of construction, lower the life-cycle cost and reduce C&D wastes, RMC will have its rightful place in the construction sector. said Dr. A.K. Mullick, former DG, NCBM. India is in fast-forward mode and time is of essence. Players like BPOs often want to start operations straight away and have no time to wait. All this is tipping the scales in favor of use of ready-mix concrete, and mechanized construction equipment at sites. So we conclude that if the quality of concrete is something that you cannot compromise on in your project owing to many critical factors at stake, RMC is the way to go! Photo Courtesy
www.ramcocement.in, www.tradeindia.com www.aquariusengineers.biz, www.lafarge.com www.conmatindia.com
Ashok Dalwani
COO-City Head, Nirmal Lifestyle Ltd.
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Sika India Pvt.Ltd
RMC Industry
Evolution of RMC in India

Vijaykumar R Kulkarni
oncrete construction scenario in India has witnessed significant changes in the past decade. Traditionally, construction involving concrete has been a laborintensive activity, and even today, an overwhelming majority of concrete produced in the country is site-mixed, and most of it is volume-batched. However, thanks to the liberalization of the Indian economy and emphasis on the development of physical infrastructure, concrete construction scenario in India especially in urban India is undergoing welcome transformation in the recent years. The demand for higher speed of construction, especially for residential and commercial housing, flyovers, highways, roads, aviation, etc. in metropolitan and other big cities of India, has necessitated the adoption of mechanized and semi-mechanized techniques of construction. The need for large volumes of concrete as well as faster speed of construction was felt. This was conducive for the development of ready-mixed concrete (RMC). The concept of RMC was not new to India. Captive RMC plants arrived in the country in 1950s; but remained confined for application in mega projects. Thus, India missed commercial RMC technology for nearly five decades! Early 1990s witnessed the beginning of RMC industry in India. The first commercial RMC facility was set up in Pune in 1992 and was quickly followed by establishment of similar facilities at other locations. The growth of RMC started with metropolitan cities like Mumbai, Bengarulu, Delhi, Hyderabad, Chennai, Kolkata later then spread to other major cities, and it is now trickling down to tier II and III cities. No authentic data is available on the RMC industry in India. Based on rough estimates, it was reported that as on December 2008, there were around 450500 commercial RMC plants producing about 25-30 million m3 of concrete per annum4. In addition, a large number of batching and mixing plants belonging to medium and large construction companies also operate as captive plants on a number of projects throughout the country. These plants are large in numbers and with the current emphasis on building physical infrastructure in the country, there seems to be a phenomenal increase in captive batching and mixing plants.
Major Hurdles to Growth In terms of cement consumed through the RMC route, the total percentage is too low and it stands at around 7-8% of the total quantity of cement produced in India during 2010-11. In most of the advanced countries, this percentage is much higher, varying from around 48% (Europe) to 73% (USA). Thus, there is a great scope for the development of RMC industry in India. However, there many hurdles for the healthy growth of the industry. Some of these are listed below. - Level playing field for RMC vis--vis site-mixed concrete: Higher rate of taxation on RMC is one of the major constraints for its faster growth. - Land for RMC plants in urban areas at reasonable rates: Non-availability of land for setting up plants in urban growth centers is one of the major stumbling blocks in speedy growth. There is a need to reserve specified area in growth centers for setting up RMC plants at reasonable rent/cost. - Regulation issues: Industry regulation through certification of RMC facilities is highly essential to ensure quality. In this regards, a good initiative is already taken by the Ready Mixed Concrete Manufacturers Association in evolving and implementing a Quality Scheme for RMC4. - Lack of knowledge of applications of RMC. - Tendency of too much dependence on labor-intensive techniques in construction. - Education and Training of industry personnel and customers of RMC. Two Indian experts have tried to estimate the future growth potential of RMC industry in the country. They have predicted that the growth of RMC in India may follow a path identical to the slow growth pattern followed by some of its counterparts internationally. Basing their estimate on the cement consumed through RMC route, they postulate that the percentage of cement consumption through RMC may reach the 10% mark by 2013-14. Thereafter, the growth may be faster and the cement consumption through RMC may reach the 25% mark by 2022, when the total number of commercial RMC plants in the country will reach 1,516
RMC Industry
Growth of Cement Industry India has the distinction of being the second largest cement producer in the world, next to China. Based on the data from the Survey of Cement Industry, the Indian cement industry comprises of around 180 large plants belonging to 55 companies, with an aggregate capacity of 290 million tonnes as of 2010. Unofficial estimate predicts that the cement industry capacity will reach a figure of around 350 million tonnes by 2012-13. Historically speaking, the indigenous cement industry has generally achieved 1-2% higher growth rate than that in the GDP . Thus, even if we assume a very conservative GDP growth rate of around 5-6% during the 12th Five Year Plan (2013-2017), it will be safe to assume that the cement industry will grow at an average rate of 7%. With this assumption, the cement industry capacity would reach 442 million tonnes in 2017, Fig 1. Size of Organized Concrete Industry Based on the cement figures, let us now find out the approximate size of the organized concrete industry in India, which comprises of companies/organizations producing concrete using modern batching/mixing plants for either commercial or captive consumption. Here, based on the previous discussion, it may be safe to assume that cement consumed through the RMC/batch-plant route will reach 7.5% in 2012-13 and 10% in 2017-18. Further, assuming that the average cement consumption per m3 of concrete produced is around 300 kg, the volume produced by the organized concrete industry in India will reach 87million m3 in 2012-13 and 147 million m3 in 2017. These are approximate estimates from a conservative angle. Yet, when compared with the production figures from other leading countries, the performance of the Indian industry seems impressive. By 2017-18, the organized Indian concrete industry will possibly rank the third largest concrete industry in the world, next to the USA and China. As pointed out earlier, the RMC culture has now spread to around 50 major cities in India and the unofficially-estimated volume of concrete produced by the commercial plants during 2010-11 was of the order of around 40-45 million m3. If concrete produced by captive plants is added to this, the total
figure may reach around 80 million m3. The organized concrete industry in India is unfortunately fragmented. There are only a handful of commercial RMC players who have an all-India presence. Since the entry barrier to the industry are low, there is a preponderance of small players operating in local markets. However, being late-comer, the RMC companies in India have one advantage, in that most of the batching and mixing plants installed in the county during the past decade are of the state-of-the-art variety with computerized controls. Regulatory Framework Immediately after its formation in 2002, the RMCMA actively participated in revising the Indian Standard specification on RMC. The old standard, IS 49267, which was first published by the Bureau of Indian Standards (BIS) in 1968 and then revised in 1976, needed one more revision to incorporate the experience gained in the commercial operations RMC plants. The second revision of the BIS standard which was published in 2003 generally proved appropriate for the industry. During the early years of its formation, RMCMA realized that in a country like India having a long history in the use of laborintensive site mixed concrete, quality of concrete has indeed been one of the major concerns of customers. It therefore took the decision of creating a quality platform for winning over the customers using site-mixed concrete. In the absence of any national regulatory framework, RMCMA decided to develop an indigenous quality scheme for ready-mixed concrete in India. It also decided that the quality scheme shall rest on two strong pillars, namely, best international practices that are suitable for Indian conditions and strict observance of the codes of the Bureau of Indian Standards. For evolving the quality scheme, RMCMA constituted a Quality Team consisting of senior representatives from member companies and eminent experts from the Indian construction industry. The quality team met on several occasions and after thorough discussions, decided to divide the quality in the scheme following two parts: - Audit-based certification of RMC production facilities; and - Guidelines for quality control and quality assurance. With the guidance from experts from construction industry, two detailed manuals were prepared covering the abovementioned two parts4, 8. The QC manual part I developed by the RMCMA contains an exhaustive Check List covering all the operational areas in RMC plant. It contains some 125 items. Out of these, conformance with some 110 items is considered to be strictly essential for achieving good quality concrete, and hence for getting the certification by the RMCMA.
RMCMA
City-wise Certified Plants

30
28 25 18 15 12 9 3 4 2 2 4 4 3 8 1 1 1 2 3 1 3 1 1 19
No. of audited plants
25 20 15 10 5 0
224 Plants 50-plus locations
M u B a mb a De ng a i lh lo re i Hy (NC de R) ra b Ko ad lk at a Co G im o ba a to Na re gp N a ur sh ik M Pu an ne ga lo r M e an i Ch pal en na Hu i Co b li ch in Va Su r Ah d od at m ar ed a ab a M d ys or Ja e ip u Tr r L u i chy ck no Ra w nc R a hi ip ur
While developing the Check List, it was ensured that the provisions in the same meet most of the stipulations in the
www.masterbuilder.co.in The Masterbuilder - July 2012 67
RMC Industry
Indian Standard, IS 4926: 2003 and the other relevant codes on concrete such as IS 4569, IS 38310, IS 910311, etc. In fact, in certain cases, the RMCMA requirements are more stringent than those of IS 4926:2003 and other codes. With a view to bring in transparency, enhance credibility and win over the confidence of customers, it was considered essential by the RMCMA to introduce a yearly audit of the RMC production facility by an external auditor. For this purpose a detailed audit procedure was drawn and the selection criteria for auditors were also finalized. The scheme was offered to members of RMCMA as well as others. One more crucial feature of the RMCMA quality scheme is its adherence to the prevailing statutory norms in India. Before undertaking any audit, the auditor seeks and verifies certificates of compliance on the following three aspects from the RMC producer: - Permission and consent to operate RMC facility from state Pollution Control Board; - Permission from factory inspector confirming adherence to health and safety norms; - Permission/license to operate plant from local body/ municipal authority. Till April 2012, RMCMA has certified around 250 RMC facilities throughout the length and breadth of country. Realizing that mere certification based on the Check List may not be sufficient to instill assurance on quality amongst customers, RMCMA prepared detailed Guidelines for QA and QC of concrete (Quality Manual Part II). The minimum benchmarks suggested in the this guideline document are based on the relevant provisions in BIS codes such as IS 4569, IS 49267, IS 38310, IS 910311, IS 381212, etc. In fact, certain benchmarks in the guidelines far exceed the provisions in different codes. Based on these guidelines, RMCMA encouraged its members to develop their own documents and
make the same available to customers on request. Recent Changes in Regulatory Framework After operating the quality scheme for RMC successfully for the past four years, RMCMA decided to raise the quality scheme to a higher pedestal. For this purpose, RMCMA recently signed an Memorandum of Understanding (MoU) with the Quality Council of India (QCI). The latter organization was set up in 1997 jointly by the Government of India and the Indian Industry represented by the three premier industry associations i.e. Associated Chambers of Commerce and Industry of India (ASSOCHAM), Con-federation of Indian Industry (CII) and Federation of Indian Chambers of Commerce and Industry (FICCI), to establish and operate national accreditation structure and promote quality through National Quality Campaign.
Proposed Structure of New Scheme

Quality Council of India
Joint Coordination Committee
Steering Committee
Technical Committee
Certification Committee Certification Bodies accredited by NABCB of QCI

RMCMA
USA
Quality Schemes in RMC Industries: A Comparison
U. K.

1913: Beginning of RMC production 1935: ASTM C 94 adopted first time 1965: Certification System commenced 1930: beginning of RMC production 1950: BRMCA formed 1968: Authorisation Scheme 1984: QSRMC launched
30 years
18 years
The MoU envisages that the quality scheme for RMC would be handed over to QCI, to be operated in an independent and impartial manner based on the best international practices. While QCI and RMCMA shall be the joint scheme owners, the governing structure of the new scheme shall be under a multi stakeholder steering committee and the scheme would be operated on a non-profit, but self-sustaining basis. It would have a defined consensus based technical criteria laid down for the ready mixed concrete plants which would be evaluated by competent third party certification bodies, who in turn, would be accredited by the National Accreditation Board for Certification Bodies (NABCB), which is a part of the international system of equivalence of accreditations and certifications, as per appropriate international standards. A multi stakeholder Steering Committee as well as the Technical and Certification Committees have already been formed and the new scheme is expected to take a final shape by July 2012. With the new scheme, the regulatory framework is expected to get strengthened and this will go a long way in ensuring healthy growth of RMC industry in India.
India
1994: Beginning of commercial RMC 2002: RMCMA established 2008: Quality Scheme commenced
6 years
RMCMA
Zydex Industries
Cement Industry Analysis
CEMENTING AGAINST ODDS:

THE INDIAN CEMENT INDUSTRY
Bhavani Balakrishna
espite allegations of cartelization and rising input costs, the Indian cement industry has registered grow that a compound annual growth rate (CAGR) of 13.14% during the 20072011 and is projected to grow at a CAGR of 10.64% over the forecast period (2012-2016) according to BRICDATA. A large part of this growth is expected due to the government's thrust on infrastructure and plans of investment to the
D
70
tune of USD 1 trillion on infrastructure during the 12th year plan. The Cement Manufacturer's Association has set an ambitious target of achieving 550 million tonnes capacity by 2020. Over the years, the housing sector has always been the largest consumer of cement followed by infrastructure, commercial and institutional and the rest by industrial segment. It is expected that the large scale investments in roads,
bridges and dams across the country along with the rise in construction in residential and commercial sector will provide the growth momentum for the cement industry. In the year 2011-12, India's cement production grew around 6.3%. The demand in the first half of the year was slow due to several factors - overall downturn in the global economy resulting in a much more lukewarm construc-
year 2011-12. One of the reasons was higher capacity additions as against incremental demand. On the supply side, while the pace of capacity additions has slowed down in 2011, this demandsupply mismatch scenario is expected to prevail for some time as major players intend to continue expanding their installed capacity on the backs of planned government construction projects. Most industry players expect that the excess capacity should be absorbed by cement demand growth. However reports suggest that with effective capacity still outpacing cement demand, capacity utilization is expected to remain below 80 percent for the next two years. While demand recovery was seen in the beginning of 2012, the ban on sand mining affected private and government construction projects apart from impacting cement prices. Furthermore, with the cement industry being cyclical, the onset of monsoon season will again register a drop in cement prices. Demand in the southern region witnessed a 10% YoY growth, thanks to negative base of 6% and firm demand in Tamil Nadu. Consumption growth slowed down in the Central region owing to slow awarding of infrastructure projects in UP under the newly formed government. All India average cement price rose by ~6% or ` 18-20/bag QoQ to ` 313 during the quarter. Eastern and Central region witnessed the highest price increase to the tune of ~ ` 40 and ` 25/bag during the quarter with an average price of ` 355 and ` 290, respectively. The report notes, prices
In the Cement sector, given the huge gaps in infrastructure and the Government's intent to bridge them through a sharp focus on infrastructure in the 12th Five-Year plan, my outlook in the long term is buoyant. That said, the surplus capacity scenario that exists today may continue for the next 3 years. In the present context, high input costs, rising energy and freight costs coupled with volatile prices, are challenges that we have to grapple with pro-actively."
Kumar Mangalam Birla

Chairman, Aditya Birla Group
rose by ` 20 and ` 5 per bag in Maharashtra and Gujarat, respectively, with an average retail price of ` 300-310 (top players) despite high prices in the prior quarter. Prices in the Northern region rose by ` 10/bag with an average price level of ` 300 for the quarter. Prices remained strong in the Southern region, except AP , which witnessed price cut of ` 10 during the quarter.
tion industry, delay in infrastructural projects and prolonged monsoon. However, the cement industry showed signs of revival from November 2011 owing to enhanced urbanization across Tier II and Tier III cities, lowcost housing across suburban and rural areas and government backed construction projects. As against capacity utilization levels of 74.4% in 2010-11, the capacity utilization levels declined to 73% in the
CEMENT CONSUMPTION
13% 6% Housing Infrastructure Commercial & Institutional 17% 64% Industrial
71
Rising Input Costs Rising input costs are a key challenge for the cement industry. Prices are expected to remain under pressure across regions in view of steep escalations in the cost of major inputs. The sector is energy intensive with coal alone costing constituting 14-23% of cost of production of cement. While Coal India announced a reduction in prices of coal in the beginning of the year, cement companies have had little relief due to the dwindling production of Coal India. Coal linkages for cement companies are expected to decline further as the industry vies with other sectors such as power. Import of coal from countries like Indonesia and South Africa is also turning costlier despite the softening of international coal prices due to the sharp depreciation of the rupee against the dollar. The coal ministry has decided to auction coal blocks based on upfront payment a company proposes to make. Cement and steel companies will have to quote above a determined floor price for each block while power and state-owned companies will pay 'reserve price' specific to each block. However, power, cement and steel companies may have to wait for about two years as the coal ministry has decided to auction the mines only after they are explored to assess actual reserves. Exploration of a block is done to assess quality and quantity of reserves present and takes about two years' time. Of the 42 coal blocks earmarked for auction to private power steel, sponge iron and cement companies, only 7 are explored. Many large companies are resorting to captive power plants in order to reduce the power costs as this source is economical and results in continual
WEST FY13E 2 37 83 FY14E 7 41 85 7 68 92 SOUTH FY13E 7 73 61 FY14E 3 80 65
Demand in the southern region witnessed a 10% YoY growth owing to firm demand in Tamil Nadu
INSTALLED CAPACITY, PRODUCTION AND UTILISATION LEVELS

400 350 300 250 mpa 200 150 100 50 0
FY1 2E FY1 3E FY1 4E FY1 5E
FY03 FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 77.3 78.6 81.8 86.4 90.3 83.3 81.4 75.5 75.9 78.4 80.4
100.0 90.0 80.0 70.0 60.0 50.0 % 40.0 30.0 20.0 10.0 0.0
74.4 73.7
Capacity
Production
Capacity Utilization
(Source: Task force report on Indian Cement Industry)
REGION-WISE GROWTH PROJECTIONS Capacity growth (%) Production (m tonnes) Capacity utilisation (%)
(Source: IIFL, August 2011)
EAST FY13E 4 35 91 FY14E 8 39 93
NORTH FY13E 5 61 89 FY14E
72
BASF India Limited
India's cement production grew around 6.3% in 2011-12
Coal alone contributes to approximately 14-23% of cost of production of cement.
supply of power. In a bid to reduce dependence on the supply of power from power utilities, cement companies in India have proposed investments of about $2 billion to ramp up their captive power generation base, a move which is expected to reduce their expenses on power up to 30% and ensure a reliable power-supply. Currently, the Indian cement industry has about 4,000 megawatts (MW) of installed captive generation capacity. With a host of green field and brown field expansion projects in the pipeline, another 2,000 MW captive capacity addition is expected in the next three to four years in the sector. Most companies are also experimenting with increased usage of alternative fuels
and optimization of coal mix to mitigate its fuel risk. The year also saw a hike of 23% in base freight by railways. Cement, being a highly freight-sensitive product, the hike in freight and diesel prices further affected the industry margins. Companies that have plants located closer to the markets and closer to the source of raw materials have an advantage over their peers, as this leads to lower freight costs. Industry margins were also impacted adversely due to changes in statutory levies. The excise duty on cement has been increased from 10% ad valorem + ` 160 per tonne to 12% on MRP after abatement of 30% + ` 120/- per tonne.
For cement cleared other than in packaged form, the duty has been increased from 10% ad valorem to 12% ad valorem. Sustainability and Green Initiatives Climate change due to the increasing concentration of CO2 in the atmosphere is a global phenomenon. Carbon emissions attributable to the cement industry are very significant and the pressure to reduce CO2 emissions in cement production will continue. Carbondioxide is emitted from the calcination process of lime stone, from combustion of fuels in the kiln, and from the coal combustion during power generation. Strategies to reduce these CO2 emissions include energy efficiency improvement, new processes, shift to low car bon fuels or waste fuels in cement production, increased use of additives in cement production, alternative cements, and CO2 removal from flue gases in clinker kilns. Increased use of fly ash as an additive to cement and concrete has a number of advantages, the primary being reduction of costs of fly ash disposal, resource conservation, and cost reduction of the product. Since the production of cement requires a large amount of energy, the substitution of cement by fly ash saves not only energy but also reduces the associated greenhouse gas emissions The diligent use of complementary cementing materials would enable a reduction in the average clinker factor (tonnes of clinker per tonne of cement)
Many large manufacturers are resorting to captive power plants in order to reduce the power costs
74
STP Ltd
Burning coal leaves behind a substance known as coal fly ash, or simply fly ash. This is an instrumental component in developing higher grade cement
The Biomass market in India is growing steadily as new initiatives and government polices usher in a new era in alternate fuels.
and the use of crop residues and industrial waste-products as alternative fuels for clinker production is another alternative to reduce the dependence on fossil fuels along with reduction in CO2 emissions. To achieve this task, cement companies have several options to further reduce the clinker factor in cement based on Portland cement clinker further replacement of Portland cements by composite/blended cements, production and use of composite cements according to existing cement standards with lower clinker content and establish new cement types with further
reduced clinker content which are outside the current cement standards. Companies are now looking at developing alternative fuels (AF) sources, in particular industrial and agricultural waste materials. Companies are also using fly ash and producing slag-based cement and other blended cements by utilizing some of the other industrial wastes to reduce the clinker factor. Fly ash is a fine glass powder recovered from gases emitted by burning coal during the production of electricity. Fly ash is a major waste of coal-based thermal power plants. Fly ash disposal is a significant environ-
mental concern as it creates huge pressures on land and water and fugitive emissions. For instance, ACC has taken up projects like Geo20 to increase usage of alternative fuels and Waste Heat Recovery (WHR) systems to improve fuel utilization efficiency, etc. to mitigate the fuel associated risks. ACC is also looking at promoting co-processing as an effective waste management solution for a number of industries. The use of biomass as a renewable source of energy registered a significant increase during the year. Special efforts were taken to serve the waste management needs of society by co-processing segregated combustibles from municipal solid waste (MSW) of a number of cities and townships in the proximity of ACC's larger cement plants. Co-processing is the act of adapting an existing industrial process whereby certain so-called 'waste' materials may be put to use to serve as alternatives resources either as fuel or as alternative raw material in cement kilns, dryers and captive power plants. Future Outlook The Indian cement industry has survived several odds in the past. While rising input costs, limited availability of coal and litigations may dampen the climate, the demand for cement will continue to grow. Photo Courtesy
www.marketresearchreports.in, www.ehow.com
Hike in freight and diesel prices has affected the industry margins
76
CICO Technologies Ltd
Crushing & Screening Equipment
Nawa Engineers Acquires Global Manufacturing Rights of 'Duracone SRM'

yderabad based NAWA Engineers & Consultants a leading player in the Indian crushing and screening marketplace through innovative and uncompromising quality of equipments and expert service has recently acquired the technical knowhow and global manufacturing rights of 'Duracone SRM' crushers from Durable Crushers Inc, USA. 'Duracone SRM' crushers is a path breaking innovation by Mr. Louis Johnson (famous for the invention and development of the first all roller bearing cone) after several years of design, testing and field proven outputs in crushing hardest of the hard rock's found in Salt River, Arizona, USA. NAWA Engineers acquisition of the technical knowhow and worldwide manufacturing rights of ' Duracone SRM' from Durable Crushers Inc is certain to enhance its leadership position in the domain it serves besides reaffirming its status as a one stop shop for crushing and screening equipments in the country. The' Duracone SRM' crusher has several innovative design, construction and operational features that are exclusive. Its unmatched superior performance in secondary, tertiary and quaternary crushing applications has won many a customer's confidence. NAWA now has the full range of high performance cone crusher to process either hard stone or mineral ores upto 700 TPH crushing capacity.
Duracone SRM400
The Duracone SRM Advantage: Duracone SRM models are extremely user friendly. If the top shell can be removed or reinstalled in 20 minutes or less, whenever a liner change or other maintenance needs that call for top shell removal is required. All major maintenance can be done from above the crusher or from outside the crusher. The combination of anti-friction roller bearings in the eccentric drive, and the hydrostatic thrust bearing under the head, allow very high loading, and at the same time very low power consumption when running empty, leaving a high percentage of motor power available for crushing .
The SRM models are field-tested for crushing river gravel with compression strength up to 70,000 psi. The low friction in the drive also prevents the shaft spinning when the crusher is running empty, or is lightly fed with segregated feed, and thus eliminates the need for a shaft brake. The anti-friction roller bearings in the drive and eccentric mechanism ensure constant geometric alignment, which reduces wear and tear on the gear drive and thrust bearings com-pared to those fitted with bronze bushes. It is perfectly well balanced, with the counter-weights enclosed inside the eccentric mechanism, and thus the counter-weights are not subject to wind resistance and abrasion. The crusher speed changes can be made, if required, because of the antifriction bearing design for the drive and eccentric mechanism, as against those fitted with bonze bushes that have speed restrictions. Low headroom for portable and stationary plants. For further details
NAWA Engineers & Consultants (P) Ltd. 'NAWAHOUSE', 8-2-334/3&4, Road No.5, Banjara Hills, Hyderabad 500 034. Ph: +91-40.2355 4071, 2355 4072 Fax: +91-40.2355 6706 E-mail: info@nawaengineers.com Web: www.nawaengineers.com
Duracone SRM500
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Fosroc Chemicals (India) Pvt.Ltd
Project Management
Efficiency at Sites: The Prime Focus

E Ravishankar
Ph.D, Research Scholar, BITS-Pilani
ith every fuel price increase and news on rupee devaluation against dollar, the thought of inflation naturally springs to our minds. As much as this phenomenon cascades down to the common man, a construction project head seems to take a major brunt. Cost escalation has impacted construction business from all directions: materials, freights, labour, interest rates and alas! from the point of passing this on to the end consumer; for inflation consumes his disposable income. When there is this difficulty of passing on the cost escalation to the customer or alternatively keeping the project within the agreed rate levels, there are only few things a construction business can do. Options are; to find out the areas where there is money drain and seal it; to increase productivity. This effectively helps control costs as money saved is money earned. In this study, from different perspectives, I find that a little paradigm shift can help builders reduce their cost levels. Cost savings One of the main areas where the money gets drained is through delay in executing projects as per schedule. While delay can happen due to various reasons that are out of control, if the areas that are within control are recognized and controlled, the builder could make some savings. While some of the areas that are out of control are climatic disturbances, land acquisition delay, bureaucratic delays in approvals, the good news is: If proper suppliers are selected for materials, and if workers are kept in good spirits, it will do enormous good in controlling costs. Delays can happen due to non supply of material in time, its indifferent quality, repeat or corrective work and due to low productivity at site. These are areas which can attract a realistic focus and attention for a builder. Many international research firms, when analyzing the risk of construction sector, came up with the conclusion that delay of project execution and increased working capital cycle are among the main criteria under consider. It is established
that delay directly eats in to the earnings of builders. Increased working capital requirement is necessitated by delay in recovery from the customers and also due to delay in project execution. Details of some of the infrastructure projects that are on schedule and delayed are as given below.
Segment
Power Road Petroleum Coal Railways Ports Steel Civil aviation Telecom
No: projects going as scheduled

42 39 22 20 18 8 5 2 6
No: projects delayed

48 80 30 18 22 12 5 4 4
Source: BMI, Ministry of statistics and programme implementation Table 1: Infrastructure projects details as of Jan 12
The above table, which reflects only the infrastructure projects, shows that in majority of the cases the delayed numbers is higher than projects going on schedule. Another fact is that in all the cases there are projects which are delayed. If we look at the changes in cost structure in residential building construction we get an idea of the tough picture:
Cost component
Raw materials Employee cost Selling and admin Others
2008
19 17 7 57
2010
22 18 8 52
change
3 1 1 -5
(% of the total cost)(% of the total cost)
Source: ISI report on residential building sector Table 2: Cost structure in residential construction
Project Management
The table shows that between 2008 and 2010 there is increase in the areas of material, staff and selling costs, as a component of the total costs, for residential building for the construction firms. The figures reflect a need for improving productivity with the help of material and staff which will effectively bring down the cost per unit, thereby increasing the earnings margin. Increased working capital cycle makes degree of leverage increase for the construction firms due to combined reasons as can be seen below.
Factor
Avg days needed for receivables Avg days of coverage for cash& equalents Avg inventory days Debt to- Equity ratio %
Urban population 2010

320 mn
Percentage of total
26%
Forecast % by Urban contrbn 2030 to GDP 2010

40% 60%
Source: AnandRathi, India construction sector, Mar 12 report Table 4: Importance of urban areas
Quarter 2 2011
114 21 61 95%
Quarter 3 2011
125 28 65 110%
Remarks
High and increased Increased High and increased High and increased
quality, price consistency and supplies. Also many activities like concrete and mortar in the construction site are done manually by mixing these inconsistent materials. The difficulty gets more pronounced in urban areas, as these areas suffer from labour shortage and increasing costs more than rural areas. Furthermore, the construction activities are more in urban areas and can be expected to increase continuously in future for two decades as can be seen below. Thankfully the un-organised sectors are converting into organized sectors, slowly but surely. Items like Aerated concrete blocks, Jointing mortar, Ready -mix concrete, Ready mix plaster, Pre cast concrete are on the way up in to an organized business category, which can help assuage some of the problems faced by construction firms. If we consider for example the case of Jointing mortar, we get some insight in to how things can work favorably. If one product, by becoming an organized sector, can bring in good amount of benefit by way of productivity, scheduled work, job satisfaction and cost savings, then if more products move in and get organized its benefit get more prominent to the construction industry. Let us take two more related examples to see some of the ways in which the builder segment can benefit from using products from organized sector in lieu of taking the same from un-organized ones. It is commonly assumed that the price of these organized sectors is likely to be slightly more than the un-organized sector. Given the benefits these bring with it, this myth gets unveiled. It needs to be remembered that in arduous climatic seasons, the un-organized sector can cost exorbitBenefits
Increased productivity Increased productivity, time and labour cost savings Ease of work, improved job satisfaction, improved productivity Improved quality, productivity. Helps avoid rework. Improvement is even better if used with cement blocks. Helps project go as per schedule.
Source: ISI report on residential building sector Table 3: Details of Residential building construction sector as of Q3 2011
The above factors reflect blockage and delay in realizing cash which can result in higher leverage and financial costs. Focus areas All the factors put together gives us a view that labour and supply are the areas of focus. There is a catch 22 situation here. On one hand the construction firms need to improve their suppliers services; ensure that it does not become cause for delay; improve productivity of employees, and on the other hand they have to improve profitability. The answer comes as this: it makes business sense to buy products that are assured of quality, gets supplied in time and helps improve productivity. In construction activities many products like sand, aggregates, timber etc. are from un-organised sector and suffer from irregularities in quantity,
Usage
Height of wall Subsequent work Ease Quality Supplies
Conventional mortar
Can be used for up to 3 ft wall in a day Needs a weeks curing before starting next work Manually work force has to mix materials to create it. Inconsistent
Jointing mortar
Can be used up to 6ft wall in a day Can be done next day Ready to use Consistent
Depends on supply of different materials by Consistent different suppliers
Table 5: Favorable aspects of Jointing mortar
Project Management
Usage
Reduction in load
Conventional Bricks
2000 Kg/m^3
Fly ash based Blocks

600 Kg/m^3
Benefits
Weight on account of wall will get reduced by 2/3rds. If this weight factor is considered at design stage it can help in reduction of dimensions in structures which gives cost savings and additional space. Increased productivity plus time and labour cost savings. Enables completion of work as scheduled or even faster. Ease of work, improved job satisfaction, improved productivity. Improves productivity. Improved shapes in structures gives workers improved confidence in their work. Help project go as per schedule. Improved usage in for construction of theatres and such other constructions needing external noise filtering. Better safety. Helps to plan the budget for the materials better.
Work time reduction
Physical mobility of 6 bricks for every block is a time consuming exercise Physically tiring Inconsistent in shape, quality and dimensions Depends on supply of different materials by different suppliers Less blockage of external noise
One block is equal to 6-7 conventional bricks Easy to use Consistent in all the aspects of shape, quality and dimensions Consistent Better blockage of external noise
Job satisfaction Quality
Supplies Sound filtering
Fire resistance Pricing
Gives far little time to escape in case of fire accidents Pricing is inconsistent throughout the year; sometimes due to climatic reasons
Has 2-4 hours fire resistance giving better chance for people to escape Pricing is more consistent
Table 6: Fly ash based concrete blocks utility
Usage
Proportion consistency Work time reduction Job satisfaction Thickness Wastage Rebound wastage
Conventional Plaster
Inconsistent, based on the mix done by different persons at work Constitutes time of mixing the materials Less satisfying Physically mixed and becomes ticker on the wall Manual work involves wastage Splashed on the walls and regularly gets rebound resulting in loss
Ready to use Plaster

Accurate and consistent Ready to use Easy to use Reduced thickness Sometimes nil wastage due to consistent mix Sticks to the wall and easy to use
Benefits
Improves work quality and productivity. Saves time and avoid work delay. Ease of work, improved job satisfaction, improved productivity. Helps get more appealing finish. Saves cost. Cost reduction, improved productivity, and better job satisfaction.
Table 7: Ready to use plaster utility
antly, almost paralyzing the construction activity and bring it to a halt. For example, it is common knowledge how difficult it is to get sand and bricks in rainy season. It will take a beating in quality, quantity, price and timely supplies during monsoon. It is reported that the Indian government has made a trillion dollar (@`48/$) commitment for infrastructure in its twelfth five year plan (2012-17). This plan envisages as many as 666 Public-Private Partnership (PPP) projects, which will naturally put pressure on work efficiency and time. The time is ripe to place premium on efficiency at site, improving productivity, reduce delay and thereby control costs, earn better and take up more projects in the long run.
Bibliography
- - - - - - Business Monitor International, (2012). India Infrastructure reportQ3 2012, March 30, 2012, p.10-11. ISI Emerging Markets, (2012). India Q3 2011- Residential Building Construction. EcoTrends Sector Analysis, p. 12. ISI Emerging Markets, (2012). India Q3 2011, Residential Building Construction. EcoTrends Sector Analysis, p. 32. Manish Valecha, Jaspreet Singh Arora, (2012). Breaking the grid lock- India Construction Sector. Anand Rathi Research, March 9, 2012, p. 5. Manish Valecha, Jaspreet Singh Arora, (2012). Breaking the grid lock- India Construction Sector. Anand Rathi Research, March 9, 2012, p.12. NBM Media Pvt Ltd., (2012). US firms keen on infra spend in India. NBM&CW May 2012, p. 24.
Choksey Chemicals Pvt.Ltd
Construction Chemicals Analysis
CONSTRUCTION CHEMICALS:
STAKEHOLDER COLLABORATION IS THE NEED OF THE HOUR
Bhavani Balakrishna
onstruction in India accounts for nearly 65 per cent of the total investment in infrastructure and is expected to be the biggest beneficiary of the surge in infrastructure investment over the next five years. Investment in construction accounts for nearly 11 per cent of India's Gross Domestic Product (GDP) and the Government has proposed investments to the tune of USD 1 trillion in infrastructure during the XIIth five year plan. Other growth drivers for construction include increasing urbanization and people's rising expectations for improved quality of living.The rise in disposable incomes has also led to a need for retail showrooms and mall spaces across the country. Despite the current slow
growth rate, according to US-based global management consulting firm A T Kearney, India remains a high-potential market with accelerated retail market growth of 15 to 20 per cent expected over the next five years. Such growth spurts in both commercial and residential construction are demanding better turnaround times in construction. There has also been a gradual change in the mind-shift of contractors towards construction due to rising quality standards and increasing awareness about global practices. Contractors are looking for speed of construction without compromising on durability aspects of concrete. More and more construction projects are placing emphasis on sustainability and structural
longevity along with speed and economy. It is only expected that such trends in construction will propel the growth of the construction chemicals industry. Construction chemicals may increase the cost of the project by 2-5% but the benefits are multi-fold. With the longer design life specified on many major projects, the use of construction chemicals is increasingly becoming a necessity. Significance of Construction Chemicals Construction chemicals industry has a variety of products, ranging from admixtures to flooring chemicals, sealants, grouts, and water-treatment chemicals. The strength of concrete has increased dramatically due to development of construction chemicals. Applications of con-
86
It calls for collaborated efforts involving all stakeholders the industry, the end users, the concerned ministry, concerned approved organization in chemicals like FICCI, codal organizers like BIS, university syllabi committees and even Planning Commission to collaborate and recognize the importance of this industry.
41 61
Construction Market Opportunity ($ Bn)

410 349
210 170
Industrial FY06-FY11
Source: Crisil research
Infrastructure FY12-FY16
Total
CCMA: COLLABORATION AT THE RIGHT TIME AND IDEAL CONDITIONS

Samir Surlaker
Managing Director, Mc-Bauchemie (I) Pvt. Ltd.
struction chemicals make concrete structures more durable while lowering maintenance & operating costs and overall lifecycle costs of a concrete structure. The construction industry in India has seen a major change in the recent years with players adapting to modern methods and fast track construction techniques to cope up with the huge demand that the real estate and infrastructure sector has created. Increasing the speed of construction of a concrete structure has benefits for almost
According to industry experts, over 85% of contractors in the country are said to be not fully aware of the uses of construction chemicals. Setting right this general lack of awareness about proper usage of construction chemicals is the main objective of The Construction Chemicals Manufacturers Association (CCMA). The association has been conducting several seminars and training programs for applicators, thereby bringing into sharp focus the key role that the construction chemicals industry can play in the nation building process. As part of its initiatives, CCMA had recently successfully hosted India's largest International Conference on Construction Chemicals (C3) on 17th and 18th of February, 2012, at Hotel Ramada, Powai, Mumbai. The central theme of the conference was, 'Emerging Material, Methods & Practices', in the field of construction chemicals. Speakers at the conference included, the virtual 'whos who' from the world of construction chemicals, drawn from academicians, scientists, and industry professionals, from around the world. The conduct of C3 could not have been timed better. The country is entering its crucial second phase of infrastructure development and the eyes of almost every other industry is towards the construction industry, as it is the one that plays a key role in the process. The larger scale of projects, which has pushed up demand for high-strength and quick setting concrete, plus the greater emphasis on quality, has automatically made a positive impact on the construction chemicals market. C3: An Unprecedented Success The conference perhaps marked the first time that such a conglomeration of leading players in the field of construction chemicals shared a common platform towards achieving a common goal, in the country. It also offered delegates a chance to get detailed insights into various aspects of construction chemicals from renowned experts, keeping in tune with one of the key objectives of CCMA, i.e., dissemination of knowledge in the field. The formation of CCMA has meant that construction chemicals manufacturers can now be assured of the fact that their requirements would be put across to various different authorities for the further growth of the industry, a factor that was earlier considered one of the growth inhibitors. In fact, as part of the conference, it was resolved that the views of the members would be put forth before the central and state governments. CCMA is already working in close tandem with other leading industry bodies with respect to liasoning with various government authorities for the betterment of the construction
Standardization and ushering in newer codes are key aspects that need to be promoted. It will also be a decisive moment in the industry if key decision maker's vis--vis planners, designers, architects and consultants specify the use of construction chemicals in projects they are associated with.
Dr. Y P Kapoor
Managing Director and Consultant, Bang Associates, Bangalore
87
Manufacturers of construction chemicals have the responsibility of increasing awareness levels in all segments of the market about the benefits of using construction chemicals from an overall life cycle perspective. This is a challenge the industry has to face boldly in its own interest.
Subu Venkatraman
MD, Sika India
every stakeholder in the value chain. Multiple admixture technologies exist or are being further developed to help support faster construction. One is Self-Consolidating / Compacting concrete (SCC) - a high-performance concrete that can flow easily into tight and constricted spaces without segregating and without requiring vibration. When large quantity of heavy reinforcement is to be placed in a reinforced concrete (RC) member, it is difficult to ensure that the formwork gets completely filled with concrete - fully compacted without voids or honeycombs. Compaction by manual or by mechanical vibrators also may be difficult. Moreover, compaction by vibra-
tion may generate delays and additional cost. This problem can now be solved through the use of SCC. SCC is placed or poured in the same way as ordinary concrete but without vibration. It is very fluid and can pass around obstructions and fill all the nooks and corners without the risk of either mortar or other ingredients of concrete separating out, at the same time there are no entrapped air or rock pockets. This type of concrete mixture does not require any compaction and it saves on time and labour. The surface finish produced by SCC is exceptionally good and patching will not be necessary. Self-compacting concrete is widely used in other parts of the globe as no vibration is needed and noise pollution is eliminated. The construction process is safer and more productive. Use of latest generation PCE based admixtures and superplasticizers give very low loss of slump over a period of time without delaying the hydration process thus improving the durability of structures. Construction Chemicals in India The present Indian construction chemical industry is estimated at INR 2000 crore of which INR 1200 crore comprise organized sector while INR 800 crore is unorganized. It is estimated that 50% of concrete produced in India these days contains one or more types of admixtures. More than 80% of business is in new built projects.
"Factors like limited awareness, conventional construction practices/ malpractices remain huge bottlenecks for the CC industry"
Dr. S K Manjrekar
Chairman & Managing Director, Sunanda Specialty Coatings Pvt. ltd.
5% 12%
2%
10%
45%
12% 14%
Admixtures Repairs & Grouts Waterproofing Tiling Flooring Sealants Others
Despite growing at a CAGR of 15% and a continuing boom in the construction and infrastructure sector, the Indian construction chemicals market represents only 2% of the global demand for construction chemicals. This is because of the abysmally low awareness and understanding of the significance of construction chemicals among building contractors. It is estimated that a majority of building contractors are ignorant about the need and benefits of these products, or simply do not care to use them as prescribed. Statistics indicate the same. India's penetration levels are 50% lower than China's penetration and 70% lower than the developed world. Treatment ratio to construction is 0.5% in India vis--vis China that has 2-3 times the treatment ratio, while USA has 3-4 times the treatment ratio. The Indian market is price sensitive and decisions are generally taken based on immediate cost and no on overall life-cycle cost. Consequently, life-cycle extending admixtures are perceived as inflating immediate construction cost rather than reducing life-cycle cost. The possibilities and opportunities to address problems of durability through admixtures are not always understood, thus admixtures are not specified to the extent they could. Limited understanding and awareness about the benefits of construction chemicals coupled with lack of standards and regulations are other reasons for the low usage of con-
88
Techny Chemy
Fly-by-night operators who offer cheap products shake up the confidence of customers due to non-performing products, not to mention the consequential damages they suffer.
Gangadharan Manari
MD, Cera-Chem Pvt. Ltd.
struction chemicals. For instance, individual houses, even in the urban parts of the country use hand-made concrete without chemicals whereas handmade concrete are not allowed to be produced in urban areas of other developed countries. Hand-made sitebatched plaster that is predominantly used in India has very low usage of admixtures. Other countries' building codes and regulations emphasize on long-term life-expectancy and sustainability of concrete structures, thus necessitating the usage of construction chemicals. Another challenge facing the market is the presence of several small players in the unorganized sector. Taking advantage of the low levels of awareness among consumers, several low value products are being sold in the market thus maligning the reputation of the entire industry. Again, availability of skilled and experienced applicators is critical to the success of construction chemicals. While most leading market players have a dedicated team of applicators and personnel who educate contractors about the use of right type of construction chemical for a particular application, the practice of employing unskilled workers in construction activity is still hampering the growth of the sector. For instance, admixtures are sometimes considered unreliable due to bad experience, though historically most problems occurred due to appli-
cation errors. However, the Indian construction chemical market is experiencing strong growth with a large number of global players establishing themselves in the Indian market such as BASF, FOSROC and SIKA. Other key players include Pidilite, MC-Bauchemie, Zydex, Perma Construction Aids, Cer-Chem, Chembond Chemicals and SWC. The Chemicals Manufacturer's Association (CCMA) was created as a platform for all the market players to address these issues collaboratively and promote and accelerate the growth of the construction chemicals Industry in India while creating awareness and maintain high standards among users. Clearly product awareness, product innovation and product affordability are vital for the success of these players. Most manufacturers have already invested in several extensive marketing programs, forums, seminars and newsletters to make users aware and educate them about the importance and benefits of construction chemicals. Investing in training of personnel and applicators will also yield benefits as correct application and better results will reinforce the user's beliefs about the significance of construction chemicals. Since India is a price-sensitive market, it will also be vital for the players to focus on product innovation that leads to affordable products with wide applications for different segments. Building regulations can also play a major role in growth of construction chemical industry in India. Incentivizing
Our Building Codes by the BIS are primitive and there are neither codes nor codes of practice for waterproofing, repairs, flooring, structural rehabilitation etc. Our civil engineering curriculum in the engineering colleges is also very old and obsolete.
M.A. Waheed
Perma Construction Aids Pvt. Ltd.
Propagation of the multiple benefits of construction chemicals is the need of the hour
Sanjay Bahadur
Global CEO, Pidilite Industries Ltd.
energy-efficient and green buildings will drive demand for suitable, innovative insulating exterior coatings and efficient facades. Governments and specification bodies should implement stricter specifications e.g. with longevity and/or productivity of construction in mind. Societies, architects, designer, engineers, contractors and concrete producers, thus, the entire value chain can be made aware of the benefits of enhanced durability of buildings through construction chemicals. By emphasizing on long term life-expectancy of concrete, protective coatings that are corrosion resistant will be an accepted feature of all concrete structures. Polluting practices at construction sites such as use of handmade concrete and plaster can be curtailed thus boosting demand ready-mix concrete admixtures and adhesive-based tile laying practices among others. It is a known fact that buildings contribute about 40% to CO2 emissions. Usage of construction chemicals can effectively help in minimizing the cement consumption for same performance, thereby reducing carbon dioxide emission. External insulation and finishing systems make facades energy-efficient and more aesthetic, water proof and low on maintenance. Low VOC content products such as adhesives, sealants, paints, coatings, carpets will also have a role to play in enabling green buildings.
90
Mangalore Chemicals & Fertilizers Ltd
Concrete Self Compacting
Self Compacting Concrete An Economical Approach

Dr. Y P Kapoor
Managing Director, Bang Associates & Director Editorial, The Masterbuilder
Self Compacting Concrete (SCC) has been promoted in the Middle East for the last eighteen years. Although targeted at the high quality end of the marketplace there has been little commercial success, despite the many advantages and savings in use of SCC. The majority of its applications have been small niche pours into congested rebar, domes, or thin wall sections. Self Compacting Concrete by its definition has to be fluid, self-compactible with high segregation resistance. To achieve these properties and to reach extremely high specification targets it is normal to use a high dose of new generation poly-carboxylate admixture plus a rheology modifier into the concrete mix. The use of these admixtures and change in mix design increase the cost significantly above that of conventional high quality concrete and this is seen as the major factor that has prevented wider use of SCC. This paper therefore studies the production of SCC with a specification for exceeding that of conventional concrete, currently in use in the Middle East, and gives a concrete mix with all the application advantages of SCC, without an excessive cost increase.
igh durability concrete will be discussed throughout this paper. It will be classed as that which has to be manually placed and include durability enhancers; GGBFS, Micro silica and PFA in the mix designs. The high durability conventional concrete in question will have a total cementitious content of between 450 to 500kg per meter cube, and coarse to fine aggregate ratio will be as 60:40 percent, and concrete will be produced at water cement ratio of 0.40 (maximum). High durable conventional concrete has to be well vibrated to achieve good compaction. It should be noted that with conventional concrete, water would tend to migrate to the surface of the coarser particles when vibrated causing porous and weak inter facial zones, which will affect the concrete durability. Therefore there will always be a difference in durability parameters of conventional concrete in a laboratory with tightly controlled conditions, compared to site batch concrete. Awareness of self-compacting concrete has spread across the world and specifically in the Middle East and India, prompted by concerns with poor compaction and concrete durability. In the U.A.E., and specifically in Dubai, there are a significant number of high-rise structures under construction and many more expected. Normal concrete technology has been
extended through SCC for easier placement of concrete, associated with other benefits. Specific instructions are necessary for designing, producing, transporting and handling of such concrete. Its innovative aspects lie in its fresh properties and the potential benefits to the contractors. The UAE, Middle East and Far East markets including India are currently experiencing a change in concrete durability specifications, such that on-site only SCC mixes can meet the requirements with continued repeatability. What is Self Compacting Concrete SCC is a concrete, which in its plastic state, flows silently under its own weight and maintains homogeneity while completely filling the formwork of any shape, even around congested reinforcement. Compaction of concrete is achieved by its own movement properties. Khayat et al defines SCC as A highly flowable, yet stable concrete is one that can spread readily into place and fill the formwork without any consolidation and undergoing any significant segregation. Materials & Mix Designs SCC can be made out of similar materials as used for conventional concrete for structural use. Maximum size of
the coarse aggregate will be dependent on the minimum spacing allowed for reinforcement layouts. Even a 40mm size of aggregate may be used. Graded aggregates will be of a great help. Fine sand content less than 150 microns will be very useful for better cohesion and reduced segregation. Mix Design, Admixture and Cement The objective of traditional concrete mix design is always to work out the most effective proportioning of materials to achieve the concrete properties in plastic and hardened state. But before looking at designing a mix for SCC, an understanding is needed of the properties required for selfcompaction and how it will be optimized using normally available materials. There are two main properties, which should be looked into, that is, as a highly fluid concrete, with segregation resistance. To achieve highly fluid concrete, a low yield stress is required and for high segregation resistance, a highly viscous concrete is needed. Fluidity and concrete viscosity may be varied by reproportioning the aggregates or by using high-grade super -plasticisers in concrete mixes. Viscosity modifiers can also be used for segregation resistance, but it will increase the yield stress of the paste, thereby affecting the mobility of the mix. Advances in superplasticiser technology have played a major role, and new generation superplasticisers based on polycarboxylate ethers promote good workability retention, and can be added at any stage of the batching cycle. Fine particles play an integral part in SCC mix designs, as SCC mixes are made with high fines. On an average the SCC mix will have 400kg to 600kg of cement. This cement weight of 500kg/m of concrete can be replaced partly by pulverized fuel ash, ground granulated blast furnace slag and silica fumes. These cement replacements will enhance the concrete properties of the mix in the plastic state and hardened state of the concrete. These cement replacements will further add durability properties to the concrete. Even limestone powder is used extensively in Europe. All fillers must be assessed for their effect on water demand, to achieve the optimum level of water for the mix. Typical guideline criteria are given in Table 1. These guidelines may be amended as per the countrys requirement of concrete specifications and locally available materials. Water demand is very critical to SCC mix design and specifically related to segregation. It is advisable to design
Materials
Coarse aggregate
Properties
Well graded to reduce inter particle friction and prevent blocking Very well graded sand available at local source. Should contain fine materials passing through 150micron sieve High content required Dependent on fillers and fines
Practical Guidelines
In practice it may vary between 700-900kg/ m Should be >50% of the total aggregate content
Sand
Cement + Fillers Water
Typically 500kg/m Typically between 130litres to 150 litres (free water) 0.28 to 0.34 for tropical Middle East conditions
Water/(Cement+Filler) ratio Admixtures Dosage to be tailored to meet the durability properties of Plastic and hardened state of concrete
May vary between 3.0 to 6.0 ltrs per m. Follow manufacturers advice Paste >40% by mix vol. Sand <50% by mortar vol.
Paste & Mortar
Table 1
the mix conservatively to maintain the plastic state concrete properties. Water demand and admixture dosage should be economically adjusted to retain the fluidity of concrete towards 90/120 minutes after batching. A slump cone flow spread of 650 mm at the time of placing the concrete will be quite acceptable to meet almost all properties in plastic and hardened state of concrete. Hardened state properties of SCC Compressive Strength At constant water cement ratios, the characteristic strength of SCC will be slightly above or at least equal to the
GGBS mix design
Compressive Strength N/mm
80 60 40 20 0
High Durability Concrete SCC 3d 7d Days 28d
Fig 1
conventional concrete of similar grade. (see Fig. 1&2) Above results indicate that the characteristic compressive strength of 60N/mm can be easily achieved. In addition to the above information, lower water to cementitious ratio with fines will help to achieve the rheological properties of concrete will make difficult to keep the strengths down.
PFA Mix Design
Compressive Strength (N/mm)
80 60 40 20 0
Care should be taken to ensure the concrete is cured correctly. Bond Strength Bond Strength behavior of conventional concrete is dependent on the reinforcing bar location, deformation of bar pattern, fluidity of concrete mix and in general contact with rebar. Interlocking of aggregates in SCC is far superior in comparison to conventional concrete, which is due to the uniform distribution of aggregates over the full cross section and the higher volume of cement binder matrix. Therefore the bond strength between concrete and reinforcement for medium to high strength concrete in SCC is higher than that of conventional concrete.
Properties
Drying Shrinkage %
Table 2
Conventional Concrete SCC 3d 7d Days 28d
Conventional Concrete
0.0208
Self Compacting Concrete

