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Phone: +91 44 28555248
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Two of India's most respected building design, engineering and construction pro-
Editor-in-Chief
fessionals recently passed away, leaving behind a legacy through their work that K.P. Pradeep
forever will touch the lives of generations to come. It is difficult to imagine India's editor@masterbuilder.co.in
built infrastructure without the contributions of these two extraordinarily talented Editor-in-Charge
men who devoted their lives to their profession of Architecture and Structural Engi- Ravi Damodaran
neering, respectively. Editor
Nigel Narayan
Charles Correa, legendary architect who is credited for the creation of modern
architecture in post-Independence India died June 16 at the age of 84. He burst Associate Editors
M.J. Krishna, M.K. Prabhakar, Sonjoy Deb
onto the world scene by conceptualizing of a new strategy for restructuring the city
of Bombay by opening up the mainland directly across the harbour. Correa was a Head - Content Development CE,
Infrastructure & Environment
truly global phenomenon who designed structures in several countries including Sadagopan Seshadri
USA, Malaysia, Saudi Arabia, Singapore, Canada and Portugal, with a majority of
Contributors
his projects being in India. The liveliness of his designs was reflected by the varied Bhavani Balakrishna, Priya,
nature of his iconic buildings: low-cost apartments, office buildings, museums, Chaitanya Raj Goyal, Snehal Joshi, P. Priya
churches, legislatures, new townships, and scientific institutes. Vice President Marketing
H. Usha Devi
C.R. Alimchandani, CMD, STUP Consultants, who died July 12 at the age of 80, was
a legendary figure in India's engineering circles and an international expert on pre- Head-New Media Initiative
Pradeep Nair
stressed Concrete Technology. He was active professionally and socially through-
out his career. Finance
R. Prema
- Past President of IE(I) 1985; Fellow of Indian National Academy of Engineering Manager Digital Production
from 1987; Played a pivotal role in establishing The International Federation for K. Sravanthi Kiran
Structural Concrete (FIB) in India. Manager Digital Media
- Winner of Gold Medal by the Japanese Construction Industry at the fib 2002 Con- Lakshmi Rahul
gress; International Award of Merit in Structural Engineering by IABSE in 2004; Creative Head
FIP Medal in 1986 in recognition of his work in Prestressed Concrete. S. Nithiyanandam
Production Manager
The organization that he led stands today as a true Indian multinational with over Caroline D'sylva
1200 professionals in more than 20 global project locations.
Digital Production Assistant
I, along with many other friends from the industry, believe that Charles Correa and R. Anand
C.R. Alimchandani will continue to remain the face and voice of modern architec- Subscription & Circulation Team
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 CONTENTS

Editor's Comment.............................10

Advertisers Index..............................16

78 ROLLER COMPACTED CONCRETE

Construction of Roller Compacted Concrete Dam:
A Case Study at Batu Hampar Dam
Classification Index..........................18
Assrul Reedza Zulkifli, Abdul Rahim Abdul Hamid,
Mohd Fadhil Arshad, Juhaizad Ahmad
News & Events..................................20
Cover Picture: Credit: www.archikey.com

46 PRECAST BUILDING: DESIGN PROVISIONS

Structural Connections for Precast Concrete Buildings -
78 ROLLER COMPACTED CONCRETE
Construction of Roller Compacted Concrete Dam:
Review of Seismic and Other Design Provisions in A Case Study at Batu Hampar Dam
Various International Codes - An Overview Assrul Reedza Zulkifli1, Abdul Rahim Abdul Hamid2,
C.A Prasad1, Pavan Patchigolla2 Mohd Fadhil Arshad3, Juhaizad Ahmad4
1,4
1
Director, METEY Engineering & Consultancy Pvt. Ltd. Faculty of Civil Engineering, Universiti Teknologi MARA,
2
Structural Engineer, METEY Engineering & Consultancy Pvt. Ltd. Shah Alam Selangor, Malaysia
2
Faculty of Civil Engineering, Universiti Teknologi
Malaysia Johor Bahru, Malaysia
3
Institute Infrastructure Engineering and Sustainable Management (IIESM),

54 RMC PLANT: CERTIFICATION

In Quest of Quality Concrete
Universiti Teknologi MARA, Shah Alam Selangor, Malaysia

Vijay Kulkarni, Technical Adviser,

Quality Council of India and Former President - ICI
86 CONCRETE: AGGREGATE REPLACEMENT
Study on Mechanical Properties of Concrete with Various Slags as
Replacement to Fine Aggregate
60 CONCRETE: RECYCLED AGGREGATES
Potential Use of Recycled Coarse Aggregates in Concrete
Ramagiri Anudeep1, K.Venkata Ramesh2, V. SowjanyaVani3
1
Post Graduation Student, Master of Technology
(Structural Engineering and Natural Disaster Management),
Subhash C. Yaragal , Vivek V B, M Padmini, M Jacob,
GITAM University, Visakhapatnam
J Niveditha1, Anil Kumar Pillai2 2
1 Professor, Department of Civil Engineering, GITAM University, Visakhapatnam
National Institute of Technology Karnataka, Surathkal 3
2 Assistant Professor, Department of Civil Engineering,
The Ramco Cements Limited
GITAM University, Visakhapatnam

66 CEMENT: CSB
Performance of Calcium Silicate-Based Carbonated
Concretes vs. Hydrated Concretes under 92 CEMENT: UFNSP
Influence of Ultrafine Natural Steatite Powder on Setting
Freeze-Thaw Environments Time and Strength Development of Cement
Jitendra Jain, Ph.D.,1, Vahit Atakan, Ph.D.,2, K. Sudalaimani1 & M. Shanmugasundaram2
Nicholas DeCristofaro, Ph.D.,3, HyunGu Jeong4, Jan Olek, Ph.D.,5 1
Department of Civil Engineering, Thiagarajar College of Engineering,
1
Sr. Research Scientist, 2Director, Research and Development, Thiruparankundram, Madurai
3
Chief Technology Officer, Solidia Technologies®, 2
Department of Civil Engineering, Kalasalingam University, Srivilliputhur
4
Graduate Student, 5Professor, Purdue University, West Lafayette, Ind.

