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should be sent to: The Editor,
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Of all the materials consumed by mankind, perhaps concrete is one of the

Editor-in-Chief
most complex and fiercely debated subjects in modern material science. K.P. Pradeep
Reams of pages have been devoted to depict the high level of sustainability of editor@masterbuilder.co.in
concrete as a material. Examples ranging from the 2000-year-old Pantheon in Vice-Chairman
K G K Moorthy
Rome to the Burj Khalifa have been cited to prove this ubiquitous material's moorthykgk@yahoo.co.in
versatility and durable nature. While concrete as a product is extremely green, Director Editorial, Construction Chemicals
but unfortunately the manufacturing process that involves cement in the Dr. Y P Kapoor
making of the concrete, contributes greatly to the level of carbon dioxide in Editor-in-Charge
Ravi Damodaran
the atmosphere. The levels are as high as one tone of carbon dioxide rises up Editor
for every tonne of the final product. The manufacture of Portland cement Nigel Narayan
accounts for roughly 6% of all human-generated greenhouse-gas emissions. Associate Editors
M.J. Krishna, M.K. Prabhakar, Sonjay Deb
Recently, many R&D houses have been working to recommend improved Head - Content Development CE,
manufacturing methods and formulations to deal with this rising issue. Infrastructure & Environment
Sadagopan Seshadri
Cutting down on emissions would mean mastering this complex material,
Contributors
which is easier said than done. The good news though is that researchers Bhavani Balakrishna, Priya,
around the world are trying their best and the results are quite encouraging. Chaitanya Raj Goyal
The Carbon Capture and Storage (CCS) technology has recently come to Vice President Marketing
H. Usha Devi
highlight. However, concerns related to high-capital costs and long-term
Head-New Media Initiative
reliability of methods that require piping carbon dioxide emissions, remain. Pradeep Nair
Pumped storage of liquefied carbon dioxide is another area, knowledge News Desk
about which remains hazy. B. Sathya Venkatesh
Credit Controller
Perhaps the way forward lies in tweaking the recipe of concrete. A research G.B. Muralidharan
team from the University of California, Berkeley, has found out how an Finance
R. Prema
extraordinarily stable compound calciumaluminum-silicate-hydrate (C-A-S-H)
Manager Digital Production
is behind the enduring structures of the ancient Roman Empire. The research K. Sravanthi Kiran
team has arrived to the conclusion that the production of lime for Roman Manager Digital Media
concrete was much cleaner, requiring temperatures that are two-thirds of that Lakshmi
meant for making Portland cement. One of the crucial ingredients in Roman Creative Head
S. Nithiyanandam
concrete was volcanic ash. It is also amazing as to how some of these Roman
Production Manager
structures endured the harsh saltwater environment. While the earlier Caroline D'sylva
ingredients cannot be used now for the simple reason that they require more Digital Production Assistant
hardening time, research is going on in various parts of the world to find out R. Anand, Sudhir Kumar Singh
Subscription & Circulation Team
how best volcanic ash could be utilized for producing concrete, for they offer Sateesh Kuniyil, S. Sasi
an excellent alternative where fly ash is not available. Corporate Office
MB Publishers Pvt. Limited
Several other alternative recipes have emerged owing to intensive research 102/11 (New No. 46/11),
such as Slag-PC cements made from ground granulated blast furnace slag Tripti Apartments, Marshalls Road,
(GBFS), Supersulfated cements, Calcium Aluminate cements, Calcium Sulfo- Egmore, Chennai - 600 008.
Ph: 044-28555248 Telefax: 28586703.
aluminate cements, Belite Calcium Sulfoaluminate cements, and Magnesium Subscription & Circulation
Phosphate cements, among other alternatives that are doing the rounds. lakshmi@masterbuilder.co.in
Website
Finding out the alternative is only half the battle won. In making them a www.masterbuilder.co.in
commercially viable option remains the bigger challenge. There are already a Karnataka
few encouraging signs, though. A California-based company, Calera claims No.40, 2nd Floor, 7th "C" Cross, Ashwini
Layout, Koramangala, Bangalore - 560047.
to have found a carbon-negative method of cement manufacturing. Carbon Phone: 080 - 25701079 / 25705888
dioxide emissions are filtered through seawater creating a chalky carbonate Mobile: 09343833191
byproduct, which is used for mixing with aggregate and water for creating Owned and Published by
K.P. Pradeep
concrete. The method enables sequestering carbon emissions and the need 102/11 (New No. 46/11), Tripti Apartments,
to heat the ingredients, says the company. Novacem, an English cement Marshalls Road, Egmore, Chennai - 600 008.
manufacturer says that it has come out with a method using magnesium Printed By
Ashok Natarajan
silicates, which do not emit carbon dioxide during combustion. It also claims Times Printers & Publishers,
that the cement absorbs far more carbon dioxide as it hardens, further New No. 57 (29), Dr. Besant Road,
offsetting the amount generated during the manufacturing process. These Ice House, Chennai - 600 014.
are sure motivational factors for the research wings as well as the commercial Disclaimer
All rights reserved. Reproduction, stored in a
investors. The study in this line is bound to intensify considering the massive retrieval system, or transmitted in any form or
consumption of cement. by any means, electronic, mechanical,
photocopying, recording or otherwise, in
Fingers crossed. Hoping a breakthrough in cement is just round the corner. 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,
K.P. Pradeep, Editor-in-Chief neither do the publishers endorse any of the
editor@masterbuilder.co.in claims made in the advertisements.
Contents

128 Editor's Comment.........................12

Classification Index..........................18
Cement: Analysis
Indian Cement Industry in Global Perspective News & Events..................................22
Sadagopan Seshadri
Chief - Content Development, CE - Infrastructure - Environment

48 Concrete: LCA
'Rethinking Concrete': Life Cycle of the Indian Concrete Industry
138 Concrete: Rheology
A Review of Fresh Cement and Concrete Rheology
Chaitanya Raj Goyal Sonjoy Deb, B.Tech, Civil Associtate Editor

56 Sustainability
New Concrete Technology in Construction Aggregates -
148 Cements
Low Carbon Cements and Concretes in Modern Construction
Their Role in Concrete and the 'Green Agenda’ A John W Harrison, Managing Director, TecEco
Christopher Andrew Clear, British Ready-Mixed Concrete Association

68 Admixtures 172 Concrete Flooring: Densifiers

An Insight into Liquid Floor Densifiers
Chemical Admixtures for Concrete: An Overview Ankita Adhikary
Deepak Kanitkar, GM – Technology and Business Development
Chembond Chemicals Limited (Construction Chemicals Division)

180 Structural Health Monitoring

76 Admixtures for Tall Structures
Bruno D'souza, Regional Business Segment Manager, Admixtures,
Structural Health Monitoring: A Dire Need of India

Asia Pacific, BASF

80 Performances and Benefits of Concrete 188 Repair and Rehab

Use of FRP Composites for Rehabilitation of Heritage Structures
Admixtures in Concrete Durability
Philippe Ortega, Vice Technical Director, CHRYSO SAS, France

88 Waterproofing
Positive Waterproofing from Negative Side
194 FRP Composites
Recent Advances in Structural Retrofitting
Samir Surlaker, Managing Director, MC-Bauchemie Using Precured FRP Profile

98 Concrete Recycling
Concrete Recycling:The Need of the Hour 200 Formwork
Bhavani Balakrishna
Factors Affecting the Selection, Economics Involved in Formwork
Sameer S. Malvankar, Dy. Manager - Engineering, Gammon India Ltd.

108 High Performance Concrete

High Performance Concrete using Microsilica
Surendra Sharma, General Manager-Concrete. Elkem South Asia. 216 Cellular Concrete
Cellular Concrete: An Alternative for
Sustainable Design & Construction
Bhavani Balakrishna
114 Prestressed Concrete
Development of Modern Prestressed Concrete Bridges in Japan
Hiroshi Mutsuyoshi1, Nguyen Duc HAI1 and S.V.T. Janaka Perera1
1
Structural Material Lab, Department of Civil and Environmental Engineering,
Saitama University 224 Advertorial
Versatile Aluminum Formwork Systems Storm Indian Market

138 172

48 98
14 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Contents

232 Concrete: Fibres

The Use of Steel and Synthetic Fibres in Concrete under
168 Pioneering Innovative and Sustainable Products

Extreme Conditions

170
Don Wimpenny1, Wolfgang Angerer2, Tony Cooper3 and Stefan Bernard4 Leading the RMC Revolution
1
Principal Materials Engineer, Halcrow Pacific 2Senior Tunnel Engineer,
Halcrow Pacific 3Consultant Elasto Plastic Concrete 4Consultant, TSE

198 Offering a Wide Array of Construction Solutions

244 Equipment: Concrete Batching Plants

Concrete Batching Plants: Emphasis on Quality and
Variety of Concrete Drives Continual Demand
M.K. Prabhakar, Associate Editor
210 Blazing a New Trail in Formwork Systems

214 Top Notch Engineering Solutions

250 Equipment: Concrete Placement

Concrete Placing Equipment: Application Requirements
Dictate Market Trends
M.K. Prabhakar, Associate Editor
221 Pioneering Foam Concrete Technology

222 A Testimony to Top Quality and Performance

256 Equipment: Concrete Transportation

Concrete Transportation Equipment: On the Move
M.K. Prabhakar, Associate Editor
226 Greaves Rolls Out High Capacity Concrete Pumps with
S Valve Technology

262 Concrete: Block Machinery

Concrete Product Machinery: Shaping Up Well 228 Stay Ahead of the Curve Via Strategic Training and Development
M.K. Prabhakar, Associate Editor

230 Magnox ILW Interim Storage Facility, Berkeley

278 Events
Growing Opportunity in India's Construction Sector
Draws Global Attention 240 Fiber Reinforced Concrete & Its Advantages

268 Building Trust through Quality Focus

284 Construction Chemicals: Industry Analysis
The Indian Construction Chemicals Market:
Building a Sustainable Future
M.K. Prabhakar, Associate Editor
270 DURAboardHD100: Bitumen Free Joint Filler

Communication Feature
272 Crack Injection System

62 CENTRILIT NC: Concrete Additive Based on 274 Interarch's Contribution to Aviation Sector in India and Abroad
Pozzolanic Alumosilicate

276 Industrial Overhead Doors: Making the Right Choice

64 Magnox ILW Interim Storage Facility, Berkeley
Hitech Concrete Solutions Chennai: A State-of-the-art
280 Concrete Testing Center
104 Evercrete Everwood and Evercrete Top Seal:
Waterproof, Preserve and Enhance Life of Wooden Structures
299 Advanced Multipurpose Waterproofing Coatings

164 Eco-friendly AAC Block is Here to Stay 303 High Performance Liquid Membrane Series Launched

244 250
256 284
16 The Masterbuilder - July 2013 ·
www.masterbuilder.co.in
Contents

Advertisers Index / Classification

AAC and CLC Blocks-Foam making machine Nuha Construction Solutions 289 S.N. Engitech Developers Pvt. Ltd. 199
Iyantra 215 Penetron India Pvt. Ltd. 91 Structwel Designers & consultants Pvt. Ltd. 177
AAC Blocks Perma Construction Aids Pvt. Ltd. 279 Repair and Retrofitting
Brickwell 281 Pidilite Industries Ltd Front Inner Sanrachana Structural Strengthening Pvt. Ltd. 117
Citadel Eco-Build Solutions 219 Polyflex 31
Rolling Shutters
Methra Industries 165 Razon Engineering Company Private Limited 101
Adhesives and Sealants Sika India Pvt Ltd 97 Gandhi Automations Pvt Ltd 13
Dow Corning India Pvt. Ltd. 75 The Supreme Industries 45 Roofing
Wacker Chemie India Pvt Ltd. 65 Construction Machinery and Equipment Leister Technologies India Pvt. Ltd. 151
Automation Doors Action Construction Equipment Ltd. 259 Roofing Fastners
Gandhi Automations Pvt Ltd 13 Wirtgen India 33
Asons Enterprise 239
Marini India (Fayat Group) 145
Block Making Machinery Atul fastners 269
Case New Holland Construction Equipment
Columbia Pakona Engineering Pvt. Ltd. 255
(India) Pvt. Ltd. 39 Roofing Sheets
Hess Concrete Machinery India Pvt. Ltd. Gatefold
ConMechAuto Consultants India Pvt Ltd 261 Hindalco Everlast Aluminium
Sri Parijatha Machinery Works Pvt. Ltd. 265
Ammann Apollo 36 / 37 Roofing & Structurals 22 / 23
Building Materials and Products
Curing Compounds Sand Making Machine
Fabtech Sterling Building Technologies
Rotho Robert Thomas 277 Robo Silicon Pvt Ltd 125
Pvt. Ltd. Cover Page
Dry Mix Mortar Sandwich Panels
Cement Manufacturers
Kerneos Aluminate Technologies 15 Metecno India Front inner
Zuari Cement Italcementi Group 131
Events & Conferences Software for Concrete
Concrete Cutting Machine
Excon -2013 291 Tekla India Pvt Ltd 141
Prime Technologies 121
ICI-CPWD 293 Steel Fiber Reinforced Concrete
Concrete Cutting Specialist
UBM Concrete Show -2014 294 Bekaert Industries Pvt. Ltd. 29
Abcon Tech & Build Aids Pvt Ltd 289
Construction Chemicals Regional Kasturi Metal Composites(P) Ltd 227
Concrete Densifier-Lithium Silicate Conference (C3R) 295
Stewols India (P) Ltd. 279
Waltar Enterprises 175 ICI-IWC (2013) 296 / 297
Tiles-Thermal Insulation
Concrete Grinding and Polishing Solutions Big 5 Construct India -2013 298
Igloo tiles 231
Surie Polex 197 SEWC -2013 299
Techny chemie 10
World of Concrete 300
Concrete Machinery and Equipment TMT Technology Supplier/Waterproofing
Facility Services
Ajax Fiori Engineering (I) Pvt. Ltd. 163 H & K Rolling Mill Engineers Pvt. Ltd. 17 / 19
Everest Equipments Private Limited 283 Reylon Facility 272
BASF The Chemical Company 51
Greaves Cotton Limited 253 Flooring
Cera-Chem Private Limited 63
Linhoff India Pvt. Ltd 347 Bekaert Industries Pvt. Ltd. 29
Cipy Polyurethanes Pvt. Ltd. 79 Chembond Chemicals Limited Back Inner
Kyb-Conmat Pvt. Ltd 222
JB Associates 183 Cico Technologies Limited 71
Schwing Stetter (India) Pvt Ltd 35
Kasturi Metal Composites(P) Ltd 227 Contech Chemicals 289
Toshniwal Systems & Instruments Pvt. Ltd. 273
Neocrete Technologies Pvt. Ltd. 135 Fosroc Chemicals (India) Pvt. Limited 85
Universal Construction Machinery & Recron 3S 243
Equipment Ltd. 161 / 235 Max Civi Chem Private Limited 59
Silicone Concepts Intl. Pvt. Ltd. 83
MC-Bauchemie (India) Pvt. Ltd. 53
Concrete Products STA Concrete Flooring Solutions 159 / 193
Stewols India (P) Ltd. 279 Multichem Group Flap cover
Buildtech India Corporation 277
Nuha Construction Solutions 289
Concrete testing Equipment Light Weight Concrete
Penetron India Pvt. Ltd. 91
Technical & Scientific Sales(TASS) 179 Keltech Energies Ltd. 137
Perma Construction Aids Pvt. Ltd. 279
Construction Chemicals Material Handling Equipment
Pidilite Industries Ltd. Front Inner
Amit Trading Corporation 105 Maco Corporation (I) Pvt. Ltd. 281
Polyflex 31
BASF The Chemical Company 51 PEB Razon Engineering Company Private Limited 101
Cera-Chem Private Limited 63 Interarch Building Systems 9 Sika India Pvt Ltd 97
Chembond Chemicals Limited Back Inner MNF Metals and Forming Pvt. Ltd. 123 The Supreme Industries 45
Cico Technologies Limited 71
Project Management Consultancy Trade Winds 283
Contech Chemicals 289
A.N.Prakash Construction Project
Fosroc Chemicals (India) Pvt. Limited 85 Wall Putty
Managemnet Consultants Pvt.Ltd 41
Max Civi Chem Private Limited 59 JK Cement Ltd. 21
Repair & Restoration/Rehabilation-Service
MC-Bauchemie (India) Pvt. Ltd. 53 Providers Waterproofing Membrane
Multichem Group Flap Cover R & M International 185 Texsa India Ltd. 95

18 The Masterbuilder - July 2013 ·

www.masterbuilder.co.in
News & Events
CONSTRUCTION EQUIPMENT
Palfinger Marine Launches Its Marine / Offshore
Cranes at Oslo Fair
Palfinger Dreggen and Palfinger
Neddeck were unveiled at the Nor-
Shipping trade fair in Oslo for the first
time. The successful integration of
Palfinger Dreggen and Palfinger
Neddeck is contributing to the unabated
growth, a company spokes person
said. At the trade fair in Oslo, the
company was successful in positioning
itself as the leading manufacturer
worldwide of customized marine and
offshore cranes as well as launch and
recovery systems. Palfinger Marine has
plans to expand its sales network by
Manitex Rolls Out New
19 Ton 1970 C Boom Truck
Manitex has unveiled the 19 ton 1970C
boom truck mounted on a two axle 4×2
chassis. The crane is one of the highest-
capacity cranes available on a two axle
chassis. The 1970C offers a 21.3 metre
three section synchronized telescopic
boom, with optional two section exten-
sion for a 36.7 metre maximum tip
height. It also features a two speed plan-
etary hoist, full load moment indicator. It
offers greater payload potential on the
truck. “The 1970C boom truck has best
features priced reasonably and is user
friendly, “Andy Robertson director of
sales and marketing said.
20 The Masterbuilder - July 2013 · www.masterbuilder.co.in
opening new sales offices in Rio de
Janeiro, Brazil, Houston, USA and
Singapore. The company plans to
serve the strong growth markets of
South America and Asia.
French Material Handling
Equipment Major Haulotte
Opens New Subsidiary in India
With a rated lifting capacity of 85 U.S. Tons,
the new Sany SRC885 rough-terrain crane
has been added to the product line to fill
a gap in the market and meet the growing
demand for higher capacity cranes. SRC
885 delivers lifting power, pick and-carry
capability and operating stability on
virtually any jobsite, regardless of terrain,
Kyle Nape, senior vice president, Sany
America Lifting Group said. The Sany
SRC885 provides reach of up to 209.7
ft. (63.9 m) through a five-section, full-
power boom. It can achieve the rated
85-ton (77 tonne) lifting capacity at a 10-
ft. (3.05 m) radius. With an overall weight
of 115,880 lb. (52 562 kg), the Sany SRC
885 is well sized for a variety of applica-
tions while still being easy to transport.
The new SRC885 is equipped with
Cummins engine, Braden winches and
hoists, a Dana transmission and Parker
hydraulics. The SRC885 achieves
maneuverability and a smooth ride
through 4×4 hydraulic powered steering
and earthmover-style tyres.To provide
stability in adverse ground conditions,
the SRC885 rough-terrain crane features
three-position outriggers that level the
crane with up to 12.4 in. (315 mm) of
ground penetration and maximum, hori-
zontal extension of 24 ft. (7.32 m). The
275-hp (202 kN) Cummins Tier 4i engine
integrates with the hydraulic system for
precision control, and multi-function load
sharing. Hydraulic joysticks provide
smooth, variable control of crane func-
tions, and the two-speed swing system
rotates 360 degrees in either direction.
Standard operator comfort, convenience
and safety features of the SRC885 include
a spacious, ergonomic cab with all-steel
construction, hydraulic joystick controls,
optimum visibility, tinted safety glass, an
opening skylight with visor and wiper
system, a sliding door on the left side of
the cab, a framed sliding window on the
right side, acoustic foam for noise
suppression and insulation, heat and air
conditioning. A six-way adjustable seat
with mechanical suspension features
arm rests and a headrest. An in-cab
monitor prominently displays the
machine's operations and provides full-
machine diagnostic capabilities, enabling
operators and maintenance personnel
to perform onboard system checks.
Haulotte Launches Entrapment
Prevention System
France based Haulotte Group has
announced the launch of its Entrap-
ment Prevention System, ACTIV'Shield
Bar. The system is being launched in
response to demands from the industry
to protect operators from this type of
risk, and reaffirms Haulotte's commit-
ment to safe working at height. Haulotte's
system alerts the operator to potential
entrapment situations and is unique in
that it features a Safety Gap, which can
protect the operator from full entrap-
ment and potentially allow them to get
out of danger. Following the alert only
reverse/lowering movements are
permitted, allowing the possibly panicked
operator to get out of trouble without
making the situation worse. And, after
being triggered, the system is easy to
reset and reactivate from the basket
which means there is no machine down-
time. The system has been designed to
preserve the machine's working enve-
lope, maintain easy access to controls,
which means no change in working
practice for the operator
News & Events
INFRASTRUCTURE
POWER
Alstom T&D India Bags ` 200 Crore Order From Bajaj Infra
Alstom T&D India has been awarded
a contract by Bajaj Infrastructure
Development Company, to supply e-
BoP (Electrical Balance of Plant)
Package for their upcoming 3 x 660
MW Super Thermal Power Project (TPP)
in Lalitpur, Uttar Pradesh. The contract
is worth approximately 200 crore. The
Lalitpur plant will be a major power
supplier to the state of Uttar Pradesh
in northern India, which has around 200
million inhabitants. Electrical Balance
of Plant systems (eBoP) feed power
to the equipment within a power plant
to maximise availability of the power
plant's electrical system. They are
essential for efficient and stable oper-
ations. Under this contract, Alstom T&D
India is responsible for the design,
engineering, supply and installation
of the eBoP at the Lalitpur plant, which
includes supply of Station Transform-
ers, Unit Transformers and other
Electricals for the project. The equip-
ment will be manufactured at Alstom
T&D's state-of-the-art transformer
CIL to Set Up Seven New Coal
Preparation Plants on PPP
Mode This Fiscal
Coal India Ltd (CIL) has proposed to set
up seven coal washeries at an esti-
mated cost of `2, 000 crore by the end
of this fiscal. This was announced by
24 The Masterbuilder - July 2013 · www.masterbuilder.co.in
facility in Naini, Uttar Pradesh. Com-
menting on this success, Rathin Basu,
Managing Director, Alstom T&D India
said, “This is Bajaj Infrastructure's first
power project using supercritical
technology. Alstom T&D India has won
several e-BoP projects in India,
particularly in the high end segment
above 300 MW and for 600/660 MW
power plants. As of now, around 9000
MW of projects are under execution
by Alstom T&D, which highlights our
expertise and leadership within the e-
BoP segment.” The Lalitpur Super
Thermal Power Project is scheduled
to be commissioned in 2015.
T.K. Sinha, general manager (project
monitoring division). The projects will be
taken up on public-private-partnership
model with a washing capacity of 15 -16
million tonnes capacity. CIL now has 17
washeries washing around 35 million
tonnes of coal. With growing demand CIL
plans for setting up around 18 washeries
with washing capacity of 98 million tonnes,
during the 12th plan period.
PM Lays Foundation
Stone of 850 MW Ratle Hydro
Electric Power Project
The Prime Minister Dr. Manmohan Singh
along with UPA Chairperson Sonia
Gandhi laid the foundation stone of the
850 MW Ratle Hydro Electric Power
project at Kishtwar, Chougan ground of
Jammu region. The project to be devel-
oped at a cost of ` 550 crore and is
expected to be completed over the next
five years. The Prime Minister also assured
that all steps will be taken by the centre
to exploit over 14,000 MW Hydro Power
potential in the state. The centre will
supply an additional 150 MW power to
overcome the current power crisis in the
state.
Adani Power Commissions
Third 660 MW Thermal
Power Plant At Tiroda
Adani Power, a subsidiary of Adani
Enterprises, has commissioned the third
660 MW unit of its thermal power plant
at Tiroda in Maharashtra. “With the
commissioning of this 660 MW unit at
Tiroda plant in Maharashtra the total
power generation capacity of the
company reached 7,260 MW,” Adani
Power said in a statement. Adani Power
Maharashtra, a unit of Adani Power Ltd,
is constructing a 3,300 MW thermal power
plant in Tiroda, commissioned its first two
units of 660 MW in last financial year
2012-13 and has a current generation
capacity of 1,980 MW.The Tiroda project
will help Maharashtra meet its electricity
News & Events
INFRASTRUCTURE
demand. The company is targeting a
capacity of nearly 10,000 MW by March
2014 and aim to generate 20,000 MW by
2020, Gautam Adani, Chairman Adani
Group said. Adani Power now has a total
generation capacity of 7,260 MW
including 4,620 MW from the Mundra
project in Gujarat and 660 MW from
Kawai Power Plant in Rajasthan.
RAILWAYS
Railways, Karnataka Govt
to Spend ` 600 Crore on Rail
Projects This Fiscal
Karnataka government with Railways has
planned to spend ` 600 crore to take up
rail projects in the current financial year,
Union Railway Minister M Mallikarjuna
Kharge said. The centre will fund an
additional ` 300 crore to take up some
works pending for long to be completed
within ten months. The rail projects
including Kadur-Chikmagalur, Kolar-
Chikkaballapura, Gadwal-Raichur and
Bidar-Gulbarga will be taken up on priority
basis.
Banihal-Qazigund section of
Udhampur-Srinagar-
Baramullah
rail link commissioned
Qazigund-Banihal railway line was dedi-
cated to the nation by the Prime Minister
Manmohan Singh and UPA chairperson
Sonia Gandhi on June 25. This will be a
major link to connect the rest of the
country with Kashmir Valley. The trial run
30 The Masterbuilder - July 2013 · www.masterbuilder.co.in
conversion of 62 km-long narrow gauge
line to broad gauge between Dholpur
and Sarmathura. “The broad gauge line
will be extended upto Gangapur city,”
he said.
of the all-weather rail connectivity to the
Valley was commissioned after the stat-
utory inspection by the Commissioner
of Railway Safety (CRS) for running
passenger trains. This opening of the rail
link will be an alternate route to Jawahar
Tunnel the only link in winter months. The
rail link will reduce the distance between
Banihal and Qazigund from 35km to 17km.
The 18-km Banihal-Qazigund section
passing through Pir Panjal ranges has
been constructed at a cost of ` 1,691
crore.
Broad gauge line to
link holy city Nathdwara
with Mandiana
A broad gauge line will be constructed
to link the holy city Nathdwara in Rajasthan
where lakhs of pilgrims visit every year.
Nathdwara will be linked with Mandiana
that is 11 km away from the city. This was
announced by the then Railway Minister
C P Joshi. Nathdwara is famous for its
17th century Lord Krishna temple which
houses the idol of Shrinathji the seven-
year-old incarnation of Krishna. A primary
alignment has been identified to connect
the temple town, and a detailed survey
will be undertaken soon to lay the broad
gauge line. There will be a modern station
at Nathdwara town, Minister said. Joshi
has also sanctioned ` 212.23 crore for
89% of land acquired for
dedicated freight corridor
project
The Dedicated Freight Corridor
Corporation of India Ltd (DFCCIL)
has acquired 89% of the 10,667
hectare land required for the 3,326
km western and eastern corridors,
which are being developed at a
cost of ` 33,000 crore. The land
that remains to be acquired is on
the Sonnagar-Dankuni section of
the Eastern Corridor in West Bengal.
This was announced by R K Gupta,
managing director, DFCCIL. The
corporation has acquired major
portion when compared to 555
hectares in 2010. The exclusive
freight corridor project envisages
1,801-km Ludhiana-Dankuni section
on the Eastern segment and 1,525-
km Delhi-JNPT stretch (Mumbai)
on the Western corridor. The corri-
dors are being developed with help
from World Bank and Japan Inter-
national Cooperation Agency (JICA).
The department is planning to
ensure delivery in time and haulage
of over dimensional cargo once the
corridor becomes operational. Civil
and track work has started on both
the Western and Eastern Corridors.
On the multi modal logistics facility
front, plans are for freight consolida-
tion centre, auto park cum loading
facility, industrial centre for process
industry, ancillary services such as
customs bonded warehousing and
cold storage, among others.
News & Events
INFRASTRUCTURE
ROADS
Cabinet Eases Norms for Expansion of Highways
The cabinet has allowed expanding
highways up to 100 km without envi-
ronmental clearance and widening
by an additional 40 metres based on
the recommendations on the
Kasturirangan Committee. Earlier
environmental approval was not
required for road expansion up to 30
km and widening up to 20 metres.
The Cabinet has also cleared the
proposal to exempt from environment
clearance mining of soil in an area up
to 2 hectares for laying the foundation
IL&FS Transportation and East
Nippon Expressway Join Forces
to Take Up Road Projects
IL&FS Transportation Networks Limited
has signed a Memorandum of Under-
standing (MoU) with East Nippon
Expressway Company Limited to work
together through a strategic alliance for
Implementation of PPP road projects.
The alliance aims at utilizing Japanese
technology and funds to carry out tech-
nical and prefeasibility studies, and other
related works of potential road projects
in India for implementation. Mr. K Ramchand,
Managing Director on behalf of ITNL
and Mr. Hiroshi Hirose, President &
CEO was the signatory on behalf of the
NEXCO in the presence of Mr. Ravi
Parthasarathy, Chairman IL&FS group.
Mr. Hirose and Mr. Ravi Parthasarathy
stated that this MoU was an extension
of the increasing industry level partner-
ship being promoted by the two coun-
tries.
32 The Masterbuilder - July 2013 · www.masterbuilder.co.in
for roads. More than projects worth `
50,000 crore were put on hold earlier
due to environment clearance made
mandatory for mining common soil.
Innovative Materials and
Techniques to Be Adopted In
National Highway Projects
The Ministry of Road Transport and
Highways have decided to use new
materials and techniques in National
Highway projects in the country on an
experimental basis, in order to promote
innovation and use of new technology in
highway construction. In this regard, it has
been decided to adopt innovative, new
materials on at least one km stretch in
widening and strengthening projects.
The promoter of these new materials
shall be required to bear the extra cost
involved in the proposal. Being the
experimental projects, failure if any of the
trial reach, would not be treated as the
responsibility of the Implementing and
Executing Agencies. This endeavour of
the Ministry would result in saving natural
resources like stone aggregates and
bitumen. This may also result in saving
in life cycle cost of road construction as
compared to road construction using
conventional materials. The time frame
on construction will significantly come
down on using latest equipments. The
new materials will be tested under Indian
conditions, traffic, rainfall, drainage, soil
conditions etc. before being put to use.
Agra Lucknow Expressway
Project to Be Completed Before
December 2016
In order to meet the deadline of
December 2016, a green strip of over ten
meters width will be developed on both
sides along the 270 kilometer Agra-
Lucknow expressway soon. This was
announced by Uttar Pradesh Chief
Secretary Jawed Usmani. The six-lane
expressway covers seven cities Agra,
Firozabad, Etawah, Mainpuri, Kannuaj,
Hardoi and Lucknow and is constructed
at a cost of ` 9,500 crore rupees. Chief
Secretary has asked the officials to design
the expressway to connect the outskirts
of the cities.
PORTS & DAMS
Gujarat Maritime Board to
Develop Maritime Cluster
Gujarat Maritime Board (GMB) has plans
to develop a maritime cluster and two
port cities similar to that available in
Singapore and Dubai. This was
announced by A K Ramesh, Vice
News & Events
INFRASTRUCTURE
Chairman and Chief Executive of the
board. GMB will develop a port city at
Mundra in Kutch district while Gujarat
Industrial Development Corporation
(GIDC), a state-run body for attracting
industrial investments, will build a second
one at Pipavav. The port city planned in
Mundra will be spread over 250-500 sq.
km, and the one at Pipavav will be smaller
at 100-150 sq. km. The government plans
to develop the cities in phases to emerge
as independent economic hubs when
developed.
Container Freight Station
Commissioned At Pipavav Port
The Central Warehousing Corporation
(CWC) has commissioned its 38th
Container Freight Station (CFS) at Pipavav
Port on June 24, 2013. The facility was
inaugurated by Shri R. L. Meena, Com-
missioner of Customs, Jamnagar in
presence of Shri T. K. Doshi, Director
(M&CP), CWC, CO, New Delhi. M/s Nirma
Limited brought first consignment of
Export and M/s HMT brought first
consignment of Import at the CFS.The
total area of CFS is 22706 sq m with
covered area of 6600 sq m and open
paved yard of 10000 sq m to facilitate
cargo storage and Impex Container
34 The Masterbuilder - July 2013 · www.masterbuilder.co.in
storage and handling. The CFS is
equipped with all modern handling
equipments.
JNPT to Set Up a Marine
Terminal at a cost of ` 2000 Crore
Jawaharlal Nehru Port Trust has
proposed to invest ` 2,000 crore to set
up a marine terminal mainly catering to
liquid cargoes like oil, acids and cleaning
compounds. L&T Ramboll is designing
and doing the project management
consultancy and have submitted the
draft Detailed Project Report (DPR) for
the marine terminal to enhance the
quantity to 30 million tonnes per annum.
At present, there is a twin berth liquid
cargo terminal of BPCL and IOC with a
capacity of 5.5 million tonnes per annum.
JNPT has also appointed URS Scott
Wilson and Howe as consultants to carry
out a feasibility study and to prepare DPR
for setting up a mega container terminal
near Nhava Island. JNPT currently
handles 44 per cent of the country's
container cargo. The fiscal ending March
2013 saw cargo handled by the 12 major
ports to 545 million tonnes, from 561
million tonnes in 2011-12.
India to Develop Multi- Purpose
Container Terminals
at Port Of Chabahar, Iran
India's biggest state-owned ports,
Kandla port and Jawaharlal Nehru port
have proposed to develop multi-
purpose container terminals at
Chabahar port in south-western Iran.
India has proposed to invest $100
million to develop Chabahar port to
boost exports to Afghanistan and offer
Iran easy access to the Indian Ocean.
India, Iran and Afghanistan have an
agreement on preferential treatment
and low tariffs for goods moved through
Chabahar port, which also has a free
trade and industrial zone in its vicinity. A
delegation led by shipping secretary
Pradeep Kumar Sinha visited Chabahar
port and had put up the proposal for the
project. The current move is also seen
as a strategy to counter China's recent
takeover of the deep-sea port at
Gwadar in south western Pakistan,
which is some 72 nautical miles away
from Chabahar. On approval this will be
the first overseas investment by any of
the 12 ports controlled by the Indian
government. The investment in Chabahar
is expected to be routed through a
company in which Kandla and JN ports,
which operate as trusts in India, would
hold equity stakes.
URBAN INFRASTRUCTURE
HUDCO to Provide ` 3000 Crore
Soft Loan for Uttarakhand
Rehabilitation
Housing & Urban Development Corpo-
ration Ltd. (HUDCO) has been instructed
to provide long term soft loans of ` 3000
crore for 20 years duration for construc-
tion of houses and for reconstruction of
Infrastructure facilities in Uttarakhand,
Shri D.S. Negi, Officer on Special Duty
(JNNURM & RAY) said. The Ministry for
Housing & Urban Poverty Alleviation will
help in planning, designing and recon-
struction of devastated houses by
deputing a technical team drawn from
 INFRASTRUCTURE
HUDCO, Building Material and Tech-
nology Promotion Council (BMTPC),
Hindustan Prefab Limited (HPL). The
government will cover all affected
Municipalities / Notified Area Councils in
Uttarakhand under Rajiv Awas Yojana
(RAY) as a special case to support
reconstruction of houses of the poor
and reconstruct and redevelop these
devastated houses. Ministry of Housing
and Urban Poverty Alleviation has
contributed ` 1.25 crore for rehabilita-
tion/ reconstruction works for the flood
and landslide victims as part of CSR
initiative.
Union Cabinet Approves
` 23,136 Crore Mumbai
Metro Line-3 Corridor
The Union Cabinet approved the
Mumbai Metro Line-3 Colaba-Bandra-
Santacruz Electronics Export Processing
Zone (Colaba-Bandra-SEEPZ) corridor.
It has further approved the conversion
of the existing State level Special Purpose
Vehicle (SPV) Mumbai Metro Rail
Corporation (MMRC) into a Joint Venture
Company of the Government of India
(GoI) and Government of Maharashtra
(GoM), with equity participation on 50:50
basis. The total completion cost of the
38 The Masterbuilder - July 2013 · www.masterbuilder.co.in
project is estimated at ` 23, 136 crore
covering a total length of 33.5 km (fully
underground). The gauge would be
standard gauge, as per the Detailed
Project Report (DPR). The project of the
Mumbai Line 3 is scheduled to be
completed in six years that is by March,
2019 from the date of start of work in the
financial year 2013-14. The existing state
level SPV for implementing the project,
namely, the MMRC shall be converted
into a joint ownership (50:50) SPV of GoI
and GoM on similar pattern as for the
Delhi Metro, Bangalore Metro, Chennai
Metro and Kochi Metro. The joint owner-
ship company will continue to be named
as MMRC. The promoters, the GoI and
the GoM, shall nominate five Directors
each to the Board of Directors of the SPV,
which shall have 10 nominee Directors.
The Secretary, Ministry of Urban Devel-
opment, GoI will be the ex-officio
Chairman of the Board. The implemen-
tation of the project would provide much
needed additional transport infrastruc-
ture to Mumbai.
Lucknow Metro Phase 1 to
Begin by Year-End
The construction work of Lucknow Metro
Phase 1will commence by this year end
with the state cabinet giving its nod for
the project. The decision was taken after
a meeting chaired by chief minister
Akhilesh Yadav and headed by the Chief
Secretary. The first phase will cover 23-
km stretch from Amausi airport to
Munshipulia and will have 21 stations.
The North-South corridor will have three
underground stations while remaining
18 will be built on elevated platforms.
The cost of the project is expected to be
around 7,000-8,000 crore rupees. Offi-
cials said, the project would largely be
funded by external financing agencies
and the remaining cost would be shared
between the Central and state govern-
ments in 50:50 ratio.
PM Sets ` 115,000 Crore
PPP Investment Target
Prime Minister Manmohan Singh
has set an investment target of `
1.15 lakh crore in PPP (public
private partnership private part-
nership) projects across infra-
structure sectors in rail, port and
power in the next six months. This
was announced at the meeting
convened with key infrastructure
ministries. Prime Minister
proposed taking up of Mumbai
elevated rail corridor at a cost of `
30,000 crore, two international
airports in Bhubaneswar and
Imphal at a cost of Rs 20,000 crore
and power and Transmission
projects at a cost of ` 40,000 crore.
There is a proposal to set up a rail
tariff authority. Finance Minister P
Chidambaram, Planning Commis-
sion Deputy Chairman Montek
Singh Ahluwalia and Ministers of
Power, Coal, Railways, Roads, Ship-
ping and Civil Aviation were present
at the meeting to finalise infra-
structure projects for 2013-14.
News & Events
POLICY
Road Ministry Proposes Stringent Rules to Make Highways Safe
The Ministry of Roadways has
proposed to bring in slew of changes
on toll rules to protect the interest of
the customers and make highways
safe. To discourage overloading of
vehicles the Ministry has planned to
increase the penalty by three or four
times apart from unloading the extra
weight. The Ministry plans to bring
transporter or transport agent into the
net by also penalizing them. Now it
has been made mandatory that that
all concessionaires building roads on
PPP must have weight-in-motion
Draft National Water
Framework Bill Released
The Ministry of Water Resources has
released Draft National Water Framework
Bill, Draft River Basin Management Bill
and Draft National Policy Guidelines
prepared by the Ministry of Water
Resources. The department has released
the bill for getting comments on Water
Sharing, Distribution amongst states,
union territories and related ministries
through expert committees. The same
has also been uploaded on the minis-
try's website http://wrmin.nic.in. All the
stakeholders can send their sugges-
tions or comments by July 31, 2013 on
nps-2012-mowr@nic.in
UP Announces 'Industrial
Services Guarantee Act'
The Uttar Pradesh government has
announced introduction of 'Uttar Pradesh
40 The Masterbuilder - July 2013 · www.masterbuilder.co.in
bridges to detect such violations. There
is also a proposal to charge truckers
and their owners involved in damaging
public property.
Industrial Services Guarantee Act' an
exclusive law to ensure issuance and
clearances to industries in a stipulated
time. The policy to be drafted by the Udyog
Bandhu will envisage provisions for
delivering notified services within the
specified time frame limits and fixing
accountability of licensing authorities
and erring officers for the delay by
imposing a penalty. In the first phase
industries, power, pollution departments,
labour and factories will be included
under the proposed act.
Union Government Proposes
To Launch NULM Scheme
The Ministry of Housing and Urban
Poverty Alleviation has proposed to
launch a “National Urban Livelihoods
Mission (NULM)” in 12th Five Year Plan,
which will replace the existing Swarna
Jayanti Shahari Rozgar Yojana
(SJSRY).NULM would focus on the
primary issues pertaining to urban
poverty such as imparting skill training,
enabling entrepreneurship develop-
ment, providing wage employment and
self-employment opportunities to the
urban poor. The proposal of NULM is at
approval stage. The annual targets under
NULM will be fixed after final approval
as per budget allocation for its imple-
mentation.
Chennai Corporation to install
bio-methanation plants
to power street lights
The Chennai Corporation has proposed
to install small bio-methanation plants
that will power lights. The civic body has
identified Villivakkam slaughterhouse to
set up two plants and one more at the
garbage transfer station in Royapuram
zone. The pilot project is expected to be
set up in three months. The bio-
methanation plants will be fuelled with
vegetable and food waste and will emit
methane. The gas will be captured and
used to generate power. The by-product,
slurry, can be used as manure.
News & Events
REALTY
Delhi Government Likely To Allow High-Rise Buildings
The Delhi government is mulling over
the proposal for vertical growth in the
city and has plans to review the
Master Plan of Delhi 2021 and finalise
on a number of amendments, including
allowing high-rises and increasing
the existing floor area ratio (FAR).
Delhi government has sought centre's
assistance to develop high-rise building
across the state. Delhi Urban Devel-
opment Minister Arvinder Singh Lovely
said, “Basic services like drainage,
water supply and power distribution
network will have to be strengthened
if vertical expansion is allowed.”
Optimum usage of land resource for
vertical growth will address the problem
of shortage of housing sector, Minister
said. The Delhi Development Authority
approved the land pooling policy that
Real Estate Regulatory
Bill to Be Introduced
This Monsoon Session
The real estate regulatory bill will be
introduced in the monsoon session of
Parliament, a top government official said.
The bill is expected to bring transparency
and accountability in the realty sector.
The Real Estate (Regulation and Devel-
opment) Bill was approved by the cabinet
to provide a uniform regulatory environ-
ment to the sector.
42 The Masterbuilder - July 2013 · www.masterbuilder.co.in
permits developers or land owners to
pool in land for constructing residen-
tial blocks.
Karnataka Government
Plans To Regularise
Unauthorised Construction
Karnataka government has proposed
to introduce an amendment to the
Karnataka Land Revenue Act 1964 to
regularise unauthorised constructions
of dwelling houses in government lands
in urban areas, official sources said.
Karnataka Land Revenue (Second
Amendment) Bill, 2012 that was passed
in both the Houses of the Legislature in
the earlier regime was returned by the
Governor H.R Bhardwaj citing that the
Bill may lead to illegal grabbing of
government land.
Punjab Government to
Regularize 5,000 Unauthorised
Colonies across the State
The Punjab cabinet has given approval
for regularization of about 5,000 un-
authorised colonies in the State. Two lakh
individual plot or building owners' across
the state will benefit, an official spokes-
man said. Basic civic amenities will be
provided for the residents of the un-
authorised colonies. The regularization
scheme will be applicable to those unap-
proved colonies constructed before April
1, 2013 and will be for a period of one
year. The residents have to pay compo-
sition fee varying from ` 2.5 lakh to ` 15
lakh for an acre. Each individual must
pay ` 50 to ` 500 a square yard for regu-
larization which will be used to provide
basic facilities. The policy does not
cover colonies, which are set up over
land belonging to the State, Central
Governments, Public Undertakings,
Panchayat lands, Waqf Board, Land
under the Punjab Land Preservation Act
(PLPA). The Cabinet also gave the nod
to the amendment in the Land Pooling
Policy to enable the land owners to
become partners in the development
process. Under the amendment, a fixed
sum of the value of land would be ensured
to the land owners.
News & Events
INTERNATIONAL
bauma Africa maiden international fair at Johannesburg
from 18 -21 September
The first bauma Africa, International
Trade Fair for Construction Machin-
ery, Building Material Machines, Mining
Machines and Construction Vehicles,
is scheduled to take place at Johan-
nesburg from 18 to 21 September this
year. The event will take place at
Gallagher Convention Centre and the
organizers Highline Tours & Travel
expect over 500 exhibitors on 60 000
sq m of exhibition space. Emerging
Africa market as well as South Africa's
status as the gateway into Africa, that
led to the first bauma Africa event,”
says MMI South Africa CEO Elaine
Free trade agreement between
China and Switzerland
to boost trade
China has signed its first free trade accord
with Switzerland a non-EU member of
Iceland in Beijing amid escalating
tensions with the European Union. China's
commerce minister Gao Hucheng and
Swiss Economy Minister Johann
Schneider-Ammann signed the bilateral
agreement in Beijing. The agreement is
expected to boost trade between the
two economies. China is targeting the
EU wine industry in retaliation for a
dispute with the European Union over
cheap Chinese solar panels.
US to unveil $7 billion plan to
upgrade African power networks
US President Barack Obama will be
unveiling a $7 billion plan to upgrade
44 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Crewe. The event will house nine
country pavilions for 200 of the key
international exhibitors from Austria,
China, Finland, Germany, Great Britain,
Italy, Korea, Northern Ireland and Spain.
African power networks and ensure
power supply to two-thirds of the popu-
lation that is without electricity. America
will focus on projects in Ethiopia, Ghana,
Kenya, Liberia, Nigeria and Tanzania
which will be built by Power Africa. The
President of America will make an
announcement during his visit to Cape
Town. US Export-Import Bank will fund
major amount of $5 billion for develop-
ment of power projects. According to
the International Energy Agency, sub-
Saharan Africa will need investment of
more than $300 billion to achieve
universal electricity access by 2030.
Geodynamics commissions
1MW geothermal pilot
plant in Australia
Tata Power announced the successful
commissioning of a 1MW geothermal
pilot plant in Australia, by Geodynamics,
an associate of Tata Power. Geodynamics
is the industry leader in enhanced
geothermal system (EGS). Geodynamics
has geothermal exploration interests in
three Australian states, and holds the
license to explore 2,000 sq km of the
Cooper Basin. Geodynamics tenements
in the Cooper Basin contain the hottest
granites on earth and are estimated to
provide a thermal resource equivalent
of 50 billion barrels of oil. Tata Power
intends to have a 20-25 percent contri-
bution from "clean power sources", which
will include a mix of hydro, solar, wind,
geothermal and waste gas generation.
Geothermal energy has been a key focus
area for the company outside India. Tata
Power is the only Indian player in geo-
thermal energy sector and is also imple-
menting a 250MW geothermal project
in Indonesia in partnership with Origin
Energy and PT Supraco. The company
has invested in geothermal energy both
conventional and EGS in Geodynamics,
an Australia-based geothermal energy
company, in 2008. Speaking on Tata
Power's commitment to clean and green
energy Anil Sardana, Managing Direc-
tor, Tata Power, stated, “The commis-
sioning of the 1MW geothermal pilot plant
is a significant milestone for the project
and with this we plan to strengthen our
footprint in the international markets. We
are committed to reducing our carbon
footprint through clean and renewable
energy generation. Our aim is to have
20-25 percent of our generation port-
folio from clean energy.” Geothermal
energy is the natural heat found within
the earth, where temperature increases
with depth, typically by 10-50 degree
Celsius/km. In EGS technology, heat is
extracted from granites located at a
depth of a more than 4,000m by circu-
lating water through them in an engi-
neered artificial reservoir. The heated
water returns to the surface under pres-
sure and is converted into electricity via
a heat exchanger and conventional
geothermal power plant. EGS technology
can potentially enable the setting up of
base load power plants that are based
on natural heat, thereby making them a
clean energy source for the future.
 Concrete: LCA
'RETHINKING CONCRETE':
Life Cycle of the Indian Concrete Industry
Chaitanya Raj Goyal
L
ife cycle assessment (LCA) is
today's sustainability buzzword,
and the industry is filled with lively
debate about its impact. As many rat-
ing systems like LEED, etc. find their
place in the movement, increasing em-
phasis is placed upon the importance
of examining all aspects of a structure.
These include not just the building itself,
but the embodied energy of materials,
the long-term effects of manufacturing
processes, the stages of construction,
building performance and operations,
durability and maintenance of existing
structures, and in the end - demolition,
materials recycling, and future land use
corollary.
48 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Even though, 80% of a building's
CO2 emissions are generated not by
the production of materials used in its
construction, but in the electric utilities
over its life-cycle, one building material,
which just cannot be ignored is Cement
Concrete and neither can one overlook
a developing nation which is producing
more than 300 million cubic meter of it
per annum!
Indian Cement Concrete Industry: Cur-
rent times
Concrete witnesses a production of
10 billion tons each year worldwide.
The total concrete market in India is esti-
mated at 300-350 million cubic meters
per annum, of which the commercial
plant produced share is 55-65 million
cubic meters. Industry players esti-
mate that this share is expected to go
up gradually from the present level of
less than 9% of the total cement pro-
duction to the global average of 70-
75%. A comparison of concrete pro-
duction figures from different countries
also reveals that the organized Indian
concrete industry is the third largest
concrete industry in the world.
This industry occupies an impor-
tant place in the Indian economy
because of its strong linkages to sec-
tors such as construction, transporta-
tion, coal and power. The growth of Indian
 Concrete: LCA

cement industry also substantiates the

growth of country's concrete sector.
India is the second largest producer
of quality cement in the world, and its
cement industry comprises 183 large
cement plants and over 365 mini cement
plants. Currently, there are 40 players
across the country and the industry is
expected to add 30-40 million tonnes
per annum (MTPA) of capacity in 2013
from the existing capacity of 324 MTPA,
operating at 75-80 per cent utilization.
Therefore, in view of the growth that
the concrete sector in India is undergo-
ing, and the large share it claims in
international concrete industry, it is
imperative that industry leaders realize
their accountability towards global
sustainability concerns and improve
their focus on life cycle of concrete man-
ufactured and used in India. Cement Production accounts for nearly 7% of global greenhouse gas emissions

Production: How does concrete fit in
the big picture?
Stepped on for hundreds of years,
concrete rarely gets the respect it de-
serves. Perhaps the most omnipresent
building material, its manufacturing is
also among the most energy-consuming
and polluting industrial processes and
analysts expect greenhouse gas emis-
sions from global concrete production
to become a considerable contributor
to climate change in the next 20 years.
Even though concrete compares
favorably to other building materials
such as steel, wood and asphalt while
analyzing energy consumption and CO2
emissions but when it comes to sus-
tainable development, there is always
an opportunity for improvement and
this is especially applicable in case of
India. For a variety of reasons, the con-
crete construction industry is not sus-
tainable; the three prime reasons
being:
1. Resource productivity this indus-
try is the largest consumer of virgin
materials such as sand, gravel, crushed
rock, and fresh water. It is consuming
Portland and modified Portland ce-
ments at an annual rate of more than a
billion metric tons. The cement produc-
tion in turn consumes vast amounts of
limestone and clay.
Obviously, large amounts of energy
and materials, in addition to financial
resources, are wasted when structures
deteriorate or fail prematurely which, in
fact, has been the case with some re-
cently built reinforced concrete bridges,
buildings and other structures in India.
2. Cement manufacturing - The prin-
cipal binder in concrete is Portland
cement, the production of which is a
major contributor to greenhouse gas
emissions. The popular Portland cement
Water
Cement
Gravel
Recycling as gravel
replacement
Concrete
granules
Landfill
Dismantling
Life Cycle of Concrete (Source: BMG Engineering)
mixes a powder of alumina, silica, lime,
iron oxide, and magnesium oxide, which
is then heated at temperatures up to
1,450 degrees Celsius.
Heating and grinding the cement
materials consumes an average of 4-5
gigajoules of energy per cement ton.
The industry as a whole uses billions of
gigajoules each year. Cement produc-
tion-through cement plant's fossil-
based energy consumption, the CO2
burned off when limestone is heated,
Concrete
additive
Ready-mix
concrete
Building
construction =
processing
Lifetime of
building

www.masterbuilder.co.in · The Masterbuilder - July 2013 49

 Concrete: LCA
associated vehicle use, and other fac-
tors account for nearly 7% of global
anthropogenic greenhouse gas emis-
sions. Other parts of the manufacturing
process such as operating mining
equipment for extracting the raw mate-
rials and transportation of the raw mate-
rials to the cement plant emit relatively
small amounts of CO2.
3. Durability - Many concrete struc-
tures suffer from lack of durability,
which has an adverse effect on the
resource productivity of the industry. In
India, most concrete is produced by
conventional methods instead of using
latest methods and equipment at most
of the construction sites and these re-
sults in:
- Inadequate control on aggregates
for size, shape and grading
- Optimum Water-cement ratio not
followed
- Labor-intensive production
- Time consuming and unorganized
operation
- Wastage of costly input materials
- Dust pollution
Each of these shortcoming's results
into a life cycle implication in some
form and they take a major toll on the
Cement - 5 mm
Silica Fume - 5 mm
Many mineral admixtures can be used to partially replace cement in concrete
50 The Masterbuilder - July 2013 · www.masterbuilder.co.in
durability of concrete. Prevalent cor-
ruption and unethical practices in the
Indian construction industry also con-
tribute immensely to this cause.
Benefits of Concrete: Time to capitalize
Concrete also brings numerous
lasting benefits that many believe far
outweigh the front-end energy prob-
lems associated with it. This is because
locally available materials for produc-
tion mean less transportation and pol-
lution, and it also offers high thermal
mass, contributing to energy efficiency
and comfort. Most concrete structures
today are designed for a 100-year life
span which increases the period bet-
ween reconstruction, repair and main-
tenance.
Also, the material's light color can
provide reflectivity that reduces air con-
ditioning loads and helps reduce the
urban heat island effect. Moreover, when
a concrete structure is demolished,
much of the material can be recycled.
Furthermore, a significant portion of
the CO2 produced during manufactur-
ing of cement is reabsorbed into con-
crete during the product life cycle
through a process called carbonation.
One research study estimates that bet-
Fly Ash - 12 mm
Ultra-Fine Fly Ash - 5 mm
ween 33% and 57% of the CO2 emitted
from calcination will be reabsorbed
through carbonation of concrete sur-
faces over a 100-year life cycle.
Despite all such benefits, the indus-
try in India is still struggling to capitalize
on the inherent and researched bene-
fits of this amazing material and as dis-
cussed before, even though concrete
is an environmentally friendly choice
with one of the lowest carbon footprints
among building materials, there is always
scope for growth when it comes to con-
serving the environment and prevent-
ing adverse climatic changes!
From production to demolition: Doing
it better
A sustainable concrete structure is
one that is constructed so that the total
societal impact during its entire life
cycle is minimal and therefore, the life-
cycle cost analysis process must eval-
uate energy use and environmental im-
pact during the entire life of concrete.
This process must include extracting
and processing raw materials, manu-
facturing, transporting, maintaining, re-
cycling, and returning to the environ-
ment. Costs and benefits must be eval-
uated and understood in both the short
term and the long term.
It does not take a genius to under-
stand that a large-scale mechanization
for production of engineered concrete
with mineral and chemical admixtures,
with the right quality control scheme,
can lead to better sustainability of con-
crete in India. There are some worthy
solutions which if comprehensively, stric-
tly, skillfully and ethically implemented,
can help the industry actually 'do it
better'!
Industrial ecology - achieving impro-
vement in resource productivity through
durability enhancement of products is,
of course, a long-term solution for sus-
tainable development. A short-term
strategy that must be pursued simulta-
neously is to practice industrial ecol-
ogy at a larger scale than is the case
today. Simply defined, the practice of
industrial ecology by a manufacturing
industry involves the reclamation and
 Concrete: LCA
re-use of its own waste products and,
to the extent possible, the waste prod-
ucts of other industries, which are unable
to recycle them in their own manufac-
turing process.
Reportedly, over a billion ton of con-
struction and demolition waste is gen-
erated every year. Cost-effective tech-
nologies are available to recycle most
of the waste as a partial replacement
for the coarse aggregate in fresh con-
crete mixtures. Similarly, industrial waste
waters and non-potable waters can
substitute for municipal water for mix-
ing concrete unless proven harmful by
testing. Blended Portland cements con-
taining fly ash from coal-fired power
plants, silica fumes, and ground-gra-
nulated slag from the blast-furnace iron
industry provide excellent examples of
industrial ecology because they offer a
holistic solution for reducing the envi-
ronmental impact of several industries.
The construction industry already
uses concrete mixtures containing
cement replacement materials, such
as 15% to 30% fly ash or 30% to 40%
slag by mass. With conventional mate-
RMC can deliver high quality, durable and green concrete
52 The Masterbuilder - July 2013 · www.masterbuilder.co.in
rials and technology; it is now possible
to produce high-performance concrete
mixtures containing 50% to 60% fly ash
by mass of the blended cementitious
material.
Also, the cement industry can re-
duce its own waste by recycling more
than 75 percent of cement kiln dust
(CKD) directly back into the cement kiln
as raw material. By doing so, manufac-
turers can conserve energy and reduce
the use of limestone and other virgin
raw materials.
P2P Initiative (Prescriptive to Per-
formance Specifications for Concrete)-
although the use of modern plant and
equipment in the production, delivery
and placement of concrete has in-
creased in India, this has not matched
improvement in the concrete specifica-
tions. On a majority of the construction
jobs, concrete is still specified by its 28-
day compressive strength and slump
at pour location. A mention is also made
regarding the use of pump or otherwise
during placement. Other mechanical
properties of concrete, namely, flexural
strength, tensile strength, modulus of
elasticity, shrinkage, creep, etc. are hardly
specified.
It must be realized that today con-
crete is no longer a mere mixture of
cement, aggregates and water. Now-a-
days, concrete produced from ready-
mixed concrete facility incorporates
more than one variety of mineral and
chemical admixtures and with their use
the designing of concrete mixes has
become more complex. This is because
the use of different admixtures affects
most of the properties of concrete in its
fresh and hardened states, such as
workability and workability retention,
compatibility between cement and
superplasticizer, compressive strength
development, later age strengths, set-
ting time, resistance to ingress of
aggressive chemicals, etc.
Therefore, it is difficult to write pre-
scriptive specifications that encom-
pass these developments. Further, in
recent years, it has been observed that
many structures constructed strictly
following prescriptive specifications
have necessarily not performed well,
especially with regards to their durabil-
 Concrete: LCA
ity. There is thus an urgent need to for a
change in specifications from prescrip-
tive to performance.
Performance specifications pro-
vide concrete producers more flexibil-
ity to optimize concrete mixtures for in-
tended performance and thus reduce
the environmental impact, including
CO2 emissions. Traditionally, construc-
tion specifications for concrete have
required unnecessarily high quantities
of Portland cement along with other lim-
its on the use of supplementary ce-
mentitious materials. These limits are
incorporated in the industry's stan-
dards and specifications. The P2P Ini-
tiative proposes to eliminate many of
these limits and evolve to performance-
based standards.
Adopting Ready Mix Concrete - it
wouldn't be wrong to say that quality
and durability always take the back
seat in Indian construction industry
along with eco friendly and ethical prac-
tices. This is substantiated by the fact
that in India, the captive consumption
of cement through RMC is just hover-
ing around 7-8% of the total cement
With RMC one can achieve almost 15.5% savings in construction costs
54 The Masterbuilder - July 2013 · www.masterbuilder.co.in
produced. The capacity utilizations are
in the range of just 30-45%, indicating
severe underutilization; the operating
margins are in the range of 4-6% and
the ROCE for most cement companies
in RMC business is negative.
All this is probably because the cost
of RMC is 20% higher than that pro-
duced at site by mixing machines and
12% higher than that produced at site
by large Batching Plants. But what
many fail to understand is that with RMC
one can achieve almost 15.5% savings
in construction costs in terms of factors
such as quality & wastage-avoidance
and the claimed service life of 100
years can actually be established.
Furthermore, even though there is a
separate code on ready-mixed con-
crete (IS 4926:2003), it is unfortunate
that cognizance of this code is not taken
in many contracts. Even when using
RMC, on many occasions, reference is
made to only IS 456, the BIS specifica-
tion on plain and reinforced concrete.
The quality control process in IS
4926:2003 has been divided into three
components, “forward Control”, “Im-
mediate Control” and “Retrospective
Control' and therefore, prepares Indian
RMC manufacturers for producing and
supplying best quality green and dura-
ble concrete using a variety of mineral
and chemical admixtures.
Conclusion
Material science has a lot of poten-
tial to revolutionize the technological
scenario in various walks of life towards
cost-effectiveness and quality impro-
vement. Today Concrete technology is
revolutionized globally, but India has to
yet to catch up with the advancements.
The key is in the hands of professionals
and builders and one need to use the
key to reach and avail the treasure of
durability.
To achieve the objective of incorpo-
rating sustainability will be a herculean
task. To start with, reasonably accurate
data is required, which is woefully lack-
ing and reliable information on rudi-
mentary data like the total concrete pro-
duction is difficult to obtain. The cement
industry also needs to play a critical role
in helping attain the desired targets.
Indian cement manufacturers need
to improve the energy efficiency of the
entire manufacturing process by
upgrading plants with state-of-the-art
equipment and should improve prod-
uct formulation to reduce energy of pro-
duction and minimize the use of natural
resources. Also, more research needs
to be conducted on cement and con-
crete towards improving their energy
efficiency and durability.
It is to be expected that rating sys-
tems such as the LEED (Leadership in
Energy and Environmental Design) sys-
tem and ECBC (Energy Conservation
Building Code) will become the norm in
near future, and material suppliers such
as concrete producers will be pressed
to compete on the basis of environ-
mentally friendly principles, that is,
reduced energy consumption, reduced
life-cycle costs, and the use of recycled
materials. There is reason to believe
that the concrete industry is well posi-
tioned for success, given the tools out-
lined herein.
 Sustainability

New Concrete Technology in

Construction Aggregates - Their Role in
Concrete and the ‘Green Agenda’
Christopher Andrew Clear
British Ready-Mixed Concrete Association

Sustainability of construction works is such an important topic that it should not be discussed by rather imprecise and emotive
terms such as ‘The Green Agenda’. Therefore this paper deals with the sustainability assessment of building with respect to their
environmental, social and economic performance before briefly covering how concrete and its aggregate constituent play a part in
sustainable construction.

For a concrete technologist the term ‘Green Agenda’ is a rather in the client’s brief or in the regulations as illustrated in Figure
more difficult concept to understand than either ‘Aggregates’ 1, abstracted from EN 15643-1.
or ‘Concrete’. Having said this it is the authors opinion there is
EN 15643 Part 1 is the general framework, and Parts 2[2], 3[3]
a degree of ambiguity associated with all three terms. This
and 4[4] the individual frameworks for environmental, social
paper sets out what ought to be considered important to
and economic performance respectively. All four parts contain
consider with respect to sustainable construction and a brief
a version of Figure 1, and in their draft stages the ‘Environmental’
consideration of how aggregates and concrete support such
box was coloured green, the ‘Social’ box coloured red and the
an initiative.
‘Economic’ box coloured blue. The use of colour in what might
The Green Agenda otherwise be considered rather dull documents such as
standards is to be applauded, however it is unfortunate that in
A problem with the green agenda is that it is often not presented this case it reinforces the misconception that ‘The Green Agenda’
as a list of important environmental, social and economic is concerned only with Environmental issues, whereas it
considerations but as a banner around which those affected should encompass Social and Economic issues as well.
by some form of change to their environment gather to resist
the change. In Figure 1 the boxes within the thick red dashed box are
those covered by the European Technical Committee entitled
However, with respect to building construction the position ‘Sustainability of construction works’, CEN/TC 350. As the
is changing as a comprehensive technical description of the EN 15643 standards state when describing the integrated
green agenda is being set out across a set of International and building performance at the concept level, the environmental,
European Standards. EN 15643-1[1] entitled ‘Sustainability of social and economic performance are one part, and the
construction works — Sustainability assessment of buildings technical and functional performance are another. Both parts
— Part 1: General framework’. This European Standard forms are intrinsically related to each other as shown in Figure 2,
part of a suite of the European Standards that set out a system
for the sustainability assessment of buildings using a life cycle
approach. The sustainability assessment is quantified to
assess the environmental, social and economic performance
of buildings using quantitative and qualitative indicators but
benchmarks or levels of performance are not set. It should be
noted that currently it is only buildings that are covered by the
EN 15643-1 framework, but there are proposals for standards
to cover the sustainability assessment of civil engineering and
other construction works.