0.0224
Fig 2
The author of this paper was involved in re-proportioning the mix while using the similar quantity of fines, as mentioned in Fig.2, and could enable to reduce the admixture dosage within limits. The details of the compressive strengths achieved are shown in Fig 3.
Mix with Fly Ash
100 80 60 40 20 0
Durability Few indices of durability have been investigated in selfcompacting concrete when compared to the same grade of conventional concrete. The results are listed in table 3, which are recorded at 28 days age.
Properties Conventional Self Compacting Concrete of high Concrete durability
2% 10mm 1970 1.0% 5mm 620
Compressive Strength (N/mm)
Conventional Concrete SCC
Water absorption BS 1881:Pt 122 Water Permeability DIN 1048 Rapid Chloride Permeability (coulombs) AASHTO T277 Initial Surface Absorption Test (ml/m/sec) BS1881:Pt 208
Table 3
3d
7d Days
28d
Fig 3
0.02
0.01
Drying Shrinkage Drying Shrinkage of SCC has been noticed to be similar to that of conventional concrete or lower, which is contrary to that expected from the lower aggregate content, which is partially expressed by the similar water content of SCC and high durability conventional concrete. The high fine content in the SCC mix may indicate slightly higher figure on drying shrinkage as compared to conventional concrete. In the UAE and in Middle East most SCC mixes are designed on very low water cementitious ratio that enables the mix to achieve lower drying shrinkage as shown in Table 2. Attention to curing is very important for the tropical conditions prevailing in the Middle East, and India to ensure that the low drying shrinkage figures obtained in the laboratory are transformed to site.(Table 2)
This indicates that durability parameters in self-compacting concrete are enhanced as compared to standard conventional concrete. Summary and Economics Self Compacting Concrete will be seen by the contractor as a material which will be useful, but demands different working practices and as such it has more advantages than disadvantages. These should be balanced against each other and economics can be worked, while listing and evaluating each parameter. In most of the cases and situations, the resultant effect will be in the favor of Self
Neocrete Technologies Pvt. Ltd
Compacting Concrete as an improvement in ease and spread of placement, quality of finish and reduced overall cost in addition to the usual technical benefits of complete and assured compaction and minimizing the voids. A summary of advantages can be listed as below - Very less dependence on skilled work force. - Faster placing time enhances total production period to be reduced. - Improved surface finish means cost of making good. - Noise elimination leads to safe working environment. - Some approximation of the offset costs can be calculated. Estimates of these show the following in UAE Dirhams per cubic metre. In summary, it is clear that self-compacting concrete offers some significant advantages over conventional concrete. Some of the economic applications may be listed, like,
Properties
Man Power Vibration Finishing Curing Repairs Formwork Plaster Overheads Total
precast elements, exposed walls and columns, water tight basements, congested reinforcement locations and column encasements. References
- - - Okamura H. Self-Compacting High Performance Concrete Concrete International, Vol. 19, No. 7, July 1997. Khayat K. Workability, Testing and Performance of SelfConsolidating Concrete. ACI materials journal, vol 96, No. 3 Glavind M. How does Self Compacting Concrete contribute to implementation of sustainable/clean technologies in the construction industry. Proceedings of self-compacting concrete, Malmo, November 2000. SKARENDHAL A. State of the art of Self Compacting Concrete. Proceedings of seminar of self-compacting concrete Malmo, November 2000. R. Gaimster and N. Dixon Self-Compacting Concrete RMC Readymix U.K. Ltd. OKAMURA, OUCHI M. Self Compacting Concrete Development, present uses and future. Proceedings of first Rilem International Sys perillum of Self Compacting Concrete, Stockholm September 1999. Building Research Establishment Practical guide for engineers using SCC. BARTOS, P . and GRAVER M. Self-Compacting Concrete, Concrete Vol. 33 No. 4, April 1999.
- -
Conventional Concrete 2.00 2.00 2.00 2.00 18.00 15.00 5.00 5.00 51.00
SCC 1.00 00 00 2.00 00 20.00 00 3.00 27.00
Saving 1.00 2.00 2.00 0.00 18.00 -5.00 5.00 2.00 25.00
- -
Authors Bio
Dr. Kapoor has spent approximately 30 years in the field of Concrete Technology, while working in Middle East and Far East and advising customers, ready mix concrete manufacturers ,suitable mix designs and appropriate use of concrete admixtures to achieve the highest degree of concrete durability for enhanced structural life.
(Above are shown as Typical Values, which may vary from Country to country.)
Nina Concrete Systems Pvt.Ltd
Communication Feature
Nano Waterproofing for Increased Life-cycle in Structures

ost building materials are by and large based on cement; these include Reinforced Concrete, Mortar, Cement Plaster, Cement Building Blocks, Cement Roofing Sheets, Cement Pipes, etc. Durability of these materials depends on weathering and environmental factors. The durability of concrete structures depends on extent of destructive reactions that occur during the life cycle of the structure. All these reactions require water as reactant or as reaction medium. If intrusion of water is reduced then these reactions can be minimized and durability of the structure can be increased. Therefore it is important to protect cementitious material from water. Selection of the technology that provides long term protection is essential. Film former or barrier technology (coating) has been used very widely. However due to weathering and UV exposure the coating has limited life (35years) and periodic reparative applications are required. The technology that provides long lasting protection from water and salt is water soluble organo silane chemistry. Organo silane compounds are only
Application of Zycosil+ on new terrace waterproofing
reactive and penetrative material that provides longevity to the structure. The Silane molecule reacts with surface OH groups and alters surface property from hydrophilic (water loving) to hydrophobic (water repellent). Water related problems Most of the building materials are very porous and have surface hydroxyl groups. These hydroxyl groups attract water because of the hydrophilic nature and similarity with the structure of water. Therefore, most of the building material easily wet and absorb water in the pores which damage the building aesthetic and reduce building structure life.
Aesthetic - Paint peel-off - Paint blisters - Fungus - Mold, Mildew - Efflorescence Structural - ASR (Alkaline silica reaction) - Freezing and thawing - Carbonation - Acid rain, sulphur attack - Corrosion in reinforce steel bar Zycosil + Nanotechnology Zycosil+ is an organosilicon product, which forms a particle size of 4-6 mm in water and penetrates deep into the
Surface preparation : remove laitance & cement, dust removal and water jet cleaning
98
Cipy Polyurethanes Pvt. Ltd
Surface wetting check, Making cement mortar bunds of 10 sqmtr and Ponding Zycosil+ solution
Waterproofing test
Sratch test to check depth of penetration
building material pores up to 1 mm. The product becomes part of the building material and makes it waterproofed. The product attributes - Oragano Silane, eco-friendly, water soluble waterproofing agent - Useful for new and existing concrete masonry structures - Thermal and UV stability - Reactive technology and convert water loving silanol groups of mineral
based building material to water repellent siloxane bonds - Easy to apply by brush, spray or roller techniques makes it user friendly - Protects against mildew, fungus, efflorescence, leaching, staining, premature ageing, scaling, spalling, corrosion of reinforced steel and salt burst Zyc3osil+ nanotechnology offers complete waterproofing solution for basement, elevator pit, underground sump, water tank, swimming pool, sewage treatment plant, sunken, utility area, stone, walls, podium, roof top etc. Quality Control Tests Rilem Test Affix Rilem tube on substrate's surface & fill water column up to 5ml. Water absorption of less than 0.2 ml in 20 minutes confirms acceptable waterproofing.
The water column pressure in RILEM test is equivalent to the pressure generated by, 140 Km/hr wind driven rain.
For further details:

25-A, Gandhi Oil Mill Compound, Gorwa, Vadodara - 390016, Gujarat, Ph:+91-265-2280865, Fax:+91-265-2280872 E-mail: info@zydexindustries.com Web: www.zydexindustries.com
Zydex Industries
100
Tekla India Pvt.Ltd
Admixture Metakaolin
Metakaolin for High-Performance Concrete

Special Correspondent
ement concrete is the most extensively used construction material. Maintenance and repair of concrete structures is a growing problem involving significant expenditure. As a result carried out worldwide, it has been made possible to process the material to satisfy more stringent performance requirements, especially long term durability. High performance is generally assumed to be synonymous with high strength, although this is not true in every case. Unacceptable rates of deterioration due to environmental effects indicate that only compliance with strength requirements, although need, is not adequate to ensure long-term, durability, which is the primary requirement for high performance. It is generally accepted, that the high
performance of the very concrete contributes to low permeability, stronger and denser transition zone between aggregate and cement paste in the concrete. This also adds to the abrasion resistance of concrete. According to ACI High Performance Concrete is defined as concrete which meets special performance and uniformity requirements that cannot always be achieved routinely by using conventional materials and normal mixing, placing and curing practices. High Performance Concrete (HPC) Concrete is probably the most extensively used construction material in the world. However, when the high range water
reducer or super plasticizer was invented and began to be used to decrease the water/cement (w/c) or water/binder (w/b) ratios rather than being exclusively used as fluid modifiers for normal-strength concretes, it was found that in addition to improvement in strength, concretes with very low w/c or w/b ratios also demonstrated other improved characteristics, such as higher fluidity, higher elastic modulus, higher flexural strength, lower permeability, improved abrasion resistance, and better durability. This fact led to the development of HPC. HPC is the latest development in concrete. It has become more popular these days and is being used in many prestigious projects such as Nuclear power projects, flyovers, multistoried buildings etc. Since 1990s, HPC has become very popular in construction works. At present, the use of HPC has spread throughout the world. In 1993, the American Concrete Institute (ACI) published a broad definition for HPC and is defined as the concrete which meets special performance and uniformity requirements that cannot always be achieved by using only the conventional materials and mixing, placing and curing practices. The addition of mineral admixture in cement has dramatically increased along with the development of concrete industry, due to the consideration of cost saving, energy saving, environmental protection and conservation of resources. However, environmental concerns both in terms of damage caused by the extraction of raw material and carbon dioxide emission during cement manufacture have brought pressures to reduce cement consumption by the use of supplementary materials. Mineral admixtures such as fly ash, rice husk ash, metakaolin, silica fume etc are more commonly used in the development of HPC mixes. They help in obtaining both higher performance and economy. These materials increase the long term performance of the HPC through reduced permeability resulting in improved durability. Addition of such materials has indicated the improvements in the strength and durability properties of HPC.
Jayant Basu Ray
MD, Constromat Consultancy & Services India PVT LTD
As far as India is concerned metakaolin actually came into the market as a cheaper material than micro silica. It was only after reputed companies started using metakaolin that the product began to generate a buzz in the market.
About Metakaoline & Its Role in Concrete and High Performance Concrete Metakaolin differs from other supplementary cementitious materials (SCMs), like fly ash, silica fume, and slag, in that it is not a by-product of an industrial process; it is manufactured for a specific purpose under carefully controlled conditions. Metakaolin is produced by heating kaolin, one of the most abundant natural clay minerals, to temperatures of 650-900C. This heat treatment, or calcination, serves to break down the structure of kaolin. Bound hydroxyl ions are removed and resulting disorder among alumina and silica layers yields a highly reactive, amorphous material with pozzolanic and latent hydraulic reactivity, suitable for use in cementing applications. Metakaolin reacts with portlandite (CH) to form calcium-silicate-hydrate (C-SH) supplementary to that produced by portland cement hydration. This reaction becomes important within the interfacial transition zone (ITZ) located between aggregate and paste fractions. This region typically contains a high concentration of large, aligned CH crystals, which can lead to localized areas of increased porosity and lower strength. Metakaolin can react with some of the CH produced by cement hydration, there by densifying the structure of the hydrated cement paste. The rates of pozzolanic reaction and CH consumption in metakaolin systems have been shown to be higher than in silica fume systems, indicating a higher initial reactivity.6 Because this reaction with CH occurs early and rapidly, metakaolin incorporation may contribute to reduced initial and final set times. In addition, this refinement in the ITZ can result in increased strength in metakaolin concrete. As portlandite in the ITZ and elsewhere in the paste is water soluble and is susceptible to deterioration in aggressive chemical environments, metakaolin has great potential for improving concrete durability. Also, because
(a) (b) Figure 1: (a) Metakaolin, (b) Self-consolidating concrete using metakaolin
the supplementary C-S-H formed during the pozzolanic reaction with metakaolin has a lower Ca/Si ratio than ordinary C-S-H, these products are believed to be better able to bind alkali ions from the pore solution, thus reducing concretes susceptibility to alkali-silica reaction (ASR). This potential beneficial use of metakaolin is particularly relevant, as silica fume agglomerates have been shown to contribute to ASR expansion in some cases. Metakaolin has also been shown to decrease concrete permeability, which in turn increases its resistance to sulfate attack and chloride ion ingress. Additionally, metakaolin may reduce autogenous and drying shrinkage, which could otherwise lead to cracking. Thus, when used as a partial replacement for Portland cement, metakaolin may improve both the mechanical properties and the durability of concrete. In general, metakaolin offers a set of benefits similar to those imparted by silica fume, including comparable strengths, permeability, chemical resistance, and drying shrinkage resistance. Physically, metakaolin particles measure approximately one-half to five micro meters across, making them an order of magnitude smaller than cement grains and an order of magnitude larger than silica fume particles. Both metakaolin and silica fume are typically used to replace 5 to 20 weight % of the cement. Metakaolin is white in color, whereas standard silica fume ranges from dark grey to black (although white silica fume is available at higher cost). This makes metakaolin particularly attractive in color matching and other architectural applications. For these reasons, metakaolin is increasingly used in the production of high-performance concrete. ASTM C618 and AASHTO M 295 classify metakaolin as a Class N (or natural) pozzolan. Figure 1 (a) and (b) shows metakaoline and self-consolidating concrete using metakaolin. Metakaolins Contribution in HPC - Improved Strength Metakaolins reaction rate is rapid, significantly increasing compressive strength, even at early ages, which can allow for earlier release of formwork. As stated by Mr. Atil Parikh, Joint Managing Director of 20Microns Globally metakaolin
is a very well accepted product. In India too the demand is fast picking up. Initially we had to educate people. We first targeted Mumbai the high rise capital of India. This is because metakaolin finds use in the M60 or M 80 grade concrete that is typically used in high-rise construction projects
(a) Control (b) With Meta Star 501 Figure 2: (a) Control Mix floor, (b) Metakaolin mix floor
- Improved Durability In addition to increasing strength, the densification of the microstructure that results from the pozzolanic and hydraulic reactions of metakaolin also leads to greater impermeability. In concretes containing metakaolin at 8 to 12% of the total cementitious materials, 50-60% decreases in chloride diffusion coefficient suggest that significant improvements in service life can be achieved through metakaolin utilization in chloride environments. In addition, metakaolin has been shown to be highly effective in mitigating expansion due to alkali-silica reaction (ASR) and sulfate attack. - Improved Early Age Behavior The relative fineness of metakaolin can result in decreased slump, but the use of water reducing admixtures or use in combination with fly ash in ternary mixes can compensate for this. Slumps of 125 to 180 mm have been achieved with metakaolin at water cementitious materials ratio (w/ cm) of 0.36 to 0.38, using 25-35% less high-range water reducing admixture than comparable mixes. Metakaolin concrete tends to exhibit a creamy texture, resulting in better finishability compared to other finely divided SCMs. This quality also improves pumpability and can be used to impart detailed surface textures to cast surfaces. In addition, the cohesiveness provided by the metakaolin allows for relatively simple formulation of self-consolidating concrete, when using an appropriate dosage of polycarboxylate water reducer as shown in the photograph at the beginning of this article. Data on the potential contributions of metakaolin to chemical, autogenous, and drying shrinkage are inconsistent, with authors reporting both decreases and increases in each form at various ages and at various addition rates. For applications with restrictions on shrinkage, additional testing, including the assessment of shrinkage-reducing admixtures and fiber reinforcement, may be advised.
Atil Parikh
Joint Managing Director of 20Microns
Globally metakaolin is a very well accepted product. In India too the demand is fast picking up. Initially we had to educate people. We first targeted Mumbai the high rise capital of India. This is because metakaolin finds use in the M60 or M80 grade concrete that is typically used in high-rise construction projects
20 Microns Limited
- Contributions to Sustainability Because of the lower processing temperature compared to cement clinker, use of metakaolin can contribute to sustainability through energy savings, as well as reductions in greenhouse gas emissions. After examining various SCMs alone and in combination and considering performance, economic, and environmental criteria, metakaolin concrete was identified as a very promising solution for the precast industry for reducing clinker content in concrete. Available Brands and Applications 1. MetaStar 501: METASTAR 501 is a metakaolin pozzolanic additive that: - Improves strength, durability, and workability of Portland cement concrete - Makes Portland cement easier to apply - Provides smoother finish - Has bright white color for white and color plasters - Reduces permeability, efflorescence, and cracking - Reduces the porosity of hardened concrete - Contains no undesirable impurities, such as carbon or sulphur, which could affect the curing rate or strength of the final PC product - Readily disperses in cement-based systems - Is safe and easy to handle Refer Figure 2 (a) and (b) for judging the difference of control and Metakaolin mix. 2. In India 20Microns is considered one of the leading producers of white minerals. The company offers a wide range of products including functional fillers, extenders, and specialty chemicals. The companys mines are spread across the country. The company offers a diverse range of customized products based on specific industry requirements. 20microns has its calcined clay mines located in Gujarat, Bhuj. For the production of calcined kaolin the material has to be put through heating up to a certain temperature around 1200oC. Metakaolin is an intermediary product which is produced at about 700-750oC during the process. Figure 2: (a) Control Mix floor, (b) Metakaolin mix floor 3. PALAIS ROYALE, Mumbai: First project in India to use M80 grade of self consolidating concrete. The Project is around 300 metres high comprising of Duplexes and Villas in it. The developers have used metakaolin as one of the supplementary cementitious material. Conclusion The beneficial effects of using metakaolin is it reacts with calcium hydroxide almost as fast as it is formed in the cement during hydration. The overall effect of removing calcium hydroxide, refining the pore structure and densifying the interfacial zone is to reduce: - - - - - Re-bar corrosion Sulphate attack Acid attack (e.g. silage clamps, food factories) Freeze-thaw damage Alkali-silica reaction (even when using active aggregates,
CNS Infrastructure Ltd
high alkali cementsand where the concrete is exposed to salt solutions) - Efflorescence Till three-four years ago, hardly anybody in India was aware of the use of metakaolin in concrete. During these four years, the developments that have taken place include increased awareness of the huge potential of production of metakaolin in the country (with huge mineral resource, that is, kaolin availability across the country), start of indigenous commercial production and many investigations on the development of concrete mixes containing metakaolin. The metakaolin is a low cost, locally produced, highly effective pozzolonic material, particularly for the early strength development, without appreciable loss in workability. It makes finish easier, reduces efflorescence, increase resistance to sulphate and chlorine attack. It maintains colour of concrete, especially in white concrete. So it can be very well used in Architectural work. As silica fume is to be imported, it is dare necessity to find locally available material at an affordable price, substitute of it, Metakaolin could be an answer to it seeing its vast exploring opportunity in India. It can bring a huge export possibilities to India; as quoted by Mr. Atil Parikh, The US is a high consumption market. It was during the last decade or so that people started to switch from micro silica to metakaolin there in a big way. Canada is another major market. Reference
- Justice, J. M. and Kurtis, K. E., Influence of Metakaolin Surface Area on Properties of Cement-based Materials, ASCE Journal
- -
- -
of Materials in Civil Engineering, September 2007, Vol.19, No. 9, pp. 762-771. Tafraoui, A. et al., Metakaolin in the Formulation of UHPC, Construction and Building Materials, Vol. 23, 2009, pp.669-674. Justice, J. M. et al., Comparison of Two Metakaolins and Silica Fume Used as Supplementary Cementitious Materials, Seventh International Symposium on Utilization of HighStrength / High Performance Concrete, Ed. Russell, H. G., Publication SP-228, Vol. 1, American Concrete Institute, Farmington Hills, MI, 2005, pp.213-236. Also on Compact Disc. Gruber, K. A. et al., Increasing Concrete Durability with HighReactivity Metakaolin, Cement and Concrete Composites, Vol. 23, 2001, pp. 479-484. Khatib, J. M. and Wild, S., Sulphate Resistance of Metakaolin Mortar, Cement and Concrete Research, Vol. 28, No. 1, 1998, pp. 83-92. Ramlochan, T., Thomas, M., and Gruber, K. A., The Effect of Metakaolin on Alkali-Silica Reaction in Concrete, Cement and Concrete Research, Vol. 30, 2000, pp. 339-344. Garas, V. Y. and Kurtis, K. E., Assessment of Methods for Optimising Ternary Blended Concrete Containing Metakaolin, Magazine of Concrete Research, September 2008, Vol. 60,No. 7, pp. 499-510. Caldarone, M. A., Gruber, K. A., and Burg, R. G., HighReactivity Metakaolin: A New Generation Mineral Admixture, Concrete International, Vol. 16, No. 11, November 1994, pp.37-40. Cassagnabere, F. et al., Metakaolin, A Solution for the Precast Industry to Limit the ClinkerContent in Concrete: Mechanical Aspects, Construction and Building Materials, Vol. 24, 2010, pp. 1109-1118. www.imerys-perfmins.com www.alcongoa.com/pdf/Alccofine_Tech_Info.pdf
STA Concrete Flooring Solutions
Concrete Durability of Structures
Durability of Concrete Bridges and Viaducts
Anil K Kar, B.Sc CE, MSCE, Ph.D

Engineering Services International, Salt Lake City, Kolkata
lot of concrete bridges, railway overbridges, flyovers and viaducts were constructed in recent years and many more are under construction. Such constructions got boosts from the golden quadrilateral highway projects, east-west north-south corridor and dedicated freight corridor railway projects, the metro rail projects in the metro cities and the need for elevated expressways/carriageways within or between metro cities. The nature of materials of construction (Fig.1) of such structures suggests that not much thought has been or is being given to the real possibility that the structures may not be available for their intended use a few decades after their construction. This suggestion is made not only because of what is clearly visible (e.g. extensive corrosion in rebars even before concreting) or known (e.g. very high C3S/C2S ratios and inadmissible content of water soluble alkalis in cement)17 but also because of observations all over the world that concrete structures, built in recent decades, have shown signs of decay and distress fairly early in life. This phenomenon of concrete structures reaching states of distress early in life is in stark contrast to concrete structures, built before the decade of the 1960s, which have proved to be durable, requiring no or little repair even 60 or 70 years after their construction. Among abounding examples of old concrete structures with good performance, one could cite the concrete bridges which were built in the 1940s over the highly polluted canals of Calcutta. None of these heavily travelled and overloaded concrete bridges in relatively corrosive environments has required any repairs till now whereas most of the concrete structures, built in recent decades, to carry todays traffic, have required minor to major repairs (Fig.2). In this context, it may be noted here that whereas the average
life span of modern concrete structures in Canada is thirtyseven years, the average life span of such structures in India is estimated to be twentyseven years. This is in the face of much longer theoretical or design life spans of bridges, tunnels and such other infrastructures.
Fig.1 : Corroded rebars in pier under construction for flyover; products of corrosion streaking down faces of pier
It can no longer be overlooked that though concrete structures, built up to the decade of the 1960s, have generally proved to be durable, the picture has changed over the years since that time. It is not uncommon for todays concrete structures to show signs of distress even during the construction stage (Fig. 3). The writer recalls a particular day some years ago when prestressed concrete girders for railway bridges at half a dozen sites were found to have developed cracks. Though the girders, many of which were yet to be launched, were constructed by different contractors with different brands of cement, the result was the same.
built structures, including concrete bridges and viaducts, are required to be durable. Such structures are required to provide service over long periods of time, that is variably set at 60 to 120 years. This article is on durability aspects of concrete bridges and elevated viaducts. The principal causes for the lack of durability of concrete bridges, viaducts and such other structures of recent vintage are identified and solutions to the problem of early distress are recommended. Much of the contents of this article is applicable for concrete structures of all types. Consequences of Not Doing Things Right In a search for durability, a question could naturally arise. In order that bridges and viaducts may be durable, will it be sufficient to have a proper design for strength, to limit crack widths under service load conditions through conventional methods of design, to specify large cover to rebars and to maintain good workmanship while building bridges, viaducts and other structures ? The answer would be in the negative. It will be seen in this paper that it will not be sufficient merely to have a good design and to maintain good workmanship in the case of bridges, viaducts and other concrete structures if such structures are to be durable. A corollary would be the case of buildings (Fig. 4). On the evidence of durable concrete structures it was earlier considered sufficient to prevent visible water leakages through concrete roofs, water reservoirs, tunnels, etc. In contrast, it is seen in the case of concrete structures, built with todays cement and rebars, that the mere arresting of visible water leakages is not sufficient for making such structures reasonably durable. As in the case of steel structures, all surfaces of todays concrete structures, which may be exposed to the atmosphere, more particularly structures, which might be intermittently exposed to water, need be given surface protection, i.e. made waterproof. If this surface protection will not be provided, situations like those shown in Figs. 5 - 7 are likely to arise. This Fig. 4 : This is why people used proposition is studied in this to waterproof structures; in the case of todays concrete strucarticle. tures, it will no longer be sufThe distressed conditions, depicted in Figs. 5 7, are
ficient to make merely the roof waterproof; there is a greater purpose to waterproofing than to arrest visible water leakages
Fig. 2 : A view of the deck of the Jogeswari flyover in Mumbai seven years after construction
Fig. 3 : Cracks in reinforced concrete shear walls for tall buildings in Calcutta even before a floor was completed (project has top designer, proof design consultant, top contractor and quality monitoring agent) in 2011
Though many may pretend not to see, the signs of decay in newly built bridges, elevated viaducts and other concrete structures of recent periods have become a matter of concern to many others. It has thus become imperative to focus on durability, as
including bridges and viaducts which may be exposed to weather, to the atmosphere. Could the provision of surface protection systems have really helped ? It has been a common experience to see that waterproofed containers of overhead water reservoirs may not show any water leakage or signs of distress but it is a different story with the unprotected staging (Fig. 7).
Fig. 5 : Abandoned hospital building in the new township of Salt Lake City, Kolkata - a stigma on society
Fig. 7 : Distress in staging of overhead water reservoir due to corrosion in rebar
The same decaying process, that must have contributed to the conditions, as shown in Figs. 5-7, continues unabated in the case of unprotected concrete bridges and viaducts. But because of good experiences in the past with concrete bridges and viaducts, engineers, in the absence of visible water leakages of the type shown in Fig. 4, have been slow to realize and recognize the fact that the innate resistance of todays concrete structures to the elements of nature is very different from such inherent properties of concrete structures of earlier periods. The inadequate resistance of recent concrete structures to the causes of corrosion has resulted in the early development of conditions of distress in concrete structures of recent vintage, and this has become the norm today. It is observed in Technical Circular 1/99 of Central Public Works Department, Government of India that : while work as old as 50 years provide adequate service, the recent constructions are showing signs of distress within a couple of years of their completion.8 Though todays concrete structures in India have a pronounced
Fig. 6 : Distress in underside of deck slab of Buckland Bridge (Bankim Setu) over the platforms at Howrah Station near Calcutta prior to major repair and surface protection in the year 2005
due to corrosion in rebars. It is easily perceived that this corrosion was possible because of the availability of moist environments around rebars and the absence (due to carbonation or chloride penetration) of the protective layers of passivation on the surfaces of rebars. Moist environments could have been avoided had the structures been given surface protection in the form of waterproofing treatment. Surface protection systems could have also prevented chloride intrusion and prevented or minimized carbonation and ingress of oxygen to facilitate corrosion. The state of the structures in Figs. 5 7 would suggest that even though there may not be visible water leakages, one need to waterproof all surfaces of concrete structures,
Silicone concepts Intl. Pvt. Ltd.
susceptibility to early decay and distress, this lack of durability in the case of todays concrete structures is a global phenomenon, and the occurrence of early distress started showing up in structures which were built since the 1970s by which time rebars with surface deformations had come into the market and the constituents of cement had undergone some changes. Papadakis, et al wrote in their paper, published in ACI Materials Journal in March-April 1991, The last two decades have seen a disconcerting increase in examples of the unsatisfactory durability of concrete structures, specially reinforced concrete ones.9 In a paper, published in 2007, Swamy too observed that The most direct and unquestionable evidence of the last two/three decades on the service life performance of our constructions and the resulting challenge that confronts us is the alarming and unacceptable rate at which our infrastructure systems all over the world are suffering from deterioration when exposed to real environments.10 Swamy further recorded that What is most surprising is that this massive and horrendous infrastructure crisis has occurred in spite of the tremendous advances that have been made in our understanding of the science engineering and mechanics of materials and structures.10 Matters have come to this pass and engineers are surprised because they failed to see or they refused to hear and admit the truth (Fig. 8). It is known that there can be surprises only in the absence of knowledge. The absence of knowledge was exemplified in the case of aircrafts hitting the World Trade Center Towers (Fig. 9), which were required to be and claimed to have been designed for aircraft impact, and yet the aircrafts, wings and all, pierced through the columns and spandrel plates on the faces of the structures to land inside the buildings and start the big fires which ultimately led to the collapse of the towers. The segmented facial elements of the World Trade Center towers had bolted connections whereas high speed aircraft impact being a postulated loading condition,
all connections should have provided continuity through thru-thickness groove welded joints so that the shock pulses could travel and the impact load get distributed and shared by the structural members over larger areas of the structures. With welded connections, there could have been damages to the facial elements of the towers, but the fuel laden wings could have fallen on the ground below. The towers could have survived. It is thus seen that there may be a gap between what we profess to know and what we really know. In such a scenario, more specifically, in an environment of tall claims of more durable constructions with newer cement and rebars, engineers have not only taken time to recognize the problem of early distress in concrete structures, they have also failed to understand its causes, and in the meantime the problem grew bigger and bigger. And the consequences have been grave It is not only that concrete structures of recent construction develop early signs of distress (Figs. 2, 3 and 5 - 7), todays new constructions, may exhibit signs of distress at the construction stage itself even when such constructions may be carried out with utmost care (Fig. 3). The situation being as it is, it cannot be disputed that structures perform the way they do, structures show signs of distress as early as they do, because these are built to do so. The way, even major structures (Fig. 10) are built, can be seen in Figs. 1 and 11 - 14.
Fig. 8 : Like the proverbial three monkeys, engineers are in the denial mode
Fig. 9 : A plane, wings and all, disappeared into one tower of World Trade Centre; another plane on its way to enter the other WTC tower
Tac System Formwork Sdn Bdh
Fig. 10 : An elevated viaduct under construction Fig.13 : Corroded rebars to be covered in concrete for construction of viaduct
rebars will be coated, and if such coatings will even be fusion bonded following prescribed surface preparation, the result is likely to be any of those shown in Figs. 2, 3, 5 - 7 and 1511. Is it possible that the cases depicted in Figs. 1-3, 5-7 and 15, could have arisen only because of a nonchalant approach to construction, as depicted in Figs. 1 and 1114, or is it possible that inherent shortcomings in materials of construction, viz., cement and rebars of recent periods, could have a role ?
Fig. 11 : Rebars stacked at site for construction of viaduct
It cannot be denied that properties of cement and rebars have changed very considerably over the years. Thus, in the context of durability of concrete structures, one may be on the wrong track if in the face of incontrovertible evidence of early distress in concrete structures of recent vintage one will continue to depend on ones experiences with durable concrete structures of the past and treat todays materials at par with materials of the past and todays concrete structures at par with concrete structures of yesteryears in terms of durability. If one does, the result can be like that depicted in Fig. 2 or like any other in Figs. 3 and 5 -7.
Fig. 12 : Casing with corroded rebars at site to be concreted for viaduct
Causes of Early Distress The first course in reinforced concrete teaches one that rebars should be free from loose mill scale, rust, dust and oil. But the way construction is carried out under expert eyes (Fig. 3) is reflected in Figs. 1 and 11 to 14. And that is part of the reason why structures reach distressed states (Figs. 3 and 5-7) early in life. If in attempts to mitigate the problem of corrosion the
So, if one will agree that something has gone wrong with todays concrete structures, a question would arise : what could have gone wrong with todays concrete construction ? The effect of any possible design flaw or change in aggressiveness of the environment can be discounted in the context of inadequate durability of concrete structures for the reasons that - the examples shown in Figs. 1-3, 5-7 and 10-15 have nothing to do with design flaws
Multichem Group
concrete structures started with constructions in the 1960s, when high strength rebars with surface deformations (HSD) started arriving in the market, engineers have overlooked the possible effects of using such rebars with surface deformations, whether cold twisted (CTD) or thermo mechanically treated (TMT), and the result is evident in (Figs. 5-7). Also, may be if the bars were not as rusted as evident in Fig. 14, may be the cracks in shear walls (Fig. 3) due to excessive shrinkage in concrete with high alkali cement could have been arrested. The changes in cement and rebars are results of various permissive provisions in the IS 45612 and other codes and guides in India and in other countries. Furthermore, it is or it should have been common knowledge that rebars and cement, supplied and supported with manufacturers certificates of compliance with codal requirements, frequently fail to meet codal requirements (Fig. 16 and Table 1) when these are put to test at independent laboratories. In the particular case of the rebars in Fig. 16, the manufacturer claimed conformance of the billets with requirements of the relevant BIS code at the time of supplying the rebars. When provided with failed pieces of rebars, the supplier (a leading manufacturer of rebars and other steel products) produced for the rebars a certificate of compliance with the relevant BIS code for rebars whereas tests by the author had shown that the bars did not meet the requirements of the specific code. Representatives of the steel maker visited the construction site and when bars of their choice were tested in their presence, they had no option but to agree that the bars of all the different sizes (8 mm to 32 mm dia) were unfit for construction. A casual approach with cement Except for the period of curing, the concrete code IS 456:200012 permits, without any differentiation, the use of ordinary Portland cement (OPC), Portland slag cement (PSC) and fly ash or Portland pozzolana cement (PPC), as if cement, capable of hydration, were inert; as if all types of cement were equal; as if any cement is quality cement. It is known to all that tests for conformance of cement with the requirements, set in the relevant codes, are performed after cement will have been used in construction and that cement manufacturers routinely come up with test certificates declaring all cements to have met all requirements of codes. This is in the face of knowledge that cement, when tested at independent laboratories, is occasionally found to be deficient.
Fig. 14 :Rusted rebar in the construction of the structure in Fig. 3 where an outside agency monitors quality and the contractor is a top name in India - a stain on profession
- old and new constructions in the same city or even on the same plot of land present strikingly different scenarios in terms of time dependent performance; older constructions performing better. Engineers have overlooked the devastating effects of using modern cement. One of many such effects can be seen in Fig. 3. It is worth recognizing here that, unlike in the case of rebars, which underwent very significant changes in their properties virtually overnight, the constitution of cement has undergone significant changes gradually over the years. Similarly, even though a close look at the observations of CPWD8, Papadakis et at9 and Swamy10 would have revealed that the problem of early distress in reinforced
Fig.15 : Concrete easily separates from epoxy coated rebars under vibratory loading conditions; all structures are required to resist vibratory loads due to earthquakes
Wirtgen India Pvt.Ltd
Table 1 gives test results on some cements of well known brands in India. OPC in India today may contain highest amounts of harmful water soluble alkalis. In this particular case % Na2Oeq is 2.37 which is much in excess of quantities that could be considered safe, whare % Na2Oeq = % Na2O + 0.658 (% K2O) In comparison, in the year 2000, 140 samples of OPC in the USA yielded on an average: Na2O (%) by mass of cement.... 0.173 K2O(%) by mass of cement ..... 0.571 i.e., % Na2Oeq = 0.55, compared to 2.37 in the above sample of OPC in India.
Fig. 16 :Brittle failures in 8-32 mm dia cold twisted rebars with surface deformations - supplied by a leading manufacturer of rebars and other steel products in India
Note : OPC ordinary portland cement PSC portland slag cement PPC portland pozzolana cement (generally, flyash cement) One consequence of the withdrawal of limits on water soluble alkalis from Indian codes on cement can be seen in Fig. 3. Thus, it cannot be suggested here that the satisfaction of codal requirements on cement in India would have automatically guaranteed concrete structures with long life spans. A casual approach with rebars Since corrosion in rebars is a problem in a majority of cases of reinforced concrete structures of recent vintage (Figs. 5-7), rebars of recent vintage must have a role in the context of durability of such structures. As in the case of cement, IS 456:200012 permits equally the use of all types of bars and other steel elements as if strength alone was all that mattered and as if these materials were inert even when it is evident that corrosion in such elements is the cause of early distress in most or many cases of concrete structures. In essence, the code IS 456:200012 suggests that the susceptibility of the different reinforcing elements to corrosion need not be a consideration. Manufacturers of rebars, engineers and constructors got the cue and no one bats an eyelid when bridges and viaducts may be constructed with corroded rebars (Figs. 1, 11-14 and 17) If all bars were or are indeed equally suitable for use as rebars, a few questions could arise, viz.,
And yet no one has ever heard of any cement manufacturer having ever found anything wrong with cement it had made and sold. No one has ever heard of any cement manufacturer having ever dumped cement it had manufactured. It is easily perceived that cement manufacturers enter into routine contracts with fossil fuel power plant authorities for the procurement of flyash. Neither this procurement of flyash is based on any check for suitability of the flyash as a raw material for the making of cement, nor has anyone ever heard of any cement manufacturer having dumped or disposed of any unsuitable fly ash. Furthermore, it is most likely for Indian cements to fail tests for requirements on limits of water soluble alkali as set in the Plain and Reinforced Concrete Code of Practice, IS 456:200012. The code requires, as many other foreign codes do, that the equivalent Na2O content in cement must not exceed 0.60%. Knowing very well that Indian cements of recent periods might not meet this requirement, the requirements for a limit on the content of water soluble alkali in cement have been withdrawn from latest versions of codes of the Bureau of Indian Standards on cement.
Chemical Content
CaO (%) by weight of cement K2O (%) by weight of cement Alkali as (Na2O)(%) by weight of cement
OPC
56.8 1.03 1.69
PSC
43.27 0.89 1.17
PPC
46.59 0.86 1.07
Table 1. Contents of Cao and Soluble Alkalis in Typical Cements Available in Kolkata, Year 2006
- why have the cold twisted HSD (high strength with surface deformations) rebars of steel, e.g., torsteel and other HYSD (high yield strength with surface deformations) rebars of steel (Fig. 18) yielded to TMT bars (HSD also denotes HYSD) - what was the need to develop TMT-CRS (TMT-Corrosion Resistant Steel) bars - what was the need to develop TMT-HCR (TMT-High Corrosion Resistant) bars - what was the need to use stainless steel rebars - what prompted recent efforts at increasing the ductility of rebars and that too as a tokenism ? And why was it considered necessary to galvanize HSD rebars or to provide epoxy coatings or other surface treatments to HSD rebars at extra cost ? Or why was it considered necessary to both galvanize and provide epoxy coating on the same bar (Fig. 19) at large additional expenses, if it were not a recognition, if not an admission, that HSD rebars (Fig. 18), without additional aid, could not give durable concrete structures ?
Familiarity breeds contempt The ease of handling rebars, the easy availability of the ingredients (irrespective of the quality) of concrete and the easy formability of such concrete, coupled with the casual approach of IS 456:200012 and such other codes, have encouraged many to take liberty (Figs. 1 and 11-14) with the construction of concrete structures, more particularly with reinforced concrete structures. The consequences can be seen in Figs. 2, 5-7 and 15. The Problem with HSD Rebars What could have gone wrong with HSD rebars ? In the case of rebars, all the emphasis is on strength. To have strength is good (Fig. 20).
Fig.18 : Hot rolled - HYSD rebars of steel
Fig. 17 : Bridge under construction with corroded rebars
Figure 19 shows an advertised rebar with surface deformations that was galvanized as well as provided with an epoxy coating. The advertiser is a leading manufacturer of rebars in the USA. No suggestion is made here that the costly protection to rebars, as shown in Fig. 19, would make concrete structures, constructed with such rebars, any more durable than a concrete structure with uncoated rebars. The structure in Fig. 15, showing easy separation of concrete from epoxy coated rebars, is a case in point.
Fig.19 : Rebar, which because of its susceptibility to corrosion is given double protection; but the result, specially under vibratory load conditions, may be no different than that shown in Figs. 2 and 15
But in the case of rebars, the emphasis has been on brute strength (Fig. 21) and nothing else. Similar to a false feeling that a muscular body will necessarily lead to a long life, it was and it continues to be overlooked in the case of concrete structures that high strength of rebars alone may not guarantee durability of reinforced concrete structures.
and 24. Bend locations and the cut ends of the rebars in Fig. 23 show that if the strains/stresses will reach or cross the yield strain or stress levels, the rate of corrosion will increase uncontrollably. Figure 24 demonstrates it more vividly. The cold twisted deformed bars (e.g. Torsteel), where the surface strains/stresses crossed the yield levels at the manufacturing stage, corroded all over the surface whereas pieces from the same bar, which were not twisted, developed minor signs of corrosion at the roots of some of the surface protrusions. All the pieces of the bars were from the same rod and these were stored bundled together inside a polybag inside a room for about a month before inspection. The writer13-15 has explained why stresses, and thus strains, in HSD rebars inside concrete are more likely, than plain bars, to reach or cross yield strain/stress levels and thus corrode early, thereby leading to distressed conditions in concrete structures early.
Fig. 20 : It is good to have strength
Fig. 21 : The emphasis in the case of rebars has been on brute strength alone and almost on nothing else
Stronger and stronger rebars were introduced and continue to be used. Token improvement in ductility is a belated thought. Besides the differences in metallurgical compositions, todays high strength rebars, compared to plain round bars of mild steel of yesteryears, are made to have surface deformations. Presumably, the need for the provision of surface deformations arose from the desire to lessen the anchor or development/overlap lengths of high strength bars (Fig. 18) But such high strength rebars with surface deformations, compared to plain round bars of earlier periods, have greater susceptibility to corrosion13-15 (Figs. 1, 12-14). In fact, HSD rebars are so highly prone to corrosion that even epoxy coatings, which may protect steel plates and other elements, fail to protect such rebars with surface deformations (Fig. 22). While this writer13-15 has explained why the presence of lugs on the surface of HSD rebars make such bars highly susceptible to early corrosion, Alekseev16, citing Russian work, stated that the durability of concrete structures with HSD rebars of steel was an order of magnitude less than the durability of structures with plain round bars of steel. A very damning observation indeed on the performance of rebars with surface deformations Besides the inherent or chronic susceptibility of HSD rebars to early and accelerated rates of corrosion, the problem becomes more acute if the stress levels will be higher, particularly if the strains /stresses will reach or cross the yield limits. Examples can be found in Figs. 23
Fig. 22 : Corrosion in HSD rebars shows through epoxy coating
Fig. 23 : Fresh TMT bars (strain/stress beyond yield at bends and cut ends invite corrosion) with surface deformations on way to delivery at site
Liugong India Pvt. Ltd
Over the period of the last five decades, the C3S/C2S ratios have increased from 0.3 to 3.0.17 A dramatic change indeed It is known that C3S, responsible for early strength of concrete, readily reacts with water, producing greater heat of hydration at the initial stages after concreting. Thus, the increase in C3S at the cost of C2S, though beneficial in countries with colder climates, is generally harmful for concrete structures in most areas of India. In addition, alkali content in todays cement in India is far too high (Table1) for concrete structures to be durable (Fig. 3).
Fig. 24 : Fresh CTD bars (with strain/ stress beyond yield invite corrosion all over the surface) and untwisted bars with surface deformations
Simply stated, todays high strength rebars with surface deformations (Figs. 18, 23 and 24), which are susceptible to early corrosion, cannot give durable concrete structures, at least not without costly pretreatment or use of corrosion inhibiting cement or without other aids, e.g., waterproofing treatment to the surface of the concrete structures. Pretreatment to HSD rebars can be costly and cumbersome. Furthermore, any pretreatment, if provided at the construction site, may not be reliable, and the pretreatment can get damaged during construction, thereby encouraging corrosion, and nullifying any claimed benefits of coatings. A negative aspect of a particular type of pretreated HSD bars is shown in Fig. 15. As at or beyond yield the surface of a rebar becomes unstable, nullifying thereby the benefits of any layer of passivation (as is provided by Ca(OH)2 inside concrete with the right type of cement) or protective coating and since surface elements of HSD rebars inside concrete structures are likely to reach yield stress/strain levels under service load conditions, tests for effectiveness of corrosion inhibiting cement need to duplicate this condition of the HSD test sample by making repeated excursion beyond the yield strain threshold with varying loads. Thus, the state of reinforced concrete structures of recent decades, constructed with HSD rebars, begs for a solution. The problem with todays cement Cement is an important ingredient of concrete and the constituents of cement have changed over the years. The main oxide compounds in cement include C3S and C2S.
For OPC in the USA, % Na2Oeq = 0.55 (average)17; for the particular sample of OPC (Table 1) in India, % Na2Oeq = 2.37, robbing OPC of its virtues of the capability to produce copious quantities of Ca(OH)2 and the ability to seal cracks through a process of autogenous healing. In India, with Na2O at percentages of about 1.17 and 1.07, and with K2O at percentages of about 0.89 and 0.86, i.e. % Na2Oeq of 1.76 and 1.64 for PSC and PPC, respectively, alkali contents in slag and flyash cement too are pretty high (Table 1). Indian cement is thus not likely to meet the standards in other countries. In fact, Indian cement may also not satisfy the limit of 0.60% which has been set in IS 456:200012 for water soluble alkali content in cement. The increased fineness of cement, including high C3A, the dramatic rise in C3S/C2S ratio and the unacceptably high alkali content have proved to be detrimental to concrete and concrete constructions (Fig. 3). Besides the type of consequences of using cement of the type, available in India today, as can be seen in Fig. 3, high alkali cement makes concrete thirsty for water. This absorbed water, when passed on to rebar regions, makes the rebars corrode early, thereby making structures distressed early unless such structures will have been provided with surface protection systems, i.e., unless such structures will have been given waterproofing treatment to prevent any ingress of water. Causes of the Problem CPWD8 Papadakis, et al9 and Swamy10 have expressed their findings on the lack of durability of concrete structures which were built during recent decades. Alekseev16 put it bluntly when he observed that the durability of concrete
structures with HSD rebars of steel was an order of magnitude less than the durability of structures with plain round bars of steel. Obviously there is something wrong with HSD rebars. The writer found out in constructing a building that whether it were rebars or cement or/bricks, the basic materials of construction would most likely be found to be unfit for (durable) concrete construction6. On the basis of the preceding, more particularly on the basis of information provided in Figs. 1, 12-14, 16 and Table 1, some factors, which play important roles in causing early distress in concrete bridges, viaducts and other structures of recent periods, can be identified as - the use of cold worked high strength rebars with surface deformations - the use of high strength rebars with surface deformations - the use of cement with high C3S/C2S ratios - the permitting of excessive quantities of water soluble alkalis in cement - the permitting of use of cement with high C3A contents - the making of the grain sizes of ordinary portland cement too fine - the lowering of the period of curing of concrete The Solution The best solution to the problem of early distress in concrete structures ought to include taking a step backward and using plain round bars of mild steel as rebars and ordinary portland cement with properties matching those of OPC of periods prior to 1970, or even 1960, and curing concrete over longer periods of time as in the past. Another solution, involving additional expenditure, would be to improve the chemistry of rebars so that such bars would be less susceptible to early corrosion. Another solution would be the use of high strength rebars with a plain surface but a deformed axis (Fig. 25)15 that can lessen the propensity of rebars for corrosion and enhance the durability of concrete structures without any added cost. Yet another solution is to provide surface protection to concrete structures so as to prevent a moist environment inside concrete and/or ingress of CO2 and O2, thereby preventing carbonation of concrete and corrosion in steel elements inside concrete. If the surfaces of concrete structures, exposed to the atmosphere, would not be given surface protection by
waterproofing treatment, conditions like those depicted in Figs. 5-7 could happen, as unprotected concrete will absorb moisture and water, and corrosion prone HSD rebars will corrode.
Fig. 25 : C-bar with a plain surface but a deformed axis as a solution to the problem of early corrosion at no additional cost
If concrete bridges, viaducts and other structures are to be made durable, particularly if improved rebars will not be used, and cement of the right constitution will not be used, one must then provide surface protection to all exposed surfaces. In other words, waterproofing can be a solution to the problem of early corrosion in HSD rebars that can be invited by the use of high strength rebars with surface deformations and cement with high C3S/C2S ratios as well as large contents of water soluble alkalis. Engineers are waking up to the reality of todays concrete structures slowly but surely. They have started learning that there is a greater purpose to waterproofing than to arrest visible water leakages (Fig. 4). The writer has written extensively during the last two decades advocating this concept of achieving durability of concrete bridges and other structures through surface protection in the form of waterproofing treatment. It has been suggested that similar to steel structures, concrete structures can benefit from surface protection. The effectiveness of surface protection systems in making concrete structures durable is not merely a theoretical proposition. This writer is privy to many structures where the worsening of structural conditions appeared to have stopped after the provision of effective waterproofing treatment. In todays scenario, any failure to take steps to prevent the ingress of water or moisture or alternatively carbon dioxide and oxygen through the provision of protective treatment on the surface of concrete structures can thus be a folly. Today, Central Public Works Department, Bureau of Indian
Standards, Indian Roads Congress and Indian Railways are among the organisations who have agreed and issued their guides, standards and circulars on enhancement of the life span of concrete structures through the provision of surface protection systems in the form of waterproofing treatment. The Bureau of Indian Standards too recognized the effectiveness of surface protection systems in enhancing the life span of concrete structures.12 Unfortunately, the engineering community appears to have overlooked the requirements set in these documents, and concrete bridges and viaducts, old and new, remain largely unprotected. Waterproofing of Bridges & Viaducts As in the case of steel bridges, concrete bridges and their supports require protection against corrosion in the steel elements. Indian Railways and several other organisations have adopted specifications for specific systems of waterproofing which were developed by the writer. Figures 26-28 show three such items of waterproofing of concrete bridges which were developed by the writer. The detailed specifications can be found in Ref. 18. The three specifications cover most cases of surface protection required for reinforced concrete bridges and viaducts. The details in Figs 26-28, originally developed by the writer, relate to specification Nos. 22.14.1, 22.14.2 and 22.14.3 in the Indian Railways Unified Standard Specifications (Works & Materials) & S.O.R.18 A couple of typical bridges, given
Fig. 28 : Waterproofing treatment for bridge deck
surface protection in line with specifications as detailed in Figs. 26 and 27, are shown in Figs. 29 and 30.
Fig. 29 : Katakhali Bridge over the Fig. 30: Bankim Setu (Buckland Goureswar River at Barunhat on Bridge) over the platforms at Howrah Hasnabad-Hingalganj Road, North 24 Station, protected as in Fig.27 Parganas, West Bengal, protected as in Figs. 26 and 27
Concluding Remarks Compared to concrete bridges and viaducts of earlier periods, such structures, built during recent decades, have suffered from early decay and distress. In most cases, this decay is due to corrosion in high strength steel rebars with surface deformations. Prominent signs of corrosion in such rebars can be seen even before concreting. Inside concrete, because of very high strains and stresses, rebars with surface deformations, compared to rebars without surface deformations, can fall prey to corrosion more easily or earlier.
Fig. 26 : Waterproofing treatment for substructure below water line and for sidewalks
The constituents of todays cement, with high C3S/C2S ratios, high C3A and large alkali contents, make todays concrete less capable of protecting steel rebars than concrete with cement of earlier periods was. Todays concrete develops more cracks and such concrete also has greater capacity to absorb water. The greater rate and depth of penetration of the carbonation front in concrete with todays blended cement make rebars in such concrete more vulnerable to corrosion compared to rebars in concrete with OPC of earlier periods when alkali contents in cement were limited and C3S/C2S ratios were low.
Fig. 27 : Waterproofing treatment for superstructure and substructure above water line
RD Mining Equipments Pvt. Ltd.
As solutions to the problem of early distress in todays reinforced concrete structures several options are suggested in the following. Implementation of any one or more of the steps will lead to an enhancement in the life span of bridges, viaducts and other concrete structures. - using plain round bars of mild steel as rebars and OPC having constituents as in the pre nineteen sixty era - Using rebars of steel with improved chemistry/metallurgy that would be more resistant to corrosion - Using C-bars (whether of low, medium or high yield strength) with plain surface and deformed axis as rebars instead of rebars with surface deformations - Providing surface protection in the form of waterproofing treatment to all exposed surfaces of concrete structures instead of providing any coatings to rebars - Improving the quality of concrete through the addition of admixtures, using low water cement ratios, achieving greater compaction and lengthening the period of moist curing. The importance of waterproofing systems in making concrete structures durable can be found in Refs. 5, 7, 8, 12 and 17. Reference 17 suggests, If water can be kept out of the system after curing, then the potential for durability related problems will be reduced markedly. whereas Ref. 12 recommends, The life of the structures can be lengthened by providing extra cover to steel, by chamfering the corners or by using circular cross-sections or by using surface coatings which prevent or reduce the ingress of water, carbon dioxide or aggressive chemicals. References
1. Kar, Anil K., The Ills of Todays Cement and Concrete Structures, paper No. 534; Journal of the Indian Roads Congress, Vol. 68, Part 2, July-September, 2007, New Delhi, www.irc.org.in. 2. Kar, Anil K., Woe Betide Todays Concrete Structures, New Building Materials & Construction World; New Delhi, Vol. 13, Issue-8, February, 2008, New Delhi; and Woe Betide Todays Concrete Structures Part II, New Building Materials & Construction World, Vol. 13, Issue-9, March, 2008, New Delhi, www.nbmcw.com. 3. Kar, Anil K., Concrete Structures : A Tale of Reverse Technology, RITES Journal, RITES Ltd., Vol. 10, Issue 2, July, 2008, New Delhi. 4. Kar, Anil K., and Vij, Satish K., Yearnings of a Reinforced Concrete Structure, New Building Materials & Construction World; New Delhi; Vol. 14, Issue-12, June, 2009, www.nbmcw. com. 5. Kar, Anil K., and Vij, Satish K., Enhancing the Life Span of
Concrete Bridges, New Building Materials & Construction World, Vol. 15, Issue 6, December 2009, New Delhi, www. nbmcw.com. 6. Kar, Anil K., Construction Materials : Products of Our Education, New Building Materials & Construction World; New Delhi; Vol. 15, Issue-8, February, 2010, www.nbmcw. com. 7. Kar, Anil K., and Vij, Satish K., Waterproofing of Structures for Durability, New Building Materials & Construction World; New Delhi; Vol. 15, Issue-10, April, 2010, www.nbmcw.com. 8. Durability of Concrete Construction, Technical Circular 1/99, Central Designs Organisation, Central Public Works Department, Government of India, No. CDO/SE(D)/G-29 dated 18.02.1999, New Delhi. 9. Papadakis, V. G., Vayenas, C. G., and Fardis, M. N., Physical and Chemical Characteristics Affecting the Durability of Concrete, ACI Materials Journal, American Concrete Institute, March - April, 1991. 10. Swamy, R. N., Infrastructure Regeneration : the Challenge of Climate Change and Sustainability - Design for Strength or Durability, The Indian Concrete Journal, The ACC Ltd., Vol. 81, No. 7, July 2007, Mumbai, www.icjonline.com. 11. Kar, Anil K., FBEC rebars must not be used, The Indian Concrete Journal, ACC Ltd. Vol. 78, No. 1, January 2004, pp. 56-62, www.icjonline.com. 12. IS 456:2000 Indian Standard Plain and Reinforced Concrete, Fourth Revision, Bureau of Indian Standards, New Delhi, July 2000. 13. Kar, Anil K., Concrete Structures - the pH Potential of Cement and Deformed Reinforcing Bars, Journal of the Institution of Engineers (India), Civil Engineering Division, Vol. 82, June 2001, Calcutta, www.ieindia.info. 14. Kar, Anil K., Deformed Reinforcing Bars and Early Distress in Concrete Structures, Highway Research Bulletin, No. 65, Indian Roads Congress, December 2001, New Delhi, www.irc. org.in. 15 Kar, Anil K., A Rebar for Durable Concrete Construction, The Masterbuilder; Vol. 13, No. 7, Chennai; July, 2011, www. masterbuilder.co.in. 16. Alekseev, S. N., Corrosion of Steel Reinforcement, Chapter 7 in Moskvin, V. (edited by), translated from the original by V. Kolykhmatov, Concrete and Reinforced Concrete Deterioration and Protection, 1990, English translation, Oxford & IBH Publishing Co. Pvt. Ltd. New Delhi, 1993, original Mir Publishers, Moscow 1990. 17. Johansen, Vagn C., et al, Effect of Cement Characteristics on Concrete Properties, Portland Cement Association, Skokie, Illinois, USA, 2005 18. Indian Railways Unified Standard Specifications (Works & Materials) & S.O.R., Indian Railway Board, Ministry of Railways, Government of India, 2010.
Lipi Polymers Pvt.Ltd
Formwork Industry Analysis
FORMWORK : Custom-Made Solutions