70 CONCRETE: CURING
102 DRY MIX MORTAR
The Masterbuilder | July 2015 | www.masterbuilder.co.in

Planning for Hot Weather Concreting Ramco Drymix Range: Innovative Solutions for
Non-Structural Applications

74 SILICA FUME
Silica Fume for High Rise Buildings 106 Dry Mix Mortar: A Trend that's Catching On

78 204

148 178
12
 CONTENTS

108 PLASTER SYSTEM

Mechanized Spray Plaster System - Perlcon Giema - 166 HIGHWAY REPAIR
Highway Repair Systems
The Only Way Forward

113 FABRIC FORMWORK: CASE STUDY

Costa Concordia Salvage Operation
172 REPAIR AND RESTORATION
Heritage Conservation: It's Not Only About
Architectural Conservation

118 Perdido Norte Pipeline Separation

178 REPAIR & REHAB
Fiber Reinforced Polymers
Muralee Balaguru, President, Green NanoFinish LLC

120 MANUFACTURED SAND

Manufactured Sand

168
Dr. Aswath M U, Professor and Head Department of Civil Engineering, WATERPROOFING
Bangalore Institute of Technology
Waterproofing Products for Complete Protection of Home

128 INTERACTION
Manufactured to Perfection:Engineered Sand Delivered On-Site
192 AWARDS
Tata BlueScope Steel's DURASHINE® Brand Recognised as
Asia's Most Promising Brand

142 Hilti TE800-AVR is a Tool Made for India

- Nitin Katyal, Sales Director, Hilti India

194 CONCRETE: UHPC

Ultra-high Performance Concrete (UHPC) Premix
198 Keeping Tiles Damage Free

132 CASE STUDY

Post Earthquake Findings of Damaged Buildings in Nepal 204 CONCRETE: WATERPROOFING
Waterproofing as a System - Practical Considerations and
Waterproofing with Cementitious Systems
Sunny Surlaker, Head - Admixtures Division
MC-Bauchemie India Pvt. Ltd.

138 CUSTOMER TESTIMONIAL

Successful Waterproofing of Flat and Domed Roofs

COMMUNICATION FEATURE

146 CONCRETE: REPAIR & REHAB

Sulphate Attack in Concrete & Mortar
112 Gandhi Automations Loading Bay Equipment
The Masterbuilder | July 2015 | www.masterbuilder.co.in

148 FOCUS: ADMIXTURES

Creating Durable Concrete with Admixtures
164 MC-MISCHOEL AEA: Mortar Plasticizing and Air Entraining Agent

164 DICHTAMENT DS – FLEX: Flexible Waterproofing System

152 CONCRETE: FLOORING SYSTEM

Innovative Flooring Systems
182 Setting New Standards in Precast Products with SFRC Technology

158 RETROFIT: CASE STUDY

Development of Retrofit Scheme for Deficient
Post Tensioned Flat Slab by Using Post Tensioned 196 Portland Slag Cement (PSC)
Carbon Laminates for Large Commercial Premises
Dr. Mangesh Joshi1, Sagar Patil2, Manish Yadav3

202
1
CEO, 2Structural Design Engineer, 3Project In-charge (Execution)
1,2,3
Sanrachana Structural Strengthening Pvt. Ltd. (SSSPL), Thane, India Gandhi Automations Working Towards A Green Tomorrow
14
 CONTENTS

Advertisers Index
A H RDC Concrete (India) Pvt. Ltd. 57
20 Microns Ltd. 173 Hilti India 143 Reliance Industries Ltd. 185
Abcon Concrete Surgeons Pvt. Ltd. 203 Hitech Scaffolding Pvt. Ltd. 209 Relyon Facility Services Pvt. Ltd. 207
ACECON-2015 220 I Rithka Alcheme 211
Action Construction Equipment Ltd. 183 Robert Thomas Metall-und
ICI-NDC (workshop on Formwork
Ajax Fiori Engg. (I) Pvt. Ltd. 89 & Scaffoldings) 221 Elektrowerke GmbH &Co., KG 203
Akemi Technology India Pvt. Ltd. 141 Igloo Tiles 53 Robo Silicon Pvt. Ltd. 31
Alpha High-Tech Polyurethanes 211 Interarch Building Products Pvt. Ltd. 8 S
Ambico Found Ocean Grouting Services 115 S.N. Enterprises 145
J
Ammann Apollo India Pvt. Ltd. 9 Sanrachana Strutural
Japeva Engineering Pvt. Ltd. 21
Strengthening Pvt. Ltd. 135
Apollo QGM Zenith Concrete Block
Equipments LLP 39 JB Formwork Systems 207 Shri Parijatha Machinery Works Pvt. Ltd. 187
Asian Laboratories 165 JBA Concrete Solutions 127 Sika India Ltd. 65
Asons Enterprise 33 Jindal Aluminium Ltd. 175 Silicone Concepts Int'l Pvt. Ltd. 139
ASV Enterprises 211 JK Cement Ltd. 17 Southland Constructions (India) Pvt. Ltd. 197
Atul Fasteners Ltd. 179 JSW Cement Ltd. Back Inner Sreevatsa Stainless Steel 211
B K Sriyani Designers 163
BASF India Ltd. 15 Kasturi Metal Composites Pvt. Ltd. 197 STA Concrete Flooring Solutions 123 / 169
Bauma ConExpo Africa -2015 215 Keltech Energies Ltd. 177 Stewols India Pvt. Ltd. 201
Bekaert Mukund Industries Pvt. Ltd. 27 Kryton Buildmat Co. Pvt. Ltd. 73 STP Ltd. 85
Bhushan Power & Steel Ltd. 49 Structwel Designers &
KYB-Conmat Pvt. Ltd. 131
C Consultants Pvt. Ltd. 167
L
CEAI -Engineeing Smart Cities 212 Suppliers to Construction
Lacrete Durakem (India) Pvt. Ltd. 19 Chemical Industry of India (CCMA) 219
CeraChem Pvt. Ltd. 81
Leister Technologies India Pvt. Ltd. 41 Supreme Bituchem India Pvt. Ltd. 207
Chembond Chemicals Ltd. 222
M Surie Polex 149
CICO Technologies Ltd. 83
Citadel Eco-Build Solutions 91 Maad Sand & Minerals Pvt. Ltd. Gatefold T