In carrying out assessments, scenarios and a functional

equivalent are determined at the building level. This level means
that the descriptive model of the building with the major
technical and functional requirements has to be been defined Figure 1: EN 15643 concept of sustainability assessment of buildings

56 The Masterbuilder - July 2013 • www.masterbuilder.co.in


where the CEN/TC 350 work programme is represented by
the boxes shaded grey as set out in EN 15643-1.
Sustainability assessments can be undertaken for the whole
building, for parts of the building which can be used separately,
or for elements of the building. This is in a complete contrast to
some simplified interpretations of the ‘Green Agenda’ which
may largely restrict consideration to just the environmental
impacts of the various building products from which the building
is made.
Figure 2: Work programme of European Technical Committee CEN/TC 350
Sustainability of construction works
Although the evaluation of technical and functional performance
is beyond the scope of CEN/TC350 standards, the technical
and functional characteristics are considered by reference
to the functional equivalent. The functional equivalent of a
building or an assembled system (part of works) shall include,
but is not limited to, information on:
- Building type (e.g. office, factory, school)
- Pattern of use (e.g. occupancy)
- Relevant technical and functional requirements (e.g.
regulatory framework and client’s specific requirements);
- required service life
There is an explicit requirement that the assessments shall be
established on the basis of specified realistic scenarios that
represent the whole building life cycle.
To ensure the results of the assessment of environmental,
social and economic performance can be readily understood
they need to be presented in a systematic and transparent
method, where Figure 3 shows the groups of information
required.
The standard EN 15643-1 makes it explicitly clear that tin the
assessment report the results shall be expressed with all the
defined indicators set out in EN 15643-2 for Environmental
performance, EN 15643-3 for Social performance and EN
Sustainability
15643-4 for Economic performance. The indicators included
in EN 15643 Parts 2 to 4 are summarized in Table 1. It should
be noted that the items in the middle column come from a
pre-Standard dated 2010, and the final lists within EN 15643
parts 2 and 4 changed significantly from the equivalent listings
in their pre-Standards.
Figure 3: The organisation of the result of the assessment in accordance with
EN 15643-1 life-cycle stages and the information groups
Table 1 is not a complete list as and EN 15643-2 includes a
list of further environmental indicators, and these are listed in
Table 2.
The detailed calculation method for the environmental
performance of buildings using the environmental indicators
set out in EN 15643-2, is set out in EN 159785 entitled
‘Sustainability of construction works — Assessment of the
environmental performance of buildings — Calculation
method.’ This standard sets out a methodology on how to
calculate and most importantly how to display the modular
information for the different stages of building assessment.
Figure 4 shows the general format for the output where for
each stage A1, A2, A3, B1… there will be a number required
for each of the environmental impacts as listed in column 1 of
Table 1, and those in Table 2 where appropriate. The natural
extension is to list the social and economic impacts as well but
the Standards for these have yet to be drafted. It is important
to remember that the eventual Table of results is for the whole
building for its whole life, so a scenario has to be developed to
cover the construction, use and end of life stages.
On the specific challenge with respect to Global Warming
Potential impact (measured by CO2 equivalent) the concrete
options to meet the demand for low-energy housing specific
research was commissioned and reported6. Figure 5 shows an
example of the results where the cumulative CO2 emissions,
embodied and operational, have been modelled for a 60 year
period for both lightweight (timber) and medium weight (block
work walls) simple semi-detached house. Due to predicted
increase in summer temperatures resulting from climate change,
the lightweight house needs air conditioning by 2021, whereas
for a medium weight home it would not be needed until 2041.
www.masterbuilder.co.in • The Masterbuilder - July 2013 57
 Sustainability

Environmental indicators EN 15643-2: 2011 Categories for social aspects prEN 15643: Economic Indicators EN 15643: 2012
Annex B.1 (informative) 2010 Annex C (informative)
environmental impacts (LCIA impact categories) Health and comfort Cost
- abiotic depletion potential - Thermal performance - economic performance expressed in cost terms
(elements and fossil fuels) - Humidity over the life-cycle Financial value
- acidification of land and water resources - Quality of water for use in buildings - economic performance expressed in terms of
- destruction of the stratospheric ozone layer - Indoor air quality financial value over the lifecycle
- eutrophication — formation of ground-level - Acoustic performance
ozone - Visual comfort
- global warming potential Accessibility
resource use (environmental aspects) - Accessibility for people with specific needs
- use of non-renewable primary energy excluding Maintenance
non-renewable primary energy resources used - Maintenance requirement
as raw materials Safety/security
- use of renewable primary energy excluding - Resistance to climate change
renewable primary energy resources used as raw - Fire safety
materials - Security against intruders and vandalism
- use of non-renewable primary energy resources - Security against interruptions of utility supply
used as raw materials Loadings on the neighbourhood
- use of renewable primary energy resources used - Noise
as raw materials - Emissions
- use of secondary materials - Glare
- use of non-renewable secondary fuels - Shock/vibrations
- use of renewable secondary fuels
- use of freshwater resources
other environmental information (environmen-
tal aspects)
- components for reuse
- materials for recycling
- materials for energy recovery
- non-hazardous waste to disposal
- hazardous waste to disposal (other than radioac-
tive waste)
- radioactive waste to disposal
- exported energy
Table 1. Indicators listed in EN 15643-2 for Environmental performance, prEN 15643-3 for Social performance and EN 15643-4 for Economic performance

Further Environmental indicators EN 15643-2: 2011 Annex B.2 (informative)
environmental impacts (LCIA impact categories)
— biodiversity
— ecotoxicity
— human toxicity
— land use change
resource use (environmental aspects)
— use of non-renewable resources other than primary energy
— use of renewable resources other than primary energy
other environmental information (environmental aspects)
— use of environmentally sustainably managed materials (grouped per ma-
terial type e.g. PEFC, FSC, responsibly sourced materials BS 8902:2009)
— use of environmentally sustainably managed fuels (grouped per fuel
type e.g. Sustainability criteria for bio-fuels ISO 13065)
Table 2. Further indicators listed in EN 15643-2 for Environmental performance
A typical concrete and masonry house with a medium level
of thermal mass has about 4% more embodied CO2 than a
lightweight house, but this could be offset in as little as 11
years due to energy savings provided by its thermal mass.
The simple semi-detached house is the sort of scenario
required for the EN 15978 analysis, but for a complete EN
15978 analysis then a further 20 environmental impacts should
be considered in addition to the single Global Warming
Potential shown in Figure 5. The EN 15978 standard is clear that
the communication of results may be limited to a selection of
indicators, and so the use of a single indicator is within scope
and the standards notes that the graphical representation
of results like that shown in Figure 5 may be useful to com-
municate results. It is also evident that trying to carry out an
assessment to encompass all or even just a majority of the
indicators may be an overly cumbersome exercise and so a
client may wish to restrict the range to those considered of
greatest importance.
What the EN 15643 series of standards clear state is that the
‘The results of possible further aggregation of these indicators
shall be clearly separated from the assessment results as
additional information’. This is an important facet as it is
evident that where environmental indicators are normalised
and/or weighted it is possible to present the assessment
results in a way that appears to represent the just the bias

58 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Sustainability
of those responsible for the manipulation system. Figure 6
below shows the results of a particular ‘E-points’ system as
applied to a tonne of coarse aggregate and a tonne of CEM
I (Portland cement), where the higher the E-points the less
environmentally desirable is the material.
Unfortunately, many clients want to be seen to be complying
with a green agenda and as all the tools and expertise to carry
out a comprehensive sustainability assessment are not readily
available the temptation is to go down a simplified route.
Such a simplified route, like those based on an E-points type
system, can give arguable results. For example we know that
the cement represents a global warming potential equivalent
to about 850 kg of CO2e/tonne[7], and that such emissions
considering world production of over 3,300,000,000 tonnes
of cement a year is generally considered to have a negative
impact on the environment. According to the E-point system
the extraction and use of one tonne of coarse aggregate in
concrete is about as half environmentally damaging as the
production and use of one tonne of cement, or say two
tonnes of coarse aggregate is equivalent to the environmental
impact of a tonne of cement. This cannot be sensible as a
tonne of cement will initially put about 850 kg of CO2e into
the atmosphere whilst even if the two tonnes of coarse
aggregate is used to make concrete it is still available. That is
the aggregate is still aggregate through the service life of the
building but also be an aggregate in a subsequent life where
as part of recycled concrete it is likely to be used either as an
unbound or bound aggregate application.
The important conclusion is that the term ‘Green agenda’ is
the wrong term and its use should be deprecated. Indeed
‘Green Agenda’ is often regarded as synonymous with
‘Environmentally friendly’ and even this is the wrong term. The
correct term to use is ‘Sustainability of construction works’
and until the necessary standards are developed for civil
engineering works the more appropriate term is ‘Sustainability
Figure 4: Display of modular information for the different stages of building
assessment in accordance with EN 15978: 2011
60 The Masterbuilder - July 2013 • www.masterbuilder.co.in
Figure 5: Cumulative Global Warming Potential, CO2 emissions
(air-conditioned)
assessment of buildings’ in accordance with the EN 15643
series and supporting standards.
Aggregate
There is a suspicion that as far as a large number of Engineers
are concerned aggregates for concrete are natural aggregates,
and should be in accordance with BS 882: 1992[9] entitled
‘Specification for aggregates from natural sources for concrete’.
To these engineers it may be a bit of a shock that BS 882 was
withdrawn on 1 June 2004, when it was replaced by EN 12620
‘Aggregates for Concrete’ which was first published in 2002
but was subsequently amended in 2008[10]. To the European
Standard aggregate is ‘granular material used in construction.
Aggregate may be natural, manufactured or re-cycled’ where it
is evident that the widest range of usable materials is included.
This type of standard supports sustainable construction as
it means that any suitable materials can be used to make
concrete, but it is up to the specifier to ensure that the correct
aggregate and concrete properties are specified to suit a
particular application.
In the past it may have been considered reasonable to specify
a high performance natural gravel or crushed rock for even the
lowest grades or performance concrete classes, and where
environmentally, socially and economically a high performance
natural aggregate can be justified then that is perfectly
acceptable. However, it should be equally acceptable that where
there is a technically sound but lower grade of aggregate
available to make a particular concrete then this will normally
be the more sustainable option. If nothing else it would help
preserve the resources of higher quality aggregates for more
demanding concrete performances or other applications.
Sometimes it may be possible to use Recycled Concrete
Aggregate (RCA) or Recycled Aggregate (RA) providing the
source and quality meet all the necessary limits with respect

Figure 6: E-points for coarse aggregate and CEM I showing contribution for
mineral resource extraction and climate change (Global Warming Potential)
to particular impurities and other materials that may be
deleterious to concrete performance. Recycled aggregates
are produced in conformity with the ‘Quality Protocol for
aggregates produced from inert waste’[11] where the material
produced must also conform to EN 12620. To help ensure that
aggregate for concrete is specified in the most appropriate
manner guidance is available as BSI Published Document
PD 6682-1[12] entitled ‘Aggregates – Part 1: Aggregates for
concrete – Guidance on the use of BS EN 12620.’
Concrete
The European Concrete Standard, EN 206-1[13], and its
complementary UK counterpart, BS 8500[14], are increasingly
being made more flexible, and hence supportive of sustainable
construction. The general concept will be that general suitability
is established at European level for; natural normal weight
aggregates, heavy-weight aggregates and air-cooled blast
furnace slag conforming to EN 12620 as well as lightweight
aggregates conforming to EN 13055[15] and aggregates
reclaimed by the concrete producer. In addition at National
level recycled and manufactured aggregates with an identified
history of use may be used as aggregate for concrete if the
suitability is established. In summary sustainable construction
is supported by widening the range of materials deemed
suitable for use in concrete, but the specifier may have to give
some additional consideration to ensure that the materials
specified are suitable for a particular application.
Conclusions
Sustainability is an issue of increasing importance to everyone,
and sustainable construction is of particular importance to
all those involved in the construction industry. Sustainable
construction is not well served by the use of ill-defined jingoistic
terms like ‘green-agenda’ and it use of this term should be
deprecated by the construction industry and its suppliers.
Concrete and aggregates have a role to play in sustainable
Sustainability
construction, but the sustainability assessment needs to be in
environmental, social and economic terms at the building level.
Acknowledgements
The author is grateful for all the input received from members
of the British Ready-Mixed Concrete Association as well his
colleagues and members of the Mineral Products Association.
References
1 British Standards Institution. BS EN 15643-1:2010 Sustainability of
construction works. Sustainability assessment of buildings. Part 1
General framework. BSI, London, 25 pp.
2 British Standards Institution. BS EN 15643-2:2011 Sustainability of
construction works. Sustainability assessment of buildings. Part
2 Framework for the assessment of environmental performance.
BSI, London, 32 pp.
3 British Standards Institution. BS EN 15643-3:2012 Sustainability
of construction works. Sustainability assessment of buildings.
Part 3 Framework for the assessment of social performance. BSI,
London, 25 pp.
4 British Standards Institution. BS EN 15643-4:2012 Sustainability of
construction works. Sustainability assessment of buildings. Part
4 Framework for the assessment of economic performance. BSI,
London, 36 pp.
5 British Standards Institution. BS EN 15978: 2011. Sustainability of
construction works — Assessment of the environmental performance
of buildings — Calculation method. BSI, London, 60 pp.
6 HACKER, J. ET AL. Embodied and operational carbon dioxide
emissions from housing: A case study on the effect of thermal
mass and climate change. Energy and Buildings 40. 2008.
7 Mineral Products Association, Cementitious Slag Makers
Association, UK Quality Ash Association. Fact Sheet 18. Embodied
CO2e of UK cement, additions and cementitious material.
Camberley, Undated but published 2012. 8 pp.
8 World Business Council for Sustainable Development. Cement
Sustainability Initiative Progress Report, June 2012. Geneva. 6 pp.
9 British Standards Institution. BS 882: 1992. Specification for
aggregates from natural sources for concrete. BSI, London, 14 pp.
10 British Standards Institution. BS EN 12620: 2002+A1:2008.
Aggregates for concrete. BSI, London. 56 pp.
11 Waste Resources Action Plan. Quality protocol for the production
of aggregates from inert waste, September 2005. 12 pp.
12 British Standards Institution. PD 6682-1: 2009 Aggregates – Part 1:
Aggregates for concrete – Guidance on the use of BS EN 12620.
BSI London, 28 pp.
13 British Standards Institution. EN 206-1:2000. Concrete — Part 1:
Specification, performance, production and conformity. March
2006. BSI, London. 69 pp.
14 British Standards Institution. BS 8500: 2006+A1: 2012. Concrete
— Complementary British Standard to BS EN 206-1 – Part 1:
Method for specifying and guidance for the specifier. Part 2
Specification for constituent materials and concrete. BSI, London.
59 & 44 pp.
15 British Standards Institution. BS EN 13055-1: 2002. Lightweight
aggregates — Part 1: Lightweight aggregates for concrete mortar
and grout BSI, London. 40 pp.
www.masterbuilder.co.in • The Masterbuilder - July 2013 61
 Communication Feature
CENTRILIT NC: Concrete Additive Based on
Pozzolanic Alumosilicate
C
entrilit NC (nano-crystallizer) is
a pozzolanic concrete additive
based on amorphous alumo-
silicate. It concerns a synthetically man-
ufactured material, not an industrial by-
product. Apart from a high uniformity, a
long-term availability is also ensured.
New generation materials like Centrilit
NC based on special nano-crystallizers
have been recently developed. These
new materials improve the properties
that are crucial for the durability of high-
performance concrete. In addition to
reducing chloride migration, an excep-
tional chemical and acid resistance of
the high-performance concrete can be
achieved with Centrilit NC. The concrete
structure is simultaneously reinforced
right down to Nano scale, density is
improved and compressive and flexural
strength as well as abrasion resistance
of the high-performance concrete is in-
creased.
The unique properties of Centrilit
NC can be utilised in all areas of ready-
made and pre-cast concrete produc-
tion that need high durability, e.g.: pre-
cast concrete, HPC in the energy,
wastewater and chemical industry. Due
to high homogeneity and reduced
tackiness compared with Microsilica-
based concrete, workability is improved
significantly. In many instances, this even
enables the production of high-perfor-
mance concrete that can be pumped. A
distinct improvement of the building
structure's aesthetics is gained due to
the fair appearance of the concrete sur-
face. Centrilit NC performs over the
Centrilit NC: Available Forms
62 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Strength Development of Centrilit NC
Control Mix
Microsilica
Centrilit NC
some of the disadvantages of Other
Superfine Pozzolans:
- Graded for dispersion in concrete
- Graded particle size
- Optimizes mixing time within con-
crete
- Good dispersion reduces unreacted
material in the mix and increase's
passivation by C-S-H gel on aggre-
gate surface
- Reduces risk of Alkali Silica Reac-
tion by Agglomeration of alumino-
silicate particles
General Advantages of using Centrilit
NC in Concrete
- Increased compressive and flex-
ural strengths
- Reduced permeability (including
chloride permeability), Increased
resistance to chemical attack and
hence increased durability
- Reduced potential for efflorescence,
which occurs when calcium is trans-
ported by water to the surface where
it combines with carbon dioxide
from the atmosphere to make cal-
cium carbonate, which precipitates
on the surface as a white residue
+ 30%
+ 33%
28 days
1 day
- Reduced effects of alkali-silica reac-
tivity (ASR)
- Enhanced workability, Better pum-
pability and finishing of concrete
- Reduced shrinkage in concrete,
due to "particle packing" making con-
crete denser
- Improved color by lightening the
color of concrete making it possible
to tint lighter integral color
- Endless quantities as it is a Factory
made Homogenous product
- Reduced dosage of super plasticizer
MC-Bauchemie (India) Pvt. Ltd.
manufactures this product along with a
host of other Construction Chemicals in
technical and financial collaboration
with MC-Bauchemie, Germany. MC-
Bauchemie (India) Pvt. Ltd. isan ISO
9001:2008 certified Company.
For further details:
MC – Bauchemie (India) Pvt. Ltd.
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
 Communication Feature
Magnox ILW Interim Storage Facility, Berkeley
T
he Intermediate Level Waste (ILW)
Interim Storage Facility (ISF) at the
site of the former Berkeley Nuclear
Power Station is one of six new highly-
engineered industrial grade Magnox
facilities to provide protection for duc-
tile cast iron ILW containers until the
eventual geological disposal facility is
available for permanent disposal. The
purpose of the ISFs is to keep the ILW
containers in a secure and controlled
environment for up to 150 years. Sto-
rage of ILW through ISFs is part of a
new and innovative Magnox approach
whereby ILW is stored in robust self-
shielding transportable containers, min-
imizing the need for shielding within the
building structure, and thus significantly
reducing decommissioning costs and
timeframes.
The Design
The six ISFs are of varying size, and
a scalable design has been developed
to accommodate the varying number of
ILW containers and stacking arrange-
ments at each site. The design aims to
minimise maintenance and maximise
low-energy passive measures to pro-
vide the required storage environment,
while also including active environmen-
tal monitoring and control measure.
Selection of design features:
- A long-life, galvanised steel frame
and insulated aluminium standing
seam roofing and cladding system.
- A curved overhanging eaves and
no rainwater gutters reduce mainte-
nance and potential sources of leaks.
Tekla BIMsight Model
64 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Magnox Project
- An electric overhead crane used to
move the containers.
- Prefabricated reinforcement edge
beams, wall panels and roll out mats
used to speed up the construction
of the 400 tonnes of reinforcement.
Interoperability with Revit model
On this project, the structural engi-
neer's model was imported using the
industry-standard open IFC format (In-
dustry Foundation Class) into Tekla
Structures and used this as a base to
produce the cast in-situ reinforced con-
crete details. The reinforcement model
was then exported into Tekla BIMsight
to overlay with the engineer's model
and issued to Arup for checking and
problem solving alongside the draw-
ings and schedules provided.
Tekla BIMsight Model
Avoiding clashes with existing piled
foundations
The framing contractor, Cara Con-
struction, requested for detailed pre-
fabricated cages where possible, which
could be manufactured off-site and sig-
nificantly speed up the construction pro-
cess. This would generally be a relatively
straightforward task, but on Berkeley
was made more complicated by the re-
use of existing piled foundations, which
had been installed in some cases up to
300mm off a regular grid. The Arup
model containing the surveyed pilecap
positions was referenced into our Tekla
model, and we were able to accurately
detail around these to ensure there would
be no clashes once the cages reached
the site. A new colour coded drawing
system was utilised to help with the fab-
rication of the reinforcement cages and
placement of rebar.
For further details:
Tekla India Pvt. Ltd.
Unit no: 112–115, Building no-2, Sector-1,
MBP, Mahape, Navi Mumbai-400710.
Ph: +91-22 61387777,
E-mail: info.india@tekla.com
Web: www.tekla.com
 Admixtures
Chemical Admixtures for Concrete:
An Overview
Deepak Kanitkar
GM – Technology and Business Development
Chembond Chemicals Limited (Construction Chemicals Division)
Use of Chemical Admixtures in Concrete
One of the most important and critical ingredient of modern
concrete is the chemical admixture. The introduction of
admixtures have changed the way we can work with the
cement concrete. As the Power’s Equation states, Vp=100w/
c-36.15 . The Porosity of concrete is inversely proportional
to W/B ratio. The first and most important role of chemical
admixtures is to reduce the water : binder ratio.
Specifications and Test Methods
IS 9103, ASTM C-494, ASTM C 1017, BS 5075 (withdrawn)
and BS EN 934 part 1, 2, 6 with supporting test methods
are commonly used, for classifying and testing chemical
admixtures for concrete. There are different classes of
admixtures, based on their effect on concrete properties.
ASTM standard C-494 classifies admixtures in 8 types from
A to G and S. Apart from reducing the mixing water, chemical
admixtures have various functions such as slump retention,
set retardation or acceleration, strength acceleration and
more. Each type needs to meet different criteria, specified in test
specifications. Moreover, there are other types like air entraining
admixtures as per ASTM C-260, integral water proofing
admixtures meeting the water impermeability requirements as
per DIN 1048, anti- wash out admixtures, corrosion inhibitors,
shrinkage reducing admixtures, foaming agents, corrosion
inhibiting admixtures and shotcrete accelerators.
Polycarboxylate Ether Based Admixtures
Chemical admixtures are based on various chemistries.
Water reduction greatly depends on the type of chemistry a
formulator uses, to design the admixture. As we know, the best
water reduction is achieved using PCE based admixtures.
This is a result of very efficient dispersion of the binder which
PCEs offer. The effectiveness of PCEs is more evident when
the W/B ratio goes below 0.35. The versatile chemistry of PCE
polymers, ensures their use in almost every Admixtures mix
design. SCC has been mostly associated with PCE based
admixtures. Along with the excellent water reduction, they also
68 The Masterbuilder - July 2013 • www.masterbuilder.co.in
produce flowing concrete without segregation. In a properly
designed SCC mix using a PCE based admixture, there is
either no need for VMAs or their usage could be limited. Now
a days modified PCE based admixtures are available which
also offer good rheology control. One of the challenges in
earlier PCEs was the increased stickiness of the concrete mix,
now there are some molecules which offer excellent reduction
in stickiness. This is often necessary while designing very high
strength mixes which have a tight water cement ratio and
high fines. There are other issues associated with PCEs such
as, rapid loss of slump, dosage and temperature sensitivity,
sensitivity to moisture content. Due to such factors concrete
producers generally avoid the use of PCE based admixtures
in lower strength mix designs. Modified PCEs are useful in
meeting the requirements of lower strength mixes. Often,
due to use of manufactured sand or stone dust, there are
issues with regard to slump retention or segregation, these
need to be addressed by smart formulations of blended PCE
molecules.
Shrinkage Reducing Admixtures
As described earlier apart from the traditional use as water
reducing agents and slump retainers, admixtures are
nowadays used for more functional roles. Shrinkage reducing
admixtures is an example. These are very effective in reducing
cracks caused due to drying and autogenous shrinkage, also
known as selfdesiccation. They act on very fine capillaries
with diameters between 2.5 to 50 nm in diameter, by reducing
surface tension within pore solution. This helps in preventing
collapse of capillary walls, thereby reducing cracking. Their
use in heavy duty industrial floors, enables increased the
spans and reduction in the requirement for number of joints.
SRAs are mainly based on Ethylene and Propylene Glycol
derivatives. While using SRAs, one must consider their effect
on final compressive strength and air entrainment. In general,
at same W/B ratio, 10-15% reduction in final compressive
strengths, have been observed. It is imperative that by
adjusting the W/B ratio, one can actually maintain the desired
compressive strengths.

The shrinkage could to some extent be determined from an
equation derived by Tomita et al
- (sh) = 390 + 2.89W - 21.77X-4.758E (x10-6)
- Where W, X and E corresponds to unit contents 3 (kg/m )
of water, SRA and expansive additives respectively.
- This suggests that SRA are more than 4 times as effective
than the expansive additives or the effective dosage of
SRAs is only 20-25% that of the expansive additives.
Corrosion Inhibiting Admixtures
Preventing or rather delaying corrosion of steel in concrete is
achieved by at least three methods. Use of corrosion inhibiting
concrete admixtures, CP systems and protective covering or
penetrative treatments. The most important factors are chloride
ingress and carbonation, apart from sulphates and other
corrosive contaminants. CIAs are mainly based on inorganic
chemicals such calcium Nitrate / Nitrite or bipolar acting agents
based on amino alcohols and Amino polycarboxylates. Various
products are available in the market and are in most of the
cases equally effective. The mechanisms are different, so as
the dosages.
Internal Curing Agents
Use of Internal curing agents for concrete are also gathering
momentum. They act by providing additional moisture in concrete
for a more effective hydration of the cement and reduced
selfdesiccation. Internal curing means the introduction of a
curing agent into concrete to provides this additional moisture.
Two major methods currently available.
- Use of saturated porous lightweight aggregate (LWA) in
order to supply an internal source of water.
- Super-absorbent polymer (SAP) particles can absorb a
very large quantity of water during concrete mixing and
form large inclusions containing free water, thus preventing
self-desiccation during cement hydration.
For optimum performance, the internal curing agent should
possess high water absorption capacity and high water desorption
rates.
Ingredients
Cement Strength Grade Type
Fine Agregates Zone or Gradation Shape
Maximum Size and Shape / Crushing
Coarse Aggregates
Gradation method
Admixtures Type Chemistry
Mineralogy
Pozolanic additions / Chemical Particle size
Composition
Ingredients and their important properties
Admixtures
Admixtures For Sprayed Concrete or Shotcrete
Most tunneling work will never be complete without the use of
gunniting or the sprayed concrete. Spraying concrete is a very
sensitive application. The nozzlemens’ job will not be easy
without the use of an accelerating admixture. Typically, quick
setting is as critical as controlling the reheology of sprayed
concrete. Accelerators combine both these requirement, thus
reducing the rebound to a great extent and achieving quick
setting.
There are more and more applications which could be discussed.
Admixtures for making pervious concrete, colorants for decorative
concrete, admixtures used for stopping the rejected concrete
from setting for a period as long as 24hrs are available.
Concrete Mix Proportioning – Science and Art What is
mix design?
Concrete proportioning or designing of a concrete mix, is an
art more than science. Although it involves a lot of statistics
and material science, more depends on the actual feel of the
concrete during the mixing and placing stages.
In general concrete mix has 4 main constituents viz. cementitious
materials, aggregates, water and chemical admixtures.
More precisely, concrete consists of coarse aggregates which
are bound by a mortar made of a paste of hydraulic binders
mixed with fine aggregates.
Mix proportioning involves, physical formulation of these
ingredients to achieve certain properties. Main criteria remains
that of mechanical properties but without achieving the fresh
concrete performance, mechanical properties can never really
be attained.
In order to achieve the desired level of workability and a
cohesiveness concrete mix, the gradation as well as granularity
of both coarse and fine aggregates, cement content, water to
binder ratio and use of a suitable chemical admixture, play a
vital role.
While doing this, apart from getting the desired performance,
one has to also remember economy and properties of available
resources, including water.
Properties
Fineness Alkalinity - -
Absorption Reactivity Density Mineralogy
Absorption Reactivity Density Mineralogy
Dosage - - -
Dosage - - -
www.masterbuilder.co.in • The Masterbuilder - July 2013 69
 Admixtures
Air in concrete is also a critical factor. Controlling the amount
of air in the mix can to a certain extent be controlled during
mix designing stage. There are two classes of concrete
viz normal (Non Air Entrained) concrete and air entrained
concrete. The amount of allowed air varies considerably in
both types. Air entrainment is achieved through the use of air
entraining admixtures. More recently, it is also known that Self
Compacting Concrete (SCC) requires a different approach,
than these two types.
Essentials of a Mix Design
Following are typically the most important factors, which need
to be taken into account while deciding the mix proportions.
- Characteristic Strength
- Air content
- Workability requirements
- Climatic conditions / exposure conditions.
- Handling conditions / Automation
- Durability
- Economy
- Aesthetics and appearance
We will take a look on, how some of the above factors help in
arriving at a desired mix proportion.
1. Characteristic strength: Compressive strength of a mix
is typically the most important mechanical characteristic.
Once we know the strength requirements, it becomes
simple to select the grade of cement, water content or W/B
ratio as well as fine aggregate content. It is well known that
reducing the W/B ratio, directly increases the compressive
strength.
2. Air Content: Air in concrete is not always desirable. In non
airentrained concrete it is desirable to have an air content
less than 1 % more than the control mix or a maximum
2.5% by its volume. A little air helps in getting better slump
and finishing of the concrete. As the air content increases,
it starts decreasing the strength and simultaneously
increase the permeability. We need to take this air into
consideration, as the density and yield depend on the
percentage of air in the mix.
3. Workability: It is the ability of fresh concrete which allows the
placement and finishing at a particular point after mixing.
The slump as it is called is measured using a slump cone
at mixing point and at the point and time of placement.
Depending on the actual application and placement
technique, the value of slump can vary between almost
zero for a pavement grade roller compacted concrete to
a flowable consistency for the SCC. Apart from this point
measure, the slump or workability may be required to be
retained, up to a certain period of time. So, the required
workability at a given time needs to be considered, while
designing a mix.
70 The Masterbuilder - July 2013 • www.masterbuilder.co.in
4. Climatic conditions and Exposure: Whether the concreting
is taking place in winter or summer matters a lot. It is also
imperative to understand the variations during the day
and nights. Under water placement, needs anti washout
admixtures and set accelerators.
We have to also consider the exposure conditions. If there
is a chance of moderate to heavy exposure to sulphates,
one needs to consider the use of sulphate resistant
cement or pozolanic additions such as fumed silica. in
case of chloride based environment, use of corrosion
inhibitors based on calcium nitrite or bipolar types, may be
necessary. Industrial environment, may necessitate use of
hydrophobic agents / corrosion inhibitor, along with low
permeability mixes.
5. Handling conditions / Automation: Whether the concrete
is hand placed, pumped, roller compacted or placed in
moulds at a precast facility, will mean a different approach
to the mix design. Each method has different requirement
of consistency, viscosity and slump retention.
6. Durability: Air entrained concrete in Freeze – Thaw zones,
use of pozolans in marine environment, low permeability
concrete in areas with heavy rain fall, use of internal curing
agents or Shrinkage Reducing Admixtures in concretes
prone to self- desiccation, are some of the examples,
how the durability needs to be accounted at mix design
stage.
7. Economy: The skill of a concrete technologist is in
designing the best mix which meets optimum performance
requirements within the allowable economy / cost. Low
cost resources such as sand and gravel, need to be
taken from the closest possible quarry. Major contribution
to the cost of these materials, comes from freight and
handling. Adjustment in gradation of these aggregates
and minimizing the cement content will automatically
result, in good economy of the mix.
8. Aesthetics and Appearance: Whether you require a plain
finish or a texture, coloured concrete or a stamped finish,
all such factors need to be considered during finalizing the
mix design.
Effect of ingredients on Properties of Concrete Cement
Grade of cement decides maximum achievable compressive
strength of a mix. Type of cement generally decides exposure
conditions as well as water demand and compatibility with
admixtures.
Fineness of cement is important to decide water demand,
initial workability, setting time as well as retention of slump.
Alkalinity is responsible for both short term and long term
performance parameters.
IS Codes : 12269, 456, 8112
ASTM codes : C-150
 Admixtures

Fine Aggregates Pozolanic Materials

Fineness modulus and gradation of sand plays an important Use of pozolanic materials has now become common. Both
part in deciding the workability and cohesiveness of concrete separate additions as well as blended cements are available.
mixes. Shape determines the flow, segregation and bleed Microsilica (Fumed Silica), Fly ash, Slag, Meta Kaolin, Risk
characteristics. Absorption value determines the amount of Husk Ash are predominant. Various specifications and test
water needed for adjustment after deciding free water content. methods are used to determine the quality of these materials.
IS Codes : IS 3812
Reactivity if any mainly with alkali needs to be mitigated using
proper means such as pozolans, Lithium Silicates etc. Density ASTM codes : C-1240, C-311, C-441, C-618, C-989
which is generally determined by mineralogy affects yield. There are different approaches to concrete mix design. We are
showing a typical example of M-30 grade concrete, designed
Coarse Aggregates
as per guidelines from IS 10262 : 2009. Here we have used
Size of aggregates decides the amount of mortar required KEM SUPLAST 128 UT which SNF based Concrete Super
to coat all coarse aggregates. It also decides the maximum plasticizer conforming to ASTM C-494 type G and IS 9103.
thickness up to which the concrete can be cast. Heavy density
aggregates are generally used in radiation shielding concrete. Mix Design Calculations as per IS 10262:2009 Stipulation
The shape and size of aggregates is also critical in achieving for Proportioning
desired workability and cohesiveness. Coarse aggregates can Grade of concrete 30
have round, angular, or irregular shape. Rounded aggregates Type of Cement OPC
because of lower surface area will have lowest water demand Type of mineral admixture Fly Ash
and also have lowest mortar/paste requirement. Hence they Maximum nominal Size
will result in most economical mixes for concrete grades up of aggregate 20mm
to M35. However, for concrete grades of M40 and above Minimum cement content 320Kg/cum
the possibility of bond failure will tilt the balance in favour Maximum water- cement ratio 0.45
of angular aggregate with more surface area. Flaky and Type of exposure Severe
elongated coarse aggregate particles not only increase the Method of concrete placing Pumping
water demand but also increase the tendency of segregation. Degree of Quality Control Very Good
Flakiness and elongation also reduce the flexural strength of Type of aggregate Crushed
concrete. Maximum cement(OPC) content 450Kg/cum
IS Codes : IS 383 Chemical admixture type Superplasticizers
Chemical Admixture brand KEM SUPLAST128 UT
ASTM Codes : C 33
Test Data for Material
Admixtures
A) Cement
Admixtures play a very important role in today’s concrete
industry. Faced with a lot of environment, space and resource a) Cement brand used U/T OPC
constraints and add to that the challenges of the modern day b) Specific Gravity of Cement 3.15
structural requirements and design diversities, no concrete B) Fly Ash
today can really be considered without the use of chemical
a) Fly ash brand used Dirk
admixtures. We are having a detailed discussion on this topic
b) Specific Gravity of Fly Ash 2.15
at the end of this article.
C) Water
IS Codes : IS 9103
ASTM Codes : C-494, C-1017, C-260 a) Source Local

Sieve Size % Passing 50 50 % Passing Specification as per IS 383

10 mm 20 mm 10 mm 20 mm Combined 100% 10 mm 20 mm
40 mm 100.00 100.00 50.00 50.00 100.00 100 100
20 mm 100.00 89.60 50.00 44.80 94.80 100 85-100
10 mm 85.40 0.25 42.70 0.13 42.83 85-100 0-20
4.75 mm 0.00 0.00 0.00 0.00 0.00 0-20 0-5
2.36 mm 0.00 0.00 0.00 0.00 0.00 0-5 -

72 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Admixtures

IS Sieve % Passing Individual Combination Combine % Lower Limit Upper Limit

R.Sand C.Sand 30 70
4.75 100.00 92.70 30.00 64.89 94.89 90 100
2.36 83.60 72.20 25.08 50.54 75.62 60 95
1.18 52.40 51.60 13.14 36.12 49.26 30 70
0.6 35.60 40.20 4.68 28.14 32.81 15 34
0.3 22.90 20.40 1.07 14.28 15.35 5 20
0.15 12.80 6.40 0.14 4.48 4.61 0 10
Pan 0.00 0.00 0.00 0.00 0 0 0
F.M= 3.17 Zone= ZoneI

D) Admixture On trial experience base adopted water- cement ratio for this
mix design is 0.42
a) Type & brand Kemsuplast 128UT
b) Specific Gravity of Admixture 1.24 0.42 < 0.45 Hence OK
c) % of dosage 1.2% Selection of Water content
E) Coarse Aggregate
From table 5 of IS 456, maximum water content
a)Source Local Source for 20m – 50 mm slump
b) Specific Gravity (SSD) 20mm 2.80 for 20 mm MSA =186Kg/cum
c) Specific Gravity (SSD) 10mm 2.78 Estimated water content
d) Combine Sp. Gr. 2.79
for 120 mm slump =208Kg/cum
e) Water absorption % 20mm 0.0%
10mm 0.0% Since use of superplastisizer
f) Free surface moisture 20mm 0.0% will reduce 15 – 20% of water & above on trial with present
10mm 0 . 0 % superplastisizer water reduction achieved is 17% So the
water content I =173Kg/cum
Coarse aggregate Sieve Analysis
F) Fine Aggregate Calculation of Cement content in design mix

River Sand Water-cement ratio =0.42

water content =173Kg/cum
a) Source of River sand Local Source Total Cementitious content will be =410Kg/cum
b) Specific Gravity of River Sand 2.65 As per IS 456 minimum
c) Water absorption 0.0% cementitious content is =320Kg/cum
d) Free moisture 0.0% 410Kg/cum > 320Kg/cum Hence OK
Crushed Sand Total cement (OPC) content =308Kg/cum
Fly Ash content % by weight
a) Source of Crushed sand Local Source
of cement @ 25% =103Kg/cum
b) Specific Gravity of
Crushed Sand 2.68 C.A % F.A% Specifications
Total %
c) Water absorption 0.0% I.S. Sieve Size in
56.00% 44.00% passing Min Max
d) Free moisture 0.0%
e) Combine Sp gr of total F.A. 2.7 40 56.0 44 100.00 100 100
20 53.1 44 97.09 85 100
Combination of Fine Aggregate Fractions
10 24.0 44 67.98
Design Calculation: 4.75 0.0 41.8 41.75 30 50
Target Mean Strength 30 + 1.65 X 5 2.36 33.3 33.27
fck+1.65X SD 38.25 1.18 21.7 21.68
Selection of Water/Cement ratio 0.6 14.4 14.44 10 35
0.3 6.8 6.75
From Table 5 of IS 456, maximum water-cement ratio for M30
=0.45 0.15 2.0 2.03 0 6

www.masterbuilder.co.in • The Masterbuilder - July 2013 73

 Admixtures

Proportion of volume of coarse aggregate& fine aggregates Test Results

From table 3 of IS 10262(2009), Vol of CA corresponding to Concrete Temperature 27oC Mix Cohesive
20 mm size aggregate and FA (Zone I) for W/C ratio of 0.50 Initial Slump - Collapse
= 0.60. Slump After 60 Min - Collapse
In present case W/C ratio is 0.42 Therefore Vol of CA is required Workability Slump After 120 Min - 210 mm
to be increase to decrease the FA content as the W/C ratio is Slump After 150 Min - 180 mm
lower by 0.08 the proportion of vol of CA is increased by 0.02 Slump After 180 Min - 140 mm
So corrected vol of CA=0.62
1 /1000
For Pumping Mix this value should be reduced by 10%
=0.047cum
So Total vol of CA
=62 X 0.9 d) Volume of Admixture @ = Admixture Qty./Sp.Gr
=0.56cum x 1/1000
Total Vol of FA = 1.00 – 0.56 = 0.44 cum =0.004cum
Percentage of Fine aggregate and Coarse aggregate are e) Volume of Water =0.173
arrived after conducting sieve analysis and combined grading f) Total cementitious material
as follows + water + admixture = 0.322cum
g) Total volume of all
Percentage of C.A. To
aggregates =1-f
total aggregates =56%
Combination ratio of 20mm:10mm =50:50 % =0.678cum
Percentage of F.A. To h) Total quantity of
total aggregates =44% coarse agg. =g x Vol of CA x Sp. Gr.
Combination ratio of Of C.A x 1000
R.Sand : C.Sand =30:70 % =1062Kg/cum
Quantity of 20mm =531Kg/cum
Combination Of All Aggregates Fractions
Quantity of 10mm =531Kg/cum
Fine Aggregates % =44% I) Total quantity of Fine agg. =g x Vol of FA x sp. Gr.
Coarse Aggregates % =56% Of F.A x 1000
=793Kg/cum
Mix Calculations
Quantity of River Sand =238Kg/cum
a) Volume of Concrete = 1cum Quantity of Crushed Sand =555Kg/cum
b) Volume of Cement = Cement Qty./Sp.Gr x
1 /1000 Compressive Strength Data
= 0.098cum Age Weight Density Load Strength N/MM2
c)Volume of Fly ash = Fly Ash Qty./Sp.Gr x Days KG KG/Cum KN Strength Average %
Constituent Materials 1 8.350 2474 250 11 11 37
Material Dry wt Moist. W.A. SSD 7 8.300 2459 500 22 74
Material 22
& Source kg/M3 % % kg/M3 7 8.400 2489 510 23 76
Cemmenti- OPC 53 308 308 28 8.380 2483 890 40 132
tious Fly Ash 103 103 28 8.390 2486 885 39 40 131
CA2: 20 MM 531 0 0 531 28 8.370 2480 892 40 132
CA1: 12 MM 531 0 0 531
Aggregates Note
FA2: R.Sand 243 0 0 243
FA1: C.Sand 567 0 0 567 The above Mix is for guidelines purpose only, all the aggregates
Admixture Kem Suplast 128 UT 4.9 4.9 are considered as in SSD condition & their Sp. Gravity are
Water Local source 173 173 considered according to materials available in Mumbai
region. For practical purpose it is always advised to conduct
Theoretical plastic density - = 2460 2460
the confirmatory trials at site conditions. Our representatives
Water / Cement Ration = 0.42 0.42
will be available for further advise if necessary.

74 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Admixtures

Admixtures for Tall Structures

Bruno D’souza
Regional Business Segment Manager,
Admixtures, Asia Pacific, BASF

Tall buildings or skyscrapers are constructed for several reasons. One reason being the creation of a status symbol, for example,
the Burj Khalifa, the world’s tallest building which was constructed to symbolize Dubai as a world city. Other more obvious reasons
for the presence of such structures would be part and parcel in the construction of central business districts in cities and also
urbanization of populations. Urbanization is taking place at a faster rate in India than most places in the world. Urbanization in
India was mainly caused after independence, due to adoption of a mixed system of economy by the country which gave rise to
the development of private sector. Population residing in urban areas in India, according to 1901 census was 11.4%. This count
increased to 28.53% according to 2001 census, and crossing 30% as per 2011 census, standing at 31.16%. According to a survey
by UN State of the World Population report in 2007, by 2030, 40.76% of country’s population is expected to reside in urban areas.
As per World Bank, India, along with China, Indonesia, Nigeria and the United States, will lead the world’s urban population surge
by 2050.

Mumbai saw large-scale rural-urban migration in the 21st
century. Mumbai accommodates 12.5 million people, and
is the largest metropolis by population in India, followed by
Delhi with 11 million inhabitants. Witnessing the fastest rate
of urbanization in the world, as per 2011 census, Delhi’s
population rose by 4.1%, Mumbai’s by 3.1% and Kolkata’s by
2% as per 2011 census compared to 2001 census. Estimated
population, at the current rate of growth, by year 2015 of
Mumbai stands at 25 million, Delhi and Kolkata at 16 million
each, Bangalore and Hyderabad at 10 million.
Hence with urbanization increasing at such a fast pace,
especially so in a developing economy such as India, puts
more pressure on available land. This answers why construction
companies in India are looking vertical space, kick-starting
the trend of high-rise buildings dotting the country scape.
Builders and architects are concentrating on building
skyscrapers primarily because they are convenient. It allows them
to create a lot of real estate on a relatively small ground area. Until
the 1990’s, the world of tall buildings was dominated by the
North American continent and the United States in particular. In
1990, 80% of the world’s tallest 100 buildings were located in
North America. Two decades later, these numbers have fallen
to 35%. This trend is the result of a dramatic and continuing
increase in tall building construction in both Asia and the
Middle East. The construction of the Petronas Twin Towers in
Kuala Lumpur built to a height of 452 m, Taipei 101 standing
at 508 m and now the Burj Khalifa in Dubai at 828 m which
stands 773 metres higher, or 15 times taller, than the world’s
first “tall building”, the Home Insurance Building completed in
Chicago in 1885, are a testimony to this fact.
There’s been an increasing trend toward construction of
structural concrete super-tall buildings for several good reasons
discussed in the following section of the paper. Whilst using
such concretes, one needs to pay greater attention not only
to aspects such as the mix design but also to its performance
with respect to handling, pumping, placing, finishing and curing.
Structural Material
For many years, steel was the material of choice for the tall
building, a fact displayed in the first 12 world’s tallest buildings.
Currently, composite, concrete and mixed-structure construction
is much more prevalent in tall structures. Only 24% of the
world’s current 100 tallest structures contain a purely steel
structural system, down from 57% in 1990.
Reinforced concrete provides twice the dampening effect
compared to steel, reducing forces on super-tall buildings due
to wind and the cost of construction. Concrete buildings are
quiet and structural concrete is naturally fire resistant. Modern
formwork systems for horizontal and vertical castings greatly
increase productivity and improvements in concrete pumping
equipment and techniques, make easy and fast delivery of
concrete possible.
Advancements in concrete technology because of newly
developed materials such as chemical admixtures have assisted
in improving the properties of concrete, including strength and
modulus of elasticity (E) making high-rise construction more
attractive. Self-Compacting Concrete is increasing in use too,
mainly due to the utilization of admixtures classified as Viscosity
Modifying Agents (VMA) and Viscosity Enhancing Agents (VEA)
and the availability of more economical fines or fillers.

76 The Masterbuilder - July 2013 • www.masterbuilder.co.in


Chemical Admixtures
Super-tall construction requires that the concrete to be
economical and yet deliver high performance characteristics.
High performance characteristics being properties such as
high strength, low water/binder ratio, flowable for extended
periods at ambient temperatures fluctuations from say 10
deg. C to 50 deg. C and most of all, pumpable to heights in
excess of 600 m.
To meet these challenges posed by various stakeholders
including engineers, contractors and ready mixed concrete
producers for the construction of such super-tall structures,
BASF embarked on an intensive R&D project. The aim of
the project was obviously to develop & deliver products
capable of meeting the demands and needs necessary for
the manufacture of such high performance concrete even in
harsh environments. The R& D work resulted in an innovative
concept being developed. This new concept is termed Total
Performance Control (TPC). TPC concept ensures that the
stakeholders achieve a concrete that is of the same high
quality as originally specified; starting from production at
the batching plant, to the delivery and application into place
and followed by its hardening process. TPC is the state-
of-the art technology that provides improved short and
long term performances of concrete by controlling the two
distinct features essential for high-quality concrete: extended
workability and low water/binder ratio. These features are the
key to the success of such an admixture system.
The key element of the Total Performance Control is
the Glenium SKY superplasticiser. Glenium SKY is an
innovative superplasticiser based on second-generation
polycarboxylate ether (PCE) polymers. It is derived directly
from the TCP concept and is specially engineered to
provide high water reduction and slump retention for ready
mix concrete simultaneously. As compared with other PCE
superplasticisers, it is possible to obtain a high quality concrete
mix with accelerated strength development and extended
workability without delayed setting characteristics. Glenium
SKY is made using nanotechnology. A nanometer is a millionth
of a millimeter – the dimension of molecules and polymeric
chains. In-house expertise in nanotechnology allows BASF to
control the chemical and physical behavior of polymers and
their interactions with cement by augmenting chain length,
side chain length and density, and electrical charges as well
as free functional groups. For the first time, nanotechnology
allows local requirements and conditions to be better met.
Self-Compacting Concrete produced using the TPC
concept provides a concrete mix with exceptional placing
characteristics, accelerated cement hydration for high early
strength development and quality concrete. The addition
of a Viscosity Modifying Agent (VMA) to Self-Compacting
Concrete with Glenium SKY superplasticiser enhances the
Admixtures
robustness of the mix by providing excellent cohesion and
anti-segregation properties. Robustness of a mix is desirable,
especially when such mixes are expected to perform under
high pump pressures and also flow for long horizontal
distances and remain stable when dropped from heights into
structural members such as columns and beams.
Mechanism of Action
The dispersion effect of superplasticisers is based on the
adsorption of molecules on cement particles, imparting a
negative charge that causes electrostatic repulsion and
steric hindrance between them and, therefore dispersion.
The hydration, and particularly the ettringite formation, works
against the superplasticiser. Already adsorbed molecules
are covered by the ettringite lawn, thus are ineffective. The
particular configuration of the Glenium SKY molecules
allows its delayed adsorption onto the cement particles and
disperses them efficiently over a long period of time.
The molecular structure is essential for the early development
of strength. With superplasticisers based on conventional
polycarboxylate ether, the molecules cover the entire surface
of the cement grain and build a barrier against contact with
water. Therefore, the hydration process takes place slowly. The
Glenium SKY molecules, on the other hand, leave sufficient
room on the cement surface to allow a rapid hydration reaction,
resulting in high early strength development.
A schematic representation of the mechanism of action of
a normal PCE superplasticiser versus Glenium SKY is given
below.
Application
Burj Dubai, called Burj Khalifa since its opening, is the tallest
building in the world by a large margin. Concrete admixtures
from BASF have made a substantial contribution to its
construction. The world’s tallest construction, reaching up 828
metres into the Dubai sky with the number of floors reported at
189, was opened on 4 January, 2010. Both, the second largest
construction, the 610-metre Canton TV Tower in Guangzhou,
China, and the second largest “house”, the 509-metre Taipei
Financial Center in Taiwan, pale in comparison with these
www.masterbuilder.co.in • The Masterbuilder - July 2013 77
 Admixtures
figures. Concrete admixtures from BASF’s GLENIUM® SKY
product line brand have made a substantial contribution to
this new world height record.
Construction went on for five years in extreme climatic
conditions. Burj Khalifa put great demands not only on the
2,400 construction workers deployed around the clock. The
staggering heights, a demanding architectural design, and
the climate required exceptional performance from concrete
admixtures as well: The hyperplasticiser of the GLENIUM
SKY brand enabled the concrete to be pumped up to a
height exceeding 600 metres without interruption. In all,
about 180,000 cubic metres of concrete with GLENIUM SKY
were used for the structure’s foundation plate as well as the
superstructure construction.
The climatic conditions posed a further challenge during the
construction of the world’s tallest building: Temperatures in
Dubai not only fluctuate between 10 °C in winter and 50 °C in
summer, but there are also temperature differences between
day and night of up to 20 °C. GLENIUM SKY and the BASF
team’s expertise counteracted these conditions and ensured
a consistently high concrete quality.
In addition, the staggering height of the Burj Khalifa and the
resulting weight of the construction cause enormous pressure
within the concrete structure. Through the use of GLENIUM
SKY, the concrete acquires a compressive strength of up to
78 The Masterbuilder - July 2013 • www.masterbuilder.co.in
80MPa – which is roughly equal to the pressure the total weight
of a small car would exert on a big toe. The high strength also
provides the concrete structure with a long service life and
ensures the sustainable usage of the building.
Conclusion
Concrete with specialized & tailored admixture systems
utilizing nanotechnology & unique polymer science can deliver
the following benefits to stakeholders of tall structures:
- Ensuring a constant high-quality concrete even at a low
water/binder ratio
- Providing concrete with extended workability at high
temperatures, without delayed strength development
- Guaranteeing a concrete that meets the original specification
from the fresh to the hardened stage
- Offering a single, versatile admixture system for many types
of applications and conditions
Refrences
- Abalos, I., & Herreros, J. (2003). Tower and Office: From Modernist
Theory to Contemporary Practice. Cambridge, MA:MIT Press.
- In L.S. Beedle & D. Rice (Eds.), Proceedings of the 4th World
Congress of the Council on Tall Buildings and Urban Habitat:
Tall Buildings- 2000 and Beyond. Chicago, IL: Council on Tall
Buildings and Urban Habitat, 3-12.
- Ali, M.M. (2001). Art of the Skyscraper: The Genius of Fazlur
Khan. New York: Rizzoli.
- Ali, M.M. (2005). The skyscraper: epitome of human aspirations.
In Proceedings of the 7th World Congress of the Council on Tall
Buildings and Urban Habitat: Renewing the Urban Landscape
[CD-ROM]. Chicago, IL: Council on Tall Buildings and Urban
Habitat.
- Ali, M.M., & Armstrong, P.J. (Eds). (1995). Architecture of
Tall Buildings. Council on Tall Buildings and Urban Habitat
Monograph. New York: McGraw-Hill.
- Taranath, B. (1998). Steel, Concrete, & Composite Design of Tall
Buildings. New York: McGraw-Hill.
 Admixtures

Performances and Benefits of Concrete

Admixtures in Concrete Durability

Philippe Ortega
Vice Technical Director, CHRYSO SAS, France

A
s larger and larger amounts of concrete will be required Even though the compacity would be comparable, the way
worldwide in the future, the need for developing the pores are distributed in the concrete, their size, will influence
sustainable construction solutions has been pro- for example the diffusion properties of aggressive chemicals,
gressively growing in our building industry, depending on and lead finally to different durability performances.
each country sensitivity and awareness. Concrete is in fact
The experience collected in the last years allows now to better
is one of the most durable –and cost effective – construction
optimize concrete mix designs in terms of durability while
material in use. Its durability is characterized by the capacity
taking into account the real performance of the concrete.
to keep over time its values in use for which it was designed
This “performance” approach requires knowing precisely the
(structural purpose, safety, comfort of users), while maintaining
conditions playing a role on the durability:
maintenance costs as low as possible.
The concreting process: it is essential to respect the best
In order to guarantee this durability, it is still common in India, as
practices in terms of concreting process. From mixing to curing,
well as in other countries, to see project designers prescribing
the way the concrete is handled will affect its quality, and,
a fixed concrete mix design, based on ultimate strengths
as a consequence, its durability. For example, a concrete
associated with a workability target. However, based on the
can be properly designed for the exposure conditions, but
experience collected over the last decade, we can state that
may finally lack durability if not properly cured, because of
durability should be rather understood by considering a larger
a non optimal cement hydration. Another key point is the
set of criteria: physico-chemical characteristics of the concrete,
rheological behaviour of the concrete: workability, viscosity,
production and placement process, as well as a perfect
cohesiveness, will provide more or less ability for placement
knowledge of the exposure conditions.
and consolidation, which is also essential for keeping concrete
In a new approach considering durability more in terms of structures durable.
performance aspects, to take better into account all the
The physico-chemical concrete properties: beside the classical
criteria mentioned above, we will see that the role of concrete
particles packing density that determines the compacity of the
admixtures becomes of great importance, and we will detail
concrete, the chemical nature of the raw materials (aggregates,
how they can directly or indirectly improve some durability
cement, SCM materials…) plays an important role: it is well
factors.
documented for example that slag and pozzolanic materials
Approaching Concrete Durability Performance Wise have a positive impact on durability, since they are able to
reduce the corrosion rate by increasing the resistivity of the
Traditionally, many project designers are used to specifying the
concrete. Furthermore, the potential reactivity between con-
durability of a concrete in terms of ultimate strengths, together
stituents has also to be considered (aggregates sensitive to
with a pre-established mix design fixing typically a maximum
ASR reaction, e.g.).
Water / Cement ratio, a minimum cement content, even
sometimes a definite dose of admixture. This “prescriptive” The exposure conditions: taking precisely into account the
approach is able to provide a certain durability for the concrete, environment in which the concrete structure will be located
as it will ensure a reasonable compacity. Nevertheless, the and the risk of attacks it will be exposed to during its service
mechanical strength of a concrete does not determine life is necessary to optimize the durability performance of the
alone the durability. As an example, two concrete with same concrete. In Europe, a first step towards this performance
strengths can show very different behaviours in terms of approach has been achieved, by introducing in the EN 206-1
resistance against sulphate attacks or alkali-silica reaction. (European Concrete standard) some specific exposure classes

80 The Masterbuilder - July 2013 • www.masterbuilder.co.in


related to corrosion induced by chlorides, by carbonation,
freeze-thaw attacks and chemical. Using these classes, the
project designer will be able to prescribe a minimum ultimate
strength, cement content and maximum water to cement ratio,
as well as the type and nature of some constituents.
In some countries like France, this performance approach has
been further investigated. Some specific durability indicators
have been defined, in association with operating modes (like
oxygen permeability, chloride diffusion, speed and depth of
carbonation). Work is still in progress to link such parameters
with the real life span of concrete structures. As an example,
we can mention the construction of the Euro-tunnel, designed
for 120 years: water permeability tests had been performed,
which confirmed the low porosity (7 % to 8 %) of the concrete,
allowing to select the final mix design parameters, especially
the water to cement ratio of 0,32 (Rc 28D between 66 to 69
MPa).
Approaching this way the durability performance wise, many
benefits can be be found using concrete admixtures, since they
will help to optimize some physico-chemical characteristics of
the concrete and even the concreting conditions.
How Admixtures can Improve Durability Related to the
Concreting Conditions:
One condition for guaranteeing durable concrete is a proper
cohesiveness. It starts with the mixing process: according to
the Indian standard IS 456, concrete should be mixed until
Class Des-
Description of the environment
ignation
4 Corrosion induced by chlorides from sea water
Where concrete containing reinforcement or other embedded metal is subject to contact with chlorides from sea water or air carying salt originating from sea
water, the exposure shall be classified as follows:
XS1 Exposed to airbome salt but not in direct contact
with sea water
XS2 Permanently submerged
XS3 Tidal, splash and spray zones
5 Freeze/thaw attack with or without de-icing agents
Where concrete is exposed to significant attack by freeze/thaw cycles whilst wet, the exposure shall be classified as follows:
XF1 Moderate water saturation, without deicing agent
XF2 Moderate water saturation, with deicing agent
XF3 High water saturation, without de-icing agent
XF4 High water saturation, with de-icing agent or sea
water
6 Chemical attack
XA1 slightly aggressive chemical environment
XA2 Moderately aggressive chemical environment
XA3 Highly aggressive chemical environment
Extract from the EN 206-1: Description of some exposure classes
Admixtures
there is a uniform distribution of the materials and the mass is
uniform in color and consistency. Mixing aid admixtures can
help in that regard, as they will reduce efficiently the mixing
time, especially in case of concrete containing high volumes
of cementitious materials, particularly hard to defloculate.
Also the placing of the concrete around the reinforcement,
fully compacted, has got a very important influence on the
final durability. It is therefore essential for the workmanship to
respect the best practices of pouring and vibrating concrete.
In addition, with the most advanced admixture technologies,
like PCP based superplasticizers, it is possible to optimize
this process, by producing highly flowable concrete that will
require less effort to place. Some of these products allow also
keeping a better control over other rheological parameters
of the mix, like thixotropy: this reversible thickening force can
lead to an early concrete stiffness, especially at low water cement
ratios, disturbing consequently the placement process.
Admixture suppliers have now developed specific molecules
to decrease this effect.
Not only the easiness of placing , but also its regularity is
another key point for a consistent and guaranteed durability:
the new generation superplaticizers allow to make for example
Self Compacting Concrete, that do not require any more
vibration. As the quality of compaction does not depend any
more on the human factor, it is possible to expect a more
regular placement quality, favourable for the durability. The
regularity is also obtained by improving the robustness of the
Informative examples where exposure classes may occur
structure near to or on the coast
Parts of marine structures
Parts of marine structures
Vertical concrete surface exposed to rain and freezing
Vertical concrete surface of road structures exposed to freezing and airbome de-icing agents
Horizontal concrete surface exposed to rain and freezing
Road and bridge decks exposed to de-icing agents:
Concrete surface exposed to direct spray containing de-icing agents and freezing splash zones
of marine structures exposed to freezing
Concrete exposed to natural soil and ground water according to table 2
concrete exposed to natural soil and ground water according to table 2
concrete exposed to natural soil and ground water according to table 2
www.masterbuilder.co.in • The Masterbuilder - July 2013 81
 Admixtures
fresh concrete to different variables: first cement chemistry
variations (the soluble alkali content especially) can lead to non
regular water and superplasticizer demand, thus impacting
workability. Today, products like alkyl phosphonate based
superplasticizers have been designed to cover a large range of
cement chemistries, and are proved to be much less “cement
specific” than the regular PCPs. Then, other variations come
also often in India from the aggregates particle size distribution:
variable fine contents, in crushed sands particularly, increase
sometimes a lot the risk of bleeding and segregation, and
therefore the durability. For that, admixture suppliers have
now in their offer some efficient molecules, known as Viscosity
Modifying Agents, able to smooth up these variations and
ensure a more regular concrete cohesiveness.
Finally, another variation that may affect the placing process is the
workability loss over time. Whereas PNS based old generation
superplasticizers were hardly able to retain workability more
than one hour, some PCP based superplasticizers, along with
other newly developed technologies called “slump extenders”
allow concrete open times up to 3 hours or more. Also, being
From a bleeding mix…to a cohesive SCC mix using a Viscosity Modifying
Admixture
82 The Masterbuilder - July 2013 • www.masterbuilder.co.in
able to maintain constantly over time a cohesive concrete
-from the time of mixing until the time of placing - avoids
producing a concrete with a too high initial workability at the
edge of segregation, as observed sometimes in India, which
minimizes the risk of getting a non homogeneous concrete at
the pouring point.
After placing, curing is the next step which is essential for
avoiding a too quick drying of the concrete surface, leading
to drying shrinkage responsible for cracks. Most admixture
manufacturers offer already different types of curing agents,
mineral or water based, that protect efficiently the concrete
surface, and therefore improve durability. Considering the
relatively high outside temperatures in India, it makes fully
sense to develop the use of such products compared to
traditional solutions - typically water spraying - less efficient
as they require many more repeated applications. To some
extend, it is also possible to minor the shrinkage phenomena
by using two other chemical types of solutions, known as
Shrinkage Compensating Agents (SCA) and Shrinkage
Reducing Agents (SRA). These liquid admixtures are able
to help reduce the capillary forces while concrete is drying
and their efficiency is excellent. As much as the SCA use
remains confidential and some time difficult to control, the
SRA technology is widely available and robust.
How Admixtures can Improve Durability Related to the
Physico-Chemical Characteristics
Getting a microstructure as dense as possible is a well
known key driver for improving concrete durability. Beside
waterproofing agents dosed in the concrete mass, able to close
to a certain extent the capillaries, and decrease consequently
the risk of penetration of aggressive substances, the super-
plasticizers play a major role, as the most recent ones – the
new generation PCPs - are able to offer almost an unlimited
reduction of the water to cement ratio. The consequence
is the possibility, together with mix design optimization, to
increase regular concrete compressive strengths up to 120
MPa and Ultra High Strength concrete (UHPC) up to 200
MPa in commercial applications. The consecutive reduction
of the porosity allows today the designers to build concrete
infrastructures up to sometimes 300 years.
However, reducing too drastically the water to cement ratio
will increase significantly the solid volume fraction in the
paste, and consequently the viscosity, as it is predicted by
the universal Krieger and Dougherty law. In India, due to
high proportions of cementitious materials necessary to
reach safely the strengths requirements, this practical limit
is often exceeded, and people start to complain about too
much “stickiness”. Some further admixture developments –
modified PCPs and alkyl phosponate based superplasticizers
– can now help about this issue, by reaching an acceptable
compromise between rheological and strengths properties.
 Admixtures
Impact of the W / C ratio decrease thanks to a PCP based superplasticizer on
water permeability
The admixture chemistry can be also very helpful to support
the use of some particular concrete raw materials, like the
Supplementary Cementitious Materials (SCM). Within blended
cements or added separately as a partial replacement for the
Portland clinker, SCM materials contribute to a significant
reduction of the carbon footprint, improving directly the durability
of the concrete, sustainability wise. Furthermore, many of them, like
fly ash or slag are able to improve some physico-chemical
characteristics of the concrete related to durability: one the
physical side, they improve further the compacity of concrete
mixes thanks to their fineness, on the chemical side they
can fight against aggressive exposure conditions, like
corrosion induced by chlorides, sulphate disorders or alkali
silica reactions (ASR). Also, the risk of thermal cracks, due
to young concrete heat generation wave and its volume
variation (expansion / contraction), especially in massive
concrete works, can be minimized using SCM materials.
Well documented, the synergy between such materials and
conventional retarding admixtures has been proven years
ago, to help to maintain temperature gradients into concrete
at acceptable levels. However, putting high amounts of
SCM materials can affect some concrete properties: often
a decrease of the workability window, due to less soluble
alkalis in the total binder, or a delay of setting times and early
strengths. Admixture suppliers are now well aware of these
issues, and they adapt their chemistry, especially the PCP
based superplasticizers, to be fully compatible with SCM
materials, by speeding up the strengthening process or by
adding some specific slump extender admixtures to retain
properly the workability.
It is worth mentioning that some admixtures were specifically
developed in order to improve specific durability performances
related to physical or chemical concrete characteristics: air
entraining agents for example, that avoid cracks due to the
volume expansion of the frozen water left in the concrete pores.
Such admixtures, providing a closely and uniformly distributed
network of air bubbles, work therefore as real durability enhancers
84 The Masterbuilder - July 2013 • www.masterbuilder.co.in
, by increasing the freeze-thaw resistance of concrete. Also,
the so-called “corrosion inhibitors”, based mostly on calcium
nitrite or more recently on amine technologies, will directly
fight against the aggressive agents - chlorides in that case.
These admixtures will chemically neutralize the chlorides,
slowing down or stopping their penetration in the concrete.
Some simplified tools (e.g. the American software Life-365)
can be actually used to simulate their benefit on the life span
of the structure.
Unlike these admixtures specifically designed for durability
purposes, it is interesting to bring up the case of products that
found a secondary function as durability enhancers. Surface
retarders is one typical example: normally designed for aesthetic
purpose (it allows to produce exposed aggregate concrete, by
removing the outer ‘skin’ of cement paste to uncover decorative
coarse aggregate), they can be advantageously used to ensure
the continuity of reinforcement at construction joints between
two concrete pours, which is a guarantee for a good durability
of the whole structure. Instead of hammering the upper surface
of the first concrete to make it rough, as we can still see on
some Indian job sites, this surface can be treated instead with
a surface retarder, providing a more regular surface attack.
The aggregates are then perfectly exposed for receiving the
new concrete, ensuring a good bound at the joint.
Conclusion
Following a mix design prescription that fixes ultimate strengths
has been often considered as a sufficient guaranty for
qualifying concrete durability. However, many other factors
related to concrete properties (more than just the porosity),
environmental conditions and production process, have a
direct influence on the durability. As we saw, concrete admixtures
producers can play a significant role in all these fields, as
they have now well understood the new potential of their
product on the durability aspect. Their contribution however -
especially with the newest superplasticizer technologies - will
be only complete if the project designers accept to approach
durability more performance wise, a trend seen more and
more in European concrete regulations.
Author Bio
Philippe Ortega is a graduate in Chemistry from Lille
university (France). He joined CHRYSO in 1998 in order to
start the first developments on Self Compacting Concrete
in the German Precast and Readymix industry. From 2002
up to now, he works in the CHRYSO concrete business
unit, in charge of the technical development and support
in many countries (India, USA, European countries…),
where he has been given the opportunity to participate to
the achievement of big job sites (ex. Nancy creek Tunnel,
USA, Millennium Bridge, Poland…).
 Waterproofing
Positive Waterproofing from
Negative Side
Samir Surlaker
Managing Director, MC-Bauchemie
W
ith the increase in infrastructural projects, use of
underground constructions is tremendously increased.
Scarcity of land at ground level necessitates underground
metros in crowded cities. Distances of rail and roads are
lowered by tunelling through mountains and under the bed
of water. Deeper basements are part of construction activities
civil and geotechnical engineers are facing challenges firstly
to gather geotechnical data and later to select construction
techniques to complete projects on schedule. In spite of
technological advancements in geological strata mappings,
the real problems are faced while actual construction is going
on. Since the exact nature of strata cannot be predetermined,
civil engineers have to resolve problems at site. Rehabilitation
of underground structures pose major problems as usually
only the internal face is accessible and the problem is always
on the other side. Movement of water is one of the major
impediment to underground construction. Leakages can
be uncontrollable and have to be repaired immediately. If
leakages are not arrested early, the consequential damages
to structures can be time consuming and costly to repair
throwing the deadlines out of gear and endangers the very
stability of structures. Fig 1 shows different types of Cracks in
Tunnel linings. Fig 2 shows critical water ingress.
Any repair based on predetermined material is bound to
be ineffective. Sound principles of civil engineering is the
88 The Masterbuilder - July 2013 • www.masterbuilder.co.in
base to all repairs, rehabilitation or retrofitting. So positive
waterproofing is possible from negative side.
In many waterproofing projects, damp-proofing systems are
specified and waterproofing is expected of them. There is a
major difference between waterproofing and damp-proofing.
As per ACI Committee 515 report, waterproofing and damp-
proofing is defined differently. Waterproofing is a treatment of
a surface or structures to prevent the passage of water under
hydrostatic pressure. Dampproofing is a treatment of surface
or structure to resist the passage of water in the absence
of hydrostatic pressure. While designing the waterproofing
system, actual service conditions are to be borne in mind. It
should be decided at this stage whether damp-proofing is
required or waterproofing is desired.
Positive side waterproofing systems are applied on the same
side as the applied hydrostatic pressure and negative side
waterproofing systems are placed on the side opposite
the applied hydrostatic pressure. Previously negative side
waterproofing was only adopted when access to positive side was
unavailable as in case of common boundary lines. Negative
side waterproofing systems were also used as repair strategy
because the positive side was inaccessible and the back fill or
protective layers had to be removed. There is an increasing trend
in the country to specify negative side waterproofing.
If the negative side waterproofing systems are unavoidable,
extreme care should be exercised during the construction
process. First and foremost, the concrete cast should be of
very low permeability without honeycombing, cracks, crevices or
any other surface defects. Efficient drainage systems are
mandatory. Provision of water stops is also mandatory, as this
is first line of defense in case of negative waterproofing. Fig
3 shows schematically the positioning of positive side and
negative side waterproofing.
It should be clearly borne in mind that negative side waterproofing
accords no protection to concrete if soils contain corrosive
chemicals. Extreme precautions should be taken at joints
 Waterproofing

Crack Injection
• Structural injection for dry cracks
• Structural injection for damp cracks
• Sealing of cracks and cavities for waterproofing
• Sealing against pressurized water
• Injections for imparting stability in Masonry structures
• Frictional Sealing of loose masonry
• External sealing using curtain injection technology
• Grid injection for dampness
Table 1 : Different types of Crack Injection

between walls and floors and careful detailing is required to

maintain integrity and water tightness. In every case it seems that
negative waterproofings are chosen over positive waterproofing Fig 2: Water Ingress which can be stopped
on account of ease of application and this trend should be
discontinued in favour of positive waterproofing. Negative
side waterproofings are also inefficient against high vapour
permeability and therefore are ruled out when the interiors are
to be used for humidity sensitive applications.

Waterproofing as a System

Waterproofing treatments cannot be carried out by application

of single material on new concrete or existing treatments. There
cannot be a single material that is right for every structure. Most
of the failures in the waterproofing treatments are on account of
this misconception. The only way to ensure reliable treatment
is by considering the waterproofing treatment as a system.
System for waterproofing can be defined as combination of
materials, preparation of specifications, application techniques
designed by taking into considerations the requirement of the
client or home owner, which would provide efficient, reliable
and long term protection to concrete structures with minimum
maintenance costs. Waterproofing should never begin with a
specific material in mind. The properties of material are to be stated
and then the material is to be selected as per the merit.
In case of underground structures the design has to consider
the soil mechanics aspect like variable strata, unsuspected
Fig 3 : Comparison of Positive Side & Negative Side Waterproofing
streams etc. which may contribute to the hydrostatic pressure.
Efficient drainage systems should be designed to avoid build
up of hydrostatic pressure due to stagnation of water against
waterproofed surfaces. If necessary, the path of water should
be re-routed with proper grading to control surface runoffs.
Well connected network of perimeter drains connected
to vertical drainage system is the key to achieving perfect
waterproofing of subgrade structures. Fig. 4 shows basement
waterproofing system designed with efficient drainage for a
very high water pressure. Geotextile filter fabrics are normally
designed for a narrow range of permeability. The filters are
efficient guard against silt collection in aggregate drainage
system as they avoid clogging of drainage conduits. Difficult
ground water conditions can be overcome by providing well
designed geodrainage systems which would eventually lower
the hydrostatic pressure on waterproofing barrier system. If a
sump is provided the pumping system should be proportionate
to collection of water.