Takes Center Stage
MB Bureau Report
f there is one market segment among construction equipment that has maintained a steady pace of growth, despite the crests and troughs of the uneconomic uncertainties that have been affecting the market over the last few years, it has to formwork equipment. While in the case of most other types of construction equipment, the major driver for demand was the infrastructure development process, for manufacturers of formwork and scaffolding equipment, it has not limited to the infrastructure development activities. Since they also have the real estate sector to cater to, they have had a far smoother ride than some other types of equipment. The formwork industry has been perhaps the biggest beneficiary of the impressive growth of the Indian construction industry over the last two decades.
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Adding to the good news for manufacturers is the fact that even though modern formwork and scaffolding systems made their way into the Indian market in the mid to late 1990s, the extent of the market tapped till now is just a minute percentage of the total potential. In fact, according to industry estimates, modern formwork systems form only about 15 percent of the market share presently, a figure that is expected to more than double by the end of the 12th Five Year Plan period (2012-17), with the continued impetus being provided to infrastructure development and the growth of the real estate sector. Getting organized The formwork industry in the country is gradually getting organized due to the entry of big ticket players in the fray. Globally reputable names such as Doka, Meva, Ulma, Paschal, Pranav, Peri, GCI Composite, Desi etc have established their presence in the Indian market over the recent past. There have been two key factors that have been driving forward the markets momentum- shortage of labour and increasing pressure on contractors to adhere to stricter quality standards and project deadlines.
Quality assurance on the job site is sometimes an issue in India. As of now, there is no specific certified body to give quality assurance on site. To avoid any quality issues we have our in-house QA-QC department which monitors quality at every stage, beginning from procurement of raw materials to dispatch. We encourage our clients to have the quality inspection done
growth. Speaking about the sectors that are driving demand for formwork systems in the country, Mr.Bharat Patel, Head- Sales & Marketing, Nav Nirman Beam Technics , pointed out that presently, The residential sector and among the infrastructure sector, metro projects are among the key market segments that are propelling demand for formwork systems. With the realty focus shifting to tier II and III cities, formwork suppliers are now catering to an increasingly diversified market with different application demands. Contractors around the country have realized that in order to meet these two criteria the use of formwork and scaffolding systems has become imperative. The increase in the size of projects, especially with respect to infrastructure and high-rise projects has also been a factor that has been pushing the demand for formwork equipment. High rise and Infrastructure Projects The consistent growth of the formwork industry in the country has been enabled by the thrust given to infrastructure development over the last decade. Infrastructure project including for those of bridges, metro stations, tunnels, airport projects, flyovers, etc
Sushil Sahani
Managing Director, Pranav Construction Systems Pvt. Ltd.
While the recent economic slowdown has slightly impacted the industry, there is no denying the fact that the industry is poised for a period of
Continued impetus to infrastructure development projects bodes well for the formwork industry
Doka India's formwork will be used in the Lokhandwala Minerva skyscraper project
climbing formworks is available in the form of Doka India's SKE50 and SKE 100 systems. The company will be reportedly using these automatic climbing formwork systems in the construction of 'Lokhandwala Minerva' a skyscraper in Mumbai that will top out at 300 m and feature 82 storeys in two separate towers. The luxury residential project is being designed by Hafeez Contractor and in use will be the SKE 50 and SKE 100 automatic climbing formwork systems that help in providing an efficient solution for achieving weather-independent construction workflow and maximum crew safety. The building is scheduled to be finished in 2014 according to the company.
Meva India's formwork during the construction of Palais Royale building in Mumbai
have been behind the rising demand for formwork systems. Adding to the demand factor is the 'vertical' growth of the country. High-rise construction is an area where specialized formwork plays a key role. Automated self-climbing formwork systems that can be lifted up hydraulically come with a host of features including, wide and protective platforms, apart from provisions for aux-
iliary systems like placing booms, apart from offering adaptability to complex wall geometries. Almost every player in the field such as, Doka, Meva, Ulma, Paschal, Nav Nirman, Pranav, GCI Wall forms., Peri, Design Desire Construction Systems to mention only a few are offering specific products catering to this growing market segment. A good example for automated
A change is always a struggle. Mindset of influential decision makers , inadequate/ inappropriate quality codes, cost factors everything plays a role in the growth".
Eldo Varghese
General Manager, Paschal Formwork (India) Pvt. Ltd.
Paschal formwork systems being used in different types of construction projects
Speaking about high-rise construction and the use of specialized formwork systems, Meva India is another company that has been associated with a landmark project- Palais Royale in Mumbai. The company had used its MAC (MEVA Automatic Climbing) system, which provides complete protection for workers with full cladding surrounding the external hanging platforms in the project. No external secondary platforms are required on the MAC. The hydraulic system of the automatic climbing system has a capacity of 20 tons per ram and a non-return rachet that locks on each cylinder. The
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Ulma Formwork Systems India Pvt. Ltd
design of the climbing system is such that the load is carried by concrete that is already set and this helps in safer and faster construction. Ulma India is another leading name that offers self-climbing formwork systems for fast, safe, and cost-effective construction of high rise buildings. According to the company these systems can be lifted in extreme weather condition up to maximum wind speed of 72 kmph. They come with wide and protective working platforms. The formwork system features provisions for attachment of auxiliary systems like placing booms along with the formwork panels.
The residential sector and among the infrastructure sector, metro projects are among the key market segments that are propelling demand for formwork systems
Ulma India's formwork in action
structures' according to the company and is used in footings, retaining walls, columns, beams, internal and external walls, track hoppers, canal drains, box culverts, water treatment plants, reservoirs, crude oil refinery storage pits, cooling towers, etc. Paschal is also the name behind the popular 'e-deck' system. The company's formwork systems
have been used in projects including, Salarpuria Hotel project, Hyderabad, Golden Jubilee project, Hyderabad, Panduranga power project, Rajamundry, Branddix Apparel City, Vishakhapatnam, TCS Building project, Bhubaneswar, Defence project , Bellary and Prestige Forum Mall in Mangalore, to mention but a few.
Bharat Patel
Head- Sales & Marketing, Nav Nirman Beam Technics
A wide range of climbing formwork systems is also offered by Peri India, another trendsetter in the industry. The company's range includes the FB 180 Platform System, CB Climbing System, ACS Self Climbing System, RCS Rail Climbing System, KG 240- KG180 Climbing Systems, and SKS Single Sided climbing system, to mention only some. Product Innovations Manufacturers are banking on specific product design to cater to different types of application. The 'Modular Panel System' from Paschal, a leading name in the industry is a good example. The modular panel system from the company is a 'one system for all vertical
Repetition in operational use up to 90-100 times is possible with systems from Nav Nirman Beam Technics
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Metro projects have emerged as a key demand driver for formwork systems
Pranav Construction Systems Pvt Ltd, is one more player which offers a range of innovative formwork systems. The company has this year introduced a range of new generation systems , which are not only light weight but have optimum life of up to even 1000 repetitions. The range includes, 'Alvert'- aluminum light weight panel system for walls, columns and lift cores, 'Modvert/ Steelvert'- alloy steel light weight panel system for retaining walls, rafts, columns, abutments with ply/steel facing and 'Aludek'- aluminum light weight modular system with drop head for faster cycle time. The company has been involved with several key projects including Palm Jebel Ali, Dubai, Doha International Airport, Bandra-Worli Sea Link, Nivedita Setu (second Vivekananda Setu) bridge in Kolkata; the Dubai, Delhi, Mumbai, Bangalore, Chennai, Kolkata, Hyderabad and Navi Mumbai metro projects, to mention only a few. In fact the company has the distinction of supplying formwork materials to every metro being consructed in India. Another good example for product innovation is available in the of the 'H-Beams' from Nav Nirman Beam Technics, which are easy to handle, light in weight, ready to use and give
perfect form finish, free from bulging and distortion. Repetition in operational use up to 90-100 times is possible with the H-Beams which are used in the construction of residential and commercial projects, industrial projects, water resources engineering, roads and bridges, and stadiums, among others. Rental Push The Indian formwork industry has evolved the years and one of the signs of maturity is available in the form of a developing rental market. Rental solutions have come in handy, especially for smaller contractors for whom outright purchase of the equipment is often a difficult proposition. In fact, rental solutions have also been instrumental in formwork equipment now entering the hitherto unexplored areas of the country. With the realty market passing through a phase of difficulty in metros, due to a variety of factors including rising property prices and interest rates, the scene has now shifted to smaller tier II and III cities and towns. Formwork systems have come as a boon to contractors in these smaller locations. Another key reason for the development of the rental market is storage space, often a neglected factor in our
country. It is in fact one of the reasons why even bigger developers are opting for rental solutions since they need not worry about storing formwork equipment. Even in the case of the rental market, according to industry analysts, the market potential realized is just the tip of the iceberg and there is a huge market that is lying untapped. Industry analysts feel that the gradual rise in the number of rental companies would automatically streamline several other processes including improvement in logistics and setting up of formwork systems at work sites in the near future. Challenges ahead While there is no denying the growth of the Indian formwork and scaffolding industry, there are still a set of challenges that the industry needs to surmount, as the country enters into a second phase of infrastructure development. Fluctuating cost of steel, sales tax and excise duty are some factors that have been said to be inhibiting the growth of the industry. The movement of the sector towards light weight and stronger materials such as aluminium has meant that higher levies are another inhibiting factor these days. Manufacturers are looking up to the
Alvert System, Industrial Project ,Gujarat from Pranav System
government to help them procure raw materials at a reasonable price in order to give the much needed fillip to an industry. The government needs to remember that India has the potential to emerge as a key exporter of formwork and scaffolding equipment. The encouraging news has come in the form of an evolving customer. Different stakeholders in the construction industry including, contractors and engineers, are now accepting formwork systems as an integral part of the construction process. Dwelling on this key point, Mr. Eldo
Varghese, General Manager, Paschal Formwork (India) Pvt Ltd, said, A 'change' is always a struggle. Mindset of influential decision makers (engineering / construction fraternity), inadequate / inappropriate quality codes, cost factors everything plays a role in the growth. Engineering community is not reluctant to change but updating themselves towards an overall change in the procedure or system, so that the transition is easier. More and more engineers are getting involved in this drastic change though their experience in other coun-
tries and the pace will definitely improve as the number goes up. Formwork is still in the inception stage in India and change is inevitable towards better growth rate. It is directly connected to time. Lack of adequate codes and the cost factors are also the reasons for the growth rate. Both are directly linked to the volume of formwork in usage. As the volume and usage of modern formwork goes up as both these factors will be tackled, a thought with which almost all leading manufacturers will agree. Another important challenge that suppliers need to take care of is quality assurance at the job site. Giving an insight into how they tackle the issue, Mr. Sushil Sahani, Managing Director of Pranav Construction Systems said, Quality assurance on the job site is sometimes an issue in India. As of now, there is no specific certified body to give quality assurance on site. To avoid any quality issues we have our inhouse QA-QC department which monitors quality at every stage, beginning from procurement of raw materials to dispatch. We encourage our clients to have the quality inspection done, a strategy which is well worth emulation. Many industry analysts believe that the formwork industry needs specific certification bodies for inspecting and then certifying formwork systems, as otherwise the largely unorganized nature of the construction industry could mean that quality sometimes could take a backseat. This apart, an evolving market also presents another challenge in the form of a maturing customer. The customer of today wants equipment that is easier to handle, adds to the sustainability quotient of the building process, is reusable and importantly, is also competitively priced. With policy initiatives expected to increase inflow of funds into infrastructure development, the formwork industry is entering a crucial growth and consolidation phase. Photo Courtesy:
GCI Wall Form Systems
www.meva.de, www.archiproducts.com www.doka.com, www.skyscrapercity.com
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GCI Wall Forms Pvt.Ltd
Form Work Pressure
Effect of Concrete Temperature and Formwork Width on Variation Pressure Formwork of Self-compacting Concrete
1 2
1 2
Amir Hosein Bakhtiarain, Morteza Askari
The Bsc. Student of Islamic Azad University, The faculty member of Islamic Azad University
In this article two complete programs about effect of concrete temperature, formwork width, on lateral pressure formwork of SelfCompacting Concrete are discussed. For considering effect of concrete temperature concrete mixtures which are built under 1030c , are used and the result show that concrete temperature hasn't considerable effect on initial pressure (after casting finishing). But in time passing, pressure reduction is significant for surveying in formwork width effect, two columns with 200 and 920mm diameter, are applied
The design of formwork systems for vertically cast elements is controlled by the lateral pressure developed by the flesh concrete. It is well established that concrete consistency, method of placement, consolidation, type of cement, temperature of concrete, maximum aggregate size, head of concrete, pore water pressure, rate of placement, and size and shape of the formwork have all marked effect on the development of lateral pressure [3-6-9]. Maxton (from Rodin [9]) studied the coupled effect of the casting rate and concrete temperature on the lateral pressure envelope for conventional concrete. Different series of low-slump concrete mixtures placed at casting rates varying between 0.6 and 2 m/h were investigated. The concrete temperature varied from 4.5 to 27 C. Maximum lateral pressure was found to increase with the increase in the casting rate and/or decrease in concrete temperature. Irrespective of the tested parameters, the pressure envelope was reported to be hydrostatic from the free surface to a certain maximum value, and then remained constant until the bottom of the formwork. For formwork design purposes, ACI Committee 622 [2] proposed the following design equations for column and wall elements, both of which take into account the rate of casting and concrete temperature: For columns: For walls:
Where Pmax: maximum lateral pressure, KPa R: rate of casting, m/h T: concrete temperature, C H: head of concrete, m Effect of concrete temperature on formwork pressure For investigation of effect of concrete temperature on lateral formwork pressure, experimental research of Assad [7] and his colleagues was used and described those below: Materials The ternary cement contained 6% silica fume, 22% fly ash, and 72% CSA Type 10 cement. The Type 30 cement, Type 10 cement, and fly ash had blaine specific surface values of 600, 325, and 410m2/kg, respectively. The silica fume had a B.E.T specific surface of 20,250m2/kg. Continuously graded crushed limestone aggregate with nominal size of 10mm and well-graded siliceous sand
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tempera- Mixture* ture, .C codification
Ternary cement, kg/m3

450 450 450 450 -
Type 30 Water, Sand (0- Coarse cement, kg/m3 (w/ 5 mm), aggregate, kg/m3 cm = 0.40) kg/m3 (5-10 mm), kg/m3
450 180 180 180 180 180 740 740 740 740 740 870 870 870 870 900
VEA, mL/ SetHRWRA L/ AEA, mL/ 100 100 kg of accelerator, m3 kg of cement cement mL/100 kg of cement
260 260 260 260 260 1000 3.8 3.8 3.9 3.7 3.3 120 120 120 135 170
10 20 30 20 20
TER-10 TER-20 TER-30 TER20-ACC T30-20
Table 1. Mixture proportions of evaluated SCC
were employed. The coarse aggregate and sand had fineness module of 6.4 and 2.5, bulk specific gravities of 2.71 and 2.69, and absorption values of 0.4% and 1.2%, respectively. Polycarboxylate-based high-range waterreducing admixture (HRWRA) of 1.1 specific gravity and 27% solid content was used. A high molecular weight cellulosic-based material was employed for the VEA to enhance stability of mixtures proportioned with 0.40 w/cm. Mixture proportion As summarized in Table 1, the investigated mixtures were prepared with 450 kg/m3 of binder content and w/cm of 0.40.The effect of concrete temperature on lateral pressure variations was evaluated by testing mixtures prepared at 10, 20, and 30 2C for the TER-10, TER-20, and TER-30 mixtures, respectively. Ambient temperatures during the sampling and testing were 14, 20, and 27C, respectively, to minimize heat loss of the tested concrete. The effect of using Type 30 cement and set accelerating admixture on the variations in lateral pressure was investigated, as they have marked effect on the rate of cement hydration. The dosage of the set accelerator was set at 1000 mL/100 kg of binder. The T30-20 and TER-20-ACC mixtures prepared with Type30 cement and set accelerating admixture, respectively, were proportioned at 20 2C and tested at 20C ambient temperature. The VEA dosage was fixed at 260 mL/100 kg of binder, and the sand-to-total aggregate ratio remained constant at 0.46 for all tested mixtures. The HRWRA and AEA concentrations were adjusted to secure initial slump flow of 650 15mm and air content of 6 2%. Instrumented column systems Two experimental columns were used to determine the lateral pressure exerted by plastic concrete. The first column measures 2800mm in height and 200mm in diameter, and was used to evaluate pressure variations of the plastic concrete. The lateral pressure was determined using five pressure sensors mounted at 50, 250, 450, 850, and 1550mm from the base. In order to enable the evaluation of pressure variation up to the hardening of the concrete, a shorter column measuring 1100mm in height and 200mm in diameter was used. Three pressure
sensors similar to those employed in the former column were mounted at 50, 250, and 450mm from the base. Both experimental columns were made of PVC with a smooth inner face to minimize friction with the concrete. Fabrication and testing program The slump flow, concrete temperature, unit weight, air volume, L-box flow characteristics, surface settlement, and setting time were determined, and the results are summarized in Table 2.
TER-10 TER-20 TER-30 TER-20- T30-20 ACC
Slump flow, mm Air content, % Initial concrete temperature, .C Unit weight, kg/m3 h2/h1 of L-box test Surface settlement, % Initial set time, min Final set time, min 655 6.5 9.5 2230 0.84 0.48 690 780 655 4.3 21.7 2265 0.81 0.34 610 705 645 5.9 30.1 2190 0.85 0.32 585 660 645 4.5 20.8 2315 0.82 0.29 440 480 640 6.2 21.7 2335 0.85 0.15 425 470
Table 2. Properties of evaluated SCC mixtures
Fresh concrete properties All SCC mixtures had L-box blocking ratios (h2/h1) greater than 0.80 indicating adequate passing ability, and relatively low surface settlement (<0.5%). Surface settlement values are shown to decrease with the increase in the initial concrete temperature. The maximum surface settlement decreased from 0.48% to 0.34% and 0.32% for the TER-10, TER-20, and TER-30 mixtures cast at approximate temperatures of 10, 22, and 30 C, respectively. The use of high early strength cement and set-accelerator are also shown to enhance the static stability of the plastic concrete. The mixtures prepared with set-accelerating admixture and Type 30 cement exhibited settlement values of 0.29% and 0.15%, respectively. Lateral pressure envelope with respect to height A typical diagram showing the distribution of lateral Pressure along the 2800-mm high experimental column
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for the TER-30 mixture is given in Fig.1. The slump flow values noted at various times are also indicated. Right after casting, the concrete is shown to develop lateral pressure close to the theoretical hydrostatic pressure. The hydrostatic pressure (Phyd) is calculated as: Phyd = g H; where , g, and H refer to the concrete unit weight, gravity constant, and head of concrete in the formwork, respectively. The relative pressures compared to Phyd at the base of the column determined at end of casting and then after 1, 2, and 3 hours were 91%, 77%, 68%, and 61% respectively.
values determined at the end of pressure monitoring are noted. Mixtures prepared with ternary cement at initial temperatures of 10, 22, and 30C develop similar relative pressures of 91% at the end of casting. This indicates that concrete temperature has no significant effect on the development of initial pressure. The maximum initial pressure is rather affected by the degree of internal friction that depends on the coarse aggregate volume and mixture consistency. On the other hand, the rate of pressure drop with time is significantly affected by concrete temperature. For example, the time to reduce the relative pressure by 25% decreased from 400 to 250 and 160 minutes for the TER-10, TER-20, and TER-30 mixtures, respectively. Alexandridis and Gardner [1] reported that concrete cast at higher initial temperature can exhibit higher cohesion through the formation of a gel structure. This can enable the plastic concrete to develop higher shear strength capable of carrying a greater fraction of the vertical load, thus resulting in increased rate of pressure drop with time. It is important to note that higher initial temperature can result in greater rate of loss in slump flow consistency, thus reducing the degree of lateral pressure. For example, slump values of 170 and 180mm were measured 5 and 3.5 hours after casting for the TER-10 and TER-30 mixtures, respectively.
Fig. 1: Variations of lateral pressure envelope with time for the TER-30 mixture
The T30-20 and TER-20-ACC mixtures developed the lowest initial relative pressures of 78% and 83%, respectively, compared to 91% for those cast at 10 to 30C initial temperatures and placed at similar casting rates of 10 m/h (Fig. 2). The incorporation of setaccelerating admixture in the TER-20-ACC mixture resulted in the highest rate of pressure drop with time; the elapsed period required to reduce the relative pressure by 25% was 88 minutes. The increased rate of cement hydration due to the incorporation of setaccelerating admixture can lead to greater cohesiveness, and hence sharper rate of drop in lateral pressure.[4] Effect of section width on formwork pressure For investigation of effect of concrete temperature on lateral formwork pressure, experimental research of Khayat[8] and his colleagues was used and described those below: Materials
Fig. 2: Effect of concrete temperature, cement Type 30, and use of setaccelerating admixture on pressure variations determined at the bottom of the 2800-mm high column
Effect of concrete temperature on variations in lateral pressure Variations of the P(maximum)/P(hydrostatic) values measured along the 2800-mm column of the five SCC mixtures placed at 10 m/h are plotted in Fig.2. Slump
A ternary cement made with approximately 6% silica fume, 22% Class F fly ash, and 72% Type 10 cement was used. A continuously graded crushed limestone aggregate with nominal size of 10 mm and well-graded siliceous sand were employed. The sand had a fineness modulus of 2.5. The bulk specific gravities of the aggregate and sand were 2.72 and 2.69, and their absorptions were 0.4% and 1.2%, respectively. A naphthalene-based highrange water reducer (HRWR) with solid content of 41%
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Paschal Formwork (I) Pvt. Ltd
Form Work Pressure
and specific gravity of 1.21 was used. A liquid-based polysaccharide was used for the viscosity-modifying admixture (VMA) to enhance stability of the plastic concrete. A synthetic detergent-based air-entraining admixture (AEA) and a carboxylic acid-based waterreducing admixture were incorporated. Mixture proportion For the SCC mixture used in this study, a proven mixture prepared using 490 kg/m3 of binder, 0.38 w/cm, and 0.44 sand to-coarse aggregate ratio was used. The VMA was incorporated at a dosage of 1325 mL/100 kg of water, and the HRWR dosage was adjusted at 6 L/m3 to secure initial slump flow of 650 mm. A dosage of 150 mL/100 kg of cementitious materials of the AEA was used. The unit weight and air content were 2280 kg/m 3 and 6.1%, respectively. Instrumented formworks As already mentioned, two experimental formworks were used. The first measured 2100 mm in height and 200 mm in diameter. The PVC tube had a wall thickness of 10 mm and a smooth inner face to minimize friction during and after concrete placement. The stress in the diaphragm caused by concrete lateral pressure was determined using five pressure sensors mounted at 850, 1250, 1650, 1850, and 2050 nun from the top. The monitoring of pressure distribution was stopped once the concrete had an approximate slump consistency of 100 mm. The second column consisted of a sonotube of 3600 mm in height and 920 mm in diameter. The column was adequately braced and reinforced. The lateral pressure was determined using two pressure sensors located at 2050 and 2880 mm from the top. The monitoring of pressure distribution was stopped once the concrete had an approximate slump consistency of 100 mm. The second column consisted of a sonotube of 3600 mm in height and 920 mm in diameter. The column was adequately braced and reinforced. The lateral pressure was determined using two pressure sensors located at 2050 and 2880 mm from the top. In this case, the lateral pressure was monitored until the hardening of the concrete. Fabrication and testing program Ready-mixed concrete was delivered to the experimental site. The ambient and concrete temperatures were 16 and 19C respectively. The slump flow, air content, JRing and Lbox flow characteristics, and surface settlement were determined for the SCC. The measurement corresponds to the mean diameter of the spread concrete at the end of flow. The JRing spread values was 600 mm and for Lbox test the measure was 0.81 and maximum surface settlement was 0.34%. The concrete was directly discharged from the mixing
truck into the formwork from the top at the desired pouring rate without stoppage or vibration. In the case of the 3600ram high column, the concrete was placed at a rate of rise of 10m/hr. For the 2100-ram high column, the formwork pressure was evaluated twice; once using a rate of placement of 10m/hr and then at 25 m/hr for a second column. The slump flow values determined upon the arrival on site of the concrete and after 1 and 2 hours were 650, 635, and 450 mm, respectively. After 3 and 3.5 hours, slump consistencies of 180 and 65 mm were measured, respectively. The initial and final setting times were determined in the laboratory at 20C in compliance with ASTM C403 and are given in Fig.3. The adiabatic temperature was also evaluated in an adiabatic calorimeter on mortar obtained by sieving fresh concrete through a 4.75-mm sieve. The heat evolved was determined by deriving the temperature rise as a function of time. The time between the initial contact of cement with water and that corresponding to the beginning of the acceleration of temperature rise was 6 hours, as also shown in Fig.3.
Fig 3: Variations of hydration and stiffening kinetics with time
Lateral pressure variations The variations of the lateral pressure envelope determined on the 2100-ram high column along with the consistency are plotted in Fig.4. Immediately after filling the formwork, the concrete is shown to act as a fluid exerting almost hydrostatic head. However, a gradual decrease in lateral pressure takes place with time. The relative pressures at the base of the column determined initially and after 1, 2 and 3 hours were 98%, 89%, 83% and 76% of hydrostatic pressure respectively. Results of the section width Influence on formwork The effect of column diameter (200 vs. 920 mm) on changes in lateral pressure is illustrated in Fig.5 by plotting the variations of the P(measured)/P(hydrostatic) values calculated at 2050 mm from the top of the formworks as a function of time. It is important to mention that both columns were cast on the job site at the same casting
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MM Castings (P) Ltd
Form Work Pressure
rate of 10 m/hr. Initially, the mixture placed in the larger column exhibited slightly greater pressure of 99% of hydrostatic pressure compared to 96% for the 200-mm diameter column. However, the rate of drop in pressure was significantly different. In the case of the former concrete placed in the 920-mm diameter column, the time required to reduce lateral pressure by 5% of the hydrostatic value was 20 minutes, resulting in a slope of 5.3 kPa/hr. Conversely, for the 200-mm diameter column, this period was 38 minutes resulting in a slope of 3.3kPa/ hr. In general, the rate of drop in lateral pressure of plastic concrete depends on the degree of thixotropy or shear recovery [9]. This phenomenon causes a build-up of the structure and an increase in cohesiveness soon after the
material is left standing at rest without any shearing action. In the case of the 200-mm diameter column, the arching effect can be relatively more pronounced than that resulting from the 920-ram diameter column. Conclusions Variations in fresh concrete temperature have limited effect on the maximum lateral pressure developed by SCC at the time of casting. However, the rate of pressure drop with time increases with the concrete temperature that promotes faster development of cohesion. The use of Type 30 cement or set-accelerating admixture can lead to 10% reduction in the initial pressure and accelerate the rate of pressure drop by two folds compared to similar concrete prepared with a ternary cement. The scale effect had an influence on the rate of drop in lateral pressure of SCC with time; however, no appreciable difference in the maximum initial pressure was observed. Immediately after casting, the SCC placed in the 200ram diameter column was found to exert slightly less pressure than that cast in the 920-ram column. This can be due to an arching effect in the relatively restricted section.
References
[1] ACI Committee 347 (2001) "Guide to formwork for concrete", Farmington Hills, 32.
Fig 4: Variations of hydration and stiffening kinetics with time
[2] ACI Committee 622 (1958)" Pressures on formwork", ACI Journal, Proceedings, and 55(2):173-190. [3] ACI Committee 622, "Pressures on formwork", ACI Journal,Proceedings, 55 (2) (1958) 173-190. [4] Assaad J, Khayat KH, Mesbah H (2003) "Variation of formwork pressure with thixotropy of self-consolidating concrete." ACI Materials Journal, 100(1):29-37. [5] Bartos, P .J.M., "An appraisal of the orimet test as a method for on-site assessment of fresh SCC concrete", Int. Workshop on Self-Compacting Concrete, Japan, (1998) 121-135. [6] Gardner, N.J. and Ho, P .T.-J., "Lateral pressure of fresh concrete", ACI Journal, Technical Paper, Title No. 76-35 (1979) 809-820. [7] Joseph J. Assaad Kamal H. Khayat "Effect of casting rate and concrete temperature on formwork pressure of self-consolidating concrete",Rilem Materials and Structures (2006) 39:333-341 [8] K. Khayat, J. Assaad, H. Mesbah, and M. Lessard "Effect of section width and casting rate on variations of formwork pressure of self-consolidating concrete ", Rilem Materials and Structures 38 (January-February 2005) 73-78 [9] Rodin, S., "Pressure of concrete on formwork", Proceedings Institution of Civil Engineers (London) 1 Part 1 (6) (1952) 709746.
Fig. 5: Effect of the section width on lateral pressure
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Igloo Tiles
Home Grown Formwork Manufacturer Shining Bright

ranav Construction Systems Pvt. Ltd. is a leading supplier for numerous landmark structures in recent times. It is a recognised brand for product, delivery and services. It has grown systematically over the past two decades and its clientele includes some of the leading names in the international and domestic arena. Having executed projects like Palm Jebel Ali (Dubai), Doha International Airport, Bandra-Worli Sea Link, the legendary Nivedita Setu (Second Vivekanada Setu) Bridge in Kolkata; the Dubai, Delhi, Mumbai, Bangalore, Chennai metro and now the Kolkata, Hyderabad & Navi Mumbai metros; flyovers that dot the cityscape of Mumbai, Nagpur, Bangalore, Chennai, Nasik and the famous Reliance Antilia. Pranav is today a name to reckon in the Indian formwork marketplace. Home grown large organized players like Pranav with the latest international technologies has not only been a successful player in India, but also have proved their mettle in the international markets like Dubai, Abu Dhabi, Qatar, Muscat, Hongkong, Macau & Tanzania. Pranav with its well equipped stateof-the-art in-house manufacturing facility spread over 56,000 sq meters at Badlapur and Pawne, near Mumbai has one of the largest formwork plants in India with annual capacity of 60,000 MT with world class Robotic welding fixtures, CNC machines, fully equipped in-house Research and Development facility, Process Engineering Laboratory and Tool room. They are well placed to play a large role in the construction growth in India & overseas, with a pan India presence Pranav has a network of
offices in Mumbai, Delhi, Hyderabad, Bangalore, Kolkata and are internationally placed at U.A.E, KSA & Kuwait. They offer products for every segment and application in all variants of materials for residential and commercial high-rises, metros, bridges, flyovers, tunneling, launching, water retaining structures and break water. As the construction industry is rapidly moving into a highly aesthetic zone,Pranav has launched Decoform formliners which define a whole new standard for infrastructure and buildings across India. These formliners support pre-cast as well as in-situ applications. These give an exact reproduction of any patterned or textured designs on concrete surfaces. A few ongoing projects using Decoform are Anik Panjrapole Link Road , Amar Mahal , Bankhode Junction flyovers, Mumbai & Bangalore Metro. Pranav has also launched the rental model where the builders and contractors need not purchase the formwork and standard systems when they could be taken on hire for the tenure of their constructions. On completion of the project, the formwork can be returned at a predetermined rate, thereby avoiding investments in formwork materials, besides the problems of storing the material after the project is completed. Nurturing excellence within the organization is another key driver at Pranav. The company ensures exciting growth opportunities for its people, and contributes to society by enriching lives around. As part of CSR, the company has invested in the Pranav
Flyover Panjarapole Pier & Pier Cap, Mumbai
Institute of Formwork and Technology (PIFT). Here, every year the company intends to train 80-100 unemployed & under-privileged in various locations and provide job opportunities through the industry.

Pranav Construction Systems Pvt. Ltd. Plot no. C-10, TTC Industrial Area, MIDC, Pawane, Koperkhairne, Navi Mumbai - 400 705, Ph:+91-22-27632602/2580/2581/2589, Fax:+91-22-27632762 E-mail: customercare@pranavind.com Web: www.pranavinfra.com
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Reinventing the H-Beam

av Nirman Beam Technics is the leading manufacturers and exporters of Formwork H-Beams in India. Its range of products includes H-12, H-16, H-20 and H-24 Beams. The company's objective is to expand the original value chain of round timber by way of cut timber and to widen and optimize the application thereof. H-Beam is manufactured at par with international standards under strict quality control and quality assurance to withstand various loads during the construction of various activities. These varieties of H-Beams along with the scaffolding forms a part of the formwork system that has been in high growth due to the rise in the number of high-rise structures and mega infrastructure projects.Formwork Timber H beams helps contractors to complete the project in less time as it is relatively easy to establish and dismantle. This modern formwork system is felt as a most important requirement in construction industry when it comes to high rise buildings. Most of the construction companies prefer to purchase Timber H Beams and Scaffolding items from different dealers to save cost. When it comes to Timber H Beam there is a need for a proper technical expert in the field of wood for consultation. Nav Nirman Beam Technics with its experience in wood over three decades and a leading brand in the manufacturing of H-Beam of different varieties is the right choice for end users. Product H-Beam is a unique introduction to overcome the cumbersome and costly procurement of timber. It has been designed to withstand multiple loads during construction activities. The members are made of seasoned
Timber Beam Wall Formwork
Ply by making the web and flange section of seasoned Pine Wood imported from Europe so as to make Timber H-Beam stronger and denser. Both the flange and web are hot processed by the wedge technology making it a composite versatile section. Uses It is used for Column Box, Formwork Making, Circular Column and Wall Shuttering and for Beam Span Base Support. Salient Features Reduction in consumption of timber. Making work at site minimized. No. of reuses - more than 8 times that of conventional timber-Quick adaptability. Dimensionally stable and uniform in size. Consistent in strength.
Cost ratio per use, H-16 beam: conventional timber = 1:3.5 Economical and long - lasting.
Applications of H-Beams: Its areas of applications include Residential Construction. Industrial Construction. Office and Building Construction. Water - Resources Engineering. Transport Infrastructure (Road & Bridge). Stadium and Sports Building Construction and to meet the growing needs of the Construction industry.

Plot No: 6, Road No : 7, IDA, Nacharam, Hyderabad - 500 076, India, Tele-Fax: +91-40-27150119, E-mail: sales@navnirman.in Web: www.navnirman.in
Nav Nirman Beam Technics
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Kumkangkind India
Kumkangkind India
Benefit from Global Expertise in Concrete Forming

aschal was founded in 1964 in Steinach, West Germany whose inhabitants are known world over for their innovation, accuracy and sense of quality. Paschal, is an internationally well-known provider for services, distribution, and production of concrete formworks, support systems, and formwork planning software in over 60 countries. Overwhelming request from it's prospective customers in India persuaded Paschal to set up its operation in India. The Indian arm of this truly global player is located in Hyderabad while the manufacturing facility is situated in Visakhapatnam. The company had successfully launched its Modular Panel, assembled in India in April, 2010 and gained very quick response from the customers. It was followed up with the launch of the e-deck system in June, 2011 once again gaining extremely positive response from the customers. Classification: PASCHAL system has unique products for Verticals and Horizontals. 'Modular' for concrete vertical structures Modular formwork systems are of various panel sizes. The panels are strong and durable, being manufactured of 6 mm-thick high quality sturdy steel
which do not corrode. Surface of these panels are covered by high quality Finnish birch plywood with a phenolic resin coating. The edges of the plywood are protected by steel frame and the gap between frame and surface is filled with a special joint filling agent. Hence, the steel frame will remain for a longer period. The efficient use of Modular form work can speed up the superstructure by 3 times compared to the traditional form work system. 'e-deck' for horizontals slabs The e-deck is a special system designed keeping in mind the Indian working conditions. Paschal's decking system has various panel dimensions. The panel frame consists of profiled steel with a height of only 7.5cm, and the facing consists of 9 layer, 12mm thick birch plywood. These panels are light in weight, weighing less than 20kg, hence leading to better workmanship and high productivity. The system doesn't require a crane facility and can be handed manually. The panel's plywood can be re-used up to 200 times (approx.) and the steel frame remains for longer period. PASCHAL's Modular system is a multipurpose system which can be used
in reality sector as well as infrastructure sector. The system is used wherever the concrete pouring is done .The most impressive part which, stands out here is the fact that only one system is used in the overall project the enables the contractors to use them for casting of Footing, Ground Beams, Columns, Lift shafts, Shear walls, Walls, Staircases, Slabs, etc. The system is also used in many infrastructure projects like power projects for track hoppers, RCC walls as well in irrigation Projects for canal Drains, box culverts, water treatment plants, and reservoirs etc. Features: Single connection technique Versatile, Flexible and Unique Self Alignment Precise Dimensions Quick adaptability User Friendly- easy Errection and Dismantling Smooth finish-plastering can be avoided
Paschal system offers its own specialized products. It provides a very wide range of services including design support. As the use of innovative construction methods gains more attention from various sectors in the industry,
Track-Hopper
Furnace wall
Columns
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Horizontal Finished Surface
Vertical Finished Surfaces
advanced formwork systems will become more widely adopted. The input through research and development by the wellestablished formwork manufacturers is no doubt a contributing factor. Various sizes Modular system: Height wise: (75 /125/150)cm, Width wise: (100/75/60/ 50/45/40/35/30/25/23/20/15/10/5). e-deck system: The individual panels have the panel dimensions (60x125,45x125, 30x125, 60x120, 45x 120,30x120, 60x90, 60x85, 60x60 and 30x60 ). Repetitive nature Paschal Modular system is unique product that can be used for any concrete structure according to its dimension panels that are being erected, so repetition wise as mentioned earlier the re-use of formwork is major factor in cost comparison for the total project. While modular panel can be re-used up-to 250 times subjected to the proper handling
the e-deck system can be re-used upto 200 times according to its durability and the handling. Since the steel frame remains for 20 years, refurbishment of the plywood is the only effort required after the maximum repetition been achieved. Surfaces finishes 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. The e-deck is user friendly system for slab. It is an easy erection and dismantling system helps in handling our slab requirements. As mentioned earlier 'e-deck' system is used for the slabs, which is the main structural (horizontal) component of the building (slab thickness up to 30 cm). In this system a special feature has been in cooperated for the fast slab cycle. The Drop and Prop head system which helps for easy movement for the slab cycle of 3 days in-order to facilitate its shifting alternatively from one floor cycle to another with less time.
The benefits of this system are Flexible Highly adaptable User friendly-easy erection Can be used without crane availability
Paschal Modular and Slab system is very easy to operate and no skilled worker is required in erection process and de-shuttering process. As now days the skilled labour, carpenter are very scarce to get in. The Modular panels can be lifted with and without crane as it weight varies 40kg sq.mtr and the e-deck is 20 kg, which can be lifted by two people and the connection technique is only key bolt and limited tools are used for erecting and dismantling the set. Limited accessories and multi usefulness, handling of the system has permitted the quick work and fasten the cycle of the casting. During the course of construction, accessibility problems may be created through segregation, temporary discontinuation, or blocking of the layout by the partially completed
Beams with Modular is Possible within.
Support of panels with Props/shoring system.
Panels placed on Beams
Panels shall be placed on Beams drop head system
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Handling and erecting of Modular and e-deck system with one connection technique
structure. Arrangements for access to work places should be properly arranged when carrying out construction planning. As by this system there is a limited scope of safety hazards (Major Accidents on sites can be avoided). RFID Technology: Since 2003, the formwork specialist, PASCHAL-Werk G.Maier GmbH has resorted a new territory of development and designed the system.
PASCHAL-I dent. Paschal uses this system consequently and successfully since 2008 with corresponding software for administration of its own rental park. During manufacturing Paschal integrates the transponder chips in formwork elements of Modular Universal Formwork. Each individual transponder installed in the element is provided with a globally unique identification number. At present, the i-dent system from
Paschal is unique feature in the of industry. The i-dent system helps in maintaining the inventory and logistics.