Civil - Aid Technoclinic Pvt. Ltd. Marini India Pvt Ltd (Fayat India) 155 Talrak Constructions Chemicals Pvt. Ltd. 191
(Bureau Veritas Group co.,) 29 MC-Bauchemie India Pvt. Ltd. 63 Tatabluescope Steel Ltd. 35
Concrete Solutions Trading Company 105 Metecno India Pvt. Ltd. Front inner -2 Technokotes 201
ConMech Auto Consultants Techny Chemy 151
Middle East - DMG Dubai 217
India Pvt. Ltd. 181
The Masterbuilder | July 2015 | www.masterbuilder.co.in

Multichem Industries Pvt. Ltd. 2nd Wrapper The Ramco Cements Ltd. 101 / 103
D
N The Supreme Industries Ltd. 43
Deep Foundation Institute
Conference (DFI) 216 Thermex Rebar Manufacturers'
Neocrete Technologies Pvt. Ltd. 171
Association 13
Dextra India Pvt. Ltd. 7 Nuha Construction Solutions 203
Total Global Pvt. Ltd. 69
Dow Corning India Pvt. Ltd. 111 P U
Dr.Fixit Institute of Structural
Padmaja Systems & Services Pvt. Ltd. 59 Ultratech Cement Ltd. Back Cover
Protections & Rehabilitation 209
Dura Build Care Pvt. Ltd. 161 Perlcon Premix Pvt. Ltd. 109 W
E Perma Construction Aids Pvt.Ltd 199 Wirtgen India Pvt. Ltd. 37
Elkem South Asia Pvt. Ltd. 77 Pidilite Industries Ltd. Front Inner -1 Y
EXCON - 2015 213 Precision Wire Industries 199 Yash Enterprises 193
G R Z
Gandhi Automations Pvt. Ltd. 11 Razon Engineering Co. Pvt. Ltd. 189
16

Zuari Cement 93,94,95,99,100

 CONTENTS

Advertisers Index / Classification

Aluminium Buildings Curing Compound Rolling Shutters

Jindal Aluminium Ltd. 175 Rotho- Robert Thomas Metall-and Gandhi Automation Pvt. Ltd. 11
Elektroweke Gmbh 203
Artificial Sand Roofing Fastners
Maad Sand & Minerals Pvt. Ltd. Gatefold Doors Automatic Asons Enterprise 33
Perlcon Premix Pvt. Ltd. 109 Gandhi Automation Pvt. Ltd. 11 Atul Fasteners Ltd. 179
Robo Silicon Pvt. Ltd. 31 Drymix Mortar Roofing Sheets
Cement Citadal Eco-build Solutions 91 Bhushan Power & Steel Ltd. 49
JSW Cement Ltd. Back Inner The Ramco Plaster Pvt. Ltd. 103
The Ramco Cement Ltd. 101 / 103 Sand Making Machine
Fabric Formwork Yash Enterprises 193
Ultra Tech Cement Ltd. Back Cover Ambico Foundocean Grouting Services 115
Zuari Cement - Italcementi Scaffolding
Group 93,94,95,99,100 Facility Services
High Tech Indeco Hiring Pvt. Ltd. 209
Reylon Facility Services Pvt. Ltd. 207
Concrete Admixtures JB Formwork System 207
Asian Laboratories (India) 165 Flooring
Sealants
Chembond Chemicals Ltd. 222 Dramix - Bekaert Industries Pvt. Ltd. 27
Dow Corning India Pvt. Ltd. 111
JBA Concrete Solutions 127
Concrete Aids
Kasturi Metal Composites (P) Ltd. 197 Splicing System
Concrete Solutions Trading Co. 105
Neocrete Technologies Pvt. Ltd. 171 Dextra India Pvt. Ltd. 7
Concrete Batching Plant Reliance Industries Ltd. (Recron) 185
Stainless Steel Tank
Ajax Fiory Engg. (I) Pvt. Ltd 89 Silicon Concepts Intl. (P) Ltd. 139
Easy Tanks (Sreenivasa Stainless Innovation) 211
Ammann Apollo India Pvt. Ltd. 9 STA Concrete Flooring Solutions 123 / 169
Apollo Infratech Group 39 Stewols India (P) Ltd. 201 Steel Fiber Reinforced Concrete
Concrete Block Making Machinery Chembond Chemicals Ltd. 222 Bekaert Industries Pvt. Ltd. (Dramix) 27
Sri Parijatha Machinery Works Pvt. Ltd. 187 Kasturi Metal Composites (P) Ltd. 197
Form Work
High Tech Indeco Hiring Pvt. Ltd. 209 Stewols India (P) Ltd. 201
Concrete Cutting Specialist Precision Wire Industries 199
Abcon Concrete Surgeons Pvt. Ltd. 203 Jb Form Work System 207
Geo Membrance Thermal Insulation Tiles
Concrete Demolition Equipment Igloo Tiles 53
Hilti India 143 Leister Technologies India Pvt. Ltd. 41
Japeva Engineering Pvt. Ltd. 21
Concrete Grinding and Polishing Solutions Light Weight Concrete
Keltech Energies Ltd. 177 Tmt Technology Supplier
Surie Polex 149
Thermex Rebar Manufacturers' Association 13
Concrete Restoration Metakaolin
Alpha High-tech Polyurethanes 211 20 Microns Ltd. 173 Wall Putty
JK Cement Ltd. 17
Concrete Testing Service Micro Silica
Civil Aid Techno Clinic Pvt. Ltd. 29 Elkem South Asia Pvt. Ltd. 77 Water Proofing
PEB BASF India Ltd. 15
Construction Chemicals
Interarch Building Products Pvt. Ltd. 8 Chembond Chemicals Ltd. 222
BASF India Ltd. 15
Metecno India Pvt. Ltd. Front Inner -2 Dura Build Care Pvt. Ltd. 161
Cera-chem Pvt. Ltd. 81
Tata Bluescope Steel Ltd. 35 Kryton Buildmat Co. Pvt. Ltd. 73
The Masterbuilder | July 2015 | www.masterbuilder.co.in