Reasons for Crack Injection

The other major avenue for water entry into structures are
cracks. Cracks threaten the durability of buildings. Moisture
ingress restricts the usage of buildings and may ultimately
lead to adverse economic effects inclusive of collapse of

www.masterbuilder.co.in • The Masterbuilder - July 2013 89

 Waterproofing

Various Injection Material Bases

PU/Hydrostructural Elastomers
• Water foam and bubble
• Adhere extremely well to wet substrates
• Good Performance with water
Cementitious
• Water is a parpt of the curing process
• Must have water to build healing crystals
• Good Adhesion
Good Performance with water
EP / Duromers
• Foam and bubble with water
Fig 4: Subgrade waterproofing system with drainage • Bubbles contain air, reduced strength
• Poor adhesion
• Bad Performance with water
Acrylic Gel/ Hydrostructure
• Consists of 80% water
• Adhesion is reasonable
• movement is excellent
• Good Performance with water
Table 2 : Different Injection Materials

effectively at a later date. The material used for such cases

must display excellent flow properties. Fig 7 shows usage of
different materials for different Injection types.
Fig 5 : Grid Injection Principle
Guideline for Material Selection
structures. The combined effect of moisture ingress and frost
The selection of material for injection in the crack largely depends
may even aggravate existing damage. Due to its increased
upon the investigation and primarily the following factors:
volume, ice causes more serious crack damage and large-
area frost heave. Cracks can endanger the stability of entire - Pattern of cracks
buildings. Apart from the structural aspects, the entire - Width of the crack
appearance of a building – an important criterion for the valuation - Movements in the crack faces
and assessment of buildings – is considerably impaired by - Due to temperature variations
cracks and deterioration that is brought about by water entry - Due to dynamic loadings
and chemicals ingress. Table 1 shows various reasons for - Moisture in the crack
Injection. Usually three different systems are specialised - Dirt in the crack
applications to solve critical problems:
Available Options
Grid Injection: Water penetration is often caused by bad
concrete compaction, honey combing or defective seals. Duromer Resins: Duromer Resins have been used for many
This is rectified by using grid injection systems a special
technology developed from the standard injection process.
Fig 5 shows a Grid Injection Principle and Fig. 6 shows the
process.

Waterbar Injection: A special injection application is waterbar

injection where waterbars are used to seal joints in moving
structures against pressurised water. However, the concrete often
proves to be a weak point in the area of the waterbar because
of inadequate compaction. Waterstop Injections effectively
clear off this defect and render structure waterproof.

Reinjectable hose Injection: Other critical areas with regard

to the watertightness of a building or structure are expansion
joints that are not sealed with waterbars. Inserting injection
pipes provides the possibility of sealing expansion joints Fig 6 : Process of Grid Injection

90 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Waterproofing
How to choose the right product - Job Conditions
These are problems which injection can solve
Sealing
Coming from
• movement cracks
• stationary cracks
• construction joints
• expansion joints
• bad construction
• All needs flexible filling
Strengthening
Cracks coming from
• mechanical damages damages caused by earth movements
• general wear and tear
• Bad construction
• All needs rigid filling
Table 3: Selection of Materials
years for the rigid injection of cracks in dry structural sections.
Epoxy resins of very low viscosity can be injected into the finest
of cracks. This guarantees a strong permanent bridging of
both sides of the crack, thus restoring bearing capacity for the
designed loads planned. This process can also be carried out
where the structure is also subject to vibration. Duromer resins
of varying viscosity can be used for injection and impregnation
depending on the width of the crack.
Elastomer Resins: If rigid injection material is used the cracks
become visible after injection or new cracks develop adjacent
to old cracking. High quality elastomer resins are a solution
for avoidance of such occurences. Elastomer resins can be
designed with distinct pore structures. An homogenous closed
cell structure is formed which enables safe sealing. The
integrated compression and decompression reserves in the
cell structure absorb the expansion and the contraction in
the crack. The effectiveness and permanency of the seal is
guaranteed by the ability to expand and contract in sympathy
with the crack movement while maintaining the tenacious
bond to crack surfaces.
Hydrostructural Resins: Hydrostructural resins cure to form
elastic membrane and impervious seals when encountered
with water. This property is very useful when the external of
building is not accessible like in buried structures and when
the external waterproofing envelope is damaged. By drilling
Fig 7: Crack V/s. Materials to be used
92 The Masterbuilder - July 2013 • www.masterbuilder.co.in
Fig 8: Showing Hydrostructure Resin PU Foam
through the structure to the interface between existing water-
proofing membrane or protection board, hydrostructure
gels can be injected to recreate the seal. Hysdrostructure
resins can be designed for high chemical and mechanical
resistances. Fig 8 shows water reactive Pu Foam. They
guarantee permanent elasticity, tenacious and isotopic bonding
and unique skin effect. Fig. 7 different material for different
injection types.
The Process of Injection
After completion of diagnosis and selection of materials for injection
the work of injection passes through following stages.
- Preparation of the crack
- Location of points (nipples) for injection
- Fixing of injection points
- Surface sealing of cracks
- Injection of resin proper
- Removal of nipples and plugging
- Removal of sealing material
- Final surface treatment after injection resin/grout hardens
Components and Machinery
Proprietary materials and machineries are available for treating
the cracks by injection system. The materials are mostly
synthetic resin based or cement based. The synthetic resins
are usually two component materials based on epoxies and
polyurethane. The cement based materials are invariably
modified with polymers to impart flowability, non shrinking
characteristics, better bonding etc.
The first step is selection of packers. It is important that packers
are in the form of metal or plastic tubes. They should be able
to be connected to the injection nozzle, so that the pressure
if any should not be lost. Thereafter, it should be possible to
tie or seal the packers, so that the resin is not lost and they
should be removable to enable the surface smoothening.
Normally there are two types of packers.

Fig 9: Different Packers for Injection
The packers, which can be stuck to the surface of the structure
along the line of crack, if the surface is even and packers
which are to be introduced in the structure after boring and
inclined at 450C to the crack plane. The spacing of injection
points depend upon the width of crack as well as the porosity
of concrete. However, as a thumb rule, in case of adhesion
packer, the spacing should be about 50% of concrete cross
section. Adhesion packers should not be used for high pressure
injections exceeding 60 bars. Fig. 9 shows both types of
packers.
Packer or Packer Systems are the link between the structure
and face of the crack and the injection nozzle. Packers must
be of adequate size to gurarantee the flow of injection resin to
the desired place with or without being displaced or debonded
due to injection pressures or rebounds. The critical selection
depends upon the access to crack, quality of surface, surface
condition as well as pressures used in injection process. Table
5 shows Technical data about packers.
There are Normally Three Types of Packers used Under
General Conditions
Adhesion Packers: for the injection of dry cracks, cavities and
Fig 10: Showing Different Packers
Waterproofing
substrates with epoxy and polyurethane resins where surface
conditions are suitable.
Drill or Bore Injection Packers: for the injection of dry, moist
and water bearing (pressurized and Non-presurrized) cracks,
cavities and substrates with epoxy, Acrylic and Polyurethane
resins
Hammer Packers: for the injection of cement injections and
acrylic gels. Fig. 10 shows different packers for Injection.
The more sophisticated the machinery, the better the control
and therefore the performance. Secifications written in
office can be perfectly adhered to at site and controlled via
good supervision. Present day gel injections with a very low
setting and reaction times require 2 component machineries
which can mix materials at the nozzle. Fully computerized
attachments can measure the pressure, control per point, idle
time, time taken for injections and this data can be mentioned
for documentation purpose. Further such data can be used by
owner to control the quantity of repair process and materials
respectively. The supervision at site is very essential to ensure
that the specifications are strictly adhered to. The temperature
plays very important role in the performance of some resin
based systems: and therefore manufacturers instructions as
to the environmental temperature as well as the temperature
of the component in which the material in injected are to be
followed.
The simplest of the injection method is the brush injection.
The resin is brushed on the non moving surface cracks and is
absorbed in capillary action. In case of pressureless injection
the material is poured into the packers especially in case of
pipes acting as packers, the use of such injection depends
largely on the dimensions of the crack. In case of structural
cracks of the width 0.2 - 1.0 mm, it is advisable to resort to low
pressure injection. This low pressure can either be created
with hand guns (sealant guns, grease guns etc) or a normal
compressor used at site. The pressure developed is around
6 - 10 bars. Depending upon the crack widths and depths,
high pressure injections can be resorted to for structural
crack repairs. It is possible to develop pressures to the tune
of 500 bars using mechanical or pneumatic transmissions.
The injection method should be clearly specified prior to
the commencement of the work and should be supervised
to conform with the specifications. Fig 11 shows Injection
Machineries.
Modern Injection Techniques
When problems cannot be resolved by conventional methods
of grouting and injections the resort can be made to modern
injection techniques in which external envelope can be
created by working from inside the structures. This means
creating positive waterproofing from negative side. This
www.masterbuilder.co.in • The Masterbuilder - July 2013 93
 Waterproofing

technology involves new machineries, new materials and
trained applicators as the technology is state of art. In order
to ensure durability and, in particular, bearing capacity, the
permissible crack width in the relevant norms is confined to a
harmless size. If this width is exceeded, there is a danger of
further secondary damage to the building or structure. Cracks
smaller than the permissible maximum width can, when
penetrated with water, also detrimentally affect the structure
concerned. To maintain and restore operational use, any cracks
appearing in a building or structure must be sealed. Various
injection procedures are used depending on the cause of the
crack and individual requirements. The material is injected into
the crack through injection packers and a specially designed
machine. The objective is the closing and sealing of the crack
as well as the expandable or rigid bridging of the sides of the
cracks.
Epoxy resins have been used for many years for the rigid
injection of cracks in dry structural sections. Epoxy resins of
very low viscosity, can be injected into the finest of cracks. This
guarantees a strong permanent bridging of both sides of the
crack, thus restoring bearing capacity for the loads planned.
This process can also be carried out where the structure is
subject to vibration. Epoxy resins of varying viscosity can
be used for injection and impregnation depending on the
width of the crack. Mineral injection systems also fulfil the
requirements of rigid injection.
The newly developed cement based suspensions are suitable,
in particular, for injecting moist cracks bearing pressureless
water as well as dry cracks and can even be used for the rigid
injection of cracks down to 0.2 mm vide.
Even newly erected buildings and structures often show
signs of defects in the form of cracks or cavities caused by
damage. Mineral injection systems really come into their own
in these cases because they are not sensitive to the moisture
contained in new concrete. Rectifying defects with mineral
polymer cement injection makes the building or structure
appear as a unified entity for inspection purposes as well as
restoring the structural integrity.
Structures located in groundwater and pressure water
environments, e.g. tunnels, reservoirs, etc., often display
pervious areas, which can considerably impair the use of the
structure in question. These pervious areas can be caused
by cracks, voids or faulty seals. Water-bearing cracks make
particular demands on injection technology. The objective
is to seal an existing structure to prevent water penetration
without impeding the normal expansion and contraction
of the structure. Structures with water-bearing cracks are
normally accessible from one side only. If the actual seal can
only otherwise be repaired at a great expense, the only truly
economical way of achieving permanent success is to use
injection technology developed polyurethane-based injection
systems for such cases and these have proved successful
over many years. Permanent seals are achieved by using
PU Injection with its outstanding material properties which
was by forming an even closed pore structure. The result
is a plastic workable product which makes flexible injection
sealing possible. Even cracks bearing pressurized water
can permanently sealed. In this case, a fast-foaming water-
stopping polyurethane, can be used.
Water penetration is often caused by bad concrete compaction,
honey combing or defective seals. This is rectified by using
grid injection systems, a special technology developed from
the standard injection process. Fig. 5 shows the principle of
grid injection of creating positive waterproofing from negative
side. Fig. 6 shows the process of injection and grid matrix.
A special injection application is waterbar injection where
waterbars are used to seal joints in moving structures against

How to choose the right product - Site Conditions

Few are only 2 site conditions which has to be taken into con-
dition when injection shall be attempted
Wet Cracks
• movement cracks
• stationary cracks
• construction joints
• expansion joints
• bad construction
• Needs Hydrostructure Resins and gels for flexible filling
Dry Cracks
• Non moving cracks
• mechanical damages
• damages caused by earth movements
• general wear and tear
• bad construction
• Needs Duromers for Rigid filling
Table 4 : Selection of Materials Fig 11: Injection Machineries

94 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Waterproofing

easily penetrate into the crack also filling the so called crack
Packers
root. This ensures a seamless, rigid bonding of the crack edges.
Adhesion Hammer These highly cross-linked duromer resins are also the right
Drill Packer
Packer Packer choice for critical joints, where all important static forces are
Aluminium- being transmitted. The properties of the injection material
Material Steel Plastic
base alloy must be compatible with the parent material. The structural
Plate 38 x 43 mechanics of the injected element should remain unaffected.
Measurements mm shank 23 115 x 13 mm 115 x 23 mm This is an important aspect when carrying out construction
mm works on concrete or masonry buildings that are classified as
Valve Orifice 1.5 mm 1.5 mm 4.5 mm historical monuments. Cement suspensions are insensitive to
varying moisture levels in the building. Even large volumes of
Permitted max
injection are possible with cementatious suspensions suitably
pressure in 60 bar 200 bar 30 bar
concrete modified to low viscosities and having non shrink properties.
They ensure a high degree of efficiency enabling a reduction
Permitted max
pressure in 20 bar 20 bar 30 bar
in restoring costs.
masonry
Conclusion
Loss of pressure 10 - 15 bar 10 - 15 bar < 1 bar
Table 5 : Technical data about packers
Occurrence of cracks is practically unavoidable in structures.
The modern building chemical technology coupled with
pressurized water. However, the concrete often proves proper equipment can solve almost all types of rehabilitation
to be a weak point in the area of the waterbar because of problems thereby providing economical solution in comparison to
inadequate compaction. This technology is further proof of demolition and reconstruction of structures. The specifications
the effectiveness of solving structural problems with special should be very clear and unambiguous. The specifications
injection systems. should at least cover points like material, viscocity, techniques
to be adopted, the equipment to be employed, type of nozzles
Other critical areas with regard to the watertightness of a and spacings, pressure to be applied etc.
building or structure are expansion joints that are not sealed
with waterbars. Inserting injection pipes provides the possibility The supervision at site is very essential to ensure that the
of sealing expansion joints effectively at a later date. specifications are strictly adhered to. The temperature plays
very important role in the performance of some resin based
The material used for such cases must display excellent flow
systems: and therefore manufacturers instructions as to the
properties. Viscocities play a major role in injection techniques.
environmental temperature as well as the temperature of the
The reaction times also are very important. Secondary injections
component in which the material in injected are to be followed.
are a must.
New Injection technology accommodates not only new
All cracks are different. They vary depending on the construction
materials but also advanced machineries and trained
material, cause, location and environment. Quite often,
applicators. The latest injection methods and processes can
cavities in the fabric of construction materials, construction
arrest heavy water leakages in couple of minutes and therefore
joints or foundations with insufficient load-bearing capacity
require injection measures. One single system is not able require precision mixing proportions and split second
to achieve durable and reliable results. Various solutions timing to achieve immediate gelation. It must therefore be
based on different materials which are tailored to specific first determined what is the purpose of injection and from
application needs are now available to users. Table 2 shows this decision one should proceed to selection of material
different available materials. A range of solutions is essential and adequate packers and machineries. Right decision at
depending upon job and site conditions. Table 3 and 4 shows this stage is prerequisite for avoidance of failure. Planning
selection of materials with respect to these conditions. The therefore and technical guidance becomes key factor in the
use of unsuitable materials or techniques may necessitate process of decision making sound knowledge of soil structure
costly subsequent reconstruction, which are more expensive interaction, technical know how of material chemistry coupled
than correct action right at the outset. These additional costs with trained applicators are required to successfully carry
are avoidable through technical approach. Experience has out the job under actual site and job condition. Any repair
shown that a superficial solution will necessitate further repair based on predetermined material is bound to be ineffective.
measures. Sound principles of civil engineering is the base to all repairs,
rehabilitation or retrofitting. So positive waterproofing is possible
Very low-viscosity, highly cross-linked series of duromers from negative side.

96 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Concrete Recycling
Concrete Recycling:
The Need of the Hour
Bhavani Balakrishna
A
s landfill costs for construction,
demolition, and land-clearing
debris continue to rise, and the
landfills becoming heavily regulated, it
makes commercial sense to seek alter-
native means of disposal of concrete
from construction and demolition oper-
ations. However, in many parts of the
world the potential to recover concrete
is overlooked, and it ends up as unnec-
essary waste in landfill.
It is estimated that roughly 25 billion
tonnes of concrete are manufactured
globally each year. Twice as much con-
crete is used in construction around the
world than the total of all other building
materials, including wood, steel, plas-
tic and aluminum. About 1,300 million
tonnes of waste are generated in Europe
each year, of which about 40%, or 510
million tonnes, is construction and de-
molition waste (C&DW).The US pro-
98 The Masterbuilder - July 2013 · www.masterbuilder.co.in
duces about 325 million tonnes of C&DW,
and Japan about 77 million tonnes. Given
that China and India are now produc-
ing and using over 50% of the world's
concrete, their waste generation will
also be significant as development con-
tinues.
A study conducted by the Jawaharlal
Nehru National Urban Renewal Mission
(JNNURM) states that in India, the con-
struction industry generates about 10-
12 million tonnes of waste annually. The
construction and demolition industry is
one of the country's largest waste pro-
ducers, contributing around 17 percent
of waste that is sent to landfill. Con-
crete, shuttering material, paint, bricks,
tiles, wood, metal, debris and masonry
account for such construction waste.
Most of this can be recycled but con-
crete and masonry, which constitutes
over 50% of the construction waste, are
not being recycled in India.
In some countries, waste concrete
is typically put in landfill but countries
like Netherlands, Japan, Belgium and
Germany are ensuring high levels of re-
covery through mandatory policies and
levies. Scarcity of aggregates is also
making recovery necessary. In the
Netherlands, crushing waste concrete
to recycle it has been common practice
for many years due to a shortage of nat-
ural aggregates and a lack of available
landfill space.
The recovery and reuse of concrete
is achievable and will contribute to sus-
tainable buildings and urban societies
of the future through savings in natural
resources, materials and energy
Significance of Concrete Recycling
Concrete recycling reduces the use
of virgin aggregate and its associated
 Concrete Recycling

environmental costs of exploitation and

transportation. Its use can potentially
shorten project delivery as a result of
expedited construction schedules due
to reduced haul times. The potential for
increased material transportation sav-
ings is even greater when there is no lo-
cally available aggregate, and aggregate
has to be trucked in from farther away.
It also reduces unnecessary landfill
of valuable materials that can be recov-
ered and redeployed. According to the
Construction Materials Recycling Asso-
ciation, recycling concrete from demo-
lition projects can result in consider-
able savings because it saves the cost
of hauling broken concrete to landfills
and eliminates disposal costs.
Recovering concrete, however, has
no appreciable impact on reducing Recycled aggre-gate accounts for 6% to 8% of aggregate use in Europe -the greatest users are the
greenhouse gas emissions as in the United Kingdom, the Netherlands, Belgium, Switzerland and Germany.

product life cycle of concrete, the main

processed to produce aggregates suit- The fine aggregate, however, gen-
source of carbon emissions is the ce-
able for use in new concrete. The pro- erally contains a considerable amount
ment production process (cement is
cessing, as with many natural aggre- of old cement paste and mortar. This
added to aggregates to make concrete).
gates, generally involves crushing, tends to increase the drying shrinkage
Concrete Recycling Sources grading and washing. This removes and creep properties of the new con-
contaminant materials such as rein- crete, as well as leading to problems
While concrete can be recycled from forcing steel, remnants of formwork, with unworkable mix and strength. The
returned concrete that is fresh (wet) from gypsum board, and other foreign mate- chloride content of recycled aggre-
ready-mix trucks, production waste at rials. The resulting coarse aggregate is gates is of concern if the material is used
a pre-cast production facility or waste then suitable for use in concrete. in reinforced concrete. The alkali con-
from construction and demolition, the
most significant source is demolition
waste.
Recycled Concrete Applications
Concrete is broken down into aggre-
gate for use in a new life. This new life is
usually road works aggregates, but in
some areas, it is also used as aggre-
gates in new concrete. Recycled aggre-
gate accounts for 6% to 8% of aggre-
gate use in Europe -the greatest users
are the United Kingdom, the Netherlands,
Belgium, Switzerland and Germany.
Use as Aggregate in Road Base and
Pavements
The recycled concrete aggregate
(RCA) can be defined as crushed con-
crete composed of aggregate fragments
coated with cement paste or cement
mortar from the demolition of the old The practice of recycling demolition waste to produce aggregate for use in road base is
structures or pavements that has been popular and widespread.

www.masterbuilder.co.in · The Masterbuilder - July 2013 99

 Concrete Recycling
tent and type of aggregate in the system
are probably unknown, and therefore, if
mixed with unsuitable materials, a risk
of alkali-silica reaction is possible.
The practice of recycling demolition
waste to produce aggregate for use in
road base is popular and widespread.
It is well established overseas, dating
back to the rebuilding of Europe after
World War II. From a sustainability view-
point, these low-grade uses currently
provide the optimal outcome in most
circumstances.
When used as a base and sub-base,
recycled aggregate has been found to
have superior strength to virgin aggre-
gate, providing a very good construction
base for new pavement. Aggregate Base
Course, or the untreated aggregates
used as foundation for roadway pave-
ment, is the underlying layer which forms
a structural foundation for paving. A
cross section of pavement would show
dirt, or sub grade, as the lowest of three
levels, with the aggregate base course
at the center and pavement (whether
concrete or asphalt) at the surface.
The main drivers for recycling con-
crete as aggregate or road metal in the
US are regional shortages/depletion of
Reuse of blocks in their original form, or by cutting them into smaller blocks, has even less environmental
impact although only a limited market currently exists.
100 The Masterbuilder - July 2013 · www.masterbuilder.co.in
virgin material and related transporta-
tion costs and the potential to claim
credits under the LEED certification for
buildings by the US Green Building
Council. Credits are awarded for divert-
ing demolished concrete from landfill
disposal by recycling it into aggregate
for road bases or construction fill and
for using a proportion of recycled con-
crete aggregate for the project.
Recycled concrete can be used as
coarse and/or fine aggregate in Portland
cement concrete (PCC) pavements.
However, concrete incorporating more
than about 10 to 20 percent fine RCM
aggregates can suffer a reduction in
quality because of the high amount of
water required to maintain adequate
workability of the concrete mix. The use
of RCA in new concrete paving mix-
tures has been reported, and research
for making RCA a more viable option
for new concrete paving mixture appli-
cations has been performed. Research
has shown that RCA can be used suc-
cessfully as both coarse and fine agg-
regate in such applications. In Austra-
lia, RCA is allowed as a coarse aggre-
gate in new concrete mixtures for curbs
and sidewalks.
Reuse for Embankments & Drainage
Fills
Recycled concrete that has not
been subjected to any additional pro-
cessing other than crushing can be used
for many types of general bulk fills, pro-
tection of roadside banks, as a fill for
drainage structures, for road construc-
tion or as embankments and noise bar-
riers. In general, recycled concrete
aggregate has good durability and re-
sistance to weathering and erosion, good
stability and little post compaction set-
tlement. However, the recycled concrete
aggregate can induce corrosion in alu-
minum or galvanized steel pipes in pre-
sence of moisture due to its high alka-
linity.
Reuse in an original form for land-
scaping and other purposes
Reuse of blocks in their original form,
or by cutting them into smaller blocks,
has even less environmental impact
although only a limited market currently
exists. Improved building designs that
allow for slab reuse and building trans-
formation without demolition could
increase this use. Hollow core concrete
slabs are easy to dismantle and the
span is normally constant, making them
good for reuse. Several broken con-
crete blocks and crushed concrete are
effectively used for landscaping. For
instance, the Nissan Advanced Tech-
nology Center in Japan used all the con-
crete debris from demolished univer-
sity buildings within the site with 70% of
the debris used as pavement subgrade
and 30% as green embankment fillers
for outdoor landscaping.
Reuse in structural concrete
Whilst the use of recycled aggre-
gate has a reasonable track record in
low grade applications, its use in struc-
tural grade concrete is a relatively new
area, though some notable structural
projects have been completed.
Need for Education & Policies for
Adoption of Recycled Aggregates
Government policies and initiatives
promoting or encouraging waste mini-
 Concrete Recycling
Many European countries prohibit discarding material in landfills that can otherwise be recycled.
mization/recycling and proposed land-
fill levies can to a large extent drive the
adoption of recycled concrete. In the
Netherlands, RCA is considered a prod-
uct rather than a waste material, and
industry is involved in the processing
procedures.
Many European countries prohibit
discarding material in landfills that can
otherwise be recycled. Taxes on mate-
rial sent to the landfill and/or taxes on
the mining of virgin aggregate also help
promote alternative uses for RCA. The
recycling rate of construction and de-
molition waste in Denmark, for exam-
ple, increased from under 25 percent in
1987, when a landfill tax was intro-
duced, to 90 percent in the following 14
year period, during which it was incre-
ased ten-fold. In 2002, the UK intro-
duced a levy on natural aggregate of
£1.60 per tonne, which was increased
this year to £1.95 per tonne ($5). This
tax increased the cost of virgin aggre-
gate from around 15 percent in London
and the Home Counties to over 60 per-
cent in some rural areas. Some 25 per-
cent of the UK's aggregate demand is
now produced from recycled and sec-
ondary sources.
The practice of recycling waste con-
crete as aggregate is also well estab-
lished in the US, but not to the extent
that it is in Europe. This may be due to
102 The Masterbuilder - July 2013 · www.masterbuilder.co.in
the fact that the USA is not a signatory
to the Kyoto Protocol and there is not a
national landfill or virgin aggregate tax.
In countries where the cost to pro-
duce RCA may be greater than the cost
of acquiring virgin aggregates, govern-
ment incentives and efforts to educate
the public on the environmental bene-
fits associated with the use of RCA are
key to promoting increased and alter-
native applications
As per the Cement Sustainability
Initiative (CSI), governments and other
key stakeholders around the world
should aim at developing economic in-
centives and legislation to promote more
recycling, particularly through green
building initiatives. It recommends set-
ting usage targets for recycled con-
crete in road construction and building
and calls on the construction industry
to gather waste data to generate reli-
able global statistics.
In India, Science and Engineering
Research Council (SERC), Ghaziabad
did an extensive research on Recycling
and Reuse of Demolition and Con-
struction Wastes with the aim of devel-
oping techniques/ methodologies for
use recycled aggregate concrete. The
experimental investigations were car-
ried out in Mat Science laboratory and
Institutes around Delhi/GBD to evalu-
ate the mechanical properties and du-
rability parameters of recycled aggre-
gate concrete made with recycled
coarse aggregate collected from differ-
ent sources. Also, the suitability in con-
struction of buildings has been stud-
ied. The properties of recycled con-
crete aggregates RAC has been estab-
lished and demonstrated through sev-
eral experimental and field projects suc-
cessfully. It has been concluded that
RCA can be readily used in construc-
tion of low-rise buildings, concrete pav-
ing blocks & tiles, flooring, retaining
walls, approach lanes, sewerage struc-
tures, sub base course of pavement,
drainage layer in highways, dry lean
concrete(DLC) etc. in Indian scenario.
Commonly cited reasons for limit-
ing the use of RCA include concerns
related with the performance and qual-
ity of RCA. For example, a common
concern is the use of RCA from con-
crete previously exhibiting materials re-
lated distress. There have been studies;
however, that demonstrate how proper
mitigation efforts can make RCA from
such concrete source a viable option.
Contractors are also concerned that
RCA will result in inconsistent quality.
Educating contractors and owner-
agencies about methods for effectively
incorporated RCA into new concrete
mixtures could help the industry over-
come this limitation. Such an education
would require understanding the char-
acteristics of RCA, revising specifica-
tions for aggregate as necessary, un-
derstanding the impact of the use of
RCA on fresh and hardened concrete
properties and on the durability of pave-
ments, and making appropriate adjust-
ments in the development of mixture
proportions and production methods.
This education would show contractors
that RCA can be a cost-effective mate-
rial that will not compromise the quality
and result in an industry wide change in
perception about the use of RCA.
There is momentum and an appe-
tite for the recycling and indeed up-
cycling of waste concrete. This is sen-
sible from a number of perspectives,
not least of which is societal expecta-
tion surrounding the issue.
 Communication Feature

Evercrete Everwood and Evercrete Top Seal:

Waterproof, Preserve and Enhance Life of Wooden Structures

N
atural wood is used in housing
and other construction pro-
jects in various areas such as
on landscaping gardens and podiums,
decks, porch, etc. The natural wood
adds to the aesthetic look of the pro-
ject. There are many row houses and
cottages that are entirely made out of
wood.
Natural wood structures need to be
protected well so that they last long.
The natural wood generally cracks when
the natural moisture from the wood
escapes the wood over a period of
time. Also due to the moisture in the air
and the contact of wood with water, it
may lead the wood to expand or crack.
Evercrete Everwood is water based
and is ready to use on natural wooden
surfaces Evercrete Everwood reacts
with the cellulose in the wood and
entraps the natural moisture of the
wood. This delays the cracking of the
wood, and the wooden structures last
longer. Evercrete Everwood also pro-
tects the wood from fungus, molds,
and insect damage, and reduces the
powder formation that may generally
be seen in wooden surfaces.
Wooden surfaces treated with
Evercrete Everwood can be painted or
polished easily, without the use of a
primer. Evercrete Everwood helps to
The right side of the piece of natural wood is treated with Evercrete EW and Evercrete TS. The area treated
with Evercrete TS, does not absorb water.
enhance the bonding of the polish, etc
with the wooden surfaces.
Once the wooden surface is treated
with Evercrete Everwood, it is recom-
mended to apply Evercrete Top Seal
over it. Evercrete Top Seal is water
based, ready to use water repellent.
Evercrete Top Seal will repel the water
that comes in contact with the wood.
The area treated with Evercrete EW and Evercrete TS
does absorb water, even during rains.
It is not mandatory to use Evercrete
Everwood and Evercrete Top Seal in
The right side treated with Evercrete Top Seal does conjunction with each other. They can
not absorb water.
be used individually as well.
In fact Evercrete Top Seal can also
be used on natural stones, to prevent
the growth of fungus, moss, algae, etc.
Evercrete Top Seal maintains the natu-
ral look of the stone, does not change
the natural colour or the texture of the
stones. It can also be used on concrete
structures which don’t need to be painted,
to maintain the natural concrete look.

For further details:

Poly Flex
E-mail: polyflex@polyflex.co.in
Web: www.polyflex.co.in
The right side of the piece of natural wood is, treated with Evercrete EW. The change in colour is uniform and negligible

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

 High Performance Concrete
High Performance Concrete
using Microsilica
Surendra Sharma
Deputy General Manager (Concrete)
Elkem South Asia Pvt. Ltd.
Need for High Performance Concrete
Concrete structure gets deteriorated on account of chemical
reactions such as corrosion of rebar or physical effects like
porosity which permits easy access of harmful ions into the
main body of concrete which makes concrete resistance weak
there by shortening the life cycle of concrete. Some of the
factors which affect durability of concrete are reinforcement
corrosion, chloride diffusion, carbonation, sulphate attack,
alkali silica reaction, frost action, leaching of concrete etc.
In practice, most of this deterioration of concrete cannot be
seen as they developed as concrete grow older.
Fig.1 below shows some of the damages and therefore as a
practicing engineer one need to design and place concrete
which is durable and sustainable in the long run.
Therefore as a good practicing engineer, the best way of
protecting these damages is to make concrete less permeable
as high degree of water saturation is seen as one of the causes
for durability problem. It becomes very essential to design
concrete with less porosity to protect the concrete as water
Fig. 1
108 The Masterbuilder - July 2013 • www.masterbuilder.co.in
is only medium through which chlorides, sulphate and other
harmful trace element can enter into concrete structure and
cause damages to concrete from inside .i.e. corrosion.
All major infrastructure projects are designed for 100+ years
and capital intensive. It becomes very essential to increase the
life cycle and produce the concrete which can last for longer
period and boost the nation’s economy. Replacing concrete
or structure is a costly affair.
ACI defines High Performance Concrete as “concrete meeting
special combinations of performance and uniformity require-
ments that cannot always be achieved routinely using con-
ventional constituents and normal mixing, placing and curing
practices.
Microsilica: Elkem Microsilica® is one of the principle products
supplied by Elkem Silicon Materials. It finds a wide range of
applications in high-strength concrete, High Performance
Concrete other building materials such as roof tiles and facade
cladding, and fire proof products for heavy industry.
Microsilica is also used for sealing tunnels and drilling oil
wells. Microsilica is proven mineral additive which has been in
use since many years to provide high performance concrete
solution to construction Industry. Worldwide 10 Million m3 or
even more concrete is produced with Microsilica. The ACI
defines Silica fumes as “very fine non crystalline silica produced
in electric arc furnaces as a by- product of the production
of elemental silicon or alloy containing silicon. Microsilica®
is having a very fine particle. The average particle size of
Microsilica is 0.15 µm.
The specific surface tested on BET method is minimum 15000
m2/Kg (See SEM Fig 2). Which provide better filler effects
and make concrete less porous and robust and it helps in
improving concrete resistance to chloride and sulphate attack.
Usually Microsilica available in condensed from. There are
two type of Microsilica available in the market.
1) Undensified Microsilica
 High Performance Concrete

High Performance Concrete 0.45um

Bulk Density - Undensified Microsilica 130 to 480 Kg/m3
Densified Microsilica 480 to 720 Kg/m3
Specific Gravity 2.2
Physical properties of Microsilica.

and when one adds water to concrete; generally following

chemical reaction takes place.

Cement hydration

Portland cement (C3S, C2S) + water = CSH + Ca (OH)2

Secondary Pozzolanic reaction with Microsilica

Pozzolana (SiO2) + Ca (OH)2 + water = CSH

Fig. 2
2) Densified Microsilica
During Microsilica production, Undensified Microsilica is
densified by use of hot air which helps in increasing its bulk
density. It is essentially a non-hazardous material and fall into
general category of nuisance dust, which is similar to cement
and many other fine particles.
The relevant standard for Microsilica in India is IS 15388-2003.
Please see below the other physical and chemical properties
specification of Microsilica as outlined by different standard.
How does it work?
Microsilica has minimum 85%-99% of SiO2 which, make it
very reactive pozzolanic material in concrete. As we all know,
water is an essential element in the cement hydration process
Meaning you get more,
CSH-gel (binder)
Denser concrete/good interface
Higher compressive strength.
Also, above chemical equation shows that free lime, Ca(OH)2
which detrimental to concrete is turned to something good
meaning more C-S-H (Calcium-Silicate-Hydrate) gel meaning
additional binder for given concrete which provide improved
strength and durability characteristics both at early age and
later age besides improving plastic properties.
Other value attributes of Microsilica in Plastic stage of
concrete
Generally the recommended dosage of Microsilica is 5 to 10%

USA EUROPE
INDIA CANADA CSA NORWAY AUSTRALIA
ASTM C CEN prEN
IS 15388: 2003 A23.5-98 NS 3045 AS 3582
1240-2004 13263: 1999
Sio2 %> 85.0 85.0 85.0 85.0 85.0 85.0
SO3%< 2 1 3
Cl %< 0.3 Report if > 0.10 Report
CaO %< 2
MgO

Si (free) %< 0.4

Total Alkalies 1.5
Free C

Moisture Content %< 3 3 2

LOI %< 6 4 4 6 5 6
Specific Surface
15 15-35 15 12
m2/gm>

www.masterbuilder.co.in • The Masterbuilder - July 2013 109

 High Performance Concrete

Bulk Density Report Report

Pozzolanic Activity Index 105%-7d accel cur- 100%-28d Normal 85%-7d IS 1727 85%-7d accel’d 95%-28d Normal Report
%> ing, w/cm=variable Curing w/p ration=0.5 Factor N=1 curing curing w/cm=0.5

Retained on 45 micron
10 10 10
sieve %<
Density, kg/M3

Autoclave Expansion %< 0.20%

Canadian Foaming Test No visible foam

Requirement of
Characteristic values.
limiting alkali only
Notes Not an official standerd charateristic values
in case of reactive
in the approval process
aggregares

by wt of cementitious content depending upon the specific
characteristics that need to be improved in the concrete mix.
Microsilica as stated earlier is a very fine material and it need
proper dispersion well in concrete matrix and it occupies
space between cement grains thereby improving permeability
of concrete mass. Typically it is said that in one grain size
of cement, 100 Microsilica grains can exits. It also helps in
improving mobility of concrete when energy is applied to
concrete.
Through the permeable structure of concrete the ingress
of chloride and sulphate ions can damage the concrete as
stated earlier and addition of Microsilica largely improved this
and protects the concrete.
Fine particles also hold other constituent of concrete better and
therefore other value addition of Microsilica is better cohesion.
This property largely helps in short creating operation as well
as helps in pumping the concrete. In addition it reduces
bleeding and segregation and aids in efficient finishing and
helps in slip form because of better finish.
These plastic properties have its own value and are of equal
important while placing and finishing concrete. The first and
foremost principle a concrete mix designer should bear in
mind is to make the concrete cohesive enough with limited
stickness, good mobility and finishability at a given workability
which enable concrete to hold its constituent together under
pressure which will be excreted during mixing, transportation
and placing of concrete. What is the use of a great mix design
made in the laboratory which cannot be placed in field? And
therefore these plastic properties becomes equally important,
Once cohesion of concrete is satisfactory then mechanical
properties such as compressive strength, E-Modulus etc and
durability characteristics tested on durability standard in terms
of permeability ,I-Sat, Rapid Chloride Penetration, Sorptivity,
Water Penetration, chloride diffusivity etc are to be taken care
of. These plastic, harden and durability characteristics have
been seen as remarkable improved by addition of Microsilica.
If someone is using higher content of cement, by adding
Microsilica he/she can reduce cement content and make
concrete less sticky too this would be a desirable largely in
pumping operation. It also help us to reduce heat of hydration
while strength is maintained which ultimately help to prevent
early age cracking.

Other value attributes of Microsilica Hardened stage of concrete.

In fully hydrated Portland cement paste, approximately

1/4th of the hydration product by mass consists of oriented,
heterogeneously distributed and weekly bonded layers of
calcium hydroxide crystals; which de-bond easily under
tensile stress thereby serving as potential sites for formation
of micro cracks. Therefore, transformation of most of this
calcium hydroxide into the calcium silicate hydrate paste
(which is the predominant phase produced by hydration of
Portland cement) would result in a much more homogeneous
hydration product.

At hardened stages, it helps in,

Fig. 3 Fig. 4 - Improving Strengths,

110 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 High Performance Concrete

Building Name Location App. Height (M) Date

Burj Khalifa Dubai 828 Tallest structure in the world, completed 2010

International Commerce Centre Hong Kong 484 Completed 2010

Petronas Twin Towers Kuala Lumpur 452 Tallest twin buildings in the world, completed 1998

Taipei 101 Taipei 508 Completed 2004, tallest LEED rating building

Guangzhou West Tower Guangzhou 432 Completed 2010

Trump Tower Chicago 423 Completed 2009

Two International Finance Centre Hong Kong 413 Completed 2003

Burj Al Arab Dubai 321 One of the world’s tallest hotels, opened 1999

311 South Wacker Drive Chicago 293 Completed 1999

Trianon Frankfurt 186 Completed 1993

World One Mumbai 442 On going

Polais Royal Worli Mumbai 320 On going

Oasis Towers Worli Mumbai 372 On going

Minerva Tower Mumbai 302 On going

Ireo Victory valley New Delhi 178 On going

- Reducing Permeability, use of cementitious materials.

- Improving Acid Resistance,
- Improving Abrasion-erosion Resistance,
- Improving Durability
As you all, are aware addition of extra cement beyond certain
mass depending upon cement type, per cu.m of cement
does not increase your strength and highly uneconomical.
And if one wants to design for higher strength and high
performance concrete, addition of Micro silica helps a lot
to achieve the desired plastic and hardened properties of
concrete with robust and workable design. There are other
mineral admixtures available based on Fly ash and GGBS,
however they have their own limitation on SiO2 content and
other and largely influence setting characteristics of concrete
as they influence hydraulic properties of concrete and in
today’s age everyone need high early strength to speed up
the construction and high ultimate strength to go vertical in
building high rise structure.
Besides this, there are enumerable advantages of Microsilica
in the concrete and Microsilica is playing very important role
to redefine High Performance concrete and allowing structural
engineer to think of reduced size of structural elements and
dream higher in the sky. And incorporation of Microsilica at
designed stage of structure results in direct saving for the
project. As a concrete mix designer we all should strike a
balance between performance and economy and it is seen
that reduced material cost per cu.m of concrete is taken only
as means of economic mix design which is not true.
Therefore concrete cost must not be compared with material
cost per cu.m but a comprehensive cost analysis is needed
which includes all cost associated right from placing to
maintenance of the structure till its design period is to be taken
in to account which will the serve the purpose in longer run.
Also there is need to go for performance based specification
rather prescriptive based specification and Microsilica will
ensure to meet the specifications.

If you see, fig 3 and fig 4, fig 3 is a hardened concrete surface
of concrete made with only cement and fig.4 is hardened
concrete surface of concrete made with Microsilica and if you
closely look at the interface of matrix or a cement glue (see
letter A in the Fig 3 & 4), you will find that Microsilica concrete
is having much less thickness of cement paste or glue or
matrix and holding the aggregate better meaning economical
Please see the summary of high rise executed in the recent
past where Microsilica has been used in the project which
one proves value additions of Microsilica.
References
- Silicafume user’s manual 2005
- Internal references from Elkem ASA

112 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Prestressed Concrete

Development of Modern Prestressed

Concrete Bridges in Japan
Hiroshi Mutsuyoshi1, Nguyen Duc HAI1 and S.V.T. Janaka Perera1
1
Structural Material Lab, Department of Civil and Environmental Engineering,
Saitama University

Prestressed concrete (PC) is being used all over the world in the construction of bridge structures. In Japan, the application of
PC was first introduced in the 1950s, and since then, the construction of PC bridges has grown dramatically. This is largely due
to several advantages such as lower initial and life-cycle cost compared to steel bridges, and superior characteristics concerning
economical and aesthetical aspects compared to reinforced concrete bridges. However, many PC bridges have been deteriorating
even before their designed service-life due to corrosion and other environmental effects. Therefore, the durability has become
a particular concern and should be seriously considered in the design and construction of PC bridges. In Japan, a number of
innovative techniques have been developed to enhance both the structural performance and the durability of PC bridges. These
include the development of new materials such as pre-grouted internal tendon, high-strength concrete and structural systems such
as external prestressing, highly eccentric external tendons, extradosed prestressing and corrugated steel web. This paper presents
an overview of such innovated technologies of PC bridges including a brief detail of their development and background as well as
their applications in the actual construction projects.

For more than half a century prestressed concrete (PC) is one Development of Innovative Materials for PC Bridges
of the most important construction materials in not only Japan
but also all over the world particularly in the field of bridge In Japan, most of PC bridges were constructed using internally
construction. The increased interest in the construction of PC post-tensioning tendons with grouting in sheaths. Recently,
bridges can be attributed to the fact that the initial and life-cycle however, problems regarding grouting condition have been
cost of PC bridges, including repair and maintenance, are of much concern because the insufficient grout of internal
much lower than those of steel bridges. Moreover, comparing tendons was found in some existing PC bridges (Mutsuyoshi
to the reinforced concrete (RC) bridges, PC bridges are more 2001). Many researches have been carried out recently for the
economically competitive and aesthetically superior due to development of new materials to enhance the performance
the employment of high-strength materials. In Japan, the first and longterm durability of the PC bridges. In this section,
PC bridge, Tyousei Bridge, was built in 1951 and since then, application of pre-grouted internal tendons and high-strength
the construction of PC bridges has grown dramatically (Figure concrete are explained with brief overview on their applications
1). However, deterioration of bridges is becoming a big social in actual PC bridge projects.
issue since many bridges are getting older over 50 years.
Pre-Grouted Prestressing Tendon
In recent years, many PC bridges have been deteriorating
Pre-grouted prestressing tendon was first developed in Japan
even before their designed service-life due to corrosive
in 1987. It is made by coating a prestressing strand with
circumstances, alkali-silica reactions, and other environmental
unhardened epoxy resin and a polyethylene protective tube
effects. Hence, the durability has become a particular concern
(Figure 2) and is embedded directly into concrete with the
and should be seriously considered in the design and con-
struction of PC bridges apart from structural safety, aesthetical
appearance and economical viewpoint. In Japan, a number of
innovative techniques have been developed to enhance not
only the structural performance but also the durability of PC
bridges. These include the development of novel structural
system and the advance in new construction materials. This
paper presents an overview of such innovated technologies
of PC bridges including a brief detail of their development
and background as well as their applications in the actual
construction projects. Figure 1 Trend of construction of different types of bridges in Japan

114 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Prestressed Concrete

polyethylene protective tube as a tendon for posttensioning.

Time of hardening is set for the epoxy resin filled in the
polyethylene protective sheath so that post-tensioning process
can be completed before hardening or the epoxy resin. The resin
has viscosity like grease before hardening, and it naturally
hardens with certain time after the completion of tensioning
of prestressing steel and bonds with concrete to form an
integrated member.

As the grout is injected into the polyethylene sheath, complete

grouting is ensured in this technique. Furthermore, con-
struction work can be saved as neither in-situ insertion of
prestressing tendonds nor grouting process is required.
Sheath and epoxy resin also provide double layer corrosion
proection to the prestressing tendons. This technique also
ensures stronger bond with concrete than conventional
cement grouting technique. Moreover, smaller diameter
of sheath makes concrete placement relatively easier and
provide higher efficiency in prestressing can be achieved as
polyethylene sheath and unhardened resin reduce the friction
during prestressing.
Pre-grouted prestressing tendon, primarily in the form of
single strands, was generally applied to transverse prestressing
of deck slabs or other work. Application to main tendons
has just started in view of the above benefits (see Figure
3). When pre-grouted prestressing strands are used for
main tendon, more prestressing strands are required than
when conventional multiple strands are used. Numerous
prestressing strands therefore should be anchored in a limited
anchorage region. Hence, attention should be paid in design
for the arrangement of pre-grouted prestressing tendons and
details of anchorage.
High-Strength Concrete
High-strength concrete (HSC) has become common in
building construction in recent years as it enables the use of
smaller cross-sections, longer spans, reduction in girder height
Figure 3 Use of pre-grouted prestressing strand for main tendons
and enhanced durability. In addition to this application, there
are a few instances of HSC being applied to PC structures
(Figure 4) (Mutsuyoshi et al. 2010). The chief advantage of
using HSC is the possibility of achieving higher prestressing
force compared to the normal concrete which will lead to
smaller crosssection and reduction in the overall weight of the
structure. Hence, the use of HSC has a good potential in the
construction of large structures.
The lower water/binder ratio in HSC may, however, cause the
increase in autogenous shrinkage which will lead to decrease
in effective prestressing force and cracking due to restraining
caused by the reinforcing steel. Conventional method of
reducing autogenous-shrinkage-strain is to use expansion-
producing admixture and shrinkage-reducing agents. However,
these materials are expensive. This problem has been
overcome by the development of new type of artificial light
weight aggregate called as “J-Lite” (Figure 5). J-lite is made
from environmentfriendly coal ash and is twice as strong
as conventional light weight aggregate. Low shrinkage ultra
HSC termed as “Power Crete” with compressive strength as
high as 120 MPa, has been developed with the use of J-lite

Figure 4 AKIBA pedestrian bridge constructed with HSC (f’c = 120 MPa) in
Figure 2 Pre-grouted prestressing tendon Akihabara

www.masterbuilder.co.in • The Masterbuilder - July 2013 115

 Prestressed Concrete
together with expansion-producing admixtures and shrinkage
reducing agents. As strength development in lowshrinkage
HSC is independent of the curing condition, it can be used for
cast-in-place applications as well.
Figure 5 J-lite
Development of Modern Structural Systems in PC Bridges
External prestressing technique is widely being used in the
construction industry. Externally prestressed PC bridges
are designed with prestressing tendons placed outside
the concrete section, but still remaining within the bounds
of the cross section of girder (Figure 6). The concept of
external prestressing has become increasingly popular in the
constructions of medium- and longspan bridges due to its
several advantages such as reduced web thickness, possibility
to control and adjust tendon forces, and ease of inspection
of tendons during construction. The Japan Highway Public
Corporation (abbreviated for JH; it is changed to three highway
companies at present), has actively adopted the concept of
fully external tendons for box girder bridges (Figure 6) since
1999 due to the improved durability performance compared
to that of internally grouted tendons. It is of importance to note
that, recently, a new construction of PC bridges with internally
grouted tendons has been forbidden by the JH due to the
bad quality of grouting of internal tendons in some existing
PC bridges (Mutsuyoshi 2001). For the better performance
of the externally prestressed concrete bridges, various new
technologies have recently been developed in Japan.
PC Bridges with Highly Eccentric External Tendons
Although externally prestressed PC bridges are well recognized
to have several advantages, however, they have lower flexural
strength compared to that of bridges with internally bonded
tendons (Virlogeux 1988). This is due to the smaller tendon
eccentricity, which is limited by the bounds of concrete section
of girder (i.e., at the bottom slab in case of box-girder bridges)
as well as the reduction in tendon eccentricity at the ultimate
116 The Masterbuilder - July 2013 • www.masterbuilder.co.in
flexural failure (so-called second-order effect). One possible
method of enhancing the flexural strength of externally PC
structures is to make the tendons highly eccentricity (Figure
7). This kind of construction is possible only when external
prestressing is used, since this allows the tendons to be
placed outside the concrete section of girder. In this concept,
Figure 6 Typical layout of an external PC box girder bridge
Figure 7 Ordinary vs. highly eccentric external tendon
the compressive forces are taken by concrete and the tensile
forces by external tendons, thus taking advantages of both
materials effectively (Mutsuyoshi 2000).
There has been extensive research conducted at Saitama
University both analytically and experimentally to study the
fundamental behavior of girders with highly eccentric external
tendons (Aravinthan et al. 1999, Witchukreangkrai et al. 2000).
From the test results of single-span beams, it was found
that by increasing tendon eccentricity, the flexural strength
can be significantly improved or, conversely, the amount of
prestressing reduced; the result is more economical structures.
By extending the concept of highly eccentric external tendons
to continuous girders, the structural performance can be
further improved. In addition, the girders consisting of linearly
transformed tendon profile were found to have the same
overall flexural behavior (Figure 8). This gives the designer to
take advantage of arranging the external tendon layout freely,
depending on the site conditions.
To verify the application of this concept to the segmental
 Prestressed Concrete
construction method, the behavior of segmental girders with
highly eccentric external tendons was also investigated and
found to be nearly the same as that of monolithically cast
girders. Hence, this gives considerable flexibility in selecting
the method of construction when designing the bridges with
highly eccentric external tendons. One of the concerns raised
for this type of structure was the shear capacity as the girder
height is considerably reduced. It was verified, however, from
the experiment on shear characteristic of model specimens
that the shear capacity of the girder with highly eccentric
external tendons is much higher than that of the conventional
girders due to the large increase of tensile force in external
tendons.
The world’s first application of the prestressing with highly
eccentric external tendon to a continuous-span girder was
in the construction of the Boukei Bridge in Hokkaido, Japan.
Considering the site conditions, the bridge was designed with
a two-span continuous and unsymmetrical girder having a
total length of 57 m as shown in Figure 9. The effective width
of the bridge varies from 3.0 m at the abutments to 6.0 m at
the central pier. A completed view of the bridge is shown in
Figure 10.
The characteristic of this innovative bridge is that the external
tendon layout takes the similar shape of the bending moment
diagram as shown in Figure 11. The structure was designed
to form a pseudo truss, with the main girder made of concrete
as compression chords, the external tendons as tension
chords, and the steel deviators as diagonal members. This
allowed the girder height to be reduced significantly, thus
making the bridge lightweight. The external tendons are
placed below the girder in the midspan region by means of
Figure 8 Linear transformation of tendon layout
118 The Masterbuilder - July 2013 • www.masterbuilder.co.in
steel struts, the function of which is similar to a truss. At the
intermediate support region, it is placed above the bridge
deck and covered with a fin-shaped concrete web member.
The combination of the subtended tendons and the fin-
shaped concrete web makes this bridge a unique one with
aesthetically pleasing appearance.
Figure 9 Layout diagram and dimension of the Boukei Bridge
Although having several advantages, PC bridges with highly
eccentric external tendons should be carefully designed and
constructed concerning the following important points. Since
the main girder, struts and highly eccentric external tendons
form a truss in this type of structure, construction precision of
individual members has a significant influence on the structure.
For this, it is necessary to give special consideration to the
techniques and procedures for constructing the falsework,
formwork and external tendons. Moreover, the vibration
characteristics under service load may be of concern due to
the smaller stiffness of the main girder caused by the reduction
in girder height. Nevertheless, the authors believe that this new
concept of prestressing would pave way to a wider use of
external prestressing technology in the construction industry,
leading to improved structural performance as well as cost
effective PC bridges. The research is in progress regarding
the possibility of applying these kind of structures to highway
bridges using precast segmental construction.
Extradosed PC Bridges
An extradosed prestressing concept, which was first proposed
by Mathivat in France (Mathivat 1988), is a new type of
structural system in which the tendons are installed outside
and above the main girder and deviated by short towers located
at supports. Considering its definition, this type of bridge is
placed between cable-stayed bridges and ordinary girder
bridges with internal or external tendons.
Extradosed PC bridges have several positive characteristics.

The girder height may be lower than that of ordinary girder
bridges, thus reducing self-weight of structures. As shown
in Figure 12, the ratio of the girder height to the span length
(H/L) in extradosed bridges ranges between 1/15 and 1/35,
while it is approximately 1/15~1/17 for box-girder bridges.
Comparing to cable-stayed bridges, the height of the main
tower in extradosed bridges is lower; hence, a reduction in
labor costs of construction can be achieved.
Figure 10 Completed view of the Boukei Bridge
Because of a lower main tower in extradosed bridges, vertical
loads are partly resisted by main girders and stress variations
in stay cables produced by live loads are smaller than those
in cable-stayed bridges. This is quite similar to the behavior of
box-girder bridges, where the main girder itself has a decisive
influence on the structure rigidity and live loads produce only
limited stress variations in tendons. Based on these facts, the
Japan Road Association has recommended that the safety
factor for the stayed cables in extradosed bridges under
design loads shall be taken as 1.67 (0.6 fpu; fpu = tensile
strength of tendons), which is same as that for tendons in
ordinary girder bridges. For cablestayed bridges, this value is
specified to be 2.5 (0.4 fpu) (Japan Road Association 2002).
Figure 11 Schematic view of layout of external tendon
Prestressed Concrete
The major difference among box-girder, extradosed and
cable-stayed bridges can be further revealed by comparing
the relationship between materials used with span lengths. In
box-girder bridges, the average concrete thickness increases
with the span length, since the girder height is a function of
the span length. On the other hand, in cable-stayed bridges,
there is almost no increase in the average depth of concrete
because the girder height is generally designed to be 2.0~2.5
m, regardless of the span length. It is interesting to note that
extradosed bridges are placed between these two types, and
the rate of increase is also thought to be midway between the
rates of the other two types of bridges.
Similarly, with increasing span length, the quantity of prestressing
tendons in box-girder bridges shows a more increase than
that in cablestayed bridges, whereas extradosed bridges yield
the intermediate value between the other two types. From the
above discussion, it can be concluded that an extradosed
bridge is similar in construction and appearance to a cable-
stayed bridge. In the light of structural properties, however,
an extradosed bridge is closed to ordinary PC girder bridges,
and the design specifications may be considered to be the
same for both types of bridges.
Figure 12 Comparison among externally box-girder, extradosed and cable-
stayed PC bridges
www.masterbuilder.co.in • The Masterbuilder - July 2013 119
 Prestressed Concrete
In case of extradosed bridges it is necessary to provide an
structural rationale rather than simply assuming an allowable
stress of 0.6fpu in design of the bridges. In this point, attention
focuses on the distribution ratio of vertical load carried by the
girders and the stay cables. Figure 13 shows the relationship
between the distribution ratio of vertical load ( ) and maximum
stress change of stay cable due to design live load ( ) of
various cable-stayed bridges and extradosed bridges con-
structed in Japan. As shown in the figure, it is difficult to clearly
distinguish between extradosed bridges and cable-stayed
bridges in terms of structural mechanics since many of the
cablestayed bridges are very similar to extradosed bridges. In
designing stay cables, stress change due to design live loads
provides an effective index that can be easily determined
through the design process.
Approximated Design Method for Stay Cables
The fatigue limit state is usually critical in the design of stay
cables. When bridge structures reinforced by stay cables, the
design of stay cables would be structural rationale by focusing
on the stress change in the stay cables rather than defining
whether bridges are cable-stayed or extradosed by assuming
allowable stress for the stay cables. This would make it possible
to design each stay cable separately and enable the allowable
stress to be set individually for each stay cable. Unlike
suspension bridges, the stress change in a cable-stayed bridge
will differ depending on the stay cables and it is not rational to
define the allowable stress using a single value of 0.4fpu. This
is reflected in the “Specifications for Design and Construction
of Cable-Stayed PC Bridges and Extradosed Bridges” (Japan
Prestressed Concrete Engineering Association 2009). The
specification allows two kinds of design method. Method A is
normal fatigue design using fatigue load and design lifetime
of a bridge. However, it is usually difficult to estimate the
amount of future traffic and heavy trucks, especially in local
roads. In that case, method B using stress change in stay
cables due to design vehicular live loads is introduced. Figure
14 shows the relationship between the allowable tensile
Figure 13 Distribution ratio of vertical load and stress change of stay cable
120 The Masterbuilder - July 2013 • www.masterbuilder.co.in
stress (fa) of stay cable for highway bridges and the stress
change due to live load regulated in the specifications.
The difference in fatigue strength between prefabricated wire
type and strand type is considered. By using prior experience
in Japan with cable-stayed, extradosed and similar bridges
having spans of up to about 250 m, method B is defined so
as to ensure adequate safety in comparison with bridges
designed using method A. Fatigue design was performed
for the estimation line of stress range for two million cycles
( 2E6) including secondary flexural bending due to girder
deflection (determined according to design conditions on
a design service life of 50 years and average daily traffic of
70,000 mixing 50% trucks) by using the structural models
of the Odawara Blueway bridge, the Tsukuhara bridge, and
Figure 14 Allowable tensile stress and stress change of stay cable
the Ibi River bridge as shown in Figure 13. Based on the
calculations the stress change due to fatigue load is about
1/3 of that due to design live loads and the stress level due
to secondary flexural bending is the same as that due to axial
forces of stay cables. It is noted that the estimation line of
is assumed to be 2(1/3)(Max ). The safety margin of
2E6 L
method B can be confirmed by comparing with fatigue
2E6
strength (fscrd) divided by a safety factor ( b).
In the stay cables designed by method B, L
is determined
to require a safety factor of about 2.0 for 2E6
with respect
to fscrd / b, in order to take into consideration the fact that the
method includes more uncertainties than method A, and in
order that the safety of stay cables does not vary greatly from
that of cable-stayed and extradosed bridges constructed to
date. In the most of extradosed bridges and some cable-
stayed bridges, the tensile stress of 0.6fpu can be used
because stress changes are low (20 to 50N/mm2). Moreover
the most rational point of this specification is that we can
choose the tensile stress in each stay cable from 0.4fpu to
0.6fpu continuously. This is based on the concept that one
value of tensile stress in one bridge is not structurally rational.
 Prestressed Concrete
Figure 15 shows the Odawara Blue-Way Bridge, which is the
first extradosed PC box girder bridge in the world and was
completed in 1994. This bridge was designed with a three-
span continuous box-girder with extradosed prestressing,
having a middle span length of 122 m, a tower height (h) of
10.5 m, and a girder height at supports (H) of 3.5 m. The ratios
of h/L and H/L are approximately 1/12 and 1/35, respectively.
Figure 16 shows the prospective view of the Shin-Meisei
bridge on Nagoya Expressway No. 3 crossing the class-
1 Shonai River in western Nagoya. From both aesthetic
and economic viewpoints, the bridge was designed with a
threespan continuous rigid-frame structure with extradosed
prestressing, which is to become a landmark of Nagoya’s
western threshold. The length of the middle span (L) is 122 m,
a tower height (h) of 16.5 m, and a girder height at supports
(H) of 3.5 m, giving the ratios of h/L and H/L of 1/7.4 and 1/35,
respectively.
Corrugated Steel Web Bridges
In PC bridges with corrugated steel webs, light-weight
corrugated steel plates are used instead of concrete webs.
Figure 15 Odawara Blue Way bridge
Figure 16 Shin Meisei bridge (prospective view)
122 The Masterbuilder - July 2013 • www.masterbuilder.co.in
The corrugated steel plate webs are capable of withstanding
shear forces without absorbing unwanted axial stresses due
to prestressing, thus enabling efficient prestressing of top and
bottom concrete deck slabs, thus resulting in an “accordion
effect” (Figure 17). Moreover, the corrugated webs also
provide high shear buckling resistance. Use of light-weight
corrugated steel plates for webs causes a reduction of self
weight of about 25% of main girders. Therefore, this enables
the use of longer spans and reduction of construction cost.
The weight of a segment to be cantilevered during erection
can also be reduced, thus longer erection segments can be
adopted and construction period can be shortened. This also
eliminates assembly of reinforcement, cable arrangement
and concrete placement for concrete webs. Thus, saving
of construction manpower, quality enhancement and
improvement of durability are expected. In addition, replacing
the damaged deck slabs is easier than that in ordinary PC
bridges.
Recently, the use of corrugated steel web has been applied to
a variety of new constructions of PC bridges in Japan (Figure
18). In addition to the rigid or box girder bridges, the concept
of corrugated steel web was also successfully adopted in the
constructions of extradosed and cable-stayed PC bridges.
Figure 17 Typical section of PC bridge with corrugated steel web
Figure 18 Ginzanmiyuki bridge with corrugated steel web
 Prestressed Concrete
Rittoh Bridge located in the southern edge of Lake Biwa, is the
first extradosed PC bridge with corrugated steel web whose
main girder has a three-celled cross section, making it suitable
for a bilaterally suspended structure with a wide roadway. The
bridge consists of four-span and five span continuous rigid-
frame structure with total span length of 495m and 555m,
respectively (Figure 19).
Figure 19 Rittoh Bridge (Extradosed PC bridge with corrugated steel web)
Conclusions
Recent techniques in design and construction of PC bridges
in Japan were presented in this paper, with emphasis on their
background and development as well as their applications in
actual structures. Not only to improve the structural properties
in terms of safety, aesthetic and economical aspects, such
innovated technologies were developed to enhance the long-
124 The Masterbuilder - July 2013 • www.masterbuilder.co.in
term durability, which is becoming one of the serious problems
in concrete structures nowadays.
Considering the development of new construction materials,
the application of pregrouted internal tendons and use of
low-shrinkage HSC were discussed. In light of new structural
systems, external prestressing with highly eccentric tendons
and extradosed prestressing are excellent examples of a
wider use of external prestressing technology to achieve a
PC bridge with improved structural performance as well as
cost-effective outlook. The corrugated steel webs, which
take advantages of steel and concrete, have proved to be
one of promising solutions that can reduce the selfweight of
main girders, thereby enabling the use of longer spans and
reduction of construction cost.
Acknowledgement
The authors wish to acknowledge the members of the
international committee of Japan Prestressed Concrete
Engineering Association (JPCEA) for providing valuable
information. The authors would also like to extend their gratitude
to Nippon Expressway Company (NEXCO).
References
- Aravinthan T, Mutsuyoshi H, Hamada Y, and Watanabe M (1999)
“Experimental Investigation on the Flexural Behavior of Two Span
Continuous Beams with Large Eccentricities”, Transactions of
JCI, 21, pp. 321-326.
- Japan Prestressed Concrete Engineering Association (2009)
“Specifications for Design and Construction of Prestressed
Concrete Cable-Stayed Bridges and Extradosed Bridges”, (in
Japanese).
- Japan Road Association (2002) “Japan Specification of Highway
Bridges-Part I Common Part, Part II Steel Bridges, Part III Concrete
Bridges”, (in Japanese).
- Mathivat J (1988) “Recent Development in Prestressed Concrete
Bridges”, FIP Note, Feb., pp. 15-21.
- Mutsuyoshi H (2000) “State-of-the-Art Report on External
Prestressed Concrete Bridge with Large Eccentricity”, Concrete
Journal, 38(12), pp. 10-16 (in Japanese).
- Mutsuyoshi H (2001) “Present Situation of Durability of Post-
Tensioned PC Bridges in Japan”, Proceedings of the 1st fib/
IABSE Workshop on Durability of post-tensioning tendons,
Belgium, pp. 75-88.
- Mutsuyoshi H, Ichinomiya T, Sakurada M, and Perera S V T
J (2010) “High-strength concrete for prestressed concrete
structures”, CPI Trade Journal for the Concrete Industry, August,
pp. 42- 46.
- Virlogeux M P (1988) “Non-linear Analysis of Externally
Prestressed Structures”, Proceedings of FIP Symposium, Israel,
pp. 319-340.
- Witchukreangkrai E, Mutsuyoshi H, Aravinthan T, and Watanabe M
(2000) “Analysis of The Flexural Behavior of Externally Prestressed
Concrete Beams with Large Eccentricities”, Transactions of JCI,
22, pp. 319-324.
 Cement: Analysis

Indian Cement Industry

In Global Perspective
Major policy and fiscal initiatives initiated to catalyze infrastructure, housing
and industrial development continue to spur the demand for cement

Sadagopan Seshadri
Chief - Content Development, CE - Infrastructure - Environment

C
ement is vital to the construc-
tion sector and all infrastructure
projects. The cement industry
occupies an important place in the Indian
economy because of its strong linkages
with other sectors such as construc-
tion, transportation, coal and power. The
sector notably plays a critical role in the
economic growth of the country in its
journey towards an inclusive and de-
cidedly conclusive growth. The con-
struction sector alone constitutes 7 per
cent of the country's gross domestic
product (GDP).
Given the right drivers, no doubt
India has become the second largest
producer of quality cement in the
world. The cement industry in India
comprises 183 large cement plants
and over 365 mini cement plants. Cur-
rently, there are 40 players in the indus-
try across the country.
Trend & 'Demand-Supply' Match
The demand for cement, being a
derived one, depends mainly on the
industrial activities, real estate business,
construction activities and investment
in the infrastructure sector. The cement
industry in India continues to experi-
ence a boom on account of overall
growth in the economy.
Demand pattern for cement in India
is cyclical; barring short-term disrup-
tions, it grows largely in tandem with
economic growth. The growth in demand
driven by GDP has been ably catered on
the supply side by growth in production
to fill up the consumption growth on all
sectors of the economy. (See figures 1,
2&3)

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

 Cement: Analysis

Product Offerings
Trend in GDP and Growth in Cement Demand
The Indian cement industry is invol-
ved in production of several types of 16%
cement such as Ordinary Portland Cement
(OPC), Portland Pozzolana Cement 12%
(PPC), Portland Blast Furnace Slag Ce-
ment (PBFS), Oil Well Cement, Rapid 8%
Hardening Portland Cement, Sulphate 4%
Resisting Portland Cement, White Ce-
ment, etc. They are produced strictly as 0%
per the Bureau of Indian Standards

1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
-4%
(BIS) specifications, and their quality is
comparable to the best in the world.
GDP growth YoY (%) Cement demand growth YoY (%)
Market Size & Growth Areas
Source: Ambit Capital, Aranca Research
The cement industry of India is Figure 1 Growth in Demand
expected to add 30-40 million tonnes
per annum (MTPA) of capacity in 2013.
The industry has a current capacity of Production of Cement (MT)
324 MTPA and operates at 75-80 per
300
cent utilization.
"It is anticipated that the cement 247
industry players will continue to incre- 250
228
ase their annual cement output in com- 207
ing years, and the country's cement 200
182
production will grow at a compound 168
156
annual growth rate (CAGR) of around 150
12 per cent during 2011-12 - 2013-14 to
reach 303 million metric tonne (MMT), 100
according to a report titled 'Indian
Cement Industry Forecast to 2012', by
50
research firm RNCOS.
There have been strong demand
drivers even in the near term in the fol- 0
lowing sectors of economy. FY07 FY07 FY09 FY10 FY11 FY12E