Plot No. 901, Road No.46, Jubilee Hills Hyderabad - 500 033, India. Ph: +91-40-66580505/23546755 Fax: +91-40-66580506 E-mail: service@paschalindia.com Web: www.paschalindia.com
PASCHAL Formwork (India) Pvt. Ltd.
Solar Sector Attract Over US$4 bn Funding

India is gradually emerging a key market as far as the solar sector is concerned. The country's solar sector has attracted investments to the tune of US$ 4.3 billion (over Rs.24,000 crore ) during April-June this year, according to the Mercom Capital Group's second quarter funding and M & A activity report for the solar sector. The Indian solar sector attracting this total funding through a total of 66 deals, which included two Indian transactions involving Azure Power and Reliance Power. While Azure Power secured a US$ 70.4 million in long term financing from the Export Import Bank of the US, Reliance Power secured a US$103 million loan from the Asian Development Bank (ADB). These two transactions were listed in the project funding category in the report. Solar power has along with wind power emerged as the key areas of renewable energy development in recent times. State governments too have been on their part aggressively trying to woo investments in the solar sector in the past couple of years.
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Plastic Shuttering
A Revolution in Construction Industry

Understanding MS Shuttering Formwork It is made out of MS Plates & MS Channel & is generally available in 3' X 1' size. MS Shuttering can be typically reused from anywhere between 40- 50 times. However, due to water corrosion, quality casting cannot be achieved beyond 15 times. Moreover, it is not labour friendly due to its heavy weight. The RCC material has a tendency to stick to the MS material, hence while deshuttering either RCC material will stick to plate & a gap will be developed in RCC or MS Shuttering may stick to RCC work so one has to deshutter it carefully & also maintain properly with oil treatment. Understand Rubber Coated Plywood Formwork It is not as heavy as MS Shuttering
Ramesh Patel, Director,

Desire Construction System & Resort Pvt. Ltd.
t is well known that formwork systems are required for casting of RCC slab, beam, column and walls. Given the current trend in India to either use MS Shuttering or Rubber Coated Plywood formwork system to cast RCC it is essential for us to understand the merits and demerits of the above options.
and can be only reused for 12 times as it gets damaged due to water contact very quickly. Although the quality of RCC work is much better in comparison to MS Shuttering a skilled carpenter is required to set the system which makes an expensive proposition. The above two materials are not Eco-Friendly, as the former consumes valuable iron while the later consumes precious the trees around us. Plastic Shuttering-The Viable Alternative Considering the labour problem & cost of formwork system we at Desire Construction Systems thought to develop an alternative formwork system which could help the industry to not only reduce construction cost but also a system that is easy to install, dismantle & handle. We were able to successfully develop for the first time in India a plastic formwork which can over most of the issues discussed above. The system has following Advantages: Distinct Feature of Desire Formwork Systems Cost Effective Labour Friendly Eco Friendly Low in Maintenance Versatile
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Speedy in Installation & Dismantle Good Quality RCC Finish is Produce
BRIEF This system gives more than 100 repetitions; hence running cost is low. The final RCC work will get smooth finish with minor joint line which does not require plaster. One can do putty & paint it. With this system one can save @ `16 / sq. ft. if you don't do plaster and hence it is cost effective. This systems is made from special -
grade plastic and hence no chemical reaction take place nor the material stick to it. Because of this property you cannot get any patched on the RCC finish. Also the gap between two plates are so negligible that no water nor cement gets leaked out at the time of RCC & it gets curing from the bottom of the plate also, which enhance the final quality of RCC casting . Comparatively our foam systems are very less in weight compare to conventional M.S. Plate (1/4th ) and Plywood (1/2). Hence it is very easy to install, dismantle, transport from one place to another. Due to easy plugging systems & east to fit makes this foam shuttering systems most labour friendly. By using Desire systems one need not nail or apply oil to the plates before casting RCC. Due to auto leveling of plugging systems the plates are automatically leveled. Hence 30 % time is saves in assembling & also while dismantling the same. All existing traditional scaffolding systems can be use in Desire
shuttering systems comfortably. You can cast Slab, Beam & Column, etc. A lot of the parts in the Desire system are supportive to each other and you can cast a beam from 9 inch to 21 inch by this same plate by simply adjusting the locking systems. Desire formwork systems is made from Petroleum waste and it's long lasting and gives more than 100 repetitions. Its replace plywood's which consumes trees and M.S. which consumes iron ore from our planet earth. Our products help in preventing this precious metal from our earth. After every usage of Desire foam systems once can easily clean the plates by water. Where as in M.S. plate one have to apply oil to clean the M.S. surface plates. In Desire plates if any breakage occurs by mishandling it can be very easily sealed by low voltage hot air gun.

B/H. Gas-Holder Tank, Idgah Road, Pratapnagar, Vadodara - 390 004 Ph: +91-0265-2580336, 2580624, E-mail: info@desireindia.in Web: www.desireindia.in
Desire Construction System & Resort Pvt. Ltd
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Universal Construction Machinery & Equipment Ltd
Concrete Batching Plants
CONCRETE BATCHING PLANTS:

Set to Play a Crucial Role in Infrastructure Development Phase II
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oncrete batching plants have become a common sight across Indian cities these days. While the stationary models with their majestic presence is now an assumed part and parcel of large infrastructure projects, rows of mobile concrete batching plants have also become a common sight on Indian highways, particularly near RTO check posts. It won't be a misnomer to say that the growth of the RMC industry in the country has dramatically transformed the construction industry in the country. What began as trickle in the early 1990s is now a thriving industry in the country. The number of commercial RMC plants in the country is estimated to be over 500 at present, and expected to double in another five years time, given the continued impetus to infrastructure development. The stricter quality control diktats and pressure to stick to tight project deadlines has been the driving force behind the growth in the RMC usage. According to Mr.Vijaykumar R.Kulkarni, Member Managing Committee & Principal Consultant, Ready Mixed Concrete Manufacturers' Association (RMCMA), considered an authority on the subject, the growth of the RMC started with the metropolitan cities and is now trickling down to tier II and III cities. Going into
There is a section of customers which wants machines that can be moved easily. We have an exclusive range of concrete batching plants designed in such a way that the plant be dismantled and moved to another site. Mobility is an important consideration these days, as far as concrete batching plants are concerned
Anand Sundaresan
Managing Director, Schwing Stetter India
details about the growth of RMC usage in the country, Mr.Kulkarni pointed out that, In addition to the commercial RMC plants, a large number of batching and mixing plants belonging to medium and large construction companies also operate as captive plants on a number of projects throughout the country. These plants are large in numbers and with the current emphasis on building
physical infrastructure in the country, there seems to be a phenomenal increase in captive batching and mixing plants, a market segment that is perhaps witnessing the most intense competition among the various types of construction equipment available in the country. Dictating the market trends has been an increasingly evolving customer. The typical customer these days wants a machine that apart from being able to process concrete should also be environment friendly, easy to install and if possible allow to be shifted to another site. Another factor that has been dictating latest trends has been economic uncertainties. The economic slowdown has meant that the influx of funds into large scale infrastructure projects is now an issue. Several key large scale projects in sectors such as power, roads, airports, and ports have been delayed in the past year. The process of awarding projects has been moving at the proverbial snail's pace. With the result the market for concrete batching plants which was galloping at an estimated CAGR of 25%-35% until the end of 2011 has now slowed down. Manufacturers though have been quick to plan their strategies accordingly. A conscious effort towards pushing compact concrete batching plants
Schwing h6 Batching Plant at Dankaur holds the all India record in PQC production of 5050 cu m in 1 day
In addition to the commercial RMC plants, a large number of batching and mixing plants belonging to medium and large construction companies also operate as captive plants on a number of projects throughout the country. These plants are large in numbers and with the current emphasis on building physical infrastructure in the country, there seems to be a phenomenal increase in captive batching and mixing plants
Vijaykumar R Kulkarni
has been observed. Even in the case of large capacity concrete batching plants, the emphasis has been on product design, which facilitates portability, ease of installation and dismantling in order to facilitate mobility. Economic Slowdown and Compact Plants The recent trends in the market for concrete batching plants have been impacted by the economic slowdown. With several large- scale infrastructure projects either stalled or delayed over the past year, manufacturers have been focusing on the small and medium scale projects in recent times. Compact plants which are easy to install,
dismantle, and move seem to be in demand. There is a section of customers which wants machines that can be moved easily. We have an exclusive range of concrete batching plants designed in such a way that the plant be dismantled and moved to another site. Mobility is an important consideration these days, as far as concrete batching plants are concerned, highlighted Mr.Anand Sundaresan, Managing Director, Schwing Stetter India, considered a market leader in the field. The company's popular models such as CP 30 are already working successfully in construction sites across the country. The company had late last year introduced the CP 30 with planetary mixer for the growing demands of the precasting industry. Another good example is the CP 18 on truck model, which according to the company can be erect at the press of a button without the requirement of a crane. The M2.5, the largest foundationless concrete batching plant in the country according to the company, is ideally suited for road, highrise and heavy construction projects. When queried whether there has been a tilt towards compact plants in the market due to the recessionary trends, Mr.Debasis Bhattacharya, Head- Sales & Marketing, Ajax Fiori, a leading name
in concrete batching plants pointed out, More than the recent economic slowdown factor, the reasons more prominent are the delay or lack of government focus in infrastructure projects and the rising interest costs. Due to time overrun and increased finance costs, most of the project costs are escalating and it is quite imperative that they will have to be managed more efficiently. This actually brings down the scale of investments in the capital equipment. In today's context, there has been a tilt towards lower capacity batching plants and we have been able to leverage quite a bit of the share. Citing his views on the trend is Mr.Mitul Patel, Managing Director, Apollo Infratech, another market leader in concrete batching plants said , Yes but not fully. Small and medium scale projects require this type of plants. Moreover, it is not as if companies have been coming out with products to cater to this particular market segment only recently. Almost every leading player in the market already had exclusive compact concrete batching plants models as part of their product portfolio. Apollo Infratech for example offers models such as ATP 21, ATP 31, and ATP 61 under its compact series. While the ATP 21 and 31 with pan mixers feature advanced micro processor control systems with LCD display, the ATP 61 with twin shaft mixer features PLC based control panel with Command Alkon (USA) automation. Another leading player in the fray, Aquarius Engineers offers the two mobile plants, MP 21 and MP 24, which can be mounted on re-usable precast foundations. The foundations can be lifted and shifted to another location. The company also offers a 'Super Mobile Concrete Batching Plant' model which comes with a unique foldable design that reduces transport cost, crainage cost, and shifting time drastically. Modular Design and Ease of Transport Manufacturers have been focusing on coming out with concrete batching plants that are easier to erect and commission. One of the highlights of all the
Aquarius Stationary Batching are available in various capacities ranging from 25 cubic meter to 240 cubic meter per hour of compacted concrete output
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Ajax Fiori Engineering (I) Pvt. Ltd.
Ajax Fiori's Fully Automatic Computerised Radius Lift Arm Batching Plant
More than the recent economic slowdown factor, the reasons more prominent are the delay or lack of government focus in infrastructure projects and the rising interest costs. Due to time overrun and increased finance costs, most of the project costs are escalating and it is quite imperative that they will have to be managed more efficiently. This actually brings down the scale of investments in the capital equipment. In today's context, there has been a tilt towards lower capacity batching plants and we have been able to leverage quite a bit of the share
Debasis Bhattacharya
Head- Sales & Marketing, Ajax Fiori
recent models has been the emphasis on modular design, something that helps make concrete batching plants easy to assemble or dismantle, apart from aiding in their transportability. Good examples for manufacturers focusing on innovative product design for ease of erection and transportability is available in the form of some of the models offered by Ajax Fiori, a company that offers a wide range of concrete batching plants ranging from radius lift arm batching plants to bin type and dragline type batching plants. Its RLA 20 radius lift arm plant can be erected within a day and can be transported in just 2 trucks. Similarly, the American Bison radius lift arm plant model with its modular design can be transported in 3 trucks. The bin type CBP 30 is a compact model from the company that can be erected in a small space envelope of 5.25m x 11.25m. REL-Construction Equipment Division is another leading name that offers concrete mixing plants models such as the Mo60 that are manufactured as per Wiggert Gmbh design, which require minimal site preparation, shortest operational set-up time, come fully preinstalled and are easy to transport. Yet another good example is the 'On Wheel
Concrete Batching Plant' model from Universal Construction Machinery & Equipment. The planetary mixer batching plant comes with Universal feeding system has belt conveyor aggregate feeding system to load the aggregate into the mixer hopper. The mixer hopper has load cell based weighing system which automatically stops the conveyor when desired quantity of aggregate is loaded in the mixer hopper. Singh Construction Equipments offers fully automatic 25 cum/hr plant with pan mixer and reversible drum mixer, which is compact, portable and requires just a few hours for commissioning.
Yes. But not fully. Small and medium scale projects require this type of plants (lower capacity plants)
Mitul Patel
Managing Director, Apollo Infratech
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Columbia Pakona Engineering Pvt.Ltd
Apollo Infratech offers a compact series of concrete batching plants
Conmat, an established industry leader in construction equipment also offers fully automatic mobile concrete batching plants in the 20, 25 and 35 cum/hr capacity range. The mini concrete batching plant model from Safari Construction Equipment is another good example for product innovation. The mobile concrete batching plant features extra chassis support, centralized grease lubricating system, smart hopper design to reduce spillage and an automatic water control system. Bigger Plants will make a Comeback The market for concrete batching plants is expected to bounce back by the end of the year. With the government making its intentions clear about investing an amount to the tune of US$1
trillion towards infrastructure development as part of the 12th Five Year Plan period (2012-17), the growth rate of the market is expected to return to that of
Revathi Equipments In technical colloaboration with German equipment manufacturers, offers the full range of Concreting equipments in India
the earlier heady days in a few months time. The continued thrust on manufacturing with the setting up of several industrial corridors, IT parks, SEZs, and sector specific industrial parks is also expected to fuel demand. Policy initiatives towards facilitating influx of funds into infrastructure projects are another positive sign. When it comes to compact concrete batching plants, there is one more market segment where they play a key rolereal estate. While the country's real estate scenario may be passing through a dull phase, especially in the metros, the Tier II and Tier II cities offer plenty of scope for manufacturers of concrete batching plants to make further in-roads. This is especially true in the case of compact concrete batching plants that are easy to commission and can be shifted, since they can be just what the doctor order for project developers. There are also indications that things may at last return to normalcy in the real estate sector soon, lead by the growth of the retail sector, another good sign for concrete batching plant suppliers. While the demand for compact concrete batching plants is ex-pected to continue for a while, it is only a matter of time before the demand for larger models is expected to pick up.
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Venus Equipment and Tools Pvt. Ltd
Concrete Admixtures
Rice Husk Ash An Ideal Admixture for Concrete in Aggressive Environments

Dr. R N Krishna, Ph.D (Civil Engg.)
Concrete Technologist, Ex.Secretary General, Indian Concrete Institute, India. Proprietor, KC Contech Manufacturer of Rice Husk Ash
The use of durability enhancing mineral admixtures or supplementary cementing materials has gained considerable importance the last decade or so as a key to long service life of concrete structures1. There are many mineral admixtures that are used in way through out the world but rice husk ash stands out as an eco-friendly, sustainable and durable option for concrete. This paper attempts to bring out the effectiveness of rice husk ash as a versatile concrete admixture and discusses some versatile application of rice husk ash concrete.
ice husk is the outer cover of paddy and accounts for 20-25 % of its weight. It is removed during rice milling and is used mainly as fuel for heating in Indian homes and industries. Its heating value of 13-15 MJ/kg1.2 is lower than most woody biomass fuels. However, it is extensively used in rural India because of its widespread availability and relatively low cost. The annual generation of rice husk in India is 18-22 million tons and this corresponds to a power generation potential of 1200 MW4. A few rice husk-based power plants with capacities between I and 10 MW are already in operation and these are based either on direct combustion or through fluidised bed combustion. Rice husk is characterised by low bulk density and high ash content (18-22% by weight). The large amount of ash generated during combustion has to be continuously removed for a smooth operation of the system. Silicon oxide forms the main component (90-97%) of the ash with trace amounts 2.7 of CaO, MgO, K2O ) and Na2O. Manufacture Rice husk ash is produced by burning the outer shell of the paddy that comes out as a waste product during milling of rice. Since they are bulky disposal of husk present an enormous problem. Each ton of paddy produces about 200kg of husk and this rice husk can be effectively converted through controlled burning. At around 500C a valuable siliceous product that can enhance the durability of concrete in the chemical composition of rice husk ash is
obtained. Variations in the burning temperature much above or below will drastically alter the silica content of the ash. It is estimated that one fifth of the five hundred million tons of world annual paddy production is available as rice husks. Only a small quantity of rice husk is used in agricultural field as a fertilizer, or as bedding etc. and stabilisation of black cotton soils. The manufacture and batching of rice husk ash involves bulk handling of a light raw material and proper and a controlled burning methodology has to be adopted. Grinding of the ash is done after necessary cooling and can be done to any desired fineness. The author manufactures RHA and adopts a fineness value of around 4200blaine. There is another difficulty in the manufacturing of RHA. Namely burning of the raw husk to a high temperature for a sustained period makes it extremely difficult to cool the ash to normal temperature. This is also compounded by the inherent nature of raw husk to retain heat for a considerably long time. Therefore the method adopted is to allow the burnt husk to stay for some time and subsequently cool with water. However, when this is done the Ash is saturated with moisture and therefore grinding becomes a challenging task-especially with an abrasive material like RHA. Therefore drying of RHA is a must. Among the several methods that are possible normal sun drying and / or drying using paddy driers are the cheapest options. Another point to be borne in mind is the variation in the raw material composition from different sources and therefore
Concrete Admixtures
the material has to be tested for chemical composition. However the durability enhancement properties of rice husk ash when blended with cement makes it the most eco-friendly versatile supplementary cementing material to concrete. The following properties of concrete are considerably altered when blended with RHA : - Reduced heat of hydration leading to minimal crack formation in higher grades of concrete. - Reduced permeability at higher dosages. - Increased chloride and sulphate resistance/mild acids. Therefore RHA can be used as an effective and green supplementary cementing material. RHA can be used for a wide variety of applications starting from a simple water proof coating to an admixture for cement to resist a wide variety of chemicals including mild acids like lactic acid(milk) alkalies, etc. in bathroom floors, swimming pools, industrial factory floorings, foundation concreting when concrete is exposed to both chlorides and sulphate attack and as an effective repair mortar to resist chlorides. A small study was conducted to assess the chloride resistance of RHA concrete and proves that RHA can be used as an effective corrosion inhibitor in concrete: An ideal corrosion inhibitor has been defined as a chemical compound, which, when added in adequate amounts to concrete, can prevent corrosion of embedded steel and has no adverse effect on the properties of concrete. Corrosion inhibitor admixtures are used to delay or retard corrosion of reinforcing steel in concrete. In this part of the study, corrosion resistance of Ordinary Portland Cement concrete with commercially available zinc rich epoxy coatings for reinforcing bars was studied and compared with RCC specimens using rice husk ash. The commercially available rice husk ash (Hyper 2000 manufactured by the author) was used for the study to prove its efficacy as an effective corrosion inhibitor. Details of chemical composition are given in Table 1 for three different samples from different places in the country. M 30 and M 35 grades of concrete with Ordinary Portland Cement (OPC) and Rice Husk Ash Cement (replacing OPC 30% by weight) have been used. Polymer based coating and Zinc rich coating were the two different coatings applied on the surface of the steel rebars. Chemical Composition Preparation of Specimens Beam specimens of section 100 mm x 150 mm and length of 1000 mm were selected. For the beam specimens, main reinforcement of 2 numbers of 10 mm diameter, hanger
reinforcement of 2 numbers of 8 mm diameter and shear reinforcement of 6 mm diameter two legged stirrups of HYSD bars were used. The surface of rebars was derusted using wire brush and rust clear solution in order to remove any loose rust particles. The coating material was applied over the surface of the rebars with a brush and was allowed for curing. The initial weight of the rebars was taken and then the rebars were tied together to form the skeleton reinforcement cage. Twelve numbers of beam specimens were cast during M30 and M35 grades of concrete. After curing them for a period of 28 days, the specimens were transferred to Fiber Reinforced Plastic (FRP) tanks and were subjected to accelerated corrosion process.
Sample Marked as :
Loss on ignition Silica (as SiO2) Aluminium (as Al2O3) Iron (as Fe2O3) Titanium (as TiO2) Calcium (as CaO) Magnesium (as MgO) Sodium (as Na2O) Potassium (as K2O)
Table : 1 Sample : Rice Husk Ash
1
8.71 83.60 3.05 1.10 Nil 1.80 1.28 0.17 0.29
2 (Percent By Mass)
7.00 84.00 3.84 0.60 Nil 2.85 1.35 0.13 0.23
3
3.07 90.47 3.13 0.32 Nil 1.96 0.35 0.22 0.48
Acceleration of Corrosion Process Galvanostatic method was used to accelerate the corrosion process. In this method, the embedded steel acts as anode and an external stainless steel plate acts as cathode. The beam specimens were impressed a selected current intensity under low voltage conditions. The specimens and the stainless steel plates were immersed in an electrolyte solution of three-percentage sodium chloride concentration to simulate the conditions of seawater. The current was applied using a regulated D.C. Rectifier. The accelerated corrosion process was carried out for a period of fifteen days. Thereafter, concrete samples from the cover portion near main rebars were collected to determine the pH value and chloride content. Then the beam specimens were broken and the rebar grid was taken out separately, from which the main rebars were separated. Then the rods were cleaned and wiped. The weight of rebars was determined to estimate the weight loss. (Table 2). Discussion of Test Results For the M30 grade contol concrete with RHA, the beam specimen with uncoated rebars showed 50% less loss of weight than that of the similar control concrete specimens with OPC. The same trend was observed for specimens
Concrete Admixtures
of M35 grade of concrete also. The beam specimen with uncoated rebars showed loss of weight of 41 % less than that of the specimens with OPC for M35 grade. For coated rebars with and without rice husk ash concrete, it is observed that the use of rice husk ash contributes to a significant reduction in weight loss when compared to OPC concrete with the same coatings.
Beam Designation Initial Weight (gms)
1086.9 1108.6 1062.3 1063.5 1092.7 1073.5 1086.7 1105.7 1075.6 1065.5 1091.5 1074.8
Final Weight (gms)

942.4 1062.0 1047.5 993.4 1051.0 1065.8 1004.2 1089.9 1063.3 1017.4 1076.6 1068.3
Loss of Weight (gms)

144.5 46.6 14.8 70.1 41.7 7.7 82.5 15.8 12.3 48.1 14.9 6.5
Loss in Percentage
M30 Grade OPC Concrete

M30 OPC control M30 OPC Z* M30 OPC IP** M30 RH control M30 RH Z* M30 RH IP** M35 OPC control M35 OPC Z* M35 OPC IP** M35 RH control M35 RH Z* M35 RH IP** 13.29 4.20 1.39 6.59 3.82 0.72 7.59 1.43 1.14 4.51 1.37 0.60
Fig. 2 -SEM of RHA Fig. 1 - SEM of OPC Concrete
M30 Grade RHA Blended Concrete
* zinc rich primer ** polymer based primer Table: 2. Weight Loss of Rebars
paste. Fig.1 and 2 show Scanning Electron Micrograph of OPC and RHA respectively. SEM of rice husk ash blended concrete clearly shows large number of silicon fibers in concrete. These silicon fibers are seen to be very effective in substantial resistance to corrosion of RHA blended cement concrete. Earlier experiments combined with SEM observations suggests that the structure of rice husk ash is similar to the composite material with silica tubes filled with cellulose material with the matrix consisting of lignin2. These silica fibers constitute the greatest advantage when using rice husk ash in concrete and are responsible for its impressive performance in corrosive environments. Miscellaneous Applications of RHA Rice husk ash has been effectively used as simple cementitious coatings for concrete surfaces to act as a waterproofing barrier coupled with higher chemical resistance. Photograph shows a typical coating application of RHA in a water-treatment plant. Fig.3 Rice husk ash has also been extensively used as an effective
The chloride content of cover concrete in the beams cast with rice husk ash cement is less than that of beams cast with Ordinary Portland Cement by 29 % in case of M 30 grade of concrete. For M 35 grade of concrete with RHA, it is 12 % less than that of specimens with OPC (Table 3). It shows that the rice husk ash cement is very effective in controlling the entry of chloride ions into the concrete. This reduction in chloride content can be considered to be of significant order. Concreting with RHA poses no difficulties at all in fact the consistency / plasticity of the mix shows considerable improvement. However, the initial slump of fresh concrete is slightly reduced. Microstructure studies of RHA Scanning Electron Micrographs (SEM) of OPC and RHA cement concrete samples were taken for manification of 2000 X. The samples were prepared out of hardened cement
Venus Equipment and Tools Pvt. Ltd
Concrete Admixtures
repair mortar without the use of SBR latex /Acrylic polymer bonding agents as seen in the photographs. Fig.4 Field observations done by the author for concrete blended with RHA (Hyper 2000) at 10% by weight has shown that RHA is intact on the concrete floor subjected to constant salt water usage Even after more than 2 years of exposure.
Fig. 4: Beam
Fig. 3: Tank
Neither plastic shrinkage cracks nor long term drying shrinkage cracks were observed.
pH Value Percentage of chloride content mg/g of concrete dust
0.600 0.540 0.490 0.340 0.490 0.325 0.485 0.620 0.285 0.340 0.630 0.255 -
Beam Designation
Conclusion The production and use of RHA in India should be considerably increased given the fact that RHA contributes significantly to a green building. It not only reduces the consumption of cement due to blending but also solves waste disposal problem. Rice husk ash therefore can be effectively used as a sustainable concrete option in severe environments and can be considered a class apart from all other mineral admixtures due to its unique microstructure and the resultant benefits in concrete and its multi various application possibilities. Considerable study needs to be done on applications of RHA as repair mortars, coatings and soil stabilization. Reference
- Role of Rice-Husk Ash and Silica Fume in Sustainable Development by P .K.Mehta and I.Nakagawa, Proceedings of the International Symposium on Concrete Technology for Sustainable Development in the twenty first century, Hyderabad, India, Feb.1999 Pyrolysis of rice husk by Anshu Bharadwaj, *, Y. Wang, S. Sridhar and V. S. Arunachalam ; Center for Energy and Environment Studies and Department of Material Science and Engineering, Carnegie Mellon University, Pittsburgh, PA 15213, USA

M30 OPC control M30 OPC Z M30 OPC IP M30 RH control M30 RH Z M30 RH IP M35 OPC control M35 OPC Z M35 OPC IP M35 RH control M35 RH Z M35 RH IP 11.3 11.6 11.3 11.7 11.7 11.4

11.5 11.4 11.5 11.8 11.9 11.7
* zinc rich primer ** polymer based primer Table 3 - pH Values and Chloride Content Cover Concrete
Nawa Engineers & Consultants Pvt. Ltd.
Transit Mixers
SMALL IS THE
MB Bureau Report
here are certain sights and sounds which have come to symbolize the rapid strides made by the Indian construction industry in recent times, powered by the infrastructure development and real estate boom of the last decade or so. One of them is the presence of various types of earthmoving equipment such as backhoe
CONCRETE TRANSPORT EQUIPMENT:
NEW BIG
T
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loaders, excavators and wheel loaders at various infrastructure development projects. Among concreting equipment, perhaps the most visible among the lot are the transit mixers. Concrete on the go is the buzzword these days in the industry and these mean machines have transformed the building process. The rapid strides made
by the Ready Mix Concrete (RMC) sector have been instrumental in the spurt of transit mixers in the country. A gradual change in the mindset has meant that today contractors prefer RMC for even small residential units, secure in the knowledge that quality concrete would reach the project site on time, thanks to transit mixers. The speed at which quality
Transit Mixers
The demand for higher speed of construction, especially for residential and commercial housing, flyovers, highways, roads, aviation, etc. in metropolitan and other big cities of India, necessitated adoption of mechanized and semi-mechanized techniques of construction. The need for large volumes of concrete as well as faster speed of construction was felt. This was conducive for the development of readymixed concrete (RMC)
Mr.Vijaykumar R.Kulkarni
concrete reaches a site is the key today, a factor that has helped the RMC industry evolve, speaking about which Mr.Vijaykumar R.Kulkarni, Member Managing Committee & Principal Consultant, Ready Mixed Concrete Manufacturers' Association (RMCMA), observed, The demand for higher speed of construction, especially for residential and commercial housing, flyovers, highways, roads, aviation, etc. in metropolitan and other big cities of India, necessitated adoption of mechanized and semi-mechanized techniques of construction. The need for large volumes of concrete as well as faster speed of construction was felt. This was conducive for the development of readymixed concrete (RMC). Transit mixers are the ones that have played a key role in ensuring that speed. The transit mixers market has been growing at a healthy rate of 25% -30% until recently before the economic slowdown put brakes on it to some extent. It is one market segment among construction equipment where manufacturers need to be constantly on their toes, getting to know the exact needs of the customers and changing tracks accordingly. It is not surprising there-
fore that this is one market segment which has seen several product innovations. With competition intensifying by the day, it is not surprising that manufacturers are focusing their R & D efforts on coming out with products whose design and features are dictated by the variety of applications and sometimes by unique regulations. A good example is available in the form of Schwing Stetter India's 30 cu.m metre transit mixer model Nimo. The capacity of the transit mixer model makes it one that can be used during daytime in India, a country where the bigger over 60 cu.m models are allowed to ply only during the evenings and night. A lot of R & D has also gone into designing the smaller capacity transit mixer. Going into details about the type of material that has been used, Mr.Anand Sundaresan, Managing Director of the company explained, We make sure that only high quality corrosion resistant material is used in manufacturing our transit mixers, since they have to deal with concrete most of the times. Similarly, a lot of care is taken to ensure that every component is designed keeping in mind the various applications of the transit mixer. The advent of self-loading transit mixers is another case in point for applications dictating product design. Apart from the dexterity that these machines offer, they are also ideally suited for both inter-site and intra-site transportation of concrete, which makes them ideally suited in the Indian context. Advent of Self-Loading Transit Mixers One of the key reasons for the growth
We make sure that only high quality corrosion resistant material is used in manufacturing our transit mixers, since they have to deal with concrete most of the times
Anand Sundaresan
Managing Director, Schwing Stetter India
of the market for self-loading concrete mixers has been its versatility. These mixers have become the staple whenever the requirement is small to medium concreting jobs at semi-urban areas and remote project sites. Since it does the combined job of a batching plant and a transit mixer, it offers a win-win proposition for all the stakeholders involved in the project. Ajax Fiori is a name that is considered a trendsetter in the field. The company offers it's successful, 'Argo' Series of self-loading mobile concrete mixers Argo 1000 (1 cu.m), Argo 2000 (2 cu.m) and Argo 4000 (4 cu.m) versions. Going into details about the company's range, Mr.Debasis Bhattacharya, Head- Sales & Marketing of Ajax Fiori observed, Self-loading mobile concrete mixer is a product concept that is redefining the concrete equipment usage in the infrastructure industry. As a pro-
Apollo Infratech offers 2m3 and 4m3 models, apart from the larger 6m3 capacity transit mixer
Transit Mixers
Versatile Machine: Ajax Fiori's self-loading concrete mixer (from top) in a tunnel project, power transmission project, urban development project and irrigation project.
duct category, it undoubtedly has the highest growth rate around 40% YOY. Its USP is that whenever you require small to medium concreting jobs at semi-urban areas and remote project sites, it does the combined job of a batching plant & transit mixer. It is actually a mobile batching plant in the true sense unlike the portable chassis mounted batching plants being sold as 'mobile' plants by most other manufacturers. Mr. Bhattacharya felt that the company is yet to tap the entire market potential of the self-loading mobile concrete mixers and being the pioneers and market leaders, have a huge responsibility towards this. Another company that has carved a niche for itself is Apollo Infratech, which has in its product portfolio the highly versatile, self-loading transit mixer model ASTM2. Self-loading concrete mixers are
The ATM2 model has a capacity of 2m3 and is mounted on LCV ideal for narrow areas at site for small pours. The ATM 4 has a capacity of 4m3 and can be mounted on 6 wheel truck of 15T. Also ideal for small pours. The ATM 6 has a capacity of 6m3 and can be mounted on 10 wheel (Twin axle) truck of 25T
more often than not used in some of the remotest corners of the country, particularly in the case of infrastructure projects. Some good examples of such applications are in the case of drains & culverts, irrigation canals and concrete roads. Similarly, with the real estate focus now shifting to tier II and tier III cities, self-loading concrete mixers are also growing in demand in these areas. These self-loading mobile concrete mixers usually come with a four wheel drive and an ability to negotiate even slushy conditions, apart from offering a short turning circle, which means improved maneuverability, all aspects that are considered crucial particularly in urban areas in India where space is often available at a premium. Machines for Smaller Pours
Mitul Patel
Managing Director, Apollo Infratech
Manufacturers have been keeping a close watch on the changing require-
176
Bharat Road Development Combines Private Limited (BRDC)
Transit Mixers
ments and focusing their R & D efforts towards the same. With several large infrastructure projects being delayed due to the latest economic slowdown, there has been a distinct shift towards lower capacity machinery, a trend that can also be seen in the case of transit mixers. Optimum utilization of capital intensive equipment among contractors is another factor that is driving the demand for even smaller capacity transit mixers in India, which was till now a predominantly 6 cu.m country. The growing demand for smaller truck mixers from realty project developers for example has meant that an entire new segment is emerging. A good case in point is 'Nimo' from Schwing Stetter India. The company has set a trend with its smaller 30 cu.m 'Nimo'. The model is a good example for product innovation. With the common 6 cu.m class transit mixers not being allowed inside cities during peak traffic hours, it meant that there was only a small window, available for RMC delivery at sites. The Nimo is the only transit mixer can be delivering RMC during daytime, according to the company. Another advantage with the model is the fact that it can be maneuver easily throws narrow roads, an aspect that is common to most Indian cities and towns. Similarly, the smaller capacity also means a more economical option for sites where it does not make sense to send a larger transit mixer for the contractor. Companies have been focusing on offering as wide a repertoire as possible in order to cater to different market segments. Apollo Infratech, for example, along with its self-loading concrete mixer also offers the ATM2, ATM 4 and ATM 6 models of transit mixers. Explaining the various application areas of the models, Mr.Mitul Patel, Managing Director of the company said, The ATM2 model has a capacity of 2m3 and is mounted on LCV ideal for narrow areas at site for small pours. The ATM 4 has a
Schwing Stetter India's Nimo transit mixer model
capacity of 4m3 and can be mounted on 6 wheel truck of 15T. Also ideal for small pours. The ATM 6 has a capacity of 6m3 and can be mounted on 10 wheel (Twin axle) truck of 25T. With several large scale infrastructure projects either getting stalled or delayed, the key point to note here is the focus on smaller pours. With contractors under pressure to stick to project costs and with the focus presently on small scale projects, apart from realty
projects, there has been rising interest in lower capacity transit mixer models. With a turnaround of the economy though, the bigger models could once again be ruling the roost. Ajax Fiori also offers the XVJ 4001 transit mixers with drum capacity of 4m3. This is apart from its larger XC600 model. The former features a unique drum design made of highly durable steel, optimized positioned spirals with anti-wear protection, efficient hydraulics with planetary drive, rugged & compact mixing units, water tank and pump and special loading hopper and unloading chute, among others. Another leading name in
A Greaves Cotton transit mixer in action
178
Universal Construction Machinery & Equipment Ltd
Transit Mixers
The 4 cu.m transit mixer from Singh Construction Equipments
the field is Greaves Cotton, which apart from its GCM 65 XL model in the 6m3 capacity range also offers the GCM 45 XL model with 4m3 capacity. Truck mixers from the company feature low centre of gravity which creates an ideal balanced load distribution, obtaining better driving position and perfect stability, particularly in narrow bends, traits that are so crucial in a country like India. Another company that offers transit mixer options is Singh Construction Equipments, which offers a 4m3 model apart from the standard larger capacity 6m3 model. The lower capacity model comes with a host of features including
drum made up of ST 52 Grade wear resistance plate, guide roller assembly, water tank with level indicator and userfriendly operating control panel, to mention only a few. Growing Market As the country steps into another crucial phase of infrastructure development, transit mixers are all set to play a crucial role once again. With the government planning investments to the tune of US$1 trillion for infrastructure development during the 12th Five Year Plan period (2012-17), the market potential for transit mixers remains high.
Debasis Bhattacharya
Head- Sales & Marketing, Ajax Fiori
Self-loading mobile concrete mixer is a product concept that is re-defining the concrete equipment usage in the infrastructure industry. As a product category, it undoubtedly has the highest growth rate around 40% YOY. Its USP is that whenever you require small to medium concreting jobs at semi-urban areas and remote project sites, it does the combined job of a batching plant & transit mixer. It is actually a mobile batching plant in the true sense unlike the portable chassis mounted batching plants being sold as 'mobile' plants by most other manufacturers
Manufacturers have been talking to customers and coming out with product innovations tailored to the Indian market. A good example for it is the growing market for self-loading concrete mixers, which offer the versatility of being extremely maneuverable, apart from being a combination of a mini batching plant and a transit mixer. Similarly, the recent slowdown has meant that manufacturers are looking at tapping other market segments, and are not averse to experimenting with lower capacity transit mixers, as is the case with Schwing Stetter India's Nimo. Product innovation would remain the mantra for suppliers in the near future. With the pace of awarding infrastructure project expected to pick up by the end of the year the demand for larger capacity truck mixers is also expected to increase. In fact, several global players are now eyeing the growing truck mixer Indian market, given the fact that RMC is making deeper inroads into the hinterlands of the country. It won't be a surprise if India emerges the key market globally for truck mixers, considering the fact concrete more often than not is not prepared on site and has to be transported. Photo Courtesy:
www.knn24x7.com, www.sceindia.in
180
Unisteel Engineering Works
Equipment Concrete Placement
CONCRETE PLACING EQUIPMENT:

When Newer Markets Beckon
MB Bureau Report
f there is one particular market segment among construction equipment that is almost always in news, then it has to be that of concrete placing equipment. Not a single day seems to pass without some or the other news about concrete placing equipment. From setting new records in vertical concrete pumping to pumping concrete over record distances horizontally, manufacturers are pushing the limits of technology these days. The growing choice has come as good news to the Indian customer, who can now pick and choose from a wider variety on offer, both with respect to stationary, as well as truck mounted boom pumps.
According to industry estimates, an average of about 2500 units of concrete pumps are being sold in the country annually in recent times, a number that is surely bound to increase, given the continued impetus being provided to infrastructure development. The growth rate has been significantly higher in the case of stationary concrete pumps with a CAGR of about 25% -30% in the recent few years and slightly lesser in the case of truck mounted boom pumps. Manufacturers have been keeping their eyes and ears open and coming out with products that cater to the changing needs of the customer.
182
The economic uncertainties of the last few years has been instrumental in certain patterns emerging in recent times in the concrete pump market, especially so in the case of boom pumps. The slowdown in the economy has meant delays in several large-scale infrastructure projects, resulting in manufacturers having to focus on mid to lower capacity product ranges in the recent times. Boom in 20 m Height Range The market for boom pumps in India has been on the rise from the turn of this decade. Pushing the demand has been spurt in metro projects, high-rise projects, power projects, flyovers, bridges, road projects, etc., to mention only a few. The good news for manufacturers is that the growth phase has just begun and not peaked, with the government envisaging investments to the tune of US$ 1 trillion during the 12th Five Year Plan period (2012-17). The economic uncertainties of the past couple of years have meant that manufacturers have been trying to come out with select products for different market segments. Product innovation and versatility is another area where manufacturers have been focusing. The emerging scenarios, vis--vis different applications are also dictating the trend. The delays in large scale infrastructure pro-
The slowdown in large scale infrastructure projects seems to have temporarily slowed down the momentum for boom pumps with a reach of over 30 m
jects has meant that manufacturers are now focusing more on the 20 m height range when it comes to boom pumps, while there was a time a few years ago, when leading players in the fray were concentrating on the 40 m range. The change in focus has also been dictated to a large extent by the unique application requirements in India. For example, the real estate sector is a major demand driver for concrete pumps, particularly in the case of high-rise pro-
jects. However, there are certain constraints that are unique to India, which makes its cities ideally suited for the 20 m height range, so far as boom pumps are concerned. Cramped urban environs that are so typical of Indian cities mean that boom pumps with a shorter unfolding height are preferred, explaining the slew of offerings in the 20 m height range in recent times. The need for truck mounted boom pumps that could be driven through the typical narrow roads of India, apart
Schwing Stetter India's S 20 is ideally suited for crowded urban environs
Aquarius Engineers is another leading name that offers a 20 m concrete pump boom. The product has been designed for catering to various applications including building, road, and bridge projects. The truck mounted boom pump is ideally suited for smaller reach jobs, where there could be restrictions on the set up area. REL- Construction Equipment Division is another company that offers a boom placer ideally suited for cramped urban environs. Its 17 meter boom placer model comes equipped with a KOEL6 cylinder salve engine and a 120 bar pressure pumping unit. Vertical Pumping Drives Demand While there may been a distinct trend towards the 20 m height range that has emerged recently in the case of truck mounted boom pumps and stationary boom placers, the competition continues to be intense in the case of stationary concrete pumps. While established players have been focusing on consolidating their presence and introducing newer products, a slew of new players have also entered the fray. The economic uncertainties elsewhere in the world, especially in Europe, have meant that India today is a key market when it comes to concrete pumps.
Schwing Stetter India is another market leader offering a wide range of stationary concrete pumps
from being able to work among closelyspaced buildings has been the key reason behind the emergence of the 20 m height range of boom pumps. A good example is available in the form of the BSF 20.07 model from one of the pioneers in the industry, Putzmeister. An ideal starter boom pump, especially for road contractors and RMC companies, this price competitive boom pump model is ideally suited for companies that are still not capable enough of investing in a bigger boom placer. Another market leader which offers a boom pump model in the range is
Schwing Stetter India. The S 20 boom pump from the company with 20 metres boom is ideally suited for bridge construction. The RZ fold of the boom with extremely short unfolding height of 3.85 m makes it ideal for use in cramped construction sites and for tunnel lining. The boom pump also features banana outriggers that give it a very small working footprint, again an advantage when it comes to working in cramped construction sites. The company also offers the S 17 model, ideally suited for inner city pumping applications.
Aquarius Engineers is another leading player offering 20 m boom pump
184
United Steel & Structurals Pvt. Ltd
The spurt in high-rise projects has also come as good news for stationary concrete pump manufacturers. Newer records are being set as far as vertical pumping is concerned. A good example is the THP45 D model from RELConstruction Equipment Division. The pump has been used to pump concrete to a vertical height of 29 floors in a project. The company also offers the THP 60 D model which with a pressure of 120 bar can pump concrete over 900 metres horizontally or 165 metres vertically, according to the company. The GCP 350 D/E Deluxe from Greaves Cotton is another good example for a concrete pump that can pump concrete over long distances. The pump features the 'rock valve' technology and can generate high pressure- even up to 86 bars, which can enable theoretically a maximum placing distance of 430 m and 120 m horizontally and vertically, respectively. The company also offers the GCP 950DS model with 'S Valve' design for high pressure applications up to 116 bars with 87 cu.m output. Apollo Infratech is another industry leader which offers a range of concrete pump models such as the SAP-50 and SAP-20. The companies range of concrete pumps have been part of various thermal power projects in Madhya Pradesh, Chattisgarh and Jharkhand, apart from, high-rise building projects in Mumbai and other metros. They
Zoomlion 37-4R Booom Pump
have also been part of canal projects in Gujarat, where difficult downward concrete pouring is involved. Aquarius Engineers is another name that is catering to the high-rise project segment with its 2109 D EHP model. Similarly, Schwing Stetter has its popular SP8800 and SP 2880 models which are designed for high-rise construction projects, apart from a slew of stationary concrete pump models. Putzmeister similarly has its BSA 1408 HD ideally suited for pumping concrete in the height range of 200 to 250m. The company's BSA 1409 model had recently pumped concrete over 1100 metres horizontally
inside a tunnel at the Bhilangana hydro electrical power project in Uttarakhand. Turnaround Expected The Indian market for concrete pumps is entering into a crucial second phase of growth where clear cut trends are emerging in the market. While the recent economic slowdown may have meant a significant tilt towards the 20 m boom height, as far as truck mounted boom pumps and stationary boom placers are concerned, a change towards larger reach boom pumps is expected by the end of the year, once the economy shows signs of revival and there is a spurt in implementation of delayed large-scale infrastructure projects. The demand for stationary concrete pumps that have been growing at rapid pace of 25%-30 % over the recent few years is expected to continue in the near future. With space being sold at a premium, there has been a definite spurt towards going vertical in most of the Indian cities. What would be heartening for stationary concrete pump manufacturers is the fact that the trend is now being witnessed even in the smaller Tier II and Tier III cities, where 20 plus storied highrise projects are now sprouting up. Photo Courtesy:
www.roadsbridges.com, www.concretepumpdepot.com www.turemachines.en.made-in-china.com
Apollo Infratech's SAP 50 model in action
186
Robo Silicon Pvt.Ltd
Manufactured Sand
Inspiring Saga of Challenge & Change

As per the sense from the market there is major shift in the mindset of the construction industry towards exploring substitutes for river sand. Across the world there is growing support for the increased use of manufactured sand. The imperative need for clean sand eliminating the constraints of river sand like availability, price fluctuation among many factors has made RoboSand A perfect substitute for river sand. Expertise with different Rocks and locations Our success at Hyderabad triggered a series of opportunities and it lead to massive expansion an investment. We manufacture Robosand & RoboAggregates from granite, basalt and charconite rocks based on type of deposits. The current plants operated by us are 14 in number located in Hyderabad, Bangalore, Pune, Navi Mumbai, Mangalore, Coimbatore, Vijaywada and Vishakapatnam. The products conform to IS 383 standards and tested by reputed labs like NCCBM, JNTU, Torsteel etc. The patronage from quite a few RMC Players like Ultratech, ACC, RDC, RMC India and some reputed builders & Infra operators has aided us grow into an organization clocking turnover of more than 150 Cr. Process Improvements We have strong internal test methods to ensure the right output from our plants that meets the customer specifications. We do sieve analysis thrice a day to monitor the gradation of the product & get it whetted once a
Vijay K. Kosaraju,
Managing Director, Robo Silicon Pvt Ltd
obo Silicon's story began way back in 1999 with inception of the plant at Keesara - Hyderabad, commissioned in 2001. Then on we have navigated through an enduring and gratifying journey of excellence and innovation. The metamorphosis is manifest not only in the range of products, scale of operations and scope of expansion to set up 14 Plants all over India but also in the large contribution we have made for building community & its allied industries such RMC players, structural consultants and architects through continual efforts in creating admirable product & knowledge capital. RoboSand Parameters influencing the acceptance The use of RoboSand as a substitute for river sand is primarily due to cubicle particle shape, perfect gradation, absence of impurities and increasing laws to regulate the river sand mining, implemented by various states. The other factors are the general decline in the availability of river sand and pressure from active environmental groups to protect the nature. The rapid rise in the construction activity in the last decade has contributed to the wide gap between the quantity supply and quantity demand of river sand. A lot of damage has been caused to the eco system due to unregulated dredging operations on the sand beds. It is a well-accepted fact that sand plays a very important role in the production of concrete. The features of workability, strength and durability are directly dependent on the properties of the sand used in the making of concrete.
month from external agencies such as Civil Aid, E-Cube & Structwell. The quality function with trained lab personnel is proactive in terms of monitoring the input material & is completely empowered to take decisions on stopping the production till it is rectified, if the output is not as per specification. We have invested in each of the plant to establish a full-fledged quality lab with complete set of equipment for material testing and in course of investing to make one of them a center of excellence for product testing facility. Manufacturing Process and IS Standars The sand is manufactured in a three stages by crushing process. The raw material is either granite or basalt rock (natural rocks) based on the deposit of that particular belt. TheVertical Shaft Impactor (VSI) which is also referred as sand making machine is tertiary stage. The process adopted is similar to the river sand generation by nature. The VSI applies the principle of rock hit rock collision at a high velocity shaping the sand particles and aggregates. The plant works on the principle of continuous feed closed circuit and
Robo Sand Acceptance limits as Per IS 383: IS Sieve Typical %Passing %Agepassing for Normal River Sand (IS3831970) Size mm ZoneI ZoneII ZoneIII ZoneIV 4.75 99.75 90 to 100 90 to 100 90 to 100 95 to 100 2.36 81.25 60 to 95 75 to 100 85 to 100 95 to 100 1.18 61.75 30 to 70 55 to 90 75 to 100 90 to 100 0.60 43.25 15 to 34 35 to 59 60 to 79 80 to 100 0.30 27.25 05 to 20 8to 30 12 to 40 15 to 50 0.15 14.50 0to 10 0to 10 0to 10 0to 15 Note: For Manufactured Sand, the permissible limit on 150microns IS Sieve is increased to 20percent as compared to that of river sand. #75 Microns of<5%isafraction of size reduction process generated sequentially during Production of RoboSand
190
Sri Parijatha Machinery Works Pvt. Ltd.
Manufactured Sand
adopts the technique synonymous to nature's production of river sand. The complete manufacturing process takes minutes and is governed by the tons per hour of feed. The product is produced to IS 383 standards. Customer Perspective Technical challenges The customer is concerned as there is no mention of the following characteristic of manufactured sand in several IS Codes or Mix design Proportioning methods: Micro fractions of 75 microns. Effect of Particle shape. Weight age to parameters of manufactured sand for calculation of water cement ratio. Review of Mix design Methods. -
for a given mix, hence impacts the cement consumption for given workability. It improves the compatibility and cohesion characteristics of green concrete. It also reduces the mortar content of concrete for making concrete mixes which is pump able. It reduces segregation and bleeding characteristics of green concrete. It improves physical characters tics of hardened concrete including compressive strength, flexural strength, and abrasion and impact resistance of concrete. It also reduces the permeability and improves the durability of concrete.
aggregate (crushed, rounded, irregular gravel) and workability for calculation of aggregate to cement ratio. We find that: All the above methods except the DOE method, do not give consideration to different permutations of natural and crushed, coarse and fine aggregates. None of the above methods recognizes the flakiness of the coarse and fine aggregates.
Effect of coarse aggregate on water demand: Mix design done at our laboratory indicates following influence of flakiness/ elongation on the water demand: If slump is kept as a constant:
Combined (flakiness elongation) Index 0to 10% 10 to 20% 20 to 30% 30 to 40% + Water Demand +0Kg/m3 +5Kg/m3 +10Kg/m3 +20Kg/me
Weight age to parameters of manufactured sand for calculation of water cement ratio: It is well know that the shape of aggregate influences the specific surface of concrete. The specific surface governs the water demand of concrete and water demand in turn determines the cement content. All the existing mix design methods have an inherent limitation of not having particle shape as an input parameter. Review of Mix design Methods: The ACI Method: This method considers size of aggregate and slump as input parameters for calculation of water demand. The DOE Method: This method takes in to account the slump, size of aggregate and type of aggregate (crushed/uncrushed) for water demand calculation. RRL Method: This method take in to account the gradation of fine aggregates (zone), size, type of coarse
Effect of shape of fine aggregate on water demand

Natural sand +0Kg/m3 Manufactured sand (shaped) +15Kg/m3 Stone dust +30Kg/m3
Micro fractions of 75 microns Some of the study's finding concluded that, compared to concrete made from natural sand, high fines concrete generally had higher flexural strength, improved abrasion resistance, and higher unit weight and lower permeability due to filing the pores with micro fines. There is no appreciable difference in drying shrinkage in concrete made with manufactured sand as compared to natural river sand. There is improved abrasion resistance of concrete made with manufactured sand as compared to concrete made with river sand. For achieving better abrasive resistance, micro fines in manufactured sand are required within limits. Effect of Particle shape: Well shaped aggregates have the following advantages:Better shape reduce the water demand
Developing new testing proportioning methods Government IS Standards There is a compelling need to study shape characteristics of manufactured sand, effect of micro fines on concrete characteristics such as modulus of elasticity, shrinkage creep etc. Concrete Mix Proportioning by resorting to particle packing approach is the need of the hour, when it comes to use of manufactured sand as a replacement to natural river sand. This kind of syndicated study would reassure the customers & give confidence to the new users. Acknowledgements Dr.C.S.Vishwanath's article in Masterbuilder. Shri. Ujwal Kunte - Managing Director Durocrete Study on 'Shape of Aggregates - The missing link in Concrete'.
192
STA Concrete Flooring Solutions
Corrosion Research
Performance of Concrete Flexural Elements Reinforced with C-Bars
Dr. Anil K Kar1, and Dr. M.S. Haji Sheik Mohammed2