CICO Technologies Ltd. 83

Lacrete Durakem (India) Pvt. Ltd. 19
Dura Build Care Pvt. Ltd. 161 Ready Mix Concrete Multichem Group 2nd Wrapper
Kryton Buildmat Co. Pvt. Ltd. 73 Rdc Concrete (India) Pvt. Ltd. 57 Padmaja Systems & Services Pvt. Ltd. 59
Lacrete Durakem (India) Pvt. Ltd. 19
Repair and Rehabilitation Perma Construction Aids Pvt. Ltd. 199
MC -Bauchemie (India) Pvt. Ltd. 63
BASF India Ltd. 15 Pidilite Industries Ltd. Front Inner -1
Multichem Industries Pvt. Ltd. 2nd Wrapper
Chembond Chemicals Ltd. 222 Razon 189
Perma Construction Aids Pvt. Ltd. 199
Razon Engineering Co. Pvt. Ltd. 189 Kryton Buildmat Co. Pvt. Ltd. 73 Reliance Industries Ltd. (Recron) 185
STP Ltd. 85 MC-Bauchemie (India) Pvt. Ltd. 63 Rithika Alcheme 211
Multichem Group Front Inner -2 Sika India Pvt. Ltd. 65
Construction Machinery & Equipment Perma Construction Aids Pvt. Ltd. 199 Supreme Bituchem India Pvt. Ltd. 43
Action Construction Equipment Ltd. 183 Talrak Constructions Chemicals Pvt. Ltd. 191
Pidilite Industries Ltd. Front Inner -1
Ajax Fiory Engg. (I) Pvt. Ltd. 89
Razon Engineering Co. Pvt. Ltd. 189 Techny Chemy 151
Ammann Apollo India Private Ltd. 9 Technokotes 201
Sriyani Designers (Paradigm) 163
Appolo Infratech Group 39
Conmech Auto Consultants India Pvt. Ltd. 181 Repair & Rehabilitation & Retrofitting Water Proofing Applicators
KYB-Conmat Pvt. Ltd. 131 Service Providers Nuha Construction Solutions 203
Marini India Pvt. Ltd. (Fayat India) 155 Sanrachana Structural Strengthening Pvt. Ltd. 135 SN Enterprises 145
18