1. Housing growth Figure 2 Supply: Growth in Cement Production

Source: Department of Industrial Policy and Promotion, Aranca Research
The Housing segment accounts for Notes: MT - Million Tonnes, E - estimate

www.masterbuilder.co.in · The Masterbuilder - July 2013 129

 Cement: Analysis
All India
CAGR 10%
196.4
177.5
163.4
FY08 FY09 FY10
Figure 3: Growth in Domestic consumption of cement (mtpa)
Source: CMA, Edelweiss, Aranca Research; Note: MTPA - Million Tonnes Per Annum
a major portion of the total domestic
demand for cement in India. Between
2010 and 2014, demand for housing
units is estimated to be 4.3 million, lead-
ing to a higher demand for cement for
homebuilding. Growing urbanisation,
an increasing number of households
and higher employment are primarily
driving the demand for housing.
Initiatives by the government are
expected to provide an impetus to con-
struction activity in rural and semi urban
areas through large infrastructure and
housing development projects.
2. Infrastructure growth
The government is strongly focused
on infrastructure development to boost
economic growth. It plans to increase
investment in infrastructure to USD1
Industrial
4%
13%
Commercial
Residential
63%
Figure 4 The 'Consumption Areas' Spread
130 The Masterbuilder - July 2013 · www.masterbuilder.co.in
demand for office space in India is
being driven by the increasing number
of multinational companies and the
265.9 growth of the services sector. Strong
236.3 growth in tourism, including both busi-
210.2 ness and leisure travel, has boosted
the construction of hotels throughout
the country.
Estimated demand by real estate
segment between 2010 and 2014:
Office (240 million sq ft), Retail (55 mil-
lion sq ft), Hospitality (78 million room
nights)
FY11F FY12F FY13F
Main Players
Although the Indian cement indus-
try has some multinational cement
giants, like Holcim and Lafarge, which
have interests such as ACC, Ambuja
trillion in the 12 th Five Year Plan (2012-
Cement and Lafarge Birla Cement, the
17), compared with USD514 billion
Indian cement industry is broadly home-
under the 11 th Five Year Plan (2007-12).
grown. Ultratech Cement, the country's
Infrastructure projects such as Dedi-
largest firm in terms of cement capac-
cated Freight Corridors as well as new
ity, holds around 22% of the do-mestic
and upgraded airports, and ports are
market, with ACC (50%-owned by Holcim)
expected to further drive construction
activity. The government in-tends to
expand the capacity of the railways and GDP (PPP) (2011) US$4.42bn
the facilities for handling and storage to GDP/capita (2011 est.) US$3700
ease the transportation of cement and Population (July 2012) 1205.1m
reduce transportation costs. Area 3,287,263km
Integrated plants 146
3. Commercial real estate growth
Integrated capacity 302Mt/yr
The demand for commercial real Grinding plants 55
estate segments, comprising retail Grinding capacity 63.5Mt/yr
space, office space and hotels, as well
as civic facilities, including hospitals, TOTAL CAPACITY 365.5Mt/yr
multiplexes and schools, has been ris- Table 1: Summary Statistics - India &
ing due to the growth in economy. The The Cement Industry
All India
10.0%
7.5% Ambuja Cement
ACC
Infrastructure 15.0% Ultratech Cement
20%
Jaypee Cement
66.1% 1.4%
Others
Figure 5: Market share by installed capacity (2011)
 Cement: Analysis
and Ambuja (50%-owned by Holcim)
having 15% and 13% shares respec-
tively.
Many of the remaining dozen top
players are Indian and are (in order of
diminishing market share); Jaiprakash
Associates (10%), The India Cements
Ltd (7%), Shree Cements (6%), Century
Textiles and Industries (5%), Madras
Cements (5%), Lafarge (5%), Birla Ce-
ment (4%) and Binani Cement (4%).
Between them, the top 12 cement
firms have around 70% of the domestic
market. Around 100 smaller players
produce and grind cement on a wide
range of scales but are often confined
to small areas.
An understanding of what factors
influenced in the making of the compo-
sition of this industry as it is, essential to
make prudent decisions on what are
interventions needed and whether these
issues will be instrumental in steering
the Indian Cement Industry towards a
consolidation over the next years. Most
answers may lie in,
'What does a new entrant experi-
ence in this sector? ',
Which can be summarily put as:
- Entry barriers are high as huge capi-
tal investments required present
substantial barriers to entry and
achieving economies of scale.
- Buyers' power - Substantial market
concentration among large players
ensures low bargaining power of
buyers.
- Substitutes threat - Cement, as of
now has practically no substitutes
and this is positive.
- Players' rivalry threat - The Indian
cement market is oligopolistic in
nature, characterised by tacit collu-
sion, where large players partially
control supply for better price disci-
pline. There have been off late CCI
trying though to intervene to set this
right. But as of now cement firms
rule the roost.
Government - The Right Initiatives
India would require overall cement
capacity of around 480 MT. The indus-
132 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Some of the initiatives taken by the
Government to further promote the
sector are as under:
Ÿ Excise duty rationalised for pack-
aged cement, whether manufactured
by mini cement plants or others.
Ÿ Packaged cement, whether man-
ufactured by mini-cement plants or
others, attracts differential excise
duty depending on the retail sale
price per bag. It is proposed to pre-
scribe a unified rate of 12 per cent + `
120 (US$ 2.16) PMT for non-mini
cement plants and 6 per cent + ` 120
(US$ 2.16) PMT for mini-cement
plants. It is proposed to charge this
duty on the retail sale price less
abatement of 30 per cent
Ÿ The Indian construction industry
has shown significant development
over the years with eminent and effi-
cient engineers at the helm and is
among the best in the world, said
Anand Sundaresan, Managing Direc-
tor, Schwing Stetter (India) while inau-
gurating a conference on 'Latest
Trends in Construction Industry'
Ÿ The private sector is expected to
contribute 44 per cent of the total pro-
jected spend of US$ 100 billion on
roads and highways over the Twelfth
Five Year Plan (2012-17) period.
try will have to add another 150 MT of
capacity during the period, according
to the latest report from the working
group on the industry for the 12th Five
Year Plan (2012-17).
The major policy and fiscal initia-
tives are expected to catalyze infra-
structure and industrial development in
the region, spurring the demand for
cement.
Investments: Confidence Makers
The cement and gypsum products
sector has attracted foreign direct
investments (FDI) worth ` 11,779.04
crore (US$ 2.12 billion) between April
2000 to February 2013, according to
the data published by the Department
of Industrial Policy and Promotion (DIPP).
Some of the major investments in the
sector are as follows:
- Barings Private Equity Asia has picked
up a 14 per cent minority stake in
the Indian unit of cement major
Lafarge, for ` 1,427 crore (US$
257.11 million)
- Sinoma International Engineering
(Hong Kong), a part of the Chinese
state-run National Materials Group
Corp, has entered the Indian
cement equipment industry by ac-
quiring a majority stake in Chennai-
based equipment manufacturer
LNV Technology
- Dalmia Cement plans to invest
` 1,800 crore (US$ 324.32 million)
to increase the company's cement
manufacturing capacity over the
next two years. The company also
plans to set up a 2.5 million tonne
(MT) greenfield unit in Karnataka
- Ambuja Cements plans to invest
` 2,000 crore (US$ 360.33 million)
to enhance its cement capacities in
Rajasthan and northern region. The
proposed project at Rajasthan
would add five MT capacity to the
total cement production of India
- Reliance Cement Company (RCC),
a subsidiary of Reliance Infrastruc-
ture Ltd, has commenced produc-
tion of cement from its first manu-
facturing unit at Butibori, Nagpur in
Maharashtra
Holcim, the Switzerland-based ce-
ment major, says India is among the
robust of markets in Asia. It has said so
at a time when the country's cement
sector faces rising costs and poorer-
than expected demand, despite this
being the peak construction period.
The company operates in India
through group companies ACC and
Ambuja Cements. It has said its out-
look for Asia continues to be positive
and that India, Indonesia and Philip-
pines rank among the most promising
growth markets. Its latest annual report
says prospects for the construction
industry are very good in these coun-
tries, given the high demand for infra-
 Cement: Analysis
structure expansion projects, as well
as the need for low-cost housing.
Holcim is expanding its production
capacity in India. ACC plans to raise
this from the existing 30 million tonnes
per annum (mtpa) to 35 mtpa, in a
phased manner till 2015. As part of this
project, a new plant at Jamul in the
state of Chhattigarh is under process.
Also at Jamul, grinding capacity is
being replaced. Part of the clinker pro-
duced in Jamul is earmarked for the
expanded Sindri grinding plant (in
Jharkhand) and for the new grinding
plant in Kharagpur (West Bengal).
ACC and Ambuja have a combined
capacity of 57 mtpa, around 16 per
cent of India's overall cement making
capacity of 360 mtpa.
Lafarge plans to expand its India
operations across the country despite
an anticipated slowdown, the French
major's chairman and CEO Bruno
Lafont said citing a new study that says
India will become the world's third-
largest construction market by 2025, to
support his buoyancy. The study by
Global Construction Perspectives and
Oxford Economics expects India to
add 11.5 million homes a year to be-
come a $1-trillion, or about 59 lakh crore,
a year market, even though it has cut
India's short-term growth prospects.
"The attractive growth of the con-
struction industry will be higher than the
short term economic growth. India is
one of our focus countries, as we want to
expand our operations from the North
"The attractive growth of the
construction industry will be
higher than the short term
economic growth. India is
one of our focus countries,
as we want to expand our
operations from the North
East to the rest of the
country,"
Bruno Lafont
CEO, Lafarge
East to the rest of the country," Lafont
told ET.
Lafarge is present in 65 countries
and Lafont says there is no easy coun-
try to work in. "The path that the Indian
authorities is taking is working; we are
happy in India," he says, but adds that
Lafarge would like to see a "simplifica-
tion of the framework of regulations so
projects can move faster."
Lafarge, which has opened a labo-
ratory in India to promote innovations that
are close to the market, will focus on
India's booming Tier 2 cities, Lafont says.
www.masterbuilder.co.in · The Masterbuilder - July 2013
Industry trends; Healthy & Wise
There has been an increasing pres-
ence of small and mid-size cement
players. Marked observation is of new
entrants and existing marginal ones'
capacity additions,
- Presence of small and mid-size ce-
ment players across regions is in-
creasing, which helps to diminish mar-
ket concentration of industry leaders
- Small and mid-size players have
been constantly increasing their in-
stalled capacity to cater to increas-
ing cement demand
Moreover, there is an Increasing sale
of blended cement, which was not so
earlier.
- The proportionate sales of blended
varieties of cement - Portland Pozzo-
lana Cement (PPC) and Portland
Blast Furnace Slag Cement (PBFC)
- has risen over the years
- During 2011, blended cement
accounted for 75 per cent of total
cement production in the country
The third factor that has emerged is
the serious attempt on Cost reduction
through the use of alternate fuels
- Major cement manufacturers in India
are increasingly using alternate fuels,
such as even bio-energy to fire ce-
ment kilns
- This is not only helping to reduce
production costs of cement com-
panies, but is also proving effective
in reducing emissions
133
 Cement: Analysis

complementing factors. Firstly, the fact

Company/Plant Strategy Benefits that (expensive foreign) coal, the domi-
nant fuel for the Indian cement industry
Use bioenergy through
acts as a strong driver towards effi-
Madras Cement's
Alathiyur plant burning of coffee hust Annual cost savings of USD 1.7 million ciency. This is complemented by a skilled
and cashew nut shells
knowledgeable engineering force that
maximizes operating 'equipment & sys-
India Cements Ltd's Use Low Sulphur Heavy
Annual savings of USD6500 approx.
tems' efficiency levels. Coal is a reliable
Dalavoi plant Stock (LSHS) sludge
as alternate fuel and stable kiln fuel that has helped
Indian kilns to be very finely tuned for
Use tyre chips and better efficiency.
UltraTech's Gujarat Reduction of about 30,000 tonnes of
Cement Works rubber dust as carbon emissions annually GHG emissions: in the matter of
alternate fuel
CO2 emissions per tonne of clinker,
India performs not that well, as CO2
Substitute 10% of released is 837 kg/t of clinker though
Lafarge's Arasmeta Higher energy savings and
plant coal used in kilns lower carbon emissions
with rice husk this is close to the global average. In
this respect cement, industries will have
to switch to alternate fuels of which Ger-
Figure 6 : Illustration of Successful use of alternate fuels in cement production
many is one of the best examples.
An illustration of successful imple- ity that the GNR programme received Indian cement industry too has entered
mentation of alternate fuel usage in data on (reference 2010 the most this arena (See fig. 8) but this is an
cement production to reduce produc- recent year for which data is available). aspect that has to be fully customized
tion costs is shown in Figure 6. Brazil and China, which also have rap- so that a proper balance in bet-ween
idly-developing large cement indus- carbon footprint and efficiency is main-
The Sustainability Score tained.
tries, performed slightly less well.( See
Energy efficiency: The Indian cement Figure 7) Finally, 'Low Carbon Technology
industry is one of the most energy effi- For all the three countries, it is the Roadmap' for the Indian cement indus-
cient, according to the World Business recent expansion of the industry that try is already under launch. The road-
Council for Sustainable Development's provides this thermal efficiency, an obvi- map will outline a possible transition
(WBCSD) Cement Sustainability Initia- ous consequence of the newly installed path for the cement industry to reduce
tive's (CSI) Getting the Numbers Right modern plants being more efficient its direct emissions by 18 per cent by
(GNR) data programme.7 than older ones. The comparison evi- 2050. Indian cement majors ACC Ltd,
Despite the large capacity of Indian dently is with the EU27 group of coun- Shree Cement and Ultratech have
cement industry, the country perfor- tries (and the USA to a greater extent), signed a cooperation pact to support
med extremely well in terms of specific which have older units. low-carbon investments in India. The
energy consumption per tonne of clin- In the Indian case, efficiency achi- pact was signed in Geneva with mem-
ker produced, with an average 3130 evement and its sustenance in the new ber companies of the World Business
MJ/t across the 50% of cement capac- capacity additions is attributable to two Council (WBC) for Sustainable Devel-

4500 1000
Specific energy consumption (MJ/t clinker)
Specific energy consumption (MJ/t clinker)

4000 900

3500 800
700
3000
600
2500
500
2000
400
1500
300
1000 200
500 100
0 0
USA Germany EU27 Brazil WORLD China India China USA India Brazil WORLD EU27 Germany

Figure 7 Energy Efficiency Figure 8 GHG Emissions

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

 Cement: Analysis
opment's Cement Sustainability Initia-
tive and International Finance Corpora-
tion (IFC).
Additional capacity requirement-
What to Expect?
An improved capacity utilization not-
withstanding the surge in continued
demand is pushing up increasingly the
need for installed capacity addition.
Installed capacity increased at a
CAGR of 13 .6 per cent over FY06-11
while production witnessed an increase
of 9.1 per cent during this period.
Total capacity of 331 MT is esti-
mated to have been created in FY12.
Considering the sharp growth in
construction, infrastructure and real es-
Additional capacity creation as per the 12th Five Year Plan
12.9
FY12
Figure 10: Capacity Creation
450
400
Amount of Cement (Mt)
350
300
250
200
2011
Figure 11 Capacity v/s Capacity Utilization
136 The Masterbuilder - July 2013 · www.masterbuilder.co.in
primarily based on the pace of activities
All India
82 in the business, financial, real estate and
78 77 infrastructure sectors of the economy,
all of which are racing ahead, cement
demand will continue to demonstrate
healthy growth trend. Cement being
the most preferred building material
FY11F FY12F FY13F worldwide for all construction works
from housing and industrial construc-
Figure 9 : Forecasted capacity
utilization levels of cement players (%) tion to the creation of infrastructures
like ports, roads, power plants, etc. the
tate in the Indian economy, It is logical industry will expand by leaps and
that the 12 th Five Year Plan estimates bounds. As for the Indian cement in-
additional capacity requirement will dustry, it is globally competitive with the
surely reach 139.7 MT by FY17 industry having demonstrated healthy
trends in terms of cost control and a
What lies 'Ahead'?
continuous technology upgradation.
By virtue of Cement's demand being While India is experiencing growth
in all areas, the industry and the cement
market is moving ahead even in the
wake of world-wide economic reces-
sion. The domestic environment too is
38.7 spurred up by initiatives taken by the
35.5 Government of India to various infra-
30.2 structure projects, road network and
25.3 housing activities with a huge 1.15 lakh
crore investment basket. The right
moves by the government should be a
13.4 big compliment to an industry which
too has done a lot of good work on
capacity addition, utilization, efficiency
and environmental measures.
FY13 FY14 FY15 FY16 FY17
References
1. ACC Ltd. http://www.acclimited.com/
2. World Bank Indicators website.
3. United States Geological Survey.
100 4. Cement Manufacturers' Association
website: 'http://www.cmaindia.org
95 /portal/static/DynamicHistory.aspx
90 5. 'Global Cement Directory 2013,' PRo
Publications International Ltd., Epsom,
Capacity utilisation rate (%)
85 UK, November 2012. Global Cement
80 http://www.globalcement .com/
6. Singh, S.P. 'Assessment of competi-
75
tion in cement industry of India,' Com-
70 petition Commission of India & Vinod
Gupta School of Management, IIT,
65
Kharagpur,.
60 7. World Business Council for Sustain-
55 able Development, Cement Sustaina-
bility Initiative.
50
8. Global Cement website, 'Cement
2012
2013
2014
2015
2016
industry in India,' http://www.ibef.org/
industry/cement-india.aspx, Updated
November 2012.
 Concrete: Rheology

A Review of Fresh Cement and

Concrete Rheology
Sonjoy Deb, B.Tech,
Civil Associtate Editor

R
heology is the science of the deformation and flow
of matter, and the emphasis on flow means that it is
concerned with the relationships between stress, strain,
rate of strain, and time. Available literatures have helped to
overcome perceptions of the difficulty of rheology with its
often mathematically complex relationships. Flow is concerned with
the relative movement of adjacent elements of liquid and
in shear flows liquid elements flow over or past each other,
while in extensional flows elements flow towards or away from
each other. In a shear flow, imaginary parallel layers of liquid
move in response to a shear stress to produce a velocity
gradient, which is referred to as the shear rate, equivalent to
the rate of increase of shear strain. Elongation or stretching
flows are rarely found in cement systems but there may be
some elongation at the entry or exit of a pipe. They will not be
considered further here. The rich variety of material behaviour
can be characterised in various ways, of which the flow curve
showing how shear stress and shear rate are related is very
common, but equally data may be presented as the variation
of viscosity (the ratio of shear stress to shear rate) with shear
rate or time.
Basic Information on Rheology
Rheology is the scientific description of flow. The rheology
of concrete is measured with a concrete rheometer, which
determines the resistance of concrete to shear flow at various
shear rates. Concrete rheology measurements are typically
expressed in terms of the Bingham model, which is a function
of:
- Yield stress: the minimum stress to initiate or maintain flow
(related to slump)
- Plastic viscosity: the resistance to flow once yield stress is
exceeded (related to stickiness)
Concrete rheology provides many insights into concrete
workability. Slump and slump flow are a function of concrete
rheology. Refer Figure 1 for a typical rheometer and typical flow
curve.

138 The Masterbuilder - July 2013 • www.masterbuilder.co.in


Workability versus Rheology
- Workability tests are typically empirical
- Tests simulate placement condition and measure value
(such as distance or time) that is specific to the test method
- Difficult to compare results from one test to another
- Multiple tests needed to describe different aspects of
workability
- Rheology provides a fundamental measurement
- Results from different rheometers have been shown to be
correlated
- Results can be used to describe multiple aspects or
workability
Figure 1: Rheometer and Typical Flow Curve
Concrete Flow Curves
- Flow curves represent shear stress vs. shear rate
- Bingham model is applicable to majority of concrete
- Other models are available and can be useful for specific
applications (e.g. pumping)
- Very stiff concrete behaves more as a solid than a liquid.
Such mixtures are not described by these models.
Refer a Flow curve in Figure 2.
Rheology Measurement: Typical Geometry
- Rheometers must be uniquely designed for concrete
(primarily due to large aggregate size)
- Results can be expressed in relative units (torque vs.
speed) or absolute units (shear stress vs. shear rate)
Concrete: Rheology
Figure 2: Flow Curve
Some Concrete Rheometers are shown in Figure 3 below:
Rheology Testing Methods for Cement Based Materials
There are well−established rules for the sizes of apparatus
and sample to ensure that rheological measurements are
reliable, chiefly that any gap must be 10 times the size of the
largest particles and that the ratio of outer cylinder radius to
inner must be less than 1.2. For coarse granular materials like
concrete this means that a coaxial cylinders viscometer is
impracticably large, requiring a sample volume of 2.5m3 [1],
whereas a specially designed one for mortar is feasible [16,17]
and cement pastes are well within the capability of any of the
wide range of laboratory instruments available commercially.
These principles are equally applicable to other geometries
and mean, for example, that the cone and plate viscometer
cannot be used for suspensions because the gap is zero
under the apex of the cone. This led to the development of
the truncated and annular plate and cone geometries [8].
Fresh concrete
Because of the impracticability of using a coaxial cylinders
viscometer of anything like ideal dimensions for fresh concrete,
Tattersall and co−workers developed a highly successful
and practical apparatus in which an interrupted helical
impeller rotates in a cylindrical bowl of fresh concrete and the
www.masterbuilder.co.in • The Masterbuilder - July 2013 139
 Concrete: Rheology
behaviour is analysed using the theory of mixing [1]. This has
been developed further by Domone and Banfill [18] and the
current computer assisted model of the Two−point apparatus
is available commercially [19]. Following calibration it can
deliver the yield stress and plastic viscosity of fresh concrete
in fundamental units. Other, broadly equivalent, approaches
to the measurement of fresh concrete rheology have
produced the IBB rheometer [20], the BML rheometer [21]
and the BTRHEOM [22]. These instruments were developed
in different countries and the question naturally arose as to
whether the results can be compared. The first attempt to
answer this was a programme of comparisons achieved by
bringing all four instruments together at a single location with a
fifth, the Cemagref−IMG [23], a large (0.5m3) coaxial cylinders
instrument used as a standard, all under the sponsorship of
the American Concrete Institute [24]. While each instrument
characterised fresh concrete as a Bingham material and the
yield stresses and plastic viscosities measured on the 12
concretes tested remained in the same rank order, the results
fell into two groups. The Cemagref−IMG and BTRHEOM
agreed well, and the Two−point and BML agreed well,
with the second group giving a generally lower yield stress.
Pairwise correlations were highly significant and enable the
result of one test to be predicted from another. Since the
BTRHEOM uses parallel plates, the Cemagref− IMG uses
coaxial cylinders, the Two−point uses an interrupted helix
rotating in a cylinder and the BML uses coaxial cylinders this
agreement is encouraging.
Mortar
Mortar can be considered to be fresh concrete without the
coarse aggregate and its testing has attractions for the study
of the effects of ingredients at small scale. A coaxial cylinders
viscometer, while feasible, proved to be inconvenient and
Banfill described the use of the Viskomat as a small calibrated
mixer for mortar testing [25]. More recently Jin [26] used a
scaled down interrupted helix (like the Two−point impeller)
Figure 3: Rheometers
140 The Masterbuilder - July 2013 • www.masterbuilder.co.in
in an extensive study of the mortar fraction for design of self
compacting concrete and demonstrated that its rheology
could be predicted with a high degree of certainty from tests
on the rheology of the mortar.
Progress with cement paste
Experimental challenges for testing cement pastes and
slurries are the risks of slippage at the walls of the viscometer,
sedimentation of the particles and plug flow. Depletion of
particles at the viscometer surface can result in a thin (<1mm)
layer of water which facilitates bulk flow of the sample,
superimposed upon the shearing flow within the rest of the
material. The result is an underestimate of the stiffness of the
sample [27]. The slip can be avoided using a roughened
surface and Mannheimer [28] showed convincingly that
slippage reduced measured yield stress by 85%. This is
supported by comparisons between smooth coaxial cylinders
and a vane−in−cup apparatus: slippage in the former
reduced the measured yield stress by 50% but oscillatory
measurements at lower stresses were indistinguishable [29].
However, proof that slippage does not occur with roughened
surfaces above the yield stress has been elusive. At the high
water contents representative of concrete, the particles in
cement pastes may separate gravitationally and centrifugally
and this can cause errors. When measurement geometries
include devices to keep the paste homogeneous the results
are much more satisfactory. These include angled blades
to lift the particles [30], recirculating pumps [31], blades
with interlocking fingers [32] and more conventional mixers
[33]. The problem of plug flow, when the shear stress does
not exceed the yield stress everywhere in the sample and
some part of the sample does not shear, was first raised by
Tattersall and Dimond [34] but has never been satisfactorily
resolved. They found that hitherto irreconcilable anomalies
in breakdown measurements were explained when filming
the flow in the gap of a coaxial cylinders viscometer revealed
that a solid plug of paste formed and was either stationary
(rough cylinders) or slid round slowly (smooth cylinders).
No satisfactory explanation has ever been offered for this
anomalous plug flow but its existence casts doubt on all
experimental data where full shearing flow has not been
confirmed visually.
Rheological Results of Cement Based Materials
It might be expected that the rheology of the more complex
material, concrete, containing a wider range of particle sizes,
would be more complicated than that of one of its constituent
materials, cement paste, but in fact fresh concrete has proved
to be simpler and considerable practical progress has been
made with it and, more recently, with mortars.
Concretes
Much work has been done on the effects on the rheology of
 Concrete: Rheology

Self-compacting
Material Cement paste, grout Mortar Flowing concrete Concrete
concrete
Yield stress N/m2 10-100 80-400 400 50-200 500-2000
Plastic viscosity Ns/m 2
0.01-1 1-3 20 20-100 50-100
Structural breakdown Significant Slight None None None
Figure 4: Rheology of cement paste, mortar and concrete

concrete of mix constituents and their relative proportions, mathematical forms, all of which indicate the existence of a
cement properties and admixtures and cement blending yield stress:
agents [1,17,20,21,35]. Concrete conforms to the Bingham
model and does not show structural breakdown over the
(1)
range of shear rates used in the test. Yield stress and plastic
viscosity vary in a complex fashion with composition and this (2)
makes rheology measurement a versatile way of controlling
the quality of fresh concrete production: tests carried out on
(3)
the fresh concrete can show up changes in the mix composition
which may have implications for the concrete’s hardened (4)
properties and performance in use [35]. With the recent advent of
self−compacting concrete, characterised by a very low yield (5)
stress, it has been found that the thickeners used to prevent
segregation in use by raising the viscosity of the water also
change the flow curve from the normal Bingham behaviour to (6)
Herschel− Bulkeley type behaviour (see below) [26].

Mortars (7)

Mortars undergo structural breakdown and measured data
are sensitive to the previous shear history of the sample,
but the equilibrium flow curve conforms to the Bingham
model [25] The effects of composition are similar to those
observed in fresh concrete and mortar tests can be used as
small scale predictors of concrete rheology [26, also Banfill,
unpublished].
Cement Pastes
There are qualitative and quantitative disagreements between
the results for cement paste reported by different research
workers. The flow curve has been reported to fit several different
Where A, B and C are constants.
Additionally the numerical values reported for the rheological
parameters cover a very wide range, which cannot be wholly
explained by variations in the materials used. It can only be
accounted for by accepting that differences in experimental
technique and apparatus of different workers have a much
greater effect than has been generally realised. Differences
in the shear history at the time of test, undetected plug flow
and slippage at the smooth surfaces of a viscometer could
all combine to give experimental variations as large as those
reported. However, there is general agreement on two fun-
damental qualitative aspects of the behaviour of cement pastes.

142 The Masterbuilder - July 2013 • www.masterbuilder.co.in


Comparison of Cement Pastes, Mortar and Concrete
Figure 4 shows that there is a trend in the rheological properties
of cement−based materials, as quoted in the literature, which
can be explained semi quantitatively by the presence of
aggregate in the coarser grained materials. The flow properties
of suspensions are governed by the interfaces between solid
and water and, in terms of the surface area of contact, the
dominant contribution is due to the cement−water interface.
This is progressively diluted by the presence of aggregate. Thus,
for example in one comparison, two cements which gave pastes
whose rheological parameters differed by a factor of two
produced concretes of indistinguishable flow behaviour [1].
The yield stress and plastic viscosity increase as the maximum
particle size increases. This is because in a typical concrete at
least 50% by volume is in the form of aggregate which is capable
of withstanding the applied stresses without deformation:
consequently the yield stress is higher, a point confirmed by
the increase with increasing aggregate content in concrete [1].
The increased plastic viscosity is partly due to the increased
interparticle contact and surface interlocking, as demonstrated
by the fact that for two concretes with the same yield stress
containing rounded and angular coarse aggregates, the
plastic viscosity of the latter is higher. It is also partly due to
the inability of the aggregate to be sheared: when an overall
shear rate is applied to an imaginary concrete consisting of
aggregate and paste 50:50 per cent by volume, the shear
rate within the solid aggregate particles is zero and that in the
paste is. This higher shear rate results in a higher stress and
resistance to flow in the paste which in turn accounts for the
increase in measured plastic viscosity of the bulk material.
In contrast, the yield stress and plastic viscosity of cement
paste increase as the cement gets finer [44], which reflects
the dominance of the water−cement interface in this system.
Evidently the influence of particle size is a surface area effect in
fine grained pastes and a simple volume effect in the coarser
grained concretes. Perhaps further work on particles suspended
in dispersions will suggest the particle size range where the
Concrete: Rheology
change from one influence to the other occurs.[45]
Models for Particular Situations
Pumping
Transport of fresh concrete by pumping through pipes to
the point of placement has been used since the 1930s and
is an obvious candidate for rheological study, to help select
pumping equipment and conditions. Pipe flow of a Bingham
material is well characterised and the variation of shear stress
from a maximum value at the wall of the pipe to zero at the
centre line means that a plug of solid unsheared material
moves surrounded by a zone of shearing flow from which
pressure−flow rate equations have been derived [1,7].
However, this assumes that the material is homogeneous,
whereas pumped concrete actually forms a layer of paste
which lubricates the wall and facilitates flow. Therefore the
pumpability of a concrete is mainly governed by its ability to
form and maintain this layer under the pumping conditions
and an acceptance test has been developed [48]. In fact,
practical problems with blockage of pipe work have meant
that most pumping trials have had to be done at full scale,
which is both costly and inconvenient.
Interactions at the Surface of Formwork
A related problem requiring a knowledge of friction at a
concrete−wall interface is the pressure on formwork, which is
lower than the equivalent hydrostatic pressure because of the
yield stress within the material and the friction at the wall [50],
but empirical predictions underestimate the actual pressures
measured for modern highly fluid concretes. Friction between
steel and fresh concrete was measured in a tribometer based
upon moving a steel plate between opposed pressurized
cylinders filled with concrete which exert a known stress
normal to the surface [51,52,53]. Applying the coefficient
of friction between steel and concrete determined in this
apparatus enabled preliminary estimates of the formwork
pressures exerted by fluid and self compacting concrete to
be compared with those measured in full size formwork up to
www.masterbuilder.co.in • The Masterbuilder - July 2013 143
 Concrete: Rheology
12 meters high. This confirmed the complexity of the factors
affecting formwork pressure and showed that it is about 25%
less than hydrostatic for a self−compacting concrete, but
the contribution of friction depends on surface roughness,
concrete rheology and particle size distribution.
Vibrational Compaction
Vibration is the most popular means of compacting fresh
concrete into formwork and around reinforcement and there
is an extensive literature on the effects of such features as
frequency, amplitude and acceleration, but several recent
papers have significantly advanced understanding. Practically
vibration removes the yield stress of fresh concrete which
then flows under its own weight [54,55] and the important
characteristic of the vibration is the peak velocity. The fluidity
of vibrated concrete, defined as the reciprocal of its low shear
rate viscosity, is proportional to peak Vibrational velocity up to
a critical value, above which it is constant, and the viscosity
of the vibrated concrete is proportional to the plastic viscosity
of the unvibrated concrete [56]. This work enabled the effect
of vibration to be defined phenomenologically but a more
rigorous investigation was recently completed by Teixeira et
al [57].
The Action of Superplasticisers
It has long been established that superplasticisers can have
spectacular but sometimes unpredictable effects on the
rheology of cement systems. The yield stress of cement and
concrete are reduced to very low values by the dispersion
of flocculated cement particles [1]. However, the progress
of the hydration reactions causes stiffening (slump loss)
and this can be a serious practical problem. Flatt and Houst
proposed that there are three components of the behaviour of the
superplasticiser added to the system [59].The first part is consumed
by intercalation, coprecipitation or micellization within the
hydrating cement minerals, forming an organo−mineral phase.
The second part is available for adsorption at the surface of
cement particles and is effective in dispersing the flocs, but
the adsorbed amount is not easily measured since current
analytical methods are based on the amount removed from
solution and this cannot distinguish between admixture
consumed in the first part and adsorbed on surfaces [60,61].
Conclusion
Rheology is important because of the scope it offers for
characterising fresh cement paste, grout, mortar and concrete,
and for understanding how they perform in practical applications.
Without satisfactory fresh properties it is unlikely that the
desirable properties of the hardened materials can be achieved.
Their rheology is dominated by the structure that exists in the
cement paste, but in mortar and concrete the structure has
been partially or fully broken down during mixing. As a result
they conform closely to the Bingham model and their behaviour
144 The Masterbuilder - July 2013 • www.masterbuilder.co.in
during pumping, vibration and in formwork can be explained
by reference to that model. Reliable instruments for testing
the coarser grained materials are available and experience
in comparing the data is growing. In contrast there remain
apparently conflicting results for cement pastes, which are
probably due to the different experimental techniques used
by different workers. The important effects of shear history,
mixing energy and wall slippage on the results obtained in
viscometers are only now being generally understood. Rheology
can be optimized to ensure concrete performance
Reference
[1] Tattersall, G.H., Banfill, P.F.G. The rheology of fresh concrete, Pitman,
(1983), 356pp
[2] Banfill, P.F.G. (editor) The rheology of fresh cement and concrete,
Spon, (1991), 373pp.
[3] Bartos, P.J.M, Marrs, D.L., Cleland, D.J. (editors) Production methods
and workability of concrete, Spon, (1996), 541pp.
[4] Skarendahl, A., Petersson, O. (editors) First international RILEM
symposium on self−compacting concrete, Spon, (1999), pp.786.
[5] Nonat, A. (editor) Why does cement set? An interdisciplinary
approach, 2nd International RILEM workshop on hydration and
setting, RILEM Publications Sarl, (1997), 419pp.
[6] Barnes, H.A., Hutton, J.F., Walters, K. An introduction to rheology,
Elsevier, (1989), 199pp.
[7] Barnes, H.A. A handbook of elementary rheology, Institute of
Non−Newtonian Fluid Mechanics, University of Wales, (2000),
200pp,
[8] Banfill P.F.G., Kitching, D.R.Use of a controlled stress rheometer to
study the yield value of oil well cement slurries, The rheology of fresh
cement and concrete, Spon, (1991), pp125−136.
[9] Bombled, J.P. A rheograph for studying the rheology of stiff pastes:
application to cement setting, Revue des Materiaux de Construction,
no. 673, (1970), pp.256−277.
[10] Barnes, H.A., Carnali, J.O. The vane−in−cup as a novelrheometer
geometry for shear−thinning and thixotropic materials, Journal of
Rheology, vol.34. (1991), pp.841−866.
[11] Gregory, T. The measurement of early strength development in
polymer modified cement pastes, 5th International congress on
polymers in concrete, (1987), pp.205−208.
[12] O’Keefe, S.J. Rheological properties of polymer modified cement
pastes, PhD thesis, Bristol Polytechnic, (1991), pp.232
[13] Banfill, P.F.G., Carter, R.E., Weaver, P. Simultaneous rheological and
kinetic measurements on cement pastes, Cement and Concrete
Research, vol.21, (1991), pp.1148−1151.
[14] Schultz, M.A., Struble, L.J. The use of oscillatory shear to study flow
behaviour of fresh cement paste, Cement and Concrete Research,
vol.23, (1993), pp.273−282.
[15] Keunings, R. A survey of computational rheology, 13th international
congress on rheology, (2000), vol.1, pp.1.7−1.14.
[16] Banfill, P.F.G. Feasibility study of a coaxial cylinders viscometer for
mortar, Cement and Concrete Research, vol.17, (1987), pp.329−33.
[17] Banfill, P.F.G. A coaxial cylinders viscometer for mortar: design and
experimental validation, Rheology of Fresh Cement and Concrete,
Spon, (1991), pp.217−226.
[18] Domone, P.L.J., XuYongmo, Banfill, P.F.G. Developments of the
two−point workability test for high−performance concrete, Magazine
of Concrete Research, vol.51, (1999), pp.171−180.
For complete list of the reference kindly view the digital edition.
 Cements

Low Carbon Cements and Concretes

in Modern Construction
A John W Harrison
Managing Director, TecEco

A multidisciplinary analysis and review of low carbon cements and concrete is provided. Options are set out in a table and explained
in the context of a wide range of disciplines and concepts. The paper takes a lateral thinking approach and calls for a change in mindset,
teaching methods and the way standards are written so that the business model of cost cutting prevalent in the industry can change. It finds
that significant de-carbonation will result not so much by changing the chemistry of existing cements or by developing new ones but
by focussing on properties affecting lifetime energies and making CO2 and other wastes resources to manufacture synthetic carbonate
aggregates and introducing carbon capture during manufacture or Portland and other hydraulic cements.

There are some significant problems facing humanity including
climate change, ocean acidity and food shortages, land
degradation and water pollution by wastes. At the 2007 “Driving
CO2 Reduction” National Conference held in Melbourne on
13 & 14 September 2007 M K Singh stood up and said “I want
the cement industry to be the saviour of the world”. Concrete
can be and those in the industry who take on this challenge
will succeed. We must however think outside the square and
develop new technical paradigms1.
Cement production was 3.4 billion tonnes in 2011 and the
concrete produced with it roughly 28 billion tonnes. The annual
carbon emissions from the cement in this huge material
flow amount to roughly 2.9 billion tonnes of carbon dioxide,
or 8.8%2 of total anthropogenic carbon emissions making
cement a significant source of emissions. If other associated
supply chain releases are included, significantly more.
China and India between them are now consuming 40 times
more cement and concrete than the USA. India currently
produces around 210 million tonnes of cement, second to
China at around 2 billion tonnes (25).
There is a solution to global warming, salinity and many other
global problems and it is potentially very profitable. TecEco
Gaia Engineering utilises the huge flow of concrete to create
an enormous CO2 sink and I will explain this as I go through
the options and issues for cement and concrete in modern
construction.
cement does not have change so much as the composition of
concrete. Cement is only around 10% of concrete. The use of
a high proportion of SCM’s coupled with synthetic carbonate
aggregates made from flue CO2 and waste magnesium ions
and other materials effecting properties3 would make concrete
made with any hydraulic cement currently associated with
emissions a very green material with net sequestration.
Mehta summarised some of the techniques used by architects
for dematerialisation (15) but did not consider the effect of
dematerialisation on lifetime or operational energies and
TecEco have realised the potential of carbon capture during
manufacture.
These and other alternatives are summarised with reference
to Table 1 that follows. I then address the options, dealing with
those that have been dealt with in the literature adequately
more briefly than others that have not.
Alternative Binders
There are a large number of alternative binders and many
options to improve the energy and emissions associated with
their manufacture. Given necessary brevity and the fact that
they have been dealt with extensively by others most of them
are presented as Table 2 - Future Binder Contenders with

According to the British Research Establishment (BRE) we cannot

address de-carbonation without changing the composition
of cement and fuel derived emissions will diminish slowly for
purely economic reasons (19). Papers describing numerous
different binder formulations abound and I have written some
of them.

The BRE are applying the wrong emphasis. The composition of Figure 1 - Predicted Global Cement Demand and Emissions (19)

148 The Masterbuilder - July 2013 • www.masterbuilder.co.in


Figure 2 - Mehta’s Triangle (15)
Differentiated Supply Chain Options on the next page. Data
on production emissions with and without capture in most
cases is included.
Noticeably the hydraulic cement group dominated by Portland
cement is the largest and there are many variants providing
high early strength, sulphate resistance etc. Many of the new
cements are variants of a Portland cement theme.
Hydraulic Cements
There is significant potential for carbon capture with cements
made with a calcination step such as most if not all hydraulic
compositions. This potential is covered in more detail under
the heading Alternative Manufacturing Processes.
Slag-lime or slag – Portland Cement (PC) cements. Slag is made
from ground granulated blast furnace slag (GBFS) which is
a waste and latently hydraulic. It can be used with activators
such as Portland cement (PC), lime and/or reactive magnesia
Option Description Players
Alternative Binders Numerous and described in Table 2 Scientists
- Future Binder Contenders with Dif- (Cement
ferentiated Supply Chain Options Chemists)
CO2 Capture during Reduce process emissions. Cements Scientists.
Manufacture that involve calcination can be made TecEco and
without releases. Calix.
Replacement of Blending with Limestone with ce- Cement
Portland cement by ment to reduce net emissions has technol
Limestone met with some success and is now ogists
incorporated into many standards.
There are however issues.
Replacement of Blended cements that contain a high Cement
cement by SCM’s volume of replacement materials technol
(SCM’s) such as fly ash, slag ce- ogists
ment (gbfs), pozzolans, silica fume,
rice husk ash etc. High replacement
cement concretes often have im-
proved properties such as rheology,
less shrinkage, greater durability etc.
The use of reactive MgO makes the
use of higher proportions of
SCM’s possible.
Cements
(according to our patents) to make a cement4.
Calcium sulfoaluminate cements & belite calcium sulfoaluminate
cements are low energy cements that can be made from
industrial by products such as low calcium ( class F) flyash and
sulphur rich wastes. The main hydration product producing
strength is ettringite. Their use has been pioneered in China and
more recently in the UK.
Calcium aluminate cements are hydraulic cements made from
limestone and bauxite. The main components are monocalcium
aluminate CaAl2O4 (CA) and mayenite Ca12Al14O33 (C12A7)
which hydrate to give strength. Calcium aluminate cements are
chemically resistant and stable to quite high temperatures.
Belite cements can be made at a lower temperature and contains
less lime than Portland cement and therefore has much
lower embodied energy and emissions. Cements containing
predominantly belite are slower to set but otherwise have
satisfactory properties. Many early Portland type cements
such as Rosendale cement were rich in belite phases. (See
http://www.tececo.com/links.cement_rosendale.php.)
Reactive magnesia blended with other hydraulic cements and
Supplementary Cementitious Materials (SCM’s)5 Reactive
magnesia (rMgO)6 is a powerful new tool in hydraulic cement
blends. 15-30% improvement in compressive strength and
greater improvements in tensile strength, much faster setting,
better rheology and less shrinkage and cracking, less bleeding
and long term durability have been demonstrated with 50 %
replacement and more of PC by flyash and GBFS. We believe
autogenous shrinkage has been solved.7 rMgO is an ideal
Standards &
Drivers Barriers
Guides
Sustainability and Conservatism, out dated software. Prescrip- A few guides and
profit. tion standards and approvals draft standards (e.g.
systems (see http://www.tececo.com /sustain with Geopolym ers)
ability.permissions_rewards.php.)
Sustainability, Inability to think laterally. Fear of change Common sense!
carbon taxes.
Economic Buyer hesitancy. New standards
cost/benefit, emerging because
sustainability, industry driven.
Leed, GBC, r & d
& procurement
Policies.
Economic cost / Conservatism, out dated software. Prescrip- Mix design methods.
benefit, tion standards and approvals LCA & LCCA. New
sustainability, systems (see http://www.tececo.com/sustain better software.
Leed, GBC, r & d ability.permissions_
& procurement rewards.php.)
Policies.
www.masterbuilder.co.in • The Masterbuilder - July 2013 149
 Cements

Dematerialisation Innovative architecture and engineer- Architects Economic cost / Prescription standards and approvals systems Design codes, LCA
ing. More durable concretes. & benefit, (see http://www.tececo.com/sustain & LCCA
Engineers sustainability, ability.permissions_rewards.php.)
Leed, GBC, r & d
& procurement
Policies.
Mix Optimisation Appropriate particle packing, better Cement Economic Conservatism, inappropriate software. Mix design methods.
admixtures and use of brucite technolo- cost/benefit, Prescription standards and approvals systems LCA & LCCA.
hydrates to release water for more gists sustainability. (see http://www.tececo.com/sustain New better software.
complete hydration ability.permissions_rewards.php.)
Product Differentia- Mineral composites other than Materials Economic Inability to think outside the box. Fear of Standards, LCA &
tion and Specialisa- concrete with just stone aggregate scientists cost/benefit change LCCA
tion can improve sustainability. E.g.
composites with a high “R” value
Changing the An emphasis other than on the bind- Scientists Sustainability, Inability to think outside the box. Fear of Common sense!
emphasis er to improve sustainability. E.g. Use economic cost/ben- change. Technical issues (?).
of synthetic carbonate aggregate. A efit. Technical merit
greater focus on properties having a
high impact on lifetime energies.
The Right Business Although not a technical matter the Consultants Profitability in a Conservatism, standards and legislative
Model right business model is essential for changing business environment.
progress to be made. environment
The Right Framework Legislative restrictions and standards Scientists The need to Conservatism, inability or unwillingness to
to Operate in throughout the world are prescrip- and change change.
tive in nature and this and a lack of Consultants
training is holding back innovation.
There is a strong need to throw away
dogma for what it is and get back to
science.
Table 1 - Ways to make Cement and Concrete More Sustainable.

additive as it aids the dissolution of SCM’s and contributes mortars. As water of crystallisation is not also taken up, the
positively to many other properties (See REPLACEMENT OF solid produced to input mass ratio is lower than for magnesium
CEMENT BY SCM’S 7 based carbonating binders which is a disadvantage.

Chemical Cements Other Cements

Magnesium Phosphate Cements are chemical cements that
rely on the precipitation of insoluble magnesium phosphate
from a mix of magnesium oxide and a soluble phosphate. They
include some of the oldest binders known8 and are potentially
very green if the magnesium oxide used is made with no
releases or via the nesquehonite (N-Mg route) which is part
of the TecEco Gaia Engineering solution (See ALTERNATIVE
MANUFACTURING PROCESSES. It would also be good if a
way is found to utilise waste phosphate from feedlots9.
Carbonating Cements
Reactive Magnesia Based Carbonating Binders can, like
lime, be used for full thermodynamic cycle binders such as
carbonating mortars. Reactive Magnesia (rMgO) has the
advantage of also taking on water of crystallisation so the
solid produced for input mass ratio is higher than for lime
based carbonating binders. rMgO can also be made without
releases10.
Geopolymers are potentially very green but suffer from a
number of fundamental flaws that will restrict their use and
increase risk outside factory environments where they are
currently being mainly used. They suffer from the nanoporosity
durability flaw and the fact that water is not consumed in their
setting with the result that making them fluid enough for easy
placement is difficult.
Because geopolymers are nanoporous soluble aggressive
agents can get into them and attack aggregates. What makes
them risky to use is the variability of results obtained. The
problem is that the amount of water added is critical - too
much and they are insufficiently alkaline or too little and they
cannot be placed. Getting over these problems has been the
main area for research and some success has been achieved
as geopolymer premix concretes are commercially available
as at the time of writing in Australia for non - structural
applications.

Lime Based Carbonating Binders can, like magnesia, be used Sialites are a neologism for rocks made in a manner mimicking
for full thermodynamic cycle binders such as carbonating natural rock forming processes. 11 The technology is not new

150 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Cements

CO2 /tonne output in 1 year)

Net Emissions (Sequestra-

Process CO2 (tonnes CO2 /

(tonnes CO2 / onne output)

tion) (tonnes CO2 / tonne

Re – absorpti on (tonnes
Total Emissions (tonnes
Decarbo nation CO2

Example of Cement
CO2 / tonne output)

output in 1 year)
Cements Based on

tonne output)

to/proponent
Type applies

Comment
Process

Type
PC Conventional .266 0.498 .764 .004 .760 Ordinary portland Most dense Normal premix. No sup-
cement concretes plementary cementious
or pozzolanic materials
PC Permeable .266 0.498 .764 .144 .620 Carbonated ordinary Gas permeable No supplementary
block Portland cement blocks substrate cementious or
formulation pozzolanic materials
42% PC 8% .199 .209 .408 .001 .407 Terniary mix with Most dense concretes Faster setting and
MgO 25% MgO additive. higher early strength
Flyash 25%
GBFS
PC With capture .266? .266? .004 .266? Recapture during Most dense No supplementary
calcination. concretes cementious or
pozzolanic materials
MgO 750- Conventional .240 1.092 1.322 -1.092 .240 Eco- Cements sorel & Historic and Sorel and Mg phos-
1000oC magnesium phosphate conventional phate cements. TecEco
cements. Eco-Cement Force
carbonated pure MgO
(Cambridge University)
MgO <750oC Tec-Kiln .240 .240 -1.092 -.851 Eco-cement Brucite TecEco, Cambridge Sorel and Mg phos-
(with capture) (MgO) boards University phate cements. TecEco
Eco- Cement Force
carbonated pure MgO
(Cambridge University)
MgO <450oC MgCO3 .3H2O .378 .007 .385 -1.092 -.706 Eco-cement concrete, TecEco, University TecEco, University of
Conventional pure MgO concretes of Rome La Sapienza. Rome La Sapienza.
calcination
MgO <450oC MgCO3 .3H2O .378 -1.085 -.706 -1.092 -1.798 Eco-cement concrete, TecEco N-Mg route TecEco
Tec-Kiln pure MgO concretes
(with capture) Novacem concretes?
MgO <450oC MgCO3 .3H2O .369 -.743 .374 -.874 -1.248 Eco-cement concrete, TecEco N-Mg route TecEco
20% PC 80% Tec-Kiln pure MgO concretes
MgO (with capture) Novacem concretes?
Silicate route Novacem, Calix? After Klaus Lackner?

CaO Conventional .266 .785 1.051 .785 .266 Carbonating lime mortar Calera, British Lime
Assn & many others
CaO CaCO3 Tec-Kiln .266 .266 .785 -.518 Carbonating lime mortar Calera, British Lime Small net sequestration
(with capture) Assn & many others with TecEco kiln
C3S Conventional ? 0.578 >0.578 ?  >0.578

C2S Conventional ? 0.511 >0.511 ? >0.511 Belite cement Chinese & others

C3A Conventional ? 0.594 >0.594 ? >0.594 Tri calcium aluminate Increased proportion
cement
C4A3S Conventional ? 0.216 >0.216 ? ? Calcium sulfoalumin Chinese & others
ate cement
Geo polymers Flyash + NaOH 0.16 0.16 Geopolymer Alliance,
Geopolyer Institute,
University Melbourne

152 The Masterbuilder - July 2013 • www.masterbuilder.co.in


Table 2 - Future Binder Contenders with Differentiated Supply Chain Options
Notes to Table 2 - Future Binder Contenders with Differentiated Supply Chain Options
1. http://www.tececo.com/files/spreadsheets/TecEco-CementLCA15Jan2013.xls, 2. Quillin, K. and P. Nixon (2006). Environmentally Friendly MgO-based cements to support sustainable con-
struction - Final report, British Research Establishment., 3. http://www.geopolymers.com.au/science/sustainability Much of the thermodynamic data used in this table has been calculated using
TecEco’s LCA Tool downloadable from the TecEco web site at http:// www.tececo.com/files/spreadsheets/TecEco-CementLCA15Jan2013.xls. The tool is in the form of an editable Excel spread
sheet with no password that calculates energy and emissions to the factory gate only. Please send any corrections or suggestions to a.john.w.harrison@tececo.com
as it has been known by some for years how to solidify some
fly ashes12 for example.
Alternative Manufacturing Processes
So far the industry response has mostly been to:
- Modernise and upgrade plant
- Convert wet to dry plant processes
- Convert shaft to rotary kilns
- Install preheating, more efficient burners etc.
- Improve grinding and other efficiencies.
- Burn cheaper waste fuels. Burning waste materials with
high calorific value including timber, tyres, solvents, waste
oil, animal fats, carbon waste from the aluminium industry
(14) etc. has met with opposition in some countries
because of the associated pollution.
- Reduce kiln temperatures and adjust the composition of
cement accordingly with more aluminates and less alite13.
Capture During Manufacture
Significant sequestration can be achieved with capture of
CO2 from kilns but the problem, which has not been solved
yet for any form of sequestration, is what to do with it. One
approach taken by Ramesh Suri of ACC in 2006/7 was to
use Algae to consume the CO2 and produce bio fuel14. The
problem lies in the sheer volume of CO2 produced and in
making the sequestration process profitable. To meet this
challenge TecEco is developing the N-Mg sub-process of
Gaia Engineering that will sequester huge amounts of CO2
as synthetic carbonate that can be used as aggregate or as
feedstock to make rMgO for its cements15.
Manufacturing Taking Advantage of Full Thermodynamic
Cycles
The manufacture and use of Portland cement does not involve
a full thermodynamic cycle and there is therefore little point in
splitting the process into the endothermic16 and exothermic17
sub processes18 with one or two exceptions such as the
manufacture of Syngas19.
It is a different situation with carbonating cements containing
rMgO such as TecEco Eco-Cement. Recapture occurs with
net sequestration possible if CO2 is also captured during
calcination.
The real game changer and pinnacle of industrial ecology is
our N-Mg sub process of Gaia Engineering that will produce
large quantities of nesquehonite (MgCO3.3H2O) from waste
Cements
magnesium cations such as found in oil process water and bitterns
and if this source runs out then from any brine containing
Mg++(step 1).
Nesquehonite can then be calcined in our Tec-Kiln without
releases (step 2) to make rMgO and the CO2 fed back into
the process (step 1) to precipitate more nesquehonite.
The rMgO is then used as a binder to agglomerate massive
amounts of nesquehonite to make synthetic carbonate
aggregate or in TecEco Eco-Cements where it re carbonates
(step 3).
The sequestration into synthetic carbonate aggregate without
saturating the market for aggregate is sufficient to solve the
global carbon problem as can be seen from the graph in Figure
6 below.
Eco-Cement binders according to TecEco Pty. Ltd.’s patents
are ideal for agglomerating synthetic carbonate aggregate
and from the graph the total sequestration possible given
2011 – 12 concrete production is over 22 billion tonnes which
is around 2/3 of that needed to consume all anthropogenic
emissions. As a matter of proportion, the particular cement
used in the future becomes less important in relation to the
total sequestration possible in concrete if the focus is also on
aggregate.
TecEco call this breakthrough technology Gaia Engineering
and it is a whole new way of thinking about industrial ecology
and associated molecular flows. Gaia Engineering can
profitably solve the problem of global warming and related
problems such as ocean salinity and in doing so mitigate
other problems such as pending food shortages15.
Replacement of Portland Cement by Limestone
Limestone is now routinely being added to Portland cement
in varying proportions around the world and some success
is being claimed mainly as a result of the improved particle
packing.
Compton and Chandler make it clear that Portland cement
is not the best possible additive however when they say
“limestone is generally considered to be the poorest potential
performer of the available suite of mineral additions and as
such considerable effort is focused on developing Portland-
limestone cements that achieve the current general purpose
Portland cement performance” (2)
By adding limestone to Portland cement the industry may be
www.masterbuilder.co.in • The Masterbuilder - July 2013 153
 Cements
reducing the effectiveness of better and more suitable mineral
additions such as rMgO and supplementary cementing
materials (SCM’s) classified and ground as necessary to
optimise particle packing. The SCM’s most commonly used
include fly ash, ground granulated blast furnace slag and
silica fume. Greater consumption of such wastes should be
encouraged not compromised by a lowering of pH caused by
the addition of limestone.
Hooton, Nokken and Thomas make it clear “One area where
there is very little data is on the influence of limestone cements
when used in conjunction with SCM’s. A question that needs
to be answered is whether the use of limestone cements will
reduce the replacement levels of SCM’s that can effectively be
used.” (8) A theoretical analysis of the issue is on our TecEco
and Gaia Engineering web sites20
At the present time “considerable effort is focussed on
developing Portland-limestone cements that achieve the
current general purpose Portland cement performance” (2).
The goal is to find out just how much ground limestone can
be added without compromising the properties of normal
cements too much. The argument is that “limestone is the
obvious choice for most cement manufacturers. It is a
fundamental raw material at cement plants, and high grade
limestone is readily available through its use as a supplement
to amend raw meal chemistry. Limestone is abundant, pure
and soft and makes an ideal mineral addition to be inter-
ground with clinker and gypsum during cement milling” (1)
Given the theoretical evidence I present on the TecEco web
site20 it is essential that cement that consists of clinker and
gypsum in the right ratio with 5 % or less of limestone21 and
nothing else continues to be made available for downstream
blending as the economics of other mineral additions will
change and many work much better such as rMgO which
would otherwise compete with limestone for interstitial sites
between cements grains.
Reactive magnesia blended with Portland cement and SCM’s
results in significant improvements in properties as detailed in
the next section. The problem is that best results are achieved
Figure 3 - Options for Portland Cement Manufacture
154 The Masterbuilder - July 2013 • www.masterbuilder.co.in
if it is fine enough to also fill interstitial sites between grains of
Portland cement.
Replacement of Cement By SCM’S
Portlandite should not be left in a concrete because it is far too
reactive. On the other hand consuming it all in the pozzolanic
reaction also has technical issues. Mistakes are routinely
made. Portland cement can be blended with pozzolans such
as flyash which will consume Portlandite (Ca(OH)2) in the
pozzolanic reaction. It is important however that not all of the
Portlandite is consumed as calcium will start leaching from
CSH22 if it is. As an alternative pH buffer we recommend the
addition of rMgO which hydrates to brucite. The equilibrium
pH of Brucite is approximately 10.5 and the pH of CSH
Figure 4 – Manufacture of MgO from Magnesite with and without Capture
around 11.2 (22). The pH of a CSH and Brucite assemblage
in equilibrium will not fall much below 10.5.
According to the 12th plan in India around 10 million tonnes
of GBFS are produced annually (10). In a recent article by Dr
Yashpal Singh a figure of around 175 million tonnes of flyash
was estimated for 2012 (20).
As most SCM’s are wastes their use is obviously more
sustainable than digging up limestone, grinding it and adding
it to cement and the paradox is that the use of limestone may
compromise the use of SCM’s as explained in the previous
section.
In many parts of the world builders are negative about the
use of SCM’s because when added, concretes take longer
to gain strength. Grinding cement finer to compensate for
the negative chemical effects of limestone should have been
considered as one way of making it more reactive with SCM’s
such as flyash however this costs money. Another is to air
classify pozzolans increasing their reactivity.
A way of accelerating the setting of mixes containing a high
proportion of SCM’s is to include about 8-10 % rMgO as a
proportion to PC in a mix. The reason is because when
dissolved in water Mg2+ has a profound effect on the polarity
of all species in solution that can be polarised. Of particular
 Cements

dimensional distress in the proportions we recommend and

Figure 5 - The N-Mg Sub-Process of Gaia Engineering
interest in relation to cement are water and its disassociation
species.
Mg++ is a strong kosmotrope and strongly attracts electrons
and brucite (including microcrystallites) has a strongly charged
surface. Water dipole strength is increased and propagated
in mix water. Water and its disassociation species such as
hydroxides have reduced negative electron clouds around
protons. Dissolution of SCM’s by proton wrenching occurs
more readily, speeding up reactions and making their use
more acceptable to builders24.
does not act in the same way.
Dematerialisation
Dematerialisation is a technique for reducing the materials
used by design and has been practiced for many years
by some architects. As the subject was covered by Mehta
extremely well (15) I will not elaborate. I refer readers to Figure
2 - Mehta’s Triangle on page 3 and comment that the impact
of dematerialisation on lifetime energies must be considered.
Mix Optimisation
Mix optimisation is mostly an art and should be a science.
It is not practiced widely enough and there are a lot of
shortcuts in the software used. More often than not the “rule
book” of prescriptive standards is religiously followed without
questioning why. For example the use of gypsum to prevent
flash set even when blended with SCM’s.
An important aspect is particle size and charge. It is not
just what is in the mix but the particle size range of each
component and how they fit together in 3D space. The smaller

With about 8-10% of reactive magnesia (rMgO) added, 50%

or more of (SCM’s) can be used and the resulting concretes
still outperform ordinary Portland cement concretes25. This
may not be achievable with higher additions of inter-ground
limestone. Surely the goal should be to use SCM’s most of
which are wastes.