1 2
Proprietor, Engineering Services International, Kolkata Professor, Department of Civil Engineering
ompared to concrete structures of the first-half of the previous century, concrete structures of recent decades have suffered from early decay and distress. In most cases, this decay shows up as spalling of concrete or cracks in concrete structures, which are most often caused by corrosion in rebars in the case of reinforced concrete structures. There can be many different reasons for early corrosion in rebars of the last four or five decades. It should not be difficult to recognize that chemical properties of the material of the rebars must have a role in the process of corrosion. But what could have accelerated the process of corrosion in rebars of recent decades? Just as it could be easily recognized that the chemistry of the material of the rebar would have a role in the process of corrosion, it could also be recognized that the problem of early distress in reinforced concrete structures came into limelight following the introduction of high strength (Fe415 and higher) rebars with surface deformations in the 1960s and 1970s. These bars could be easily recognized by the presence of lugs or protrusions on their surface (Fig.1).
Mohammed, et al.1 observed in tests that, compared to rebars with a plain surface, rebars with surface deformations corroded faster. Alekseev2 too recognized the greater (compared to the case of rebars with a plain surface) propensity of rebars with surface deformations for early corrosion. Alekseev2 could be quoted thus : In accelerated tests, the durability of reinforcement specimens with a stepped (deformed) profile may be roughly an order less than that of smooth specimens since the former have space concentrators on the surface of the bases of projections which represent sites of preferential formation of cracks. Kar3-5 has shown that besides cold work (Fig. 2 as in Torsteel, Tiscon, etc.), the presence of surface lugs/ protrusions/ribs on the surface of rebars of the present generation predisposes such bars (Figs. 1 and 2) to early corrosion. Cold twisted deformed (CTD) bars (Fig. 2), which were the most highly susceptible (to corrosion) among rebars, have virtually been withdrawn from the market. Engineers, however, still continue to use rebars with surface deformations (Fig.1). In order that strength capacities of rebars can be increased without costly change in chemistry, bars are generally given thermo mechanical treatment, as in the TMT process, in India and in some other countries. The preference for surface lugs has been due to the perceived need for limiting the anchor/bond or lap length of todays high strength (Fe 415 or greater) rebars. As
Fig. 1.Typical high strength rebars with surface deformations but of straight line configuration, which replaced plain round bars starting the decade of the 1960s
Fig. 2. Typical cold twisted deformed (CTD) rebar with lugs and protrusions on the surface and stresses beyond yield on the entire body
Corrosion Research
stated in the preceding, the lugs invited early corrosion in rebars and early distress in reinforced concrete structures. Thus, with an objective of using high strength (Fe 415 or higher) rebars without surface lugs and yet limiting the lap length within reasonable limits, Kar6-8 had proposed Cbar (Figs. 3 and 4), characterized by its plain surface and a deformed (wavy/undulated) axis.
The test beams had no ties or stirrups that could have prevented lateral thrust, if any, by the curved bars in tension due to transverse loads on the beams. Under two-point load tests (Fig. 5) on beams with equal (except for differences in configuration of rebars; Fig 4) reinforcement, the crack and failure patterns at ultimate loads were identical (Figs. 6 and 7). There was no sign of spalling of concrete when C-bars were used as reinforcing bars. It needs to be noted here that in order to avoid any possible confining effect of ties/stirrups, no such tie or stirrup was used in the beams in Figs. 5-7. Tests, monitored at another test centre for response under
Fig. 3. View of partial lengths of some C-bars, characterized by deformed axes and the absence of any surface lugs
Reservations were, however, expressed by individuals that because of its curved shape, C-bar, under tension, could push off concrete in the tension zone of flexural members, e.g., reinforced concrete beams. In such expressions of reservations, it was overlooked that, as an element in a composite construction, a rebar, bonded to concrete, performed differently than a bar would have under tension if it were to pass through an opening of a curved shape.Nevertheless, tests were performed to see if indeed there could be spalling of concrete if beams were to be reinforced with C-bars and loaded transversely. Test Results Though limited in number, independent load tests on reinforced concrete beam elements at three universities have shown that there is no discernible ill effect of using Cbars (Figs. 3 and 4). On the contrary, the use of C-bars could possibly make reinforced concrete structures much more ductile than concrete structures which may be reinforced with conventional (with straight axis) rebars.
Fig. 5. Two point load test on reinforced concrete beam
Fig. 6. Crack patterns in the bottom face of beam reinforced with proposed C-bars (plain round bars with deformed axes (Figs. 3 and 4))
Fig. 4. Proposed rebar (in the front) with a plain surface and a deformed axis
Fig. 7. Crack patterns in the bottom face of beam reinforced with conventional plain round bars with straight axis
Corrosion Research
increasing three point load, showed that deformation at failure of elements, reinforced with C-bars, could be much higher than the ultimate deformation of conventionally reinforced elements (Figs. 8 and 9).The ultimate capacity of the beam with conventional plain round bars (Figs. 7 and 8) was reached when there was failure of bond between rebars and their surrounding concrete. No stirrups were used and there was no spalling of concrete when C-bars were used as rebars. There were no end hooks for rebars which were used in preparing the beams in Figs. 6 and 7. Additional Confirmatory Test
60.0 54.0 48.0 42.0 36.0
To dispel any lingering doubt, yet another pair of tests on beams (Figs. 10 and 11) were conducted at Structural Engineering Laboratory, B.S. AbdurRahman University, Chennai to see if the use of C-bars in flexural elements could in any way lead to any spalling of concrete. To study the spalling effect, if any, of using curved rebars, one of the beams involved an extreme example in the form of a simply supported beam having a rectangular cross section and a central camber of 30 mm in the tension zone, i.e. at the bottom (Fig. 11). No ties/stirrups were used. Objectives of the Test - To determine the Modulus of Rupture of the normal rectangular beam (Fig. 10) and rectangular beam with 30mm central camber (curved beam) (Fig. 11) - To study the spalling/pushing out effect of C-bars during flexure test. Test Method ASTM C 293-02 : Standard Test Method for Flexural Strength of Concrete (Using simple Beam with Center-Point Loading) Details of Test Specimen - Normal rectangular beam of size 1270mm (L) X 200mm (W) X 150mm (D). The beam is reinforced with 2 10mm dia. M.S. rebars with bends at end and spaced 100mm apart in the tension zone. The reinforcement was provided with an effective cover of 30mm at bottom and 20mm at sides. The 6mm dia. M.S. spacer bars were provided near supports to maintain stability. - Curved Beam : Rectangular beam of size 1290mm (L) X 200mm (W) with height of the beam varying from 180mm in the bearing length (150mm) at either supports to 150mm at centre which gives a central camber of 30mm. The beam is reinforced with 2 nos. curved M.S. rebars of 10mm dia. with a central camber of 30 mm. The reinforcement was provided with an effective cover of 30mm at bottom and 20mm at sides. The 6mm dia. M.S. spacer bars were provided near supports to maintain stability. Concrete of M25 grade made from 53 grade ordinary Portland cement, 20mm downgraded aggregate, locally available river sand and potable water was used for the study. The mix design was done as per IS 10262 : 1982 - Recommended guidelines for concrete mix design and the mix proportion was 1 : 1.567 : 3.27, w/c ratio : 0.45 with hand mixing. Test Description
Load, Kn
30.0 24.0 18.0 12.0 6.0 0 1.1 2.2 3.3 4.4 5.5 6.6 7.7 8.8 9.9 11.0
Displacement, Mm
Fig. 8. Load deflection response of beam reinforced with plain roundbars

60.0 54.0 48.0 42.0 36.0
7.10
14.20
21.30
28.40
35.50
Load, Kn
30.0 24.0 18.0 12.0 6.0
3.56
10.55
17.75 Displacement, Mm
24.85
31.95
Fig. 9. Load deflection response of beam reinforced with C-bars
The test was conducted in the 3000kN capacity digital U.T.M. with computer interface facilities as per guidelines
Razon Engineering Company Private Limited
Corrosion Research
outlined in ASTM C 293-02. The specimen was placed over supporting rollers with an effective length of 880mm. The width of the roller was just sufficient to accommodate the width of the specimen. The load applying block consisted of rectangular metal block with a curved assembly. The specimens were placed such that the finished surface faced upwards and capped with plaster of paris in the central region to level irregularities in the surface. The load was applied centrally and gradually without shock at a constant rate until failure of the specimen. Sensitive dial gauge was fitted near central portion in the compression side (which is the possible location to fit dial gauge) to capture load deflection behaviour. The U.T.M. was interfaced with a computer to capture the overall loaddeflection behaviour. Figure10 shows the Test set-up and failure pattern of the Normal Rectangular Beam and Figure 11 shows the Test set-up and failure pattern of the Curved Rectangular Beam. The ultimate loads, loads at first and second cracks and the failure patterns were observed carefully. The modulus of rupture was calculated using the formula Modulus of Rupture, R (MPa) = (3PL) / (2bd2) Where P = Maximum Applied Load, N L = Span Length, mm b = Average width of specimen at fracture d = Avg. depth of specimen at fracture Results and Observations Table 1 shows some observations on flexural strength test. It can be observed that ultimate load for the Normal Rectangular Beam (Fig. 10)was observed as 37.91kN. The first and second cracks were observed at 21kN and 29 kN,
Fig. 10. (b) Failure pattern of Normal Rectangular Beam
respectively with locations near center (15mm and25mm from center) in the tension side, direction parallel to the applied force. The failure pattern was complete cracking of cross section under the application of load which is an expected typical failure as shown in Fig. 10 (b). The Curved Beam (Fig. 11) uses two special C-bars which had a single curvature for the entire length of the beam. During the application of load, no pushing out or spalling effect on concrete was observed. For the Curved Rectangular Beam, the ultimate load was observed beyond 42.50 kN. The first and second crack loads were observed as 21.50kN and 28.50kN, respectively. The cracks originated in the tension zone at around 75 80mm from centre on either side and those progressed towards the loading point in the compression side. The failure pattern was typical cone shaped failure under the applied load as shown in Figure 11(b).
Fig. 10. (a). Test set-up of Normal Rectangular Beam
Fig . 11 (a) Test Set-up of Curved Rectangular Beam
Corrosion Research
Specimen Details
Rectangular Beam 1270x200x150mm Curved Beam 1290x200x180mm (with 30mm central camber)
Ultimate Load (kN)

37.95
First crack load (kN)

21.00
Second crack load (kN)

29.00
Failure Pattern
Complete cracking of cross section under the applied load Typical cone shape failure under the applied load.
Modulus of Rupture (MPa)

11.13
More than 42.50
21.50
28.50
12.47
Table 1: Observations on Flexural Strength Test
40 35 30
Load (kN)
25 20 15 10 5 0 0 1 2 Deflection (mm) 3 4 Curved Beam Plain Beam
Fig. 12. Load - Deflection Behaviour at Central Zone in the Compression side during Flexure Test
Fig. 11 (b) Failure pattern of Curved Rectangular Beam
No pushing out or spalling effect on concrete in the deformed locations of C-bar was observed when the specimen was subjected to transverse loading. Fig. 12 shows the Load-Deflection behaviour at central zone in the compression side during flexure test. It can be seen that almost a linear behaviour exists up to 17.50kN for the Normal Rectangular Beam followed by appreciable increase in deflection upon further increase in load up to 33kN. For the Curved Rectangular Beam, linear behaviour was observed up to 14kN followed by appreciable increase in deflection upon small increases in load up to 32kN. The test results confirm that there need be no concern for any pushing out or spalling of concrete as tension in proposed C-bars (rebars with a plain surface and a deformed axis) increases under increasing load. Increased Energy Absorbing Capacity and Ductility It was observed from tests at the second test center, where the performance of a rectangular concrete beam, reinforced with a pair of C-bars (Figs 3 and 4) was compared to the performance of a rectangular concrete beam, reinforced with a pair of conventional rebars of the same diameter
and plain surface, that the use of C-bars, which are less prone to corrosion than rebars with surface deformations are, could lead to a several fold increase in the ductility of reinforced concrete elements (Figs. 8 and 9). Test results at the third test center too have shown the same trends as can be seen in Fig. 13, which is a replotting of Fig. 12.
40 35 30 25 20 15 10 5 0
Load (kN)
Curved Beam Normal Beam
0.5
1.5
2 2.5 Deflection (mm)
3.5
Fig. 13 Load - Deflection Behaviour at Central Zone in the Compression side during Flexure Test
Standard Beam Ductility = 1.52/0.39 = 3.89 Area under load-deflection curve = 12 kN-mm Curved Beam Ductility = 3.41/0.22 = 15.5 Area under load-deflection curve = 37 kN-mm
Corrosion Research
The computations under Fig. 13 show that there is a great potential for a significant increase in both energy absorbing capacity and ductility if curved rebars, as in C-bars,will be used in lieu of conventional rebars with a straight axis. Concluding Remarks As a solution to the problem of early distress, and thus directly as a means for the construction of structures with enhanced life span and indirectly as a step towards minimization of the carbon foot print and global warming, C-bars were proposed by Kar6-8 for use as rebars in reinforced concrete constructions; C-bar costs nothing more to manufacture than what it takes to manufacture any other bar of the same chemistry and it is amenable to any special treatment, if it will be so desired. Concerns were raised by some that because of their curved axis, C-bars, if used as rebars, could lead to spalling of concrete in the tension zone of reinforced concrete elements. Tests at three universities have conclusively demonstrated that the use of C-bars, which corrode much less than rebars with surface deformations do and which cost no more than any other bar of the same metallurgy to make, would not lead to any spalling of concrete Tests have further revealed that the use of C-bars in concrete elements can greatly enhance their ductility and thus lead to very significant increase in their energy absorbing capacity; all at no added cost. Acknowledgement The authors acknowledge the help of Mr. S. ShafeerAhamed, Assistant Professor; and Mr. S.C. Jayakumar, Mr. H. Sheik Mohamed, Mr. R. Sridhar, Ms. V.Harini, Ms. C. Hemalatha,
Ms. R. Jeyalakshmi, Ms. V. Sofia, M.Tech. Students, B.S. AbdurRahman University and attached to Dr. Hajis Research Group in the conduct of the tests depicted in Figures 10-13 and in Table 1. References
1. Mohammed, T.U., Otssuki, N., and Hisada, M., Corrosion of Steel Bars with respect to orientation, ACI Materials Journal, American Concrete Institute, March-April, 1999. 2. Alekseev, S. N., Corrosion of Steel Reinforcement, Chapter 7 in Moskvin, V. (edited by), translated from the original by V. Kolykhmatov, Concrete and Reinforced Concrete Deterioration and Protection, 1990, English translation, Oxford & IBH Publishing Co. Pvt. Ltd. New Delhi, 1993, original Mir Publishers, Moscow 1990. 3. Kar, A. K., Concrete Structures --- the pH Potential of Cement and Deformed Reinforcing Bars, Journal of the Institution of Engineers (India), Civil Engineering Division, Vol. 82, June 2001, Calcutta, pp. 1-13. 4. Kar, A. K., Deformed Reinforcing Bars and Early Distress in Concrete Structures, Highway Research Bulletin, No. 65, Indian Roads Congress, December 2001, New Delhi, pp. 103114. 5. Kar, A. K., Deformed Rebars in Concrete Construction, New Building Materials & Construction World, Vol. 12, Issue 6, December 2006, New Delhi, pp. 82,83,86,88,90, 92,94,96,98,100 and 101, www.nbmcw.com. 6. Kar, A. K., Improved Rebar for Durable Concrete Constructions, New Building Materials & Construction World, Vol. 16, Issue 1, July 2010, New Delhi, pp. 180-199, www. nbmcw.com. 7. Kar, A. K., Rebar for Durable Bridge and Other Concrete Constructions, Indian Highways; Vol. 39, No. 3; The Indian Roads Congress (IRC), New Delhi; March 2011pp. 59-65. 8. Kar, A. K., A Rebar for Durable Concrete Construction, The Masterbuilder; Vol. 13, No. 7, Chennai; July 2011, pp. 224236, www.masterbuilder.co.in.
JBA Concrete Solutions Pvt.Ltd
Self Healing Concrete
Self-Healing Concrete
Sonjoy Deb, B.Tech,Civil
Associate Editor
Tiny cracks in concrete do not necessarily affect structural integrity in the short term, but they do allow water and other chemicals to seep into the structure, which may cause problems over time. Self-healing concrete has embedded clay particles that contain dormant bacteria and a food source. When a crack appears in the concrete, water seeps in and activates the bacteria. When they wake, the bacteria eat their packed lunch and then conveniently excrete chalk, which fills the crack.
oncrete will continue to be the most important building material for infrastructure despite being prone to cracking. Tiny crackson the surface of the concrete make the whole structure vulnerable because water seeps in to degrade the concrete and corrode the steel reinforcement, greatly reducing the lifespan of a structure. Concrete can withstand compressive forces very well but not tensile forces. When it is subjected to tension it starts to crack, which is why it is reinforced with steel; to withstand the tensile forces. Structures built in a high water environment, such as underground basements and
marine structures, are particularly vulnerable to corrosion of steel reinforcement. Motorway bridges are also vulnerable because salts used to de-ice the roads penetrate in to the cracks in the structures and can accelerate the corrosion of steel reinforcement. In many civil engineering structures tensile forces can lead to cracks and these can occur relatively soon after the structure is built. Repair of conventional concrete structures usually involves applying a concrete mortar which is bonded to the damaged surface. Sometimes, the mortar needs to be keyed into the existing structure with metal pins to ensure that it does not fall
away. Repairs can be particularly time consuming and expensive because it is often very difficult to gain access to the structure to make repairs, especially if they are underground or at a great height. Self-Healing of Concrete Self-healing concrete is a product that will biologically produce limestone to heal cracks that appear on the surface of concrete structures. Specially selected types of the bacteria genus Bacillus, along with a calcium-based nutrient known as calcium lactate, and nitrogen and phosphorus, are added to the ingredients of the concrete when it is being mixed. These self-healing agents can lie dormant within the concrete for up to 200 years. However, when a concrete structure is damaged and water starts to seep through the cracks that appear in the concrete, the spores of the bacteria germinate on contact with the water and nutrients. Having been activated, the bacteria start to feed on the calcium lactate. As the bacteria feeds oxygen is consumed and the soluble calcium lactate is converted to insoluble limestone. The limestone solidifies on the cracked surface, thereby sealing it up. It mimics the process by which bone fractures in the human body are naturally healed by osteoblast cells that mineralize to reform the bone. The consumption of oxygen during the bacterial conversion of calcium lactate to limestone has an additional advantage.Oxygen is an essential element in the process of corrosion of steel and when the bacterial activity has consumed it all it increases the durability of steel reinforced concrete constructions. The two self-healing agent parts (the bacterial spores and the calcium lactatebased nutrients) are introduced to the concrete within separate expanded clay pellets 2-4 mmwide, which ensure that the agents will not be activated during the cementmixing process. Only when cracks open up the pellets and incoming water brings the calcium lactate into contact
with the bacteria do these become activated. Testing has shown that when water seeps into the concrete; the bacteria germinate and multiply quickly. They convert the nutrients into limestone within seven days in the laboratory. Outside, in lower temperatures, the process takes several weeks. Refer Figure 1 for self- healing process. History of Self-Healing Concrete Bio-concrete was first introduced as a way of sealing Mount Rushmore. The idea of bacteria-mediated concrete was first introduced by a US research group led by Prof Sookie Bang in the late 1990s. She had the idea of using it as a sealer on Mount Rushmore, which was subject to the effects of the climate. The team at the South Dakota School of Mines and Technology developed a bacteria/ glass-bead system that it believed increased the strength of concrete by 24 per cent. Unfortunately, the application of the theory was never taken forward due to a lack of interest among the commercial engineering sector at the time. Finding the right bacteria The starting point of the research was to find bacteria capable of surviving in an extreme alkaline environment. Cement and water have apH value of up to 13 when mixed together, usually a hostile environment for life: most organisms die in an environment with a pH value of 10 or above. The search concentrated on microbes that thrive in alkaline environments which, can be found in natural environments, such as alkali lakes in Russia, carbonaterich soils in desert areas of Spain and soda lakes in Egypt. Samples of endolithic bacteria (bacteria that can live inside stones) were collected along with bacteria found in sediments in the lakes. Strains of the bacteria genus Bacilluswere found to thrive in this high-alkaline environment. Backat Delft University the bacteria from the samples were grown in a flask of water that would then be used as the part of the watermix for the concrete. Different types of bacteria were incorporated into a small block of concrete. Each concrete block would be left for two months to set hard. Then the block would be pulverized and the remains tested to see whether the bacteria had survived. It was found that the only group of bacteria that were able to survive were the ones that produced spores comparable to plant seeds. Such spores have extremely thick cell walls that enable them to remain intact for up to 200 years while waiting for a better environment to germinate. They would become activated when the concrete starts to crack, food is available, and water seeps into the structure.This process lowers the pH ofthe highly alkaline concrete to values in the range (pH 10 to11.5) where the bacterial spores become activated. Finding a suitable food source for the bacteria that could survive in the concrete took a long time and many different nutrients were tried until it was discovered
Figure 1: Schematic of self-healing process in bacterial concrete. (A) water enters from the left into a micro crack activating the embedded bacterial spores. (B) the active bacteria seals the cracks with the production of limestone, protecting the embedded steel reinforcement (brown bar) from attack and erosion
that calcium lactate was a carbon source that provides biomass. If it starts to dissolve during the mixing process, calcium lactate does not interfere with the setting time of the concrete. The Basic Mechanism The basic mechanism of bacteria remediate cracks is shown below-
Some Research Studies (1) An engineering student Michelle Pelletier from the University of Rhode Island (URI) announced that she has developed a self-healing concrete that would be inexpensive to produce.Michelle Pelletier, collaborating with URI Chemical Engineering Professor Arijit Bose, created a concrete matrix that was embedded with a micro-encapsulated sodium silicate healing agent. When cracks formed in the concrete, the capsules ruptured and released the agent into the adjacent area. The sodium silicate reacted with the calcium hydroxide already present in the concrete, and formed a calciumsilica-hydrate gel that healed the cracks and blocked the concretes pores. The gel hardened in about one week.When Pelletiers concrete was stress-tested to the point of almost breaking, it proceeded to recover 26% of its original strength. By contrast, conventional concrete only recovers 10%. Pelletier believes that she could boost the strength of her mix even higher, by increasing the quantity of the healing agent. Refer Figure 3.
HOW DOES BACTERIA REMEDIATE CRACKS?

CHEMISTRY OF THE PROCESS Microorganisms (Cell surface charge is negative) draw cations including Ca2+ from the environment to deposit on the cell surface. The following equations summarize the role of bacterial cell as a nucleation site. Ca2++Cell Cell -Ca2+ Cell -Ca2++CO32- Cell -CaCO3 The bacteria can thus act as a nucleation site which facilitates in the precipitation of calcite which can eventually plug the pores and cracks in concrete
Interest from Industry When the idea of bacteria mediated concrete was first mooted by US academics in the late 1990s by the research group of Professor Sookie Bang, testing and application of the theory was not taken forward because there was a lack of interest from the commercial engineering sector for such a product.The R&D process still has some way to go but several big industry players have created partnerships with Delft University to develop applications of self-healing concrete. Investment funding from industry is now forthcoming. The concept is to engage with one major player from each concrete sector. Delft is therefore developing self-healing concrete products for specific civil engineering markets that will not be in competition with one another. Products will be developed for sectors such as tunnel-lining, structural basement walls, highway bridges, concrete floors and marine structures. Pure concrete products will take two years to develop and products with steel reinforcement will take four years. Refer Figure 2 for the before and after pictures of a slab of self-healing concrete.
Figure 3:Michelle Pelletier with her self-healing concrete
(a) (b) Figure 2: Before-and-after pictures of the surface of a slab of self-healing concrete. The crack is visible in the left-hand image (a) and on the right (b), the white limestone has filled up the gap
2. Researchers at Northumbria University in the U.K. are developing a self-healing concrete. Dr Alan Richardson, a Senior Lecturer in Construction in the School of the Built and Natural Environment is using ground-borne bacteria bacilli megaterium - to create calcite, a crystalline form of natural calcium carbonate. This can then be used to block the concretes pores; keeping out water and other damaging substances to prolong the life of the concrete.The bacteria is grown on a nutrient broth of yeast, minerals and urea and is then added to the concrete. With its food source in the concrete, the bacteria breeds and spreads, acting as a filler to seal the cracks and prevent further deterioration. It is hoped the research could lead to a cost-effective cure for concrete cancer and has enormous commercial potential. While further research is needed, Dr Richardson
Rockster Recycler India Ltd
is hopeful that the repair mortar will also be effective on existing structures. So-called concrete cancer may be caused by the swelling and breaking of concrete and is estimated to cost billions of pounds worth of damage to buildings .Dr Richardson said: This project is hugely exciting. The potential is there to have a building that can look after itself. 3. At Delft University, Dr. HenkJonkers is developing a biological concrete that uses specially selected bacteria of the genus Bacillus, alongside a combination of calcium lactate, nitrogen and phosphorus, to create a healing agent within the concrete.If untouched, these agents can remain dormant in the concrete for centuries. But if water begins to seep into the cracks, the spores of the bacteria start to germinate and feed on the calcium lactate. This consumes oxygen, which in turn converts the calcium lactate into limestone that solidifies and seals the surface. The removal of oxygen also improves the durability of the steel reinforcement. They are using clay pellets that are around 2-4mm wide to make sure that the agents are not activated during the mixing process. The problem with this is there is need to use relatively high volumes of this porous aggregate within the concrete mix which results in gain of self-healing but lose of strength of the concrete. The clay pellets make up 20 per cent of the volume of the concrete that would otherwise be made of a harder material. This is estimated to weaken the concrete by around 25 per cent, which is far too much for applications that require high compressive strength. Jonkers is now working on using a compressed powder instead of pellets that will hold the self-healing agent in less than one per cent of the volume of the concrete. 4. Researchers at Ghent University are using the microorganism Bacillus sphaericus with urea as a nutrient source to create calcium carbonate. Researcher Dr. Nele De Belie said they have first discovered the bacterium as it was causing problems closing up water pipes. They realised the same bacteria could help enhance the durability of concrete. Instead of using a porous aggregate to hold the self-healing agent, the Ghent team opted to place the material in a hollow glass capsule with an internal diameter ranging from 0.8 to 4mm. As the concrete cracks, the capsules break, releasing the self-healing agent. This method eliminates the need for porous aggregates and retains the strength of the concrete. During the course of its research, the team found that the bacteria struggled to fill cracks of more than 300mm. It has since developed a solution that is purely synthetic, by using polyurethane capsules, which foam in moist environments, and an accelerator that shortens the reaction time. Initial tests
have shown that the foam can expand 25-30 times more than a bacterial solution. But the team havent given up on biological process yet. Environmental Advantage Self-healing concrete could reduce the significant CO2 emissions that result from concrete production. Because the production of concrete is very energy intensive when mining, transportation and concrete plants are considered the industry is responsible for about 10 per cent of all CO2 emissions in the US. If self-healing concrete can lengthen the life of the concrete and reduce maintenance and repairs, it will ultimately reduce the production of excess amounts of concrete and result in a decrease in CO2 emissions. Conclusion Self-healing concrete is a kind of smart concrete and becoming one of the research focus both in material and civil engineering field. Self-healing concrete is likely to provide the greatest global benefit over the coming years. Current technologies under development include autonomic systems, where cracks are automatically repaired with internally released resins, as well as more natural autogenic systems, such as swelling and hydration of cement paste into cracks. This can be significantly enhanced by systems that help to close up the cracks, such as activating embedded shrinkable polymer bars. Considering that over 6 billion cubic meters of concrete is used annually, and that the majority of its durability problems originate from cracking, then the development of smart cementation material with the ability to self-heal cracks offers potentially massive savings to the annual amount of money spent on repair and maintenance of concrete structures. Reference
- - http://www.gizmag.com/student-creates-self-healingconcrete/15237/ h t t p : / / w w w . s c i e n c e d a i l y . c o m / releases/2012/04/120426105001.htm?utm_ source=feedburner&utm_medium=feed&utm_campaign=F eed%3A+sciencedaily+%28ScienceDaily%3A+Latest+Scie nce+News%29 http://www.torontosun.com/2012/04/27/self-healingconcrete-could-save-millions-research http://www.guardian.co.uk/artanddesign/2011/sep/11/ architecture http://www.theengineer.co.uk/in-depth/wise-crack-selfhealing-concrete/1008203.article h t t p : / / w w w. t h e e n g i n e e r. c o . u k / n e w s / s e l f - h e a l i n g concrete/1002629.article h t t p : / / w w w. i c e v i r t u a l l i b r a r y. c o m / c o n t e n t / r e l a t e d / advert?advert=05072011 http://www.scientific.net/AMR.250-253.405
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Ironite Co. of India Ltd
Steel Fibre Reinforced Concrete (SFRC): Areas of Application

he use of steel fibres in grade slabs such as industrial floors, warehouses, ports and highway pavements has been prevalent in many countries for over 4 decades. They are known to have been widely used in Hydro sector, particularly tunnel linings and slope stabilization. In India, thanks to the improvements in steel fibre technology and more user experiences in terms of economy and durability, the use of Steel Fibre Reinforced Concrete (SFRC) is gaining traction. Advancements in admixture technologies over the last few decades coupled with developments in fibre manufacturing technology (e.g. collated/glued fibres) have enabled easier mixing, batching and improved workability of SFRC. There is an increased understanding in the industry that each fibre type behaves differently and this fact must be considered while specifying steel fibres and designing SFRC elements in various projects. However, it is also true that absence of appropriate material specifications for SFRC and lack of Indian standards for testing and design has led to a rather slow acceptance of the concept. Behaviour and Characterization of SFRC SFRC is a concrete that has a homogenous distribution of randomly oriented discontinuous and discrete steel fibres. Steel fibres are introduced in the concrete matrix during the mixing of its constituent ingredients. Upon hardening, these fibres improve the
Steel Fibre Reinforced Concrete
P/2
P/2
L/3
L/3
L/3
Plain Concrete
Deflection
Figure 1: Behaviour of SFRC
properties of concrete such as ductility, fracture toughness, energy dissipation, impact resistance, fatigue resistance and limiting of crack propagation. Under tension, as cracks start propagating inside concrete, steel fibres present in the matrix bridge the cracks and transfer the tension across them during this process. Thus, SFRC actually causes no considerable increase in the flexural strength (modulus of rupture) of the concrete yet contributes in improving the load carrying capacity of a structural system on account of increased toughness and rotation capacity. The behaviour of plain concrete and SFRC is made clear with the help of a four point beam bending test as illustrated in Figure 1. It is observed that for plain concrete, a sudden and brittle mode of failure occurs after the peak load is reached which then is used to calculate the flexural strength of the concrete. When sufficient ductility is ensured in the beam with the addition of steel fibres in concrete, a strain softening phenomenon is observed after the load at first crack or peak load in the beam. Thus, with this kind of toughening behaviour in the beam, post-crack flexural strength of SFRC is guaranteed . Adding steel fibres purely on a volume fraction basis has its disadvantages in that it fails to differentiate between various kinds of steel fibres and considers the volume of steel added as the only criterion. This is obviously not true because for a given volume of fibres, smaller diameter fibres are more in number than the larger ones. This consequently results in a larger network of fibres within the concrete matrix which would definitely alter the performance of the concrete due to higher confinement. Similarly, aspect ratio (length/diameter) of the fibre has a greater bearing in the
Figure 2: Fibres Galore All Fibres are not alike
performance of SFRC in that higher aspect ratios yield better performance due to longer anchorage lengths and fibre network. Apart from the differences in sizes and aspect ratios, steel fibres may come to differ in shape (straight/ hooked end/undulated), form (fibres glued together with water soluble glue/ loose), tensile strength (high/medium/ low) and materials (mild steel/galvanized/ stainless). Thus, all fibres are not alike (Figure 2) and must be selected based on the requirements of the user and applications they will be put to use. SFRC Applications Fibres working in Ultimate Limit State (ULS) One of the major goals of design of structures is to provide for predictable ductile failure modes and avoid brittle unpredicted modes. In other words, the first crack in the structural system must never be the last crack and there should be multiple load paths to have some redundancy. In all systems where this holds (meaning statically indeterminate structures), steel fibres come across as excellent substitutes to conventional concrete. Moreover, the fibres contribute to the bending stress block by allowing the tension side of concrete to be used in the moment resistance calculations as shown in Figure 3. The following paragraphs list appropriate applications for SFRC use in both ULS
208
Load
e
Figure 3: SFRC Stress Block: Bending ULS
Figure 5: Plain Concrete Slab Brittle Failure and SFRC Slab Ductile failure
Grade Slabs One of the major application areas of SFRC happens to be "slab-on- grade" (industrial flooring, concrete pavements, ground slabs etc.) where it has been a wellestablished building material and a meaningful alternative to plain or reinforced concrete. Slab-on-grade can be defined as a slab that can be fully supported by a sufficiently compacted sub-base (see Figure 4). The general loading cases in such a structure include stationary loads due to racks, pallets, containers etc. and moving loads like trucks, stackers and fork-lifts . As a design basis, bending moments are calculated according to the appropriate ground support and loading conditions. Depending on whether the slab is plain concrete or SFRC, appropriate design approaches have to be used. Conventional plain concrete slabs work only up to a point where the stresses in the slab lie within the elastic range of the material. As soon as the stresses in the slab exceed the elastic threshold range, the plain concrete cracks in a brittle manner, losing its capability to carry any further substantial loads. Such a scenario in slabs leads to large cracks which require costly
repairs. SFRC slabs on the other hand work on the principle of load redistribution which allows the use of a plastic design approach where the stresses in the slab are not just limited to an elastic threshold value, but are allowed to go beyond by the sheer capability of this transformed material. The plastic design approach allows for the full properties of SFRC to be put to use. Real scale lab tests performed to characterize the behaviour of plain concrete vis--vis SFRC reveal a lot of differences. Results show distinct and large cracks appearing in plain concrete slabs that run through the section, dividing the slab into various pieces as soon as the moment capacity is reached while SFRC on the contrary allows for yielding of the slab by progressively smearing the excess moments, leading to finer cracks as illustrated (Figure 5). Shotcrete Tunnel Linings Construction of tunnel linings forms an integral part of any tunnel drilling activity. After the drill and blast operation inside a tunnel, the surrounding rock mass requires some kind of a temporary support which is typically provided by thin shotcrete linings. The role of such a shotcrete lining is not to try and support the original ground pressures but to stabilise the deformations required to
mobilise the inherent ground strength. Consider an illustration (Figure 6) which details the Ground-Lining interaction inside a tunnel. As excavation proceeds, ground moves into the tunnel and radial pressure required for equilibrium reduces as the ground strength is mobilized. Following completion of lining at B, load from the ground causes inward movement of lining until a point C of equilibrium at which radial pressure required for equilibrium is provided by the lining. Rock supports in tunnels involve a constant risk of unexpected loads and deformations. In such a case, the best safety is achieved by having a shotcrete layer support that allows for the highest possible fracture energy i.e. toughness or ductility. Segmental Linings Segmental linings are the support system for shield Tunnel Boring Machine (TBM) excavated tunnels. Precast concrete segments are assembled inside the shield to form a series of rings (Figure 7) that become the support structure of the tunnel. Such tunnels are mainly used for water transportation and metro rail projects. It is possible to partially or fully replace conventional steel bar reinforcement with steel fibres in recast segments based on the loads acting in the ring section. Steel Fibres in precast segments help in decongesting steel reinforcement cages and are greatly reduce the chipping and spalling of concrete in segments during handling, stacking and installation (Figure 8). Unreinforced concrete cover areas even in heavy conventional rebar reinforced segments are often prone to damage. Steel Fibres provide a 3 dimensional reinforcement in the entire
Figure 4: Grade Slab Example A Container Freight Station made of SFRC
Figure 6: Working of SFRC Tunnel Linings
Figure 7: SFRC Segmental Lining Tunnel
209
Uncracked
Cracked
Figure 8: Spalling of Unreinforced Segment Edges
section of the segments greatly reducing the extent of such damages. Structural Elements Steel Fibres have been used in structural elements world over to achieve a variety of objectives best suited and justified on a case-to-case basis. For example, the world famous Oceanographic Park at Valencia, Spain (Figure 9) had steel fibres shotcreted in conjunction with steel mesh to allow for an easy installation due to the curvature of the structure and accommodate the limited design shell thickness (6 cm to 12 cm). Similarly, fibres have been known to reduce congestion of reinforcements in link beams and beam column junctions in tall buildings. Rafts and foundation slabs of buildings have also been getting equal attention in extreme cases where the regular reinforcements are too congested and the bar diameters are already too high ( 32 mm) to allow for further increase. In such cases, steel fibres become most suited as they contribute substantially to the moment capacity of the sections. Fibres working in Serviceability Limit State(SLS) Apart from bending, fibres work in containing cracks in axial direction as well. Steel fibres lead to formation of
Post crack tensile strength
Figure 10: Controlling of Crackwidths by SFRC
controlled crack patterns with reduced crack widths, and thus appropriate for crack width design. Consequently, in cases where clients impose stringent limits on crack-widths and liquid tightness, less rebar reinforcements are required (smaller diameter, larger distances) and the durability and serviceability of the structural elements is greatly improved. Liquid Tight Floors Some industrial/warehouse floors need to be designed in such a manner that they have to act as a secondary barrier against hazardous goods that may leak from the storage containers. Usually a very stringent crack-width limit of 0.1 mm is imposed on the floor in such industries (Figure 11). Such projects are almost certainly required to be combined reinforcement (Mesh + Fibres) to fully leverage the benefits of the composite system in an optimal manner. Water Tight Raft Foundations Similar in concept to the liquid tight floors, the primary concern for rafts is
the seepage due to uplift forces of water from beneath which can lead to certain crack-width requirements for the structure. For example, the project illustrated in Figure 12 involved the use of combined steel fibres + rebar reinforcement to reinforce the load bearing foundation slab. Calculated crack width was 0.2 mm. The 60 cm thick slab had an uneven bottom and was founded on rock, crushed rock and piles which increased the possibility of restraint cracks. A combined fibres + rebar solution got rid of the problem and led to major savings for the contractor due to reduction in construction time because of simplification of the slab reinforcing scheme.
Figure 12: Example- "Court House", Flemmingsberg Sweden
Conclusion We have seen until now as to how steel fibres have certain technical advantages that make then suitable and preferable for the applications listed. However, one must also not forget that using fibres to replace steel reinforcements in part or whole make sense practically on site as well in terms of saving man-hours (with the reduction/ elimination of bar bending activities) and construction time (no rebars to be laid). With increased understanding of properties of SFRC, coupled with standardization and further improvements in fibre manufacturing, one is bound to see an increase in the use of steel fibres in construction in the coming years.

Bekaert 'Ph: +91-20-66276600 E-mail: building.india@bekaert.com Web: www.bekaert.com
Figure 9: The Oceanographic Park, Valencia
Figure 11: Example- An SFRC liquid tight floor in Waldenburg, Germany
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Action Construction Equipment Ltd
Energy Efficient Initiatives from The Supreme Industries
Atul Khanna
GM-Insulation Division The Supreme Industries Ltd.
hermal Insulation requirement is felt where-ever comfort conditions are desired and energy to be optimally utilized. Broadly speaking, where the insulation is used to prevent heat loss from the process the term hot insulation is used. Where the insulation is used to prevent heat gain to the process the term cold insulation is used. However in recent times radiant
Underdeck Insulation
heating or cooling has gained a lot of popularity. Thus classification could be on basis of application, such as 'Hot' or 'Cold'. This classification could then be further sub-divided into the products that determine such applications,
Duct Insulation
wherein the products offered by The Supreme Industries Ltd. and the competing products form part of the cold insulation applications. Among all energy efficiency technologies, advanced thermal insulation stands out as the one that could reduce energy consumption most effectively. For a good insulation with 95% of air and low solid content, the processing cost becomes the dominant factor in the performances/cost equation. Installation of thermal insulation is indeed a sound investment because of the immediate payback from energy savings and especially if we can keep the cost low. Lower insulation costs, combined with rising energy expenses, would automatically expand the efforts in energy efficiency. With electricity consumption in the commercial sector accounting for nearly 8% of the total electricity consumption, the old adage energy saved is energy generated holds good. It is said that 70% of India is yet to be built and with construction industry in a boom, the growth of the
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Pipe Insulation
service sector and technologies assisting build the industry are imperative. In this direction, the Government has initiated the Green Building movement of sustainable habitats. The 12th Plan envisages certain mandatory measures by the Government to make the Green Culture implemented for new government buildings coming up all over the country and thus consumption of products which conserve energy demand are expected to rise. Supreme Industries offers thermal insulation solutions to customers that are appropriate and cost-effective. The company follows the philosophy of SAVE Supreme Always Value Efficient. The drivers of this conviction are applied intelligence and innovation to enable cost-effectiveness and precision in delivery. Every requirement is studied
in great detail, various solutions are taken into consideration and the most suitable one is implemented. Ranging from superior protection, energy-saving insulation and long-lasting solutions in the civil industry, Supreme is capable of providing apt solutions to its customers. Supreme's Thermal Insulation Division offers solutions in the following areas: - Ducting Insulation in hospitals, shopping malls, airports, PEBs, IT/ BPO etc. - Pipe insulation for split AC tubings, chiller piping, drain pipes, chilled water lines etc. - Floor insulation in server rooms, data centres, medical & diagnostic centres, and control rooms for petrochemicals.
Underdeck insulation in PEBs, textile units, malls, airports etc. Overdeck and wall insulation in commercial buildings, residential buildings, cold storages etc.
Quality at its best: A methodical, systematic and stringent approach to quality ensures durability to all their products. The company adheres to international quality standards while manufacturing products. ISO 9001:2000 and ISO 14001 certifications and NABL accreditation for various plants is a testimony to their serious approach to quality.

The Supreme Industries E-mail: insulation@supreme.co.in Web: www.supreme.co.in
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Proven and Reliable Lifting Solutions from Gandhi Automations

andhi Automations is a leading company in entrance automations & loading bay equipment. It offers wide range of Bolzoni Auramo lift tables that provide an effective solution to most lifting problems. Bolzoni Auramo lift tables have earned a great reputation over the years for its safe and reliable features. According to the company, the safety of the operator during the use of lift tables is paramount. Its tables comply with the European safety of machinery standards EN 292, machinery directive 98/37/EC and safety requirements for lift tables EN 1570. Gandhi Automations has a wide range of tables and options available to meet different requirements and its wide experience provide customized customers' solutions. Lift tables for all models include Aluminum safety bar, stopping
descent of the platform on contact with obstructions. Safety clearance between scissors to prevent trapping during operation. Safety check valve to stop the lift table lowering in the unlikely event of the hose break. Protection against overloading. Low voltage control box with updown buttons and emergency stop. Maintenance props (for safe maintenance operation). Removable lifting eyes to facilitate handling and lift table installation.
Type 1-E Ergo-lift single scissor for evenly distributed load. Designed as a work station to provide improved ergonomic conditions to ensure the health, safety and comfort of the operator together with improved productivity. Load applied: evenly distributed. Top platform smooth surface. Max. 20 cycles per hour. One shift a day. Single acting hydraulic cylinders with drainage. Upper and lower travel limited by mechanical stops. Self lubricating bearings on pivot points. Hydraulic power pack inside the table provided with relief valve against overloading and compensated flow valve for controlled lowering speed. Electrical equipment controlled by electronic system. With low voltage transformer and thermal overload protection. Wide range of accessories available to achieve even higher safety functions where conditions require.

2nd Floor, Chawda Commercial Centre Link Road, Malad (W,) Mumbai 400064. Ph: +91-22- 66720200, Fax: +91-22-66720201, E-mail: sales@geapl.co.in Web: www.geapl.co.in
Gandhi Automations Pvt Ltd
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Esquire - CMAC Pvt.Ltd
Innovations in Concrete and Epoxy Floorings

then trowelled by means of notch-trowel, de-aired using spike rollers and are allowed to set for a minimum period of three days after which the matrix attains a minimum compressive strength of 300 Kg/sq.cm. You can create various deigns and patterns using different coloured micro-toppings to obtain a floor of stunning looks and functionality. A case study is presented below which would give you an idea of what can be achieved with this material.
B M Nagarajan, Director
Neocrete Technologies Pvt. Ltd.
echnological innovations in rawmaterials, pigments and additives as well as the architects' and customers' desire to offer unique floorings have spurred the evolution of plain vanillaconcrete into a work of art. Concrete has ceased to be only a functional flooring and has been transformed into an aesthetic and decorative flooring capable of withstanding large foot-falls as well as vehicle movement. Besides, it is amenable to creating designs, colours, patterns, texture etc thus satisfying the need of a creative mind of an architect. In similar vein, epoxy floors have also graduated from being the hygiene or an industrial floors to an exquisite and vibrant flooring solutions suitable for various commercial flooring requirements such as hotel-lobbies, pubs, commercial establishments, restaurants, museums, schools etc. This two-part article aims to give you an overview of such options available today. Concrete Floorings: Some of the decorative options available in concrete floorings are as follows: Coloured micro-toppings Polished concrete Textured concrete Stamped concrete Broom-finished concrete Engraved concrete Acid-etched concrete Cast-in-situ cement terrazzo
5.Coloured micro-topping is a powder supplied on 10Kg bag. It only needs addition of water (2 to 2.5 litres) to make it a flowable compound. Pour the mix into the respective patterns and level it with notched trowel.
1.Concrete is ground so as to remove laitance, loose particles etc and provide a mechanical key
6.Immediately cover the area in which the flooring is applied with plastic sheet and sprinkle water to reduce rapid evaporation. (failure to do so will result in cracks)
2. Create grooves as per design provided by the architect and insert metal strips into the grooves
7.Pour various colours one after another ensuring that thickness of one pour does not exceed 5mm.
3.Fix the strips with special epoxy primer
Now let us take a brief look at various options available: Coloured micro-toppings: Coloured micro-toppings are polymermodified, cementitious floor toppings that are available in powder form and needs only water to be added at the job-site, mixed well and poured over properlyprepared and primed concrete floor. It is
8.Repeat the process once more in order to get 10mm thick floor topping
Polished concrete: Polished concrete can either be done by spreading liquid floor-hardener over the new concrete or over micro-topping and then polishing it by means of special scrubbers to provide a glossy, smooth
4.Apply two-component water-based primer over the surface on which topping has to be applied. Allow it to become tacky (max half hour) before applying Coloured micro-topping
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Broom-finish concrete: Broom-finish concrete can either be done on new concrete after spreading specially formulated coloured powder over the new concrete or over coloured micro-topping over an existing concrete and then creating broom-finish using special brooming tolls to provide a aesthetic broomed surface. It is ideally suitable for pathways and walk-ways. profiling before applying different coloured acid stains and then washing and sealing. It has to be done by highly trained applicators. Cast-in-situ cement terrazzo Cement terrazzo tiles were in vogue for a long time in India. However cast-insitu cement terrazzo floorings have got the fancy of designers in order to deliver stunning looks and maintenance-free floors. Cement terrazzo floors are widely preferred in most of the airport terminals around the world due to its maintenancefree characteristics. Engraved concrete: Engraved concrete is typically performed by acid staining the concrete and then engraving the concrete using special tools and equipment. Engraved concrete floors are highly durable and the engraving is usually up to 12mm deep and the engraved designs look as if the design was inlaid into the concrete. Engraved concrete truly gives a beautiful and aesthetic look. It is amazing how a humble concrete can be transformed into a beautiful, and durable floor with stunning array of colours and patterns without losing the rustic cement surface texture by the innovations in raw-materials as well as the ingenuity of formulators combined with the workmanship of artisans. The second part of the article will deal with innovations in epoxy floorings
Photo: Courtesy : Durocem, Italy
and dense concrete surface. By carrying out this process over coloured microtopping will provide a beautiful, aesthetic and decorative polished surface that are ideally suitable for retail outlets, logistic centres and alike. Textured concrete: Textured concrete can either be done on new concrete after spreading specially formulated coloured powder over the new concrete or over coloured micro-topping over an existing concrete and then creating
Photo: Courtesy : Matcrete, USA
texture by texture mats to provide a beautifully coloured and textured surface. By using a contrasting powder-release, you can create an antique look as well Stamped concrete: Stamped concrete can either be done on new concrete after spreading specially formulated coloured powder over the new concrete or over coloured micro-topping over an existing concrete and then creating pattern and texture by stamping mats to provide a beautifully coloured and textured surface. By using a contrasting powderrelease, you can create an antique look as well.
Photo: Courtesy : Concrete Art Fx Inc, Canada
Acid-etched concrete: Acid etched concrete (also known as stained concrete) is an excellent way to transform an old, worn-out floor into a stunning, decorative floor that are suitable for commercial and residential structures. Staining involves proper preparation of concrete by grinding and

13-A, Satellite Tower, Film City road Goregaon (East), Mumbai - 400 063. Ph: +91-22-32937981 E-mail: neocrete@gmail.com Web: www.neocrete.co.in, www.neocrete.in
Neocrere Technologies Pvt. Ltd.
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Turkish CE Major Spreads its Wings in India

umerous brands of light and medium range of construction equipment companies have been flooding the booming Indian construction equipment marketplace in recent times. While some are struggling to get a foot hold due to various reasons Turkey's Palme Makina has quickly spread its wings across the country thanks to its Indian representative BRDC. In fact Palme in association with BRDC promises to make India their next home and has chalked out exciting plans and rollouts in the near future. The main manufacturing base at Ankara the Turkish capital has seen Palme grow over the last several decades from a dedicated supplier to the East and West European armies to one which realized its worth when the brand 'Palme' was an instant success in the same markets. The highly motivated team of workmen who have long term experience in the field contribute to high quality output. The engineering and testing facilities ensure that the best available technology is accorded resulting in the highest standards that customers expect. The crucial R&D is headed by the promoters ensuring the latest and only best technology is incorporated into Palme products. The team also specializes in offering its base including R&D for developing new machines as per customer's requirement. For many years Palme-Makina was contracted to manufacture components, assemblies and thereafter entire machines for military requirements for the defense of many European countries. This fundamental background has resulted in today
Double Drum Vibratory Roller
Palme's assurance of high quality standards and long term goals set for India. In India Palme products have been seeing a steady uptick ever since their launch at EXCON 2011. Some of its interesting product line-up includes a variety of Light Compaction Equipment's like Walk Behind & Ride-On Double Drum Vibratory Rollers. The model range comes with some of the most exciting features available in the market however, at a price which many contractors have realized is highly economical after gauging the output of these machines for several months now. Another of Palme's excellence is its Forward Vibratory Plate Compactors which, are made with a robust frame and exciter offering unmatched compaction and reliable choice of engines making them a worthy investment. While offering a host of features the remote control operated Double Drum Vibratory Roller offers the contractor highest standards of safety while working in deep trenches protecting from cave-ins or wall slides. The Ride-On Double Drum Vibratory Roller is a sure competition to many international manufacturers when compared to the output and ownership costs comparison over its life span. The high compaction offered is utilized to compact various grades of soil and aggregates to varying magnitudes. Another focus of the PalmeMakina product line are their mobile LightTowers or Light Masts. A wide variety of eight models for different applications and a choice of petrol / diesel engines from more than one manufacturer speak volumes on the flexibility to accommodate the customer's requests. Areas as small as an indoor to even large spaces like paving or earth-excavation jobsite to more serious requirements like mining and boundary border lighting all are achieved from the various models are on offer from single filament and 6 mtr mast upto the completely hydraulic steel carriage way mounted masts for as high as 30 mtrs offer immense value to this product line. Other products like to Dampo and Hermod are very innovative in their multirole special machines for a variety of
Light Compaction Equipment
activities as their compact design has hardly any competition. Palme-Makina's range also includes Asphalt /Concrete Professional Saws for pavement and airport applications whereas their special model caters to deep cable trenching with a Ride-On Model with capacity of over 800 mm. Concrete flooring equipment range include Scarifiers, Vibrators in engine to High VPM High Frequency with Converters; Walk Behind Trowels and Screeds to complement the range. In India Palme-Makina is represented by BRDC with their offices headquartered in Mumbai.