Wirtgen India Pvt. Ltd. 37 Structwell Design & Consultant Pvt. Ltd. 167 South Land Construction (India) Pvt. Ltd. 197
 NEWS & EVENTS
CONSTRUCTION EQUIPMENT
Ajax Fiori Sets up New Service & Training
Centre in Hyderabad
Ajax Fiori, one of India's leading manu-
facturers of concreting equipment (Self-
Loading Concrete Mixer, Batching Plants
and Concrete Pumps), recently opened
a state of the art Service & Training Cen-
tre of 15,000 sq. ft in Nacharam, Hyderabad
as part of its expansion plans.
The company has been serving the
infrastructure industry in India since
inception in 1992, bringing in pioneering
concepts and world class technology
concreting equipment adapted to suit
Indian environment. In line with Ajax-
Fiori's corporate philosophy of best in
class pre & after sales support to its cus-
tomers, company is widening its distri-
bution network further through addi-
tional stock & touch points, and this
facility at Hyderabad is one more step
towards this direction.
Speaking during the inauguration, Mr.
K. Vijay, Managing Director of Ajax-Fiori,
said “This facility following on the steps
of our Bangalore Service Centre shall
immensely benefit our customers in
the markets of Telangana and Andhra
Pradesh. We recall our journey two
decades back when our first batch of
self-loaders worked in irrigation pro-
jects. We have come a long way since
then and today our aim is to optimize
the economic life and productivity of our
Anand Sundaresan: New
President of the Indian
Construction Equipment
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Manufacturers' Association
(Icema)
Indian Construction Equipment Manu-
facturers' Association (ICEMA), the only
representative body for the Construction
20
machine base, hence the need of such
state-of-the art centres”.
He also added “With the renewed focus
and the promise of delivering complete
concreting solutions, we aim to
strengthen our position further among
the top two concreting equipment man-
ufacturers in India. Despite sluggish-
ness of last few quarters, we are opti-
mistic about the medium and long term
prospects of the Indian concreting
equipment Industry outlook. Today, we
take pride to inform that Ajax Fiori has
the competency and is investing further
to expand and provide more innovative
and cost-effective solutions for the con-
struction sector. Having foreseen the
product's suitability across various
applications and the increased demand
across geographies, Ajax Fiori has
ambitions to create a significant pres-
ence beyond Indian shores in the com-
ing years.”
Equipment industry in India, announced
the appointment of Anand Sundaresan,
Vice Chairman & Managing Director,
Schwing Stetter India Pvt. Ltd. and Arvind
Garg, Vice President Head Construction
& Mining business of L&T Ltd, as Presi-
dent & Vice President respectively of the
association for a period of two years with
effect from July 01, 2015. As a part of their
new role, they will be responsible for stra-
tegic initiatives of the association to achieve
its objectives and act as a catalyst for the
construction equipment industry.
Commenting on the appointment, Mr.
Anand Sundaresan said “ICEMA has been
instrumental in promoting the construc-
tion equipment industry in India that has
led to the progressive growth of our coun-
try's infrastructure. I am honored and priv-
ileged to lead this prestigious institution
and will ensure that, as President, my
expertise and experience makes signifi-
cant contribution to the growth of the con-
struction equipment industry in India.”
Mr. Anand Sundaresan comes with over
three decades of experience in various
Indian and multi-national companies. He
joined Schwing Stetter India, in 1999 as
Executive Director. He became its Man-
aging Director in January 2002 and Vice
Chairman & Managing director in 2013. As
a transformational leader, he steered the
business of Schwing Stetter India forward
by introducing best-of-breed products
backed by German technology for the Indian
construction industry.
Hitachi Announces
Production Cuts, Sights Ailing
Chinese Economy
Hitachi Construction Machinery Co. is the
latest major construction equipment
manufacturer from China to announce
production cuts to cope with the ailing Chi-
nese economy.
According to a press release from the
company, Hitachi is preparing to cut pro-
duction by about 40 to 50 percent for the
July-September quarter to push excess
stockpiles into the market as sales drop
below expected levels.
Further, industry analysts have expressed
concern that the Chinese economy shows
no signs of recovery and sales of major
equipment such as excavators will most
likely match declines in April and May.
“At this moment, it feels odd construction
plans exist but they are not being imple-
mented,” Chief Executive Officer Yuichi
Tsujimoto said at Hitachi Construction's
Tokyo headquarters earlier this week. “I
had expected demand in China would fall
but not that much.”
However, Mr. Tsujimoto said that India has
been showing signs of recovery as Prime
Minister Narendra Modi's push to develop
coal projects to secure energy supplies has
resulted in a number of queries from cus-
tomers.
He also added that the company will be
focusing more on sales of parts and after-
sales services as they plan to double their
market for such services to about 300 bil-
lion yen by March 2019.
 NEWS & EVENTS
INFRASTRUCTURE
POWER
India seeks $2 bn funding for ambitious
rooftop solar projects
The government of India is in talks with
the World Bank and the Asian Develop-
ment Bank (ADB) for a loan of USD 2 bn.
The fund would be used to provide
cheaper loans for rooftop solar projects
according to Upendra Tripathy, Secre-
tary, Ministry of New and Renewable
Energy.
India has huge rooftop solar ambition.
The Ministry aims to facilitate creation
of 40,000 MW of rooftop solar power
plants 23 per cent of the total renewable
energy target of 175,000 MW by the year
2022.
At a function held to launch a funding
scheme of the government-owned
finance company, Indian Renewable
Energy Development Agency (IREDA),
Chhattisgarh power
generation capacity
touches 16,000 MW
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Installed power generation capacity in
Chhattisgarh touched 16,000 MW in the
financial year 2014-15 and achieved the
second position, according Aman Kumar
Singh, Principal Secretary, Chhattisgarh
Energy Department. The Chhattisgarh State
Power Generation Company Ltd has been
continuously excelling in electricity gen-
eration and ensuring uninterrupted qual-
ity power supply to citizens of the state, he
said.
As per a report from the Central Electric-
ity Authority, Chhattisgarh remained in
the second position in the country in power
22
Tripathy termed the 40,000 MW rooftop
ambition “challenging” and said “ev-
eryone should help”.He added that a
survey conducted by the Ministry showed
that if all government offices put up roof-
top solar plants, they would add 1,500
MW of capacity.
The government is also getting funds from
other agencies, such as the German
Development Funding Company, KfW,
Tripathy added.
production in the previous fiscal, while it
ranked sixth in the FY 2013-14.
In 2000, when the state was formed, total
power demand was 900 MW, which has
now gone up to 3,550 MW, Mr. Singh said
adding that the number of consumers,