The focus of my efforts in the past few years has been to find
ways of making reactive magnesia much more cheaply so it
will be blended with Portland cement and SCM’s as a matter
of routine as it should be. Readers should however be aware
that some manufacturers are actively selling magnesia for use
in concrete without stating the reactivity in possible breach
or circumvention of our patents and possibly dangerously as Assumptions
well because magnesia that is not highly reactive can cause Tec-Cement concret with synthetic magnesium carbonate
aggregate
Percentage by weight of cement in concrete 12.00%
Percentage by weight of rMgO in Tec-Cement 9%
Percentage by weight Ca (OH)2 in cement 29%
% of Ca(OH)2 in concrete that carbonates 10.00%
Proportion cement that is flyash and/or GBFS 20%
1 tonne Portland Cement 0.867 Tonnes CO2
Proportion concrete that is aggregate 80.0%
CO2 captured in 1 tonne aggregate 1.084 Tonnes CO2
Net CO2 sequestration 1 tonne rMgO (N-Mg route, 1 complete 1.794 Tonnes CO2
recycle)
CO2 captured hydration and carbonation of tonne Cao (in PC) 0.785 Tonnes CO2
Figure 6 – Sequestration capturing CO2 from the air in the N-Mg process using
TecEco’s Tec-Kiln Figure 7 - The Sequestration Potential for Synthetic Carbonates in Concretes

156 The Masterbuilder - July 2013 • www.masterbuilder.co.in


the average size of each addition the more particle charge
becomes important26.
What is or is not included should be carefully considered with
end use in mind and many changes are suggested in this
paper. RMgO for example accelerates first set because it goes
negative at the surface as the pH rises as demonstrated in
Figure 10 above/
It is important to realise that packing considerations apply
to all components in a mix, not just the cement and that small
component substitutions can make a big difference to pro-
perties and the amount of cement required to achieve a
given strength. Less cement for a given strength is more
sustainable.
A pioneer in this field is de Larrard from France (13)(12) and
the TecSoft27 project at TecEco has been initiated to implement
some of his math.
Mix optimisation is also too focussed and should be better
connected with need as discussed in the section with the title
Product Differentiation and Specialisation.
Product Differentiation and Specialisation.
It has been said in the industry that “all that is grey is great, all
we make goes out the gate”. Significant amounts of energy
would be saved with specialisation for differentiated market
niches. Market penetration would also increase with the
development of new concrete product.
With rising energy costs and an urgent need to improve
sustainability additions to cementitious composites that
improve lifetime or operating performance are an import
part of a profitable future. Many waste streams can offer a
wider range of properties for purposes such as thermal
insulation or weight reduction. With the use of rMgO any toxics
are encapsulated as well as immobilised and bonding to
alternative included materials such as agriculture or domestic
wastes is dramatically improved as are fire resistant properties.
Concretes with high thermal mass for heat retention and
Figure 8 - Gaia Engineering
Cements
concretes with greater elasticity and plasticity for road pavement
are other examples.
New mineral composites incorporating waste streams with
low thermal flow characteristics will be in high demand (e.g
sawdust blocks) in the future and will drive this differentiation.
Cementitious composites such as concrete can take a lead
role in reducing lifetime energies and become part of the
solution instead of the problem.
Changing the Emphasis
It is essential to think of concrete not just cement as each
component has a role in the performance at every stage. It we
think whole of concrete as recommended by Ken Hover (9)
and many others then it becomes much easier to understand
the material and issues concerning it such as sustainability.
There is too much emphasis on strength and not enough on
durability and properties. As discussed under the heading
Product Differentiation and Specialisation. Concretes with a
wider range of properties such as low conductance or light
weight could play a major role in reducing the lifetime or
operational energies of structures.
About seven years ago now I realised that aggregate is 80%
or more of most concretes and therefore represented an
opportunity to sequester huge amounts of carbon dioxide as
synthetic carbonate in our Gaia Engineering process explained in
this document under the heading Capture during Manufacture
and in a lot more detail at www.gaiaengineering.com.
The Right Business Models
For a long time a cost cutting model has dominated the efforts
of players in our industry however if we are to move forward
and fulfil the potential of solving many of the world’s problems
this will have to change. New innovation based business
models will have to be adopted.
Most governments have realised that innovation is important
and in relation to this some interesting statistics are coming
Figure 9 –The Mg++ ion drags electrons to it exposing more electro positive
protons23
www.masterbuilder.co.in • The Masterbuilder - July 2013 157
 Cements
out of the Department of Industry, Innovation, Science,
Research and Tertiary Education in Australia that conclusively
demonstrate that innovative companies perform better (See
Figure 11)
Figure 10 The Change in the Surface Charge of Metal Oxides with pH. (21)
Companies in the construction sector including the concrete
industry do not spend much on research as shown in Figure
12. The main reason why is because our industry is bound
by a framework of standards, legislation and conservatism
that has resulted in low margins. It is no wonder cost based
business models prevail.
The Right Framework to Operate in
The concrete industry in most countries operates with a
restrictive framework of standards and guides and supporting
legislation that breeds conservative managers who do not
innovate and a cost cutting business model. Our engineers
are taught to rely on out of date dogma not rely on science or
their common sense. Change must occur if we are to move
forward on sustainability and take advantage of emerging
opportunities for carbon trading. Given the lack of training and
education at the base level this will be a difficult challenge.
An Inappropriate Permissions and Rewards Systems
At Concrete Solutions 09 (6) I spoke about the tremendous
potential for players in the concrete industry to make money
as a result of inevitable change yet many barriers still exist as I
have discussed. One of the greatest remains our ill-conceived
permissions and rewards systems28 designed with the false
notion that they protect the status quo. There is a rising current
of change that I helped initiate and prescriptive standards and
inappropriate legislation is getting in the way.
Standards for cement and concrete are still prescription based
in most countries and even the Green Building councils in the
US, Australia and elsewhere have fallen into the same trap of
locking in the status quo and stifling innovation. Prescriptions
should be confined to guidelines on how to do things. Standards
should set out minimum performance requirements in a chosen
range of categories. In order to take advantage of carbon
158 The Masterbuilder - July 2013 • www.masterbuilder.co.in
trading the industry should also consider using standards,
modified as suggested, as a way of providing benchmarks for
minimum embodied energy and emissions. Existing standards
could be relegated to a role as guides.
Legislative Frameworks fall into the same trap as standards
with too much restriction although some governments such
as my own here in Australia pay lip service to the need for
change as evidenced by renaming departments with the
word “innovation” included. The way forward surely lies in
better education and training and the conversion of standards
to guides. The concrete industry produce and place the most
used and important materials in construction yet in many
countries no qualifications of even basic training are required
by those practically involved. This deplorable situation must
improve and hopefully the training is not rote but such that it
awakens minds to the possibilities.
The Right Policies to Support Research and Development
to Improve Sustainability
Few governments have ever managed to get the mix of
stick, incentive and procurement right or even remotely
efficient. The level of control continues to increase without
the leadership to drive it. As Lord Stern made clear in his
review of the economics of climate change (23) there are
huge opportunities for emissions reduction in building and
construction, not just in reducing the embodied energy and
emissions of the materials we make but by changing the way
we design structures and the way we utilise the materials we
use to build them.
The biggest problem is that governments do not follow their
policies through the supply chain. It is no good supporting the
Research and development of for example carbon capture
methods without making sure there are financial sticks and/or
incentives to encourage the changes required to the process
of making cement.
Back to Science
There are too many non - scientific dogmas in the cement and
concrete industry.
At TecEco we have relied on science to explain what we
Figure 11 - Increases in Business Performance by Innovation status 2008 – 9(4)
 Cements
observe. By using science rather than applying dogma it is
easier to understand what is really happening and see a way
forward for improvement.
Conclusions
It is time cement companies adopted a business model that
connects innovation with profitability. In many other industries
profitability is understood to be a function of research and
development and that the regular release of new technically
improved product generates revenue growth. Progress towards
de-carbonation will be slow unless this occurs.
Engineers should be taught science not dogma and standards
need to be rewritten as benchmarks not prescriptions. The
legislative framework in many countries needs a broom through
it and governments need to realise that the concrete industry
could in fact be the saviour of the world as M K Singh bravely
arose and said29.
All this can only be achieved if there is a change in mindset,
a strong desire to move the agenda towards greater sustain-
ability forward, a willingness to throw away the rule book, a
whole new modern scientific lateral thinking.
Last century there were many different mineral cement
contenders and Portland cement was only one of them. By
1900 it emerged as the dominant formulation. In the future a
new differentiation of product based on properties will probably
occur and this will be a good thing as it will result in greater
margins and product more suited to particular use such as,
for example, the development of binders suitable for utilising
wood waste to make insulating composite products for the
outside of buildings including rMgO for fire retardation. The
major barrier to implementation will be the mindset of our
managers and out dated prescription based standards.
John Phair said at the conclusion to his paper that “Further
developments and new techniques must continue to be
introduced into the cement and concrete industry. Green
chemistry will play a significant role in facilitating a holistic
industrial ecological approach to cement from a fundamental
level. This will provide distinct alternatives to an OPC dominated
Figure 12 – Australian R & D Expenditure by Industry Size (Bubble diameter)
Employment and Gross Value Added. (3)
160 The Masterbuilder - July 2013 • www.masterbuilder.co.in
cement market.” (18). There will be greater diversification and
alternatives but in my view the market will still be PC and PC
derivative based but only if new formulations and production
processes that include capture are implemented such as our
N-Mg process which produces synthetic carbonate aggregate.
Chemistries that fix known “sleeper” issues such as Portlandite
content will need to be embraced including our own Tec and
Eco-Cement technologies. With the use of a high proportion
of SCM’s, particularly if pre - blended the addition of gypsum
and limestone are questionable. As Paul Hawken makes clear
in “The Ecology of Commerce,”concrete that is more durable
is more sustainable(7).
By adopting a whole of concrete approach there is much more
scope for sustainability. The obvious target in construction
is to lower lifetime or operational energies so we should be
thinking properties as well as strength and durability and this
will require product diversification.
Paradigm changes such as our Gaia Engineering project will
modify the supply chain to focus on carbon capture and then
use the CO2 produced to manufacture synthetic carbonate
aggregate.
A new approach to cement and concrete formulation cannot
evolve without the realisation that concrete can be part of the
solution not the problem.
Portland cement concretes are the most ubiquitous and will
probably remain so because immense economies of scale
make them relatively cheap and sustainability problems can
be overcome by carbon capture with CO2 used as synthetic
carbonate aggregate and a reformulation excluding limestone
and gypsum and including reactive MgO and a mix of classified
fine and normal SCM’s in high proportion.
Footnotes
1 The technology paradigm defines what is or is not a resource.
2 The Chinese government (16) estimate that 861 kg (net) of CO2 are
emitted for every tonne of Portland cement clinker produced. The
production of 3.4 billion tonnes cement would results in emissions of
2.9 billion tonnes CO2. Global emissions are around 33 billion tonnes
(17) so the current contribution of cement production globally as 2.9/33
x 100%, or 8.8%.
3 The inclusion of additions that introduce properties such as thermal
capacity and lower heat transfer rates have significant scope to reduce
lifetime or operational energies. Many of these additions can be
sourced from waste streams.
4 We include for convenience GBFS in our definition of hydraulic cements
in our patents in most countries and claim the right to reMgO GBFS
mixes. Beware of infringements. We do not think reactive magnesia
(rMgO) a good activator but it is an excellent additive and facilitates
more rapid dissolution
5 The NRMCA’s CIP 30 – Supplementary Cementitious Materials
includes pozzolans which by themselves do not have any cementitious
properties and other materials such as ground blast furnace slag that
do.
6 The magnesia must be reactive and be wary of imitations that are not
 Cements
7 Much more detailed information is available in the TecEco web site in
the downloads area.
8 Dung + MgO in ancient Indian stupas.
9 Thereby solving an environmental pollution problem.
10 See under the heading Alternative Manufacturing Processes.
11 The name Sialite is attributable to Dr Henghu Sun and others of the
Pacific Resources Research Center in California, in collaboration with
Tsinghua University in Beijing; see (24) for a description.
12 Depending on the composition
13 Pers comm. WA (Tony) Thomas – Chief Engineer Concrete, Boral
Construction Materials
14 http://www.tececo.com/files/newsletters/Newsletter64.htm
15 See www.gaiaengineering.com home page and some of the latest
movie downloads at http://www.gaiaengineering.com/movies.php
16 Calcination of limestone.
17 Reaction of quicklime (CaO) with clays, shales etc to produce clinker.)
18 More processes result in more process energy.
19 Dr Sheila Devasahayam at the SMaRT Centre, School of Materials
Science and Engineering, The University Of New South Wales, is
researching pyroprocessing CaCO3 with an additive to produce
Syngas
20 In the technical areas of www.tececo.com and www.gaiaengineering.
com under the heading “Ground Limestone in Portland Cement - A
Good Idea or Lost Opportunity”.
21 Preferably none at all
22 Properties will change and CSH is thought to become more brittle (5).
23 Water is in equilibrium with hydroxide and hydronium ion ions. When
acidic or basic compounds are dissolved the equilibrium is pushed
towards more hydronium or hydroxide ions respectively. e.g.: H2O
<=> H3O+ + OH The hydronium ion is highly solvated and H5O2
+, H7O3 + and H9O4 + are increasingly accurate descriptions of the
environment of a proton in water. Chemists represent a hydronium ion
as just a hydrogen ion (H+, as in the figure) in place of H3O+
24 See the web page Reactive Magnesia - A Theoretical Explanation of
Properties in the technical area at www.tececo.com
25 See Presentation 50 at http://www.tececo.com/document.conference_
presentations.php
26 It is not well known that electrostatics plays a significant role in the
setting of concrete (11)
27 See www.tecsoft.com.au
28 See also http://www.tececo.com/sustainability.permissions_rewards.php
29 See Introduction
References
1 CHALMERS, DES, MARSTON, ERIK. Principles and practices in the
use of limestone mineral addition in general purpose cements. 2012,
38(1):
2 Compton M, Chandler J. Elevated limestone mineral addition impacts
on laboratory and field concrete performance. Concrete in Australia.
2012, 38(1):27 ‑ 33.
3 Department of Industry, Innovation, Science, Research and Tertiary
Education(Australia).AustralianInnovationSystemReport2012[Internet].
Department of Industry, Innovation, Science, Research and Tertiary
Education (Australia); 2012. Available from: http://www.innovation.gov.
au/Innovation/Policy/AustralianInnovationSystemReport/AISReport
2012.pdf
4 Department of Innovation, Industry, Science and Research (Australia).
Australian Innovation System Report 2011 [Internet]. Department
of Innovation, Industry, Science and Research (Australia); 2011.
Availablefrom:http://www.innovation.gov.au/Innovation/Policy/
Australian Innovation System Report/ AISR2011 /wp-content/
uploads/2011/07/Australian-Innovation-System-Report-2011.pdf
162 The Masterbuilder - July 2013 • www.masterbuilder.co.in
5 Glasser FP. Pers. comm. 2002,
6 Harrison AJW. The Implementation and Advantages of Carbon Trading
in the Concrete Industry. In: Concrete Solutions. Luna Park, Sydney:
Concrete Institute of Australia; 17-19 Sept 09.
7 Hawken P. The Ecology of Commerce. New York: Harper Collins;
1993.
8 Hooten, R. D, Nokken, M, Thomas, M.D.A. Portland-Limestone Cement:
Stte-of-the- Art report and Gap analysis for CSA A 3000. University of
Toronto for the Cement Association of Canada; 2007.
9 Hover, Kenneth C. Concrete Design and Construction from the Inside
Out. In: Concrete in the Third Millenium. Brisbane, Australia: Concrete
Institute of Australia; 2003.
10 Indian Bureau of Mines. Indian Minerals Yearbook 2011 [Internet]. 2011,
[cité 2013 janv 15] Available from: http://ibm.gov.in/IMYB%202011_Slagl.
pdf
11 Labbez C, Nonat A. The Cement Cohesion: an Affair of Electrostatics.
In: Iutam Sympiosium on Swelling and Shrinkage of Porous Materials.
Petropolis, Brazil: 2007.
12 De Larrard F, Sedran T. Mixture-proportioning of high-performance
concrete. Cement and Concrete Research. 2002, 32(11):1699.
13 DE LARRARD F. Concrete Mixture Proportioning: A Scientific Approach.
E & FN Spon; 1999.
14 MCGRATH TM. Sustainable cement and concrete. Concrete in
Australia. 2012, 38(1):15‑15.
15 MEHTA PK. Global Concrete Industry Sustainability. Concrete
International. 2009, Vol 31(2):4.
16 MEP. Technical Requirements for Environmental Labeling Products:
Low-carbon Cement (Discussion Paper) [Internet]. Ministry of
Environment Protection, China; 2012. Available from:http://www.mep.
gov.cn/gkml/hbb/bgth/201112/W020111208396803781008.pdf (in
Chinese)
17 PETERS GP, MARLAND G, LE QUERE C, BODEN T, CANADELL JG,
RAUPACH MR. Rapid growth in CO2 emissions after the 2008-2009
global financial crisis. Nature Clim. Change. 2012, 2(1):2‑4.
18 PHAIR JW. Green chemistry for sustainable cement production and
use. Tutorial Review. 2006,
19 QUILLIN K. Low-CO2 Cements based on Calcium Sulfoaluminate
[Internet]. Available from: http://www.soci.org/News/~/media/Files/
Conference%20Downloads/Low%20Carbon%20Cements%20Nov%2
010/Sulphoaluminate_Cements_Keith_Quillin_R.ashx
20 SINGH, YASHPAL. Fly Ash Utilisation in India [Internet]. [cité
2012 janv 15] Available from: http://www.wealthywaste.
com/fly-ash-utilization-in-india
21 SMALL RJ, PETERSON ML, ROBLES A, KEMPA DK. Using a buffered
rinse solution to minimize metal contamination after wafer cleaning
[Internet]. MicroMagazine.com. 2005, Available from:http://www.
micromagazine.com/archive/98/01/small.html
22 SPENSE, ROGER FP. Chemistry of Cement Solidified Waste Forms. In:
Chemistry and Microstructure of Solidified Waste Forms Symposium.
Oak Ridge: D. Lewis Publishers; 1992. p. 1 ‑ 39.
23 STERN N. The Stern Review on the economics of climate change
[Internet]. 2007, Available from: http://www.hmtreasury.gov.uk/
independent_reviews/stern_review_economics_climate_change/
stern_review_report.cfm
24 SUN, HENGHU, JAIN, R, NGUYEN, K, ZUCKERMAN, J. Sialite
technology: Sustainable alternative to Portland cement. Clean
Technologies and Environmental Policy. 2010, 12503 ‑ 516.
25 USGS. Mineral Commodity Summary - Cement [Internet]. 2012, (2012):
Available from: http://minerals.usgs.gov/minerals/pubs/commodity/
cement/mcs-2012-cemen.pdf
 Communication Feature
Eco-friendly AAC Block is Here to Stay
I
t won't be wrong to say that this is the
age of environment-friendly building
materials and strategies. Autoclaved
aerated concrete (AAC) blocks can be
counted among the most popular eco-
friendly building materials that are avai-
lable. While there are several brands
available, Cell O Con autoclaved aer-
ated concrete blocks from Methra In-
dustries India has carved its own dis-
tinct identity.
These concrete blocks are cured in
an autoclave, which is a large pressure
vessel measuring 45 meter length and
3 meter in diameter. Steam is fed into
the autoclave at high pressure i.e. 800
kPa, and a temperature of 180 degrees
Celcius. The AAC blocks are produced
using Portland cement, lime and pul-
verized fuel ash or Portland cement, lime
and fine sand. A small quantity of gyp-
sum is also added.
Autoclaved aerated concrete is quite
different from dense concrete, both in
the production and in the composition
of the final product. In the case of dense
concrete it gains strength after about
two days and most of its strength after
a month. On the contrary, as soon as
the AAC blocks are removed from the
autoclave and cooled, they are ready
for use.
Cell O Con AAC Block
164 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Manufacturing Process
As part of the manufacturing pro-
cess, cement, lime, and PFA are mixed
to form a slurry. Fine aluminum powder
is added to produce a cellular structure.
The density of the final product varies
depending upon the quantity of alumi-
num powder added to the slurry. Slurry
is poured into moulds, and thereafter,
two processes occur simultaneously.
The cement hydrates to normally pro-
duce ettringite and calcium silicate
hydrates and the mix gradually stiffens
to form the green cake.
The green cake rises in the mould
due to the evolution of hydrogen gas
formed from the reaction between the
fine aluminum particles and the alka-
line liquid. These gas bubbles give the
material its cellular structure.
When the cake has risen to the re-
quired height, the mould moves along
the track where the cake is cut to the
required block size. Depending on the
actual production process, the cake
may be demolded entirely onto a trolley
before cutting, or it may be cut in the
mould after the sides are removed. The
cake is cut by passing through a series
of cutting wires.
At the cutting stage, the cakes are
green. If they are too soft the cut blocks
may fall apart or stick together. If they
are too hard, the wires will not cut them.
The cakes are loaded into the auto-
clave and kept inside for 8 to 10 hours.
When removed from the autoclave and
cooled the blocks will achieve their full
strength and packed ready for transport.
Cell O Con AAC blocks are manu-
factured using latest technology. The
tests conducted on the Cell O Con AAC
blocks by the Structural Engineering
Research Centre, CSIR Chennai and
M/S Hitech Lab, conform to IS 2185,
which vouches for their quality.
Key Benefits
Cell O Con AAC blocks exhibit ex-
cellent insulation properties. Apart from
superior thermal insulation, these AAC
blocks also offer excellent acoustic insu-
lation. Sound transmission class ratings
up to 60 are possible with AAC blocks.
The AAC blocks are also highly
resistant to water, sun, wind, fire, ter-
mites and pests. AAC blocks are made
up of natural inorganic material that does
not burn. This ensures that there is no
need for any additional fire proofing
material.
Ease of construction is another major
advantage with AAC blocks. Apart from
being easy to transport, they are also
easy to handle, groove, drill and nail.
Utilities can be easily routed through
the AAC blocks.
In a nutshell, Cell O Con AAC blocks
are eco-friendly, light weight, help re-
duce dead load, enable more carpet
area, require minimal external and in-
ternal plastering and energy efficient,
making it a favorite with contractors,
builders and developers.
For further details:
Methra Industries India Pvt. Ltd.
62 Panchali Amman Koil Street,
Arumbakkam, Chennai - 600106
Ph: +91-44-23638652,
E-mail: admin@methras.in
Web: www.methras.in
Autoclaved Aerated Concrete Blocks
 Communication Feature
Pioneering Innovative and
Sustainable Products
T
he Indian construction industry
has been growing at a rapid rate
over the past two decades. It is
not surprising then that a host of inno-
vative products and solutions have
been hitting the market regularly cater-
ing to the needs of the industry. How-
ever, while there could be several new
products entering; only a select few
have been successful in making a mark.
Two such remarkable products are 'i.light'
and 'TX Active' from Zuari Cements,
which is part of the globally well-known
Italcementi Group. Zuari Cement's steady
Milan Lorenteggio Eco-Technological Complex
168 The Masterbuilder - July 2013 · www.masterbuilder.co.in
growth has seen the company emerge
as a leader with a capacity of 6.2 million
tons. The company has three plants,
which include two manufacturing units
at Sitapuram and Yerraguntla, and a
grinding center at Chennai. The com-
pany's manufacturing units are ISO:
9001 and ISO: 14000 certified, respec-
tively. Zuari Cement has been ad-
judged as a “Power Brand” after a rig-
orous survey conducted by ICMR among
consumers across India based on
reach, availability, demand and growth.
Earlier in 2011, Zuari cement has also
been awarded with “Master Brand” by
the CMO council Asia.
'TX Active' and the Photocatalytic Active
Principle
Zuari's innovative products, 'TX Active'
and 'i.light', add to the sustainability
quotient of a building. 'TX Active' works
on the photocatalytic active principle
and is a truly innovative and unique
product. 'TX Active' is photo catalytic
cement that abates some contaminants
in the air, thereby offering the perfect
solution to pollution.
What exactly is photocatalysis, one
is bound to ask. Photocatalysis is a nat-
ural phenomenon in which a substance
known as a photocatalyst uses light to
expedite the rate of natural oxidation
process. Using light energy, photoca-
talysts can induce the formation of
strong oxidizing reagents, which de-
compose some organic and inorganic
substances in the atmosphere through
oxidation. Photocatalysis promotes
faster decomposition of pollutants and
prevents them from accumulating.
It is proven that concrete and ce-
ment-based products produced with
'TX Active' will reduce pollutants asso-
ciated with motor vehicle exhaust, heat-
ing exhaust, fuel combustion and other
commercial and industrial processes.
These include, Nitrogen Oxides (NOx),
Sulfur Oxides (SOx), volatile organic
compounds (VOC's) and Particulate
Matter (PM), among others. Moreover,
the 'TX Active' ingredient can never be
used up. This is because the principle
ingredient is a catalyst that accelerates
the natural oxidation process and is not
consumed in the process. Therefore,
as long as the concrete remains intact,
UV light can trigger the process, and
the principle remains indefinitely.
The 'TX Active' range consists of TX
Arca cement developed in 1996. White
concrete made using TX Arca cement
offers extraordinary brilliance and self-
cleaning properties, which ensures

that the original beauty of buildings last
for years. The TX Aria environmental line
provides a comprehensive range of
cement products and binders for for-
mulation into all varieties of mortars,
stuccos, cementitious veneers and many
other concrete end uses.
Proven Technology
'TX Active' photocatalytic cements
have been used extensively in the Euro-
pean market for over a decade. Their
effectiveness has been thoroughly
tested and thus certified by important
independent research centers (CNR,
ARPA, Ispra Research Center). Its for-
mulation is the result of 10 years of re-
search, tests and applications carried
out by CTG, Group Technical Centre, a
company in the Italcementi Group which
has led to the final formulation of the
photocatalytic active principle. The first
project of recognition was the Dives of
Misericordia Church in Rome, designed
by Richard Meier, a world-renowned
architect. In addition, many other pro-
jects with different applications such as
precast buildings, roadways, paver
blocks, tunnels, etc., have been com-
pleted.
The perfect testimonial for the effi-
cacy of the self-cleaning 'TX Active' ce-
ment can be found at Vodafone Village
in Milan. Covering 67,000 square me-
ters, the village provides accommoda-
tion to over 3,000 employees of
Dives Misericordia
Communication Feature
Vodafone. The architects chose 'TX
Active' for it guaranteed a constantly
clean facade, thanks to the combined
action of the active ingredients and sun-
light.
Hotel de Police in Bordeaux, France
is another good example for the effi-
cacy of the photocatalytic principle. A
total of 750 panels, cover an area of
5,400 square meters of architectural Dives Misericordia
precast concrete. 'TX Active' was cho-
rstate 35 West Bridge spanning the Mis-
sen to preserve the aesthetic quality of
sisippi River in downtown Minneapolis,
the building. Similarly, 'TX Active' rough
USA.
surface finishing was selected for the
Air France Headquarters, Roissy-Charles 'i.light'- The Revolutionary Precast Con-
de Gaulle building, which is located crete Panel
amid high concentrations of hydrocar-
A precast concrete panel that can
bons from aircraft exhausts. In the case
transmit light is a concept that was,
of Ciments du Maroc's headquarters in
until now, deemed possible only in sci-
Casablanca, Morocco, the building's
ence fiction movies or literature. Today
circular structure was made with tradi-
it is reality thanks, to 'i.light', a precast
tional concrete covered with a white
concrete panel that can transmit light.
mineral coating of 'TX Active'.
Obtained by bonding special resins in
The Academy of Sant'Eufemia, the
an innovative mortar, 'i.light' not only
largest Yoga center in Europe, boasts
lets natural and artificial light in but also
of an external photocatalytic pavement,
allows seeing objects placed behind
about 3,000 sq.m, made up of photo-
the panel and creating a surprisingly
catalytic interlocking paving stones.
transparent effect.
Self-cleaning, pollution busting court-
The story of how 'i.light' came into
yards have been designed using 'TX
being makes for interesting reading.
Active' in an affordable green housing
'I.light' was actually created at the
project in the City of Highland Park, a
request of the architect responsible of
municipality on the outskirts of Chicago.
designing the Italian Pavilion for Expo
Another interesting project is the
Shanghai 2010, who wanted a cemen-
gateway elements cast with 'TX Active'
titious material capable of transmitting
photocatalytic cement on the new Inte-
light.3,774 transparent panels of 'i.light'
were produced and used to cover a
total surface of 1,887 sq. m., amount-
ing to about 40% of the pavilion's entire
shell. The effect was to create a se-
quence of light and shade constantly
changing throughout the day. The
Italian pavilion was a huge success
attracting over 6 million visitors. In fact,
the Chinese Government was so
impressed that it decided to make it a
permanent pavilion which would not be
dismantled after the expo.
For further details:
Zuari Cement
Ph: +91-080-41194408,
E-mail: zclmkt@zcltd.com
Web: www.zuaricements.com
www.masterbuilder.co.in · The Masterbuilder - July 2013 169
 Communication Feature
Leading the RMC Revolution
T
he Indian construction industry has
seen a steady increase in demand
for ready-mix-concrete (RMC) over
the last two decades. Stricter project
specifications, rising emphasis on adhe-
ring to quality standards and tighter pro-
ject deadlines have all been behind the
increased penetration of RMC in India.
A name that has played a pioneering
role in this growth story is that of RMC
Readymix (India), one of the largest RMC
manufacturers in the country. RMC Re-
adymix (India) is part of Prism Cement
Limited, India's largest integrated buil-
ding materials company with a wide
range of products from cement, RMC,
tiles & batch and kitchen accessories.
The company has three divisions, viz.
Prism Cement, H & R Johnson (India),
and RMC Readymix (India). Prism
Cement Limited also has a 74% stake
in Raheja QBE General Insurance Com-
pany Limited, a JV with QBE Group of
Australia.
Established in 1996, RMC Readymix
(India) currently operates 88 RMC plants
in three cities and towns across the
country. The company has also ven-
tured into the aggregate business and
operates large quarries and crushers.
RMC Readymix (India) has been at the
forefront in setting high standards for
plant and machinery, production, qual-
ity systems and product services in the
ready-mixed concrete industry.
170 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Quality Assurance
Increasing demand has meant that
RMC Readymix (India) has been striv-
ing hard to expand its production capa-
city. It has recently added two key loca-
tions to its existing network, Bhopal, in
the heart of India and Guwahati, the eco-
nomic and industrial hub of Northeast
India.
One of the cornerstones of the com-
pany's success story has been its
unflinching commitment to quality. As
part of its initiatives, RMC Readymix
(India) has added another feather in its
cap. One of its labs – attached to White-
field Plant in Bengaluru - was subjected
to NABL Certification. The lab has achi-
eved the distinction of getting the
accreditation under ISO/IEC: 17025:
2005, in the field of 'Mechanical Testing
of Aggregate and Concrete'.
Latest Generation Concrete
The demand for specialized con-
crete for specific applications is rising
by the day. Catering to this demand,
RMC Readymix (India) offers a wide
variety of concrete to its customers.
These include:
- MegacreteTM - high strength con-
crete for large structures.
- EasycreteTM – flow able concrete
requiring less labour & effort for
placement.
- FRCcreteTM – concrete incorporat-
ing polypropylene & steel fibres for
ground slabs, eliminating the need
for reinforcing steel.
- FoamcreteTM – light weight concrete
for thermal insulation, acoustics,
fillers, etc.
- ColourcreteTM – Concrete in a wide
array of colours for aesthetic pur-
pose
- HighdensecreteTM – High density
concrete for special applications
such as radiation shielding in hos-
pitals, reactors, etc. and to add dead
weight to structures.
- ThermocreteTM – Concrete at lower
temperatures for mass concrete
pours.
- Pervious Concrete – concrete de-
signed to capture water run offs &
for rain water harvesting.
With its quality-focused approach
and expertise in the field of delivering
latest generation concrete, we are sure
to hear more about RMC Readymix (In-
dia) in the future.
For further details:
RMC Readymix (India)
Mobile : 09769801903
Toll-free: 1800-22-3454
E-mail: customercare@rmcindia.com
customer.connect@rmcindia.com
 Concrete Flooring: Densifiers
An Insight into Liquid Floor Densifiers
Ankita Adhikary
I
n many cases, the best floor-covering is nothing. Leaving
the concrete slab exposed and finishing it as the floor can
be economical, aesthetically successful, and sustainable.
It is so durable that it may well be the ‘ultimate’ floor – the last
floor that will ever need to be installed in the space. The key to
optimizing the performance of concrete as a floor is densifiying.
Densifiers make concrete floor more durable, and abuse-
resistant. Densification eliminates wear - induced powdering
of the surface known as dusting. It makes the surface less
permeable to liquids, improving stain-resistance and making
cleaning easier and more eco-friendly.
A dilemma sometimes faced by concrete floor contractors
and owners is what to do about a recently installed or existing
industrial floor that has a weakened surface. After concrete has
been Installed, how can contractors most effectively correct
the dusting, poor abrasion resistance, and high porosity that
characterize such a surface? (Weakened floor surfaces are
typically caused by adding excess water to the concrete, poor
172 The Masterbuilder - July 2013 • www.masterbuilder.co.in
finishing techniques, and a poor-quality cure.) Obviously,
removing and replacing the concrete is not a favorable option,
because it is disruptive, labor-intensive, and costly. A simpler,
less expensive option is to use a liquid chemical treatment to
harden and densify the concrete surface. Refer Figure 1 for a
hardened concrete floor.
Need for Densifier
New or existing concrete can be improved by densification.
It transforms concrete into a more practical flooring solution,
and is applicable to a wide variety of projects. Owners of retail,
commercial, and institutional environments are opting to
expose the concrete floor instead of covering it. Densification
expands appearance finishing options, enabling the success
of finishing techniques such as burnishing and polishing. A
densified, diamond polished concrete slab can achieve a
high gloss that can rival the look of natural polished stone at
a fraction of the cost. A slab burnished to a sheen after den-
sifiying can achieve almost as attractive a result, but faster

and even more affordably. Combined with techniques like
dyeing, staining, or grinding to expose aggregate, a broad
palette of visual options are available for taking concrete
beyond a featureless gray surface. The cost of densification
and polishing is competitive with the least expensive floor
coverings available. Even with the added expense of coloring,
it is still more affordable than the lowest end carpet or stone
floors. Densifiers are also used where appearance is not a
concern because of the improved performance of the slab. As
it is easy to keep clean and safe, the densified floor is suitable
for warehouses, factories, and maintenance facilities such as
automobile service bays. Chemical densifiers (also called
hardeners or densifier / hardeners) are a small investment that
leads to long-term savings and improved performance for
decades.
About Liquid Densifier
Liquid floor hardener formulations vary from manufacturer to
manufacturer, but they usually contain inorganic compounds
that undergo a series of complex chemical reactions with the
available lime in mature concrete. Some liquid hardeners also
contain special proprietary ingredients to make treated floors
more resistant to chemical attack and wear and to improve
the aesthetics of the finished surface. Unlike solvent-based,
membrane forming sealers, which usually contain resins and
hazardous solvents, most liquid floor hardeners contain
inorganic compounds that are water soluble and comply with
today’s environmental, health, and safety regulations. Wetting
agents (surfactants) are usually added to a liquid hardener to
help the product penetrate the pores of the concrete substrate.
The efficiency of the floor hardening treatment increases with
the depth of penetration, which usually ranges from 1/8 to 1/4
inch.
Figure 1: A typical hardened concrete floor
Concrete Flooring: Densifiers
Though manufacturers of liquid floor hardeners sometimes
use the word “sealer” to describe their products, a liquid
hardener is actually a treatment, not a surface coating like
most membrane - forming organic sealers. A drawback to
applying a membrane to concrete is that the membrane tends
to wear away in high-traffic areas. Not only is the worn coating
unattractive, the unprotected concrete is susceptible to
chemical attack by acids and caustics. Liquid floor hardeners
not only protect concrete surfaces, they protect the concrete
down to the depth of penetration. Also, the hardeners don’t form
a coating or membrane on the concrete surface, so they don’t
scratch; peel, show tire marks, or require recoating.
Working Principle of Liquid Densifier
As soon as a liquid floor hardener is applied to a concrete
substrate, a chemical reaction takes place between the
inorganic compounds and lime (whether hydrated or unhydrated)
in the pores of the concrete matrix. The primary product of
this reaction is a mixture of dicalcium and tricalcium silicate
compounds, which hydrate (react with water) even further to
produce a chemical compound called calcium silicate hydrate, or
tobermorite gel. The ultimate strength and binding properties
of hydrated Portland cement are primarily due to the presence
of tobermorite gel in the concrete matrix. Therefore, liquid
hardeners increase concrete strength by increasing the
concentration of tobermorite gel. Liquid floor hardeners can
also increase concrete’s density.
When the tobermorite gel forms in the concrete pores, its
crystalline growth effectively blocks voids in the concrete,
decreasing the pathways for moisture movement. Since
chemicals attack concrete by penetrating the matrix, the
presence of an insoluble gel in the substrate’s pores and on its
surface greatly increases the concrete’s chemical resistance.
In addition to the benefits of strength gain and chemical
resistance, a liquid hardener can enhance the beauty of a
troweled floor by giving it a polished look. This high sheen
results when the treated floor is polished by mechanical
means. Floors treated with liquid hardeners will not dust when
abraded or polished.
The drawing below shows a cutaway view of a rough, porous
floor prior to floor- hardener treatment. When light strikes the
Figure 2: Working Principle of concrete hardened floor versus untreated
concrete floor
www.masterbuilder.co.in • The Masterbuilder - July 2013 173
 Concrete Flooring: Densifiers
irregular surface, the light is reflected in all directions. This
scattering of light makes the concrete surface appear dull.
After a floor has been treated with a liquid hardener, the pores
are filled with tobermorite gel and the concrete surface can
be polished smooth. When light strikes this smooth surface,
it is reflected uniformly, so the floor shines. Refer Figure 2 for
how concrete hardened floor works as compared to normal
concrete floor.
Application Tips of Liquid Densifier
Ideally, concrete floors should be treated with liquid floor
hardeners at least seven to 14 days after placement, or after the
cement has had sufficient time to hydrate. Cement hydration
increases the amount of available lime in the concrete, thus
increasing tobermorite gel formation. In addition, this waiting
time allows the pores of the concrete to dry, so the liquid
hardener can penetrate the concrete surface rather than
merely lying on it. It is much easier for a liquid hardener to
displace air than water in the concrete voids. True liquid floor
hardeners should not be applied to fresh concrete at the
time of initial cure, because the concrete is still saturated with
moisture. This saturated condition prevents the hardener from
penetrating the surface. Also, liquid hardeners should not be
applied as curing compounds, since they do not meet the
requirements of ASTM C 309, “Standard Specification for Liquid
Membrane- Forming Compounds for Curing Concrete.” Always
check the manufacturer’s recommendations for when to apply
its product.
The type of cure used on new floors prior to application of
chemical floor hardeners is very important. Liquid hardeners
must penetrate the concrete surface to undergo the chemical
reaction that imparts density and hardness, but they can’t
penetrate a membrane forming curing compound. If a curing
compound has been used, be sure to remove it before applying
a liquid hardener. ACI 302.1R- 89, “Guide for Concrete Floor
and Slab Construction,” recommends moist curing floors
that will later be treated with a liquid floor hardener or other
surface treatments. Surface preparation of the floor before
hardener application is also important. The surface must be
174 The Masterbuilder - July 2013 • www.masterbuilder.co.in
thoroughly cleaned to open the concrete pores and allow
for hardener penetration. Typical cleaning methods include
chemical cleaners and high-pressure water. Some chemical
floor hardeners contain magnesium fluosilicates, which are
low- grade toxic chemicals. When applying these products,
be sure to wear protective clothing such as rubber gloves,
boots, and goggles. Typically, fluosilicate hardeners are
supplied in concentrated form and must be diluted with water
before application.
Non fluosilicate floor hardeners, that are more commonly
used today are colorless, odorless, biodegradable, and VOC-
compliant. Many manufacturers offer 10- year warranties with
these products. When using a non fluosilicate floor hardener,
apply a slight flood coat to the concrete surface, covering
about 200 square feet per gallon. Next, scrub the material into
the surface with a stiff-bristle broom or janitorial floor- scrubbing
machine for 15 to 30 minutes, until the product begins to
gel or become slippery. Wet the material lightly with a water
spray, and then rework it into the surface for another five to
10 minutes. After this process, rinse the floor and remove any
excess material with a mop or squeegee. This final step is
important, because residue is more difficult to remove if it is
allowed to dry.
Application Areas of Liquid Densifier
Typical applications for liquid hardeners include floors in
warehouses, industrial plants, shopping malls, stores, schools,
food-processing plants, and hospitals. Installation costs vary,
depending on the required surface preparation and size of
the project. The degree of surface hardness and density that
can be achieved with a liquid hardener depends on the quality
of the concrete surface. Liquid hardeners can improve the
abrasion resistance and reduce the dusting of a lower-quality
concrete floor. On higher-quality concrete surfaces (those with
 Concrete Flooring: Densifiers

more prevalent in the North American and potassium is

predominate in Europe.
A.4 Lithium Silicates. Lithium silicates were developed to
combat Alkali Silica Reaction (ASR). ASR is more prevalent
in exterior applications where there is a constant source of
water. Lithium silicates are less susceptible to solubilization
than sodium or potassium. One of the byproducts of this
particular silicate is its ability to reduce sweating on slabs.
B. Silicinates - excellent sealer, poor hardening characteristics.
Real world typical life expectancy is 18 to 24 months, and
then it should be reapplied. Disposal of the waste material
is currently an issue.
- Silicinates are applied the same way silicates, spray, scrub,
mist, rinse, and vac.
- Silicinates can offer increased abrasion resistance over
silicates in the short term due to the coating effect of the
silicinates.
- Silicinates are either potassium or sodium.

C. Silicas – are the newest and most promising of the chemical

a lower water-cement ratio and denser finish), the need for a
hardeners:
chemical floor hardener diminishes.
- Silicas are applied simply by spraying them on the surface
Many manufacturers claim that liquid floor hardeners improve
of the slab and allowing them to dry. The surface should
the chemical resistance of a concrete floor. This is true to a
be clean and void of any curing compound. Application
degree, but one should carefully examine the chemical-
rates are between 400 to 600 square feet per gallon.
resistance requirements of the floor before proceeding with
hardener application. Though liquid floor hardeners improve
the chemical resistance of a concrete surface, they do not make
the surface 100% chemical resistant. Unfortunately, liquid
hardeners are sometimes sold as chemical-resistant products
meant to replace truly chemical-resistant coatings, such as
two-component aliphatic urethanes. For floors exposed to high
levels of chemicals, consider using a chemical- resistant coating
instead of a liquid floor hardener.

Types of Liquid Densifier

Chemical Hardeners (Densifiers) include three basic categories

of chemicals: silicates, silicinates and silica:

A. Silicates - penetrate and harden. They are not good sealers.

Disposal of the waste material is currently an issue.
A.1 The oldest is Magnesium Fluorosilicates, which have been
around since 1905. This type of product requires multiple
applications with varying rates of dilution.
A.2 Sodium Silicates Developed initially in Germany in the
1930’s. Application of the product requires that it be applied
at an average of 200 square feet per gallon, spread and
worked until the surface tension is broken, mist with water,
allowed to gel a second time and then rinsed and wet
vacuumed to remove.
Some Photographs of Densified concrete floor (Reference: Densification for
A.3 Potassium Silicates. The main difference between the High Performance Floors, By Steven H. Miller, Concrete Tech. Today – Densifying
sodium silicates and potassium silicates is sodium is Concrete)

176 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Concrete Flooring: Densifiers
- Silicas increase abrasion resistance over silicates or
silicinates by up to twice as much
- Silicas do not contribute to ASR
- Silicas do not raise the pH of the concrete since the product
is neutral 6.5.
- Silicas have the highest increase in abrasion resistance
- Silicas have reduced application and labor costs
- Silicas have no hazardous waste to remove or dispose
- Silicas do not contribute to silicosis and are not carcinogenic
unlike silicates which do contribute to silicosis and are
carcinogenic
- Silicas will not contribute to sweating or efflorescence
- Silicas performance is not contingent on dwell time unlike
silicates or silicinates
In a nut shell there are features and benefits to each of these
types of chemical hardeners. The upside for the silicates is
that they harden better than silicinates, Silicinates seal better
than silicates. Silicates have been directly linked to silicosis.
Silicates and silicinates have been tagged as carcinogens.
Silicates and silicinates must be disposed of as hazardous
material. There is significant research that documents the ill
effects of sodium, potassium silicates and silicinates on reactive
aggregate in concrete. Currently the best technology for
chemical densifiers is amorphous silica.
Advanced Densifiers
A new generation of densifiers based on colloidal silica is
replacing older densifiers based on chemical compounds
called silicates. Colloidal silica performs the same functions,
but makes the densification process itself faster, easier, more
affordable, and more sustainable. It is competitive in material
cost, and reduces time and labor expenses for densification
by as much as 75%. Colloidal silica has also been used to
rescue slabs that have not responded to silicate treatments.
The first generation of concrete densifiers was generally
made from silicate compounds such as sodium silicate and
potassium silicate; this range of silicate based compounds
was later broadened to include lithium silicate. All these silicate
compounds are highly caustic, with a pH of 11 to 12, similar
to the alkalinity of lime itself. Sodium- or potassium-silicate
application is also time consuming and labor-intensive—the
chemical has to be worked with a broom for an hour to help
precipitate silica and scrub it into the slab surface. The process
leaves behind a caustic, gelatinous slurry that has to be
scrubbed off thoroughly and disposed of. (Sodium hydroxide,
also known as lye, is a by-product of sodium silicate densifiers
and is sometimes present in their residue.) Applicators often
try to neutralize the slurry with other chemicals before disposal,
costing additional time and money. Many silicate-based
densifiers require an overnight curing period before polishing
178 The Masterbuilder - July 2013 • www.masterbuilder.co.in
can begin. Inadequate removal of sodium- and potassium-
silicates often leads to concrete discoloration by salt deposits
– a problem known in the industry as “whiting.” The only way
to remove whiting is to regrind the slab, an expensive and
time consuming process. Whiting can also be a danger with
lithium silicates if the material is over-applied, tempting some
applicators to under-apply the product and ultimately fail to
adequately densify the floor. The high pH of silicate materials
also makes them dangerous and unpleasant for applicators
to handle, especially during the removal process.
With increasing restrictions on disposal of caustic substances
and construction waste, properly getting rid of the silicate slurry
has become an issue for applicators to deal with. The new water-
borne colloidal silica product, available from Lythic Solutions
(www.lythic.com) under the trade name LythicTM Densifier,
eliminates these problems. It is made from 5-nanometer
diameter amorphous silica particles, mechanically suspended
in water rather than chemically tied up in a compound. Colloidal
silica is more immediately available for reaction in concrete
than a silicate compound – the molecule has more chemically
reactive sites, and the greater pH difference between colloidal
silica and lime makes the reaction begin quickly, within minutes
after application. The particles consist of nearly pure silica, and
the colloid’s extremely low sodium content eliminates the
danger of whiting. There is no danger of over-application. The
simplified application process reduces risks and cost, and
only minimal training is required. There is no removal step (as
required with silicates) and consequently no caustic slurry to
dispose of – only a small amount of dry powder residue that can
be boomed off, or will be vacuumed up during polishing.
Conclusion
Concrete is one of the world’s oldest construction products,
but it is continually advancing to meet the needs of the times.
Improved densifiying technology is a classic example of this
process: taking advantage of the basic nature of the material,
densifiers make a concrete slab more durable, sustainable,
maintainable, and aesthetically versatile. Densification
makes the concrete slab an ideal flooring solution for the
economic and environmental requirements of our age. The
newest densifiying technology, colloidal silica, carries those
sustainability and cost advantages to the next level, and adds
new performance levels to the densification process.
Reference
1. Look at Liquid. Floor Hardeners. By John Gill and Cyler Hayes,
(www.concreteconstruction.net/.../A%20Look%20at%20Liquid%
20Floor... )
2. Comparison of Concrete Chemical Hardeners (Densifiers). By
Roger Allbrandt, B.A. Environmental Biology, (www.absolute
polishing.com / A -brief -overview -of -Concrete -and -Chem...)
3. Densification for High Performance Floors, By Steven H. Miller,
Concrete Tech. Today – Densifying Concrete
 Structural Health Monitoring
Structural Health Monitoring:
A Dire Need of India
Yogesh Indolia, 21SHM Consultants
Dr. Gopal Rai, R&M International Pvt. Ltd.
W
ith an advent of all new struc-
tures coming up a time when
India is competing in today's
competitive global market, one cannot
tend to ignore that fact that India carries
the burden of numerous old structures
owned not only by the state but also the
people. These old structures have known
or unknown deficiencies and cannot be
identified unless a disaster is experi-
enced. However, it would be too late by
then as the damage would have already
happened in terms of human loss. This
leads to the present state of the poor
affairs and needs a careful consider-
ation to be pro-active to conduct health
monitoring and providing proper solu-
tion, and then it would be up to the owner,
may it be private or government to exe-
cute it in the national interest.
Structural health monitoring (SHM)
in general sense is a process aimed at
providing accurate and timely informa-
tion about the condition and perfor-
mance of a structure. It can be either
short term (eg. repairs efficacy) or a
long term (monitoring parameters con-
tinuously or periodically) process. A
need for SHM arises with the fact that
properties of both concrete and steel
depends on a large number of factors,
which are often hard to predict in prac-
tice. The representative parameters
selected for health monitoring of a
structure in general can be of mechani-
cal, physical and chemical in nature.
In India due to negligence and non
availability of technology, SHM has not
been taken seriously and therefore,
misses its full potential. If safety stan-
dards are emphasized and followed
SHM will grow to its full potential and be
an integral part of structural maintenance
and management. Safety is a serious
issue and should be addressed prop-
erly in the future.
In this paper, Structural Health Mo-
180 The Masterbuilder - July 2013 · www.masterbuilder.co.in
nitoring basics are covered and need
for SHM in the future Indian scenario.
Also presented are experiences in some
SHM work, which has been undertaken
and its impact on the structure both in
the United States and in India.
Introduction
As new materials and technologies
are discovered, buildings get taller, bri-
dges get longer spans and the de-signs
of structures become more ambitious,
but more complex. In view of these dev-
elopments, there is an increased req-
uirement to providing both the costs sav-
ings with regard to maintenance and a
safer environment for by preventing
structural failures.
India even being a developing coun-
try has picked up the structural devel-
opments including the new technolo-
gies. India has a rich cultural and his-
torical background which is very well
reflected in the varied amount of histor-
ical structures. These structures are very
well built and have withstood the test of
time. But due to there historical impor-
tance it becomes very important to
assess health condition of these struc-
tures, so that appropriate steps can be
taken before it is too late.
Apart from old buildings there are
high rise buildings made of steel and
concrete which have started to make
their way in India and as they need
extensive modelling, design details
and analysis before and during con-
struction it becomes important and
good to know about what has been
made and its behaviour in future.
Critical buildings (or Lifeline Struc-
tures, as they are also called) like hos-
pitals, schools, power plants etc and
buildings with large public gatherings
like sports arenas, stadiums, commer-
cial buildings, which could cause harm
to large amount of people at a time and
are something to be taken care on a
regular basis, if they suffer any damage
due to any calamity, either natural or
manmade.
The safety of dams in our country is
the principal concern of the State agen-
cies that are involved in the various
aspects of their investigation, planning,
design, construction, operation and
maintenance. While most of the dams
have performed well, there have been a
few failures. These failures, either par-
tial or complete, highlight the need to
review the procedures and the criteria
that are being adopted by the various
States with the object of establishing
the best assurance of dam safety within
the limitation of the present state-of-art.
Structural Health Monitoring (SHM)
is a process aimed at providing accu-
rate and in-time information concerning
structural condition and performance
on a proactive basis. It consists of (i)
permanent continuous, (ii) periodic or
(iii) periodically continuous recording
of representative parameters, over
short or long terms. The information
obtained from monitoring is generally
used to plan and design maintenance,
increase the safety, verify hypotheses,
reduce uncertainty and to widen the
knowledge concerning the structure
being monitored. In spite of its impor-
tance, the culture on structural monitor-
ing in India is not yet widespread.
Basics of Structural Health Monitoring
The Process of Structural Health
Monitoring is process similar to the pain
and illness experienced by human body
and how it is cured.
If the body is considered like a
structure[1]. When a person has some
damage or problem with his body, the
unhealthy condition is detected by the
nervous system and it sends signals to
the brain about the issue. Person real-

izes that he is ill and visits a doctor in
order to prevent its further develop-
ment. Synonymously the sensors act
as the nervous system and the acquisi-
tion system act as a brain. The struc-
tural expert is like an doctor for the
structure and listens to the responses
and proposes a solution/repair strategy.
The important aspects are respon-
ses in the structure. Responses which
can be commonly measured can be in
general divided in
- Mechanical: strain, deformation, dis-
placement, cracks opening, stress,
load
- Physical: temperature, humidity, pore
pressure
- Chemical: chloride penetration, sul-
phate penetration, pH, carbona-
tation penetration, rebar oxidation,
steel oxidation.
The physical diagnostic tool of SHM
is the comprehensive integration of vari-
ous sensing devices and auxiliary sys-
tems, including: [2]
- Sensory system
- Data acquisition system
- Data processing system
- Communication system
- Damage detection and modelling
system
Monitoring is not supposed to make
a diagnosis. To make a diagnosis and
propose the cure It is necessary to carry
out a detailed inspection and related
analyses. Detection of unusual struc-
tural behaviours based on monitoring
results is performed in accord with pre
defined algorithms. The efficiency of
monitoring depends on both the per-
formance of the applied monitoring sys-
tem and the algorithms employed.
Aim, Needs and Benefits
The objective of SHM is to monitor
the in-situ behaviour of a structure accu-
rately and efficiently, to assess its per-
formance under various service loads,
to detect damage or deterioration, and
to determine the health or condition of
the structure. The SHM system should
be able to provide, on demand, reliable
information pertaining to the safety and
integrity of a structure. The information
Fig 1: Major Civil Structures in which monitoring is
required
can then be incorporated into bridge
maintenance and management strate-
gies, and improved design guidelines.
There are various advantages and
positive ramifications of including
Structural Health Monitoring in civil
structures.
1. Confirm the design parameter:
Detection of damages during con-
struction which can cause any change
in properties than expected by design.
2. Quality Assurance: By providing
continuous and quantitative data, a
monitoring system helps you in asse-
ssing the quality of your structure dur-
ing construction, operation, mainte-
nance and repair, therefore eliminating
the hidden costs of damages caused
by non achieving the required designed
standards.
3. Complex Structures are well
managed: Learning how a structure
performs in real conditions will help you
to design better structures for the future.
When new materials, new technologies
and methods are involved in construc-
tion monitoring is an effective way to
know the real behaviour and to refine
structural behaviour theories.
4. To Ensure safety of people, nature
and property: Early detection of perfor-
mance degradation can save lives and
property in time by stopping exploita-
tion and access to the structure. This
guarantee the safety of the structure
and its users. It also gives us a way to
assess the possible damages after a
natural calamity or any other type of
major event which can affect the struc-
tural properties and condition.
5. Monitoring reveals hidden re-
www.masterbuilder.co.in · The Masterbuilder - July 2013
Structural Health Monitoring
sources: Many times the structure per-
formance is better than what it is de-
signed for and this gives an extra free-
dom to play with for further designs and
construction.
Economically structural health mon-
itoring process is also very reasonable
and is synonymous to buying an insur-
ance policy for your health. One pro-
tects the individual, his/her depending
family and finally gives a peace of
mind. The same is true for SHM Policy,
which gives a much more personal, local
and national image for sustainability.
- The cost of installing a system and
doing health monitoring at a given
time like construction or repairs is
0.5% to 3% of the total construction
or repair costs respectively.
- The cost of doing Structural Health
Monitoring for a period of 10 years
is 2% to 5% of total structures build-
ing cost[1].
The above points shows that SHM
is very economical and the returns are
large and worth spending for.
Scope of SHM and its need in India
Concrete and steel are two materi-
als which are mostly used in construc-
tion today, often in the form of rein-
forced concrete. These two materials in
the form of reinforced concrete have
become highly popular for construction
due to its high compressive strength,
resistance to fire, very low maintenance
cost as compared to service life, and
most importantly it being highly eco-
nomical. But due to its high require-
ment of quality control and problems
related to reliability with material prop-
erties it has some drawbacks. The steel
inside the reinforced concrete gets cor-
roded. Carbonation is a problem.
Ageing phenomenon of concrete is
very difficult to predict and this can lead
to accidents and losses. Reinforced
concrete structures in critical places
like nuclear plants makes them so
important that we have to be sure that
they are in good condition. This is
where structural health monitoring has
a role to play. It gives a way to over-
come these drawbacks with minimal
damage and loss.
181
 Structural Health Monitoring
Steps Involved with SHM
The following major steps are invol-
ved in overall process of structural
health monitoring.
- Identify structures needing monitor-
ing
- Acquire information on probable
degradation mechanisms and risks
from design engineers or owners of
structure.
- Establish expected responses to
degradations.
- Design SHM system to detect such
conditions and select appropriate
sensors.
- Install and calibrate system (Fig 2).
- Acquire, analyse and manage data.
Fig 2: Various sensors installed for assessing data
Fig 3: Data acquisition from various sensors which
are logged for analysis.
This involves alarming the concerned
people whenever there is an emer-
gency (Fig 3).
Status of Structural Health Monitoring,
World
Major drivers in this area have been
the oil industry, operators of large dams
182 The Masterbuilder - July 2013 · www.masterbuilder.co.in
and highways agencies, whose instal-
lations have received the greatest at-
tention and research effort. Also the
need to keep culturally important struc-
tures in good health has given SHM
attention.
Although worldwide SHM is a rela-
tively new term in civil engineering in-
dustry, the use of instruments to assess
the health is not new. Bridge field test-
ing using various measuring instruments
is very old activity. The objectives of
SHM are consistent with the objectives
of many of these long standing prac-
tices. SHM is in fact an augmentation of
current practice.
According to International Society
of Structural Health Monitoring and
Intelligent Infrastructure (ISHMII) lot of
bridges and structures have been
installed with sensors and are moni-
tored for any damage in European
countries[3]. This is primarily because of
the European culture having its root
way back in the past. This allows them
to retain a stock of old structures, which
have to be maintained in good condi-
tion to represent their culture. This has
driven the SHM of these structures and
made them popular. ISHMII provides
reference of many bridges being moni-
tored presently all over Europe. Some
Asian countries which have seen very
high growth in recent times due to the
manufacturing and technology revolu-
tion, namely China, Singapore, Japan,
Taiwan, have many structures under
monitoring and are doing well.
In USA the number isn't high but
appreciable work has been done. Many
universities have been involved with
research in structural health monitoring
and have also installed them on bridges
and buildings. There are many reasons.
First, unlike Europe or our country, the
US structures are fairly young (less than
300 years, compared to several centu-
ries for us). Second, the structures are
marked as historic by the US regula-
tions, which are maintained and cannot
be altered. The Historic American Buil-
dings Survey (HABS) and the Historic
American Engi-neering Record (HAER)
have considerable information on the
subject and have an excellent website. [7]
Their collections document achie-
vements in architecture, engineering,
and design in the United States and its
territories through a comprehensive
range of building types and engineer-
ing technologies including examples
as diverse as the Pueblo of Acoma,
houses, windmills, one-room schools,
the Golden Gate Bridge, and buildings
designed by Frank Lloyd Wright. Admi-
nistered since 1933 through coopera-
tive agreements with the National Park
Service, the Library of Congress, and
the private sector, ongoing programs
of the National Park Service have
recorded America's built environment
in multi-format surveys comprising
more than 556,900 measured draw-
ings, large-format photographs, and
written histories for more than 38,600
historic structures and sites dating
from Pre-Columbian times to the twen-
tieth century.
India has much more to do profes-
sionally. A lack of general awareness
and reluctance towards trying new tech-
nology and methods may have kept us
behind on this. There are government
records of many historical buildings,
which are not easily available to the
public for further professional study
and research. One can call it in a sim-
plistic manner, Report Card for Infra-
structure (as in the US) in a national pol-
icy level. In india we can learn from the
West for improving our conditions much
faster as the information is available,
communication is simpler and the world
has become much smaller to work.
Status and need of SHM, India
Residential buildings and comme-
rcial structures in India have received
very less almost in existent focus on
structural health monitoring primarily
due to owners not knowing about its
availability and poor knowledge about
them. In these cases SHM can only be
made possible and implemented in these
structures after some efforts have been
made to make them aware and edu-
cate them or forcing them into it by
legally making rules. Some insurance
plans can also be worked out for them.
Dams are structures of great na-
tional importance. Dams generally serve
the primary purpose of retaining water,
 Structural Health Monitoring
while other structures such as floodgates
or levees (also known as dikes) are
used to manage or prevent water flow
into specific land regions. Hydro-power
and pumped-storage hydroelectricity
are often used in conjunction with dams
to provide generate electricity. A dam
can also be used to collect water or for
storage of water which can be evenly
distributed between locations.
In India dams are majorly owned by
state government or the agencies gov-
erned by state government. A report on
dam safety procedures has re-vealed
that on the instrumentation side, which
is vital for monitoring of dam safety,
there appears to be a communication
gap between the officer-in-charge of
design / construction and officers who
take over maintenance[4]. There are many
instances where the officers in charge
of maintenance are not aware of the
instrumentation proposal that has gone
into the dam and there exist many miss-
ing links. The initial readings of the
instrument are rarely available for an
instrument embedded in the dam, the
absence of which has made subse-
quent analysis difficult.
Bridges are important lifeline struc-
tures, it is important for them to have
elaborate inspection and maintenance
programmes. Static and Dynamic Load
testing's are carried out in today's bri-
dges to satisfy the IS codes and safety
measures. These tests are carried only
during major events in the bridge life-
span especially the construction time
and major repairs & retrofitting. Apart
from this Permanent & Continuous mon-
itoring are required for majority of bri-
dges to prevent any human loss. These
can be also useful to assess the dis-
tress during or following any major event
like earthquake, landslides, storms etc.
Modal Analysis has come up as a
very effective way of finding damages
and overall health of bridges. Such global
methods are very important but can
only detect only global changes such
as foundation settlement, bearing fail-
ure or major defects, such as loss of
main cable tension or rupture of deck
element . But again does not need a
high density of sensors and can be
184 The Masterbuilder - July 2013 · www.masterbuilder.co.in
done minimum of optimally located
sensors.
Some work of installing advance
Structural Health Monitoring has been
done in india on very few bridges. One
of the bridge is Naini Bridge over
Yamuna River at Allahabad. This was
probably the first installation of fully
standalone new generation GPS com-
bined with advance post processing
software to continuously monitor the
bridge for various changes in climate
and operations with high accuracy for
example 3D absolute deflections can
be measured up to mm accuracy[5]. This
work was carried out by COWI/ Devcon
Infrastructure. But this kind of work has
to be carried over all important bridges for
there better understanding and safety.
A structurally deficient bridge is clo-
sed or restricted to light vehicles be-
cause of its deteriorated structural com-
ponents. While not necessarily unsafe,
these bridges must have limits for
speed and weight. A functionally obso-
lete bridge has older design features
and, while it is not unsafe for all vehi-
cles, it cannot safely accommodate
current traffic volumes, and vehicle
sizes and weights. These restrictions not
only contribute to traffic congestion,
they pose such major inconveniences
as school busses or emergency vehi-
cles taking lengthy detours.
The ASCE Infrastructure report card[6]
was devised under the leadership of
American Society of Civil Engi-neers
(ASCE) in 1997, in which the se-nior
author was personally involved. It re-
veals some important facts about In-
frastructure and also gives a lesson in
making us, as professionals, more
responsible for the national stock. We
as profession must guide and direct
such activity in India to make public
aware of the future of our infrastructures.
Conclusion and Future:
In the paper many aspects of Struc-
tural Health Monitoring were consid-
ered.
- The need of SHM gives us some
strong reasons for it to become a
integral part of a structure
- India as a developing country needs
to be more aware and cautious
about its Infrastructure. A major
event can cause irreversible losses
and hence should be well informed
in time.
- There are many important struc-
tures where instrumentation is
already being used in India like the
dams, whose various parameters
have to be looked upon, but these
are not being done effectively and can
be better with new technologies.
- Lifeline structures like hospitals and
important bridges and tunnels
should be mandated with monitor-
ing as their failure cause more losses
than any other.
- Structural Health Monitoring eco-
nomically is also light and is only
0.5% to 3% one time cost of total
structures cost and 2% to 5% for
monitoring structure over 10 years.
- It is done with some structures in India
but have to be focused more on.
Structural Health Monitoring is rela-
tively new concept worldwide and very
recent for India. It has proved to be
effective and fruitful in many countries,
now being practices often, and has a
great potential and usefulness for india
for gaining confidence over the struc-
tures we are making so that develop-
ment happens faster and with accurate
results
References
1. Branko Glisic and Daniele Inaudi, “Fi-
bre optic methods for structural health
monitoring”, John Wiley & Sons,
Chichester, 2007.
2. Guidelines for Structural Health
Monitoring, ISIS Canada.
3. International Society of Structural
health Monitoring and Intelligent
Infrastructure, www.ishmii.org
4. “Report on Dam Safety Procedures”,
Government Of India, Ministry of
Water Resources.
5. Jacob Egede Anderson, “Structural
Health Monitoring Systems”, Cowi
A/S and Futurtec OY, 2006.
6. “Report card for America's Infrastruc-
ture”, American Society of Structural
Engineers, 2005.
7. http://memory.loc.gov/ammem/col
lections/habs_haer/
 Repair and Rehab
Use of FRP Composites for Rehabilitation of
Heritage Structures
Dr. Gopal Rai
R&M International Pvt. Ltd.
A
ll heritage buildings have their
unique historical significance.
Their character defining elements
that account for its heritage values vary
from structure to structure. The master
builders of the Middle Ages were able to
use geometrical rules, developed th-
rough centuries of trial and error, to build
structural elements at times when there
was no knowledge of material proper-
ties or allowable stresses.
The preservation and strengthening
of heritage structures is tricky, the inten-
ded change in the use of such building
will invariably create difficulties to tackle,
which in turn would make compliance
with the statutory building safety and
health requirements a challenge. Another
balance to be considered is the need for
preservation of character-defining ele-
ments of the heritage buildings and the
need to comply with the minimum build-
ing safety and health standards.
Repair and strengthening by grout-
ing of brick and stone masonry walls
has been largely applied throughout
Europe on historic buildings, neverthe-
less no great effort was done in advance
and during the time to test the effective-
ness of this technique.
The seismic resistance of historic
masonry buildings is a special scenario
to consider. The seismic analysis of un-
reinforced masonry structures is a field
in its infancy, with most earthquake en-
gineers insisting that historic buildings
do not have sufficient ductility to resist a
major seismic event. Many engineers
would propose that a structure need to
be strengthened to improve its seismic
resistance, but as a profession, we
should caution that our understanding
of the seismic response of masonry
buildings is limited at present.
Many reasons are present for pro-
188 The Masterbuilder - July 2013 Ÿ www.masterbuilder.co.in
per attention to be given to these heri-
tage/ Masonry structures. The following
are the major reasons for them to un-
dergo rehabilitation, strengthening:
1. Temperature changes and expo-
sure to moisture and other environmen-
tal factors result in deterioration, weak-
ening, fatigue effects, chemical attacks,
weathering and inadequate maintenance
and distress of masonry elements.
2. Old masonry construction as un-
reinforced structures is especially vul-
nerable due to many environmental
calamities like:
s Earthquakes s Tsunamis s Excessive
rain s Soil pressure s Settlements due to
underground construction s Problems due
to construction of newer structures around
and below. s Vibrations induced due to
various factors. s Fire also weakens the
structure and calls for rehabilitation.
3. These structures are often over-
loaded over the period of time as the
requirement of floor space and strength
has become high with the today's world.
4. The use of many structures has
also changed many times during the
time. As the structure were not designed
and made for all kinds of future loads, it
is very evident that these structures
need attention and strengthening.
There are numerous ways of doing the
strengthening.
- Confinement: It literally means to
impede the deformation.
- Reinforcement: Taking use of new
materials and technology to build sec-
tions around to impart extra strength.
- Enlargement: Widening of the re-
sisting section with the addition of
new material.
- Material substitution: Removal and
replacement of damaged parts of a
structure. The materials used in the
reconstruction may be similar to the
original ones or possess better me-
chanical properties.
- Structural substitution: Creation of
new load bearing structure with mo-
dern materials, without the disman-
tling of the old one.
- Tying: Binding together different ele-
ments or different parts of a single
element.
- Propping: Supporting a part of a
structure with additional elements
made of steel or other new materials.
The main distinction has to be made
between lateral propping (strutting)
and vertical propping.
- Anchoring: Fastening an element or
a part of a structure to a firmer solid.
The most diffuse form is an-choring
to rock and soil. This intervention is
used to improve the stability of a
structure and to avoid its collapse in
case of a seismic event.
- Prestressing: Changing the stress
field in a structure or in an element
using external loads or induced com-
pression before loading.
- Isolation: Absorbing the seismic
forces and vibrations in external de-
vices usually placed between the
proper foundation and the masonry
structure.
- Soil stabilization: Intervention fo-
cused on the soil beneath the struc-
ture, aiming at an improvement of its
bearing capacity.
Most of the above techniques and
materials involve the following
- Use of heavy materials inducing dead
load
- Changing the original floor space
and creating more space constraints
 Repair and Rehab

by increasing size and inducing
new structural members
- Semi-destructive practices involved,
which are very harmful and undesir-
able for old structures as they need
to be conserved and some of them
are of high cultural values
- Changing the look and aesthetics
of the existing structure as it involves
erecting new members, enlarge-
ment of size, use of different and
new materials etc.
Finally, it is the responsibility to un-
derstand the proper requirement of
these structures as they are not from
the modern world and have to be taken
care with proper expertise and guid-
ance i.e. errors in any kind of restora-
nates applied to the external surface of
masonry have become a viable solu-
tion. The most important reason is that
they comply with the cultural value of
the building.
There are numerous possibilities in
terms of material properties and appli-
cation methodology of FRP materials in
old heritage structure as it is important
to conserve the cultural significance
and aestheticity of the structure. The
following is the major applications of
FRP composites in masonry structures.
There are two techniques, which are
normally adopted for strengthening of
masonry systems.
- Single layers of composites and
FRP wrap: In this method, separate
Shear Strengthening can be done by
using FRP Composites and applying in
horizontal directions as shown in Fig 1.
Seismic strengthening: As shown in
fig the behavior of Masonry structures
in the effect of seismic forces.
The actual cracks developed after
an earthquake is shown in Fig 3.
Roof Level
Lintel Level
Plinth Level
Masonary Building Components

tion are highly un desirable.
FRP composites when used prop-
erly on these structures, they are best
suited for tackling these problems of
masonry structures, which can be used
to make them durable, ductile and
stronger for the times ahead.
This paper further presents some
use of FRP strengthening techniques
in masonry structures.
FRP Use in Structural Repair and re-
habilitation
FRP composites have been lately
very popular in the field of structural re-
habilitation. The use of materials, like
carbon or glass fiber composites, has
considerably increased in the field of
matrix and fiber are used, and they (a)Basic Masonary Components
form the composite at the place of
application after wet Lay-up. It is
also known as wet Layup system.
- Carbon Composite Laminates: In
this method pre-cured carbon fiber
laminates/Plates are used, which are
bonded adhesively with the struc-
tural member.
The guidelines are very important
for any technology/ method to be com-
monly accepted and used. Lack of (b) Rocking and seismic forces acting on the structure.
guidelines for strengthening of masonry
structures with FRP have for been re-
sisting the use of these materials on
X Cracking of
masonry structures. The technical com- Masonary
mittee of ACI 440 is working on bringing Building
the code for use of these materials. Until Components

rehabilitation. RCC structures that have then the use of FRP composites have
been successfully rehabilitated and stren- to be made aware by publications and
gthened have considerably increased. journals. (a)The Cracks developed by the seismic forces
The FRPs present several well-known FRP can be effectively used in stren- Fig 2: The seismic behavior of the structure
advantages, including negligible spe- gthening on the walls in flexure by
cific weight, corrosion immunity, and applying procured laminates or rods The strengthening of these compo-
high-tensile strength. Flexibility and easy made of FRP in the vertical direction nents is done by applying cross lami-
application also allow a wide range of (Fig 1). nates so that they can resist the move-
application areas that is strengthening
and restoration in several damaging
conditions.
Masonry structures have always
been used since the dawn of construc-
tion, and nowadays, due to aging, ma-
terial degradation, settlements, and
structural alterations, usually some mem-
bers need strengthening to re-establish
their performance. In this aspect, FRP Fig 1. Flexure and shear strengthening of the walls Santa Monica, Northridge Earthquake, 1994
composites in the form of bonded lami- using FRP Composites Fig 3: Cracks developed in the earthquake.

www.masterbuilder.co.in Ÿ The Masterbuilder - July 2013 189

 Repair and Rehab
ment and development of these cracks
in the direction perpendicular to their
application. Examples are shown in Fig 4.
Fig 4: Diagonal Bracing of wall for strengthening
Case Study 1: Retrofitting of a Old
Bungalow in Alibag
In Alibag, an old bungalow was in
bad condition as per structural point of
view. It belonged to a known business
man in south Mumbai. Bungalow is a
load-bearing structure and number of
floor is G+1. It was found that some
horizontal crack near first floor beam.
To protect the structure from any
further cracking and harm a structural
consultant was appointed, and he col-
laborated with R&M International to exe-
cute the work. It was decided to be done
with the help of glass and carbon fiber
from both the face of the wall. The Bun-
galow and cracks are shown in Fig 5, 6
and 7.
R&M International was appointed
for the execution of the work. It was suc-
190 The Masterbuilder - July 2013 Ÿ www.masterbuilder.co.in
Fig 5: Front View of the Structure.
Fig 6: Horizontal Crack on the Structure.
Fig 7: Horizontal Crack in the wall
cessfully completed in 2012. The fol-
lowing was used to strengthen the wall.
a. Carbon FRP: First Carbon fiber is
applied over the structure. The ori-
entation of the carbon fiber sheet
was vertical as shown in Fig 8a.
b. Glass Fiber: After curing period of
carbon fiber sheet, horizontal sheet
is applied as per the drawing as
shown in Fig. 8b.
The same procedure was used to
retrofit the structure from inside.
Fig 8: a) Vertical Application of C- FRP wrap and
horizontal application of G-FRP.
Fig 8(b): The Back side view of the structure.
Case Study 2: Repair and Strengthe-
ning of Settlement affected old struc-
ture in Delhi.
The US India Foundation is located
in Caunaght place, New Delhi. The
Building under consideration was built
in 1928. The structure is a load bearing
brick masonry G+1 structure.
Due to ongoing tunneling below the
structure cracks were developed in the
brick walls and the cracks were seen in
the right hand side block of the struc-
ture. As the client wanted the structure
to be safe and strengthening measures
to be undertaken.
The following observations were
done for the cracks developed.
- The cracks were present in the right
hand side of the structure and in the
middle portion.
- The cracks were uniformly present in
all walls and columns of the structure.
- Two major cracks were present, which
could be seen to have a clear pres-
ence throughout the wall.
- The cracks were present at the first
floor as well as the ground floor.
As the cracks were present all over
the walls in the right hand side of the
structure, it becomes important to take
 Repair and Rehab
care of the cracks and to give extra
strength so as to remove any concern,
which might arise in future and makes
the structure stable.
Fig 9: Major crack developed on the 1st floor as
seen from outside
Fig 10: Cracks present as seen inside on the
columns and on the top.
Repair Methodology
The following were the steps invol-
ved in repairing and strengthening of
the structure.
- All the area where cracks have
appeared had to be cleaned and all
the plaster and other superficial and
protective materials such as the gyp-
sum, etc had to be removed where
the cracks had been noticed.
- The area where crack had propa-
gated needed to be cleaned and
exposed properly with the help of
sand papers and less impact tools.
- The crack propagation can be of
two types. They can either be on the
joint which is the more likely one, and
it can also be through the bricks.
- The cracked mortar has to be re-
moved by means of a toothing chisel
or a special pointer's grinder, to a
uniform depth that is twice the joint
width or until sound mortar is re-
ached. Care must be taken not to
damage the brick edges. Remove
all dust and debris from the joint by
brushing, blowing with air or rinsing
with water.
192 The Masterbuilder - July 2013 Ÿ www.masterbuilder.co.in
- Refilling or repointing mortar should
be carefully selected and formu-
lated. It is always advised to pro-
duce best results to fill them with
the original mortar itself. Otherwise,
a mix of 1 part Portland cement, 4
parts hydrated lime and 11¼ to 15
parts fine sand is used to fill the
removed mortar space.
- The repointing mortar should be
prehydrated to reduce excessive
shrinkage. The proper prehydration
process is as follows: All dry ingre-
dients should be thoroughly mixed.
Only enough clean water should be
added to the dry mix to produce a
damp consistency which will retain
its shape when formed into a ball.
The mortar should be mixed to this
dampened condition 1 to 1½ before
adding water for placement. The
joints to be repointed should be
dampened, but to ensure a good
bond, the brickwork must absorb
all surface water before repointing
mortar is placed. Water should be
added to the pre-hydrated mortar
to bring it to a workable consistency
(somewhat drier than conventional
mortar). The mortar should be pa-
cked tightly into the joints in thin lay-
ers (6.4 mm maximum), as shown
in Figure 5c. The joints should be
tooled to match the original profile
after the last layer of mortar is
“thumbprint” hard, as in Figure 5d.
As it may be difficult to determine
which joints allow moisture to pene-
trate, it is advisable to repoint all mor-
tar joints in the affected wall area.
- For cracks hairline in the bricks. If
a) Deteriorated b) Mortar Cut back
Mortar Joint to Uniform Depth
c) Pack Pointing Mortar d) Tool Joint to Match
in Thin Layers Original Profile
Fig 11: Repointing Methodology in the joints.
the bricks are very much damaged
it can be removed and replaced one
at a time. A small part of the brick
could also be used and replaced by
using the repointing mix as des-
cribed above.
- The whole repaired surface will be
then applied with carbon fiber wrap
as per the Fig 6. The full drawing is
enclosed with the report.
Fiber Bands
Scheme of Fiber Treatment for Strengthening walls
Fig 12: Wrapping details along the Walls which were
affected by cracks.
- The columns have to be installed
with fiber wrap with laminates where
the plane is changing as shown in
figure 7.
Laminates to
Front View confine the
Fiber Wrap
Fiber Wrap All around
the column
50 mm Grooved
inside from
Details of Wrapping at
Columns at USIEF
below and top
Fig 13: The details of confinement of columns with
FRP and Laminates
Fig 14: (a) Column Wrapping done for confinement
and strengthening (b) Wraps done over the cracks
for arresting them.
References:
1. Islam Md. R,, Inventory of FRP strength-
ening methods in masonry structures,
Masters Thesis, Erasmus Mundus.
2. Motavalli M., Guide for the design and
construction of externally bonded FRP
systems for strengthening exis-ting
structures, CNR-DT 200/2004, Rome,
Italy, 2004.
3. Maruccio C., numerical analysis of frp
strengthened Masonry structures, PhD
Thesis, December 2010.
 FRP Composites