14, Viral Apartments, Opp. Shoppers Stop, S.V. Road, Andheri (West), Mumbai-400058. Ph:+91-22-65346038 Fax:+91-22-26288753 E-mail: info@brdc.co, Web: www.brdc.co
Bharat Road Development Combines Private Limited
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Cosmos Construction Machineries & Equipments Pvt.Ltd
World-Class Products Backed by Excellent After - Sales Service
Vinayak. G, Director,
Sicoma Mixers India Pvt. Ltd.
icoma is a name that has become synonymous with world-class planetary and twin shaft mixers. The company has been pioneering two new ranges of mixers which have been designed exclusively for the Indian market,
Planetary Mixer at Concrete Pipe Factory
keeping in mind specific applications. The company's range of planetary mixers and twin shaft mixers has carved a niche for themselves in the highly
competitive Indian market. The popularity of the range of mixers can be directly attributed to factors including, product innovation, quality standards and the excellent after-sales services offered by the company. Quality Focus One of the key strategies that have helped the company keep the cost economical is the fact that it sources and assembles most of the components from domestic manufac-turers in India. Sicoma offers a readily available stock of state-of-the-art mixers at competitive prices. An in-house quality assurance team ensures that every mixer from the company adheres to international standards of quality, an approach that has been behind Sicoma's remarkable growth story. Importantly, the company also has a transparent pricing policy, one of the key reasons behind its success. Planetary Mixers The company's strong R & D focus has behind its reliable range of planetary mixers. The company designs planetary mixers for various applications, such as special planetary mixers for RMC
Planetary Mixer for Readymix
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A view of Sicoma's Factory premise
A wide-spread sales and service network has been one of the company's strong points
plants of sizes 20 cum3/hr and 30 cum3/hr capacity. The planetary mixers offered by the company come with the option of protective liners depending upon the customer requirement and nature of raw material that will be used during the mixing process. The planetary mixers have already been successfully introduced in the market in collaboration with Original Equipment Manufacturers (OEM) for reaching out to a larger customer base The planetary mixers have been designed specifically for certain standard RMC applications. Sicoma offers customers customized mixers to suit different space design constraints. The company's focused approach has meant that it is rapidly achieving market share in the small batching plant segment also. Sicoma is forging ahead in its journey as the leader in supplying concrete mixers. The company has also been the market leader for planetary mixers
for dry cast applications. It has commissioned more than 30 mixers for large companies for concrete pipes, hollow core slabs, blocks, pavers and other precast elements. Twin Shaft Mixers Apart from its modern range of planetary mixers, the company also offers twin shaft mixers in the size range, 0.75, 1, 1.25 and 1.50 cubic meters. The attention to detail and superior technology behind the company's range of twin shaft mixers has meant that they are now a preferred choice in the Indian market. With the global currency market fluctuating wildly, it is a good idea for Indian customers to go in for Sicoma mixers, since the company stocks the mixers in CKD ( Completely Knocked Down) condition and assembles them, as and when orders are received. What this means is that customers are spared
of having to deal with fluctuating exchange prices, apart from ensuring a short lead time from order to delivery. The company's products are manufactured at its new state-of-the-art manufacturing facility located in Bangalore. Excellent Service The top management of Sicoma is firm believer in the business philosophy that a sale is only the beginning of the relationship with a customer. A widespread sales and service network has been one of the company's strong points. The company understands it responsibility towards maintaining the spares required for mixers in operation. It has a dedicated warehouse for keeping stocks of spares ready. A lot of scientific analysis and planning goes into replenishment of spares at regular intervals of time. SIMPL is a company that is committed to offering service on a war-footing basis. The response time for service in SIMPL is less than 48 hours. A team of qualified technical professionals are always on their toes, ready to serve the next customer.

Plot No 36, Opp Semicon Park, Electronic City II Ph., Near SBI, Hosur Road, Bangalore-560100 Ph: +91-80-28520270, E-mail: sicomaindia@sicoma.it Web: www.sicoma.it
Twin Shaft Mixers Stock Spares Stock
Sicoma Mixers India Pvt. Ltd.
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Everest Equipments: Scaling New Heights
B.R. Tater
Everest Equipments Private Limited
verest Equipments Pvt. Ltd. part of Tater Group is one of the leading manufacturers and suppliers in the construction equipment industry. We, at Everest believe in developing high quality products, maintaining trust and providing total customer satisfaction. With works based on the outskirts of Kolkata, the quality of our products has helped us gain a continuously growing customer base. Under the able guidance of Mr. B. R. Tater (B.E. Civil), who has worked as Consultant to various projects and has very good knowledge of construction equipments and their requirements in the construction field, the company has added significant chapters in its short history. With a vast experience of over 40 years in this field, his technical inputs has helped to be the guiding force behind the company. With a diverse product range, the company promises to be a One Stop Shop for the complete requirement of construction equipments. Everest product range consists of the following:
Concrete Processing Range Mini Mobile Batching Machines, Reverse Drum Concrete Mixers, Tilting Drum Concrete Mixers available in one bag(10/7) and half bag(7/5) cement capacity and Hoist Mixers. Rebar Processing Range Rebar Bending Machine, Rebar Shearing Machine Rebar Straightening Machine, Rebar Stirrup Making Machine. Compaction Range Plate Vibrators, Walk Behind Rollers, Tamping Rammers Surface Finishing Range Vacuum de-watering system, Power Trowels, Screeds Material handling range Builder's hoists, Site dumpers, Site Lifters, Rope Suspended Platforms. Shuttering and Scaffolding Adjustable Props, Spans, Clamps,
Cuplock System
about improvements in our products so that they are better suited for the end user. We are compelled to provide technically efficient, simple to operate, high quality products. The Everest team is also compelled to provide prompt and proper service, should the need arise. With our Belief: Technology can create
Bar Bender
Couplers, Sleeves, Joint Pins, U-jacks, Base jacks, Fixed base jacks, Shuttering plates, Wall Form Shuttering, H-frames, Cuplock Systems etc. We at Everest firmly believe in our motto Quality you can trust, which guides us constantly to research into our own products to develop them better. Each product coming out of our manufacturing units is assured to be of high quality and long durability. We, here at Everest constantly strive to bring
quality products - However, only people can create quality relationships and deliver total satisfaction, which is what each member of our team believes in, we want to create history.

Everest Equipments Private Limited
Suit No: 203, South Block, 6 Waterloo Street, Kolkata-700069 Ph: +91-33-22622409, E-mail: everestepl@gmail.com
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Cosmos Sales Corporation
The Future is Greener With RoboSand
Uday Shankar
CEO & Director, Robo Silicon Pvt. Ltd.
rom a modest beginning with a single plant at Keesara Hyderabad, commissioned in 2001 to 14 plants all over India, Robo Silicon is poised to be the catalyst for change with state-of-the-art manufacturing facilities. The company ushers in a much needed sense of professionalism and standardization for manufactured sand in the construction industry. More importantly, it heralds a new era in eco-friendly construction. A practice prevalent in
the west, manufactured sand is fast becoming the preferred component in construction - be it infrastructure projects, commercial or residential complexes, manufactured RoboSand is now laying the foundation for a greener planet. RoboSand today has established itself as the preferred substitute for river sand with its cubicle particle shape, a perfect gradation and absence of impurities. Made using a rock-hit-rock collision technique, RoboSand and Roboaggregates are manufactured in a three stage crushing process using natural rocks such as granite. charkonite or basalt rock. At Robo Silicon we pride ourselves on maintaining exacting standards in every facet of the production process. Beginning with a careful selection of our quarry sites right through the drilling, blasting and the three stage manufacturing process consisting of the primary stage, secondary and tertiary stages - Robo Silicon adheres to the highest quality norms in manufacturing. Across our 14 plants the sand and aggregates we manufacture ensure consistency, workability, strength and durability to concrete. RoboSand also goes through multiple tests that ensure no impurities and adherence to the IS383 gradation as laid out by IS standards.
Little wonder then that our products are tested & certified by NCCBM, Torsteel & JNTU making them the viable option for river sand across the key segments such as the ready mix concrete segment, project segment, large & small builders & individual homes as well as the retail segment. Today, Robo Silicon partners with the leading names in the ready mix concrete segment to help develop large infra-structure projects across India having won their trust with superior products and with a guaranteed availability at all times as required by our customers.
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DCS Trading & Services Pvt. Ltd
Customer Centric Approach It is this customer-centric approach that has percolated every facet of our business. Beginning with superior products at competitive prices, Robo Silicon brings in a much needed professionalism to an otherwise unorganized industry even in the simplest things we do such as ensuring every order is accompanied by a delivery note and royalty slip. In addition we also provide a Sieve Analysis Report with every order. A customer outreach program ensures that every order is attended across multiple channels be it a toll-free number or the website for our customers to reach us. A dedicated team of well-trained service staff attends to order status and dispatch enquiries over phone across all our markets. In order to have a greater reach and to make available our products to a wide range of customers, we have been focusing on the expansion and development of our dealer channel. Our consistent efforts in this regard have meant that today we have a widespread dealer network spanning most of the regions. It is also our endeavour to maintain high standards of quality throughout the supply chain. As part of these
Customer Focused Initiatives We have been focusing on all our internal process to build a robust customer interface & facilitate many of the customer transactions. One such initiative is the weighbridge automation, software installed in our plants, which has improved our routing & scheduling plan for ensuring prompt customer delivery. It enables minimal waiting time for the vehicles taking the material to the customer as all the data is fed in the system, retrieved using barcode, when the material is weighed. The system also ensures the right product to the right customer as all the orders from SAP are mapped against the dispatches, monitored by the weigh bridge software. The other important initiative, which we have embarked, is sales force automation, a critical activity in the entire supply chain. We have mapped the sales process & are building in tool for collecting order on move by the sales team, integrated to our SAP . We are also making all the customer data available online for the sales team in the field & are building provisions to feed the prospective customer data, online. This has created an air confidence amongst the sales team & has enabled to enhance the overall end customer's experience, dealing with us. Finally, in order to educate the customers on the benefits of manufactured sand, Robo Silicon is making considerable progress in engaging with customers right at the end user through mason meets as well as expanding market reach through retail forays.The future is definitely greener as more and more construction majors shift to the eco-friendly substitute of RoboSand and RoboAggregates for their construction needs.
initiatives every authorized dealer is given a 'Certificate of Appointment', which ensures that they adhere to and maintain the high standards of quality, apart from ensuring our customers with the best quality products and service. With infusion of private equity investment from India Value Fund (IVF) that has invested in Robo Silicon's and an adherence to quality combined with a customer-centric approach has enabled us to foray for an ambitious growth in forthcoming financial years. Today we are proud of having established a nation-wide brand of trust in Mumbai, Pune, Bangalore, Mangalore, and Coimbatore apart from Hyderabad. Robo Silicon also continues to be at the forefront of innovation with RoboPlast a specialized product for Brick-working & Plaster applications to be launched very soon in the market.

Robo Silicon Pvt Ltd
Robo House, Plot No. 107-A, Road No 72, Jubilee Hills, Hyderabad - 500033, A.P . Ph: +91-40-23557210, Fax: +91-40-23547215, Web: www.robo.co.in
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Tech 9
Concrete Block Making Machinery
For Concrete Block Making Machines

The Future Shines Bright

ness has meant that today the situation has changed to such an extent that concrete blocks are the preferred choice. The turnaround has been made possible because of the advent of the latest concrete product machinery that is now available in the country today. The evolution of the concrete product machinery industry makes for fascinating reading. The market has evolved from being one that was being dominated largely by smaller manufacturers offering semi-automated machines with limited capabilities, to one which is now getting more organized, thanks to the entry of global players, offering sophisticated and higher capacity machinery that is also capable of producing a wider variety of concrete products. The latest machines are also easy to install, operate, and maintain. Adding to the excitement of concrete product machinery manufacturers is the continued impetus being provided to the precast industry. It is a market segment that is poised for a boom, given the US$ 1 trillion investment envisaged during the 12th Five Year Plan Period
t won't be a misnomer to say that the last decade has been the most eventful for the Indian construction industry. Propelled by the massive infrastructure development process, the country has seen an influx of several new technologies and materials, which have dramatically altered the market dynamics. One of the best examples for the changes in buyer behaviour patterns can be found in the form of increased usage of concrete blocks. Gone are the misconceptions about the use of concrete blocks. Increased aware-
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this could be the best time for using concrete products in the country, directly impacting the fortunes of the concrete block making machinery manufacturers. Echoing these positive sentiments is Mr.Manoj Kumar, Managing Director of Hess India, the subsidiary of the Hess Group, which is a global industry leader in concrete product machinery. Going into details on how the company has been able to tide over the recent economic slowdown, he explained that the recession has affected Hess considerably less. As a German Company we have a trust and goodwill in the market and we consider India as major and potential market. For that reason we took a strong step in India to proceed with setting up own facility with technical team. This will help us to do more engineering in India which will reduce the cost since we will be sourcing materials locally. At the same time this will be an advantage to the clients who can avoid higher import duty, said Mr.Manoj Kumar, as the reasons behind the company performing consistently well since it made its entry into the Indian market. Global Players in Fray The Indian market for concrete block making machinery which is pegged in the region of around ` 300 crore is expected to grow exponentially, on the back of the continued impetus being provided to infrastructure development
As a German company we have a trust and goodwill in the market and we consider India as major and potential market. For that reason we took a strong step in India to proceed with setting up own facility with technical team. This will help us to do more engineering in India which will reduce the cost by sourcing materials locally. At the same time this will be an advantage to the client by avoiding higher import duty instead only local taxes and able to get some tax benefits from government
Manoj Kumar
Managing Director, Hess India
and the growth of the real estate market. This being the fact, it does not come as a surprise that global players have been making a beeline for India. Companies like Hess India, Columbia Pakona, and Besser are now wellknown names in the Indian market.
(2012-17) on infrastructure development. Slowdown a Boon? The recent economic slowdown does not seem to have impacted the concrete product machinery industry to the extent it has other types of construction equipment. In fact, the economic slowdown could be a blessing in disguise for manufacturers of concrete block making machinery. With project developers trying to cut down on overall costs, due to the recessionary trends,
extending tax benefits such as by reducing VAT and excise duty on flyashbased products, which would in turn have direct positive impact on the sales of concrete block making machines. Pipe Making Machinery The concrete product machinery industry has seen the entry of newer types of equipment in recent times. Perhaps the one new type of machinery that has been often in the news recently has been that of pipe casting machines. These machines have been a long felt need of civic authorities in the country. Apart from this particular market segment, with demand spurred on additionally by water supply and irrigation projects around the country, companies including Hess India, Apollo Infratech, and Columbia Pakona are now offering specialized concrete pipe making machinery in India. GCI has the produce license for the pipe machines of Hess India. Similarly, Apollo Infratech represents Hawkeye Pedershaab, USA, a world leader in vertical cast concrete pipe technology. The range of products offered by the company includes models such as CAP 150, CageFlex 260, and CAP 200/250. These machines with vertical cast technology are known for their ability to churn out anywhere between 100 to 400 pipes in a day of various sizes. Columbia Pakona offers a fully auto-
The wider variety on offer has meant that the typical Indian customer is the proverbial king today. Companies have been focusing on bringing in machines that are ideally suited for the Indian market. A good example is Hess India's RH 500 model. The model has a heavy duty, structure with advanced electrical, electronic, and mechanical features. With a production height that varies from 50-300 millimeters, it offers a wide range of products within the dimension of 1200x670 board size. The positive height stop allows products to be produced to the specific and accurate height during the production of building blocks, interlocking pavers, and other concrete elements. Hess technology helps to maintain uniformity and dimensional accuracy with better finish. Columbia Pakona is one more player in fray which offers a wide range of concrete block machinery, along with concrete pipe machinery and roof tile machinery. Its range of concrete block
making machinery includes popular models 1600, SPM 20 and SPM 10 that are known for their ability to produce a wide variety of concrete products. Another well-known name that has made an entry into the Indian market is Besser. A good example for the company's range is available in the form of its two Bescopac models, which produce concrete units ranging from 25300 mm tall including, paving, standard and architectural block, and segmental retaining wall units. Sustainability and Flyash Blocks The increased emphasis and awareness on sustainable building practices has come as a shot in the arm for concrete block making machinery manufacturers. The rising use of flyash bricks and blocks stands testimony to this fact. Industry analysts however feel that there is still a lot that the government needs to do in order to further promote the use of flyash bricks and blocks. Leading players have been demanding that the government should come out with proactive steps such as
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Reliance Industries Ltd
Concrete Pipe Making Machine - CAP 200
Concrete Pipe Making Machine - VIHY Masterflex SC 60
matic Mach 1 machine. Some of the salient features of the pipe making machine include, automatic lowering, and raising of external moulds and pipes which means that there is no requirement of overhead crane. Similarly, since there is automatic feeding of concrete mix to the mould, there is faster filling of moulds and lower cycle times, apart from the overall reduction in manpower requirements and labour cost. Precast Another market segment that is expected to fuel the growth for concrete
product machinery is that of precast components. Rising project costs, along with the problem of severe labour shortage has meant that today an increasing number of contractors are not averse to trying out precast components as part of the construction process. In fact, precast components have become amongst the most crucial part of infrastructure projects such as roads, flyovers, and metros. Precast materials ranging from small slabs to culverts and bridges are in demand now. Precast has gained its attention in almost all sectors including, railways, road-
ways, commercial buildings, residential buildings, aviation, etc. Market Getting Organized The gradual entry of bigger players has meant that an industry which was being dominated by the unorganized sector is getting more organized now. The increase in project sizes, plus the demand for a wider variety of concrete products and that too in larger numbers in quick time has meant that a slew of globally reputable block making machinery manufacturers have now entered the Indian market, either by setting shop themselves or through tieups with leading players in the domestic market. The increased emphasis on quality, along with tighter project deadlines means that the market for concrete product machinery will continue to maintain its hectic growth rate. The increased use of concrete blocks in large-scale projects such as integrated realty townships, high-rise projects, and SEZs has also come as good news for manufacturers. The intensifying competition has meant that players in the fray are now offering value added propositions in the form of project guidance and machine commissioning, all of which bodes well for the Indian customer. The next five years could be the best time for concrete block machinery manufacturers in India.
Concrete Pipe Making Machine - CAP 150
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In Conversation
Anand Sundaresan:
The Man Who Saw Tomorrow

K.P. Pradeep, Editon-in-Chief
t takes a lot to be acknowledged as a visionary and a game changer. Immense hard work, unaccounted late nights at work, pressure and stress, with everything falling on you at the end of the day. The success story begins from the moment when all the above pays off. A living example of such successes is Mr. Anand Sunderesan, Managing Director, Schwing Stetter, India who is considered by many as the 'Man who saw Tomorrow' in the construction equipment marketplace. I recently caught up with Anand Sunderesan at Schwing's sprawling production facility that is strategically
placed on the Chennai-Bangalore highway, about 40 kilometres from my office. Sriperumbudur is today a global manufacturing hub that offers all the facilities that international industrial giants like Schwing Stetter want for their business in the country. A chartered Mechanical Engineer, with a degree in Electrical Engineering, Anand Sundaresan has over three decades of experience in various senior positions. He began his career in the R&D wing of L&T's Heavy Engineering Group and subsequently joined the construction equipment division of Greaves Cotton & Company Ltd., where
Transit Mixer production bay of Schwing Stetter in Sriperumbudur
he rose to become the Deputy General Manager, Marketing. He also had a short stint as the Sales Director in Hoesch Rothe Erde, a Thyssen Group-company before joining Schwing Stetter India as its Executive Director in June 1998. He has elevated as Schwing Stetter's, Managing Director in 2002 and has never looked back since then. Anand Sunderesan foresaw much ahead of others the fact that India's lack of infrastructure was a huge opportunity for his organization and convinced his Top bosses at Schwing Global, to set up a production facility in India to manufacture ready mix concrete equipment at the time when most players were happy dumping used equipment at a phenomenally high cost. He was instrumental in introducing many state-ofthe-art products for the construction industry in India, including the Wet Shotcreting System for tunnel lining and the computerized Batching Plants for precise concrete production. Anand Sundaresan was also credited for being instrumental in setting up a design center to cater to the requirements of the entire Schwing Group. An active member in numerous business forums, including the Indo German Chamber of Commerce, Madras Chamber of Commerce & Industry, Indian Earthmoving & Construction Industry Association, Confederation of
In Conversation
We manufacture about 700-800 concrete batching plants annually, making us the industry leader in these products. V.G. Sakthikumar
Chief Operating Officer & Marketing Head Schwing Stetter India
Indian Industry and many other associations. Sundaresan was awarded the prestigious 'Rashtriya Ekta Award' for the year 2001 presented by the National Unity Conference, New Delhi, for outstanding contribution in the Construction Industry. Under his stewardship, Schwing Stetter India was awarded 'The Best European Venture of India 2005' for outstanding contribution towards the promotion of Indo German Economic Relations. He also received 'The Best Manufacturing Excellence Award' for the year 2005 from Frost & Sullivan. Fresh from his Best CEO of India award constituted by the Stars of the Industry Group, Mumbai, a sprightly Anand Sundaresan, greeted me at his office and offered me a quick tour of his
manufacturing facility before we settled down for regular media interaction. The first thing that struck me when I entered the factory premises was the orderliness. The famed German antecedent of precision engineering backed by well designed systems was evident in every one of the bays inside the premises. The company has been a trendsetter in yet another way in the region. It was among the earliest to choose Sriperumbudur for its manufacturing set up. Its corporate social responsibility initiatives have benefitted the local populace to a very large extent. We started off our tour with a visit to the unit where Schwing Stetter Indias famous Concrete Batching Plants are manufactured. We offer a comprehen-
sive range of Concrete Batching Plants, said Anand Sundaresan, reeling off names of the models such as CP 18, CP30, which formed part of the compact series then moving on to the mobile series including models such as M1, M1.25, M2 and M2.25, etc, before going on to the Horizontal Series consisting of the HN 1 to HN 6 models. Amidst the din of the fabrication process that was going on inside the factory of a company that is today worth over ` 1000 crore, Anand Sundaresan remarked, 100 % indigenization is our goal. As far as Concrete Batching Plants go, we only import drives and gear box from Germany, while the rest of the components are available here. The team at Schwing Stetter has made sure that they are always listening to their customers, a trait that has made them come out with product innovations at regular intervals of time. The design of the concrete batching plants, which are easy to assemble, commission, and then dismantle, is a good example. Further explaining, Mr. Sundaresan said, Our models are designed for easy commissioning and disassembly, where they can be put into trucks and then moved on to another site. Added Anand Sunderesan's Mr. Dependable V.G. Sakthikumar, the Chief Operating Officer & Marketing Head of the company, We manufacture about 700-800 concrete batching plants annually, making us the industry leader in these products. The company's Concrete Batching Plants are today
One of the striking features at Schwing Stetter is its ability to foster a highly motivated workforce
Transit Mixers are designed to take on tough working conditions prevalent in India
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Schwing Stetter (India) Pvt. Ltd
In Conversation
Schwing Stetter customer training centre in Irungattukottai complex offers a variety of service training courses for its customer's
literally visible in almost every nook and corner of the country. Lack of adequate number of trained operators has been an issue that has been plaguing the Indian construction equipment industry for quite some time now and it is not surprising that Schwing Stetter India, being the trendsetter that they are, have set up an exclusive training centre, which was the next stop on our visit. The Schwing Stetter Customer Training centre in Irungattukottai complex offers a variety of service training courses for its customer's personnel in the operation and maintenance of Schwing Stetter equipment. The Sprawling 12,000 sq. ft. training centre offers certified training courses blended with theory and practice. All
customer personnel such as engineers, supervisors, mechanics and operators can undergo courses from primary to advanced level in the operation, maintenance and trouble shooting of Schwing Stetter equipment such as concrete pumps, batching plants and transit mixers, explained Mr. Sakthi Kumar, before adding that operators can also get themselves trained on any of the competitors' products too. Mr.Sundaresan highlighted the fact that customized training packages for corporate are also designed exclusively and conducted as per their requirements either at the training centre or at the customers' premises. The training centre today churns out over 800 trained operators annually.
A view of the Trailer Pump manufacturing bay at Sriperumbudur
The next stop on our tour was the spot where Schwing's transit mixes are manufactured. Right from the path breaking 3 cu.m model 'Nimo' to a 10 cu.m model, we offer a wide range of Transit Mixers, which are designed to take on the tough working conditions of India, pointed out Mr.Sundaresan, as he took me around the production area. One of the striking features of the company is its highly motivated work force. I could almost feel a familiar enthusiasm amongst almost every employee; a clear indicator of Anand Sunderesan's ability to rub of his positive attributes in his workforce. After a quick visit to the conveyor production center, we quickly moved on to the pump manufacturing bay. This is a section that any equipment enthusiast like me would love to explore as this is the birth spot of those record breaking concrete pumping machines such as the SP 1000, SP 1200, SP 1400, etc. Similarly, it also offers an entire series of trailer pumps, which includes models such as the SP 2800 and SP 8800 that are typically used in infrastructure and high-rise construction projects. Schwing's S 43 is considered India's largest boom pump on a 4 axle truck with 5 sections boom. This was also from where the company manufacturers its exclusive Separate Placing Boom models namely the SPB 25, 28, 30, and 35. We have been constantly pushing the envelope when it comes to concrete pumping, said Mr.Sundaresan while reeling off the several records that have been set by his company's concrete pumps. While the recent economic slowdown may have dampened the spirit of several in the Indian construction equipment industry, it doesn't seem to have had an impact on Mr. Sundaresan and his team at Schwing Stetter. It is only a matter of time before the market bounces back. Our commitment to the highest standards of quality and customer satisfaction means that our products will always be in demand, Mr. Sundaresan signed off on a positive note.
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Tashi India Ltd
Concrete Non Destructive Testing
Non Destructive Testing for Concrete:

Advancing Equipments & Market
Chaitanya Raj Goyal
t is estimated that the present consumption of concrete in the world is of the order of 10 billion tones every year. Humans consume no material except water in such tremendous quantities. Perhaps that is the reason that makes concrete technology such a widely researched upon field with testing of concrete taking up major portion of the pie. There has always been a need for evaluating in place properties of concrete for quality assurance and evaluation of existing conditions. Ideally these methods should be non destructive so that they do not damage the
structure and permit re-testing at the same locations to analyze the changes with time. When compared to steel, the non destructive testing (NDT) methods for concrete have been developed & have evolved at a slower pace since it is an inherently more difficult material to test than steel. The application of non destructive evaluation (NDE) methods for quality assurance of concrete structures has made considerable progress in the recent decade. Driven by technology and knowledge transfer from other areas of materials testing, a ver-
satile toolbox of methods for the investigation of RC structures has emerged from research. In the area of simulation and 3D-reconstruction of ultrasonic and radar data, progress was driven by more powerful computers and development of state of the art software for 3D re-construction and visualization of data. Today non destructive techniques are increasingly being used to diagnose various building structures thus creating a large market which has attracted various national & international players in the Testing Equipment & Instrumentation industry. Owing to their non-invasiveness
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they are the only choice in some cases promoting quick, easy & safe working. Growing market for NDT: An insight into the causes & factors Even though concrete is one of the most widely used construction material, the manner in which it is presently prepared & used to form structures, leaves many desires unfulfilled. This may mostly be attributed to lack of proper quality control & supervision during the course of construction. Often safety & durability of structures are given the green signal thereby permitting poor quality of construction. When one builds a structure, it has to perform satisfactorily over the reasonably expected life. At present the test used mainly as a basis of quality control is compression testing of cubes & it represents the potential strength of the concrete used. The main parameters determining the quality of concrete is its composition, compaction & curing. At the most it can be ensured that the composition of concrete going into the cubes & that going into the structure is the same; there may be some scope of differences in this case also. However, the methods of compaction & curing may be & usually are different for the cubes & the structural members. This is why the results obtained on cubes may not truly represent the quality of concrete in the structure. Hence the unquestionable need for non destructive testing arises. Also, non destructive testing can be applied to both old and new structures. For new structures, the principal applications are likely to be for quality control or the resolution of doubts about the quality of materials or construction. The testing of existing structures is usually related to an assessment of structural integrity or adequacy. In either case, if destructive testing alone is used, for instance, by removing cores for compression testing, the cost of coring and testing may only allow a relatively small number of tests to be carried out on a large structure which may be misleading. Non destructive testing can be used in those situations as a pre-
liminary to subsequent coring. Typical situations where non destructive testing may be useful are, as follows: 1. Quality control of pre-cast units or construction in situ; 2. Removing uncertainties about the acceptability of the material supplied owing to apparent non-compliance with specification; 3. Confirming or negating doubt concerning the workmanship involved in batching, mixing, placing, compacting or curing of concrete; 4. Monitoring of strength development in relation to formwork removal, cessation of curing, pre-stressing, load application or similar purpose; 5. Location and determination of the extent of cracks, voids, honeycombing and similar defects within a concrete structure; 6. Determining the concrete uniformity, possibly preliminary to core cutting, load testing or other more expensive or disruptive tests; 7. Determining the position, quantity or condition of reinforcement increasing the confidence level of a smaller number of destructive tests; 8. Determining the extent of concrete variability in order to help in the selection of sample locations representative of the quality to be assessed;
9. Confirming or locating suspected deterioration of concrete resulting from such factors as overloading, fatigue, external or internal chemical attack or change, fire, explosion, environmental effects; 10. Assessing the potential durability of the concrete; 11. Monitoring long term changes in concrete properties; 12. Providing information for any proposed change of use of a structure for insurance or for change of ownership. Thus due to the involvement of such numerous critical factors, we have witnessed a considerable growth in the NDT market in India & across the globe. Need of the hour: Some popular NDT equipments Broadly speaking there are 2 types of NDT methods for concrete on which the testing equipments are based on. The first type consists of the following methods which are used to calculate the compressive strength: surface hardness, penetration resistance, pullout, break off and maturity. Most of these methods are not truly non destructive and are also called 'partially destructive' because they cause some surface damage that must be repaired. The damage however is minor as com-
Schmidt hammer testing
pared to that caused by core drilling. The second type includes those methods which measure other properties to concrete such as pulse velocity, moisture content, density, thickness & dynamic modulus of elasticity. Also included in this category are infrared thermography techniques, stress wave and radar which are used to locate delaminations, voids and cracks in concrete. Here are some NDT equipments which have gained popularity in the construction industry lately. Rebound Hammer A Schmidt hammer, also known as a rebound hammer, is a device to measure the elastic properties or strength of concrete or rock, mainly surface hardness and penetration resistance. Consultants, clients and contractors prefer to use it primarily due to its speed and ease of use. This is basically a surface hardness test & should be used only on concrete where the surface has not carbonated as the results tend to be very high & unrealistic on a carbonated surface. Hence it should be used for younger concrete than for older one. In case of old concrete the carbonated layer should be chipped off or grounded to expose the core concrete & then the hammer test should be conducted. The rebound is also affected if the surface is moist. Ultrasonic Pulse Velocity Tester (PUNDIT) This is used for assessing the quality & integrity of concrete by passing ultrasound waves through the specimen / RCC member under test. This equipment can also be used to determine the presence of honeycombs, voids, cracks etc. The instrument consists of a transmitter & a receiver (two probes). The time of travel for the wave to pass from the transmitter to the receiver when kept opposite to each other is recorded in the ultrasonic instrument. The distance between the two probes (path length) can be physically measured. Hence Ultrasonic Pulse Velocity = Path length / Time. This velocity in concrete can be related to its compressive strength. The
Ultrasonic Pulse Velocity testing
key to this testing is not using the equipment but to know where to use it and interpretation of results obtained after testing. Electrical Resistivity Meter This device is used to carry out assessment of the quality/ uniformity of concrete at various depths. The instrument consists of a four probe device. Electrical current is passed through the outer probes & the potential drop is measured by the inner probes. From the current & voltage drop measurements, the resistivity of concrete can be measured. Surface resistivity measurement provides extremely useful information about the state of a concrete structure. Not only has it been proven to be directly linked to the likelihood of corrosion and the corrosion rate, recent studies have shown that there is a direct correlation between resistivity and chloride diffusion rate and even to determination of early compressive strength. Apart from quality / strength of concrete it can also give information about the total thickness of the specimen under test & the backing material (in case of tunnel lining or pavements where only one surface is available for testing & no other test can give the said information). The backing material could be concrete, water, air or rock in case of
tunnel lining. This makes it one of the most versatile NDT methods for concrete. Half-cell Potential Test Meter This instrument can be used to evaluate the probability of corrosion activity taking place at the point where the measurement of potentials is taken from a half-cell, typically a coppercopper sulfate half-cell. An electrical contact is established with the exposed steel & the half-cell is moved across the surface of concrete for measuring the potentials. Readings are however weather and moisture sensitive. It normally requires that concrete is moist before conducting the tests. Cover Meter or Rebar Locators This gadget is useful for the determination of concrete cover, location of embedded rebars & estimation of size of embedded rebars. The instrument is based on the magnetic technique & is calibrated for different purposes. The cover thickness is important from the point of view of estimation of initiation of corrosion. The location & estimation of bar diameter becomes useful in structures where there are no structural drawings available. Carbonation Depth Detector The quality of concrete cover holds
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Roljack Industries
nation is again dependent upon various factors for reliability. The conversion of concrete core (typically 3 or 4 inch diameter core) strength into 150 mm saturated cube strength depends upon the effect of coring; shape factor; size effect; direction of coring with respect to placing of concrete and the h/d ratio. With so many factors contributing to the final 150 mm saturated cube strength, the strength variation may be + / - 10% - 15%. However, it can be used to confirm the results of UPV differing largely in the values & also for co-relation. Hence the UPV & core results should be judiciously used, interpreted & co-related. Future of NDT in India
The half-cell potential test meter
the key to the process of corrosion initiation. Hence when the concrete cover is carbonated the process of corrosion enhances due to the reduction in the alkalinity surrounding the rebars. The estimation of carbonation depth thus helps in predicting the period of protection from corrosion. This is mostly used in conjunction with other NDT tests. Chlorides (as Cl) Determination from Chlorimeter Apart from (or after) the carbonation of concrete, the natural protection to steel is lost & thus the chlorine present in the atmosphere is free to attack the embedded steel. Above a threshold value of chlorine ions along with degree of alkalinity of concrete, the rate of corrosion increases. Hence it becomes important to estimate the chlorine ion content to comment on the corrosion of steel.
In-situ Water Permeability Apparatus This instrument is useful for comparing different grades of concrete depending on the permeation of water through the concrete. It consists of a chamber that can be sealed after filling water. After keeping the desired level of pressure, as the water penetrates the pressure drops & a micrometer screw gauge fitted with the instrument is used to keep the pressure constant. The penetration of the screw gauge is used to determine the penetration of water in volume. Core Drilling & Testing Machine These are used to conduct a partially destructive test that is used to corelate the various other properties of the concrete viz. UPV, electrical resistivity, rebound number etc. It is customary to take cores of 4 inch diameter for compressive strength determination. Concrete core drilling for strength determi-
These NDT methods are being used extensively despite the lack of testing standards for many of the methods. The development of testing standards is critical for proper application and expanded use of NDT methods for evaluation of concrete constructions. The non destructive testing should however be carried out by agency having sound & sufficient knowledge & experience in this field as well as behavior of concrete. With the growing rate of deterioration of the nation's infrastructure, the necessity for including NDT and field instrumentation in engineering curriculum has become more apparent than ever before. Bringing these developments into the state of practice, into everyday use on construction sites by trained engineers rather than researchers still remains a major challenge in India. To earn the trust of industry, the reliability of these NDT methods should be established and adequately verified to prove that their application is worth the additional expense and effort. With the improving focus on structure quality and construction industry becoming highly receptive to new and upgraded technology, the future bodes well for the Indian NDT sector. Photo Courtesy:
www.matcoinc.com, www.suntechassociates.com www.ndtjames.com, www.ntu.edu.sg www.pcte.com.au, www.hellotrade.com
Rebar locator
Core Drilling Machine
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Atul Fastners Ltd
C&D Recycling A Sustainable Community Development Approach

applicable quality standards. The C&D debris waste stream is comprised of four major sub-categories: land clearing debris, transportation related debris, building construction, demolition debris and disaster debris. The India infrastructure industry in India is growing in every area in a big way. Innovations, techniques and new equipment are broughtin to make the construction of projects more efficient. However, what is not gaining importance here is the recycling of the construction and demolition debris generated every day from various construction sites in the country, from old infrastructures buildings, roads, dams, bridges, chimneys etc. What ever is however, being done today is limited to low-value applications like landfills, for sub-base of roads or construction sites. As the construction industry continues to boom, the continued availability of space in these landfills is going to be threatened. Not only the initiatives from the
Subhash Niyogi, CEO

Rockster Recycler India Pvt. Ltd.
Very Common scenes even in hi-tech cities in the country
educe, Reuse, Recycle should become a household mantra for every Indian family. What is however, needed for us is a robust recycling management program for C&D materials. Recycling means the process of collecting, sorting, cleansing, treating, and reconstituting materials that would otherwise become solid waste, and returning them to use in the form of raw material for new, reused, or reconstituted products which meet the
Demolition debris dumped in the empty finds no recycler!
government, but also manufacturers elsewhere in the world are working on their target of recovering coarse and fine aggregate from recycled concrete, with quality as close as possible to the original constituents, institutions are busy in R&D for reuse of recycled concrete. The approach is to analyze the difference between fresh aggregate and traditionally-produced recycled aggregate, and then to set about improving it. Management of C&D waste has already become major concern for our town planners, and challenges of increasing awareness about recycling. In India, it's a common practice for most of C&D projects including individual households to find its place to pile waste on the road or below the flyover, resulting in traffic congestion or into nearby vacant area. It is reported that total waste from India's construction industry could reach 12-14 mt per year. It is time for us to follow the guidelines of Waste Reduction and Recycling Plan as part of any construction project permit. The C&D waste adversely affects the economy and the environment. Waste negatively impacts the environment. Degradation of the natural landscape occurs through leaching from impro-
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Guaranteed Mixer for Industrial Waste into Resources

n any construction work, the choice of suitable materials is of paramount importance . One is always on the lookout for materials which can give superior performance and also reduce the current levels of construction. Blended Cement: Blended cements have worldwide acceptance. This is because of its advantages over the ordinary Portland Cement from technical, economical and the ecological angles. Blended cement is obtained by blending with Portland cement clinker other component materials which are hydraulic or latent hydraulic or pozzolonic in nature which when ground with Portland cement clinker gives the blended cement. In India two types of blended cements are very readily available viz., Portland Pozzolana cement and Portland slag cement. Portland Pozzolana Cement: (PPC) This cement is manufactured by blending 10--25% fly ash with ordinary Portland cement. Blending could be done either at grinding stage or else OPC clinker can be separately ground and then blended in powder for using sophisticated blenders. The source of fly ash is thermal power plants where the fly as is collected through ESP . The benefits of fly ash based cement solely depend on quality of fly ash, its fineness, chemical composition, carbon content and percentage of glassy and crystalline silica. Portland Slag Cement: This cement is manufactured by blending ground granulated blast furnace slages powder with ordinary Portland cement. In this case also blending could be done at grinding stage or separately. G.G.B.F,S is a byproduct obtained in the manufacturing process of Pig Iron. Use of GGBS mixed with OPC imparts superior properties to the concrete in terms of durability. It improve strength and reduces the cost of concrete. Promotion of such material in India is needed. Toshniwal offers the innovative Norwegian technology mixer which is absolute test proven mixing efficiency for manufacturing blended cement product. The mixing quality is very good, and mixing time for most applications is very short about 30 seconds for a filling capacity of 20 to 40% (filling to the top of the shaft is 100%) or full capacity). Due to the very short mixing time high throughput can be achieved, the influence of shear is negligible. As a result, the Mixer is suitable not only for processing non aggregating, segregating and slightly cohesive materials, but also for friable ones. Also these mixers had proven record for the building materials and construction care products like Building Material: Dry Mortar Renders Wall Plasters Wall Putty (Dry) Floor Screeds Skim Coats Blended Cement. Construction Care: Integral Water Proofing Compound Grouts Flour Hardener Repairing Mortar Tile Joining Compound Thermal insulation products Fire Proof Cement Wall Paper Compounds. Toshniwal provides the customized blending requirement such as Pilot Scale Mixer Trials Production based product trials Contract blending operation, etc. Further details from: M/s. Toshniwal Systems & Instruments Pvt. Ltd., 267, Kilpauk Garden Road, Chennai - 600 010, India Phone No: 91-44-26445626 / 26448983 Email: mixer@toshniwal.net / Web : www.toshniwal.net
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perly lined landfills. On the other hand, recycling in general, has economic and environmental benefits for communities. It can reduce the need for new landfills and their associated costs. Recycling can support industrial development as the recycled materials serve as raw materials for manufacturing and other uses. The reuse of materials, conserves resources by reducing the need to extract virgin resources or introduce new chemicals into the environment. Not disturbing existing natural resources and by reducing noxious manufacturing processes, recycling prevents emissions of many greenhouse gases and water pollutants. Recycling also saves energy through avoided extraction and manufacture processes. The other positive aspect of recycling is significant job creation and business development potential associated with recycling. In US, the remanufacture of recycled materials supports more than one million manufacturing jobs and adds more than $100 billion in revenue. Not to talk about the research and development of 'greener' technologies that require skilled individuals and significant
Items Labor Equipment Transport
Additives and water is injected into the mixing system through tanker connected to the machine
capital investment. Thus a wide variety of job skills are possible to develop this industry. Promoting ''deconstruction'' iin-place of 'demolition' Deconstruction means, planned breaking of a structure with main target of reuse. The economics of construction are evaluated by the costs of local debris, landfill, tipping fees and available alternative markets for recovered
Demolition Traditionaldemolitionlabor force Traditionaldemolition equipment May be high depending on distancetoappropriate disposal facilities Demolitionpermit Asbestos permit Disposal permits Can be high depending on area and type of Waste Taxes on transport and disposal Minimal, If any
materials. Factors influencing the decision are labour costs and speed of disassembly process itself. When demolition is an integral part of new construction at the same site, the efficiency of deconstruction affects the direct costs of labour and equipment and also affect the time costs of the project. Economic Evaluation: Demolition: Demolition labor + Demolition equip + Disposal cost + Permitting + Other = Total Demolition Cost Deconstruction: Deconstruct labor + Deconstruct equip + Permitting + Other - Revenue from salvage (estimated @ 50% of material value) = Total Deconstruction Cos Cost has an impact on the feasibility of C&D Recycling For the contractor, the costs have major impact on the feasibility of C&D recycling. A project disposal costs can range from 0.5-30 percent of a project, thus, construction costs savings can motivate the construction and demolition industry to implement new recycle and reuse C&D materials. Contractors should understand that using new materials and discarding scrap from them means developers to pay for materials twicefirst for the purchase and then again for disposal. Case
Deconstruction (Reuse and/or Recycle) Higher labor costs (hand labor required) May require specialized equipment Reduced waste transport
Permits
Demolitionpermit Asbestos permit Avoidedor reduced
Tipping fees
Taxes Return value
Potential loss
Tax credits for deconstruction Revenue from sale of salvaged items, reduced tipping fees, tax deduction for donated items, save $$ on fill Schedule extension, higher labor costs
May need to purchase more raw materials if reconstruction at same location
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Spraying system on the machine
Social costs: include missed opportunities for employment and job training, community involvement in reshaping local built environments, and neighborhood. C&D waste management plans that utilize recycling can help to reduce development costs of new and rehabilitated projects. These savings can, in turn, stimulate additional development and improve the bottom line for construction firms. Economic Development through C&D Recycling C&D recycling can be used as part of a larger industrial development effort to bring higher wage jobs to a region. Recycling supports economic development and the improvement of communities. Recycling and reuse can create jobs and revenue. It provides opportunity for development of small business, job training opportunities, and reduced landfill expansion needs. Studies indicate that manufacturing of secondary materials increases the economic impact of recycling collection and processing many folds. The collection and processing phases provide low skilled and entry-level workforce opportunities. Reference worthy to mention here is the initiative taken by Kolkata Corporation: In Kolkata the recycling of bituminous city pavement is carried out using on site cold mixing techniques, or at a central asphalt mixing plant. The benefits includes reduced use of asphalt, energy savings, a reduction in aggregate requirements and finally the
Recycling of C&D Debris
studies indicate that 80 percent of building materials could be reused or recycled. What we need is the C&D waste management plans that utilize recycling to reduce development costs of new and rehabilitated projects. These savings can, in turn, stimulate additional development and improve the bottom line for construction firms. When it is initially cheaper to send C&D debris to the landfill, rather than to recycling, most contractors will choose the cost saving option. We in our cost analysis for a project, mostly adopt the concept of first cost perspective. Any option is valued primarily by the initial investment. In this perspective we do not take into account lifecycle costs, environmental impacts, and social and human capital investments. Here, life cycle costs involve extraction costs, transportation costs, operating costs, and disposal costs of construction materials. In our present system, these costs do not play any role into decisionmaking. Our current environmental and social frameworks do not encourage decision-makers to consider long term and comprehensive costs. Environmental costs: It is the cost associated with disposal of potentially recyclable materials that include - loss of habitat when pristine land is used for new landfills or expansions of existing landfills, increased extraction of virgin natural resources for new construction products which otherwise could be replaced by the recycled material, leaching from landfilled items into soil and groundwater1, and increased dust and noise levels polluting air quality from demolition activities.
reduced traffic congestion. In cold insitu recycling the milled or excavated chunks of road asphalt is pulverized, mixed with cement, bitumen emulsion, foamed bitumen or other available additives, and making up the deficit aggregates after lab tests. The mix is either made in-situ or in-the-plan, paved or compacted. In hot recycling the pulverized asphalt RAP is added with the required fresh aggregates and bitumen and mixed in the recycling plant. The recycled hot mix is paved and compacted as in conventional process. The up-gradation of in-situ recyclers done by FAE-Group Spa., Italy is worth mentioning here. As against conventional milling and recycling machine, FAE MTH 225 class of machines are capable of not only milling and recycling of RAP in-situ but at the same time it is also able to crush the boulders or large stone beneath the top asphalt of the existing pavement or if it is required to add the aggregates just by crushing larger stones in-situ by the same machine in a single process. On-site Recycling of C&D or RAP: Rockster Recycler from Kormann Recycler GmbH, Austria has a single machine solution for crushing and screening of either C&D debris or RAP .