which was 18.91 lakh at the time, has
jumped to 41 lakh.
ReNew Power, Hareon
Solar to jointly develop
72mw-solar plant in AP
ReNew Power and Chinese renewable
energy major Hareon Solar will jointly
develop a 72 mw solar power project in
Andhra Pradesh. According to a press
release, the two companies will invest
jointly in the project that will provide elec-
tricity to more than 30,000 households and
curb 115,895 tonnes of CO2 emissions
each year.
This is Hareon Solar's first investment in
India. The company will also supply and
install its crystalline silicon solar modules
to this project, which is being developed in
Kurnool district of Andhra Pradesh. The
delivery, totaling 234,161 modules, will
begin in August 2015 and is scheduled to be
completed by December 2015. The
schedule for commissioning the project is
March 2016.
The electricity generated from the project
would be sold under a 25-year power pur-
chase agreement with the Southern Power
Distribution Company of Andhra Pradesh
Ltd.
REC modifies norms to lend to
renewable energy projects
Speaking at a conference on Green Energy
organised by the CII Ashok Awasthi, Exec-
utive Director said REC has modified its
lending norms to suit wind and solar pro-
jects. He mentioned four broad changes
in REC's lending norms for renewable
energy projects.
First, the moratorium period has been
increased from 'six months from the com-
mercial date of operation' of the project, to
one year from COD. Second, the require-
ment for collateral security has been
removed. Third, the repayment period for
the loans can now be up to 15 years. Finally,
the debt-equity ratio has been made more
liberal renewable energy projects need
only 25 per cent capital to be eligible for REC
loans and in certain cases, REC wouldn't
mind a D-E mix of 80:20, Awasthi said.
He added that REC's tweaking of the lend-
ing norms would set a precedent in the
industry and other financial institutions
would follow suit.
India to open solar
expansion programme
with $330 million aid
According to reports India will open its solar-
expansion programme this month by
 NEWS & EVENTS
INFRASTRUCTURE
offering ` 2, 100 crore to set up projects
across five states. Speaking to Bloomberg
Ashvini Kumar, Managing Director, Solar
Energy Corp. of India said that the company
will invite bids for a total of 3 gigawatts of
capacity in Gujarat, Madhya Pradesh, Uttar
Pradesh, Karnataka and Tamil Nadu.
He went on to add that that Solar Energy
Corp. will tender 700 megawatts in Gujarat,
750 megawatts in Madhya Pradesh, 370
megawatts in Uttar Pradesh and 500 mega-
watts each in Karnataka and Tamil Nadu.
India aims to set up 25 solar parks by 2019,
accounting for a fifth of the 100-gigawatt
target.
PGCIL clears ` 2247 Cr
for Green Energy
Corridor project
The Masterbuilder | July 2015 | www.masterbuilder.co.in
The Board of Directors of Power Grid Cor-
poration of India Ltd have accorded the
investment approval for 'Green Energy
Corridors: Inter-State Transmission
Scheme (ISTS) - Part - C' at an estimated
cost of ` 2,247.37 crore, with commis-
sioning schedule of 36 months from the
date of investment approval.
The Green Energy Corridor project is
aimed at transmission of renewable energy
from generation points to the load centres
by creating intra-state and inter-state
transmission infrastructure. The intra-
state transmission component is being
implemented by respective states while
28
PGCIL is executing the inter-state part.
It seeks to address intermittency and vari-
ability aspects as well as grid integration
issues of large-scale renewable energy
generation.
BHEL commissions
500 MW Thermal unit in TN
Bharat Heavy Electricals Limited (BHEL)
has successfully commissioned the second
500 MW unit at Tuticorin Thermal Power
Station (TPS). The first 500 MW unit of the
project was commissioned by BHEL in
March, 2015. Tuticorin TPS has been set up
by NLC Tamil Nadu Power Limited (NTPL),
a joint venture of Neyveli Lignite Corpora-
tion (NLC) and Tamil Nadu Generation
andDistributionCorporation(TANGEDCO).
The project is situated near the
Thoothukudi (Tuticorin) port on the shore
of the Bay of Bengal. Earlier stages of
Tuticorin TPS comprise five units of 210 MW,
all installed by BHEL in three phases
between 1979 and 1992. The BTG, Civil and
BoP order for two 500 MW sets was placed
on BHEL by NTPL reflecting the customer's
confidence in the company's technologi-
cal excellence and capabilities in execut-
ing such projects.
Naidu seeks Centre's
support for renewable
energy projects
Andhra Pradesh Chief Minister
N Chandrababu Naidu has sought the cen-
tre's support to make his state a 'model state'
in renewable energy projects including
solar and wind hybrid projects.
Chandrababu Naidu met coal, power and
new & renewable energy minister Piyush
Goyal here and discussed various issues
related to development of power and
renewableenergysectorinAndhraPradesh.
“We have discussed issues related to
development of power sector in the state,”
Goyal said after around a two-hour long
meeting with the chief minister.
Under the National Solar Mission, India has
increased its targeted solar power gener-
ation capacity by five-fold to 100Gw by
2022.
India to export 500 Mw power
to Bangladesh through
SAARC Grid soon: POSOCO
Power System Operation Corporation
(POSOCO) is confident the country would
begin to export an additional power to an
extent of 500 megawatt (Mw) to Bangla-
desh as soon as the work on SAARC grid is
accomplished in the next one year.
Addressing delegates at the National Con-
ference on 'Power Transmission and Dis-
tribution' organized by of PHD Chamber of
Commerce and Industry V K Agrawal,
executive director, National Load Despatch
Centre, POSOCO said “We could also draw
considerably higher volumes of hydropower
from nations such as Bhutan and Nepal.”
Indian government finalised a consensus
over inter-country grid connecting the
SAARC countries, which was pending for
four years, in a meeting held with the rep-
resentatives in the annual SAARC energy
ministers meeting in Delhi in October 2014.
Piyush Goyal, minister of state for coal,
power and renewable energy had then
said initial discussions would start for an
integrated power transmission grid con-
necting India with its neighbouring nations,
wherein excess production of power in one
region can be used to meet deficit else-
where.
 NEWS & EVENTS
INFRASTRUCTURE
RAILWAYS
Maharashtra govt to invest ` 10,000 cr to
develop railway infra
Speaking at the ground breaking cere-
mony of Sawantwadi Railway Terminus
in Sawantwadi district in Konkan region,
Maharashtra Chief Minister, Devendra
Fadnavis said that his government will
be invest `10, 000 Cr to develop the rail-
way infrastructure of the state.
He said infrastructure development forms
the basis of the economic development
of any state and the state government is
committed towards developing roads,
railways, airports and port network
across Maharashtra. The Chief Minis-
ter further added that the state govern-
Banihal -Katra railway
link to be completed by 2020
The railway link from Banihal to Katra,
connecting Kashmir valley with the rest of
the country, would be completed by the
year 2020. Speaking at a press confer-
ence A.K.Puthaia, General Manager,
Northern Railways said that the railway