Recent Advances in Structural Retrofitting

Using Precured FRP Profile

Dr. Mangesh Joshi

MD, Sanrachna, India

R
ecent developments in the field of fiber reinforced ing materials create a mandate for economy in the selection
composites have resulted in the development of of FRP materials for structural strengthening/repairs.
highly efficient construction materials. Now days the In structural strengthening/repairs applications, in-situ
use of fiber reinforced polymer (FRP) composites in civil engi- FRP wrap system has now days gained wide acceptance.
neering applications is gaining high importance. In-situ FRP However, it's being more labor oriented process; the quality
warp system has wide acceptance and now days it has of the work highly depends on the skill set of the workmen,
become the common method of strengthening and/or repair environmental conditions and ease of access at site. The par-
of RCC structures. Taking into considerations the limitations ticular silo structure is located at very remote place in North
of the in-situ FRP wrapping, it has been constant endeavor India. It's difficult to work with the polymer matrix system at
by SSSPL to develop the innovative system in FRP compos- such a low temperature environment. And access to the
ites itself. As a part of such consistent efforts, recently structure was also an issue. Therefore, it was decided to
SSSPL have successfully delivered a project for strengthen-
ing of RCC silo structure at Dalla, India, using specially
designed pre-fabricated FRP stiffeners. The basic problem
with the RCC silo structure was its faulty construction and
hence, it had completely lost the verticality. This resulted into
eccentric loading under its own weight. And considering the
pressure imposed by the content ultimately resulted into
undue moments at the different levels of the RCC wall of the
silo structure. Therefore, in order to improve the load carry-
ing capacity of the structure, specially designed FRP pre-
fabricated stiffeners were used. The main advantages of
using FRP pre-fabricated stiffeners are excellent quality and
ease of installation at site
The repair of the structures with conventional materials is
often difficult, expensive, hazardous and disruptive to the
operations of the existing structures. The removal and trans-
portation of large amounts of concrete and masonry materi-
als causes concentrations of weight, dust, excessive noise,
and requires long periods of time to gain strength before the
structure can be re-opened for service. On the contrary,
FRP, though originally developed for the aerospace industry,
are being considered for application to the strengthen-
ing/repair of structures. It's mainly due to their low weight,
ease of handling and rapid implementation. A major devel-
opment effort is underway to adapt these materials to the
strengthening/repair of buildings and civil structures.
Appropriate configurations of fiber and polymer matrix have
to be developed to resist the complex and multidirectional
stress fields present in structural members. At the same
time, the large volumes of material required for structural
strengthening/repair and the low cost of the traditional build- Figure1: Misalignment in the vertical wall of the silo structure

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

 FRP Composites

U.P. Cement Projects (D.C.F.) Date:- Size of the RCC silo structure: 18000 mm ID, total elevation =
x x Plumb Checking of Blending Silo (K-5)
68000 mm
N
During Operation of Slip Form
Y
The structure was out of the alignment throughout the
height as per the initial survey report as shown in figure-1
Due to such loss of vertical alignment in the basic RCC
structure, the additional forces/moments imposed onto the
structure were calculated considering P-Δ analysis

60.00 m Horizontal FRP

Stiffeners @
Vertical FRP Stiffner 6000 mm spacing
@ 4000mmc/c

54.00 m

Vertical FRP Stiffner @ Horizontal FRP

2000 mm c/c distance Stiffeners @
4000 mm spacing

30.00 m
Legent:-
T = Top
B = Bottom KEY PLAN
Vertical FRP Stiffner @ Horizontal FRP
Stiffeners @
design and develop the pre-fabricated FRP strengthening 1000 mm c/c distance
2000mm spacing
system, which can easily be installed at site by way of adhe-
sive bonding as well as mechanical fastening system with
the existing RCC structure. Since it's a pre-fabricated system
18.00 m
produced in the control environment at factory, the quality of
Figure 3: Schematic arrangement of FRP stiffeners
such system is much better than in-situ system. Being spe-
cial modular design, the mass production was feasible with
40 mm 60 mm 40 mm
limited numbers of moulds, which resulted into significant Cross-Section of
product cost saving. Transportation and installation at site FRP Stiffner
was very easy due to modular design and light-in-weight of 50 mm
3 mm nominal
those stiffeners. thickness
50 mm
Design and Analysis
Project: Strengthening of RCC silo structure- K5 Project, Figure 4: Typical sectional details of FRP stiffeners

Vertical GRP Stiffeners

Cicumferential GRP stiffeners

a) FE Model from level of 19.373m to b) FE Model showing FRP stiffening

68m. Eccentricity is modeled
based on the input data
Figure 2: FE model
arrangement. For clarity, in the present Joint Jacket in GRP
view only partial stiffeners are shown
from elevation of 19.373m to 37m.
Such stiffening arrangement will be
provided up to elevation of 68m
Figure 5: Typical inter-stiffener joint details

www.masterbuilder.co.in · The Masterbuilder - July 2013 195

 FRP Composites

Conclusion
As per the structural analyses, the maximum stresses
induced in the fiber-reinforced composite stiffeners were well
within the allowable limit. The allowable limits were deter-
mined based on the safety factors calculated as per
EUROCOMP Design Code and Handbook1. Actual laminate
test results2 were obtained during design stage itself to
determine the mechanical properties (tensile strength and
modulus) of the laminate. And hence, the design was based
on the realistic material properties. The project was com-
pleted in September 2011 within actual execution time span
of eight weeks. And since then the system has been suc-
cessfully performing under service conditions.
Acknowledgements

Figure 6: FEA Results: Stresses in FRP Stiffeners (Maximum stress = 3 MPa < allowable We acknowledge the entire team of SSSPL involved in the
strength of FRP as per EUROCOMP Design Code) _ Safe process of design, development and installation this innova-
tive FRP strengthening system.
In order to counteract those additional forces/moments,
References
FRP stiffening system was designed considering the special
geometrical form and reinforcements using glass fiber- - John L. Clarke, “Structural Design of Polymer Composites-
epoxy system. EUROCOMP Design Code and Handbook”, Chapman
Owing to the complex nature of the problem and solution and Hall, London, 1996
system, the structural analyses were carried out using finite - Mechanical test reports on FRP laminates
element techniques. Figure 2 below shows FE Model con- - Input data like survey reports, 2D drawings, etc provided
sidered in the analyses by client

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 Communication Feature
Offering a Wide Array of
Construction Solutions
S
.N.Engitech Developers is one of
the leading solution providers for
improvement / protection / repair
of concrete structures in the country.
The company provides comprehensive
solutions to the construction industry in
diverse areas. These include, water-
proofing system, repair/rehabilitation,
strengthening structures, expansion joint
systems, rebar fixing, Trimix flooring,
core cutting and protective coating.
S.N.Engitech has been associated
with several landmark Civil Engineering
projects around India. Its wide array of
project expertise include hydro power,
industrial buildings, corporate houses,
real estate, factory buildings, food pro-
cessing units, roads & runways, etc. With
a team strength of over 40, the company
has its corporate and registered office
located in Faridabad and a branch
office in New Delhi. The team provides
immediate and responsive product and
sales support via email, phone and VoIP
to customers around the country.
The company has built up cherished
long-term rapport with several globally
renowned names. Some of the top play-
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USA, BASF India Limited, Chryso,
Germany, and various other national
and internationally well known princi-
ples. The company is the sole technical
partner, distributors and approved
applicators for the entire range of the
Repair & Rehabilitation of Dam
198 The Masterbuilder - July 2013 · www.masterbuilder.co.in
famed SealBoss range of products in
India.
Expertise in Ensuring Watertight
Systems
The company's expertise in the field
of water proofing is evident in one of its
recent projects in Gumani Dam, loca-
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in 1970-71 at the origin point of Gumani
River has a catchment area of 7 sq.miles.
This earthen dam with rubble masonry
abutment walls and a spillway is the only
water source for the nearby Air Force
Station Base at Singharsi. The client was
experiencing a number of leakage points
at the interface of spillway wall and abut-
ment walls. Cracks were also seen at
both the abutment walls. The down-
stream face of spillway had also devel-
oped signs of wear and tear. This is when
S.N.Engitech's expertise was sought
by the client.
The team from S.N.Engitech remo-
ved all the loose vegetation and chemi-
cally treated the surface to stop further
ingress of natural penetrating vegeta-
tion. The applicators then drilled 14-20
diameter holes for injection of Colloidal
Silica and Microfine Cement as and were
required. NRC packers of SealBoss Corp
USA were fixed at required C/C distance
and depth at different heights and sur-
face of the abutment wall. Pointing of
raked-off cement mortar from the area
of leakage in D/S face of spillway was
done and filled with high strength Poly-
urea Quickfix 6060 from SealBoss
Corp. After this, SealBoss 1510 and
SealBoss FlexGel2 were injected into
the designated areas forming a water-
tight PU seal. SealBoss 1430 LV Resin
was then injected at designated places,
further helping in making it a complete
watertight system.
Another Successful Project
The Malana Hydroelectric Dam at
Haryana is another project for which
S.N.Engitech's expertise was sought.
The client was experiencing water in-
trusion through joints and perimeter of
the dam. Malana is a run-of-river facility
that uses water from the Malana Stream,
a tributary of the Parvati River. The pro-
ject was commissioned in July 2001.
As part of the repair method, all the
paint was removed by chemical / man-
ual means from the joints and perime-
ter cracks. The surface was then pre-
pared with the application of epoxy
compound to the face of the substrate.
The applicators drilled holes at a 45
degree angle into the joints and cracks,
intersecting the substrate halfway
through thickness. Spacing of the ports
was 3 packers per meter. SealBoss 1510
and SealBoss FlexGel2 were then in-
jected into the joints and cracks form-
ing a watertight polyurethane seal.
The surface was then treated with a
moisture insensitive epoxy compound
and fiber glass cloth for final water tight
finish.
For further details:
S N Engitech Developers Pvt Ltd.
Booth No. 10, Basement Sector-16A,
Market Faridabad-121002
Ph: +91-129-4132000,
E-mail: snengitech@yahoo.in
Web: www.snengitech.com
 Formwork

Factors Affecting the Selection,

Economics Involved in Formwork

Sameer S. Malvankar
Dy. Manager - Engineering,
Gammon India Ltd.

Appropriate selection of a formwork system is a crucial factor in successfully completing most building projects. However, in practice,
selection of an appropriate formwork system has traditionally depended mainly on the intuitive and subjective opinion of practitioners with
limited experience. This paper, discusses the guidelines on how to choose formwork, factors affecting the selection, economics involved in
formwork and the present scenario of formwork in India. This article can assist engineers to determine the appropriate formwork system at
the inception of future projects.

Formwork is a die or a mould, including all supporting structures,
used to shape and support fresh concrete until it attains
sufficient strength to carry its own weight. It should be capable
of carrying all imposed dead and live loads apart from its own
weight.
A formwork system is defined as “the total system of support
for freshly placed concrete including the mould or sheathing
which contacts the concrete as well as supporting members,
hardware and necessary bracing”. However, “System” implies
a fully compatible arrangement of formwork with a minimum of
individual components with reusable elements intended to solve
each forming task thereby rationalizing the forming work.
Formwork system is among the key factors determining the
success of a construction project in terms of speed, quality,

200 The Masterbuilder - July 2013 • www.masterbuilder.co.in


Figure 1 – Main cost type in a typical building project
cost and safety of works. Nowadays, most projects are required
by the client to complete in the shortest time possible as a
means to minimise costs. For high-rise buildings, the most
effective way to speed up works is to achieve a very short floor
cycle — to have the structure of a typical floor completed in
the shortest time. On the other hand, aiming purely at speed
often contradicts the achievement of other quality standards.
Problems such as misalignment, misplacement, deflective
concrete or holding up other works causing serious interruption
can result.
The basic parameters of formwork are:
- Quality: in terms of strength, rigidity, position, and dimensions of
the forms
- Safety: of both workers and the concrete structure
- Efficiency: in operation, the ease of handling, erection and
dismantling, number of repetitions within the optimal limits
- Economy: the least cost, consistent with quality and safety
A) share of Formwork Cost
In a typical multi-storey reinforced concrete building, formwork
cost is the largest cost component. Formwork cost accounts
for nearly 20-40% of cost of concrete and involves more than 60%
cost of time. Overall formwork related cost have significant
share ie.10% in the total construction cost.
Figure 2 - Integrated formwork/concrete lifecycle
Formwork
A large proportion of the cost of formwork is related to formwork
labour cost. Significant cost savings could be achieved by
reducing labour cost. An exemplary comparison reveals that
the additional concrete use of up to 15% is economical than
the handling of angular forming areas, since their assembly is
rather time-consuming and the cost per square meter is higher
than that for a straight surface.
B) An Integrated Formwork/concrete Life Cycle
The process of providing formwork and concrete is highly
integrated. In the figure 2, the left circle represents the
formwork life cycle, while the right circle represents the
concrete construction life cycle. The two intersection points
represent the beginning and the end of concrete construction
life cycle. It should be noted that the phases ‘cure concrete’
and ‘stripping of formwork’ are interchangeable depending on
the type of structural element. For example, columns and walls
are cured after stripping the forms while slabs and beams are
cured before and then stripped.
C) Economy of Formwork and Significance
1. Economy in design of a concrete structure
The architect or design engineer can also contribute much to
reduce formwork cost by keeping the requirements of formwork
economy in mind when one is designing the structure. At the
time of design, consideration of the materials, methods that
will be required to make, erect and remove the formwork. Avoid
varying sizes in columns and beams; Usage of same sizes
to the possible extent economizes the design permitting the
reuse of formwork without alteration.
2. Economy in design, planning and building formwork
In designing, planning and building formwork, the contractor
should aim for maximum economy without sacrificing quality
and safety. Short cuts in design or construction th at endanger
quality or safety may be false economy. For example, if forms
do not produce the specific surface finish, much hand rubbing
of the concrete may be required; if forms deflect excessively,
bulges in the concrete may require expensive rectification
measures.
Figure 3 - Categories of formwork classification
www.masterbuilder.co.in • The Masterbuilder - July 2013 201
 Formwork
- Limit the size of formwork panels or systems to largest
possible that can be handled at site.
- Standardize formwork making, erection and stripping to
maximum possible extent
- Minimise the amount of components and accessories like
nut, bolts, nails etc. to avoid risk of losing
- Create a material cost awareness cost of material con-
sciousness in the personnel
- Control reuse and repetitions. Specially plywood and timber
- Standardize various formwork systems
coordination and cooperation between engineers, contractors
are necessary to achieve the goals. Saving depends on
inventiveness and knowledge of the contractor. Judgment
in the selection of the materials and equipment, in planning,
fabrication and erection procedures, and in scheduling reuse
of formwork, will expedite the job and cut costs.
D) Various Formwork Systems
Formwork can be classified according to a variety of categories
as follows: (Refer Figure - 3)
Classification according to sizes
- Small-sized formwork
- Operation by workers manually Wooden and aluminium
formwork
- Large-sized formwork
- Crane facilities are required in the operation Reduce the
number of joints and to minimize the number of lift Stiffening
components -studs and soldier
Classification according to location of use
Various elements in the structure have specific design and
performance requirements in the use of formwork. Some systems
are more adaptive for specific location of use, such as
- Irregular frame structure – Conventional traditional timber form.
- Wall, Column – Girder form, Frame panel form, climb form
or jump form
- Slab – Conventional timber form, Modular slab formwork,
primary-and-secondary beam method, Panel form, Drop
head beam- panel system, table form
- Repeated regular section – tunnel form, modular aluminium
form
- Core walls, shells- Climbing formwork, Jump form and slip-form
- Precast structure- steel /aluminium mould forms
Classification according to materials of construction
- Timber: most popular formwork material -low initial cost
-high adaptability to complicated shape-labour intensive
and environmental unfriendly
- steel: hot-rolled or cold-formed sections heavy weight -
suitable for large-sized panels
202 The Masterbuilder - July 2013 • www.masterbuilder.co.in
- Aluminium: stiff and light weight-higher material and labour
cost-excellent finish
- Plastic: recyclable, tough, lighter weight
- Sacrificial concrete panels- Left in place formwork
Classification according to nature of operation
- Crane independent- Manually handled formwork -Self-
climbing formwork
- Crane-dependent formwork
- Gantry, traveling and tunnel type formwork system
E) Evaluation / Selection Criteria for Formwork System
Earlier formwork was once built in-place, used once, and
subsequently wrecked. The trend today, however, is towards
increasing prefabrication, assembly in large units, erection by
mechanical means, and repetitive use of forms. These de-
velopments are in tune with the increasing mechanisation of
production in construction sites and other fields.
Formwork planning includes detailed layouts, cycle plans,
calculation of optimum amount of material for the site, observance
of fixed schedules and selection of the most appropriate and the
most economic formwork system to be used at the construction site.
Figure 4 - Parties involved in formwork selection process
Different Parties involved in formwork selection
The proper selection of the formwork systems to be used in
concrete structure is concern to all involved parties.
The following selection criteria have to be considered:
1) Geometry of building / structure
Internal layout
Some buildings may have very simple layouts with few i n-situ
walls and floor plates framed with regularly spaced columns,
as seen in many commercial and office buildings. However,
some developments feature very complicated load bearing
internal walls that can make the casting process difficult.
Structural forms
Like internal layout, the structural form of buildings also affects
the formwork options. For example, buildings with a structural
core in the form of a vertical shaft limit the use of other formwork
 Formwork
systems other than those of a self-climbing nature. Buildings
in flat slab design make table forms or flying forms the most
obvious choice. For buildings with regularly arranged shear
wall designs, the best selection is large-panel type steel forms
or other types of gang forms.
Consistency in building dimensions
Some buildings may have non-standardised dimensions
due to the architectural design and layout or to fulfill other
structural requirements. These include the reduction of sizes
for beams, columns and walls in high-rise buildings as the
structure ascends. Formwork systems like the climb-form or
steel form, may be quite difficult to use in such situations, due
to the frequent adjustments of the form to meet the changes in
dimensions may eventually incur extra cost and time.
Headroom
Higher headroom increases the amount (height) of staging
required and can also create accessibility and safety problems.
It can also make the erection of formwork, ensuring formwork
stability and the placing of concrete more difficult.
Building span
Large building spans also create problems similar to those with
high headroom situations. In addition, long-span structures
generally have larger beam sections, heavier reinforcement
provisions, or accompany post-tension works. This will further
complicate the formwork’s design and erection process.
Repetitive nature
High-rise block-shaped structures usually require highly
repetitive cycles and this is favourable to the use of formwork.
However, the degree of repetition in building with very large
construction area like a podium or underground structures
such as basements is limited and the use of formwork, as an
expensive resource, becomes very critical.
2) Project Planning/speed of work
The over-all construction sequence must be planned to use
formwork in efficient manner and to permit the optimum
investment in formwork to meet schedule requirements.
Contractor should plan formwork and job sequence at the
time of making a bid. Project planning such as the phasing or
sectioning arrangement, integration of the structure, site layout
and set-up arrangements or hoisting provisions and concrete
placing facilities are influencing factors when considering
formwork selection and application.
When working with buildings with large construction areas
and horizontal spread, projects can be expedited by the
introduction of additional sets of formwork, to create more
independent work fronts. This will, of course, increase the cost
of construction. For high-rise buildings, increasing the number
of formwork used cannot always expedite the project, for the
critical path still depends on the floor cycle. However, a properly
204 The Masterbuilder - July 2013 • www.masterbuilder.co.in
selected, designed and arranged formwork system will increase
work efficacy for each typical cycle. In some cases, adding
half or a full set of formwork, especially for the floor forms, may
help to speed up the cycle as the additional set can provide
more flexibility when the form is struck at an earlier time.
3) Construction process, methods
For selecting formwork one must know the sequence of con-
struction activities and methods to be followed. Construction
method will always give idea about inter dependency of the
activities, specifications and additional requirements in pour.
This will enable us to workout appropriate system which fulfils
the construction needs.
4) Site logistics
Exceptionally small or very large sites sloped or very crowded
sites, proximity to sensitive structures, sites where other major
activities are underway, or sites with many physical or con-
tractual restrictions will increase the difficulty of working with
formwork. There is no specific solution to improve the situation
in general and problems are tackled according to individual
circumstances.
Accessibility to work during the course of construction,
accessibility problems may be created through segregation,
temporary discontinuation, or blocking of the layout by the
partially completed building or, in cases constructing a shaft-
type core wall is constructed in an advanced phase, the shaft
may stand independently for a long period of time before it
is connected to the horizontal elements. Proper access to
all components should be considered while planning a site
layout.
5) Climate condition
Formwork systems are sensitive to weather conditions. Typically, in
vertical forming systems, the newly placed concrete is supported
by the wall already cast below it. The lower wall section must
get the sufficient strength to support the fresh concrete above.
The rate of strength gain of lower wall is influenced by the
ambient temperature, moisture content, and the freezing and
thawing cycles.
Another factor that affects the economy of the selected system
is the effect of stopping formwork activity and concreting
because of extreme weather conditions. In the case of a slip-
form, the work is usually continuous, 24hrs around the clock.
If the slip-form stops because of weather conditions, it may
impact structure as well as cost.
6) Labour efficiency
Considering the availability and qualification of the work force,
improving labour cost efficiency is a major factor, especially in
markets experiencing a building boom. Here, the qualification
of workers tends to be low in relation to ever higher demands
posed by construction methods.

7) Cost of formwork system
This is a vital factor for deciding formwork system as one must
know the capital provision for formwork in the project. It is
always beneficial to work out these details at the time of bid.
Cost is influenced by three components;
Initial cost or make-up cost:
Includes cost of transportation, materials, assembly and erection.
Reuse cost of formwork system:
The formwork system cost goes on reducing as we increase
reuse of same. The re-use for traditional timber formwork is
usually limited due to the durability of the plywood sheathing.
The optimum number of uses for timber form usually ranges
from 12 to 14. Thus, it is still sufficiently economical to use timber
formwork for high-rise buildings at heights in accordance to the
multiple of the usual re-used times. Although the metal form
can be re-used many times, the high initial cost of providing
the form often discourages its selection, especially when there
is no need to reuse them too many times, for example in a
low-rise development. A careful balance between cost, speed,
performance and the quality of output should be properly con-
sidered when making the selection.
Figure 5 - Factors affecting selection of formwork system
Formwork
8) Maintenance & storage cost:
It includes cost of stripping, repair, storage, etc. Formwork
materials are a valuable asset of company, If proper care is
taken during handling and storage, much return is obtained
on the investment. Formwork needs to be handled correctly,
maintained, repaired if necessary and finally, cleaned regularly.
Avoiding damage reduces costs incurred. Proper storage of
formwork materials gives easy reconciliation, faster retrieval of
material, better space management and avoid unnecessary
expenditures, improve safety at work place.
9) Availability of lifting devices (Crane time)
Many factors should be considered before employment of a
construction plan and the selection of the right formwork system.
These include considerations of whether there will be lifting
appliances provided for the erection of formwork; whether these
appliances will be able to access the work spot to assist in the
operation as the structural works proceed; whether any special
equipment will be required for striking the forms; and how the
removed formwork panels can be transported to other spot to
continue work.
Characteristic to high rise building sites is the confined and
congested space availability for working. Crane time and space
is regularly limited. In general, reinforcing (rebar) activities are
most critical, since lifting the reinforcement to building level is the
most crane- time consuming job of all. Thus, the capability of
formwork to rely less on or be used independently of crane time
is critical in high rise construction.
10) Simple logic of the system
Formwork system ought to be self-explanatory to use, this
automatically eases the usage for the engineers/supervisor and
also the labour who are end users of the system.
11) Working safety
Formwork should be self-securing with safe access and working
platforms. Thus, it is not left to the end user whether they takes
safety measures or not. Creating a safe work environment for
the entire work force involved in the construction process, has
become the pivotal issue in emerging construction markets.
12) Special requirements on Concrete surface/finish
Fair-faced concrete demands very high quality formwork in terms
of surface treatment of the panels, tightness of the formwork
joints and in dimensional accuracy. Requirements are slightly
relaxed where the concrete surface is to be finished at a later
stage.
13) Area or volume of cast per pour
The optimum volume of cast per pour depends on the types
of formwork used, the particular elements of structure to be
placed, the actual scale of work, and different levels of provisions
of plant facilities. Usually a volume of concrete ranging from 60-
200 cubic meters per pour can be comfortably handled in most
www.masterbuilder.co.in • The Masterbuilder - July 2013 205
 Formwork
site environments. It also depends on whether the concrete to
be placed is for the vertical elements only or also includes the
beams and slabs, as a means of saving an additional phase
in the overall work cycle.
14) Involvement of other construction techniques
Tensioning and prefabrication activities are often involved in
construction. This may create certain impacts on the use of formwork,
especially where precast elements are to be incorporated
during the casting process. Provision should be made for
temporary supports or slot spaces and box out positions in
the formwork for the precast elements, or extra working space
for placing stressing tendons and onward jacking.
15) Provision of construction joints in structures
Many a times a large number of construction joints are inevitable
in a large structure because of the subdivision of works into
effectively workable sizes. The provision of construction joints
can challenge the output and affect the quality of the concrete.
Careful selection should be made to ensure a particular
formwork system can satisfactorily allow such arrangements.
16) Inventory- The fewer, the better
The most frequent time & cost consuming activity of formwork
assembly is the loose and small components/accessories.
The lesser inventories will help to reduce risk of losing parts
and provide ease in construction.
F) The Current Situation in India
In the past, India had been lagging behind over the other
advanced countries in applying advanced and safe concepts
for formwork in reinforced concrete construction resulting in
a poor surface quality, wastage and low productivity of the
people involved in concrete construction. This unfortunate
situation continued for a long time because of availability and use
of very cheap unskilled labour and very few skilled personnel
who have had professional training for formwork jobs.
With increasing demand and competition and reducing project
completion times, there have been significant developments in
the construction industry in terms of experience and mastering
of the required managerial, construction or engineering skills
for handling very large and complex projects. At the same
time, the motivating factors highlighted above have created
an eagerness and readiness within the industry to advance.
From the building construction point of view, the use of better
formwork systems is no doubt a very direct way for introducing
innovative methods in the construction of buildings.
- Formwork labour cost is so immense that any innovative
system resulting in a labour cost reduction is highly lucrative.
- Fulfillment of fast track construction schedule provides
fewer choices, one of which is to adopt more innovative
formwork systems.
- Traditional systems can hardly satisfy the tight quality
standard that is required nowadays.
206 The Masterbuilder - July 2013 • www.masterbuilder.co.in
- Similarly, traditional systems can hardly satisfy current
safety and environmental standards.
- The accumulation of experienced crews makes the
application of more sophisticated formwork systems more
reliable and economical.
- Many developers view the application of innovative technology
in the construction process as a positive image-building factor.
G) Major Systems Dominate Today’s State of Art Formwork
Approach in High Rise Construction
- Slab edge protection by screens, providing a safe working
environment on the construction levels
- Modular slab formwork, operated independently of the
crane time, adapted flexibly to different building geometries
and floor layouts
- Undisturbed shoring for slab with drop beam systems
- Frame formwork for columns and walls
- Crane dependent climbing formwork for shear walls/mega
columns
- Crane independent climbing formwork for core
H) The Potential and Limiting Factors of Innovative Technologies
in the Built Environment of India Potentials
- The public’s expectation (government, developers, building
users) are rising all the time.
- More stringent regulations have been imposed to control
the performance of the construction industries.
- Accidents are costly, especially where human casualties
are involved (both for the reasons of compensation, image
and government records).
- The development or importing of advanced technology
have become more common and market affordable.
- The industry is gradually accepting the production of
higher performance buildings involving a more expensive
resource input.
Limitations
- Insufficient research and development in most contracting
firms or other supporting units.
- Lack of working space on construction sites (both on-site
and off-site work areas).
- Training opportunity (including on-the-job training) is still
limited for both the professionals and other workers.
- No guarantee of a consistent market environment for
the development and continual application of innovative
technology in construction (learned skill and experience
will lose eventually).
- The extensive use of cross wall design especially in most
residential buildings and small-scaled projects makes the
use of more innovative formwork system less feasible.
- The exceptionally large scale and complex nature of projects
in terms of the site condition as well as structural and
building design confine the application of more advanced
and sophisticated formwork system.
 Formwork

I) The Industry or Individual Corporations May Consider Formwork Standards

for the Following Measures:
Indian
- Explore ways to streamline and re-engineer the work
IS 14687-1999 Falsework for concrete structure guidelines
structure at both industrial and corporate levels.
- Invest steadily in the human resources development and IRC 87-1984 Guidelines for the design and erection of falsework for road
bridges
to train competent and high quality staff with the required
attitude and readiness to work in the new environment. IS 2750-1964 Specification for steel scaffoldings
(1995)
- Invest steadily in the research and development of
technologies that are particularly suitable for the built International
environment of India
ACI 347-04 Guide to formwork for concrete
- Strengthen the linkages among government departments,
developers, consultants and contractor firms in the promotion, ACI 347.2 R-05 Guide for shoring / reshoring of concrete multi-story
development, cooperation and implementation of more buildings
innovative projects. ACI SP-4 Formwork for concrete
- Government or other institutions may consider providing BS 5975-2008 British standard code for practice for temporary works
funding to support research and development for the procedures and the permissible stress design of falsework
exploration, recommendation or setting up of guidelines DIN 4420 & 4421 German standard for formwork
and standards in the application of newer technology and DIN 18218 Pressure of fresh concrete on vertical formwork
work systems in construction. CIRIA Report 108 Concrete pressure on formwork
Conclusion
References
1. Selection of formwork system, is highly dependent on 1. ACI 347_04, “Guide to formwork for concrete”, American
individual site/project environment concrete institute, 2005
2. Economy of formwork can be achieved with seamless 2. Hanna A. S. & Sanvido V.E. , “ An interactive knowledge based
collaboration between owner, architect, designer teams on formwork selection system for building”, Computer integrated
and contractor. And it can aid in the effective use of advance construction, 1989
formwork systems
3. Hurd M. K. “Formwork for concrete”, American concrete institute,
3. The structural form of the building is one of the critical factors 1915, 6th edition
to determine the choice of formwork
4. Raymond W. W. M. , “Application of formwork for high rise and
4. System products can contribute much in the success of complex building structures-Hongkong cases”, Division of
formwork application building science & technology, city university of Hongkong.

208 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Communication Feature

Blazing a New Trail in Formwork Systems

I
t won't be a misnomer to say that the
Indian formwork and scaffolding
industry has grown by leaps and
bounds in recent times. With project
specifications getting complex and
scales increasing, there has also been
a corresponding increase in the pres-
sure on contractors, who not only need
to complete projects on-time and within-
budget, but also have to adhere to
stringent quality standards. Coming to
their aid have been modern formwork
and scaffolding systems.
While it is true that several names
have entered the fray, there are only few
players who have been able to carve a
niche of their own. The customer today
wants formwork systems that are easy
to use, affordable, and score high when
it comes to safety and quality. A name
that immediately comes to mind when
you think about all these factors is Maini
Construction Equipments. It is the name stage of a project. Right from design- rienced top management team, which
to watch out for in the Indian formwork ing, to the actual erection, Maini pro- firmly believes in using the latest tech-
industry. vides complete support with regard to nology, when it comes to manufactur-
What makes Maini stand out from formwork and scaffolding systems. Its ing, and constant upgradation of the
the crowd is its commitment to quality, range of steel scaffolding includes cuplok same at regular intervals of time. Its
safety and sustainability. This ISO 9001- systems, props, spans, metriform, wall state-of-the-art production facilities in
2008 certified company, offers a wide form and customized systems. Faridabad, NCR and Rudrapur, Uttara-
range of aluminum formwork systems. khand, are manned by some of the fin-
A Name to Watch Out For
What sets its services apart is the com- est talents in the industry. Perhaps the
plete involvement of the team in every A key asset to Maini is a vastly expe- best testimonial for Maini is in its
remarkable growth story, in a relatively
short span of time. The eventful journey
started in 1986 when Maini Scaffolding
Company was incorporated. It was ear-
lier a dealer. By 1996, it had entered the
mainstream and made deep inroads
into the Indian market. The company
started aluminum formwork in 2008 and
is today considered a pioneer, which
offers end-to-end solutions in this highly
competitive industry. The fact that in just
about five years of time Maini has cre-
ated such a brand recall speaks vol-
umes about its commitment to superior
quality and excellent technical support
services. Today it is considered the only
Indian company to manufacture all types
of system formwork under one umbrella.

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

 Communication Feature
Economical and Environmental Sus-
tainability
A penchant for being innovative
and unique has been the driving force
of the company. A good example of it is
available in its utilization of specialized
design software. Maini is considered a
trendsetter with its 'Maini Software', which
provides a 3D platform for fast, profes-
sional planning of formwork and scaf-
folding systems. From a simple base-
ment to a complicated industrial build-
ing, from wall & slab formwork to plat-
form systems and scaffolding- the most
diverse problems can be solved using
the software.
Sustainability is the buzzword in the
construction industry these days, and
this is another area where Maini has
focused. Its panels are made of 100%
recyclable aluminum. These panels are
212 The Masterbuilder - July 2013 · www.masterbuilder.co.in
recyclable under normal industrial pro-
cess. These panels can be used by un-
skilled workers, so typical of the Indian
market, without dimensions or quality
getting affected. In comparison to con-
ventional wooden formwork, these are
reusable for more than 250 times and
are environmental-friendly. It saves the
site from wasteful items, while also
keeping the environment clean for work-
ers. It also helps to organize the opera-
tion line up more efficiently to produce
economical construction. This ensures
both economical and environmental
sustainability.
Excellent technical back-up sup-
port is another area where Maini is a
frontrunner. Experienced Maini super-
visors are sent to site to train the super-
visory staff and labour in the proper han-
dling of the equipment and to assist in
getting started, to establish the desired
work cycle. This improved coordination
and construction management enables
the equipment to be cycled at optimum
speed and ensures that the results in
terms of system efficiency and speed
of output are outstanding. No wonder
Maini formwork systems have been
part of several key infrastructure pro-
jects, including, bridges at Karnal to
Ambala Highway for NHAI, Allahabad-
Naini Bridge, Mumbai-Pune Express-
way, Delhi Metro, Delhi Airport, Kolkata
Airport, etc, to mention only a few.
For further details:
Maini Construction
Equipments Pvt. Ltd.
Ph: +91-11-49686800,
Email: info@mcepl.com
Web: www.mainiformwork.com
 Communication Feature
Top Notch Engineering Solutions
S
harp Engineers, (Prop. M/s. Sharp
Designers & Engineers India Pvt.
Ltd.) offers worldclass products
and services in projects and engineer-
ing solutions like acoustics enclosures,
core drying ovens, stainless steel &
glass fit-outs/finishes and aluminum
formwork systems. The company esta-
blished in 1987 has its state-of-the-art
manufacturing facility located in Chakan
Construction Chemicals & Waterproofing
Perma Construction
Aids Pvt. Ltd.
Complete Solution for the
Construction Industry
Refer Page No.: 279
Sika India Pvt. Ltd.
Sika adds value to your concrete
Refer Page No.: 97
better together
Bekaert Industries Pvt. Ltd.
Dramix® steel fibres- Leaders in
reinforcing tunnels since 1985*
Refer Page No.: 29
To know more on the products, solutions and services offered by the leading brands featured above write to: masterbuilderads@gmail.com
214 The Masterbuilder - July 2013 · www.masterbuilder.co.in
near Pune. The plant is equipped with
modern machinery such as CNC turret
punches, CNC press brakes, laser cut-
ting machines, painting & powder coat-
ing plants as well as NC controlled
shearing facilities.
Sharp Engineers has extensive ex-
perience in the field of glass and stain-
less steel interiors. The company's abil-
ity to understand every client's unique
requirements and come up with stun-
ning designs, while also being cost-
effective has made it a preferred choice
today. Apart from interiors, the com-
pany also creates customized designs
for spiral stair cases, canopy, wall /ceil-
ing cladding, ramps, bridges, etc.
Sharp Engineers' easy to use and
economically viable aluminum form-
work systems conforming to the latest
Pidilite Industries Ltd. Polyflex
Whatever the roof, we'll Modified hybrid acrylic
waterproof it. polymer
Refer Page No.: 6 Refer Page No.: 31
The Supreme Industries Trade Winds
The most compressible filler board for House of Construction Chemicals
Expansion joints
Refer Page No.: 45 Refer Page No.: 283
Flooring
Cipy Polyurethanes Pv. Ltd. Ironite Co. of India Ltd.
Solutions for your coating needs Tough floors. For a smoother life.
Refer Page No.: 79 Refer Page No.: 191
DIN18218 standards are aimed at
achieving faster forming, de-shuttering
andreducing concreting cycle times,
apart from guaranteed superior finish
and near total saving of plastering work,
thereby making it a cost effective solu-
tion. High level of accuracy is ensured
for every client, right from designing to
onsite erection of formwork systems,
an approach which has been behind
the company's success story.
For further details:
Sharp Engineers
Gat NO. 301/2, Nanekarwadi (CHAKAN)
Tal. Khed, Dist. Pune - 410501,
Ph: +91-2135-320601
E-mail: marketing@sharpeng.com
Web: www.sharpeng.com
Razon Engineering Company Pvt. Ltd.
For complete waterproofing solutions
Refer Page No.: 101
CONCRETE SOLUTIONS
Bringing Life To Concrete
JB Associates
Bringing life to concrete
Refer Page No.: 183
 Cellular Concrete
CELLULAR CONCRETE:
An Alternative for Sustainable Design & Construction
Bhavani Balakrishna
C
oncrete is one of the most wi-
dely used construction mate-
rials in the world. The produc-
tion of concrete, notably it's most im-
portant ingredient, cement, poses
several sustainability issues that need
to be managed. Significant amounts
of coal are used in the kilns to make
clinker, which is the major compo-
nent in cement. Electricity is needed
to run the machinery for grinding and
blending in order to make the clinker
and then to process it with other ma-
terials into cement. The whole produc-
tion process emits large amounts of
greenhouse gas (GHG) emissions
and the quarrying of raw materials pro-
duces local impacts such as noise
and dust.
Because of limited natural resour-
ces, concern over GHGs, it is nece-
ssary to look for sustainable solutions
for future concrete construction. The
future viability of the concrete com-
munity will be determined by its res-
ponse to the global issue of sus-
tainability. New research and tech-
216 The Masterbuilder - July 2013 · www.masterbuilder.co.in
nology, and the rapid development of
the green building movement clearly
point out that change in current life
styles are essential if we are to main-
tain and improve our way of life. One
of these changes includes the use of
materials that will extend the service
life of concrete and additionally make
concrete a contributor to the more
efficient use of energy and raw ma-
terials.
A sustainable concrete structure
should have a very low inherent energy
requirement, be produced with little
waste, produce durable structures,
have a very high thermal mass while
leading to lower carbon emissions.
One such alternative that comes close
to the above description is cellular
concrete.
Cellular concrete, also known by
many other names such as aerated
concrete, air-cured lightweight con-
crete, autoclaved cellular concrete,
cellular light weight concrete and cel-
lular light-weight, is engineered, low-
density concrete with versatile fea-
tures that can solve several con-
struction, mining, and manufacturing
challenges.
Cellular concrete is more durable
when compared to traditional insula-
ting materials, especially when con-
sidering potential chemical / fire ex-
posure such as in process facilities.
Compressive strengths are typically
greater than four times that of plastic
foam. It also has fireproofing, insula-
tion, sound attenuation and energy
absorbing characteristics.
What is Cellular Concrete?
Cellular concrete is a lightweight
construction material consisting of
Portland cement, water, foaming agent,
and compressed air. The foam is for-
mulated to provide stability and inhibit
draining (bleeding) of water. Pozzolans,
such as fly ash, and fibers are often
added to the mix to customize com-
pressive and flexural strengths. Cel-
lular concrete typically contains no
sand or aggregate. By trap-ping air
bubbles within the concrete, a light-

weight, insulating material is formed.
There are three ways of making the
air and the voids needed for a cellular
concrete. Many companies sell rich,
thick, long lasting foam that is added
to cement slurry. This foam is made
by using special foam generators. A
second way to make cellular con-
crete is to use Expanded Polystrene
(EPS) for the voids. A third way to
make the air bubbles needed for cel-
lular concrete is to use an alumi-num
powder. The aluminum powder
reacts with the water in the mix that
creates tiny hydrogen bubbles that
creates the air voids. Water and
cement are mixed to form slurry.
Then foam, EPS beads, or aluminum
powder is then introduced into the
mix. Foam is the most common agent
used for the air bubbles. And it is also
the least expensive.
There are two primary methods of
adding the externally generated foam
to a slurry mix to produce cellular con-
crete. The first is to add the foam to a
batch mix, such as a drum mixer truck
or a stationary mixer such as used in
precast plants or on-site for large
jobs. The second is to add the foam
“in-line” to a pipe-line carrying the
slurry mix or into the hopper of a con-
tinuous mixer such as used on volu-
metric truck mixers.
Concrete foaming agents used
for the production of the externally
generated foam fall into two main cat-
egories: The first is protein based,
which usually means animal by-pro-
ducts. In recent years, more foaming
agents are synthetic based materials.
Blended foam liquid concentrates
(blends of protein and synthetic in-
gredients) were introduced later to
technicians additional tools for pro-
portioning cellular concrete mixtures
to meet demanding project or pro-
duct performance requirements. The
additive chemicals and structure used
for the foaming agent can affect the
bubble size, foam life, and general
“toughness” of the foam. For the fini-
shed cellular concrete, this in turn
affects such properties as compre-
ssive strength; shrink during setup and
cure, uniform aggregate dispersion,
pumping stability, practical lift thick-
ness, and compatibility with admixtu-
res. As the density of all light-weight
concrete is reduced, it becomes ever
more difficult to maintain the properties
noted above and the foaming agent
and foam generation equipment be-
come increasingly important.
The mix design chosen for the pro-
duction of cellular concrete can have
a great effect on the properties after
curing as well as the ability to place
the material. In general, if the appli-
cation is geotechnical or other types
of fill, the mix design can be quite simple
and is not too difficult to develop.
However, as soon as there is any struc-
tural element requirement introduced,
then mix design can become critical.
There is not a single “best” mix design
for production of cellular concrete and
the final design is also dependent on
local materials, batching techniques,
foam mixing and placement methods.
Benefits of Cellular Concrete
Cellular concrete provide superior
performance, more efficient constru-
ction, and reduced cost when com-
pared to alternative construction and
manufacturing technologies because
of its following properties.
High Strength/Low Density/Light-
weight
Typical cast densities range from
25 to 55 per cubic foot, with com-
Wet 28-Day Compressive
Density Strength
(kg/m3) (MPa)
400 0.71
450 0.84
500 1.14
550 1.51
600 1.98
www.masterbuilder.co.in · The Masterbuilder - July 2013
Cellular Concrete
pressive strengths of 40 to 750 psi,
respectively. With its low density, cel-
lular concrete imposes little ver-tical
stress on the substructure, a particu-
larly important issue in areas sensi-
tive to settlement. Due to its low den-
sity, cellular concrete is a viable solu-
tion for reducing loading on bur-dened
soil. Additionally, cellular con-crete is
less susceptible to differential settle-
ment. Heavier density cellular con-
crete with higher strengths is pro-
duced and used for specialty appli-
cations.
High Fluidity
High air content makes it easy to
pump materials long distances at low
pressures. The material is naturally
self-leveling and fills the smallest
voids, cavities, and seams. When pla-
cing in excavations cellular concrete
conforms to every sub grade contour.
Rapid Installation and Minimal Site
Disruption
High volume production and place-
ment (via hose) of cellular concrete is
a continuous operation from a mobile
central plant on location. Since the
foam is the largest volume contributor
in cellular concrete, limited deliveries
of the raw materials are required, re-
sulting in minimal disruption to the
construction site.
When used as pavement under-
layment and recharge bed in per-
meable pavement applications, per-
vious cellular lightweight concrete
can reduce the amount of excavation
required by as much as 50%, mini-
Thermal R Value
Conductivity per Inch
(W/m/K) (OF ft2 hr/Btu)
0.075 2.0
0.080 1.8
0.086 1.7
0.092 1.6
0.97 1.5
217
 Cellular Concrete
mizing site disruption, saving time
and money, and reducing the pro-
ject's carbon footprint.
More Flexibility for Specific Construc-
tion Challenges
Cellular concrete can be constru-
cted into various formations and pro-
files. It can be produced as a non-
permeable or a permeable material
capable of reducing loads without
disturbing or re-directing natural water
flow. It also forms a rigid, well-bon-
ded body after hydrating; thus, it is
effectively a freestanding structure on
its own and does not impose lateral
loads on adjacent structures.
Pervious to Water
Cellular concrete is optimal for
applications where drainage is need-
ed. It is capable of reducing loads
without disrupting or redirecting the
natural flow of water.
Reduced Sound Transmission
When used in roof deck, flooring,
cast-in-place walls, floors or roofs,
High air content makes it easy to pump materials long distances at low pressures
218 The Masterbuilder - July 2013 · www.masterbuilder.co.in
block or per-fabricated elements, fir
or partition wall applications, or as
cavity fill for vehicles, the void struc-
ture of cellular concrete reduces the
passage of sound.
Thermal Insulation
Cellular concrete provides good
insulating qualities. It is thermally effi-
cient and is an unmoving insulation
material which maintains long term
in-place stability for a variety of con-
struction and industrial applications.
Cellular concrete mixes harden to
provide a material with proven high
temperature resistant characteristics
which permit it to be used as a fire
resistant material.
Provides Shock & Energy Absorption
Used beneath roadways, bridges,
and ramps, buildings and other struc-
tures, it reduces soil loading while
adding compressive and shear
strength. As cellular concrete is com-
pressed during impact, resistance
increases and kinetic energy is ab-
sorbed. In America and Japan in par-
ticular, contractors and engineers
frequently use cellular lightweight
concrete provide shock absorption in
earthquake zones.
When used in roof deck, flooring,
in-situ affordable housing, cast-in-
place walls, floors, or roofs, or block
or prefabricated element applica-
tions, cellular concrete provides proven
deformation resistance properties
and an ability to absorb loads and
crush in a controlled manner. Cellular
concrete is also fire resistant.
Recyclable
Cellular concrete is inert and can
be safely removed and reused. One
green use of recycled cellular con-
crete is as aggregate in vegetated
roof construction (green rooftops).
Recycled Content
Cellular concrete can incorporate
ground granulated blast-furnace slag
or fly ash in the slurry or grout mix
design without adversely affecting
cellular concrete performance. The
use of these post-industrial by pro-
ducts eliminates the need to landfill
the materials and reduces the need
for virgin materials in cellular concrete
production and the environmental
impacts from the extraction and pro-
cessing of these virgin materials.
Reduced Carbon Footprint
Cellular concrete is produced on
site in most construction and manu-
facturing application or at a pre-cast
facility within 200 miles of the con-
struction site. Local production re-
duces shipping distances for building
materials, minimizing fuel require-
ments for transportation and handling,
and associated energy and carbon
dioxide emissions.
On-site production of cellular con-
crete in geotechnical applications re-
duces a project's carbon footprint sig-
nificantly. Projects with volumes excee-
ding 10,000 cubic yards of geotech-
nical fill use an on-site batch plant that
 Cellular Concrete

Typical Cellular Concrete Applications logic and economic resulting costs dur-
ing the phase of utilization, and guar-
Construction, • Insulating cellular concrete roof decks with 2-hour fire ratings (UL-listed) antees longterm building and living
Renovation, • Insulating roof deck fills • Composite insulated roof decks • Floor/ceiling fill quality. Cellular concrete has a prac-
and systems • Cast-in-situ affordable housing • Cast-in-place walls, floors, and
tically unlimited service life. Due to
Rehabilitation roofs • Pre-cast, reinforced-concrete wall, floor, and roof panels • Air-cured,
cast-in-situ lightweight concrete blocks and pre-fabricated elements • Permeable the extremely low thermal con-
pavement underlayment and recharge beds • Firewalls • Slab-on-grade insulation ductivity of up to l = 0.06 W/(mK),
and subbase fill • Underground thermal conduit linings • Pipeline and culvert cellular concrete is a suitable buil-
installation (bedding and backfill) • Roadway rehabilitation • Retaining wall backfill ding material for use in energy-saving
Geotechnical • Replacement of unstable soils • Annular grouting • Density-controlled load building projects.
and Mining relief • Load-reducing fill over structures • Void fills • Structural fills • Permeable Cellular concrete doesn't contain
fills / Stormwater runoff retention • Controlled, low strength material ( CLSM) any toxic substances or release any.
Manufacturing • Thermal insulation for doors, safes, storage tanks, coolers, etc. This applies to both the processing
• Sound absorption for partition walls • Fireproofing panels and the entire life cycle of cellular con-
• Architectural elements • Cultured stone crete. Even in the event of a fire, no
harmful gases are released.
produces and pumps cementitious slab. Foam liquid concentrate manu- The outstanding balance of source
slurry, with trucking needed only for factures and distributors also provide reduction, energy efficiency, low em-
the delivery of cement. training and technical support for cel- bodied energy, absence of toxins and
lular concrete used in pre-casting and ozone depleting substances, and noise
Cellular Concrete in Jobsites
other manufacturing appli-cations. reduction make cellular lightweight
It is important to procure and place concrete the ultimate green building
Cellular Concrete & Sustainability material.
cellular concrete from contractors who
have extensive experience in cellular Cellular concrete delivers a more
Challenges & Future Outlook
concrete installation. Typical equip- complete sustainable solution by sig-
ment used for production of cellular nificantly reducing the amount of raw Despite its versatility, cellular con-
concrete in job sites are foam gene- material needed and the energy crete has lagged in popularity due to
rators made specifically for job site. required to mold it into a shape for a general lack of awareness about
Contractors also work with project construction the benefits of this construction ma-
engineers to ensure the wet density Up to 5 m3 of cellular concrete can terial in the construction community.
of the material produced at the job be made from 1 m3 of solid raw mate- Again, while there are design specifi-
site is within a specified range of the rials. Thanks to this efficient use of cations and protocols for traditional
designed wet-density project mix and resources, cellular concrete actively materials, there are very few educa-
meets project strength requirements. contributes towards sustainable eco- tional tools that are available in the
Cellular concrete is most typically nomical methods of building. industry or a knowledge consortium
placed by pumping. Owing to its high The cellular concrete industry that construction professionals can
fluidity, cellular concrete is not affected strives for as environmentally-friendly resort to while implementing cellular
by long pump runs. They have been production as possible. Process-re- concrete solutions. Also, past poor
successfully pumped beyond 500 lated emissions from the use of fuels experience with foam liquid concen-
feet vertically and 5000 feet horizon- are continually optimized, and redu- trates, lack of technical support and
tally. Cellular concrete can also be ced to a minimum. The use of pri- proper production and installation
placed by other methods such as mary energy during the manufacture guidance has discouraged the use of
bucket cranes, ready-mix truck chute of cellular concrete is comparatively cellular concrete solutions in the in-
placement, wheelbarrow placement, low. The production of cellular con- dustry. There are still a few qualified
and even hand placement from car- crete is free of waste and waste water. contractors in the industry and con-
ried buckets. Left-over cellular concrete which struction professionals who have ex-
Installation and finishing methods arises during the manufacturing phase perienced the wonders of cellular
differ for each type of cellular concrete and on the construction site are fed concrete and it is the true partnering
applications. As most cellular concrete back into the production. between these stakeholders of the
is covered by another material, it is not The high quality of the cellular con- industry can lead to the adoption of
surface finished like a typical concrete crete products guarantees low eco- cellular concrete worldwide.

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


Pioneering Foam Concrete Technology
I
yantra is a leading provider of foam
concrete technology in the country.
The company provides plant, ma-
chinery, technical knowledge and allied
chemicals for setting up foam concrete
plants of any capacity, for various
applications across the world. The com-
pany's modern manufacturing facility is
located in Vishakapatnam, Andhra
Pradesh. Spread over a sprawling
4,800 sq.mts the plant is equipped with
the latest equipment and appropriate
standards for manufacturing foam con-
crete machinery. A competent and
skilled 50 member strong team, taking
care of technical and non-technical as-
pects, is another asset for Iyantra.
Its range of machines includes pop-
Foam Concrete mixer
Kasturi Metal Composites Pvt. Ltd.
Build strong, last long
Refer Page No.: 227
Silicone Concepts Intl. Pvt. Ltd.
Installing New Floors or Renovating existing
surfaces? HTS has the right size machine
for you and your job
Refer Page No.: 83
To know more on the products, solutions and services offered by the leading brands featured above write to: masterbuilderads@gmail.com
ular models such as, IFCS (BAV), IFCS
(SAV) and IFCS (FAV). The company
manufactures specially designed foam
generator for foam concrete produc-
tion. Iyantra's foam generators come
with corrosion resistant coated steel
body along with timer, air compressor
and lance units. Iyantra's foam con-
crete mixers are uniquely designed to
mix foam throughout the concrete in an
even manner without destroying the
foam, for accurate density and continu-
ous production. The foam concrete mix-
ers come with inbuilt water discharging
system and digital weighing scale sys-
tem. The mixer body is built with high
gauge steel, while the shaft and other
parts are made from alloy steel to bear
Bricks
Flooring
Neocrete Technologies Pvt. Ltd.
A path everyone wants to tread, but does not know
where to go…We offer the complete solution…
Refer Page No.: 135
Concrete Flooring Solutions
STA Concrete Flooring Solutions
We Deliver Faster, Flatter, Floors.
Refer Page No.: 159 & 193
www.masterbuilder.co.in · The Masterbuilder - July 2013
Communication Feature
high impacts and loads. Some other
offerings of Iyantra include, foam con-
crete pumps, screw conveyors, belt
conveyors, silos, silo accessories, cen-
tralized control panels, wire cutting
machinery, foam concrete block
moulds, foam concrete conveying trol-
leys and other ancillary equipment.
A protein based foaming agent
'Conlite' is yet another quality product
of Iyantra. 'Conlite' is a 100% bio-degra-
dable foam concentrate, which forms
very stable bubbles, which impact nec-
essary porosity to foam concrete. The
company also offers synthetic-based
foaming agent, hardeners, plasticizers
and other construction chemicals used
in foam concrete technology.
For further details:
Iyantra
3-2-611/2, 1st Floor, KGN Plaza,
Opp. Howard Public School,
Himayat Nagar, Hyderabad- 500029
Ph: +91-40-27630666
E-mail: vsimha309@yahoo.com
Web: www.iyantra.com
Recron 3S
It takes anything you can throw at it. Like
400 tons of steel. 100 times a day
Refer Page No.: 243
Stewols India Pvt. Ltd.
Give your concrete the strength of steel.
Refer Page No.: 279
221
 Communication Feature
A Testimony to Top Quality and Performance
C
itadel Eco-Build Pvt Ltd is the larg-
est supplier of aerated autoclaved
concrete (AAC) blocks manufac-
tured by Biltech Building Elements Ltd in
India. The company has added yet
another feather to its cap. It has been
rated by top rating agency, CRISIL, as
the “High Performance and Moderate
Financial Strength” company. The rating
assures Citadel Eco-Build's customers,
principals, investors and bankers that
they can bank on a reliable company,
which means business and which val-
ues and follows ethical business prac-
tices no matter what the circumstances.
In addition to supplying quality AAC
blocks, Citadel are also manufacturers
of GreecoBond- a ready to use, wet mix
mortar, especially suited for AAC blocks/
engineered blocks and GreecoPlast- a
ready to use plaster. The company has
been growing by leaps and bounds under
the dynamic leadership of its founder
Amol Shitole.
Citadel Gallery
A strong R & D focus has enabled Cit-
adel to bring these innovative, eco-
friendly new products to clients- prod-
ucts which save time and reduce con-
struction cost. Citadel has always been
a trendsetter. It is also the first company
to come out with an exclusive gallery for
its customers across the metros, where
there are facilities available for testing
products and display of products. This
222 The Masterbuilder - July 2013 · www.masterbuilder.co.in
OPEN APPLY
gallery setup is available in the following
cities like Pune, Mumbai, Goa, Kolhapur,
Solapur, Aurangabad, Hingoli, Baramati
& Karnataka.
It has been the endeavor of Citadel
Group, right from the time of its inception
to provide safer, more affordable perma-
nent housing and structures. The com-
pany is committed to utilizing environ-
ment-friendly 'Green' building materials
for construction purposes.
Citadel is committed to providing the
industry with products which help in
designing structures that are hurricane,
wind, pest and fire resistant, apart from
being environmentally responsible. The
company is for promotion of housing that
is energy efficient and safe. It achieves
this by promoting building materials that
eliminate many of the dangerous toxins
and allergens, so commonly found with
conventional construction methods of
today.
Citadel's quest for the 'Perfect Green
House' has led it to combining two unique
and superior products - GreecoBond
and GreecoPlast. According to the com-
pany by incorporating these two prod-
ucts, we can minimize or eliminate unsafe,
toxic and flammable materials from buil-
FORGET
ding structures, and at the same time
dramatically reduce costs. As a respon-
sible corporation and one of the largest
eco-friendly building products suppliers
in India, Citadel has been in the forefront
in endorsing sustainable construction
strategies.
One of the key reasons for the com-
pany's rapid growth has been its excel-
lent support services. Its team of quali-
fied engineers helps clients to calculate
the exact quantity of AAC materials re-
quired for projects, thereby reducing ex-
cess procurement cost. The team also
provides technical know-how about AAC
to project managers and site engineers.
Strict adherence to quality standards
is another hallmark of Citadel. Test certif-
icate and weight slips are provided with
every delivery by the company. The com-
pany also makes sure that the material is
delivered on time, every time.
A rapidly expanding client base of
over 1000 stands testimony to the com-
pany's remarkable growth story.
For further details:
Citadel Eco-Build Pvt. Ltd
795/35, Samadhan Apt., Bhandarkar
Road, Pune - 411004
Ph: +91-20-2565 6575, 6528 9672,
Web: www.citadelecobuild.com
 Advertorial

Versatile Aluminum Formwork Systems

Storm Indian Market

T
he Indian formwork industry is
presently going through an excit-
ing phase of development.
Several innovative technologies are
making their way into the Indian mar-
ket. Hi-Lite Systems, a global pioneer
when it comes to aluminum systems
now offers its quality range in India. The
company, formerly known as Jackson
Scaffolding, started its eventful journey
in 1952. Hi-Lite designed its first alumi-
num shoring system in 1974, the first
Project 1: Hoggs Hollow Bridge in Toronto - Contractor
company in the world to do so. Since Dufferin Construction
then there has been no looking back.
Factors including, reduced mainte-
nance, lower costs, less handling and
incredible versatility make aluminum
systems from Hi-Lite the ideal choice
for a variety of construction projects.
Let us take a closer look at these alumi-
num systems.
Aluminum Shoring Systems- For
Speed, Economy & Quality
Hi-Lite Systems is a pioneer in alu- Gaumont Disneyland – Paris

minum shoring systems. It is now offer-
ing its wide range in India, which is ide-
ally, suited for both infrastructure and
real estate projects.
Aluminum shoring frames from Hi-
Lite are known for their reliability, dura-
bility and quality. The average lifespan
of these frames is over 20 years.
Additionally, with an amazing 70%
scrap value, even after 20 years, they
make for excellent investment. The fact
that they are much more durable and
offer a higher scrap value, makes them
score over steel shoring frames.
The durability of the systems has
been clearly proved. A drop test, which
was conducted at IIT, conclusively
proved the fact. In a free fall test of alu-
minum frame from 20' height in all
directions and that too repeatedly, the
frames showed no defects. In order to
ensure higher strength of aluminum,
the company uses pure billets and not
scrap metal. Tests done at IIT show that
the frames are 50% more stronger than
in cases where scrap metal has been
used, while also ensuring longer life
Project 2: Athabasca River Bridge - Largest Bridge of
and enhanced safety. Alberta - Size of Five Football Fields - Contractor:
Another major advantage with the Flatiron Constructors
aluminum shoring frames from Hi-Lite
Systems is the fact that they can be slew of value-added services including
erected a mind-boggling 10 times faster help with financing. Excellent site –sup-
than steel frames. They also score high port and technical back-up services is
when it comes to safety. There are no another advantage that is offered by
loose parts and they come integrated Hi-Lite Systems. This ensures quality
with couplers and pins. This ensures assurance on site, while additionally
that the systems are very safe for work- speeding up construction work, without
ers to climb, erect tower, with non- any compromise on the quality front.
slippery rungs.
Aluminum Telescopic Flying Forms-
These quality aluminum formwork
For Incredibly Fast Cycle Times
systems are now being manufactured
in India. Hi-Lite Systems also offers a With aluminum telescopic flying

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


Bracket - Connected to Abutment Wall for Bridge Refurbishment
formes from Hi-Lite Systems, contrac-
tors have been able to achieve remark-
able cycle times of as less as 3 days.
The aluminum telescopic flying form
systems from the company are ideally
suited for multiple storied buildings
and infrastructure projects. One of the
major advantages is its light weight
which makes handling and assembling
easy. The modular component system
ensures quicker turnaround times. The
telescopic design ensures that the
modular component system can be
adjusted for differing floor heights and
for other complex construction geome-
Telescopic Flying Form
1st Project in Gujarat (RES & COMM)
Advertorial
sites of L & T India alone, a fact that
speaks volumes about the quality and
performance of the systems.
Hilite is trying to achieve 3 days
cycle time for residential and commer-
cial projects in Mumbai and Pune.
tries. The system can be used on typi-
cal floors and non-typical floor too,
where floor heights are different. In this
case just by pulling the pin out, the tele-
scopic struts can be extended, as per
the floor height, before the pin is Aluminum Brackets In Gang Form
adjusted again.
The light weight of the system also
means reduced crane time or in some
instances, such as in the case of lighter
sized frames, no requirement of cranes
at all. This is something that is just not
possible with either timber or steel
forms. Another major advantage with
the aluminum telescopic flying frames
is drastic reduction in labor costs. The
stripping of the system is also not labor,
time or cost intensive. In fact, it can be Feature of Aluminum Bridge Overhang
done by a minimum number of con- Brackets:
struction workers.
- 1/3rd The Weight of The Steel
These systems have enabled con-
Bracket = Capacity 8000 KG with
struction cycle times which were till
safety factor 1.5:1
now considered practically impossible.
- Top Down Adjuctment – Extreamly
A good example is available in the form
Safe For Workers – Saves Huge
of Casino Structures, located in Atlantic
Labor Costs
City, New Jersey, US, where Hi-Lite
- Connect 5 To 6 Brackets Together –
Systems has been able to achieve an
and Fly Together –saves Man Hours
incredible cycle time of 3 days using
And Labour Costs
the aluminum telescopic flying form. In
India too the company has been able to
achieve a cycle time of 5 days for a pro- For further details:
ject of L & T. Hi-Lite Systems India Pvt. Ltd.
VIRAG H BHACHECH
With so many advantages, it is not (VP – SALES & ENGG)
surprising that aluminum telescopic 5B1, Fifth Floor, J.P. Tower - 7/2,
flying formwork from Hi-Lite Systems is Nungambakkam High Road, Chennai - 600034.
Mob: 09409541938 H.O.: Toronto Canada,
finding an increasing number of takers Tel No.: 001-647-880-4032
in India. In fact, the company has sup- E-mail: virag@hi-lite-systems.com
plied its products to 60 construction
The Masterbuilder - July 2013 · www.masterbuilder.co.in 225
 Communication Feature
Greaves Rolls Out High Capacity
Concrete Pumps with S Valve Technology
Designed for heavy duty construction activities in
high-rise commercial, residential buildings and infrastructure worksites
G
reaves construction equip-
ment business, part of Greaves
Cotton Limited, one of India's
leading engineering companies, re-
cently launched its high capacity con-
crete pumps, with contemporary S Valve
technology. The Greaves S Valve sta-
tionary concrete pumps are available in
three models: GCP 5500, GCP 6500
and GCP 8500. Designed primarily for
infrastructure concreting operations,
these high performance pumps are
used for heavy duty construction activi-
ties in high- rise commercial and resi-
dential buildings and infrastructure
worksites such as tunnels, dams, brid-
ges, irrigation etc.
All three models of the stationary
concrete pumps are powered by fuel
efficient and emission compliant en-
gines and integrated with contempo-
rary hydraulic systems and components
that are designed to deliver concrete
perform under challenging pumping
condition. Greaves Concrete pumps
ensure the lowest cost per cubic meter
of concrete pumped. A fully electrical
GCP 5500 Concrete Pump
226 The Masterbuilder - July 2013 · www.masterbuilder.co.in
control panel with remote as a standard
feature can operate both on the piston
and the rod side. This results in a maxi-
mum concrete output of 50-80 cubic
metres per hour, varying from model to
model.
The hard chrome platted concrete
cylinder in the pumps offer extended
service life against wear and corrosion.
The replaceable hard rams are designed
to withstand high pressure and are high
wear resistant. The internals are well
designed so as to allow for minimum
wear and tear, thereby minimising re-
placement and maintenance costs.
Speaking at the launch, Sunil
Pahilajani, MD & CEO, said, “Being an
increasingly demanding business,
technologically superior products are
the need of the hour. With the launch of
Greaves S valve concrete pumps, cus-
tomers can be assured of reliable, best-
in-class product backed by a strong
after market support.”
“The S valve concrete pumps add
to our existing range of concrete offer-
ings making Greaves a comprehensive
and total player in the infrastructure seg-
ment. Customers can now avail tech-
nologically advanced S Valve concrete
pumps, which are durable, economic
and highly cost-efficient. The intelli-
gently designed features provide func-
tional superiority and ease of use," said
R. Nandagopal, CEO, Construction
Equipment Business. He added, “Our
endeavour is to respond to customer
requirements and market demands.
This launch is a testimony to our contin-
uous efforts in innovation and product
development. Complementing our wide
range of products is our countrywide
extensive service network, which caters
to discerning customers anytime, any-
where.”
About Construction Equipment Busi-
ness
Playing a vital role in India's infra-
structure development, Construction
Equipment Business offers a wide range
of concreting and compacting equip-
ment. Products include Automated
Batching Plants, new-generation con-
crete Mixers, Concrete pumping sys-
tems, Soil compactors and Heavy and
Light Tandem Rollers. Greaves Cotton
has established three dedicated plants
near Chennai, for the manufacture of
specialized construction equipment and
systems. The manufacturing facility is
located at Gummudipoondi, Chennai,
TamilNadu.
For further details:
Ms. Bhavna Singh
General Manager- Corporate
Communications
Greaves Cotton Limited
Ph: +91-22- 24397626
E-mail: bhavna.singh@greavescotton.com
 Communication Feature
Stay Ahead of the Curve Via Strategic
Training and Development
T
he battle for retaining and attract-
ing new talent occupies a special
position when it comes to shap-
ing the future health of an organization.
The shortage of right talent, accentu-
ated by easy access through internet
sourcing, puts a very high premium on
acquiring, retaining and developing
talent for most organisations. With
each passing year, the gap between
supply and demand is only increasing,
and the gap between academics and
practice is ever widening.
In this scenario, training in organi-
sations, physically, socially, intellectu-
ally and mentally becomes essential
for not only retaining and developing
talent but also to facilitate higher levels
of productivity. However, it is not just
theoretical knowledge, but experiential
knowledge that grant the ability, the
skill, the understanding, and the infor-
mation, which every individual need to
acquire in order to be able to function
effectively and perform efficiently.
Today, it is the quality of human
resources, which is the prime mover in
any organization; however, well-
endowed it may be with the machines,
materials and even money. Training is
the most effective tool in systematic
development of the knowledge, skills
and attitudes required by employees to
perform adequately on a given task or
job. It can take place in a number of
ways, on the job or off the job; in the
organization or outside the organiza-
tion. Staff training and development is
a work activity that can make a signifi-
cant impact on the overall effective-
ness and profitability of an organiza-
tion. Hence, systematic approach to
training encompassing holistic training
is essential in organizations.
We have been often asked; are
investments in the area of training and
development linked to the bottom line
within the business? Increasingly, high
performing organisations today are
recognizing the need to use the best
training and development practices
228 The Masterbuilder - July 2013 · www.masterbuilder.co.in
available to enhance their competitive
advantage. Training and development
is an essential element of every busi-
ness if the value and potential of its peo-
ple are to be harnessed and grown.
Many studies have highlighted the
clear links between well designed and
strategic training and development ini-
tiatives and the bottom line within the
business. The image of an industry and
of individual employers is also influ-
enced by the extent and quality of staff
training and development.
Potential employees, with their
focus on career progression and
development, in such an open labour
market will assess the track record of
prospective employers in this vital
area. In today's business climate where
all industries are experiencing staff and
skills shortages, companies are faced
with stiff internal and external competi-
tion for quality employees. Each
employer who invests seriously in the
area of Training and Development will
reap the benefits of an enriched work-
ing environment with higher levels of
staff retention as well as increased pro-
ductivity and performance.
While the percentage and time
spend on training staff may be useful in
order to get an overview of the com-
pany's commitment to training and
development, it is the manner, ap-
proach and content of the training ini-
tiatives as well as their assessment and
follow up which determine success. It
is all too easy to throw money at a per-
formance problem and assume that a
training course will sort it out, when this
may well be just putting a plaster over
an open wound. Training initiatives
need to be strategically aligned to the
overall company mission and goals.
They need to be designed and deliv-
ered with the aim of helping staff
achieve their departmental as well as
personal goals, so the trend of
increased involvement by line manag-
ers and employees is a positive devel-
opment in terms of ownership of the
Nagesh Rammurthy
Project Management Professional
A N Prakash Construction Project Management
Consultants Pvt. Ltd
Nagesh Rammurthy is a certified
Project Management Professional
(PMP) with over 25 years of experi-
ence in the areas of project con-
struction strategies, controlling, deli-
very, closing & handover and learn-
ing & development. He graduated in
Civil Engineering from Bangalore
Univer-sity in 1989 and currently
holds the postion of Director, School
of Construction Management Ex-
cellence, A N Prakash Constr-uction
Project Management Consultants
Pvt. Ltd. (ANPCPMC). He has worked
with Consultants, Constructors, De-
velopers, and Architects in various
capacities and has published sev-
eral research papers on Construc-
tion Project Management.
training and learning program. By adop-
ting a strategic approach to training
and development rather than an un-
planned and ad hoc one, training and
development initiatives become more
targeted, measurable and effective.
In order to remain competitive and
to ensure excellent staff are attracted to
and remain within the organization,
companies need to ensure that the
training and development of all
employees is an issue which is taken
seriously. By investing in the develop-
ment of the people who are the face of
the business, companies can get
ahead of the competition and excel in
 Communication Feature

what they do. One of the most impor-
tant aspects of managing people lies in
helping employees become more
effective in their jobs and being able to
adapt to that job or another job as
he/she matures within the organiza-
tion. This requires a high level of co-
ordination between employee training
and development and the range of
other personnel functions, such as
recruitment and selection, perfor-
mance appraisal, reward systems and
employee relations. Identification of a
company's training needs, designing a
relevant training plan, selecting and
implementing the resulting training pro-
gram and evaluating its success are
therefore, integral elements of the over-
all Human Resource Development pro-
cess. However, for any of these func-
tions to be effective, the training plans
and policies must be in line with the
organisation's strategic objectives.
Studies have indicated that most effec-
tive training are those which include
both cognitive training, interpersonal
skills followed by those which include
psychomotor skills or tasks.
The training function is increasingly
considered to be a key player in help-
ing the organization achieve its goals
through its people as it is becoming
more generally accepted that there is a
strong correlation between organiza-
tional success and investment in train-
ing and development. There is now a
growing awareness on the importance
of a planned approach to training and
development as a tool for competitive
advantage, staff recruitment, selection,
retention and motivation. Increasingly,
organizations are turning to specialists,
with demonstrated experiential suc-
cess to work as coaches for ushering
their organizations into such action
learning programs.
With the focus on experiential
coaching and learning, the Training pro-
grams result in improved performance
and other positive changes that serve
as antecedents to excellence in job per-
formance. These practitioner-led train-
ing programs with its accent on multi-
ple delivery mechanisms and focus on
techno-managerial training, including
regular training effectiveness studies
and fine-tuning, help organizations
bring their employee development and
retention aspirations to fruition.
Finally, many organizations have
realized that they serve their customers
best, by focusing on their most valu-
able assets – their human resources,
for, honing the skills of these assets
ensures not just customer retention,
but unleashes the innate innovative-
ness in these resources to create ever
increasing value for the customer. Sooner
than later, this is going to become the
key differentiator between the success-
ful companies and those that also ran.
Wouldn't you want to be the former?
For further details:
A N Prakash CPMC Pvt.Ltd
491,"Viswakarma", East end road, 9th
Block Jayanagar, Bangalore 560069,
Ph: +91-80-26639780
Fax : +91-80-26639780
E-mail: bd@anpcpmc.com
Web: www.anpcpmc.com

Steel Fiber Reinforced concrete Sand Making Machine

better together

Bekaert Industries Pvt. Ltd. Kasturi Metal Composites Stewols India Pvt. Ltd. Robo Silicon Pvt. Ltd.
Dramix® steel fibres- Leaders in Pvt. Ltd. Give your concrete the strength of The Eco-Friendly alternative to river
reinforcing tunnels since 1985* Build strong, last long steel. sand

Refer Page No.: 29 Refer Page No.: 227 Refer Page No.: 279 Refer Page No.: 125

Software for Concrete Adhesives and Sealents Cement Manufacturers

Tekla India Pvt. Ltd. Dow Corning India Pvt. Ltd. Wacker Chemie India Pvt. Ltd. Zuari Cement Italcementi Group
Tekla structures BIM complete A fire rated joint sealant that no one else Sustainable solutions for cementitious Just what a greener world needs. Pure
concrete solutions can match! tile adhesives light and air.
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Concrete Densifier- AAC and CLC Blocks-

AAC Blocks Foam making machine
Lithium silicate

Autoclaved Aerated Concrete Blocks

Waltar Enterprises Brickwell Citadel Eco-Build Solutions Methra Industries Iyantra

Largest Manufacturer and exporter No pre & post wetting saves No pre & post wetting saves A Green Revolution for India's no. 1 company in light
of Lithium Silicate Natural Resources, Time & Energy Natural Resources, Time & Energy Future Buildings weight concrete technology
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To know more on the products, solutions and services offered by the leading brands featured above write to: masterbuilderads@gmail.com

www.masterbuilder.co.in · The Masterbuilder - July 2013 229

 Communication Feature

Microtopping by Neocrete
B M Nagarajan, Director, Neocrete Technologies Pvt. Ltd.