No. 500, 17th Cross, Ideal Home Society, RR Nagar, Bangalore - 560098 Ph:+91-80-28604528 E-mail: subhash@rocksterindia.in Web: www.rocksterindia.com
Recycling of Asphalt RAP
Rockster Recycler India Pvt. Ltd.
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Concrete Corrosion
Accelerated Short-Term Techniques to Evaluate Corrosion in Reinforced Concrete Structures

Associate Editor
The phenomenon of corrosion of reinforcement bar in concrete is a time dependant process. Under severe environmental conditions also, it takes years for the steel reinforcement to be corroded and to cause deterioration of reinforced concrete (RC) structures. However when it becomes imperative to evaluate the relative performance of different types of steel and binder in a short time, the accelerated corrosion test can be adopted. The accelerated corrosion test does not always reproduce the actual corrosion still it can simulate to some extent the steel corrosion found in real RC structures.
n recent years an increased research effort has been focused upon corrosion of reinforcing steel in concrete and upon techniques whereby such damage can be reduced or haulted. Although the problem has been most apparent on reinforced concrete bridge decks, it also occurs on support structures (girders, piles, piers, etc), industrial plants and marine docking facilities.
Steel embedded in concrete is normally subjected to an alkaline environment which subsequently passivates the steel, forming a stable oxide film. The corrosion protective properties of concrete are dependent upon maintaining an alkaline environment in intimate contact with the steel. Any condition which disrupts the environment around the steel can result in disruption of the passive film and initiate
Concrete Corrosion
corrosion process. Marine environments and deicing salts both provide significant concentrations of chlorides which can penetrate the concrete to destroy the passive film on the reinforcing steel and reduce the pH of its environment. As the corrosion process proceeds, an accumulation of solid corrosion products forms at the metal-concrete interface. The corrosion product formed absorbs water and increases in volume. The volume of corrosion products (rust) is 2.56 times larger than the volume of the steel used in concrete which is the reason behind cracking and spalling of the concrete in the corrosion propagation phase as this increase in volume of rust products exerts enormous stress on the surrounding concrete. These stresses have been reported to be as high as 450MPa. Numerous variables have been determined to influence the occurrence of reinforcing metal corrosion and concrete cracking. These may be categorized as pertaining to (i) nature of the embedded metal, (ii) nature of concrete, and (iii) nature of the environment. Chemical and electro chemical properties of the embedded metal itself are important with regard to the first category. Also included here is the influence of caotings, either metallic or inorganic, applied to the reinforcing metal. Variables in category two are the concrete mix design, including special admixtures or inhibitors, the water-cement ratio, the cement type and the depth of cover. The foremost factor of interest in the last category has been the chloride ion concentration. Particularly lacking in the testing of reinforced concrete for its corrosion protective properties has been an accelerated test or test procedure. An exemption to this is the technique developed by Tremper et.al. in 1958, which involves exposure of a freely corroding, partially submerged reinforced specimen. The principle of this technique is that the region near or below the water line becomes anodic due to Cl- penetration; and corrosion of this area is driven by the cathodic portion of the reinforcing steel, which is in the air. A disadvantage to this test procedure is the length of the time required for data to be evolved. This is inspite of relatively small concrete cover the reinforcing metal (Approximately 0.75 inches 0r 1.9 cm). For greater cover even longer times should be required. One of the famous test that is being adopted these days is accelerated corrosion test or Impressed voltage test. The test has gained popularity because of its simplicity and more user friendly behavior. Accelerated Corrosion Test The setup for accelerated corrosion test (also known as impressed voltage test) is shown in Figure.1 and Figure.2. It consists of a DC power supply, two stainless steel plates, a data logger, test specimen and the container containing the required dosage of NaCl solution. Beam specimens
with a centrally embedded steel bar are used for the accelerated corrosion test. The specimens are tested at the required age after preparation. The steel bar (anode/ working electrode) of the beam specimen is connected to the positive terminal and the stainless steel plates (cathode/ counter electrode) are connected to the negative terminal of the DC power source. The corrosion process is initiated by applying a constant voltage to the system. The current response is continuously monitored and recorded by the data logger. In addition the specimens are daily inspected visually for the onset of cracks. The data logger is set at a sampling frequency of 1min for recording the corrosion current of the circuit. The accelerated corrosion test is terminated after cracking of the specimen when the rate of increase of corrosion current with time was negligible.
Computer Digital multimeter with single channel data logger D.C.Power Supply
Beam Specimen Steel Plate Container NaCl Solution
Figure 1: Schematic test set-up for accelerated corrosion test
Figure 2: Test set-up for accelerated corrosion test
Data Analysis An important facet of this test is definition of specimen failure. In all cases test is considered to commence at the time of application of the impressed current. Specimen failure is defined as that time corresponding to onset of a large current increase. The example in Figure 3 illustrates schematically the generalized nature of current variations in the constant voltage test method. Initially it can be seen that some relatively small amplitude variations are encountered; but after that at later stage a large increase in current occurs. It is considered that this corresponds to growth of a crack within the concrete and to a corresponding decrease in electrical resistance. Crack growth is sub sequently incremental and is comprised of successive stages of propagation, which relieves tensile stresses, and
Waltar Enterprises
Waltar Enterprises
Wendt India Ltd
Concrete Corrosion
arrestment, which gives rise to additional solid corrosion products accumulation. Time to failure also have been shown in this example. Figure 4 shows a cracked beam specimen after the accelerated corrosion test.
20 18 16 14 12 8 6 4 2 2 4 6 Time, Days 8 10 12
Current, Millamps
10
Observed Crack
an automatic titrator (Make Metrohm, model: 848 Titrino plus). The titrator is equipped with a screen display that can display the chloride content automatically when appropriate inputs are fed. For determination of free chloride, three grams of the powdered concrete sample is transferred to 100ml beaker and 50ml of distilled water is added. The sample is then heated gently and thoroughly mixed by a stirrer. The solution is then cooled and filtered using Whatman No.1 filter paper and the free chloride content is then determined by titrating against 0.1 M AgNO3 solution in the automatic titrator. The results are expressed as percentage of free chloride by mass of concrete. (b) Mass Loss analysis of the corroded reinforcement bars- After the beam specimens are corroded and the measurement of half-cell potential and free chloride ion content are taken, the beam specimens are jackhammered to remove the corroded longitudinal steel bars. The corroded bars are cleaned with a wire brush to ensure that they are free of any adhering concrete or corrosion products. After this the procedure stated in ASTM G 1-03 is adopted for the cleaning of the corroded steel specimens and for determination of mass loss. For the purpose of cleaning, the cleaning solution used is 500 ml of hydrochloric acid with 3.5 gm of hexamethylenetetramine added with reagent water to make it 1000 ml. Each specimen is cleaned several times with this solution and mass loss is noted after
Figure 3: Corrosion Current Vs. Time Graph
Figure 4: Cracked beam specimens
Other Parameters Determined There are various parameters of corrosion performance of reinforced concrete that can be evaluated from the accelerated corrosion test. This includes (a) free chloride content at cracking measurement, (b) mass loss measurement, (c) critical corrosion current, (d) post depassivation cracking time. Hence it can be seen that one test can give so many parameter study opportunities. (a) Determination of free chloride content of cracked beam specimens-The beam specimens after accelerated corrosion test and half-cell potential test are analysed for free chloride content, since free chloride content is mostly responsible for corrosion of steel reinforcement in concrete. The concrete powder is collected by drilling on all four sides of the beam specimen i.e. cracked side and other three uncracked sides. The free chloride content is determined by potentiometric titration using
Time to Failure
Figure 5: Corroded steel bars obtained after breaking the beam specimens
Fine Equipment India Pvt. Ltd.
Alpha High-Tech Polyurethanes
Concrete Corrosion
each cleaning. The mass loss corresponding to the cleaning time after which no significant increase in mass loss observed is used as final value of the mass loss. The clean bars are then weighed and the percentage mass loss for each bar is calculated. Refer Figure 5,6 for corroded steel specimens after breaking of the beam and before carrying out the mass loss analysis. A typical way of mass loss calculation is shown in Figure 7.
Discussion on the Accelerated Corrosion Test The test can be carried out by varying the impressed DC voltage, the result would be increased or decreased time to failure. Various researchers used various voltages, however six volt is found to be an adequate value to complete the tests within a reasonable length of time. The beauty of the test is that it continues 2hours a day and 7 days a week continuously, the only attention that needs to be given is frequent checking of the crack appearance period. Early research indicated that three test specimens are adequate for each type of mix or material. Test data indicate that sufficient accuracy could be obtained since the data analysis method used here averages the three values. Judgement and expertise should be used where premature specimen failure occurs. If one of the three specimens fails the first few days and the other two continue for a long period, the data from the prematurely failed specimen should not be used. Visual inspection of this one specimen will probably show improper preparation of the specimen. Longer time-to-failure and higher resistance are indicative of improvement over the standard mix and the ability to better deter the intrusion of chloride to the reinforcing steel. Preliminary research results established that a continuation of testing to a point where cracks became 0.79mm and larger caused pollution from seepage of corrosion products into the water. For the purpose of these tests various researchers used various chloride concentrations, based on the exposure level the concrete structure will be exposed when put on use. Two methods of monitoring and testing have been used viz. the Constant Current Method and the Constant Voltage Method. The Constant Current Method consists of maintaining a constant current output to reach specimen and visually determining the time at which the specimen fails. Bothe the Constant Current and Constant Voltage Methods have certain limitations but can be varied to accommodate various materials tested. It must be recognized that these test procedures are sensitive only to the cracking tendency which results from a given induced rate of corrosion of the embedded reinforcing steel. In this test, the prismatic specimen is accompanied in some instances by development of an aqueous solution on top of the specimen surface. The pH of the top liquid has been found to be approximately 1.9, presumably due to hydrolysis of initial corrosion products. Because of this and also because of the relatively low electrical resistance of the top liquid, corrosion can occur pre-ferentially at this location. Occurrence of this can lead to erroneous conclusions. In order to permit this liquid to drain away from the reinforcing steel, the specimen preparation procedure specifies a 100 slope to the top surface.
Figure 6: Specimen after breaking (spots of corrosion are visible)

Mass Loss Calculation 1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 Data Series 2 Equation: y = 0.0048x + 1.4777 R2 = 0.9991
Mass Loss (grams)
Data Series 1 Data Series 2
10
12
14
16
18
20
Time (minutes)
Figure 7: A typical plot of mass loss versus cleaning time obtained
(c) Critical Corrosion Current- From Figure 3, the current corresponding to the failure stage is noted and is called critical corrosion current. (d) Post depassivation cracking time- From Figure 3, the time corresponding to the specimen failure is called post depassivation cracking time.
Concrete Corrosion
Conclusion - This Procedure provides an accelerated method of testing reinforced concrete for relative corrosion protective characteristics. - Because of the flexibility of the method, other materials such as claddings and coatings on reinforcing steel, and concrete coatings and sealants can be tested and compared. - This procedure should not be used to establish the life expectancy of reinforced concrete materials since the actual voltages found in the field can vary drastically. As mentioned earlier resistivity varies as the corrosion process proceeds. Changes in temperature and salinity found in the filed may greatly affect the time to failure. Until a correlation between corrosion rates in the field and in the laboratory for specific materials and mixes is established, this procedure should be used as a method for comparison only. - If properly worked upon this test can be utilized for finding various parameters related to concrete durability. This test can also be used for comparison between various building materials. This test can be utilized for simulating various aggressive field conditions by varying the chloride content and voltage applied. Reference
- IlkerBekir Topu, Ahmet Raif Boga. Effect of ground granulate blast-furnace slag on corrosion performance of steel embedded in concrete. Materials and Design 2010; 31: 3358 3365. Mohamed Ismail, Masayasu Ohtsu. Corrosion rate of ordinary and high performance concrete subjected to chloride attack by AC impedance spectroscopy. Construction and Building Materials 2006; 20: 458469. T.A. Soylev, M.G. Richardson. Corrosion inhibitors for steel in concrete: State-of-the-art report. Construction and Building Materials 2008; 22: 609 622. B. Elsener. Macrocell corrosion of steel in concrete: implications for corrosion monitoring. Cement & Concrete Composites 2002; 24: 6572. A. Poursaee, A. Laurent, C.M. Hansson. Corrosion of steel bars in OPC mortar exposed to NaCl, MgCl2 and CaCl2: Macro and micro-cell corrosion perspective. Cement and Concrete Research 2010; 40: 426430. BuluPradhan, B. Bhattacharjee. Performance evaluation of rebar in chloride contaminated concrete by corrosion rate. Construction and Building Materials 2009; 23 23462356. A. Poursaee, C.M. Hansson. Reinforcing steel passivation in mortar and pore solution. Cement and Concrete Research 2007; 37: 11271133. Marco Ormellese, Luciano Lazzari, Sara Goidanich, Gabriele - -
Fumagalli, Andrea Brenna. A study of organic substances as inhibitors for chloride-induced corrosion in concrete. Corrosion Science 2009; 51: 29592968. - Bulu Pradhan, B. Bhattacharjee. Corrosion zones of rebar in chloride contaminated concrete through potentiostatic study in concrete powder solution extracts. Corrosion Science 2007; 49: 39353952. A.A.A. Hassan, K.M.A. Hossain, M. Lachemi. Corrosion resistance of self-consolidating concrete in full-scale reinforced beams. Cement & Concrete Composites 2009; 31: 2938. IlkerBekirTopu, AhmetRaifBoa, FatihOnurHocaolu. Modeling corrosion currents of reinforced concrete using ANN. Automation in Construction 2009; 18: 145152. Ha Minh, Hiroshi Mutsuyoshi, KyojiNiitani. Influence of grouting condition on crack and load-carrying capacity of posttensioned concrete beam due to chloride-induced corrosion. Construction and Building Materials 2007; 21: 15681575. M.M. Al-Zahrani , S.U. Al-Dulaijan, M. Ibrahim, H. Saricimen, F.M. Sharif. Effect of waterproofing coatings on steel reinforcement corrosion and physical properties of concrete. Cement & Concrete Composites 2002; 24: 127137. Abdul-Hamid J. Al-Tayyib and Mesfer M. Al-Zahrani. Corrosion of Steel Reinforcement in Polypropylene Fiber Reinforced Concrete Structures. ACI Material Journal 1990; 87: 108-113. Mustafa Sahmaran, Victor C. Li, and Carmen Andrade. Corrosion Resistance Performance of Steel-Reinforced Engineered Cementitious Composite Beams. ACI Material Journal 2008; 105: 243-250. Tae-Hyun Ha, SrinivasanMuralidharan, Jeong-HyoBae, YoonCheol Ha, Hyun-Goo Lee, Kyung-Wha Park, Dae-Kyeong Kim. Accelerated short-term techniques to evaluate the corrosion performance of steel in fly ash blended concrete. Building and Environment 2007; 42: 7885. ErhanGuneyisi, TuranOzturan, Mehmet Gesoglu. A study on reinforcement corrosion and related properties of plain and blended cement concretes under different curing conditions. Cement & Concrete Composites 2005; 27: 449461. M. Maslehuddin, M.M. Al-Zahrani, S.U. Al-Dulaijan, Abdulquddus, S. Rehman, S.N. Ahsan. Effect of steel manufacturing process and atmospheric corrosion on the corrosion-resistance of steel bars in concrete. Cement & Concrete Composites 2002; 24: 151158. ASTM C 876. Standard test method for half-cell potentials of uncoated reinforcing steel in concrete.Annual Book of ASTM Standards, American Society for Testing and Materials; 1991. IS 383-1970 (Reaffirmed 2002).Specification for coarse and fine aggregates from natural sources for concrete. New Delhi: Bureau of Indian Standards. Neville AM, Brooks JJ. Concrete technology. Delhi: Pearson Education; 2004. ASTM G 1-03. Standard practice for preparing, cleaning, and evaluating corrosion test specimens.West Conshohocken, PA; 2003.
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Crystalline Concrete Admixture
Satish Ghanekar
Sr. Manager, Choksey Chemicals P . Ltd. Waterproofing for Water Tank High Rise Buildings
he Construction Industry in India has witness arrival of new Technologies and systems for critical areas to be waterproofed in recent years. Concrete is a complex area and world over technologist are trying to explore its behavior. Many articles are published using various types of chemicals which are referred by our Industry. In this article it's my sincere effort to let experts in our industry to know our latest offering to make concrete more watertight and making structures more resistant to weathering effects. In order to cater to waterproof vast concreting and to cater to growing demand of Ready Mix Concrete ( RMC'S) we at Choksey Chemicals P . Ltd. have tied up with renowned British Company established in 1996 having presence worldwide Known by the name Cormix International Limited. The very first in line to be offered is Conmix H2O Stop which is a integral waterproofing admixture by crystallization.
This is a high grade easy to handle integral waterproofing admixture for both waterproofing and concrete corrosion protection using unique nanotechnology to chemically modify cement matrix by reacting with the cement paste to reduce pores & capillary size. The reaction between the product and cement paste produces a non soluble crystalline structure through the pores & capillaries. The product Conmix H2O Stop is available in liquid as well as powder form giving several advantages such as sealing hairline cracks upto 0.4mm, making concrete waterproof throughout, concrete mix is protected against chloride and sulphate ingress, improves chemical and carbonation resistance, acts as a permanent solution by integrally waterproof reducing opportunity for freeze thaw damage thereby improving workability and strength of the concrete. The most important and unique features of Conmix H2O Stop it it's ability
to withstand hydrostatic pressure. This can be used for potable water tanks / structures since it is a non toxic in nature. The liquid form gives added advantage over the powder forms available in market as by using liquid - clumping is avoided. The product proves to be commercially viable due to dosages of 0.8 1 % by weight of cementitious material. We recommend Conmix H2O Stop to be tested in trial mixes to determine optimum dosage to check workability, slump retention and retardation in advance. The contracting firms in India engaged in infrastructure projects where mass concreting is under taken will be saving on time and cost to a certain extent with the use of Conmix H2O Stop and waterproofing contracting firms will have a definite help to watertight areas like reservoirs, tunnels, foundations, basement, swimming pool, wet areas by adopting this unique integral waterproof admixture by crystallization. We at Choksey Chemicals are always ready to provide onsite solutions and give our expertise recommendations due to presence of Branches across country.

Choksey Chemicals P. Ltd. 111, Industrial area, Sion (E), Mumbai - 400022 Toll free 1800 220 474 E-mail: contact@chokseychem.com Web: www.chokseychem.com
Basement Waterproofing Waterproofing for Swimming Pool
256
Everest Equipments Pvt.Ltd
Brickwell
Case Construction Target New Heights in Indian Market with the Launch of New Generation Steer Skid Loaders
ase New Holland Construction Equipment India Pvt ltd (referred to as Case India), a leading construction equipment manufacturer in India launched its new generation Skid Steer Loaders thus expanding its product offering by entering the compact loader segment to shore up the needs of customers in industrial, infrastructure and agriculture applications. Case India is a part of CNH Global NV which is a majority owned subsidiary of Fiat Industrial S.p.A. Case is presenting the new skid steer range as part of its strategy to increase and consolidate the brand's presence in the country. Currently it claims the crown of domestic leadership in the Vibratory
D. K. Narang,
Managing Director, Case India
Compactor segment and also claims to be among the top two players in the Backhoe Loader segment. We have consolidated our top position in the vibratory compactor segment and we are
a market leader in the loader backhoe segment. concluded D. K. Narang, Managing Director, Case India, We are today expanding our offering with technologically advanced skid steers. We have a clear focus on product development with high quality standards and efficient after sales services to prove our superior product value and win the satisfaction of our customers in the marketplace. The SR skid steer range has now been made available in the market with two aggressive models, the Case SR130 and SR150. This range of compact and multi-purpose machines raises the bar for premium power, increased torque and enhanced operator
Case New Holland Management Executive
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Backhoe Assembly Line
comfort and visibility. The radial lift Case SR130 and SR150, having an operating capacity of 590 kg and 680 kg respectively, are engineered for digging, prying and pushing. For their performances, these skid steer loaders have recently been named in the U.S. magazine Construction Equipment's Top 100 Awards. Some prime features of these compact and flexible new generation machines include improved fuel efficiency, 25% wider interior, easy to maintain, higher load carrying capacity and more power and performance thanks to the mighty Shibaura Engine. These new loaders are equipped with new power stance chassis with up to 21% longer wheelbase and 30/70 front/ rear weight distribution to lift and haul more material. Keeping the Indian market and conditions in mind the latest products
are featured with best-in-class hinge pin height & break-out force, outstanding departure angle, operator comfort through more room & 360-degree visibility. Combined with ride control, these loaders provide superior stability and operating speeds, regardless of jobsite conditions. These loaders are available initially with two replaceable tool attachments, i.e., the default bucket and the rolling broom and are also available in a multi terrain version available on demand. These 100% imported skid steers face stiff competition in India from the already well established brands like Doosan, JCB and Terex Vectra owing to a lofty 28% customs duty imposed on these imported products. But with encouraging response from existing clients, Case plans to gain customer trust and widen its stronghold by focusing on their product's distinguiPiero Arrivabeni,
Marketing Director Case International Region
shing features and customer support services. When asked to comment on how they plan to manage the costquality tradeoff for this product in India, it being a cost sensitive market, Mr. Piero Arrivabeni, Director Marketing of Case International region elucidated,
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gradually start producing these skid steers locally also to gain on the cost advantage. commented Mr. D.V. Junnakar, Head-Sales & Marketing Case India on local production of their new product range. The manufacturing facility at Pithampur: Following the acquisition of the full ownership of its previous Indian joint venture with L&T last year, Case Construction has wholly owned manufacturing operations in Pithampur, near Indore, Madhya Pradesh. The new company, Case New Holland Construction Equipment India Pvt Ltd (referred to as Case India), counts today on a network of 57 dealers and more than 150 outlets. With this investment, CNH confirms its commitment to a strong manufacturing base for its construction equipment business at the Pithampur plant. This 40 acre lush green campus in Pithampur industrial area was commissioned more than a decade ago has been used ever since to manufacture top class Backhoe loaders and Vibratory compactors. It is equipped with stateof-the-art facilities, such as high precision laser and cutting machines, welding robots, CNC machine tools, a new automated powder coating system and
D V Junnarkar - Head Sales and Marketing

Case New Holland Construction Equipment (I) Pvt. Ltd.
We are a global company but excel at adapting our products as per the local requirements thereby providing excellent design strength and creating products ready for heavy Indian duty. We also provide the best after sales services and also our special focus on operator comfort and efficiency along with minimal maintenance will help us gain over our competitors. Case India already manufactures its Vibratory Compactor range and the Backhoe Loader range at its Pithampur factory near Indore, its sole constuction equipment manufacturing facility in Asia. With the arrival of volumes, we'll
a variable speed assembly line. The factory holds ISO 9001 certification for design and manufacture of construction and road building equipment and ISO 14001 certification for environmental management. The semi automated assembly shop and the fully automated paint shop for Loader Backhoes is spread on a generous 15400 sq. m land while the vibratory compactor fabrication and assembly line cover a 7400 sq. m patch of the campus. Currently the plant produces 5 machines including 3 models of Vibratory Compactors and 2 models of Backhoe loaders. It also serves as a storage base for the new steer skids. The Pithampur manufacturing facility has a capacity to produce 5 units of Vibratory Compactors and 16 units of Backhoe Loaders per shift of 8 hours depending on the variable speed of the assembly line. Special focus has been provided by Case India on the 'green aspect' of their equipments and production unit. Along with the eco friendly paint Oxsilane that is being used to paint the component parts of the equipments, the campus includes a big rain water harvesting system and boasts of a 30% green patch on the 40 acre facility. Also included in the campus is a training centre to facilitate on the job training for the existing and new employees with various courses of different durations to Case India dealers. As it is integrated into the CNH manufacturing network, the Pithampur plant will introduce world class manufacturing methodologies to bring it in line with CNH production system and quality standards in the coming future.

Case New Holland Construction Equipment (India) Pvt. Ltd.
"Boomerang", Chandivali Farm Road, Near Chandivali Studio, Andheri (East) Mumbai - 400072. Ph: +91-22-61271840 Fax: +91-22-61271850 E-mail: caseindia@cnh.com Web: www.casece.com
Case India Products
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ROTHO - Robert Thomas Metall- and Elektrowerke GmbH & Co. KG
Sicoma Mixers India Pvt. Ltd
Exploring the Block Making Market with Mr. Jayaram Ramesh

Managing Director, Sri Parijatha Machinery Works
ments. Nevertheless, bigger plants with huge investments are surely going to increase in the coming years. Therefore, the Indian market for concrete block making machines in terms of value may be in the region of ` 120` 150 crore. What is the lead time involved from a customer placing an order for a block making machine to delivery, installation, and handover? Typically what are the steps involved in the turnkey solution process? Normally the lead time from placing the order to fully setting up the plant which includes the time for building the infrastructure, lead times for machines delivery, installation, commissioning, trail production for a typical plant of around 10,000 blocks per day or 600 sq. mt paving should take around 6 months time. However, for bigger plants the time required could be higher. Firstly, the investor/entrepreneur should conduct a detailed market survey to understand what the market needs, like product range (types included), availability of raw materials and distance from source, market size, and requirement apart from various other relevant factors. Later, depending upon the capacity requirement an adequate size of land is identified with provision for further expansion. The hard part of course is choosing your long term associate- the best supplier for the plant and machinery. Then it is important to set up a good team for production, sales, and quality control. What according to you are the steps that the government needs to take in order to further promote the use of flyash bricks/blocks which could boost the market for concrete product machinery? Flyash is now very popular in the concrete industry compared to a few years ago when it was more of a nuisance value. But, due to its extensive use of late there is slowly a shortage of availability especially to smaller concrete block manufacturers since the bulk of the fly ash is consumed by large cement plants and related industries. Therefore, the government should step in and ensure equitable distribution of flyash to all players in the industry by fixing percentage wise quotas especially in state run power plants. Also, to promote its use Government should extend tax benefits by reducing VAT and Excise duty to manufacturers of flyashbased products which of late have been removed in most areas. A large part of the block making machinery market is still dominated by the unorganized sector making cheaper semi-automated machines. What has been your strategy to counter such competition? It is a fact that the unorganized small manufacturers are making very cheap and low quality machines which churn out low quality products. This damages the reputation and credibility of the product as is the case now with many brick, block and paving block manufacturers spread all over India. The best way to counter this can be to educate the customers about the quality requirements and standards of these products and how it can be consistently achieved. Then the un-organized sector will either upgrade themselves or will ultimately close down. For this we plan to hold nationwide seminars and training sessions to manufacturers to educate them about how to produce good quality products.
Jayaram Ramesh, MD, Sri Parijatha Machinery Works pvt. ltd.
ree Parijatha Machinery Works has carved a niche for itself as a leading manufacturer and exporter of concrete block making and Terrazzo tiles machinery. The company offers a comprehensive range of products including, automatic block making machines, planetary mixers, conveyors and batching systems for tile and block plants. The company with a strong R & D focus has its modern manufacturing unit located in Bangalore. Another key forte of the company is its team of experienced technicians who take care of every aspect, including, installation, erection and commissioning of the machinery. In an exclusive interview to The Masterbuilder, Mr. J. Ramesh, Managing Partner of the company gave insights into the concrete block machinery industry in India, the company's product offerings and the industry's future. Here are excerpts from the interview. How big according to you, in terms of value, is the Indian market for concrete block making machines? At present the big investors in this industry are a little skeptical in investing in huge capacity plants due to the lower ROI considering the fact that there are many small manufacturers who can offer good quality products with lower investments and of course lower risks but with having to manage higher labour require-

1-D, 2nd Phase, Peenya Industrial Area, Bangalore-560058. Ph:+91-80-23572332 Fax:+91-80-28392894 E-mail: parijatha@sify.com Web: www.parijatha.com
Sri Parijatha Machinery Works Pvt. Ltd.
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Nuha Constructions Solutions
Kalyan Industries
Akarsh Specialities
Hitech Concrete Solutions Chennai Pvt. Ltd.
Concrete ASR
Alkali-Silica Reaction in Concrete

Associate Editor
he aggregate fraction of concrete is often thought of as an essentially inert filler material, extending the active cement paste to more economic volumes. In practice this is an oversimplification, with most aggregates likely to react to some degree with the highly alkaline environment created by hydrating cement. Ordinarily this is beneficial; partial dissolution of the aggregate particles surface enhances bonding with the cement phase. However, in extreme cases the chemical reactions that can occur are sufficiently disruptive to pose a threat to the structural integrity of the concrete. The most common damage-causing interaction between cement paste and aggregate is alkalisilica reaction (ASR), the name reflecting the essential interaction between the alkali264 The Masterbuilder - July 2012 www.masterbuilder.co.in
rich pore fluid of the concrete and aggregate containing the mineral silica (SiO2). Susceptible rock types have a mineralogy in which silica is present in either an amorphous phase or a highly strained or crypto-crystalline form. The reaction sequence is broadly as follows - Initial depolymerisation and dissociation of reactive silica minerals in the aggregate under highly alkaline conditions. - Hydrolysis of the resulting dissolved silica, by sodium and potassium hydroxide derived from the pore fluid, to produce a solid alkali-silicate gel. - Hydration of the gel.
Concrete ASR
The presence of the alkali-silicate gel is not damaging to the concrete per se. However, gels of the appropriate formulation have the capacity to absorb large quantities of water. The consequent volume expansion may generate internal tensile stresses in the vicinity of 67 MPa, sufficient to crack both the affected aggregate and surrounding cement paste. ASR typically manifests itself through extensive surface map cracking, although restraint due to structural loading or reinforcement may modify the observed cracking pattern. The progress of the reaction can be extremely slow, and signs of distress may only appear when the concrete is years to decades old. The tensile strength and elastic modulus of the concrete are compromised as the severity of the reaction develops, but compressive strength is usually little affected. This has led to suggestions that ASR problems may be more aesthetic than structural, providing the concrete is well-reinforced, but the potential durability impact must also be borne in mind.
the cations Na+ and K+ difuse toward the hydroxide ions to react with them and the resulting product is a gel-like material. According to Powers and Steinour the migration of cations of Na+ and K+ is slow, therefore the migration of Ca2+takes place. If the gel is high in calcium then the gel is not expansive when exposed to water and, therefore, may not induce cracking in concrete. This theory rests on the assumption that calcium could be available. Diamond found that there is very little calcium in the pore solution. This is expected since the high pH causes the volubility of Ca(OH)2 to be depressed. Nevertheless, calcium could be dissolved from the solid phase of cement paste to produce a gel. Most researchers do not mention the distinction between safe and swelling gel but there are acknowledgments that there are more than one composition of gel produced by ASR.
Old concrete pier heavily damaged by ASR. Trondheim, Norway
Typical map cracking in a concrete damaged by alkali silica reaction (ASR)
ASR Mechanisms Most researchers agree that the main reaction of ASR is the reaction between certain forms of silica present in the aggregates and the hydroxide ions ( OH-) in the pore water of a concrete. Very early in the hydration of cement calcium ions are incorporated in the hydration products but potassium and sodium stay in solution and eventually they are partially incorporated into calcium silicate hydrate (CS-H) and monosulfate. Hydroxide ions from the hydration of portland cement result in a pore solution having a pH of at least 12.5. Soluble alkalies raise the pH to about 13 or higher. Also, the amount of alkalis present in the pore water is related to the amount of soluble alkalis present in the cement. The hydroxide ions will attack a silica surface. If the silica is well crystallized the vulnerable sites are only at the exterior surface of the aggregate, but in the case of poorly crystallized silica, there are many vulnerable sites in the aggregate structure, leading to disintegration of the silicate network. To keep a neutral charge balance,
The formation of the gel per se is not deleterious. The deterioration of the concrete structure is due to the water absorption by the gel and its expansion. R is reported that the RH must be higher than 80% for the gel to swell although it can be formed at lower relative humiditys. As the tensile strength of the system is exceeded, cracks will form and propagate. As there is not a preferential direction for cracks to propagate and also the sites of crack initiation are randomly distributed in the specimen, map cracking will be characteristic of ASR deterioration. The sites of the cracks are determined by the location of the reacting silica on the aggregates and the availability of OH- in the vicinity. Aggregate reactivity testing The obvious solution for avoiding problems with ASR is simply to use a non-reactive rock type. Unfortunately there is no single test that can be unreservedly recommended as a fool proof method for screening potential aggregates for which no historical performance records exist. Consequently a conservative engineering approach is suggested, checking the aggregate performance by more than one technique and taking appropriate measures where the test results indicate caution is justified. The first step in the evaluation
Concrete ASR
of a new aggregate source should be the commissioning of petrographic examination in accordance with ASTM C 295 (or an equivalent method). This determines whether the rock contains any of the reactive silica, which indicate potentially deleterious performance. The examination should preferably be carried out by a geologist with previous experience in the assessment of the mineral constituents of concrete aggregate, and must also include an inspection of the quarry site to assess variability in the rocks composition. If the petrologists report indicates a potentially reactive aggregate then either the aggregate should be treated as deleterious and appropriate mitigation measures taken, as detailed below, or further testing should be undertaken to clarify the significance of the risk posed. A wide variety of test methods have been proposed for determining ASR susceptibility, most of which involve using the suspect aggregate to produce mortar or concrete beams and measuring their eventual expansion under humid conditions. Due to the slow-developing nature of ASR, the test methods necessarily accelerate the reaction by artificial means such as elevated temperature and alkalinity, potentially distorting the result. This, combined with the fact that many tests historically originated as performance discriminators for the aggregates in one particular geographic region, means the potential for generating false positive or false negative results is considerable. Tests recommended for New Zealand, on the basis of both relative speediness and reasonable fidelity to aggregate behaviour observed in the field, include the ASTM C 289 chemical test and the ASTM C 1260 rapid mortar bar method. ASTM C 289 measures the dissolution of silica and corresponding reduction of alkalinity that occurs when a pulverised sample of the test aggregate is mixed with a 1 mol dm-3 solution of sodium hydroxide at 80C for 24 hours. When plotted graphically, this pair of results can be used to classify the aggregates likely behaviour as innocuous or deleterious according to boundaries derived from the inservice performance of previously tested aggregates. The method has been criticised for giving misleading results, primarily with aggregates derived from sedimentary sources, but has been found to correlate well with observed site concrete performance for the volcanic rocks that represent the bulk of New Zealands potentially reactive aggregate. In the ASTM C 1260 test the suspect aggregate, crushed as necessary to achieve the specified grading, is made up as sand-cement mortar bars of a fixed water-to-cement ratio. The bars are stored in a strongly alkaline solution, maintained at 80C for a minimum of 14 days, and their increase in length is measured periodically. A variety of criteria have been suggested to delineate potentially harmful performance, with a maximum permissible expansion of 0.1% after 14 days testing being the most usual quoted. Some authorities recommend longer testing periods to
distinguish between non-reactive and slowly-reactive aggregates. It is generally accepted that tests of this type may be somewhat over-sensitive, identifying aggregates known to perform acceptably in the field as potentially deleterious. Variations on this method such as ASTM C 1567 are also used to evaluate the effectiveness of SCMs (supplementary cementitious materials) for the suppression of ASR.
Supplementary cementitious materials. From left to right, fly ash (Class C), metakaolin (calcined clay), silica fume, fly ash (Class F), slag, and calcined shale.
Mitigation techniques Avoidance of susceptible aggregate is not always a practical or economic possibility. An understanding of the chemistry governing ASR allows for the development of approaches that allow potentially reactive aggregate to be safely used. Feasible mitigation techniques broadly encompass: - ecreasing the pH of the concretes pore solution to suppress the initial silica solubility - educing the free alkali metal ion (sodium and potassium) concentrations present to restrict gel formation - educing the permeability of the concrete to restrict water ingress, hence preventing the gel from expanding. New Zealand has followed a de facto route of controlling the alkali content of concrete, courtesy of an informal agreement amongst local cement manufacturers to restrict the free alkali content of their cement to less than 0.60% Na2O equivalent. Figure 3 demonstrates just how sensitive the development of ASR can be to this parameter. Note that cement is not the only source of soluble alkalis in concrete, however, and contributions from the aggregate, mix water and chemical admixtures also need to be assessed. Normal concrete, as defined by NZS 3104: 2003, made with a potentially reactive aggregate, can be expected to be durable for 50 years, suffering only cosmetic damage if a maximum concrete alkali limit of 2.5 kg/m3 is observed. Where alkali limits of less than 2.5 kg/m3 are not achievable, or the concrete performance requirements are particularly demanding, SCMs can be used to successfully suppress damaging levels of expansion. SCMs function via a number of beneficial modes: all
Perma Construction Aids Pvt.Ltd
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Hitech Concrete Solutions Chennai Pvt. Ltd.
Concrete ASR
typically reduce the permeability of the concrete, limiting its capacity to imbibe water. By replacing cement, they also physically dilute the amount of free alkali metal ions available in the concrete. SCMs with true pozzolanic characteristics react with the calcium hydroxide produced by the cement hydration reaction, helping lower the alkalinity of the concrete below that of the pH needed to support the formation of the alkali-silicate gels. It is also believed that these gels can only be formed in the presence of calcium ions, whose concentration is reduced by the pozzolanic reaction. Paradoxically, finely divided and highly-reactive amorphous silica in the form of silica fume or equivalent natural silica sinter is one of the most effective means for reducing the risk of ASR. This can be explained by the fact that where reactive silica contents are initially low, adding additional silica, e.g. in the form of a reactive aggregate, ordinarily increases the potential for gel formation. However, if the silica addition is great enough, and the particles size fine enough, the ratio of free alkali metal ions to the surface area of the reactive silica becomes unfavourable, suppressing the formation reaction. This mechanism is also assumed responsible for the phenomenon of pessimum proportions observed with certain aggregates, whereby the severity of the ASR developed has a clear maximum which is not found to correspond with a ratio of reactive to unreactive aggregate in the concrete equal to 100%. Conclusion From this brief overview of the existing literatures on ASR, the following summarizes present knowledge on ASR: - ASR is a reaction between the OH in the pore solution with amorphous or poorly crystallized silica in the aggregates. - The reaction product imbibes water and expands. - The presence of water or RH higher than 80% is necessa~ for the gel formed to expand and induce concrete cracking. - Some siliceous mineral admixtures deplete the alkalis horn the pore solution, lowering the pH, therefore decreasing the likelihood of ASR. - The aggregate type and size distribution play a significant role in the expansion measured in concretes - Other factors influencing the cracking due to ASR include air entrainment and possibly W/c. A combination of currently identifiable trends will likely increase the need for concrete suppliers and specifiers to take precautions against ASR damage in the immediate future. These trends include: economic and environmental pressures encouraging reduction of the kiln temperatures used for the manufacture of cement, thereby increasing its alkali content; depletion of aggregate sources in urban
areas requiring the use of potentially deleterious material (e.g. Taranaki andesites); and routine recycling of washwater in ready-mix plants allowing alkali levels in mix water to exceed those normally encountered in potable town supplies. However, the industry is fortunate to have access to a wide range of SCMs capable of both enhancing the fresh and hardened properties of concrete and reducing the risk of ASR. Referencen
- - Hobbs D. W., Alkali-Silica Reaction in Concrete, Thomas Telford, London 1988 Diamond S., Penko M., Alkali Silica Reaction Processes: The Conversion of Cement Alkalis to Alkali Hydroxide ,G. M. Idorn Inter. Symposium, Durability of Concrete ACI SP-131, 1992 Diamond S., Alkali Reactions in Concrete Pore Solutions Effects, Proc. 6th Int. Conf, Alkalis in Concrete, Idom G.M. and Rostam S. eds. 1983, p. 155-166 Figg J., An Attempt to Provide an Explanation for Engineers of the Expansive Reaction between Alkalis and Siliceous Aggregates in Concrete, 6th Int. Conf Alkalis in Concrete Copenhagen 1983. Helmuth R., Stark D. Alkali-Silica Reactivity Mechanisms, in Materials Science of Concrete III, J. Skalny cd., ACS 1992 Stark D., Alkali-Silica Reactions in Concrete, in Simificance of Tests and Properties of Concrete and Concrete Makirw Materials, Klieger P . and Lamond J. eds. ASTM STP 169C, 1994 Idom G.M., Johansen V., Thaulow N., Assessment of Causes of Cracking in Concrete, Materials Science in Concrete III, Amer. Ceramic Sot., New York, 1992 Alkali-Silica Reaction and High Performance Concrete, Chiara F. Ferraris, Building and Fire Research Laboratory, National Institute of Standards and Technology, Gaithersburg, MD 20899, August 1995. ASTM C 28903. Standard Test Method for Potential Alkali-Silica Reactivity of Aggregates (Chemical Method). American Society for Testing & Materials, Philadelphia, USA. ASTM C 29503. Standard Guide for Petrographic Examination of Aggregates for Concrete. American Society for Testing & Materials, Philadelphia, USA. ASTM C 126005a. Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method). American Society for Testing & Materials, Philadelphia, USA. ASTM C 156704. Standard Test Method for Determining the Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar- Bar Method). American Society for Testing & Materials, Philadelphia, USA. Freitag SA, Goguel R and Milestone NB. 2003. TR 3 Alkali Silica Reaction: Minimising the Risk of Damage to Concrete. Guidance Notes and Recommended Practice. 2nd Edition. Cement and Concrete Association of New Zealand, Wellington, New Zealand. Mindess S and Young JF. 1981. Concrete. Prentice-Hall Inc, New Jersey, USA. Neville AM. 1995. Properties of Concrete. 4th Edition. Addison Wesley Longman Ltd, Essex, UK.
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Photo Courtesy
www. robertdmoser.wordpress.com, www.bam.de, www.bam.de www.cement.org
Vertical & Green Summit (Tavess)
Charting Out its Own Distinct Growth Path

REST is manufacturing and supplying ISO 9001:2008 certified, integrally jointed punch sheet orientated HDPE/PP Geogrids along with allied products like welded and hexagonal mesh gabions, wire mesh products, concrete precast units, RCC panels, and PCC modular blocks. The Una plant is South Asia's first such advanced manufacturing facility. The plant has a state-of-the-art automation, energy saving green process and cutting edge quality control. We intend to produce the entire range of geosynthetics from the Una production unit within 2017. Competition in the field of geosynthetics is intensifying by the day. What makes your product range different from others? The so called competition in geosynthetic products was mainly due to surfacing of a few new service providers in last 4-6 years, who are supplying cheap materials from low cost destinations. For manufacturers of newly established units the imported cheap products are no real threat, as these products are recognized as undependable and expensive in the current global high price scenario and devaluation of Indian rupee. Even otherwise, there is no effective competition of other products to our integrally jointed oriented HDPE/PP Geogrids in India. Other products like knitted polyester mesh being manufactured by other producers are no match against our integrally jointed products, though they enjoy some market share due to low awareness levels of the users. We believe that with sustained awareness build up, the misconception of users will change. Our punched sheet orientated integrally jointed Geogrids ,used as reinforcement are manufactured through a special process after extrusion of punched sheet by stretching the molecules of polymer in mono or bilinear directions. This advanced manufacturing technique produces Geogrids of very high secant modulus with very low creep characteristic and long-life designed up to 120 years. Only integrally jointed and oriented HDPE/PP Geogrids are optimally suitable for soil reinforcement purposes due to their optimum interaction and stress-strain compatibility with the soil. The soil particles develop a strike through within the Geogrid apertures primarily due to the integral joints. This phenomenon of interlocking resulting from this strike through develops anoilgrid interaction, which is independent and different than the friction, sets HDPE/PP geogrid apart from other synthetic materials tried as reinforcement. The Geogrid provides an effect of pseudo- cohesion when used in a layered soil mass, which makes it eminently suitable for the construction of vertical walls and steep slope, or improves the stability of an existing slope significantly. The forces imposed by the particles of soil are transferred to an integrally jointed Geogrid strand, which serves as a tensile member providing a tensioned membrane effect. To achieve equilibrium through this tensile inclusion, the system must have effective particle strike through the joint of strands, achieved by optimum soil Geogrid interaction. These characteristics are absent in other plastic mesh such as knitted and coated polyester grids, or polyester straps, which don't have the junction strengths, although these may have been sold in market in the garb of Geogrids, in spite of a clear definition of Geogrid directed in MoRTH specification. Tell us about your recent R & D achievements? ENVIRO GEO has recently added new wider Geogrid range in Uniaxial and Biaxial products
Som S. Sarkar, Chairman,

ENVIROGEO Group
NVIRO GEO is one of the leading and oldest geotechnical engineering companies in the country. It has now grown into a preferred geotechnical EPC contracting company, with proven expertise in the field. In an exclusive chat with The Masterbuilder, Mr. Som S. Sarkar, Chairman of the company spoke about the company's product range, areas of specialization and future plans. Here are excerpts from the interview. Give us an overview of your organisation and the solutions your offer? ENVIRO GEO is an established source of Geosynthetics and allied products since 1989 in India, providing design engineering services, turnkey installation contracting, involving the most discerning internationally accredited range of Geosynthetics meeting leading European standards. The company is India's first and only ISO 9001:2000 certified value added geotechnical system and service provider. Enviro Geo's sister unit Reinforced Soil Technologies (REST) is engaged in manufacturing of geosynthetics and allied products from their state of the art production & testing facility in Una Himachal Pradesh, India.
270
ICI- 20th Annual Awards-2012
Uniaxial range in Polyethylene: 50kN, 60kN, 65kN, 80kN, 90kN, 100kN, 120kN, 130kN, 150kN, 160kN. Biaxial range in Polypropylene :15kNx15kN, 20kNx20kN, 30kNx30kN, 40kNx40kN, etc.
We have also recently added stateof-the-art mechanized reinforced turfing system for erosion control. Similarly, we have recently added reinforced Weldmesh and Hexagonal mesh Gabion systems in our product portfolio. Give us a few examples of infrastructure projects where your products have played a key role? The company has provided over 120 structures with specialized system design in the field of civil, hydraulic, and industrial infrastructure projects. A few key projects where Enviro Geo systems have been used include: Okhla Flyover project, followed by Hanuman Setu flyover, Ashram Chown Flyover, Punjabi Baug flyover, Andrews Gunj flyover, Mayapuri Flyover, etc for Delhi PWD, all over 10-18 yrs old. 14 road strengthening and widening projects under Maharastra PWD. 12 asphaltic reinforcement projects under Maharastra PWD. 50+ RE wall projects under NHAI and PWDs at Haryana, W. Bengal, UP , Bihar, Punjab, J&K,AP , Orissa, Jharkhand & Maharashtra etc. 2 RE wall projects at Noida under Noida authorities. 4 RE wall projects under MSRDC. 28 m high slope protection for Udhampur railway yard under Jammu Udhampur rail link.
Erosion controlling of entire Ranchi Airport. Counter-erosion and landslide stabilization for 8th Mile at Tadong, Sikkim. High embankment construction over soft soil at Palacole for AP PWD. Counter-erosion and slope stabilization for Tehri dam. 12 km long counterscarp retaining structure for Hyderabad Ring road.
Take us through the quality assurance system that you have in place? ENVIRO GEO as system supplier is India's first and only ISO 9001:2000 certified Value added geotechnical system and service provider. All the products are currently under final evaluation stage for CE marking. Enviro products are produced under stringent quality standards meeting European norms of Construction Product Directive, EN ISO 13249, 13250, 13251, 13253, 13254, 13255, 13256, 13257, and 13265, covering applications in road, railways, erosion control, basal stabilization, etc. Our products are continuously batch tested under stringent EN ISO standard and GRI-GG quality control tests, involving testing at the Polymer lab, Geosynthetic Products lab and Applied Lab for application worthiness and characterization. Enviro Geo provides warranted Conformity Certification for product use and design data. Broadly speaking how do your products add to the sustainability quotient of the construction process? ENVIRO GEO is engaged in the engineering business offering modern technology for social development
'Assuring Sustainable Environment', as part of its mission. Creating harmonized interface between Man, Technology, and Environment is integrally focused for achievement of the company's business goals. In this direction the group has provided pioneering direction in Indian subcontinent with engineered geosynthetic solutions since 1989. Providing 'Sustainable Environmental Development' with concern for improved environmental safety and standards through modern engineered solution in the field of Environmental Geotechnology therefore continues to be our main business interest area and the group's objective mission. As the name suggests Enviro geosynthetic products are engineered for environmental sustainability. They are non polluting, prevents green house emission, supports plant life, aids and abets flora and fauna, non restrictive to microbial, underwater and primal life form, nonreactive to naturally occurring minerals, solvents and soil elements, non reactive to gases, apart from being non irritants to human habitats and environment. We provide complete turnkey solutions, by using modern geosynthetics to bring down construction cost and time substantially, with far improved performances, longer utility and life span and sustained conservation of precious building material offering a green solution.
1401- 1410, DLF Galleria, DLF City Ph-IV, Gurgaon-122002. Ph: 0124-5050615-616, Fax: 0124-5050617 E-mail: admin@envirogeo.com Web: www.envirogeo.com
Enviro Geosynthetics P. Ltd.
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Construction Risk Management (Marcus Evans)
Fly Ash Concrete
Masonry Grout for Sustainable Development