The Masterbuilder | July 2015 | www.masterbuilder.co.in
track from Jammu to Katra has been com-
pleted and the 110 kilometers link from
Katra to Banihal is the final portion that will
be connecting the Kashmir valley with the
rest of the country.
He added that 85 percent of work involves
tunnelling and the rest was related with
bridges and all efforts are being made to
complete this project on time.
MMRC to award Works
Contract worth for 32.5Km
Metro-III Corridor in Sept
According to Ashwini Bhide, Managing
30
Director, Mumbai Metro Rail Corporation
ment will give priority to Chiplun- Karad,
Ahmednagar-Parli-Beed and Vardha-
Nanded-Yevatmal railway route which
will help connect the interiors of
Maharashtra.
(MMRC) will award contracts for civil works
worth `11000 crore for 32.5 km long Colaba-
Bandra-Seepz corridor in Sep' 2015.
The fully underground corridor will pro-
vide connectivity by Metro to Western sub-
urbs, Island city and the international air-
port. Ashwin Bhinde added that MMRC
will carry out technical evaluation by mid-
September and then award the work orders
before the end of month.
MMRC plans to complete the project by
2019. The actual work on the ground is
expected to begin in December or Janu-
ary 2016.
Centre considering Rail Bridge
linking Rameswaram and
Talaimannar
Union minister of state for road transport,
highways and shipping, Pon Radhakrishnan
revealed that the centre is considering a
proposal to establish a rail bridge linking
Rameswaram and Thalaimannar in Sri
Lanka. If the project materialises, the two
countries would be linked.
A short boat ride used to connect the rail-
way lines that ended at Talaimannar in Sri
Lanka and Dhanushkodi in India, which
was in operation till 1966. During his visit
to the city last week, the Union Minister told
reporters during an informal chat that the
BJP government is considering a proposal
to establish a bridge to connect the two
countries.
Suresh Prabhu lays Foundation
Stone for New Station Building
at Aurangabad
Suresh Prabhakar Prabhu, Minister of
Railways laid the foundation stone for
Aurangabad Railway Station New Build-
ing Phase-II” at a glittering function held
at the Station premises on, 3rd July, 2015.
Addressing the large gathering, the Min-
ister assured that Marathwada region of
Maharashtra will get due priority in the
plans formulated by the Railways. The
plans for rail development in Maharashtra
will be drawn up taking into confidence
the State Government too, the Railway
Minister added. The doubling of Railway
line project between Mudhked and
Parbhani to a distance of 81 kms has been
allocated `100 crores, he informed. Like-
wise Akola Khandwa Guage conversion
project; Beed Ahemednagar Parli Vaijanath
new Railway line project etc., in the state
willbegivenemphasis,Mr. Prabhu stated.
Expressing confidence that in spite of the
challenging times being faced by Indian
Railways, a host lot of initiatives will be
undertaken to overcome the same in the
ensuing four years, said the Minister. The
rail budget plans were put to implemen-
tation with zeal and in 36 days, 39 works
were fulfilled as assured in the budget, a
record of sorts. An online monitoring sys-
tem is in place to keep an eye on the day to
day working ofthe organisation,he informed.
 NEWS & EVENTS
INFRASTRUCTURE
ROADS
Government plans to convert national
highways into green corridors
The NDA government is planning to con-
vert 90,000 kms of country's national
highways into green corridors, for which
it intends to shortlist at least 1,000 con-
tractors who will undertake the task of
planting trees.
"We have taken a decision that one per
cent of cost in construction is for tree
plantation and other things. We are going
to create 1,000 contractors in the coun-
try. They will have their own nurseries.
They will plant new trees and create a
green area on national highways," Road
Transport & Highways Minister Nitin
Gadkari has said.
The new green policy, he explained, will
pave way for creation of employment as
PM Narendra Modi for
connectivity between new
road projects and airports
The Masterbuilder | July 2015 | www.masterbuilder.co.in
During a meeting held to review the prog-
ress of highway construction in the NE
region, Prime Minister Narendra Modi
directed officials to ensure good connec-
tivity between the new road projects and
near by airports.
He also said that the agreement for seam-
less movement of road traffic between India,
Bangladesh, Bhutan and Nepal would not
only have a profound impact on the econ-
omy of the region but would also bring ben-
efits from the environmental perspective,
by reducing travel times.
32
He urged officials concerned to explore all
well as contribute towards the economic
growth of the country.
India's road network of 33 lakh kms is
the second largest in the world and con-
sists of 92,851 kms of National High-
ways, which constitute only 1.7 per cent
of the road network but carry about 40
per cent of the total road traffic.
possibilities of innovation in the materials
andtechnologyaspectsofroadconstruction.
Finance Minister Arun Jaitley and Road and
Highways Minister Nitin Gadkari were also
present on the occasion
Mumbai to get rail,
road double-decker bridge
Mumbai will get its first double-decker
bridge on P D’Mello Road at CST that will
include railway tracks and a motorway.
Tracks on On P D’Mello Road, will be laid
at an elevated level and cars will ply above
as the Eastern Freeway will be extended
up to GPO junction.
According to reports, Central Railway has
plans to shift the Harbour line corridor to the
west of CST. Platforms between CST and
Dockyard Road station will be constructed
at the elevated level and will be equipped
with escalators. The tracks will be at least
20 ft from the ground while the Eastern
Freeway extension will be at a height of close
to 45 ft. The cost is estimated to be around
` 1,500 crore.
PMO Sets Deadline To Finish
Stalled Pink City Expressway
Prime Minister, Narendra Modi’s office has
taken special initiative to finish the Pink City
Expressway linking Delhi and Jaipur and
set an October deadline for the project.
The 225 km (140 mile) highway is still miss-
ing seven bridges, several stretches need
to be widened to the projected six lanes, and
miles of land have not yet been acquired.
The road should have opened three years
ago. KMC Constructions is the builder of
the project. Modi placed a $12.6 billion bet
in this year’s budget on road building, with
$16 billion more to be spent on railways,
looking to create jobs and boost economic
capacity.
Centre clears ` 3,500 crore
for road projects in
J&K: Altaf Bukhari
In an attempt to provide better road infra-
structure for Jammu and Kashmir the
centre has cleared two road projects worth
3500 crore in Srinagar and Jammu city.
According to Altaf Bukhari, Jammu and
Kashmir Roads and Buildings the
accomplishment of these ambitious pro-
jects would go a long way towards
decongestion of traffic movement in these
cities.
 NEWS & EVENTS
INFRASTRUCTURE
Bukhari was speaking while in a visit to
Panthachowk area of the city to review the
progress on removal of bottlenecks and
road-widening works. The Minister added
the road-widening would be completed in
this vital area within two months as most
of the chronic bottlenecks have been