N
eocrete specializes in trans-
forming mundane concrete
flooring into a work of art. Their
passion in taking up challenging assig-
nment combined with their quest for
innovation has resulted in their execut-
ing a beautiful floor in one of the presti-
gious towers that has come up in the
heart of Mumbai. Nestled in Lamington
road, this tower promoted by Earth
Developers boasts of a number of firsts
in this area. Multi-story parking areas,
automatic state-of-the-art lifts, PU coat-
ing of parking decks, stamped concrete
in entrance portico and a designer con-
crete in ground and fifth floor are some
of the bold initiatives taken by the de-
veloper.
The sequence of events is as follows:
Concrete is ground so as to remove
laitance; loose particles, etc and pro-
vide a mechanical key. If the area has
lot of undulations, it is necessary to level Our cementitous micro-topping viz. lent flow with the addition of water. Mix
the floor with self-leveling cementitious Neoflor 4010 is formulated with high- the material and pour into the respec-
underlay. In this case, we leveled it with quality polymers & UV resistant pig- tive receptacle one-by-one.
our product Neoflor 3010. ments and is designed to give an excel- Pour various colours one after
another ensuring that thickness of one
pour does not exceed 5mm.
Apply two coats of sealer coats to
provide enhanced properties of sheen,
ant-fungal and abrasion resistance.
The enclosed photo speaks volumes
about the capability of our micro-top-
ping to provide a most amazing floor that
provides beauty and elegance unmat-
ched by any other product.

For further details:

Neocrete Technologies Pvt Lt
Prepare design templates based 13-A, Satellite Tower, Film City Road,
on the design which should be made to Goregaon(East), Mumbai - 400063
Ph: +91-22-32937981,
the exact scale. Position the templates
Email: bmnagarajan@gmail.com
over the area and draw the pattern on Web: www.neocrete.co.in/www.neocrete.in
the floor.

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

 Concrete: Fibres

The use of Steel and Synthetic Fibres

in Concrete under Extreme Conditions
Don Wimpenny1, Wolfgang Angerer2, Tony Cooper3 and Stefan Bernard4
Principal Materials Engineer, Halcrow Pacific 2Senior Tunnel Engineer, Halcrow Pacific
1

Consultant Elasto Plastic Concrete 4Consultant, TSE

3

The tunnelling and maritime environments can provide extreme conditions for reinforced concrete. Exposure to aggressive saline
water can be combined with design lives of 100 years or more. In recent years, traditional carbon steel reinforcement has been
substituted by the use of steel fibres and, more recently, by synthetic fibres for sprayed concrete and precast items, such as tunnel
segments. This paper describes some of the factors which have prompted the change from rebar to fibres and includes a detailed
consideration of the specific durability design aspects of fibre reinforced concrete use within desalination facilities.

The use of fibres to enhance the properties of construction
materials can be traced back over 4000 years to the use of
straw in bricks and horse hair in plaster. Fibres can reduce
plastic cracking in fresh concrete and enhance the post-crack
ductility of hardened concrete. The elimination of reinforcement
fixing can have significant time, cost and safety benefits. Whilst
the random orientation and dispersal of fibres means they are
not as efficient as conventional reinforcement for dealing with
predictable stresses, they are able to resist crack propagation
under unforeseen stresses, particularly those arising close to the
surface of elements during construction and in service, such as
impact.
Fibres can be particularly beneficial under extreme environments,
such as exposure to chlorides and fire. Fire and abrasion
resistance are enhanced and the discrete nature of fibres means
that the risk of corrosion and associated spalling is significantly
reduced.
The mining and tunnelling industry makes extensive use of fibres
in sprayed concrete linings for underground support. Fibres allow
the lining to retain ductility, even under high deformation, which is
critical for safety. Precast tunnel segments have utilised both steel
and synthetic fibres for handling and improved fire resistance
respectively (1). Marine works have used synthetic macro fibres
to eliminate corrosion risk under exposure to seawater (2).
This paper provides a review of structural and durability design
approaches based on published guidance. It should be noted
that performance is dependent on the particular fibre type,
including the manufacturer.
Fibre reinforced concrete
Fibre types
The principal fibre types in BS EN 14889 (3,4) are shown in
Figure 1. The shape and surface texture of the fibres is important
in determining their effect on concrete properties. Fibres should
fail by gradual pull-out after disbondment from the cement matrix
in order to provide ductility and features such as hooked ends,
crimping, twisting and embossing are intended to promote friction
associated with the pull-out mode of failure.
Table 2 summarises the characteristics of two widely used fibre
types and compares the attributes of concrete made with these
fibres to conventional concrete.
Short term laboratory and field studies on the durability of uncracked
steel fibre reinforced concrete (SFRC) indicate carbonation induced
corrosion is restricted to those fibres immediately below the
surface (5). Galvanic corrosion and spalling do not appear to
occur (6), but there is a potential for corrosion at cracks (7). This
is important, as it could ultimately lead to sudden failure of the
concrete due to fibre breakage rather than ductile failure by fibre
pull out (5). It is recommended that limiting crack width of 0.1 to
0.2mm be adopted, depending on the service conditions.
Corrosion of steel fibres will cause staining and where this would
be unacceptable, galvanized steel is sometimes used (as the
solubility of zinc is increased when chloride ions are present,
stainless steel and synthetic macrofibres are more appropriate in
a chloride-rich environment).
Structural synthetic fibres are an alternative to steel fibres for
controlling handling damage and providing long-term ductility.
They are not significantly affected by exposure to seawater (8)
or sodium chloride at temperatures of 20-40°C (9). However, the
maximum service temperature should ideally be limited to 60°C
and exposure to some chemical agents, such as chlorine gas,
should be avoided.
Field examples
Evidence of satisfactory performance of fibres in concrete
elements is important in providing confidence to potential users.
Unfortunately, there is relatively limited information on long-term
durability of FRC in the field. For example, steel and synthetic
macrofibres have only been employed in sprayed concrete since
the 1970s and the 1990s respectively.
Table 3 summarises a selection of projects where the concrete is
exposed to extreme service conditions. Despite the many projects

232 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Concrete: Fibres

utilising fibres, the duration in service is modest compared to the
design lives of 100 years, or more, which are increasingly required.
Structural design
Design methodology
The design of an FRC section follows the same approach used for
the design of reinforced concrete, with appropriate modifications
for material properties in the tension zones. In reinforced concrete the
properties of the concrete and reinforcement can be determined
separately. For FRC the properties of the composite of fibre and
concrete, such as tensile splitting strength, flexural strength at
first crack and residual flexural strength, should be determined
concurrently. These properties can utilised in standard equations,
which define the load capacity of the composite element.
Initial designs may use manufacturer’s data or data from previous
projects to estimate the material properties. However, it is important
that the validity of the data is checked and that the performance
of the material is demonstrated by testing in pre-production trials and
by regularly sampling throughout production.
Figure 2 shows the stress-strain diagram adopted within the Rilem
design method. The values of stress and strain in the diagram
are defined in RILEM TC-162 TDF (10) and the design standards
using this approach such as Eurocode 2 (11) or NZS3101 (12).
Similar recommendations are given in guidance by the German

Characteristic Steel Fibres Synthetic micro-fibres Synthetic macro-fibres

Characteristic of Fibres
Shape/Texture Cold drawn hooked ends Straight smooth Continuously embossed
Collation Glued bundles Fibrillated Uncollated
Length (mm) 60 12 48
Diameter (mm) 0.75 0.02-0.03 0.5-1
Tensile Strength (MPa) 1050 30 550
Elastic Modulus (GPa) >200 2 10
Dosage (kg/m3) 25-35 1-2 6-10
Service temperature (°C) 300 60 60
Melting point (°C) >800 150 150
Base material Carbon steel Polypropylene Polyolefin (polypropylene, polyethylene)
Comparison with conventional concrete (Unreinforced except where indicated by*)
Workability Reduced Slightly reduced Slightly reduced
Plastic shrinkage cracking Unaffected Reduced Slightly reduced
Early-age thermal cracking Reduced Unaffected Reduced
Long-term shrinkage cracking Reduced Unaffected No data
Stray current corrosion Reduced Unaffected* Eliminated
Durability in chloride exposure* Increased Unaffected* Greatly Increased
Fire spalling resistance Slightly Increased Greatly Increased Increased
Compressive strength Unaffected Unaffected Unaffected
Residual flexural strength Increased Unaffected Increased
Impact strength Greatly Increased Unaffected Increased
Flexural toughness Increased Unaffected Increased
Abrasion resistance Increased Slightly increased Slightly increased
Freeze-thaw resistance Slightly increased Increased Increased
Flexural energy absorption Greatly Increased Unaffected Greatly Increased
Concrete permeability Slightly increased Slightly increased Slightly increased
Pump wear Increased Reduced Reduced
Hazard from handling and protruding
Safety* Increased Increased
fibres
Fibres may float and protrude in poorly
Finishing Extra care during floating Exposed fibres soon abrade
designed mixes
Table 2. Comparison of steel and synthetic fibres

www.masterbuilder.co.in • The Masterbuilder - July 2013 233

 Concrete: Fibres

Figure 2. Stress-strain diagram for fibre reinforced concrete

test specimen and the actual structure. Care should be taken in

the choice of test method (eg. beam or panel) and specified limit.
In particular, high residual flexural strength requirements at high
deflection values may have no relevance to the design and prove
unnecessarily difficult to achieve.
The full life of the structure should be considered in the structural
deign (5). For example, bursting performance of tunnel segments
Figure 1. Fibre types to BS EN 14889 during construction is based on tensile splitting and compressive
strength. Permanent loading for the serviceability limit state is
Concrete Association and in Concrete Society Technical Reports
normally based on ensuring elastic un-cracked behaviour and as
63 and 65 (13, 14).
such relies on the flexural strength at first crack. The ultimate limit
Although codes and recommendations mainly provide information state allows for some plastic behaviour and utilizes the residual
regarding steel fibre reinforced concrete, the design principles flexural strength. However, fibres are generally not relied upon
apply equally to other structural fibres. Testing may be required to as the primary reinforcement in plastic hinge regions. Structural
confirm the validity of some of the design factors and allowance designs for serviceability generally incorporate limits on stress,
should be made for the difference in stress-strain behaviour, long- strain (eg. 10 microstrain in the tensile section) or crack width (eg.
term performance and implications of exceptional load scenarios, 3mm maximum for durable fibres).
such as fire.
Due to the random distribution of the fibres in a concrete matrix,
The properties determined from specific tests will differ from the there is no recognised method to calculate crack widths in fibre
full-scale structure. The designer should verify that properties reinforced structures. A reliable first approximation of crack widths
are based on representative concrete samples and provide can be estimated in members subject to axial and bending forces
adequate allowances for the variability of the test method, the by derivation of stress-strain diagrams in a linear elastic analysis.
pattern of loading and the difference in geometry between the Crack widths can be therefore be predicted according to the
Date
Project Country Application Fibre type entered
service
Halsney Tunnel Project Norway Sprayed concrete lining to a sub-sea tunnel Macro-synthetic 2005
Atlantic Ocean Tunnel
Norway non-corrodible reinforcement in a sub sea tunnel Macro-synthetic 2009
Project
E18 Motorway Norway Sprayed concrete lining to tunnel close to waterfront Steel 2009
E18 Motorway Norway non-corrodible reinforcement in ground with high sulphide levels Macro-synthetic 2009
Sydney Northside
Australia sprayed concrete lining under chloride exposure Macro-synthetic 2003
Storage Tunnel
Docklands Light Rail track slab subject to stray currents and sulfate and chloride
United Kingdom Macro-synthetic 2004
Extension exposure
Sprayed concrete repair to abrasion damaged aggregate storage
Quarry Bins United Kingdom Steel 1998
bins
Blackpool South Shore United Kingdom Precast revetment units subject to handling, abrasion and seawater Macro-synthetic 2006
Channel tunnel rail link United Kingdom precast segments subject to fire loading Steel and micro-synthetic 2003
Gold Coast Desalination
Australia Segmental lining for intake and discharge tunnels Steel 2008
Project
Table 3. Examples of fibre reinforced concrete under extreme conditions.

234 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Concrete: Fibres

following equation: conditions during construction and any maintenance outages

should be considered, as these may be more severe than those
w = b (h-x) (1)
in service. Table 4 indicates the input parameters defining the
where w is the crack width, b is the strain at the extreme service conditions and the characteristics of the concrete mix.
tension fibre, h is the section thickness and x is the depth of the
compression portion (Figure 3).
However, the values obtained from such assessments are often
higher than the 0.1 to 0.2mm limit for steel fibres in extreme
exposure conditions (Section 2.1). Furthermore, the design
methods are not reliable enough to ensure these crack widths will
be consistently achieved. A prudent design approach for SFRC
exposed to chloride from seawater or de-icing salts is to prevent
the section from cracking during serviceability loading.
Long-term performance of FRC is heavily influenced by the
interaction between the fibres and the concrete matrix. Two aspects
are particularly important. Firstly, the aim of the addition of fibres is
to avoid the brittle failure associated with unreinforced concrete.
In FRC the development of excess strength and hardness in
Figure 4. Relationship between creep deflection at 100 days and imposed load
the enveloping concrete matrix may result in a change from for ASTM C1550 panel test (16).
ductile behaviour to brittle behaviour, as fibres fracture instead of
gradually pulling out of the matrix (15). The surface level of chloride will vary depending on the salinity
in the environment and amount of contact the concrete has with
Secondly, the discontinuous nature of fibres means that they
the environment. For concrete in the marine environment the
may exhibit slip within cracked concrete leading to creep under
surface chloride level will typically vary from 1-2% for submerged
sustained loading. Recent research by Bernard on the creep
and atmospheric exposure to 4% for wetting and drying. For
of cracked FRC (16) indicates that creep depends on the fibre
desalination schemes where the salinity can be 50% higher
type, dosage and applied load (Figure 4). The results are specific
than seawater surface chloride levels may be correspondingly
to the particular fibre types tested. The designer needs to verify
increased.
the influence of creep behaviour on the structure and provide
appropriate contingencies in the design, such as limiting the The carbonation and chloride models used in durability design
tensile stresses. are discussed below.
Durability Design Carbonation Model
Design Methodology The carbonation model commonly used is based on work by the
The durability design for steel fibre reinforced concrete involves Building Research Establishment (17) showing a good correlation
the prediction of carbonation and chloride ingress and the between the carbonation rate and oxygen permeability. The latter
associated corrosion. In conventionally reinforced concrete, is predicted based on the cement type, concrete strength and
corrosion damage to the concrete, such as spalling or cracking, duration of curing. Gas permeability or diffusion testing should be
would often be used as the serviceability limit state. In the case carried out on proposed concrete mixes to validate the assumed
of FRC, the loss of cross-sectional area of fibres by corrosion oxygen permeability value.
determines the depth of concrete over which the contribution of The modelling is normally deterministic rather than probabilistic,
fibres to tensile and flexural strength should be ignored by the
structural designer. A limiting value of 20% loss is typically used. General input parameter Specific input parameters

The accuracy of the assumed exposure conditions is critical to Relative humidity (%) Temperature Carbonation: Carbon Dioxide Level
(°C) 28-day cube strength (MPa) (%) Intrinsic oxygen Permeability
the validity of the predictions. In the case of a desalination facility,
Cementitious content (kg/m3) Tri- (m2) Curing (days)
calcium aluminate level of cement
Chloride: Background and surface
(%) Slag, fly ash or silica fume level
chloride levels (%) Chloride diffu-
(%) Reinforcement diameter (mm)
sion value (m2/s) and age (days)
Fibre thickness (microns) Cover
Aging factor Exposure type (wetting/
(mm) Allowable corrosion loss (%)
drying, submerged, atmospheric)
Service life (years)
Steel type (stainless, carbon)
Additional protective measures
(coatings, corrosion inhibitor)
Figure 3. Calculation model for estimation of crack width in fibre reinforced
members subject to axial compression and bending Table 4. Input parameters to durability modelling

236 The Masterbuilder - July 2013 • www.masterbuilder.co.in

 Concrete: Fibres

in that it adopts single values for each parameter rather than

allowing for variation and then predicting the likelihood of different
outcomes. The adopted values often reflect the worst likely
conditions for temperature and carbon dioxide levels. The carbon
dioxide level will typically lie between 0.04%, the average outdoor
value, and 0.1% for poorly ventilated spaces (17).
Relative humidity is a key parameter affecting carbonation and a
sensitivity analysis should be carried out to encompass the range
of possible values during construction and in service.
Typical output from the model is shown in Figure 5.
Chloride Model
The chloride ingress by diffusion is predicted using a model based
on published research (18). The model uses Fick’s second law of (b) Graphical output showing loss of fibres during construction period
Figure 5. Typical output from carbonation model
diffusion:
concentration at depth x (m) after exposure time t (s), Csn is the
notional surface chloride level (% by mass of binder) and erf is
(1)
the error function. The diffusion coefficient will increase with
where Dc is the diffusion coefficient (m2/s), Cx is the chloride temperature but reduce with age, dependent on the concrete mix
and the exposure conditions. The model allow for these effects,
Summary of Input as well for as the release of chlorides due to carbonation (18).
Parameter units value The chloride diffusion coefficients assumed in the design should
be verified by appropriate testing, such as the NTB 492 method
relative humidity % 85
(19).
temperature °C 25
The chloride levels increase until the threshold chloride level is
carbon dioxide level % 0.03
surpassed and then corrosion is initiated. The threshold level
28-day cube strength MPa 50 depends upon the cementitious type, service temperature,
cementitious content kg/m 3
400 presence of corrosion inhibitors and reinforcement type (eg.
ggbs level % 0 carbon steel, stainless steel).
pfa level % 30 The rate of corrosion of steel is assumed to increase as the
minimum cover mm 30 chloride level in the concrete adjacent to the steel increases.
bar diameter mm 16 For example, the tidal and splash zone in marine conditions:
fibre thickness micron 750
(3)
acceptable loss of section % 20
where CR is the corrosion rate (microns/year) and Cx is the
curing days 3
chloride concentration (% by mass of binder) at the depth of
oxygen permeability 10-6m2 1 the steel reinforcement. The corrosion rate will depend on the
service life years 100 temperature and relative humidity. An adjustment for temperature
can be made using Arrhenius law (18).
Summary of Output (rebar)
The model allows different corrosion mitigation measures to be
corrosion initiation 52years assessed, including: changes to the concrete mix and the use
of protective coating, integral waterproofers, silane, controlled
propagation of 0.1mm cracks 3years
propagation of 0.3mm cracks 15years permeability formwork and stainless steel reinforcement.

service life to 0.1mm cracks
cover for service life
service life to 0.3mm cracks
cover for service life
Summary of Output (fibres)
depth of loss of section of 20%
(a) Summary of input and output
55years The cumulative corrosion from each stage of the structures life is
41mm calculated and used to estimate a depth over which the effect of
the fibres should be ignored, in a similar way to the carbonation.
67years
Figure 6 shows typical graphical output from the modelling.
37mm
Conclusions
Fibres provide significant advantages over reinforced and plain
32mm
concrete under extreme conditions, including exposure to fire,
abrasion and seawater. Steel fibres and synthetic macrofibres

www.masterbuilder.co.in • The Masterbuilder - July 2013 237

 Concrete: Fibres
(a) chloride ingress 50mm depth
Figure 6. Output from chloride model
increase post-crack ductility. This is an important consideration
for use in ground support,
Steel fibres by virtue of their discrete nature and small diameter
appear to eliminate galvanic corrosion and associated spalling
damage compared to steel rebar and enhance resistance to
chloride and carbonation induced corrosion. However, maximum
crack width should be limited to 0.1-0.2mm depending on the
service life and exposure conditions. Synthetic macrofibres are
non-corrodible but will be affected by elevated temperature and
some chemical agents.
Structural design methods are available for fibre reinforced
concrete. These should use values of compressive, flexural and
tensile strength based on performance tests on the FRC and
should consider the whole life of the element. Serviceability limit
state design should generally be based on elastic behaviour of
an uncracked section using flexural strength to first crack data.
Ultimate limit state design can allow for some plastic behaviour
using residual flexural strength data.
The interaction between the concrete matrix and the discrete
fibre is critical. SFRC may lose ductility when the concrete matrix
becomes too strong leading to fracture rather than pull-out the
fibres. Creep due to slip and elongation of fibres is also an issue.
Deformation and creep in cracked FRC depends on fibre type,
dosage and loading.
Durability design of facilities, such as desalination schemes,
should assess the conditions during construction, operation and
at times of outages. Carbonation and chloride ingress can be
predicted from models based on published research. The loss
of cross-section of fibres by corrosion can be used to estimate
the depth of concrete over which any effect of fibres on flexural or
tensile strength should be ignored.
References
1. Greenhalgh J., “Segmental linings – the future is steel-fibre-reinforced”,
Concrete Magazine, October 2003, pp 19-20.
2. Perry B., “Synthetic macrofibres storm to the front of coastal defence
innovation”, Concrete Magazine, November 2006, pp 72-73.
238 The Masterbuilder - July 2013 • www.masterbuilder.co.in
(b) loss of section of fibres for outages of
3. British Standards Institute, “BS EN 14889-1 Fibres for concrete, Part 1:
Steel fibres- definition, specifications and conformity”, BSI, London, 2006.
4. British Standards Institute, “BS EN 14889-2 Fibres for concrete, Part 2:
Polymer fibres- definition, specifications and conformity”, BSI, London,
2006.
5. King M. R., and Alder A. J.,”The practical specification of steel fibre
reinforced concrete (SFRC) for tunnel linings”, Proceedings of
Underground Construction 2007 Conference, London, Brintex Ltd.
6. American Concrete Institute, “ACI 544.4R Design considerations for steel
fibre reinforced concrete”, 1996
7. Bernard E. S., “Durability of cracked fibre reinforced shotcrete”, 2nd
International Conference on Engineering Developments in Shotcrete,
Cairns, Australia, October 2004, In Shotcrete: More Engineering
Developments (Bernard E S ed) Taylor and Francis, London, 204, pp
67-80
8. Hannant D. J., “The effects of age up to 18 years under various exposure
conditions on the tensile properties of polypropylene fibre reinforced
cement composite”, Materials and Structures, Vol 32, No 216, March
1999, pp 83-88.
9. Basell, “Prof-fax and Moplen Polyproplene Chemical Resistance”, Data
sheet 08/02, 2002.
10. Rilem, “Final recommendations of TC162-TDF, Test and design methods
for steel fibre reinforced concrete, design method”, Materials and
Structures, Vol 36, 2003, pp 560-565.
11. British Standards Institution, “BS EN 1992, Eurocode 2, Design of concrete
structures, Part 1-1, General rules for buildings”, BSI, London, 1994
12. NZS 3101, Concrete Structures, “Part 2- Commentary on the Design of
concrete structures, Appendix C5A, Test and design methods for steel
fibre reinforced concrete subject to montonic load”, 2006, pp 7-13
13. Concrete Society, “Guidance for the Design of Steel-Fibre-Reinforced
Concrete”, Technical Report 63, 2007.
14. Concrete Society, “Guidance on the use of Macro-synthetic-fibre-
reinforced Concrete”, Technical Report 65, 2007.
15. Bernard, E.S. 2008. “Embrittlement of Fibre Reinforced Shotcrete”,
Shotcrete, ACI, Summer edition, pp 16-21.
16. Bernard E. S., “Creep deformation of cracked fibre reinforced shotcrete
panels for Elasto-plastic concrete”, TSE Report Number 189, March
2008.
17. Quillin K. ”Modelling degradation process affecting concrete”, CRC Ltd,
2001.
18. Bamforth P. B., “Enhancing reinforced concrete durability, Guidance on
selecting measures for minimising the risk of corrosion of reinforcement in
concrete”, Technical Report 61, 2004.
19. NTB 492, “Concrete, mortar and cement based repair materials: chloride
migration coefficient from non-steady migration experiments”, Nordtest
method, 1999.
 Communication Feature

Fiber Reinforced Concrete & Its Advantages

Samit Singhai
Director- Technical, Kasturi Metal Composites (P) Ltd.
case of industrial flooring sector, peo-
ple tend to use onsite small mixers
more. To promote steel fiber reinforced
concrete in India and to give superior
quality and stronger concrete to the
nation, Kasturi has started manufactur-
ing glued hook end steel fibers here. Till
now customers had no choice but to
import them from other countries.
Kasturi is the first and only manufac-
turer of glued hook end steel fibers in
the country.
Apart from providing Duraflex
Glued Hook End Steel Fibers for Ball
Steel Fibers for friction industry,
Polypropylene Fibers for concrete rein-
forcement and Steel Wool Rolls. This
ISO 9001:2008 Certified company has
a state-of-the-art manufacturing unit
manned by some of the finest talents
from the industry. The company also
has an exclusive R&D unit, which
ensures constant improvement in the
product range, apart from ensuring
that the production processes are in
line with government recommended
environment safety measures.
The company has a dynamic team

K
asturi Metal Composite (P) Ltd
is a leading manufacturer and
exporter of a wide assortment of
steel fibers. With a mission to provide
India with best quality products featur-
ing latest technology, at most economi-
cal prices, Kasturi has launched glued
hook end steel fibers in India.
Considering today's market scenario,
where unavailability of skilled labour for
proper mixing and placing of steel
fibers in concrete is an issue, Kasturi
has launched Duraflex Glued Hook
End Steel Fibers for the industrial floor-
ing and tunnel shotcrete sectors to
ensure Ball Free mixing. It is a fact that
concrete mixing machinery varies from
site to site in India and especially in the
SFRC (Steel Fiber Reinforced Concrete) Industrial Flooring-A Super Crack Resistance concrete
Free mixing, Kasturi also actively part-
ners all its clients by providing them
with optimum design solution as per
TR34 British Standards for Concrete
Industrial Flooring. This helps the client
to achieve ultimate design with opti-
mum dosage of Duraflex Steel Fibers
and maximum cost savings. The onsite
technical team of the company assists
the client to handle various mixing, plac-
ing and finishing issues. Every member
of the team is professionally trained
and well equipped to resolve any oper-
ational problems that may arise during
the process of laying industrial flooring.
The company's wide range of prod-
ucts includes Duraflex Steel Fibers for
concrete reinforcement, Durabond
of professionals at the helm of affairs.
Mr.Samit Singhai is the Director-
Technical of the company. A technocrat
with wide ranging experience in the
field of steel fibers, Mr.Singhai has
been one of the key players responsi-
ble for the remarkable growth story of
the company.
Cement Concrete, whether con-
taining natural or waste glass aggre-
gate is relatively brittle, and its tensile
strength is typically only about one
tenths of its compressive strength.
Concrete by itself is naturally very brit-
tle, lacking ductility when tension or
impact loads are imposed. When sub-
jected to tensile stressed, un-reinforced
concrete will crack and fail.
Traditionally concrete has been suc-
cessfully reinforced with steel bars
and/or welded wire fabric set into the
concrete where analysis indicates high
tensile stress or high impact loads.
However even well designed bar-
reinforced concrete systems will mani-
fest cracking over time.
For many applications, it is becom-
ing increasingly popular to reinforce
the concrete with small, randomly dis-
tributed fibers. Their main purpose is to
increase the energy absorption capac-
ity and toughness of the material along
with superior crack resistance.
The concept of fiber-reinforced con-
crete is not new, rather from a historical
perspective it appears much like a con-
temporary version of an old theme.
Historical records dating back to bibli-

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


cal times clearly attest to the practice of
using "straw" in building blocks. Even
Roman building practice incorporated
a type of "fiber" - horsehair, which was
widely used in the construction of many
imposing structures notably the
Colloseum. Through the ages there-
fore, the use of fibers has been a recur-
ring theme from straw in adobe, hair of
wild animals to the host of modern syn-
thetic fibers.
Steel-fiber-reinforced concrete is a
state-of-the-art composite material
made of hydraulic cements, fine or
coarse aggregate, and a dispersion of
discontinuous steel fibers. It may con-
tain pozzolans and additives com-
monly used with conventional con-
crete. The amount of fiber in concrete
mixes typically ranges from 0.5 percent
to 2.0 percent by volume, although
smaller amounts have been used suc-
cessfully in reduction of plastic- and
drying-shrinkage cracking. According
to the Portland Cement Association,
steel fiber contents greater than 2.0 per-
cent result in poor workability and fiber
dispersion within the concrete mix.
However, the main effect of adding
steel fibers in concrete, that is also the
main advantage of SFRC and the most
useful regarding design of hyperstatic
construction (like slab on ground), is its
post-crack behavior or toughness of
SFRC. Steel fibers in concrete start act-
ing when the first crack appears and
have the ability to absorb and redistrib-
ute the loads (or energy), so that the
SFRC will still be able to bear loads
even after the formation of cracks. In
fact, SFRC has a ductile behavior or
toughness and therefore, that surplus
of flexural capacity from the plastic
phase (post-crack ductility) can be
used for design of structure when
deformation must be controlled like
slabs or for structures where deforma-
tions controlled the design like under-
ground linings. It is the reason why, for
the same thickness, a SFRC slab on
Without Fibers
BRITTLE
Micro cracks
CONTINUOUS REINFORCEMENT
With Fibers
DUCTILE
Micro cracks Fibres
DISCRETE REINFORCEMENT
Communication Feature
ground can support higher loads than - Compatible with all surface finish
a conventional concrete slab. and coating techniques.
The addition of these fibers provides
DURAFLEXTM Steel Fibers and
improvements of the engineering prop-
DUROCRETETM PP Fibers are high
erties of the concrete such as Impact
strength fibers, with favorable shape,
strength, toughness (post-crack ductil-
orientation, and strength. The steel fibers
ity), ability to resist cracking and mate-
are known to have possessed high ten-
rial disintegration, as well as fatigue
sile strength and ductility. The most sig-
resistance. The exact amount of
nificant factor affecting resistance to
increased strength depends on many
crack propagation and strength of the
variables, especially fiber content. With
fibrous concrete and mortar are
fiber contents of 1.5 percent to 2.0 per-
cent by volume, direct tensile strength - Shape and bond at fiber matrix inter-
will increase 30 to 40 percent, and flex- face
ural strength (first crack) will increase - Volume fraction of fibers
50 to 150 percent. - Fiber aspect ratio and Orientation
of fibers
- workability and Compaction of
Concrete
- Size of Coarse Aggregate
- Mixing
Benefits of Duraflex SFRC Floors To
the Owner
- Less Cost, High Quality, Longer Life
of Floors
- Resistance to micro cracks propo-
gating into macro cracks
- Provides high impact resistance
- Excellent surface finish can be
achieved
- Eliminates spalling due to corrod-
ing reinforcement
- Reinforces the edge helping to pre-
vent joint failure
To the Consultant
- Cusomized Design Support
- Suitable for wide range of applica-
tions Fiber Blends for various FRC (Fiber reinforced
- Ease in designing for complete life Concrete) applications – WAY TO LOOK FORWARD!
span of Concrete Floors Performance of conventional con-
- Ensures Optimum use of material crete is enhanced by the addition of
and Technology. fibers in concrete. The brittleness in con-
- Reduce steel reinforcement require- crete is reduced and the adequate duc-
ments tility of concrete is ensured by the addi-
tion of Fibers in concrete. The main rea-
To the Contractor
sons for adding steel fibers to concrete
- Faster construction matrix is to improve the post-cracking
- Reduced labor cost response of the concrete i,e., to improve
- Easy to handle, mix, place and fin- its energy absorption capacity and appa-
ish variety of Floors surfaces. rent ductility, and to provide crack resis-
- Environmentally friendly tance and crack control.
www.masterbuilder.co.in · The Masterbuilder - July 2013 241
 Communication Feature
Fiber Blends – Concrete can be rein-
forced blends of steel and/or synthetic
and/or cellulose fibers. The reason for
using fiber blends is to enhance the
properties of concrete by combing the
benefits that each particular fiber type
can impart.
There is no fiber type that can
encompass all the desired properties
of fresh and hardened concrete in
terms of, for example, providing load
bearing capacity at cracked sections,
crack control, spalling resistance at
elevated temperatures, improved abra-
sion, impact and frost resistance.
However, appropriate blends of fibers,
with or without, traditional reinforcing
bars can lead to synergetic effects, i.e.
combinations of different fiber types
can enhance concrete in both its fresh
and hardened states.
Microfibers
P
Microcracks
Large fibers
Stress P
Short microfibers
Large fibers
Plain matrix
Strain
Properties of Fiber Blends Reinforced
Concrete
Steel/Steel Fiber Blends
Small steel wire fibers are effective
in micro-crack bridging, leading to an
increased fractural energy and higher
flexural strength. Their use, when blended
with larger steel wire Fibers, can dra-
matically increase the peak load and
post-cracking performance of concrete.
In other words, by combining steel
fibers that are effective in both micro-
cracking and in macro-crack bridging,
synergetic effects will increase the
fractural energy absorption capacity
and toughness of the concrete.
Steel/Micro Synthetic Fiber Blends
Steel Fibers do not contribute sig-
nificantly to the performance of plastic
concrete, because their strength and
stiffness differs too much from the prop-
242 The Masterbuilder - July 2013 · www.masterbuilder.co.in
erties of concrete at an early age. Micro
polypropylene fibers are better suited
to take up stresses in plastic concrete
due to their lower elastic modulus. Fur-
thermore, their ability to interfere with the
capillary forces by which water bleeds
to the surface of concrete reduces the
risk of plastic settlement due to water
evaporation. Consequently, a blend of
large steel fibers and micro polypropy-
lene fibers can combine structural rein-
forcement with plastic crack control.
The micro synthetic fibers in the con-
crete also increase its resistance to
spalling in fire situations.
Synthetic/Synthetic Blends
As previously mentioned, micro syn-
thetic fibers have been used for many
years to effectively control plastic shrin-
kage cracking as well as plastic settle-
ment cracking in concrete floors and
slabs. However, once the concrete has
set and begun to gain strength, there
are no benefits with respect to crack
control. Macro synthetic fibers are
dimensionally much bigger than micro
synthetic fibers and therefore they pro-
vide very few benefits to the plastic con-
crete (although there are some com-
mercially available macro synthetic fibers
that are claimed to perform a similar
role to that of micro synthetic fibers).
The main role of synthetic/synthetic
blends is to control plastic cracking (in
fresh concrete) and drying shrinkage
cracking (in hardened concrete), and
to improve post-cracking toughness,
subject to the previously mentioned
provisos on the long-term properties of
macro synthetic fibers. Micro synthetic
fibers also increase resistance to
spalling in fire situations.
Steel/Synthetic Blends
A more recent development in fiber
reinforced cement-based composites
concerns the use of hybrid blend of
Steel and Synthetic PP Fibers. The con-
crete toughness can be optimized by
using steel fibers that will affect the
cracking process during different stages
of loading and micro-fibers improve
composite strength by bridging micro-
cracks and, therefore, delaying the
coalescence of these cracks into macro-
cracks. On the other hand, macro-fibers
are more effective in bridging larger
crack openings. Therefore, blend can
be considered a multifunctional mate-
rial that is able to achieve a set of
desired performances by the use of
different Fiber types; as a second exam-
ple, toughness and ductility can be pro-
vided by high-modulus fibers, shrink-
age cracking control by low-modulus
fibers, conductivity by carbon fibers.
For further details:
Kasturi Metal Composites Pvt Ltd
Regus, Level 13, Platnm Techo Park,
Plot no 17 & 18, Sect 30A, Vashi,
Navi Mumbai - 400705
Ph: +91-721-2590293/95
E-mail: info@steelfiberindia.in
Web: www.steelfiberindia.in
 Equipment: Concrete Batching Plants
Concrete Batching Plants:
Emphasis on Quality and Variety of Concrete
Drives Continual Demand
M.K. Prabhakar, Associate Editor
T
he Indian construction industry
has had a fairy tale run over the
past two decades or so. It all started
with the opening up of the economy in
the early 1990s and the ensuing boom
in construction. The entry of global play-
ers brought with it several new technol-
ogies and a greater focus on quality.
The way concrete was produced
underwent a sea change. Leading this
revolution were the modern concrete
batching plant models. By the turn of
the century, India had become one of the
key markets for concrete batch plants.
It is one market segment that has been
maintaining a steady pace of growth of
around 20% consistently from the early
2000s, whatever may be the state of the
economy.
Dictating the trends has been an ever
- evolving customer, who today wants a
concrete batching plant that should
offer optimum performance, fuel effi-
ciency, is environment-friendly, should
be easy to install and if necessary must
be portable enough to shift to another
location. Manufacturers on their part had
244 The Masterbuilder - July 2013 · www.masterbuilder.co.in
to ensure that they provide all this at a
fair price, particularly in the context of
the price-sensitive Indian market. Things
have however, taken a turn in recent times,
with contractors understanding that the
long term gains would always offset any
higher initial investment. With the mar-
ket getting segregated along certain
specific lines, the job of manufacturers
has become in a way a lot easier. For the
large scale projects they offer the big-
ger machines, while for the real estate
sector and smaller projects there is a
vast range of compact batching plants
available in India today.
The Indian construction industry has
seen the steady growth of ready-mix-
concrete (RMC) sector over the last two
decades. With the increased demand
for specialized concrete such as self-
compacting concrete, fiber-reinforced
concrete, temperature-controlled con-
crete, etc, contractors have found an
able ally in the latest generation concrete
batching plants. Stricter specifications
and stringent quality standards have
made the use of concrete batching
plants almost imperative. Following the
patterns in the developed world, RMC
could soon overtake site-mixed-
concrete (SMC) in popularity stakes here.
All these factors have been fuelling the
growth rate of concrete batching plants
in the country. The growth rate is poised
to increase rapidly, given the increased
adaption of RMC both in the infrastruc-
ture and real estate sectors.
Tough Competition
As mentioned earlier, leading play-
ers are focusing across a range of
capacities, catering to different market
segments. A lot of R&D is also going into
coming out with product innovations to
suit the needs of the Indian market. For
example, with labour costs getting
steeper by the day and labour also
becoming difficult to find, companies
are focusing on self-loading mecha-
nisms in concrete batching plants. A
good example for this is available in the
form of the popular CP30 model from
Schwing Stetter India. The plant with
planetary mixer comes in three ver-

sions, star, compartment and inline. CP30
inline version with skid and conveyor
can help contractors cut down on labour
costs. The company had also in recent
times come out with the latest version
of HN1 horizontal batching plant, fea-
turing planetary mixer with twin discharge
and inclined belt conveyor system, ide-
ally suited for precast application.
Schwing Stetter India also offers other
popular models such as the M2.5, the
largest foundationless concrete batching
plant in the country, according to the
company, and the CP18.
Linnhoff India is another leading
player that has made major inroads into
the Indian market with its wide range of
concrete batching plants. The 'Eurotec'
Series of concrete batching plants from
the company have proven their mettle
in several parts of the world. Among its
specialties is the 'Eurotec Control Sys-
tem' (ECS), which ensures optimal
homogenous mix. Going into details
behind the system, Mr.Ashok Tanna,
Managing Director of the company
explained, “The ECS is a batching soft-
ware for full use of the plant automation
through a user- friendly windows inter-
face. The system is easy to learn and offers
security features to protect sensitive
data and input. Plant controls can eas-
ily be switched between fully automated
and total manual control giving full flexi-
bility to the plant operators. Software
options allow the system to be accessed
remotely via modem giving head office
the choice to monitor plant production
and material consumptions. Data down-
loaded from the control system can be
readily utilized in Microsoft Windows
software allowing office staff to incor-
porate the data into various accounting
packages. “Additional options for extra
aggregates, silos and even moisture
control sensors too can be easily inter-
faced with the software system.
Another leading player which has
been focusing on unique technology to
cater to a discerning customer is Ajax
Fiori. The company's 'Radius Lift Arm
Batching Plants' ranging in capacities
of 20 cu.m per hour to 30 cu.m per hour,
feature the unique 'Swinging Radius Lift
Equipment: Concrete Batching Plants
“The ECS is a batching soft-
ware for full use of the plant
automation through a user-
friendly windows interface. The
system is easy to learn and
offers security features to pro-
tect sensitive data and input.
Plant controls can easily be
switched between fully auto-
mated and total manual control
giving full flexibility to the plant
operators".
Ashok Tanna
Managing Director, Linnhoff India
Arm' technology. Self-loading of aggre-
gates and sand with minimum wastage
is ensured due to the two radius lift arms,
swinging almost 180 degrees. The plant
also eliminates the need for bins /parti-
tions like traditional systems as the radius
lift arms pick up material from the ground.
It also offers compact batching plants,
Plants that are easy to set up and require less labour to operate are in demand
www.masterbuilder.co.in · The Masterbuilder - July 2013
which include the dragline type and the
compartment bin type with planetary
mixer in the 30 cu.m per hour capacity.
The planetary mixers are manufactured
in-house in collaboration with Eurostar,
Italy. The company also offers the 'inline
bin' type batching plants in the capacity
range of 30 cu.m per hour to 180.cu. Per
hour.
Suppliers are concentrating on
models with modular design to enable
easier installation. Aquarius Engineers
for example, offers stationary concrete
batching plants featuring modular design
under its 'SP' series. The company also
offers two mobile plants, MP 21 and MP
24, which can be mounted on re-usable
precast foundations. The company's
range of concrete batching plants fea-
ture control system based on require-
ment or application. Explaining the top
features of the control system,
Mr. Sudhakar Waggh, Country Manager
(Service) of the company stated, “Our
batch control system is user-friendly and
capable of providing data in CSV for-
mat, delivering concrete with 100%
accuracy for cement and additives, and
allows remote access for after sales
service & troubleshooting.” Other top
features include GSM/ISM synchroni-
zation for delivering online reports and
messages on phone and mails, con-
245
 Equipment: Concrete Batching Plants

“Our batch control system is

user-friendly and capable of pro-
viding data in CSV format,
delivering concrete with 100%
accuracy for cement and addi-
tives, and allows remote access
for after sales service & trouble-
shooting”

Sudhakar Waggh
Country Manager (Service), Aquarius Engineers The real estate sector has been helping sustain demand for concrete batching plants

crete slump indication, continuous level
indicator for cement, and a 'mixer mind'
feature for better performance of mixer.
With competition intensifying, man-
ufacturers are also focusing their R&D
on making plants 'greener'. A good case
in point is available in the form of the
range offered by Universal Construc-
tion Machinery & Equipment. The com-
pany offers concrete batching and mix-
ing plants which are environment-
friendly due to the adoption of electric
drives, which do not emit any pollutants
and also ensure low noise. Highlighting
the other salient features of the tech-
nology, Mr.Rajesh Kawoor, Vice-
President (Concrete Business) of the
company explained, “Our batching
plants are also equipped with dust filters
and dust collectors, which limit dust
pollution to a great extent. The latest
batching plants offered by us are fitted
with advanced control systems which
ensure optimization of energy due to
superior operating efficiency. “
Another popular player that offers a
wide range is Apollo Infratech. The com-
pany offers popular models such as
ATP 20, ATP 30, ATP 45/ATP 60 and
ATP 90/ATP 120. It also offers models
such as ATP 21, ATP 31, and ATP 61
under its compact series. Similarly,
Speedcrafts is one more name that
offers a wide range of concrete batch
mix plants which includes models SCP-
30, SCP-45, SCP-60 and SCP-90 rang-
ing in capacities from 30 cu.m per hour
to 90 cu.m per hour. It also offers com-
pact, mobile concrete batch mix plants
in the 20 cu.m per hour capacity range.
Speedcrafts also offers mobile concrete
batching plants with output ranging up
to 30 cu.m per hour capacity.
Conmat, another leading brand in
construction equipment market, also

Aquarius Engineer's concrete batching plant Mobile plants are doing well in smaller towns and cities

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

 Equipment: Concrete Batching Plants

“Our batching plants are equip- 20, 25 and 35 cu.m per hour capacity
ped with dust filters and dust range. Macons , a familiar name in the
collectors, which limit dust pol- construction equipment industry, offers
bin type plants under the 'MCP'series, and
lution to a great extent. The lat-
compact plants under 'MAC' series. Sany
est batching plants offered by us
India is yet another top brand that offers
are fitted with advanced control concrete batching plants, consisting of
systems which ensure optimi- models SPB05 and SBP10.
zation of energy due to superior With the gradual penetration of RMC,
operating efficiency “ deep into the rural parts of India, and
the continued thrust being provided to
infrastructure development under the
XII Five Year Plan, several new players are
expected to enter this lucrative market.
Positive Signals Emanate
There are several sectors which are
driving demand for concrete batch
plants, notwithstanding the recent
Rajesh Kawoor recessionary trends. The transportation
Vice-President (Concrete Business), Universal
sector, for example, has been one, what
Construction Machinery & Equipment
with several highway projects, many of them
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mobile concrete batching plants in the announcing key projects offers immense
scope. The realty sector, especially in
smaller towns and cities, is another mar-
ket that is driving demand, especially for
compact sized plants. Manufacturers too
have taken note of this trend and come
out with models that offer mobility.
The recent announcement from the
Prime Minister, Dr.Manmohan Singh
about ramping up measures to improve
infrastructure comes as a shot in the arm
for the concrete batching plant manu-
facturers. The Prime Minister has set an
ambitious investment target of `1.15
lakh crore in PPP projects across core
infrastructure sectors such as rail, power
and port in the next six months, at a
meeting convened with key infrastruc-
ture ministries recently. The announce-
ment is yet another testimony to the
continued thrust being provided to
infrastructure development. All these
developments translate into a period of
sustained demand for concrete batching
plants in the near future.

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 Equipment: Concrete Placement
Concrete Placing Equipment:
Application Requirements Dictate Market Trends
M.K. Prabhakar, Associate Editor
T
he ways and means to convey
and place concrete have under-
gone a sea change over the last
three decades and in a way have played
a big role in the proliferation of mega
projects, which were earlier considered
impossible. Whether it is the tallest
building or the longest tunnel, if there is
one thing common among all major
projects, it has to be the equipment being
used for conveying and placing con-
crete. From setting new records in ver-
tical concrete pumping to pumping
concrete over record distance horizon-
tally, it is one market segment that has
grown steadily in India. According to
industry estimates around 2500 units
of concrete pumps are being sold in
250 The Masterbuilder - July 2013 · www.masterbuilder.co.in
the country on an average every year.
Given the consistent thrust to infra-
structure development and with the
scale of projects getting bigger by the
day, these numbers could grow expo-
nentially in the coming future.
Among concrete pumps, stationary
concrete pumps are the preferred choice
followed by boom pumps. Concrete
pumps is a market segment which has
seen intensifying competition, with
manufacturers fighting it out on as much
on the plank of technology as price.
Leading players have also been ramping
up their existing manufacturing and ser-
vice networks in a growling market.
Higher & Longer
Concrete pumps have always
enjoyed consistent demand in the Indian
market over the past two decades. With
the need to pump concrete higher and
longer, while also not compromising on
the end-quality of concrete, it is one
product category, whose usage has
become almost imperative for contrac-
tors. The market for concrete pumps in
India is passing through one its most
crucial phases. It is a phase which is
witnessing consolidation by big names
and enthusiastic competition from the
not-so-big ones. The market which has
maintained a healthy growth rate of
20%-30% consistently over the past
decade could grow at a quickened pace
in the near future, what with the positive
forecasts for the economy. It is also one

market segment among concreting
equipment which is set to witness intense
competition in the near future.
The demand for boom pumps has
hit the upward curve over the past five
years. Pushing the demand has been
the spurt in infrastructure projects. A good
case in point is the number of metro
projects around the country. From
building elevated viaducts and stations
to underground construction, where boom
pumps play a key role in areas like side-
wall construction, they are now a much
sought after type of equipment for metro
projects. Manufacturers have spotted
the rising opportunities and come out
with range of capacities specifically
tailored to meet the demands in India.
Horses for Courses
As mentioned earlier, application
has been driving demand patterns for
concrete pumps in the country. Increas-
ing high-rise construction in metros
and booming mid-rise construction in
smaller cities, for example, has neces-
sitated pump models specifically tai-
lored for the need. Therefore, vertical
pumping capabilities have been an area
of focus among concrete pump manu-
facturers in recent times. Several new
models catering to this market segment
have been launched in recent times. A
good example can be found in the form
of the SP1600 model unveiled by Schwing
Stetter India recently. It had earlier
Nothing is impossible: Thanks to powerful concrete pumping machines, there has been a spurt in mega
infrastructure projects in recent times
Concrete pumps play a key role in adhering to strict project deadlines
launched the SP1400 and SP1800
models for high-rise construction.
Schwing Stetter India also has in its
range, the powerful SP3600, with twin
circuit 160 bar pressure valve, ideally
suitable for concreting beyond 200
metres height, and comes in an aes-
thetic aerodynamic design. The com-
pany's other trailer pump models include,
SP1000, BP350, SP1200, SP2800, SP
4800 and SP8800.
Aquarius Engineers is another lead-
ing name that is catering to the high-
rise project segment. Its 700, 1000, 1400
and 2100 series of high performance
pumps are used for high-rise and long
www.masterbuilder.co.in · The Masterbuilder - July 2013
Equipment: Concrete Placement
distance conveying. A unique feature
of all Aquarius concrete pumps is the
water cleaning system and effective
reverse pumping of concrete. A pump
regulator protects the hydraulic system
from overheating and the engine from
overloading. Aquarius Engineers range
includes its latest new look models 703D,
1004D and 1405D.These models feature
a canopy which helps bring down sound
levels of the pumps drastically, a factor
so crucial , especially in urban environs.
Global players have been entering
the Indian market in recent times, either
by setting up their own manufacturing
units or with tie-ups with domestic play-
ers. Universal Construction Machinery
& Equipment Ltd for example has now
tied up with Zoomlion for distribution,
marketing and service of its concrete
pumps in India. Going into details on
what gives the range the edge over
competition, Mr.Rajesh Kawoor, Vice-
President (Concrete Business) of the
company explained, “All the concrete
and truck mounted boom pumps man-
ufactured by Zoomlion and offered by
Universal are equipped with an auto-
matic centralized lubrication system
which ensures proper and timely lubri-
cation. The models are also equipped
with hydraulic accumulator which avoids
overloading on the hydraulic systems,”
features that become necessary in order
251
 Equipment: Concrete Placement

to take on the rough and tumble of Indian

working conditions.
Suppliers are focusing their R & D
efforts towards coming out with machines
that are ready to meet the evolving chal-
lenges such as larger scales of projects.
Putzmeister India for example has its
BSA series of trailer pumps with free-
flow hydraulics mechanism that helps
in pumping large quantities of concrete.
Some of its popular models include,
702D, 1403HE, 1404HD, 1405D, 1406E,
1407D, 1408D and 1409D.
Apollo Infratech is one more top
name which offers a range of concrete
pump models such as the SAP -50 and
SAP-20. The companies range of con-
crete pumps have been part of various Increase in core infrastructure projects like tunneling is keeping demand consistent for concrete pumps
thermal power and canal projects in
Madhya Pradesh, Chattisgarh and The GCP 350 D/E Deluxe model spurt in real estate, as well as infra-
Jharkhand, apart from, high-rise build- from Greaves Cotton is another power- structure projects. Manufacturers are
ing projects in Mumbai and other met- ful concrete pump that can generate keeping a close watch on the develop-
ros. One more leading name in the fray high pressure, up to 86 bars with the ments and strengthening their service
is REL- Construction Equipment Divi- ability to placing concrete at distances network reach in order to tap into this
sion, with its Revathi Waitzinger mod- of over 400 metres horizontally and 100 potentially huge market for trailer
els- THP 45D, THP50D and THP60D, metres vertically. Another top brand is mounted concrete pumps.
which are designed for long distance Sany, which offers stationary pump
conveying. The Boom Continues
models including, HBT30C- 1006DY,
HBT40C-1408DIIY, HBT50C-1410DIIY Boom pumps are gradually making
“All the concrete and truck and HBT60C-1413DY, to mention only their presence felt in India. Their sales
mounted boom pumps manu- a few among its extensive range. figures, hovering around the 150 units
factured by Zoomlion and With competition getting intense by a year till recently, is bound to rise, fol-
offered by Universal are the day in the stationary concrete pump lowing the spurt in metro and flyover
market segment. Newer market oppor- projects. Manufacturers have been
equipped with an automatic cen-
tunities are also emerging in the form of banking on innovative product design
tralized lubrication system and a varied capacity range to cater to
hinterlands that are now witnessing a
which ensures proper and
timely lubrication. The models
are also equipped with hydrau-
Bhavani Balakrishna
lic accumulator which avoids
with inputs from Knight Frank Research
overloading on the hydraulic
systems”

Rajesh Kawoor
Vice-President, Universal Construction
Machinery & Equipment Pvt Ltd. Aquarius Engineers' 43 m boom pump model

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

 Equipment: Concrete Placement
the evolving market dynamics. Pointing
out the demand drivers for boom pumps,
Mr.Sudhakar Waggh, Country Manager
(Service), Aquarius Engineers observed,”
High volume concrete work in minimum
time and high mobility make boom
pumps preferred equipment for pro-
jects such as mass housing projects,
slum rehabilitation projects, industrial
projects, bridge projects, metro projects,
road projects, RMC business, etc. Addi-
tionally, the demand for stationary boom
placers is picking up for high-rise build-
ing projects in cities like Mumbai, Noida,
Bengaluru, Pune, etc.”
While earlier there was a lot of hype
about longer reach booms , today you
have a scenario where there are boom
pumps ranging from 20m to the over 40
m range , having created their own mar-
ket niche in India. Recent times have seen
intense competition in the 20 m height
range, since these boom pumps with a
shorter unfolding heights and which
could be driven through narrow roads,
are ideally suited for urban centres of
India. The 20 m boom pumps have come
as the ideal starter boom pumps for road
contractors, metro contractors and RMC
companies that want a price-competitive
machine that performs efficiently.
With project scales getting bigger, higher capacity stationary and boom pumps could be in
demand in the near future
254 The Masterbuilder - July 2013 · www.masterbuilder.co.in
With clear market differentiation,
companies are focusing on offering
specific solutions, as far as boom pumps
are concerned. Aquarius Engineers for
instance, offers a 20 m boom pump,
apart from 32, 36 and its recently intro-
duced 43 m model, with a 5-section, 'RZ'
folding boom. Schwing Stetter India
also offers a wide range that includes
models- S43, S36, S20 and S17,
designed for infrastructure projects.
Universal Construction Machinery &
Equipment offers boom pumps of
Zoomlion with boom vertical and hori-
zontal reach range of 35.6 x 31.6 metres
and 18.2 x 21.6 metres. The Zoomlion
boom pumps are equipped with twin
hydraulic pumps for pumping and agi-
tating, ensuring high reliability. Another
salient feature is the quick piston change
technology. The boom pumps also fea-
ture PLC technology which according
to the company ensures optimization
of the hydraulic system resulting in lower
fuel consumption.
An extensive range of boom pumps
is also offered by Sany India under its
'SY' and 'SYG' series. One more name
that offers models in varied boom reach
capacities is Putzmeister India with its
BSFM 20-3, BSF M32-4 and BSFM46-
5 models.
”High volume concrete work in
minimum time and high mobility
make boom pumps preferred
equipment for projects such as
mass housing projects, slum
rehabilitation projects, industrial
projects, bridge projects, metro
projects, road projects, RMC busi-
ness, etc. Additionally, the
demand for stationary boom plac-
ers is picking up for high-rise
building projects in cities like
Mumbai, Noida, Bengaluru,
Pune, etc”
Sudhakar Waggh
Country Manager (Service),
Aquarius Engineers
Discerning Customer
The Indian market for concrete pumps
is entering a rapid growth phase. With
demand expected to pick up further, it
is also a market where the competition
is also getting more intense by the day.
While several leading global players have
already set up shop here, there are sev-
eral others, who are waiting to get a
foothold in this lucrative market. Apart
from key infrastructure projects such
as metros , which have always been
driving demand for concrete pumps,
encouraging news is also coming from
the reality market, which is expanding,
in the true sense of the word. The realty
boom which was earlier witnessed in
the metros has spread to the deep hin-
terlands. Infrastructure projects are also
coming up in remote areas. Suppliers
therefore face challenges in the form of
logistics and service network. Project
assistance and prompt technical sup-
port services are among value additions
that customers have taken as given, given
the highly competitive scenario. In how
well they serve this demanding customer
lies the key for the success of suppliers.
 Equipment: Concrete Transportation
Concrete Transportation
Equipment: On the Move
M.K. Prabhakar, Associate Editor
T
he market for concrete transport
equipment has been maintaining
a healthy growth rate of 25% -30%
in recent times, the recessionary trends
notwithstanding. The increased use of
transit mixers has kept manufacturers
on their toes. Customers' preferences
have forced product innovations. Man-
ufacturers have been focusing their R &
256 The Masterbuilder - July 2013 · www.masterbuilder.co.in
D efforts in coming out with design and
features that suit the unique applica-
tion requirements of the Indian market.
Perhaps the rising popularity of self-
loading concrete mixers is the best
example for applications dictating prod-
uct design and popularity. The maneu-
verability of these machines, especially
onsite, and their ability to double up as
a mini batching plant has made them
extremely popular in recent times.
Innovative Strategies
In a rapidly evolving market, manu-
facturers have been focusing on inno-
vation in design and incorporation of new
technologies in order to woo a customer,
who is no longer driven only by price but
 Equipment: Concrete Transportation

is looking for added value. Manufactur-

ers have been constantly getting feed-
back from end-users and incorporat-
ing changes in their transit mixer mod-
els to maintain that competitive edge. It
is no different in the case of transit mix-
ers. Manufacturers keep talking to end-
users to keep coming out with innova-
tive features. A good example for inno-
vation can be found in the form of the 7
cubic metre transit mixer of Schwing
Stetter India, which comes with optional
accessory of ad mixer dosing system,
an addition which is ideally suited for a
country like India, where quality assur-
ance onsite is a major issue. Schwing
Stetter offers a wide range of transit mix-
ers under its 6, 7, 8, 9, and 10 cubic
metre series. Off-ered in three different Apollo Infratech offers transit mixers in the 2, 4 and 6 cubic metres capacities
versions, i.e., mixer with slave engine,
mixer with PTO drive and mixer moun- wear protection, efficient hydraulics with metre, 4 cubic metre and metre capaci-
ted on trailer, they come with a host of planetary drive, rugged & compact mix- ties, respectively. These transit mixers
advanced features including, plastic ing units, water tank and pump and spe- feature long life mixing drum and spi-
extension chute, water metre, hydraulic cial loading hopper and unloading rals made of ST-52 materials. Similarly,
chute adjustment mechanism and ¾ flap chute, among others. Greaves Cotton offers the GCM 45 XL,
drum cover. The company has also set In a market like that of India, it makes with 4 cubic metre capacity for smaller
a new trend with the launch of its 3 sense for manufacturers to offer a cho- pours and the larger GCM65 XL model
cubic metre capacity 'Nimo'. With the ice, as wide as possible, because of for bigger pours. Transit mixers from
common 6 cu.m class transit mixers not the variation in project scales. Apollo the company feature low centre of grav-
being allowed inside cities during peak Infratech, for example, offers ATM2, ity which creates an ideal balanced load
traffic hours, it meant that there was ATM 4 and ATM6 models, in the 2 cubic distribution, obtaining better driving
only a small window, available for RMC
delivery at sites. The Nimo is the only
transit mixer can be delivering RMC dur-
ing daytime, according to the com-
pany. Another advantage of the model
is the facts that it can be maneuvered
easily throw narrow roads, an aspect
that is common to most Indian cities
and towns. Similarly, the smaller capac-
ity also means a more economical op-
tion for sites where it does not make
sense to send a larger transit mixer for
the contractor.
One more name that offers both
smaller and higher capacity transit mix-
ers is Ajax Fiori. Its range includes the
XVJ 4001, and the XC 6000 models,
with drum capacities of 4 cubic metres
and 6 cubic metres respectively. Transit
mixers from Ajax Fiori comes with a
host of features such as a unique drum
design made of highly durable steel,
optimized positioned spirals with anti- Smaller capacity transit mixers like Nimo are ideally suitable for smaller pours in cramped urban centres

www.masterbuilder.co.in · The Masterbuilder - July 2013 257

 Equipment: Concrete Transportation
Tweaks in traffic rules can further boost sales of higher capacity transit mixers in India
position and perfect stability, particu-
larly in narrow bends, traits that are so
crucial for safe driving in India.
With India continuing to be a key
market for transit mixers, it is not sur-
prising that many overseas players are
looking to enter the market. KYB, for
instance, which is the largest transit
Ajax Fiori self-loading concrete mixer at a construction site.
It is difficult to imagine infrastructure projects without self-loading mobile concrete mixers these days
258 The Masterbuilder - July 2013 · www.masterbuilder.co.in
mixer producer in Japan, has recently
entered into a strategic partnership with
Conmat India. With recession hitting
European markets hard, there have
been indications that many big names
from Europe are eyeing the Indian tran-
sit mixer market. Similarly, Sany, a global
leader in construction equipment an-
nounced production of truck mixers from
its production unit in Pune a few years
ago. Truck mixer models from the com-
pany include, TM0601, TM002 and
TM0603.
A Glut of New Machines
Convergence seems to be the name
of the game, whether it is electronics or
even in the case of construction equip-
ment. A single machine that does mul-
tiple jobs is what the typical Indian con-
tractor is looking for, and that is what
they get with self-loading concrete mix-
ers. These mean machines are mobile,
they mix concrete and help in laying it
too, making it an all-rounder, that has
become imperative construction sites.
Their self-loading nature means sav-
ings on labour costs too. These mixers
have become the staple whenever the
requirement is small to medium con-
creting jobs at semi-urban areas and
remote project sites. They offer excel-
lent mobility onsite. With almost all mod-
els featuring 4 wheel drives and superb
maneuverability, they are cut out for the
rough and tumble of Indian construc-
tion sites, where slushy conditions are
common. They also complement larger
capacity concrete batching plants and
transit mixers at major infrastructure
projects too, adding to their versatility.
With their popularity picking up, it is
no wonder that competition is intensify-
ing in this market segment. One of the
first names to enter the fray was Ajax
Fiori, with its 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. These
mixers feature the indigenously devel-
oped 'Concrete Batch Controller' (CBC)
with print facility, so that reports can be
generated right on the side. The closed
cabin offers superior protection, safety
and comfort to the operator.
With India emerging as a lucrative
market for self-loading mobile concrete
mixers, several global majors have been
announcing strategic tie-ups in recent
times. Apollo Infratech for example, ea-
rlier announced strategic partnership
with Carmix, Italy. The company offers
 Equipment: Concrete Transportation
Growing RMC market penetration in India is good news for truck mixer suppliers
a wide range of self-loading mixers,
including models such as 5.8 XL, 3.5TT,
2.5TT, 25FX and One.
Similarly, another leading name
who has entered the fray in recent
times is Speedcrafts. It has entered into
collaboration with Dmix SRL of Italy to
start production of self-loading con-
crete mixers in their manufacturing facil-
ity at Har-dwar. The company's range
includes models- DS 1000 (1 cu.m),
DS 2500 (2.5 cu.m) and DS 4000 (4
cu.m). Some of the salient features of
these models include an optimal mix
due to special drum configuration, elec-
tronic batching system, high maneu-
verability and excellent road holding
capability, among others.
One more leading name that offers
self-loading mobile concrete mixers is
Macon. The company offers models
available in the 1, 1.2, 2, 2.5, 3.5 and 4
cu.m capacities. Some other top fea-
tures include, 35% gradeability, 180
degrees reversible driving post and
electronic weigh batching unit.
Apart from the infrastructure sector,
260 The Masterbuilder - July 2013 · www.masterbuilder.co.in
the realty sector is another key market
segment that has been driving de-
mand for self-loading concrete mixers.
With the focus now also shifting to
smaller tier-II and tier-III towns and cit-
ies, as far as real estate development is
concerned, demand has been spurred
on by projects in India's hinterland. Their
ability to offer a short turning radius and
negotiate slushy conditions, which are
commonplace in Indian construction
sites, especially in cramped urban cen-
tres, have made them a favourite with
contractors. When it comes to infra-
structure projects, these machines are
ideally suited for a variety of projects
such as concrete pavements, airport
runways, irrigation canals, drains, cul-
verts, etc., to mention only some.
Upwardly Mobile
The market for concrete transporta-
tion equipment is not going to plateau
down anytime soon. With the kind of
infrastructure projects envisaged under
the 12th Five-Year Plan Period (2012-
17), the demand for these machines is
only expected to increase. The next de-
cade could see a rapid growth phase
for these mean machines. The realty
sector has also emerged as one of the
key market segments for concrete trans-
portation equipment. Suppliers have
taken note of the trends and are trying
their best to come out with products
tailored to suit the unique requirements
of the Indian market.
Global players have been keeping
a keen eye on the Indian market. With
the pace of award of infrastructure pro-
jects expected to pick up steam soon,
it won't come as a surprise if many of
them jump into the concrete transpor-
tation equipment bandwagon. What is
required is further push to the RMC sec-
tor. Archaic traffic rules prevalent in
many of our cities too need to be
looked into, for they have long been an
unnecessary hindrance to the growth
of the transit mixer market. Once things
are set right, concrete transportation
equipment is one market segment that
could grow by leaps and bounds.
 Concrete: Block Machinery
Concrete Product Machinery:
Shaping Up Well
M.K. Prabhakar, Associate Editor
I
n a vast majority of the case of mid-
sized construction equipment, there
has been an interesting trend witne-
ssed over the last decade or so. There
has been a gradual transition from the
dominance of the unorganized sector to
that of an organized one. Perhaps, now-
here is it more evident than in the case
of concrete product machinery. A lot of
it has got to do with entry of global play-
ers and increasing awareness levels
about latest technologies. Adding to
262 The Masterbuilder - July 2013 · www.masterbuilder.co.in
the transition was the fact that today's
contractor is under more pressure than
ever before to deliver quality, on-time and
within budget.
The Indian market was earlier being
dominated by the smaller, semi-auto-
mated or manually operated machines.
Several Chinese machines were also
doing the rounds of the market. They still
do, but are no longer the staple. The entry
of global players in the field has chan-
ged market equations. The more 'aware'
customer of today demands machines,
with larger capacities, which are easy to
set up and which also feature green
technologies.
Consistent Demand
The recent recessionary trends do
not seem to have much of an impact on
concrete product machinery manufac-
turers. With contractors under pressure
to stick to or cut down on project costs,
concrete blocks have come as a boon.