Associate Editor
The use of High Volume Fly Ash (HVFA) in construction is a solution to environmental degradation being caused by the cement industry. The concept very much fits into the era of sustainable development. As cement industry, itself, is responsible for 7% of worlds carbon dioxide emissions, responsible for global warming, attention needs to be drawn by construction industry to solve the problem. High Volume Fly ash mix contains lower quantities of cement and higher volumes of Fly Ash (up to 60%). From the literature available, it is found that the proportions of Fly Ash in Concrete can vary from 30% - 80% for various grades of concrete.
oncrete masonry has many proven sustainable benefits including low maintenance requirements, long lifecycle, high recyclability, high reusability potential, and lower energy cost over life span. The concrete masonry industry could become even more sustainable by
reducing the use of Portland cement, whose production generates approximately one ton of carbon dioxide per produced ton. A possible way to achieve such a vision is to increase the substitution levels of fly ash and ground granulated blast furnace slag for Portland cement in
Fly Ash Concrete
masonry grout low substitution levels have already been used for many years. The high volume replacement of Portland cement will most likely not cause a decrease in cements production, but it will cause a better use of available resources. There are several benefits of increasing the substitution levels of fly ash and slag for Portland cement in masonry grout. The benefits include:(a) using 100% recycled materials, (b) reducing their disposal in landfills, ponds, and (in many places around the world) in river systems, (c) making construction more affordable because less expensive materials are used, (d) possible construction industry expansion without increasing greenhouse gases emission, (e) making the masonry concrete construction more competitive, and (f) alleviating the demand for Portland cement, especially in developing countries where masonry construction is the preferred construction method. All these benefits, however, can only be achieved if these materials can be used without compromising building code requirements. History The earliest literature available on the use of Fly Ash is in 1932 which was carried out by Cleveland Electric Illuminating Company and The Detroit Edison Company. However, the use of Fly Ash in concrete was first carried out by Davis and his associates in University of California in 1937. Though extensive research was carried out throughout the world to promote the use of Fly Ash in construction, only a few milestones could be achieved till1960 and that too in developed countries only. As far as India is concerned, the first ever study on use of fly ash in concrete was carried out in 1955 by CBRI, Roorkee, in the form of a review of American and Australian research work on Fly ash. Later, Fly ash was used in small proportions in mass concreting for dams and other hydraulic structures.
About Fly Ash Fly ash is a fine, light-brown powdery waste product obtained from the dust control equipment of coal-fired power plants. A large volume of this waste product is produced every year. It is a pozzolan which combines with calcium hydroxide in the presence of water to form cementitious compounds. Though some secondary uses for it are found, much of it finds its way to land fills. For over 60 years, fly ash has been employed in Portland Cement concrete as a supplementary cementing material. Fly ash for use in concrete products must meet the requirements of ASTM C618, which defines two classes of fly ash: Class F (which requires a source of calcium hydroxide such as cement or lime) and Class C (self-cementing). Class F is typically used in concrete products. In concrete products, fly ash slows the rate of compressive strength gain and acts as a plasticizer, so it improves the workability of plastic grout. Replacement of up to 15% (typically by weight)of Portland cement by Class F fly ash is currently a common practice in grout mix designs. Need of High Volume Fly Ash Addition For a variety of reasons, the concrete construction industry is not sustainable. First, it consumes huge quantities of virgin materials. Second, the principal binder in concrete is Portland cement, the production of which is a major contributor to greenhouse gas emissions that are implicated in global warming and climate change. Third, many concrete structures suffer from lack of durability which has an adverse effect on the resource productivity of the industry. Because the high-volume fly ash (HVFA) concrete system/masonry grout addresses all three sustainability issues, its adoption will enable the concrete construction industry to become more sustainable. Characteristics of HVFA Grout/Concrete The characteristics defining a HVFA concrete mixture are as follows: - Minimum of 50% of fly ash by mass of the cementitious materials must be maintained. - Low water content, generally less than 130 kg/m3 is mandatory. - Cement content, generally no more than 200kg/m3 is desirable. - For concrete mixtures with specified 28-day compressive strength of 30 MPa or higher, slumps >150 mm, and water-to-cementitious materials ratio of the order of 0.30, the use of high-range water-reducing admixtures (super plasticizers) is mandatory.
Fly-Ash sample as taken from as ash impoundment
- For concrete exposed to freezing and thawing environments, the use of an air-entraining admixture
Fly Ash Concrete
resulting in adequate air-void spacing factor is mandatory. - For concrete mixtures with slumps less than 150 mm and 28-day compressive strength of less than 30 MPa, HVFA concrete mixtures with a water-to-cementitious materials ratio of the order of 0.40 may be used without super plasticizers. Mix Proportions A leading researcher has given typical range of component materials for different levels of strength of HVFA concrete as shown in Table 1. The most important point to be noted here is the amount of water which is varied within a narrow range between 100-130 kg/m3 by using a combination of one or more tools such as a super plasticizing admixture, a high qualityfly ash, and well-graded aggregate. Depending on the desired strength levels, the content and the fly ash/ cement ratio of the binder can be varied. As the water content between the different strength levels does not vary much, it is necessary to increase the cementitious materials substantially to achieve higher strength. When very high strength is needed at an early age, it can be obtained by adopting one or more of the following methods: a higher ratio between Portland cement and fly ash, substitution of a high-early strength Portland cement for ordinary Portland cement, and replacement of a portion of the fly ash with a more reactive pozzolan such as silica fume or rice-husk ash. Figure 1(a), (b) shows grout samples during casting. Figure 2 shows curing of grout specimens in dry and wet condition. Compression Test Results and Discussion Compression test samples were made from the grout specimens by saw cutting the grout specimen to the dimensional requirements of ASTM C1019 (as shown in Figure 3). The test samples were cut two days prior to testing. After cutting, samples were returned to their
Strength level(MPa)
28 days 90 days to 1 year Mix proportions (kg/m3) Water Cement, ASTM Type I/II Fly ash, ASTM Class F Water/cement Coarse aggregate,19 mm max Fine aggregate 120-130 100-130 125-150 0.40-0.45 1100-1200 800-900 115-125 150-160 180-200 0.33-0.35* 1100-1200 800-900 100-120 180-200 200-225 0.30-0.32* 1100-1200 800-900
Figure 3: Saw-Cutting of Grout Specimens from Concrete Masonry Unit Figure 1: (a) Grout samples during casting, (b) Grout placement
Figure 2: (a) Grout specimen curing in dry condition, (b) Curing in wet condition
specific curing environment until testing. The specimens were capped and tested in compression in accordance with ASTM C1019 as shown in Figure 4.Grout specimens were cured in either dry or wet conditions. The average compression strength (of three specimens) for the dry cured grout specimens made by replacing 0, 20, 30, 40, 50 and 60% of Portland cement with Class F fly ash, and tested at 0, 7, 14, 28, 42 and 56 days after casting, are shown in Figure 3. Corresponding compressive strengths for wet cured grout specimens are shown in Figure 4.
Low
20 40
Moderate
30 50
High
40 60
Mechanisms by which Fly Ash Improves the Properties of Concrete Fly ash as a water reducer-Too much mixing-water is probably the most important cause for many problems that are encountered with concrete mixtures. There are two reasons why typical concrete mixtures contain too much
Table 1: Typical mix proportions for different strength levels
BC India
Fly Ash Concrete
mixing-water. Firstly, the water demand and workability are influenced greatly by particle size distribution, particle packing effect, and voids present in the solid system. Secondly, to plasticize a cement paste for achieving a satisfactory consistency, much larger amounts of water than necessary for the hydration of cement have to be used because Portland cement particles, due to the presence of electric charge on the surface, tend to form flocs that trap volumes of the mixing water. It is generally observed that a partial substitution of Portland cement by fly ash in a mortar or concrete mixture reduces that water requirement for obtaining a given consistency. Experimental studies have shown that with HVFA concrete mixtures, depending on the quality of fly ash and the amount of cement replaced, up to 20% reduction in water requirements can be achieved.
influenced by the amount and the quality of the cement paste present. It increases with an increase in the cement paste-to-aggregate ratio in the concrete mixture, and also increases with the water content of the paste. Clearly, the water-reducing property of fly ash can be advantageously used for achieving a considerable reduction in the drying shrinkage of concrete mixtures. Thermal Cracking Thermal cracking is of serious concern in massive concrete structures. However, with a HVFA concrete mixture containing 50% cement replacement with a Class F fly ash, the adiabatic temperature rise is expected to be 30-35oC. As a rule of thumb, the maximum temperature difference between the interior and exterior concrete should not exceed 25oC to avoid thermal cracking. This is because higher temperature differentials are accomplished by rapid cooling rates that usually result in cracking. Evidently, in the case of conventional concrete it is easier to solve the problem either by keeping the concrete insulated and warm for a longer time in the forms until the temperature differential drops below 25oC or by reducing the proportion of portland cement in the binder by a considerable amount. The latter option can be exercised if the structural designer is willing to accept a slightly slower rate of strength development during the first 28 days, and the concrete strength specification is based on 90-day instead of 28-day strength. Water-tightness and Durability In general, the resistance of a reinforced-concrete structure to corrosion, alkali aggregate expansion, sulfate and other forms of chemical attack depends on the water-tightness of the concrete. The water-tightness is greatly influenced by the amount of mixing-water, type and amount of supplementary cementing materials, curing, and cracking resistance of concrete. High-volume fly ash, when properly cured, are able to provide excellent water-tightness and durability. Properties of HVFA Grout - Easier flowability, pumpability, and compactability. - Better surface finish and quicker finishing time when power finish is not required. - Slower setting time, which will have a corresponding effect on the joint cutting and lower power-finishing times for slabs. - Early-strength up to 7 days, which can be accelerated with suitable changes in the mix design when earlier removal of formwork or early structural loading is desired. - Much later strength gain between 28 days and 90 days
Figure 4: Grout Specimens (a) During Compression Test and (b) After Testing
4000 3500 3000 2500 2000 1500 1000 500 0 0-day 7-day 14-day 28-day 42-day 56-day Grout Age 0%, Dry Cure 20%, Dry Cure 30%, Dry Cure 40%, Dry Cure 50%, Dry Cure 60%, Dry Cure Percent Portland cement replaced with Class F Fly Ash
Compressive strength (psi)
Compressive strength (psi)
Figure 5: Compressive strength of dry cured specimen

4500 4000 3500 3000 2500 2000 1500 1000 500 0 0-day 7-day 14-day 28-day 42-day 56-day Grout Age 0%, Dry Cure 20%, Dry Cure 30%, Dry Cure 40%, Dry Cure 50%, Dry Cure 60%, Dry Cure Percent Portland cement replaced with Class F Fly Ash
Figure 6: Compressive strength of wet cured specimen
Drying Shrinkage Perhaps the greatest disadvantage associated with the use of neat portland-cement concrete is cracking due to drying shrinkage. The drying shrinkage of concrete is directly
Fly Ash Concrete
or more. (With HVFA concrete mixtures, the strength enhancement between 7 and 90-day often exceeds 100%, therefore it is unnecessary to overdesign them with respect to a given specified strength.) - Superior dimensional stability and resistance to cracking from thermal shrinkage, autogenous shrinkage, and drying shrinkage. In unprotected concrete, a higher tendency for plastic shrinkage cracking. - After three to six months of curing, much higher electrical resistivity, and resistance to chloride ion penetration, according to ASTM Method C1202. - Very high durability to the reinforcement corrosion, alkali-silica expansion, and sulfate attack. - Better cost economy due to lower material cost and highly favorable lifecycle cost. - Superior environmental friendliness due to ecological disposal of large quantities of fly ash, reduced carbondioxide emissions, and enhancement of resource productivity of the concrete construction industry. Conclusion Throughout the world, the waste disposal costs have escalated greatly. At the same time, the concrete construction industry has realized that coal fly ash is relatively inexpensive and widely available by-product that can be used for partial cement replacement to achieve excellent workability in fresh concrete mixtures. Consequently, in the modern construction practice 15%-20% of fly ash by mass of the cementitious material is now commonly used in North America. Higher amounts of fly ash on the order of 25%-30% are recommended when there is a concern for thermal cracking, alkali-silica expansion, or sulfate attack. Such high proportions of fly ash are not readily accepted by the construction industry due to a slower rate of strength development at early age. The highvolume fly ash concrete system overcomes the problems of low early strength to a great extent through a drastic reduction in the water-cementitious materials ratio by using a combination of methods, such as taking advantage of the super plasticizing effect of fly ash when used in a large volume, the use of a chemical super plasticizer, and a judicious aggregate grading. Consequently, properly cured high-volume concrete products are very homogenous in microstructure, virtually crack-free, and highly durable. Because there is a direct link between durability and resource productivity, the increasing use of high volume concrete will help to enhance the sustainability of the concrete industry. In conclusion, the high-volume concrete offers a holistic solution to the problem of meeting the increasing demands for concrete in the future in a sustainable manner and at a reduced or no additional cost, and at the same time reducing the environmental impact of two industries that
are vital to economic development namely the cement industry and the coal-fired power industry. The technology of high-volume fly ash concrete is especially significant for countries like China and India, where, given the limited amount of financial and natural resources, the huge demand for concrete needed for infrastructure and housing can be easily met in a cost-effective and ecological manner. The test results from reported literatures as discussed in this paper indicate that up to a 50% replacement of cement in grout may be a sustainable alternative for masonry. In addition, high volume replacement of Portland cement with fly ash in concrete products acts as a plasticizer, which in grout mixes may help increase the flow ability of grout in concrete masonry wall construction. Testing of both grout samples and composite prisms may be considered when using grout mixes with high replacement of Portland cement with class F fly ash. Reference
- - - - Malhotra, V.M. High-Performance, High-Volume Fly Ash Concrete. Concrete International 24(7), 2002, pp. 30-34. Malhotra, V.M. High-Performance, High-Volume Fly Ash Concrete. Concrete International 24(7), 2002, pp. 30-34. Owen, P .L. Fly Ash and Its Usage in Concrete. Journal of Concrete Society 13(7),1979, pp. 21-26. Jiang, L.H., and V.M. Malhotra. Reduction in Water Demand of Non Air-Entrained Concrete Incorporating Large Volume of Fly Ash. Cement and Concrete Research 30,2000, pp. 17851789. Hanle, L., Jayaraman, K., and Smith, J., CO2 Emissions Proile of the U.S. Cement Industry,U.S. EPA 05-03-2006, 2006. Hogan, F, Meusel, J., and Spellman, L., Breathing Easier With Blast Furnace Slag, Rock Products: Cement Americas, Jul/ Aug 2001, 11-15. Malhotra, V.M., High-Performance High-Volume Fly Ash Concrete, Concrete International, V. 24, No. 7, July 2002, pp. 30-34. Bouzoubaa, N. and Malhotra, V.M., Performance of LabProduced High-Volume Fly Ash Cementsin Concrete, Concrete International, V. 23, No. 4, April 2001, pp. 29-33. Cross, D, Stephens, J, and Vollmer, J., Filed Trials of 100% Fly Ash Concrete, Concrete International, V. 27, No. 9, Sep. 2005, pp. 47-51. ASTM Standards, ASTM International: C143/C143M, Standard Test Method for Slump of HydraulicCement Concrete, 2010 C476, Standard Specification for Grout for Masonry, 2010. Mehta, P .K. Concrete Technology for Sustainable Development. Concrete International 21(11), 1999, pp. 4752. Mehta, P .K. Durability: Critical Issues for the Future. Concrete International 19(7), 1997, pp. 69-76.
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Photo Courtesy
www.explow.com
Join the BIM Workflow with Your iPad or iPhone

ekla BIMsight Note is a free, purpose-built tool for instant communication on-site and onthe-move. The application connects notes to the full Tekla BIMsight project. A remark that would previously have stayed in a text message or had been forgotten after a phone conversation is now attached to the project. The Tekla BIMsight Note tool leaves a traceable mark to the BIM workflow so information is not missed. Tekla BIMsight maintains the communication trail. The app gives even those without BIM or CAD capabilities a possibility contribute to BIM projects. Using Tekla BIMsight Note is as easy as sending a text message or email. In the office and in the middle of mud and dust misconceptions are less likely to happen if
you can actually see an image of the problematic part that needs to be discussed. Now a tool for seeing and discussing the exact matter fits into your pocket. Download Tekla BIMsight Note free from the Apple App Store with iPad or iPhone. The full version of Tekla BIMsight is available for Windows computers and tablets. Your notes are attached to the workflow in full Tekla BIMsight.
To know more about Tekla BIMsight:

Tekla India Pvt. Ltd. Ph: 022-61387777, E-mail: info.india@tekla.com Web: www.tekla.com
Tekla BIMsight Note, available in the Apple App Store, allows you to con-tribute to Tekla Open BIM workflow via iOS mobile device. With this new application, anyone can use an iPhone or iPad to receive and reply to notes created in Tekla BIMsight. Just see the combination of note text and image and communicate your thoughts to other users of the model.
Tata BlueScope Bags the Prestigious - PEB Project of the Year Award
Tata BlueScope Building Solutions has won the 'PEB (Pre-engineered Building) project of the year award' at the Essar Steel Infrastructure Excellence Awards 2012. The award was conferred upon Tata BlueScope Building Solutions for the successful execution of the 'Coated Steel Manufacturing Plant' of Tata BlueScope Steel at Jamshedpur. This is for the second time that Tata BlueScope Building Solutions has won the coveted PEB Project of the Year award. It had earlier won the award for the East West Gas Pipeline PEB project of Reliance Gas Transportation Infrastructure Limited in the inaugural edition of Essar Steel Infrastructure Excellence awards in 2009. The Honourable Union Minister for Urban Development, Shri. Kamal Nath handed over the award to Mr. Rajiv Upadhyay, Vice President, Tata BlueScope Building Solutions at the award function organised in New Delhi on May 8, 2012. Tata BlueScope Building Solutions was recognised for the successful completion of the Coated Steel Plant project, which involved designing, manufacturing, supplying and erection of 26 non-identical metal building structures
including the tallest PEB of 42.3 Meters height for metal coating line. The buildings were designed to meet the unique but diverse requirements of an integrated industrial project. The innovation in building design, manufacturing and construction techniques reduced the risks associated and improved the overall speed of construction. The project was completed safely without any Loss Time Accident.
280
Buildmat 2013
Rising Dampness Compound

ising dampness in super structure causes paint and plaster to peel off. Similarly it causes wood to smell and warp, allows a total fungal growth thereby leading to deterioration of the structure. Samafit VK damp proofing chemical eliminates this problem by sealing the wall and providing an impermeable barrier to the passage of the walls. Samafit VK enters the capillaries and convert the hydroscopic to hydrophobic by the process of silicification. Samafit VK is a two component product which has to introduce into a zigzag pre-drilled holes separately after proper timing gap. The two components reacts in the capillaries and form product which makes the capillary non wettable. Therefore the water does not rise in the capillaries against the gravity but depresses and
controls the rising dampness. Samafit VK therefore protects the structures from the dampness which normally encourages the moss and fungus growth and root growth. The walls are rendered dry for better plastering and painting. Samafit VK can be universally used whereas
the water ingress is due to capillary action. Samafit VK can be effectively used for masonry super structures as well pores construction materials which are unconventional. It can be very effectively used for old structures, monuments, and for structures in area which are having high water table as to prevent the rising dampness occurring due to splashing rains in the lower unprotected zones. Samafit VK is most efficient in solving the problems of the capillary action.
411, Arenja Corner, Sector 17, Vashi, Navi Mumbai-400703, Ph:+91--22-27892856/27880803, Fax:+91-22-27893870, E-mail: Info.india@mc-bauchemie.com Web: www.mc-bauchemieindia.com
MC Bauchemie (India) Pvt. Ltd.
Shard is Now Europe's Tallest Building
London has added one more landmark to its rapidly rising skyline. The Shard has been officially unveiled in Central London. The building is the tallest in Europe and would become yet another iconic landmark in the city as it rises 1,000 ft into the skyline. Designed by Italian architect Renzo Piano, this mixed developed has restaurants, a luxury hotel, and plush luxury residencies. However, the tower's reign as the tallest building in Europe is likely to be short-lived. The rapidly rising 332 metre Mercury City Tower in Moscow could soon be holding that coveted status. The skyscraper in Russia is most likely to upsurp the title by the end of 2012.
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WISE India
Record Number of Exhibitors at bauma China 2012

he International Trade Fair for Construction Machinery, Building Material Machines, Construction Vehicles and Equipment, bauma China is already in the news for setting a new exhibitor record. As of February 2012, over 1,900 companies have already applied to exhibit at the event, that takes place in November 2012, at the Shanghai New International Expo Centre (SNIEC). Collin Davis, Exhibition Group Director at Messe Mnchen International, is upbeat: "It was our aim to offer our exhibitors improved conditions for their presentations in the halls. And, as we have eight more halls available for this year's event, we have been much better able
to meet their space requirements. Demand for space on the open-air site far currently exceeds the space available. Important key players, however, are making use of the additional hall space. In total, 300,000 square meters of space is available at bauma China 2012. Interest from the industry worldwide continues at a high level: Austria, Finland, Germany, Great Britain, Italy, Korea, Spain and the US will each be taking a pavilion at bauma China. About Messe Mnchen International (MMI) Messe Mnchen International is one of the world's leading trade-fair companies. In Munich alone it organizes around
40 trade fairs for capital and consumer goods, and key high-tech industries. Each year more than 30,000 exhibitors and over two million visitors take part in the events held in the New Munich Trade Fair Centre, the ICM International Congress Centre Munich, and in the M,O,C, Events and Order Centre. In addition, Messe Mnchen International organizes trade fairs in Asia, Russia, the Middle East and South America. With six subsidiaries in Europe and Asia and more than 60 foreign representatives actively serving over 90 countries, Messe Mnchen International has a worldwide business network. The Group also takes a pioneering role as regards sustainability: It is the first trade-fair company to be awarded energy-efficiency certification from the technical inspection authorities TV SD. bauma China, 27 - 30 November 2012, Shanghai, China, www.baumachina.com
Other forthcoming events of MMI bauma Africa, 18 - 21 September 2013, Johannesburg, South Africa, www.bauma-africa.com bC India A Bauma Conexpo Show, 5 - 8 February 2013, Mumbai, India, www.bcindia.com bauma, 15 - 21 April 2013, Munich, Germany, www.bauma.de/en

Trade Fair PR Manager, Central Division Marketing & Communication Ph:+49 89/9 49-21478 Fax:+49 89/9 49-21489 E-mail: sabine.wagner@ messe-muenchen.de Web: www.bauma-china.com
Sabine Wagner
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INSTRUCT
Composite Materials
The Impact of Basaltic Fibre on Selected Physical and Mechanical Properties of Cement Mortar
Associate Editor
asalt is of the family of igneous rocks which means it melts when heated up, as a thermoplastic material. Basalt is volcanic magma which has solidified in the open air. Basalt has always been used for its hardness in road surfacing and in construction as a filling stone. Also after brought to the molten stage, it is molded into construction parts, as for example floor tiles and as internal lining in steel pipes transporting abrasive and hot compounds. Basalt stones come with different chemical compositions, and only particular chemical compositions and physical
characteristics of basalt allow its extrusion into continuous thin filaments with useful properties. The nominal diameters of these continuous filaments now come in the range 9 to 24 m. It is mainly used (as crushed rock) in construction, industrial and high way engineering. One can also melt basalt (1300-1700C) and spin it into fine fibres. When used as (continuous) fibres, basalt can reinforce a new range of (plastic and concrete matrix) composites. It can also be used in combination with other reinforcements (e.g. basalt/ carbon).
Composite Materials
Brief history Credit has to be given to a Frenchman from Paris, Paul Dh, who in 1923 got a US patent for extruding filaments from basalt. It is known that in the 1950/60s in Moscow and in Prague, in todays Russia and Czech Republic among other places, research in this field started. In the 60s and 70s, intensive R&D efforts took place in the North-West of the USA which by the way has large basalt deposits. In the 1960/70s the defense ministry of the Soviet Union got interested in the potential of this technology for military and space applications. All R&D was concentrated in Kiev, Ukraine. Budgets were unlimited. This research eventually became successful. The technology was kept secret and the object of little publication. The research institutes and production plants dealing with it were off limits. It is in 1990/ 92, in Perestroika, the technology was declassified. This allowed its application in the civilian field. General Basalt Fibers Technical Features as Belowt - Permanent flame retardant resistance: Limiting oxygen index (Loi) >70 - Extraordinary high softening temperature (point): >1200 Celsius degree - Operating temperature range: from -260 to 760 Celsius degree - High tensile strength (breaking strength): 3200 MPa - Low elongation at break: 3.1 % - High elastic modulus: 89 GPa - Density: 2.7 gram/cubic centimeter - Low thermal conductivity: 0.035 W/mK - High sound absorption coefficient: 0.95 - Low moisture absorption: 0.1 % - High specific volume resistance: 1x1012 ohmm - Radiation proof lead equivalent: 0.0073 mm Pb Water-absorbing capacity of basalt fiber is much less than 1%, of fiberglass - up to 10-20%. For comparison, industrially manufactured fiberglass, especially of neutral composition, absorbs substantial amount of moisture in humid air, which weakens its physical-technical and longevity properties and eventually leads to fiber damage. On contrary, low nonvolatile water absorbency of basalt fiber ensures stability of thermal and physical characteristics in case of continuous service. Basalt fiber has high chemical stability and pertains to the first dimming class and greatly exceed fiberglass in acid, alkali and steam resistance characteristics. The disadvantages of fiberglass compared to basalt fiber are spinosity of threads, and discharge of the finest dust at disintegration of thermal insulation at thermal-cycle loads. Due to high elastic modulus, basalt fiber strength is 35-40% higher than that of fiberglass - the fiber is more elastic, non-spinous. Materials of basalt fiber
have a greater operating life as compared to materials of fiberglass. Super-thin basalt fiber is firmly knitted by natural cohesive attraction. Basalt fibers are chemically stable to exposures of aggressive means and steam and do not accumulate radiation. Costs of basalt fiber production are markedly lower (by 15-20%) compared with other mentioned fibers manufacture owing to one-stage basalt fiber production scheme. Yield of basalt fiber from basalt is 100%. Notice also that basalt fiber producing facilities are compact, environmentally safe and waste-free (only products of cumbistion of natural gas, cooled and cleaned in filters, are emitted to atmosphere). The sole factor, hindering wide application of basalt fiber in Russia is very low volume of their commercial production. The present story reports the study on cement mortar with basalt fibre intrusion for its mechanical and physical properties by Institute of Structural Engineering at Poznan University of Technology.
German Marina Norderney gets first basalt fibre-reinforced docks. In a multiphase project, The German marina will be protected from the areas typical gales and high seas by ground-breaking 21st-century technology. The first such installation in the world, X-Line basalt fiber-reinforced docks from SF Marina are replacing 30-year-old aluminum units.
Outcome Experimental Investigation Carried out in Institute of Structural Engineering at Poznan University of Technology : Tests have been carried out in the laboratory of the Institute of Structural Engineering at Poznan University of Technology. The aim of the tests was to check the influence of added basaltic fibre on some selected physical and mechanical properties of cement mortar. An attempt was made to calculate the optimum amount of the basaltic fibre, allowing the best mechanical properties of the mortar to be achieved. For mortar preparation cement CEM I 32.5R and standard quartz sand were used (according to PNEN 196-1). The tests were carried out to check bending
Composite Materials
strength and ultimate compressive strength after 3, 7 and 28 days. The measurement of shrinkage in the first 28 days of mortar curing was also made. The tests were performed on standard cement mortar prisms with dimensions of 4 x 4 x 16 cm. The results of preliminary tests show that the effective impact of the basaltic fibre on the change of basic physical and mechanical properties of the mortar decreases in case of the fibre amount higher than 2% and lower than 0.2% of the mortar weight. That is why samples for the tests were made by adding to the mortar the basaltic fibre totalling 0.3, 0.8, 1.3 and 1.8% of the mortar weight. The basaltic fibre used for tests was cut into pieces of approx. 6.5 mm. Base prisms with no fibre content (0.0%) were also made up. During the whole period the samples were stored under laboratory conditions in the temperature of 18C and a relative air humidity > 90%.
decreased by another 7.5% in comparison with the base prisms (0.0%). The lowest decrease (approx. 4.5 %) was noticed in samples with the fibre content totalling 0.8% of the volume. It may be assumed that the main reason for this is high fragility of the used basaltic fibre, its relatively small elongation at break and high adherence to the mortar. The mortar which was used to make samples is characterized by fairly high shrinkage. After more than twelve days of curing, the shrinkage strength causes cracking of the basaltic fibres. This would explain a high increase of bending strength after 3 days of curing and a lower increase after 7 days as well as a significant decrease after 28 days of mortar curing. Observation of the prisms cross-sections after the tests revealed that the basaltic fibre was diffused in the mortar at random and spatially. During breaking of the samples, approx. 90% of the fibre got broken and the remaining 10% were torn out of the mortar. This demonstrated considerable adherence of the mortar to the basaltic fibre.
Bending Strength
0.00 After 3 Days After 7 Days After 28 Days 5.3 7.8 6.7
Basaltic Fibre Content (%)

0.30 6.0 8.0 6.2 0.80 5.8 8.3 6.4 1.30 6.0 8.1 6.2 1.80 6.1 8.2 6.2
Table 1: Bending Strength of Mortar Prism
Ultimate compressive strength The achieved test results are presented in (Table 2). The presented results are the arithmetic average of measurements made on 12 samples. Standard deviation for achieved results of ultimate compressive strength is between 3.0 and 8.1%. After 3 days of curing a significant increase of ultimate compressive strength (of 10%) was observed only for the amount of 0.8% of the fibre in the mortar. For the remaining tested prisms, with the fibre content of 0.3%, 1.3% and 1.8%, the ultimate compressive strength remains on the same level in comparison to the base samples or is slightly higher, which is within the measurement error. After 7 days of curing we can observe stabilization of the strength for 0.3%, 0.8% and 1.8% of the fibre content. In case of the fibre amount equalling 1.3%, we can see a slight decrease of the ultimate compressive strength. However, the reason of such results might be a measurement error. After 28 days of curing, test results are much more differentiated. For small contents of fibre we can observe a significant increase (over 20% for 0.3% of the fibre content and almost 8% for 0.8% of the fibre content). For the fibre amount equalling 1.3%, the strength compared to that of the base samples did not change and for the content reaching 1.8% there was a visible decrease of the strength (of over 15%). The mortar with 1.8% of the fibre content was characterized by much worse workability
Basalt Fibre strands for Concrete
Test results for the bending strength The results achieved during the tests are presented in (Table 1). The presented results are the arithmetic average of measurements made on six samples. Standard deviation of the obtained results of bending strength is between 1.6 to 8.3%. The analysis of the data included in (Table 1) demonstrates that the addition of basaltic fibre increases the bending strength by 13% on average. The achieved increase is practically independent from the amount of added basaltic fibre. After 7 days of mortar curing the bending strength is highest. The highest increase of the bending strength (of approx. 6.5%) in comparison with the base mortar is achieved by adding basaltic fibre equalling 0.8% of the mortar weight. After 28 days of curing the achieved bending strength was lower than after 7 days. The reason for this was probably the use of cement of high initial strength for tests. For prisms with an additive of fibre equalling 0.3%, 1.3%, 1.8%, the bending strength
Forensic Geotechnical Engineering
Composite Materials
and worse possibility of its thickening than others. This might have had a decisive impact on its lower ultimate compressive strength.
Ultimate Compressive Strength
0.00 After 3 Days After 7 Days After 28 Days 30 40 39
Basaltic Fibre Content (%)
0.30 31 41 47
0.80 33 40 42
1.30 30 37 39
1.80 31 41 33
in case of 0.3 to 0.8% of the fibre content in the cement mortar after 28 days of curing and exceeding the amount of the fibre addition by 1% results in significant worsening of mortar workability and possibility of its thickening and adding the basaltic fibre to the mortar causes a smaller shrinkage, proportionate to the fibre content. Researchers recommended an optimum amount of the basaltic fibre in the mortar, allowing the best mechanical properties to be achieved, ranges from 0.5% to 0.8% of the cement weight. The addition of basaltic fibre in the content as mentioned above will cause the decrease of shrinkage of the cement mortar by approx. 15 to 20%. Basalt fiber is a modern XXI-century material, combining ecological safety, natural longevity, and fire safety (incombustibility). Good understanding of its useful mechanism continues to be gained. These fibers, alone or combined with others, go through the first transformation step, producing: e.g. wovens and nonwovens, braids, knits and chopped fibers. Coatings can be applied for outdoor use, for oils and greases resistance, for impermeability to water and permeability to air, for anti-slip and anti-soiling, for continuous skin contact, for high abrasion resistance, for heat insulation through intumescence, for colored or fluorescent appearances, etc. Basalt has advantage over glass fibres interms of mechanical, thermal and chemical properties. In a time where we are looking towards fibres in concrete, Basalt fibres can be a very good choice considering its beneficial characteristics. However more detailed research may be needed to explore its other effects on the cement concrete/mortar. Reference
- - - - - - - Aketoma Basalt fabrics, tubes, prepregs, rods etc. http:// www.laseroptronix.com Jiri Militky, Vladimir Kovacic; Ultimate Mechanical Properties of Basalt Filaments, Text. Res. J. 66(4), 225-229 (1996) Stephen Cater; Editorial, International Composites News, (40) March (2002) Basalt Fibre Products, http://www.mendex .de/services3. html Tengiz Chantladze; Industrial assimilation of the effective type of fibre with multicomponent charge, http://www.tctv.ne.jp Basaltex, The thread of stone, http://www.basaltex.com Sergeev et al.; Basalt Fibers A Reinforcing Filler for Composites, Powder Metallurgy and Metal Ceramics, 33(910), 555-557 (1994) Bednr M., Hjek M.; Hitzeschutztextilien aus neuartigen Basalt-Filamentgarnen, Technische Textilien, 43 (November), 252-254 (2000) http://basaltfiberworld.blogspot.in/2011_05_01_archive.html
Table 2: Ultimate Compressive Strength
Test results concerning shrinkage The shrinkage values given in (Table 3) are the arithmetic average of measurements made on 3 samples. The measurements were made with the accuracy of 0.005 mm. From the achieved results we may see that the highest shrinkage value is achieved in the specimens with no fibre content. Shrinkage after 28 days decreases proportionately to the increasing fibre content in the mortar. Measurements made after 3, 7 and 14 days of curing show that the proportionality of the shrinkage to the fibre content is maintained during the whole 28-day period of measurements. It proves that the phenomenon of breaking of the basaltic fibre, observed during the tests of bending strength after the first week of mortar curing, practically has no impact on weakening of its anti-shrinkage properties. The fibre, broken into small pieces, considerably decreases the shrinkage of the mortar. The data from (Table 3), shows the dependence between the fibre content in the cement mortar and its 28-day shrinkage. It was conclude by the reasearchers that in the tested range of the basaltic fibre content in the mortar, increasing the fibre amount by 0.1% of the cement mortar weight, results in lower shrinkage of the mortar by approx. 0.0024 mm/m, i.e. by approx. 3.1% in comparison to the mortar with no fibre content.
Basaltic Fibre Content (%) Shrinkage (mm/m)
0.00 0.077 0.30 0.058 0.80 0.060 1.30 0.046 1.80 0.027
Table 3: Average Shrinkage of Mortars after 28 days of curing
Research Outcome From the analysis of the test results as well as the observation made during these tests the Researchers concluded that: The addition of basaltic fibre causes noticeable increase of 3 and 7 day bending strength; after 28 days of curing, there is a decrease in bending strength and The highest bending strength in comparison to the base samples was achieved in case of 0.8% of the fibre content after 7 days of curing and the highest ultimate compressive strength was achieved
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ICI - 2 days National Seminar on Modern Equipments for Concrete Construction
Site Report
Putzmeister India's BSA 2110 HP D Pumps Concrete up to 200m at High-Rise Project in Mumbai
utzmeister is a name that has become synonymous with worldclass concreting equipment. The global major's Indian subsidiary, Putzmeister India, with its wide range of technologically advanced range of concreting machinery, has carved a niche for itself in the domestic market. Its concrete pumps for example, have been setting newer records in pumping concrete longer and higher in India. A
recent example is the company's concrete pump BSA 2110HPD pumping concrete up to a height of 200 m at a project in Lower Parel, Mumbai. Pumping concrete to record heights in the case of high-rise projects is not something that is new to Putzmeister. After all the company's concrete pumps were used to pump concrete to record heights of over 600 m during the construction of Burj Khalifa, the world's
tallest building. The company's BSA 2110 HP D model stationary concrete pump , along with its boom placer model, MX-34-4, was used by the project developer Shree Ram Urban Infrastructure Limited for pumping concrete up to 200 m at their high-rise project located in the Lower Parel area of Mumbai. The pipeline layout that was used in the project include, horizontal pipe layout
292
Site Report
of 70 m, vertical pipe layout of 198 m, along with the use of a concrete boom placer, MX- 34-4. Slurry was screened and then poured into the pump hopper in order to avoid any possible lumps that could complicate initial pass. The Grade of concrete pumped during the project was M60. Initially slurry of almost 2 cu.m was passed through the pipeline. A total of 95cu.m of concrete was successfully pumped during the project, with a set output of 25 cu.m /hour (as required) at a height of almost 200m from ground level. The project is yet another feather in the cap of the world-record setting BSA 2110 HP D long stroke, high-performance concrete pump. With its ability to pump concrete to record heights, with pressure and output guaranteed, this concrete pump has virtually attained newer heights with this latest high-rise project in Lower Parel, Mumbai. handling and lift table installation.

Putzmeister Concrete Machines Pvt. Ltd.
N-4, Phase 4, Verna Industrial Estate Goa - 403722, India Ph: +91-832-6696090, E-mail: info@pmw.co.in Web: www.pmw.co.in
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Tall Buildings
EXTREME : ENGINEERING World's Most Anticipated Skyscrapers

Chaitanya Chaitanya Raj Raj Goyal Goyal
he recent years have witnessed a reeling construction & architecture industry, struck by everything from mortgage meltdowns to the deep-rooted global recession. As the financial crisis has hit several nations, construction has slowed on both residential and commercial projects, leaving architects and builders to come up with creative ways to keep their firms afloat. Thus the phrase 'Sky is the Limit' might soon feel faulty to use as the world's best engineers and architects are all set to break and push this limit further with an
array of skyscrapers lined up, both in concept and action. Under Construction: The Top 10 giants Building data firm Emporis has compiled a list of the top 10 "future skyscrapers" ones currently under construction that will be among the world's tallest when they are completed. Each of the ten newcomers will stand more than 500 meters tall, and they are all due to be finished by 2016. Only Burj Khalifa will remain in the 10 tallest buildings by 2016 - and 9 out of the top 10 structures
will be in Asia. While Burj Khalifa will remain the tallest building in the world (at 828m), the Middle East's cloud-touching clutch of giants will be overtaken by China, which is building six of the 10 tallest skyscrapers, followed by South Korea which has two buildings in the future list. If other proposed building plans are put into motion, there could soon be skyscrapers that dwarf the Burj in height. But for now, these buildings are the tallest under construction. Let us start from the shortest among the 'Tallest 10'!
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Tall Buildings
10
Busan Lotte World Tower
Pentominium
10. Busan Lotte World Tower, Busan, South Korea This 107 floor, 510.5 m (1,674 ft) supertall skyscraper project in Busan, South Korea is expected in 2016. The tower complex construction which began in 2009 is divided into 4 construction phases including a huge department store, cinema, luxury hotel, an observation deck, offices, and cultural facilities. The tower's underground parking space will be able to accommodate over 2,400 cars owing to the 6 underground floors. Concrete casting in the 4.0m thick, triangular (75m) mat foundation of the tower began in March 2012. A massive 24,840 cubic meter of low heat SCC - 40 Mpa grade was poured in the mat built from 2225 ton of re-bar. The structure has been designed well to tackle the wind and seismic loads owing to the extreme conditions this region faces. Busan Lotte World will have 45 elevators with a max speed of 10m/s to facilitate quick movement. 9. Pentominium, Dubai This 122 floor marvel will touch the mark of 516m and will become the world's tallest residential tower covering a total built up area of 163,720m2. The construction started in 2009 and the building was expected by 2013 before the
construction was halted in August 2011 leaving mere 22 floors completed. Each residential floor in this building will span an area of over 600 m2 including 4-bedrooms apartments, swimming pool, an observation deck, a private cinema, a health club, a banqueting hall, a cigar lounge and a business centre. There are six basement levels and the structure is supported by a piled raft system comprising large-diameter bored piles cast in situ. The pile cut-off levels are founded about 24 m below existing ground level at an elevation of 19.4 m DMD. Approximately, 5,000 tones of rebar and 3 15,000 m of concrete were used in casting the pile raft foundation. This tower
will harbor 23 elevators with a top speed of 8 m/s. 8. Dalian Greenland Center Dalian, Liaoning, China Dalian Greenland Center is a skyscraper under construction in Dalian, Liaoning, China. It is expected to have 88 floors and be 518m tall. The anticipated completion date is 2016. The tower will host 265 residential apartments, 260 luxury hotel rooms and commercial workspaces with an observatory deck. The tower's GFA is 247,000m2 and the total development GFA is 287,000m2. The complex will support 37 elevators with a top speed of 9m/s. It also includes
Dalian Greenland Center
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CTF Tianjin Tower

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lope, optimized day lighting and landscaped green site areas among its sustainable strategies. Prior testing of 18 different schemes within a wind tunnel has led to a design with the least movement and quiet interior in comparison to other implemented skyscrapers. 6. One World Trade Center, New York A memorable architectural landmark for New York City and America, the 105 story tower will soar to 541.3m in the sky and is expected by 2013. The building includes some characteristic design elements intended to protect it from future terrorist attacks, such as a 185-foot windowless concrete base designed specifically to withstand truck bombs, three-foot reinforced concrete walls in all stairwells and elevator shafts, and a dedicated set of staircases for firefighters. Above the concrete base, the building starts to take its shape after the 20th floor. As it rises, eight isosceles triangles built into the building's faade come together to form a perfect octagon near the middle of the tower. The high rise is being constructed with two concrete cores and concrete on metal decks utilizing an innovative placing system. 5. Goldin Finance 117, Tianjin, China Located in Tianjin, this 117-storey tower will become the tallest building in
One World Trade Center
4 basement floors for parking and other service facilities. It uses state of the art technology to overcome the wind and seismic forces that pose a major challenge to this structure. 7. CTF Tianjin Tower, Tianjin, China The 96 story CTF Tianjin Tower (530meter) houses offices, 300 service apartments and a 350-room, 5-star hotel beneath its boldly arched top. The gently curving glass skin conceals eight sloping columns that lie behind the primary bends of the elevation. Integral to resolving gravity and lateral loads, these sloping columns increase the structure's stiffness in response to seismic concerns. Strategically placed, multi-story wind vents combined with the aerodynamic shape of the tower dramatically reduce wind forces by reducing vortex shedding. The 4.2-million-square-feet project has been designed to LEED gold standards with a high performance enve-
the city upon completion, soaring to 600m. The upper portion will house a luxurious hotel and the lower portion will contain office space. Construction began in 2008, and the building was scheduled to be completed in 2014, becoming the second tallest building in China, surpassing the Shanghai World Financial Center. In late January 2010 it was announced that
Goldin Finance 117

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world records, such as the tallest hotel in the world (601m ), the tallest clock tower in the world, the world's largest clock face and the building with the world's largest floor area (15,00,000 m2). Even the concrete section of the Mecca Royal Clock Tower would be taller than the current second-tallest building in the world The complex includes 96 elevators with a top speed of 6m/sec. The new clock tower, standing approx. 1,969 feet, is six times the height of Big Ben's clock tower in London and features four clock faces, each 43 meters in diameter, legible from up to 10 kilometers away. 3. Shanghai Tower, Shanghai, China Standing at 632-meters, the mixeduse Shanghai Tower began in 2009 and the construction is estimated to get completed by 2014. The tower will have 121 floors, with a total floor area of 380,000 meter square. The steel structure will rise to 632m wrapped around a 565.6 metre tall central concrete core. The design is tiered into 8 levels above ground with floor-plates, approximately the shape of triangles, creating the base of each tier that in front has an outer glass faade wrapped around it rather like a burrito that gently tapers in and out creating a subtle zoomorphic appearance. Recessed deeply from the external faade are the main floors, creating an area in between that contains huge atriums. These will have their space used to turn it into a bioclimatic tower, complete with trees as much as ten meters tall that can help naturally regulate the cooling of the building between its double skin. The faade's taper, texture and asymmetry work in partnership to reduce wind loads on the building by 24%, construction had been suspended. Con- offering considerable savings overall in struction resumed in 2011, with comple- both building materials and construction costs. In addition, the building's spition estimated in 2015. Sustainability is high on the builder's raling parapet collects rainwater, which agenda as a LEED platinum target had is used for the tower's heating and air conditioning systems. Wind turbines been set for the design team. located directly beneath the parapet 4. Makkah Clock Royal Tower, Mecca, generate on-site power. Saudi Arabia BASF's concrete admixture Rheoplus This tower is a building complex in 325 helped facilitate the project's objecMecca owned by Fairmont Hotels and tive to continuously pour 61,000 m3 conResorts. The complex holds several crete for the foundation slab in a period
of 60 hours. This has resulted in a new world record. 2. Pingan International Finance Center Shenzhen, Gaungdong, China The Pingan International Finance Center is a 115-storey supertall skyscraper that is expected to be completed in 2015, and will be the tallest building in China, standing a total of 660m high. The building has a total gross floor area of 378,600 m2 plus a basement area of 90,000 m2. The project will consist of offices, supporting facilities, a conference center, and parking. It will seek LEED certification. The selected structural system consists of a composite concrete core with steel outriggers connecting to eight super-columns. The exterior frame is
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composed of seven double layer belt trusses located at the mechanical and refugee floors. The exterior belt trusses are interconnected with a super diagonal at each exterior face of the building. The project also includes a steel-framed 11-story podium with high-end shopping arcades, restaurants and roof-top cafes. Thornton Tomasetti has performed extensive nonlinear dynamic time history seismic analysis. 1. India Tower, Mumbai, India India Tower is a super-tall skyscraper under construction in the city of Mumbai in Maharashtra, India. If completed as proposed, the 125-storey tower would stand 720m high, and would become the world's second-tallest skyscraper, after the Burj. The project has gone through many evolutions over the last few years. The project was first proposed by the Dynamix Balwas realtor group in 2008 as a more modest 85-story, 988 feet-tall tower. Construction began on the latest iteration, designed by Fosters + Partners,
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in 2010, but was put on hold the following year with no word about changes to the projected completion date, or whether the project will continue at all. Construction is challenging and will consist of three cast in-situ concrete cores which continually taper. This means that the formwork will need to be re-
adjusted on every storey. If construction re-starts Doka (temporary works specialist) will be using 2,785m2 of large area formwork, with 173 automatic climbers to help erect it. The future is vertical With the number of people living on earth growing exponentially (7 billion in the last 100 years), there is no room for cities to expand on the ground, especially in the big overcrowded areas, and that is why architects are planning many ways of expanding through the air. It was always pretty obvious what the future was going to look like. Gleaming glass and steel skyscrapers would puncture the atmosphere like silver needles in a pincushion. Architects' vertical leapfrogging, however, isn't likely to stop at the Burj Khalifa. While the tower will be a tough one to beat, it is likely to remain at the pinnacle for only about another half-dozen years. Developers around the world have proposed numerous new skyscrapers. Some projects have leapt off the drawing boards, though plans for many record-breaking towers have been scuttled because of the global economic spasms of the past couple years. But thankfully we have witnessed a shift from glamour towards functionality in high rise construction. The future will see many more amazing and insane designs as the human race moves towards a rapidly transforming era!
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Realty
The Big Squeeze: Mumbai Developers Battle Unsold Inventory Pile-up

he Mumbai real estate market for high-end homes has stagnated during fiscal year 2012 as buyers have largely kept away from the market expecting an impending dip in prices in the near future. Knight Frank Research, a property consultancy firm, analyzed residential market comprising projects with a sales potential of above ` 30 crore in the Mumbai Metropolitan Region (MMR). According to their study of the
residential market for June, the wait could pay off. More Unsold Inventory piling up as a result of the Sinking Demand: With only 45,000 apartments sold in the Mumbai metropolitan region during 2011-12, well below the market average of 70,000 to 80,000 units annually, the future of real estate in the metro seems slightly shaky with such disappointing
absorption rate. Absorption numbers in FY 2012 are estimated to have dropped by more than 60% from its 2007 hey days and 35% from FY 2011 to an estimated 45,000. The Mumbai market currently has an unsold inventory to the tune of 80,000 units which is approximately valued at INR 1,050 billion at current prices. But prices continue to stay high despite weak demand. But a combination of rising in-
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New Project Launches put on hold: The Navi Mumbai, peripheral western suburbs and Thane micro-markets have seen comparatively higher number of projects launched in the previous two quarters causing vacancy levels to spike while South & Central Mumbai which only offer products at the premium end of residential price band are experiencing highest vacancy levels. "Vacancy levels are as high as 48% for units launched in the ` 2 crore and above price bracket vis-a-vis 37% for the overall Mumbai market and the MMR market has witnessed a steep drop of almost 40% in project launches in FY 2012 compared to the previous period the report said. Over 55,000 housing units were launched in 2011-2012, as compared to the 92,000 units launched in the previous year. Supply was also constrained during the year as developers delayed project launches in the hopes of selling off existing stocks to ease pressure on prices. Mounting Debt: Rising interest rates, soaring input costs including land, labour and construction material have limited developers' option to cut prices, according to the study, as they were hard-pressed to maintain their current operating margins of 30-35 per cent. Developers are hard pressed to deleverage their positions in the Mumbai residential market as they are getting buried under continuously rising debts with the market offering them little respite, according to the Knight Frank study. The total debt position of five major Mumbai based developers adds up to ` 62 billion as on March 2012, while they are holding on to a total unsold inventory of approximately ` 143 billion, which is 14 % of the total Mumbai residential market. In the context of various sources of funding drying up and new launches hitting the market, the developers may re-plan their pricing strategy in such a way that the unsold inventory is mone-
tized within four to six quarters instead of the currently estimated eight to ten quarters, as per the study. Concentration in Northern Suburbs of MMR: The core residential market in Mumbai is steadily shifting north of the Mumbai Metropolitan Region as people move away from the central business districts to buy a home that fits their budget. An estimated 73% of the total residential units under construction is concentrated on the northern fringes of the Mumbai market. Developers are looking to tap into the largest chunk of buyers looking for apartments priced up to INR 7.5 million. Thus, an estimated 55% of units under construction presently belong to this price bracket. Economic Slowdown and Rising Cancellations a cause of worry: Developers in a bid to liquidate their higher-priced inventory have been more open to negotiation in the premium segment, reducing prices up to a maximum of 25 per cent for the sake of a sizeable upfront payment. The number of cancellations is on the rise in the last few quarters indicating the investors' worry. Project approvals that were practically stalled in 2011, have started coming through again as the Development Control Regulations were amended early this year. However, demand is likely to remain subdued due to the prevailing uncertainty in the economy. Future Pricing Expectations: The stagnant real estate prices today suggest a stalemate between buyers and sellers, but market indicators strongly hint at an imminent inflection point. The increase in inventories coupled with the ongoing slack in absorption would put downward pressure on prices. Mumbai's residential property market will stagnate over the next couple of years until prices decline to match affordability and income levels rise.
ventory and high interest rates could force a correction in prices shortly, argues the report. This unsold inventory constitutes 37% of the total residential supply under construction. The investors' segment that makes up approximately 20% of the market demand has been observed to be actively offloading its real estate holdings, thereby adding significant shadow supply into these micro-markets the report elaborated.
E.Scape
A Nest for Human Beings

f you thought that only birds live in nests, then think again. Gayson Fann from California has built a giant nest for his family. His garden with the nest in the middle has now become a talk of the town. Apart from being aesthetically pleasing, the nest is also structurally sound. Fann has harvested wood from nearby forests for building the nest. Fann has used Eucalyptus tree branches that can be found in abundance in the forests of California for creating this amazing nest. He actually uses counter sunk screws with the help of which the branches are bent and then set in place. However, he is such an expert that he makes sure that the screws are invisible and everything appears as natural as possible.
A 'Floating'
Bus Stand
Inspired by Alien Spaceships
o, this is not a spaceship which has landed suddenly on Mother Earth. It is off all things a bus stand in Spain. A brainchild of Spanish Architect Eustaquio Martinez, the unconventional design of the bus stand has had visitors thronging the place, some of them just to take a look at the breathtaking, seemingly levitating structure. The fact that there are no columns that support the overhang add to the feeling that as if the top heavy part of the structure is floating in the air. Located in Santa Cruz, Tenerife in Spain, the architect has used colors carefully to blend with the surroundings.
ew York City is fast emerging as the capital of roof gardens. Everything from vegetables to even trees are being grown in a city where land is available at a premium. The city which is famous for its skyscrapers has been grappling with the issue of increasing its green cover and seems to have found a novel way of doing it. With an increasing number of buildings having roof top gardens and farms, the very meaning of the word 'farm living ' or 'farm houses' is assuming a new meaning in the 'always' city. Organic farming seems to be the order of the day as residents of the city are experimenting with a variety of greens. The rooftops of the city are now getting a greenish tinge and offer a commercial, as well as healthier alternative for the inhabitants of the buildings. According to Joe Nasr, co-author of Carrot City: Creating Places for Urban Agriculture, New York City has emerged as the undisputed capital of rooftop farms. He also expects the trend to increase more rapidly in the near future. Apart from the obvious commercial agriculture benefits, another benefit has been observed in the city due to the rooftop farms. These farms have been able to capture millions of gallons of storm water and divert them into the sewer system in a systematic manner, an avowed goal of the city's Mayor, Michael R.Bloomberg.
Want to See Greenery in New York? Just Look Up
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