According to industry estimates, the
market for concrete block machines
has clocked a healthy 25%-30% growth
rate in the recent past, the recessionary
trends notwithstanding. What is also in
favor of concrete product machineries is
the fact that concrete blocks and other
products are being used in both infra-
structure and real estate sectors. The
demand therefore is sustained. If there
is a lull in infrastructure projects, it can
be offset by the real estate sector and
vice-versa.
Evolving Market Trends
The continued thrust being provided
to infrastructure development and the
growth of the real estate sector has meant
that India has emerged as a key market
for concrete block making machines
over the past decade. Global players
are entering the fray and consolidating
their presence. The focus is on being
closer to the market, by setting up man-
ufacturing facilities in India. Hess India,
the Indian arm of a global leader in con-
crete product machinery, has made
steady progress in recent times. When
queried upon the logic behind the com-
pany starting manufacturing facilities in
India, when others have adopted a cau-
tious stand due to the economic uphea-
vals of the recent past, Manoj Kumar,
Managing Director of the company ob-
served, “A plus point for Hess in starting
local facilities in places like India and
Brazil, which have higher import duties,
is that we were able to support the cus-
tomer in saving the import duty and
freight cost. Further by offering local
support and service, the customers are
able to get real confidence while invest-
ing. As a Germany company, we have
the trust and goodwill in the market, and
we consider India as a major market
with huge potential. For this reason, we
have taken a strong step to proceed
with the expansion of our Indian base.
This has helped us to do more engi-
neering in India, by reducing the cost of
the materials without compromising on
quality. Decision to source locally has
given Hess India a greater edge over
the competition,” words that sum up the
Global players are entering the fray and consolidating their presence in India
sound reasoning for global players try-
ing to set up manufacturing base here.
Hess India offers a variety of ma-
chinery including, concrete block ma-
chines, handling systems, autoclaved
“As a Germany company we
have the trust and goodwill in
the market and we consider
India as a major market with
huge potential. For this reason
we have taken a strong step to
proceed with the expansion of
our Indian base. This has helped
us to do more engineering in
India, by reducing the cost of the
materials without compromising
on quality. Decision to source
locally has given Hess India a
greater edge over the competition”
Manoj Kumar
Managing Director, Hess India
www.masterbuilder.co.in · The Masterbuilder - July 2013
Concrete: Block Machinery
aerated block machines, concrete pipe
machines and press machines. Hess
India has also started production of wet
cast press machines in India together
with forest Press from UK. The company
that offers a range of models globally
including Multimat RH 2000-3, Multimat
1500-3, Multimat 760, Multimat 600-2
and Multimat RH -500 has been focus-
ing on coming out with machines that
are ideally suited for the Indian market.
With competition intensifying com-
panies are focusing on value added
services. Prompt technical support ser-
vice, is something that is crucial of it
helps in avoiding machine downtime.
Columbia Pakona Engineering, which
is the Indian joint venture company of
Columbia Machine Inc USA for instance,
has a strong thrust on offering technical
support services. Highlighting this point,
T.P.Soji, Senior Manager Marketing, of
the company explained,” We have a
strong, well experienced customer ser-
vice team based out of our factory at
Vadodara. This service support along
with local availability of all spares for our
equipment has given us an edge over
our competitors who are planning to
start such facilities in India. “ The com-
pany has been manufacturing complete
block machinery plants including aggre-
gate/cement storage, batch-mixing
plants, block machines, pallet and pro-
263
 Concrete: Block Machinery

duction handling equipment, moulds,

etc for its customers in India for over ten
years. The company provides a range
of concrete block machines from the
economical 2-Block machine model
SPM20 to the 12-Block machine model
SHP 5000C. In addition to their versatil-
ity in manufacturing a wide range of
products, these machines feature the
unique vertical vibration technology. This
results in superior product quality aris-
ing from uniform density, throughout
the height of the product, between prod-
ucts within a single pallet or cycle and
between products of various pallets or

”We have a strong, well

experienced customer service
team based out of our factory at
Vadodara. This service support
along with local availability of all
spares for our equipment has
given us an edge over our
competitors who are planning
to start such facilities in India “
Rapid urbanization has made scenes like this commonplace in India
to watch out for when it comes to con-
crete pipe making machines. Going into
details on the opportunities available,
Mr.Manoj Kumar of Hess India pointed
out that the pipe industry is completely
dependent on governmental policies
and decisions. He further added, “The
market potential really huge in India and
substantial part of its development is
poised for growth on account of indus-
trialization, urbanization, economic de-
velopment and people's rising expecta-
tions for improved quality of living. Cer-
tain states like Gujarat, Haryana and
Tamil Nadu already prepared a long term
plan. This may be in the form of con-
necting the rivers by canals or pumping
water through pipe lines either for agri-
culture, industrial or domestic usages.”
Not surprisingly several global ma-
jors are eyeing the Indian market. It was
only sometime ago that companies like

T.P. Soji
Senior Manager - Marketing,
Columbia Pakona Engineering Pvt Ltd

cycles. According to the company, pro-

ducts manufactured using its equip-
ment have lower material costs arising
from reduced cement consumption and
superior height control with an accu-
racy of + /-0.5mm.
Several other global companies
could be following suit soon and setting
up base in India in the near future, con-
sidering the encouraging market trends.
No Longer a Pipe Dream
With water supply projects becom-
ing a major focus among civic authori-
ties, India has emerged as the market Concrete pipe making machinery has got a fillip due to demand for pipes from civic authorities

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

 Concrete: Block Machinery
HawkeyePedershaab, considered a
global leader in the field, have entered
the fray. A joint venture between Apollo
Infratech and HawkeyePedershaab,
offers concrete pipe making machines
of various capacities. The JV offers mod-
els CAP-150, CAP-200 and VIHY
Masterflex SC60. The CAP-150 and
CAP-200 machines are used for pro-
ducing concrete pipes, manhole sys-
tems, box culverts, lined pipes, jacking
pipes, etc. While the pipe manufactur-
ing capacity of CAP-150 is 300mm to
1500 mm diameter, it is 300 mm to 2000
mm diameter in the case of CAP-200.
The M1600 model from Columbia Pakona Engineering
The VIHY Masterflex SC 60 is used for
mass production of small-diameter, non-
reinforced concrete pipes. It is also
capable of producing branch pipes and
gulley pots.
Use of Industrial Waste
The rising emphasis on environment-
friendly building strategies has also been
one of the key reasons behind the grow-
ing market for concrete block making
machinery. Manufacturers are focusing
on machine models that utilize indus-
trial by-products such as fly ash in a big
way. Hess India for example has been
doing lots of R&D in concrete and fly
Concrete blocks are here to stay
266 The Masterbuilder - July 2013 · www.masterbuilder.co.in
ash related products and developed
systems. According to Manoj Kumar, it
has installed plants with leading names
like Jindal and KJS in India. In the case
with the plant with Jindal, transportation
and manual interference were avoided,
with the ash reaching the Hess machine
directly through a closed conveyor. He
further added that other than fly ash, the
company also offers machines that are
able to use GGBS (Ground-granulated
blast-furnace slag) and even Pumice. It
has also supplied similar machines to
steel companies like Tiscon, Ruuki, SSAB,
Rockwool and Kuttner for steel brique-
tting.
Similarly, Columbia Pakona Engi-
neering offers the SPM20 model, capa-
ble of manufacturing 8000 to 16000 num-
bers of hollow/solid blocks or 50000
numbers of fly ash bricks in a day. It's
SPM26 model is capable of manufac-
turing 80000 fly ash bricks or 15000 to
25000 hollow/solid blocks in a day. In
addition, the company also offers the
1600 model which is capable of manu-
facturing 20000 to 35000 hollow / solid
blocks or 125000 fly ash bricks in a day
and model SHP5000 C PRO, which is
capable of manufacturing 40000 to
75000 hollow/solid blocks or 150000 fly
ash bricks in a day. “Many of our cus-
tomers have started using slag from
steel plant as a replacement for aggre-
gates for the manufacture of bricks and
blocks,” said T.P.Soji, Senior Manager-
Marketing of the company, highlighting
the increasing awareness levels about
using environment-friendly technolo-
gies and construction strategies in India.
Dynamic Market
The concrete product machinery
market is entering an exciting phase.
There are several international players
queuing up to take advantage of a luc-
rative market. Many of them are either
setting up manufacturing units or look-
ing to tie-up with domestic players to
establish their brands in India. All this
spells good news ultimately for the cus-
tomer, who now has a wider choice to
choose from.
However, challenges remain for
manufacturers. For one, the rising input
costs are one factor for which they look
towards the government for help. The
authorities concerned should come out
with plans to encourage increased use
of concrete products. Fortunately, for
the manufacturers the signals towards
this end are already visible. There has
been rising emphasis on using precast
components. The increased use of con-
crete blocks and products in large-
scale projects such as integrated realty
townships, high-rise projects, highway
projects and SEZs has also come as
good news for manufacturers.
 Communication Feature
Building Trust through Quality Focus
B
uildtech India Corporation (BIC)
is a leading producer of a wide
range of cement paver blocks,
designer tiles, shot blasted pavers, kerb
stones and concrete blocks. Apart from
manufacturing, as a service provider, the
company also undertakes laying con-
tracts for paving blocks and exterior
tiles. Its commitment to high quality, along
with cost-effective and sustainable solu-
tions has made BIC a preferred choice
since its inception in 2008.
The versatile produce range
offered by Buildtech finds varied appli-
cations. The cement paver blocks from
Buildtech are ideal for both domestic
and commercial pathways and drive-
ways. They are sturdy, do not break,
enhance the aesthetic value of drive-
ways and pathways, while also being
easy to maintain. Cement paver blocks
used for external floors are in great
demand owing their unbeatable com-
bination of aesthetics, durability and
economy.
The company also manufactures
designer paver blocks, which are
made in addition with white cement.
The designer paver blocks add to the
Designer Pavers
Designer Tiles
268 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Cement Paver
looks of buildings, while also being
durable and long lasting. Some of the
paver block types/shapes offered by
BIC include, Trihex, Dumble (I shape),
Barbeque, Unipaver (zigzag) and
Hexagon. These paver blocks come in
various sizes including (a) Light Use -
40mm width, which are used as side-
walk pavers, garden walk pavers, swim-
ming pool side walks, footpaths, cycle
path, etc, (b) Medium use- 60mm
width- used typically in open restaurant
area, hotel drive area, farm house drive
road, shopping malls, parking lots, rail-
way stations, etc, and (c) Heavy Use-
Kerb Stones
Shot Blasted Paver
80 mm width, used for applications
such as factory compounds, petrol
pumps, industrial floors, bus terminal,
warehouses, etc.
Buildtech's shot blasted pavers are
the preferred choice for several appli-
cations. Use of high quality materials pro-
vides the shot blasted pavers with opti-
mal level of durability and makes them
last long. Application areas of shot blas-
ted pavers include, exteriors and open
spaces like foot-paths, side-ways, garage,
parking, open areas, promenades,
swimming pool decks, building com-
pounds, verandah, etc, to mention only a
few, where good finish, anti-skid prop-
erties or textured look is desired.
BIC also offers a range of kerb sto-
nes, known for their sturdy construction
and endurance, which are used as kerb
elements to demarcate roadway edges,
pedestrian pavements, footpaths and
the likes. They are also used for adding
style and grace to the floors as well as
the pavement areas buildings or a con-
fined area.
BIC is also one of the leading manu-
facturers of concrete blocks, hollow blo-
cks and solid blocks. Environment-fri-
endly in nature, these blocks are ideally
suited for the construction of both com-
mercial and residential buildings.
For further details:
Buildtech India Corporation
No. 8/16, 2nd Floor, Round Building,
Anna Nagar West Extension,
Chennai - 600101,
Mob: +91-9840084687
E-mail: info@buildtechcorp.in
Web: www.buildtechcorp.in
 Communication Feature

DURAboardHD100:
Bitumen Free Joint Filler
filler board, closed-cell joint filler mate-
rial available in the board or sheets
form. It is very light weight. This makes
it very easy to handle and install. Being
polymer based, it is rot proof and bac-
teria resistant.
The striking features of 'DURAboard
HD100' are:
Ajay Mohta
General Manager, Construction Accessories Division,
- Bitumen free - can be cut into any
The Supreme Industries Ltd size with a normal knife
- Excellent recovery of 95 percent
- Isolation joints in machine founda-
tion.
The construction industry across
the world, is witnessing a tremendous
boom. And India is no exception!
Government polices and expenses on
infrastructure have helped the sector
grow at higher levels, and the same
pace is likely to be seen in the coming
years too. This industry comprises of
many components, including con-
struction of heavy and civil engineering

A
n expansion joint is an assembly after compression up to 50 percent (highways, bridges, railway tracks, air-
designed in-order to safely - Polymer based – hence it won't dete- ports, etc.), real estate (both residential
absorb the heat-induced expan- riorate also over a long period as well as commercial) development,
sion and contraction of various con- - Resilient and does not distort under and specialized construction products
struction materials, to absorb vibration, normal load from wet concrete (such as architectural products, electri-
to hold certain parts together, or to - Non-staining cal connections, decorative items, etc.)
allow movement due to ground settle- The 12th plan (2012-2017) envis-
'DURAboardHD100' can be used in:
ment or earthquakes. ages a massive $ one trillion invest-
Throughout the year, building - Expansion joints in building, con- ment into infrastructure development
faces, concrete slabs and pipelines crete structure thereby, providing a major boost for the
expand and contract due to the warm- - Expansion joints in concrete roads, civil construction industry. The impor-
ing and cooling through seasonal vari- parking areas, industrial flooring etc. tance of civil construction industry can
ation, or due to other heat sources. If - Joints in bridges, decks, water re- be gauged from the fact that it is the
expansion joints were not imple- taining and water excluding struc- second largest economic activity after
mented in bridges, building, highways tures etc. agriculture. With estimated investment
etc. the intense heat in the summer
would expand the metal, brick, or con-
crete materials in a structure resulting
in developing cracks and may eventu-
ally end up breaking.
Furthermore, in the winter, the harsh
cold temperatures would make the
materials contract in nature, and this
would also result in disastrous circum-
stances.
'DURAboardHD100' (formerly
SILflex/Capell HD100) is an exclusive
compressible filler board specially
designed to be used as expansion joint
filler in concrete brick, block work and
isolation joint, where is readily com-
pressible low load transfer joint filler is
required. Its excellent recovery prop-
erty makes it the most suitable product
for this application.
'DURAboardHD100' is a high per-
formance, pre-moulded compressible DURAboardHD100 in Columns

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


DURAboardHD100 in Roads
in construction pegged at 11 percent of
India's Gross Domestic Product (GDP)
– it holds huge untapped potential.
Around Rs. 15,099.84 billion is likely to
be invested into the infrastructure sec-
tor over the next five to ten years in seg-
ments such as power, roads, bridges,
city infrastructure, ports, airports, tele-
communications – this is expected to
give impetus to the construction indus-
try nationwide.
The role of organizations like
Supreme Industries in supporting the
construction industry has become pro-
minent and critical. Exposure to world-
class expertise and advent of global
players has led to infusion of new mate-
rials, equipment and technologies in
the construction practices in India.
However, quality along with cost-effec-
tiveness remains a serious challenge.
Moreover, the gap between the re-
quirements of the construction industry
and solutions available remains unful-
filled.
The Supreme Industries Ltd, foun-
ded in 1942, pioneered many path-
breaking products in the country and
became trendsetters in plastic prod-
ucts by introducing many advanced
solutions for various applications and
industries. Ajay Mohta, General Manager,
Construction Accessories Division, the
Supreme Industries Ltd, talks about the
company's star brand, 'DURAboard
HD100'.
The construction accessory divi-
sion of Supreme has developed cus-
tomized solutions, specifically for the
construction requirements of various
segments. “All our products have been
developed after continuous research
and understanding the needs of the
changing demands of the new-gene-
ration constructions. Many of these
products have been pioneered by
Supreme,” he said. He further explained,
“A case in point is the creation of a low
compression set filler board
'DURAboardHD100' especially for
expansion joints application, to replace
less effective bitumen board based
solutions.
“The division offers new generation,
better alternative products to conven-
tional materials like rubber, metals, and
wood, thus being cost effective. The
'DURA' ranges of products are manu-
factured from virgin raw material and
we do not use any CFC / HCFC gases.
www.masterbuilder.co.in · The Masterbuilder - July 2013
Communication Feature
At every stage of the manufacturing pro-
cess, a stringent quality check method-
ology assures the reliability of the prod-
ucts,” he added.
However, Ajay Mohta, raised his
concerns over use of old specification
of bitumen by some government orga-
nizations. “They still hesitate to use new
generation products,” said worried
Mohta. Using bitumen based boards
and cork sheets, which disintegrate
over a period of time, absorbs water
and hardly recovers once compressed
- it defeats the purpose of application. It
absorbs water and oozes bitumen
thereby staining the structure.
Supreme has a number of satisfied
customers (government, semi- gov-
ernment and private) who have
stopped using and recommending bitu-
men boards/ corks sheets after under-
standing the benefits of 'DURAboard
HD100' concludes Ajay Mohta.
For further details:
The Supreme Industries
Mobile No.: 09831020808
E-mail: dura@supreme.co.in
Web: www.supreme.co.in
271
 Communication Feature

Crack Injection System

A
s a principle, the grouting injec-
tions systems should be
selected based on the crack or
cavity width. The following materials
can be selected from the MC-
Bauchemie Range:
a) For cracks ≥ 2mm width Centricrete
b) For cracks > 0.2 to 2mm width
MC-DUR 1264 Epoxy System
Centicrete is a ready to use, Hy-
draulically Setting, Polymer Modified
Waterproof grout for injection and filling
of cracks and cavities. Centricrete
injection grout is produced with care-
fully selected water repellent and silici-
fying chemical compounds and inert
fillers to achieve varied characteristics
like water impermeability, non-shrinkage,
free flow, etc. Centricrete creates an
integral waterproof barrier and prevents of application varies from simple brush with MC-Bauchemie, Germany. MC-
water penetration and rising damp- treatment to sophisticated two compo- Bauchemie (India) Pvt. Ltd. is an ISO
ness. Centicrete injection grout is suit- nent pressure injection machines. The 9001: 2008 certified Company.
able for gravity as well as pressure application time of MC-DUR 1264 de-
grouting. This grout is pumpable when pends on the amount of resin mixed and For further details:
the water-powder ratio is about 0.45 to the ambient temperature. The mixing MC – Bauchemie (India) Pvt. Ltd.
0.50 i.e. for 30 Kgs Centricrete, 13.5 to ratio of Resin to Hardener is 100:18 Pbw. 411, Arenja Corner, Sector 17, Vashi,
Navi Mumbai - 400703,
15 litre of water. MC-Bauchemie (India) Pvt. Ltd. Ph:+91-22-27892856/27880803,
MC-DUR 1264 is a two component, manufactures these products along with Fax:+91-22-27893870,
low viscosity Epoxy injection resin for E-mail: Info.india@mc-bauchemie.com
a host of other Construction Chemicals Web: www.mc-bauchemieindia.com
structural repair of cracks. This method in technical and financial collaboration

Key Performance:
Ÿ Dimensional Stability Ÿ Fast Setting
Ÿ Quick Drying Ÿ Rapid Hardening
The Solution For:
Ÿ Excellent Mechanical Performance Ÿ Rapid
Return to Service Ÿ Crack free Application
The worldwide reference for Example of Applications:
calcium aluminate technology Ÿ Precision Grout Ÿ Concrete Repair Mortar
Ÿ Road Repair Mortar Ÿ Tile Adhesive and Grout
in drymix mortars Ÿ Waterproofing Mortar Ÿ Waterstop
Ÿ Self-leveling Flooring

www.kerneos.com

The Wait is finally over Kerneos is the ONLY BIS certified company for Sales & Promotion of Calcium Aluminate Cement in India.

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

 Communication Feature

A Unique Dry Powder

Mixer from Toshniwal

D ry powder blending is at the heart of many processing

industries today. However, it still remains to be the least
understood of all the processes. Mixing and blending of dry
ingredients occurs frequently in building materials such as:
- Dry Mortar
- Construction Chemicals
- Renders
- Wall Plasters
- Wall Putty (Dry)
- Floor Screeds
- Skim Coats
- Blended Cement
However, the uniqueness of each individual product
formulation, usually mean that no two blending processes
are ever the same.
From the basic blending of two similar materials to the
blending of many different ingredients with different charac-
teristics, today's mixers have a wide variety of possible
applications. Although mixing and blending technology has
greatly improved over the years with the advent of modern
blenders that are now capable of mixing of all kinds of
powders the process of selecting the best blender and the
correct overall system design of a specific application, still
remains an art form owing to the many variables involved.
Given today's “Lean Manufacturing “ environment, it has
become imperative for one to carefully consider blending
times, equipment flexibility, Product segregation i.e
demixing of the blended product in post blending.
Toshniwal Mixer
Toshniwal offers the
innovative Norwegian
technology mixer which
is an absolute test pro-
ven mixing efficiency for
manufacturing the buil-
ding material product.
The mixing quality is
extremely good, and
mixing time for most applications is very short about 30
seconds. Due to the very short mixing time high throughput
can be achieved, the influence of shear is negligible.
M/s. Toshniwal Systems & Instruments Pvt. Ltd.,
267, Kilpauk Garden Road, Chennai - 600 010, India
Phone No: 91-44-26445626 / 26448983
Email: sales@toshniwal.net / Web : www.toshniwal.net

www.masterbuilder.co.in · The Masterbuilder - July 2013 273

 Communication Feature

Interarch's Contribution to
Aviation Sector in India and Abroad

S
ince the inception in 1982, the
company has been instrumental
in the aviation sector. The very
first project for Interarch was the IGI T2
in New Delhi. Interarch was the first
company to introduce window cover-
ings through their product TRAC and
first one to introduce engineered metal
roofing and cladding systems. Interarch
entered into infrastructure projects as it
bagged the largest order for turnkey
supply of one-of-its-kind composite
roofing system and pre engineered
roof structural system for the Indira
Gandhi International Airport Terminal-
3, New Delhi which was completed in
2010.
For airports, the prime concerns,
Project Snapshot: Delhi Cargo Services Centre
functionally and aesthetically, are usu-
ally the large clears span framing can buildings, Air plane hangars, Cargo
be easily made in steel. Steel is also and freight stations, warehouses, fire
faster in construction in comparison to station buildings and roof and ceiling of
other materials and less disturbance at buildings.
site, which further results in faster con- Some of the Nitty-gritty's that worked
struction resulting in early occupancy & in favor of the application in steel were,
early return on investment. For large Smaller manageable parts no mat-
storage of cargos, vertical multistory ter how large the final structure - Helps
steel buildings and retrieval system, logistics and reduces transport costs
steel helps in faster storage and deliv- Bolt-On assembly - All sections are
ery. Steel can offer highest architectural designed to align perfectly during Project Snapshot: Delhi Cargo Services Centre
flexibility in design and fabrication. assembly
The product has been successfully Ready to build - Shaped, welded
applied for various steel structures and tested for designed load condi-
under this sector, like Airport terminal tions

Building Location Indra Gandhi International Airport, New Delhi

Building Usage Cargo Warehouse-ground + 2 multistory building
Area 25000sqm
Length in meters 366m Air Deccan Hanger
Width in meters 102m
Height in meters 22m
Key Features Ÿ 22m height
Ÿ 3 level multi storey warehousing built entirely in pre-engineered steel
Ÿ 1:40 roof slope with Tracdek Standing Seam roof system (virtually flat roof)
Ÿ Each floor designed for 150 MT/ Sq M DL + LL and for forklift movement
Project Snapshot: Delhi Cargo Services Centre DAIL IGI T3 Terminal

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

 Communication Feature

Indian Airlines Air Cargo Warehouse

Jet Airways Air Cargo Warehouse
Spice jet Air Cargo Warehouse
Delhi Cargo Service Warehouse
Air Deccan Aircraft Hangar
HAJ Terminal
Shri Mata Vaishno Devi Shrine Board Helicopter Hanger
Star Track Terminals Warehouse
Delhi Cargo Terminal 3 Air Cargo Warehouse
Airport Haj Terminal Haj Terminal Building
Nagpur Airport Roofing
Hyderabad International Airport Roofing&False Ceiling System
Taj Flight Kitchen
Delhi Airport False Ceiling System
Bagdogra Airport False Ceiling System Manufactured to endure - Speciali-
Mumbai Airport False Ceiling System zed coatings and treatment available
Bangalore Airport False Ceiling System for longevity
Chennai Airport False Ceiling System Shipped smart - Smart logistics and
shipment synchronized with construc-
Guwahati Airport False Ceiling System
tion requirements at project site.
Bhopal Airport False Ceiling System
Raipur Airport False Ceiling System For further details:
Lilabari Airport False Ceiling System Interarch Building Products Pvt Ltd
Agartala Airport False Ceiling System E-mail: info@interarchbuildings.com
Web: www.interarchbuildings.com
Major Projects Executed

www.masterbuilder.co.in · The Masterbuilder - July 2013 275

 Communication Feature
Industrial Overhead Doors:
Making the Right Choice
G
andhi Automations Pvt Ltd is
considered an industry leader
in the field of entrance automa-
tion systems and loading bay equip-
ment in the country. The company
offers a wide range of products that
includes, high speed industrial doors,
sectional overhead doors, dock level-
ers & dock shelters, aircraft hangar
doors & shipyard doors, motorized roll-
ing shutters, tail lifts & scissor lifts and
boom barriers & gates. One if its spe-
cialties are automatic industrial over-
head doors, the ideal solution for all
industrial needs. The weather resistant
industrial doors offer maximum safety
and best use of transit openings.
The compact size of the automatic
industrial overhead doors leaves more
available space both inside and out-
side the premises. These overhead
doors ensure a better use of inside
space as the side runners vertically
Sectional Overhead Doors
276 The Masterbuilder - July 2013 · www.masterbuilder.co.in
move the door along the wall and paral-
lel to the ceiling. The doors are installed
above the opening, thus ensuring a
better use of the transit opening.
Other top features of the automatic
industrial overhead doors from Gandhi
Automations include:
- Easy and practical to open and
operate: As these doors slide verti-
cally, stopping in the proximity of
the ceiling, they blend in with the
architectural features of the build-
ing. Their compact size ensures
more available space both inside
and outside of the premises. The
doors are also easy and practical to
use, especially if the original Ditec
motors are used.
- More environmental control: Heat
insulation and soundproofing
ensured by heat-insulated panels
improve working conditions on the
Sectional Overhead Doors
premises and ensure energy sav-
ings.
- Light and aesthetically pleasing
environments: The panels can also
be manufactured with the addition
of practical portholes or full alu-
minium sections featuring polycar-
bonate or unbreakable glass pan-
els, wire meshing or air grilles.
- They add value to the premises and
meet all requirements: The design
and different solutions offered
ensure the door to be aesthetically
pleasing and perfectly suited in any
architectural environment – from
modern and traditional industrial
buildings to fine commercial build-
ings. The doors can meet any
industrial and commercial require-
ment and add value to the building
they are installed on. These doors
are built to ensure the highest ease
and flexibility of use which, in turn
ensures a quick, hassle free and
accurate replacement of old doors.
- Reliability: All products are affixed
with a CE mark.
For further details:
Gandhi Automations Pvt Ltd
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
 Events

Growing Opportunity in India's

Construction Sector Draws Global Attention
Unprecedented international & local response for mega building & construction
show organized by FICCI, Ministry of Urban Development and DMG events

S
purred on by the boom in the real
estate segment which accounts
for nearly 43% of the construc-
tion spend, India's growing construc-
tion industry is attracting a large num-
ber of global players. According to a
PwC report prepared for the organizers
of The Big 5 Construct India, the real
estate sector is forecasted to grow at a
CAGR of 3.6% during 2012 to 2016,
with a total market for this segment dur-
ing this period estimated to be US$ 380
billion (approx. ` 22,800 crore)
To provide a platform to the large
number of international manufacturers
keen on entering the Indian construc-
tion market, FICCI (Federation of Indian
Aptly, the show focuses on “build- “Construction in India offers
ing products and construction technol- huge potential to those looking
ogies." As in other industries, wide- to develop and expand their
spread deployment of advanced tech-
business, and The Big 5 Con-
nology products is helping the con-
struction industry to improve quality,
struct India Show is a perfect
timeliness of project delivery and per-
formance as well as to address long
term sustainability and environment
related concerns.
The Big 5 Construct India show will
feature a staggering range of the latest
local and international building mate-
rial and construction products with sev-
eral companies exhibiting their prod-
ucts for the first time in India. These Muhammed Kazi
products include innovative technolog- Project Managar, The Big 5 Construct India

Chambers of Commerce and Industry), ically advanced polyurethane products

the Ministry of Urban Development, Gov-
ernment of India (MUD), and dmg events
are organizing a mega building & con-
struction show in Mumbai from 2nd to
4th September this year at the Bombay
Exhibition Centre. The show has evoked
overwhelming response and has received
confirmations from 10 international
country pavilions, including Germany,
Italy, Spain, Turkey, UK, Iran, Greece,
Taiwan, Korea & China. In addition, lead-
ing companies from countries like India,
Thailand, Japan, UAE, Oman, Vietnam,
Singapore, France, Australia, etc have
confirmed their participation.
Emerging technology trends are
redefining the Indian construction
industry and taking it to the next level
globally. Technology is emerging as a
catalyst of change as the industry grap-
ples with challenges like escalating pro-
ject costs and prolonged construction
periods. Technology holds the key to
address these issues and enables the
sector to react to changing market con-
ditions effectively and efficiently.
for water proofing, flooring and roofing;
the super stretch and wrap ultimate
multipurpose rescue tape that could be
used to fix virtually anything; and seam-
less sculptural wall surface designs,
seamless contemporary resin floorings
and decorative resin wall panels.
“We have participated in other edi-
tions of The Big 5 in other parts of the
world and they all offered us many
opportunities to showcase our prod-
ucts and promote our business. This
time too we plan to exhibit our range,
including rebar, wire rod and heavy sec-
tions. We believe that this event will be
good for our business, knowing that it
is taking place in a market that is grow-
ing every year and poised for excep-
tional growth. Other benefits of being at
the show include making direct contact
with our end customers and network-
ing with new ones,” said Mr. Moham-
med Al Afari, AVP Emirates Steel.
“Construction in India offers huge
potential to those looking to develop
and expand their business, and The
Big 5 Construct India Show is a perfect
place to cultivate new opportunities in
the region”, said Muhammed Kazi, Pro-
ject Manager, The Big 5 Construct India.
A series of free seminars and panel
discussions will complement the show
floor activity providing participants with
up-to-the-minute information, trends
analysis and best practice case stud-
ies to improve the decision making pro-
cess and encourage investment. The
Big 5 Construct India show will be held
at the Bombay Exhibition Centre, Gore-
gaon, Mumbai from 2nd to 4th Sep-
tember 2013.
The leading names supporting the
event are as follows: Platinum Partner:
Emirates Steel; Associate Partner:
ARC; Seminar Partner: Tekla Stone;
Pavilion Partner: CDOS; Knowledge Part-
ner: PwC.
For more information contact
Angelique Botes,
Marketing Manager, DMG Events
Tel: +971 4 4453770
Email: angeliquebotes@dmgeventsme.com

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

 Communication Feature
Hitech Concrete Solutions Chennai:
A State-of-the-art Concrete Testing Center
C
hange is the only constant goes
an old adage and nowhere is it
more applicable than in the case
of concrete. The concrete of today is no
longer just a combination of water, ce-
ment and aggregates. While the produc-
tion formula may be still simple, the pro-
duction process has undergone a sea
change, what with the increase in demand
for specialized concrete such as self-
compacting concrete, temperature con-
trolled concrete, fibre-reinforced con-
crete, etc. Stringent quality standards are
also dictating the way concrete is pro-
duced and used. Testing of concrete
therefore, has emerged as a key area in
the construction industry globally. India is
no different. As the country builds its
infrastructure, concrete testing is a field
that has now gained importance.
One name that has made rapid strides
in the field is Hitech Concrete Solutions
Chennai Pvt Ltd, an NABL accredited Lab-
oratory in Chennai. A consulting com-
pany, it specializes in providing solutions
to various concreting issues through in-
situ and laboratory testing. Its founders
are structural engineers with over two de-
cades of experience in various non-de-
A host of non-destructive and partially destructive testing equipments are available at
Hitech Concrete SolutionsChennai
280 The Masterbuilder - July 2013 · www.masterbuilder.co.in
structive testing techniques, as well as
concrete technology. The company which
offers solutions in the areas of concrete
technology and non-destructive testing
(NDT) for quality related issues has its
state-of-the-art laboratory located in
Chennai.
Focus Areas
Formerly known as NDT Consultancy
& Services, most of the equipment was
already in place when Hitech Concrete
Solutions was formed. “After the forma-
tion of Hitech Concrete Solutions, a num-
ber of equipments for NABL conformity
were acquired by us,” pointed out Dr. K.
Balasubramanian, Managing Director of
the company. According to him, the com-
pany's main focus area has been NDT.
Hitech Concrete Solutions is also into
suggesting appropriate repair methodol-
ogy with BOQ based on NDT. Material
testing and concrete design mixes are its
other areas of concentration. Hitech Con-
crete Solutions is also into training of site
engineers in the areas of concrete tech-
nology and waterproofing. Going into
details behind the training initiative,
Balasubramanian explained, “Initially
We have signed an MOU
with CSIR-SERC for possible
out-sourcing of consultancy.
This will also help in under-
taking more R&D and S&T-
related related initiatives for
the industry.
Dr. K. Balasubramanian
Managing Director
Hitech Concrete Solutions Chennai Pvt. Ltd.
when we started, we didn't want to enter
into any rat race with others. Since I had a
strong exposure to the power sector,
what I started to do was to go into the sec-
tor and offer training to their site engi-
neers. This helped in being some kind of a
stepping stone”. The company also allows
students on a selective basis to use the
lab facilities for their Post Graduate thesis.
In addition to this, it encourages con-
struction chemical companies to use its
lab facility and Balasubramanian further
added that BASF is one of its regular clients.
Hitech Concrete Solutions got its
NABL accreditation recently in April, 2013
in the areas of NDT and Mechanical test-
ing(testing of construction materials
including bricks and blocks and steel re-
bars). Other significant milestones achi-
eved by the company include signing of
an MOU with CSIR-SERC for possible
outsourcing of consultancy, which would
help it undertake more R&D and S&T
related initiatives.
Infrastructure
Sound infrastructure has been a cor-
nerstone of Hitech Concrete Solution's
 Communication Feature
The cement lab is temperature and humidity controlled for conducting various tests on cement
as per relevant Indian Standards.
success story. The company's premise in
Chennai has a cement lab, concrete lab,
chemical lab and NDT lab. A host of non-
destructive and partially destructive test-
ing equipments can be found in the labs.
The cement lab is temperature and
humidity controlled for conducting various
tests on cement as per relevant Indian
Standards. The concrete lab is equipped
with pan mixer, vibrating table, various
workability measurement devices and an
accelerated concrete testing chamber. A
The company caters to several sectors such as power, institutional buildings & factories, infrastructure
projects and marine structures.
282 The Masterbuilder - July 2013 · www.masterbuilder.co.in
3000 kN cube Compression Testing
Machine (CTM) and a 1000 kN Universal
Testing Machine (UTM) for the testing of
cubes and steel rods can also be found in
the concrete lab. The concrete lab is also
having facilities for testing of the various
constituent materials of concrete, viz.,
fine and coarse aggregate. The lab can
give economical concrete design mixes
based on trial mixes for the various
grades and using mineral admixtures.
The chemical lab is equipped with
state-of-the-art facilities with Fume Cup-
board to evaluate the chemical composi-
tion of reinforcing steel rods and water.
For non-destructive and partially-destruc-
tive testing, Hitech Concrete Solutions
has equipments such as Ultrasonic Pulse
Velocity (UPV) Tester, Rebound Hammer,
Profometer, Half Cell Potential Measuring
Device, Rapid Chloride Penetration
Tester (RCPT) and Pile Integrity Tester.
The company caters to several sec-
tors such as power, institutional buildings
& factories, infrastructure projects and
marine structures. Some of its top clients
include names such as Larsen & Toubro
Limited, Gammon India, Reliance Infra-
structure, Lanco Infratech, JMC Projects,
ITD Cementation, NCC Limited, BGR
Energy Systems, Bridge & Roof, CCCL,
Soma Infratructure, Afcons, Panduraga
Energy, Coastal Energen Power Corpora-
tion, KSK Mahanadi Power Company
Limit, Sterling Resorts, NABARD, Orchid
Chemicals, Lafarge Concrete, Ultratech
Concrete, Marg etc. to mention only a few.
Some of the major projects which it has
been associated with include, Amarkantak
Power Project at Korba, Sasan Ultra Ther-
mal Power Project, CMRL, Vizhinjam
Port, DGNP, Vizag to mention only some.
As part of its future plans, Hitech Con-
crete Solutions has lined up some inter-
esting initiatives. Going into details about
them, Balasubramanian said, “One of the
emerging opportunities is in the field of
testing of epoxies and other testing re-
quirements of construction chemical com-
panies. Long term monitoring of infra-
structure like bridges in collaboration with
SERC and IIT is another domain that we
are looking at for the future”. Third party
auditing of quality structures and soil test-
ing are the other areas which are high on
its agenda for the future.
For Further details
Hitech Concrete Solutions
Chennai Pvt. Ltd.,
(NABL Accredited Laboratory as per
ISO/IEC 17025: 2005)
#64, Galaxy Road,
Ponniyamman Nagar,
Ayanambakkam, Chennai- 600 095.
Mobile: +91 99404 55530 /
+91 99403 88556/ +91 44 2653 0060
Web: www.hitechconcrete.in
 Construction Chemicals: Industry Analysis
The Indian Construction Chemicals Market:
Building a Sustainable Future
M.K. Prabhakar, Associate Editor
C
onstruction chemicals in India
are assuming greater signifi-
cance with the surge in residen-
tial and commercial construction due
to urbanization and emphasis on infra-
structure. The Indian construction com-
munity is gradually realizing the impor-
tance of enhancing the performance
and durability of buildings and struc-
284 The Masterbuilder - July 2013 · www.masterbuilder.co.in
tures. However, the construction chem-
icals industry in India is still in a nascent
state with the per capita consumption
of construction chemicals being low in
comparison to countries from Europe,
North America, and even Southeast Asia.
India's penetration levels are 50% lower
than China's penetration and 70% lower
than the developed world.
Market Drivers
According to a report by FICCI, the
construction chemicals market has in-
creased from ` 1,400 crores in 2007 to
` 3,100 crores in 2012. The Indian con-
struction chemicals market has shown
a strong growth rate of 17% per annum
historically and is expected to grow at a
CAGR of 19.49 percent over the period
 Construction Chemicals: Industry Analysis

2012-2016. The market revenue for the
Indian construction chemical's market
is expected to reach up to USD 1.13
Billion by the end of 2018.
A large part of this number is attrib-
uted to the growing awareness amongst
the community architects, builders, con-
tractors and owners - that construction
chemicals help in improving the quality
and performance of construction over
a longer period. Architects and consul-
tants have realized the importance of
quality construction chemicals, and they
generally tend to specify trusted brands
of construction chemicals.
The entry of foreign players in the
construction chemicals sector has also
accelerated the growth of the construc-
tion chemicals sectors. Big players are
investing efforts and manpower on edu-
cating contractors and builders on the
significance of construction chemicals.
Local R&D labs have been with an aim
to manufacture products suitable for
local conditions at affordable prices.
This has led to a subtle shift in the con-
tractors from being price conscious to
quality conscious with respect to con-
struction chemicals. And with increased
emphasis on need for affordable hous-
ing, urbanization and heightened invest-
ments in infrastructure by the govern-
ment, the demand for construction che-
micals in the future only seems brighter.
Market Split
Construction chemicals can be
classified into product categories ad-
mixtures, waterproofing systems, seal-
ants, flooring, tiling and repair & reha-
bilitation etc. There are also other mis-
cellaneous construction chemicals,
which can be used to enhance con-
struction activities.
"In Inida it is necessary to make
products that are suitable to the
local conditions because the
needs are extremely specific"
Thierry Bernard
Global CEO, Chryso
According to a report, the Indian
construction chemicals market is fore-
casted to witness exponential growth,
especially in its admixtures segment in
the next five years. In 2012, the admix-
tures and waterproofing systems con-
stituted more than 60% of the overall
construction chemicals market reve-
nues. Concrete admixtures accounted
for 42% of the total construction chemi-
cals market, while flooring and water-
proofing chemicals had a share of
14%each. Other segments include sea-
lants, grouts and adhesives, which to-
gether account for 18% of the total con-
struction chemicals market. The share
of flooring is high in the Indian market
as compared to the developed world
while the country has a lower share of
tiling, sealants and waterproofing. More
than 80% of the construction business
is from new built structures & buildings.
Market Players
The construction chemicals market
is fairly consolidated with the top play-
ers accounting for more than 50% -
60% of the market. 70% market is con-
trolled by organized sector. The rest
comprises of small and unorganized
players. 300 companies are estimated
to be operating in this segment. How-
ever, there is considerable fragmenta-
tion of individual products and applica-
tion areas. India's construction chemi-
cals market is highly competitive with
just top five companies accounting for
almost 50% market revenues in 2012.
The key vendors dominating this
market space are BASF, Fosroc, Pidilite,
SWC-Chryso, Sika, CICO, Penetron,
Vandex, Techny Chemy, MC-Bauchemie,
Cera Chem and STP. Several interna-
tional players have entered the Indian
construction chemicals market and
investing heavily in local R&D industry
as even though the market does not
make extensive use of construction
chemicals at present, the sheer size of
its potential and ongoing urbanization
makes it attractive.

Spending on Concrete
Admixtures ( $/m3)

India China USA According to a report, the Indian construction chemicals market is forecasted to witness exponential growth,
especially in its admixtures segment in the next five years

www.masterbuilder.co.in · The Masterbuilder - July 2013 285

 Construction Chemicals: Industry Analysis
Environment friendly materials such as water-based coatings, green coatings, The major industry players are in-vesting a lot in R&D activities in order to develop high
and insulation coatings are required for the constructing of green buildings value and low cost products to cater to the price sensitive Indian market.
R&D and Innovation
The major industry players are in-
vesting a lot in R&D activities in order to
develop high value and low cost prod-
ucts to cater to the price sensitive Indian
market. Current and prospective regu-
latory guidelines incentivizing energy-
efficient and green buildings will drive
demand for suitable, innovative protec-
tive coatings and safe chemicals. As a
result of the increasing focus on energy
conservation and eco-friendliness, the
need for green buildings and green
products has increased across indus-
tries in India. Environment friendly mate-
rials such as water-based coatings,
green coatings, and insulation coat-
ings are required for the constructing of
green buildings. For instance, insula-
tion coating on the roof and walls of a
building act as an insulator, providing a
cooling effect, which reduces energy
consumption and the load on air condi-
tioners. The emergence of eco-friendly
construction chemicals is one of the
emerging trends in the construction
chemicals market in India. Silicone-
based based construction chemicals
are also gaining rapid popularity.
Chryso, a key international French
specialist in construction systems, re-
cently set up its center in India, spread
over approximately 5000 square feet
now, with a provision for extension ac-
ross the total area of 10000 square feet
in the future. The R&D center is aimed
at customization of products specific to
286 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Indian conditions. The R & D center
boasts of latest pieces of equipment on
the cutting-edge of technology. Some
of the repertoire includes instruments
for testing of concrete admixtures,
waterproofers, technical mortars, and
cement additives. Concrete mixer with
speed controller to replicate the speed
of a transit mixer is key equipment.
Other instruments and facilities in the
laboratory include moister analyzer,
digital viscometer, pullout bond tester,
colour comparator, hardness tester,
humidity chambers, epoxy / pre-paint
dispenser, spectrophotometer, FTIR to
mention only some. One of the primary
"Manufacturers have the
responsibility of incresing the
awarness level on 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 Pvt. Ltd.
areas of focus in the center will be
development and upgradation of con-
crete admixture for ultra-high strength
concrete M80 and above, using poly-
carboxylate technology. Another key
area of concentration will be develop-
ing concrete admixtures to encounter
thixotrophic nature. Some of the other
focus areas include development of
aesthetic concrete, water proofing mem-
branes, PU & Epoxy base, flooring &
coatings and technical mortars, etc.
Pidilite's construction chemicals di-
vision has introduced several innova-
tive products under the Dr. Fixit brand
during the year - Dr. Fixit Low Energy
Consumption (LEC) systems for high
end waterproofing coupled with insula-
tion for terraces and walls, Dr. Fixit
Extensa, a high end puncture-proof
waterproof coating for roofs & base-
ments and Dr. Fixit Bathseal Kit, a solu-
tion for comprehensive and long last-
ing waterproofing for bathrooms. Pidilite
has an innovation center in Singapore,
which focuses exclusively on green
coatings that can lead to lower con-
sumption of electricity and therefore,
eventually leading to an important con-
tribution to green buildings. Building can
use heat insulation coatings on the roofs
or the walls. Coatings, such as Dr. Fixit
Heatshield, provide a cooling effect and
acts as an insulator, resulting in the re-
duction of air conditioning loads. This
naturally has an impact on the energy
conservation and eco-friendliness.
 Construction Chemicals: Industry Analysis
Product Categories Market Split
18%
12%
14%
14%
Vandex offers a well-rounded port-
folio of coatings for protecting structures
from water penetration such as diaph-
ragm walls or elevator shafts, under-
ground garages or swimming pools.
Vandex cementitious products for drin-
king water retaining structures are de-
signed to provide a sea of application,
exceptional resistance to leaching, pro-
tection from contamination and easy-
to-clean surfaces.
As part of its marketing initiatives,
BASF has rolled out its Master Builders
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.
Samir Surlaker
Managing Director, MC-Bauchemie (I) Pvt. Ltd
288 The Masterbuilder - July 2013 · www.masterbuilder.co.in
42%
Admixtures
Flooring
Waterproofing
Repair & Rehabilitation
Miscellaneous
Solutions brand in India - a compre-
hensive portfolio of varied specialty
BASF brands to construction industry
majors, all under one umbrella. The
portfolio of products and services mar-
keted under the Master Builders solu-
tions brand embraces chemical solu-
tions for new construction, maintenance,
repair and renovation of buildings and
infrastructure: concrete admixtures, ce-
ment additives, chemical solutions for
mining and tunneling, waterproofing,
concrete protection and repair prod-
ucts, grouts and high-performance flo-
oring products. This is expected to fa-
cilitate better access to the market and
strengthen the awareness of the con-
struction industry on our existing range
of products and offerings. The intro-
duction of Glenium technology by BASF
India in the admixtures segment is
expected to drive its market share in
the next five years.
In order to further strengthen its strong
customer-orientation and develop and
offer innovative solutions to the con-
struction industry customers in South
Asia, BASF recently announced the
opening of a new Construction Tech-
nology Center in Mumbai, India. The
new center will support joint develop-
ment with customers for new product
applications and formulations, provid-
ing an excellent venue for enterprises in
the sub-region to embrace world-class,
cutting-edge technologies in partner-
ship with BASF's technical professionals.
Challenges
Despite several players in the in-
dustry, the end user market is still suf-
fers from low awareness levels on the
application and benefits of construc-
tion chemicals. Low awareness levels
among contractors about the technol-
ogy and application of construction
chemicals hampers the growth of the
industry.
While major players of the industry
impress upon the need for the skill and
know-how to the end-user and are will-
ing to provide their teams for guidance,
training and support, there is a dearth
of skilled workers and technical exper-
tise in the industry. It also does not help
that the current civil engineering curric-
ulum and syllabus in colleges and uni-
versities do not devote much attention
to the significance of construction
chemicals on the structure and perfor-
mance of buildings.
The Indian construction chemicals
market is highly cost-conscious. The
customers demand the best quality at
very low prices and sometimes use
low-cost substitutes that may not per-
form under severe conditions. Decisions
are taken based on immediate cost not
on overall cost of ownership (life-cycle
“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
 Construction Chemicals: Industry Analysis
Despite several players in the in-dustry, the end user market is still suffers from low awareness levels on the
application and benefits of construction chemicals
cost) basis. Margins are lower because
most contractors prefer low-cost chem-
icals to reduce the overall construction
cost. High value products have limited
demand and are used only by premium
construction houses.
There are no established standards
for construction chemicals unlike other
countries where guidelines about prod-
uct performance are clearly laid out.
Furthermore, due to lack of standards
and low entry barriers, several low value
products are being sold in the market,
thus hindering the growth of the industry.
290 The Masterbuilder - July 2013 · www.masterbuilder.co.in
Future Outlook
The Indian construction chemicals
market has been termed as the “sun-
rise industry” and the term seems ap-
propriate at this juncture. The Indian
construction industry is expected to
witness a surge in the next decade and
with increasing levels of awareness about
the role and significance of construc-
tion chemicals in building sustainable,
durable and eco-friendly structures, the
growth of the Indian construction chem-
ical industry seems inevitable.
Industry Initiatives: CCMA
In 2012, the manufacturers for
construction chemicals in India came
to-gether to form the Construction
Chemicals Manufacturers Associa-
tion (CCMA) in 2012 with the aim of
promoting and accelerating the
growth of construction chemicals in
India and act as a forum to communi-
cate with the government bo-dies,
associations, chambers of commerce
and other commercial industrial and
public bodies within or outside India.
CCMA has also urged Construction
In-dustry Development Council ( CIDC)
to work with CCMA on skill develop-
ment of craftsman involved in the
application of construction chemi-
cals across India, improving specifi-
cations and creating awareness at
front-line engineers, jointly organize
CC awareness workshops across
India for all end users and influen-
cers, assist and guide CCMA to de-
velop a syllabus on basic usage of
construction chemicals and take up
and address the issue of imported
raw materials at the chemical indus-
try forum.
The market players have realized
that continuous training and educa-
tion about new technologies in con-
struction chemicals is the need. Most
of them are individually organizing
meets and workshops for their deal-
ers, distributors and other stakehol-
ders. These workshops include on-
site training to educate construction
contractors about the benefits of
using superior construction chemi-
cals, in terms of lower project com-
pletion time and ease of usage, pro-
viding technical trai-ning to workers
about appropriate usage of these
chemicals in construction will ensure
correct application and better result
and correct usage of chemicals.
Many of the big players have dedi-
cated applicator care cell, which
helps them in providing the right kind
of solutions for their problems. Pidilite
has set up a not-for-profit organiza-
tion called Dr. Fixit Institute, which
imparts training to contractors, appli-
cators, engineers and students on a
continuous basis.
 Waterproofing
Advanced Multipurpose Waterproofing
Coatings
Sameer R.Bhore, Project Manager, Multichem Group, Mumbai
I
t has been reported that heavy rains
and a burst geyser or water pipe are
one of the most damaging disasters
to a building. Waterproofing a building
plays a pivotal role in preventative risk
management. It is cheaper to outlay
money before damage is caused as
opposed to outlaying money after dam-
age has been caused.
The waterproofing should be made
mandatory for all structures and should
not an optional one. The approach to
waterproofing problem must be con-
ceptual and the selection of appropri-
ate material and proper diagnosis of the
problem and employing the right appli-
cator for executing the job is equally
important.
Waterproofing is as important as
any other parameter involved in design-
ing a structure. It is because water-
proofing also plays a vital role towards
the durability concrete as well as the
safety o the structure.
Fig. 1: A Leaking Basement
Waterproofing Methods
Water is most destructive weather-
ing element of concrete structures; water
continues to damage or completely
destroy more buildings and structures
than natural disasters. Waterproofing
techniques preserve a structures integ-
rity and usefulness through an under-
standing of natural forces and their effect
during life cycle.
What is Waterproofing?
“ Is the formation of an internal or
278 The Masterbuilder - July 2013 · www.masterbuilder.co.in
external membrane which is designed
to prevent water from entering or
escaping the concrete. Internal mem-
branes are created with waterproofing
admixture. External membranes are
applied to the surface of the concrete
nearly always on the positive side.”
External membrane is divided into
two sub categories: fluid applied mem-
branes and sheet applied membranes.
There are few types of the most com-
monly use system of waterproofing in
construction industry.
- Cementitious water proofing
- Liquid waterproofing membrane
- Bituminous coating
- Bituminous membrane
- Polyurethane liquid membrane
Cementitious waterproofing:
Cementitious waterproofing is often
used in the internal wet areas such as
toilets. Most of the time the type of
cementitious waterproofing is semi-
flexible, some even toward rigid type. It
is still good to use because internal toi-
lets are not exposed to sunlight and
weathering and so it do not go through
the contraction and expansion process
continuously
Liquid waterproofing membrane:
Liquid membrane is a thin coating
which consists of usually a primer coat
and two coats of top coats. It offers
more flexibility than the cementitious
types of waterproofing. The elongation
properties of the coating can reach as
high as 1000%. But the durability of the
waterproofing coating also depend on
what type of polymer the manufacturer
use for the making of the liquid water-
proofing.
Bituminous coating: Bituminous
waterproofing coating is made of bitu-
men based materials and it is not suit-
able for expose to sunlight. It becomes
very brittle and fragile when long expo-
sure to the sunlight unless it is modified
with more flexible material such as poly-
urethane or acrylic based polymers.
The flexibility of the finished products
always depends on the solid content of
the polymer added to the bitumen.
Bituminous membrane:
Bituminous waterproofing membrane
have torch on membrane and self adhe-
sive membrane. Torch on membrane is
the more preferred one use because of
its shelf life and ease of use during
application.
The self adhesive type must be use
fast as the bonding properties of the
membrane is reducing through time.
Very often applicators find the self adhe-
sion membrane already lose its bond-
ing properties when they want to apply.
Therefore, they have to use one addi-
tional primer to prevent the debonding
problem in the near future.
Torch on membrane have exposed
and covered types. Exposed mem-
brane often has mineral granular
aggregate to withstand the wear and
tear of the weathering and the other
types of membrane, contractor need to
apply one protective screed to prevent
the puncture of the membrane.
But one has to be very careful when
applying the protective screed which is
often cement mortar. The cement ratio
has to be high and the mixing has to be
thorough through out the process.
There is premixed type of cement mor-
tar in the market available for use for
better quality and consistency. Site mix
usually will compensate the quality of
the finish work but the cost is always
cheaper compared to premixed mor-
tar.
Polyurethane liquid membrane:
Polyurethane is also use for the flat roof
area and exposed to weathering but it
is expensive. It can offer higher flexibil-
ity. Polyurethane is very sensitive to
moisture content present, therefore
before application; one has to be very
careful evaluating the moisture content
 Waterproofing
of the concrete slab. Otherwise peeling
or debonding easily observed after
some time.
Waterproofing Technology
Hydrophilic vs. Hydrophobic:
Hydrophobic or water repellent prod-
ucts repel the water by increasing
hydrophobility. they reduce absorption
but are not enough to resist significant
of water pressure.
Fig. 2: Hydrophobic
Hydrophilic chemicals absorb and
utilize water to catalyze and react with
cement particles to produce elongated
crystalline structurers.they physically
block pores, cracks and ITZ to suffi-
ciently resist the penetration of water
under pressure.
Fig 3: Hydrophilic
Such type of waterproofing prod-
ucts is commonly called catalytic
waterproofing by crystallization, e.g.
Hydronil range of products, manufac-
tured by Multichem.
Positive and Negative-side
Waterproofing
Positive side waterproofing: When
referring to the positive side of water-
280 The Masterbuilder - July 2013 · www.masterbuilder.co.in
proofing application. We are talking
about the side where the water will be
coming in contact with the concrete.
The opportunity to waterproof the posi-
tive side is mostly there only during con-
struction.
Fig. 4: Positive Side Waterproofing
Negative side Waterproofing:
Negative side waterproofing is applied
to the inside (dry) face of a structure (or
outside of reservoir); Easy access to
the dry side makes negative side
waterproofing the first choice for reme-
dial projects.
Fig. 5: Negative Side Waterproofing
Multichem Group Provides You
Advanced Waterproofing Coatings
MULTIGUARD IW+: an integral
waterproofing product - It is always
better to add waterproofing additive in
fresh/green concrete and plaster
before they are casted/applied. Such
additives give excellent waterproofing
properties inside the body of the mass,
because of creation of cohesive mix
and internal waterproofing barrier.
Such additives are called Integral
waterproofing compounds. Multiguard
IW+ falls into this category and impart
corrosion protection to rebars along
with leakage protection.
LeakShield: LeakShield is a single
component polymer modified
cementitious high performance water-
proofing coating for concrete protec-
tion. LeakShield forms a dense, water-
proof surface barrier. It consists of
Portland cement, well-graded quartz
sand and active polymer enhanced
special chemical ingredients (with
nano technology), making a hard and
flexible membrane.
LeakShield can be used for rigid
waterproofing of water tanks, sealing
internal basement and cellar walls
against dampness, water leakage, pro-
tection of concrete structures in marine
environments, external tanking of sub-
structure concrete such as foundations
and basement walls in new buildings.
The product can withstand positive
side water pressure up to 8 bar/atm
water pressure. For terrace or exterior
waterproofing protection, product
comes in white, gray, and multiple of
colours.
Hydronil: Waterproofing of con-
crete structure by Catalytic
Crystallization
Waterproofing of rigid structures
such as basement, water tanks, swim-
ming pools, can be best protected by
catalytic crystallization based water-
proofing products. Hydronil range of
products, give near to permanent pro-
tection to the lifetime of structure. They
become part of body of concrete,
hence absolutely no chance of dam-
age by external activities. Structures
waterproofed with Hydronil products
can withstand 17 atm water head.
RainSHIELD™: Elastomeric
Waterproofing coating - RainSHIELD™
is water based high solid elastomeric
coating utilizing the latest advances in
acrylic and polyurethane technology.
Highest quality resins are combined
with reinforcing laminar pigments, an
effective biocide packages and non-
migrating fire retardant, resulting in
superior durability, weatherproofing,
ultraviolet resistance, algae/mildew
resistance and fire retardancy.
RainSHIELD™ is highly reflective, ther-
mal insulating, permanently flexible,
breathing membrane, allowing mois-
ture vapour from the substrate or build-
ing interior to escape while remaining
impervious to mass water penetration
form the exterior.
 Waterproofing

Unique Features:
- Superior Flexibility, Hardness and
Solvent Resistance.
- Bridges substrate crack up to 2mm.
- Long term crack resistance.
- Superior freeze/thaw resistance.
- Self curing.
- Very low shrinkage.
- Non-toxic and environmental
friendly product.
- Unique anti-fungus and anti-algae
properties
- Superior exterior durability and UV
light resistance.
- High temperature stability.
- Low temperature flexibility down to
–15˚c.
- Dirt pick-up resistance.
- Excellent adhesion to polyurethane
foam and many other substrates.
Fig 7
- High reflectivity which reduces wall
surface temperatures, thereby pro- thane technology. Highest quality res- available in high tensile strength ver-
longing wall life and reducing inte- ins are combined with reinforcing lami- sion for roof areas subject to heavy
rior temperatures. nar pigments, an effective biocide maintenance traffic, severe weather
- Easy application by spray, brush, or packages and non-migrating fire retar- conditions, chemical fallout etc.
roller-thus lowering application dant, resulting in superior durability, Uses:
costs. weatherproofing, ultraviolet resistance, - Cured concrete substrate (Flat or
- Low toxicity and order. algae/mildew resistance and fire sloping)
- Simple water cleanup for manufac- retardancy. ROOFSHIELD® is highly - All metal roofs
turers and contractors. reflective, thermal insulating, perma- - Polyurethane foam, Asphalt shin-
ROOFSHIELD®: Elastomeric nently flexible, breathing membrane, gles, EPDM, Hypalon, bitumen etc.
Waterproofing coating allowing moisture vapour from the sub- - Wood
ROOFSHIELD® is water based high strate or building interior to escape - Old buildings
solid elastomeric coatings utilizing the while remaining impervious to mass Conclusion:
latest advances in acrylic and polyure- water penetration form the exterior. It is Waterproofing of structure is as
important as any other construction
related activities of the project. In fact,
waterproofing will make structure more
durable and long lasting. It is also
equally important that different prod-
ucts should be chosen as per the
waterproofing requirement, e.g.
Basement is best protected by crystal-
line based technology and roofs are
protected from water and heat by using
elastomeric coatings. These coatings
can last for more than 15 years.

For further details:

Multichem Group
1, Mahavir Gaurav Building, M.D. Kini
Marg, Bhandup Village, Bhandup (E),
Mumbai - 42
Ph: +91-22-25669137, Mob: +91-9323890195,
E-mail: info@multichemgroup.net
Web: www.multichemgroup.net
Fig 6:

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

 Showcase
High Performance Liquid Membrane Series
Launched
S
TP Limited is one of the leading
names in the Indian waterproof-
ing and protective coatings mar-
ket. The company has a widespread
dealer network spanning the length
and breadth of the country. STP had
recently organized its annual North India
Regional Associates Meet. The meet,
held at the Tivoli Garden Hotel in New
Delhi, saw the enthusiastic participa-
tion of 200 leading Point of Sales (POS)
dealers from North India.
The company has always focused
on receiving feedbacks from its associ-
ate network, consisting of distributors,
dealers or applicators, in a bid to con-
stantly improve upon its product range.
STP has been an R &D led innovative
company endeavoring to deliver value
for money to its customers. The meet
saw STP launch its 'Liquid Membrane'
series.
An interactive-session, during which
there was a demonstration of onsite
application of the products, was one of
the highlights of the meet.
Addressing the associate during
the meet, Mr.K.P.Shrivastav, Chief
Executive Officer of the company
remarked, “ In our endeavor to establish
STP as the most preferred brand and
delivering value to our customers, STP
shall continue to invest in core R & D to
maintain its leadership position and to
deliver quality products at competitive
prices."
The following are the products
Mr. K.P.Shrivastava Addressing to the Gathering
278 The Masterbuilder - July 2013 · www.masterbuilder.co.in
launched by the company under the
Liquid Membrane series during the
occasion:-
TarFelt LM - Water Based Bituminous
Liquid Membrane
TarFelt LM is a single component;
water based elastomeric polymerized
bituminous emulsion with selected
graded fine fillers and some additives.
TarFelt LM is applied by brush / roller
without any use of heat. TarFelt LM forms
a tough, elastomeric, monolithic, seam-
less water proofing membrane.
ShaliUrethane LHM - Single Component
Elastomeric Modified Polyurethane
Waterproofing Membrane
ShaliUrethane LHM is a single com-
ponent modified polyurethane elastomeric
liquid applied waterproofing membrane
coating. It forms a seamless water-
proofing membrane by reaction with
atmospheric moisture. This confirms to
ASTM C-898-2009, C-836-2012 codes.
ShaliCryl RWP - UV Resistant Heavy
Duty Liquid Acrylic Roof Waterproofing
ShaliCryl RWP is an unique elastomeric
heavy duty terrace waterproofing liquid
membrane system composed of spe-
cially developed highly elastic and
resilient acrylic polymers, properly
selected and graded fillers, light fast
and weather durable pigments,
microfibers, additives and best quality
fungicidal in water medium. It is used
as liquid applied waterproofing mem-
brane for all type of building terraces.
New Product Launch
Having a unique UV cross-link curing
mechanism, ShaliCryl RWP becomes
more durable with age.
ShaliUrethane BTD - Single Component
Elastomeric Bituminous Polyurethane
Liquid Membrane
ShaliUrethane BTD is high perfor-
mance water based cold applied
elastomeric coating. This unique single
component system is ready to use
material based on PU modified bitumen
emulsion.
ShaliCryl 215 - Single Component UV
Resistant Elastomeric Exterior Coating
ShaliCryl 215 is a unique elastomeric
high build coating based on a revolu-
tionary acrylic polymer with quick-set
capabilities to resist premature mois-
ture attack. ShaliCryl 215 provides dura-
bility, flexibility, and excellent weather
resistance. Because of a unique UV cross-
link curing mechanism, ShaliCryl
becomes more durable with age. It is
easy to apply and is environmentally
safe and non-polluting. ShaliCryl 215
has inherent waterproofing qualities as
well.
ShaliBond APP - Cold Applied Adhesive
APP Membrane
ShaliBond APP is pressure applied,
synthetic rubberized adhesive with
bonding strength designed specifically
for cold application of modified bitu-
men membranes. ShaliBond APP
membrane adhesive has superior
bonding strength and high flexibility to
accommodate temperature related
expansion and contraction.
STP also introduced a virtual self-
adhesive - TarFelt APP in combination
with ShaliBond APP, on the occasion.
For further details:
STP Limited
707 Chiranjiv Tower 43 Nehru Place,
New Delhi - 110 019
Ph: +91-11-46561359, Fax: +91-11-46561358
E-mail: info@stpltd.com
Web: www.stpltd.com