already removed.
He said work is being expedited on
upgradation of Srinagar-Jammu highway
and the ambitious project is likely to be
commissioned by next year.
NHAI, PFC among 7 cos
allowed to raise ` 40,000 cr
via tax-free bonds
The government has allowed seven to
issue tax-free bonds worth ` 40,000 crore
in the current financial year that started in
April. The ceiling coupon rate for the AAA-
rated issuer of tax-free bonds has been
fixed at 55 basis points below the govern-
ment bond yield for retail investors and 80
basis points for other investors, the circu-
lar showed.
National Highways Authority of India (NHAI),
Indian Railways Finance Corporation,
Housing and Urban Development Corpo-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
ration, Indian Renewable Energy Devel-
opment Agency, Power Finance Corpora-
tion, Rural Electrification Corporation and
NTPC can issue the tax-free bonds,
according to the circular.
Centre accords NH
status to 2,000 km
roads in Odisha
The centre has accorded National High-
way status for 2,000 km of State Highways
in Odisha where ` 35,000 crore is likely to
be invested for road development. "We have
decided to link NH to Jagatsinghpur and
Jajpur on priority. Besides, a decision has
34
been taken to construct 12 NH bypasses in
Odisha", visiting Union Roads Transport and
Highways Minister Nitin Gadkari told
reporters.
Announcing that the ministry would invest
` 35,000 crore for road development in the
state, Gadkari said work for the NH pro-
jects worth ` 10,000 crore would begin
before December and the rest amount to
be spent next year.
"I have directed the National Highway
Authorities of India (NHAI) officials to pre-
pare a detailed project report (DPR) for the
proposed project works in Odisha", he said.
He said of the total 97,000 km of NH in the
country, Odisha has 4639 km of NH in its
jurisdiction. Another 2,000 km will added
to Odisha's NH list after their completion.
Govt has target to build 30 km
National Highways
every day: Nitin Gadkari
The Centre has set a target of constructing
30 km of National Highways per day within
two years and planned to spend ` five lakh
crore on road infrastructure development,
Union Minister Nitin Gadkari said.
"We have already been able to raise the
daily NH construction from two km to 14
km, registering a 7-fold rise in the last one
year. We are optimistic of crossing the tar-
get of 30 km NH construction in two years,"
Union Minister for Road Transport, High-
ways and Shipping Gadkari told reporters
recently.
Optimistic of taking up infrastructure works
in road sector in a big way in the coming
days, Gadkari claimed to have the credit of
completing Mumbai-Pune Highways in
record time and also built 55 flyovers in his
career.
"I have done it in the past and will continue
to achieve the goal," the Union Minister
claimed.
India's longest road
tunnel likely to be open for
public next year
India's longest road tunnel, being built on
Jammu-Srinagar National Highway, will
be opened for public in July 2016. The 9.2
km tunnel is part of 286 km-long four-laning
project of the Jammu-Srinagar national
highway would reduce the distance between
the two cities, Chenani and Nashri, by 30
kms. The work started on this tunnel on May
23, 2011. Road Transport and Highways
Minister, Nitin Gadkari, will visit Udhampur
to witness "the final blast ceremony" where
the National Highway Authority of India
(NHAI) engineers will drill a hole through
the final section of the tunnel.
The state-of-the-art tunnel is simulta-
neously being built from the two ends and
the NHAI teams will meet at the centre by
drilling a hole through the final section.
Once this tunnel becomes operational it
will reduce the traffic jams on National
Highway-1A that occur due to snowfall
and avalanche in winter at Patnitop. The
government statement said that NHAI is
also constructing a parallel escape tunnel
along with the main tunnel for evacuation
of commuters in case of eventuality. The
two tubes of the tunnel will be internally
connected through 29 "cross-passages".
The tunnel project will also have parking
spots after a specific distance to tow away
or shift vehicles in case of a breakdown.
 NEWS & EVENTS
REALTY
Prestige estate in talks to acquire exora business park
Prestige Estate Project is in final talks
to acquire Red Fort Capital's 62% stake
in Bengaluru's Exora Business Park val-
ued at ` 1,300 crore to ` 1,500 crore. The
transaction would be one of the biggest
in the commercial real estate sector in the
recent past. Prestige Group jointly
developed the prime office space with
Red Fort Capital and owns the remain-
square feet of built-up area and 2.12 mil-
ing 38% stake in the property. Exora
lion sq ft of leasable area. It houses com-
Business Park, located in Marathahalli,
panies such as JP Morgan Chase,
is spread over 22 acres.
Schneider Electric, Juniper Networks,
The fully leased out business park con- Price water house Coopers, Misys,
sists of three buildings with 3 million Verizon and Xerox.
Mahindra Lifespaces mulls
residential projects in AP,
Rajasthan and MP
Realty player Mahindra Lifespaces is look-
ing to promote residential projects in states
like Andhra Pradesh, Rajasthan, Madhya
Pradesh under the affordable housing
space. Elaborating about the plans,
Mahindra Lifespaces, Business Head-
Happinest, Sriram Mahadevan said the
company is looking at revised affordable
housing policies to be announced by some
States.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
According to Mahadevan the company
had sold more than 350 units of the total of
604 units in the first phase of its maiden
project in Avadi, Chennai.
Lucknow based developer
to bring Fashion TV
residences to UP
Lucknow based real estate developer New
Modern Buildwell has tied up with Paris
based International Fashion channel
Fashion TV to develop an ultra-luxury resi-
dential project in Lucknow with an invest-
ment of around ` 1,000 crore.
36
"We have got the exclusive license for
Fashion TV residences in UP, leaving aside
NCR. Our association with Fashion TV is
another step towards providing homes
which are perfect combination of luxury and
comfort," said PN Misra, founder and CEO,
New Modern Buildwell Pvt. Ltd.
The project named Fashion Homes and
will be located within 5,250 acre Sushant
Golf City and will be spread in 10 acres with
two high-rises of 29 floors each. It will offer
3 and 4 BHK homes and penthouses, in
sizes ranging from 3,500 sq ft to 6,000 sq
ft. The residences would cost between
` 1.75 crore and ` 5 crore.
"The construction of the project has started
and we aim to give possession of the same
by 2018," Mishra added.
Puneet Dalmia invests
` 50 crore in realty startup
Puneet Dalmia, managing director of
cement major Dalmia Bharat Group, has
invested ` 50 crore in a one-month-old
Delhi startup which seeks opportunities
in contract building individual homes.
The investment will give Dalmia a 74%
stake in Prithu. Nitin Bansal, its cofounder
and managing director, will hold the rest.
Dalmia made the investment in his indi-
vidual capacity.
Dalmia said in the next two-three years,
the company will invest ` 100 crore the
funds he put in and another ` 50 crore from
expected internal accruals. The startup
will initially focus on the Delhi market.
The market it is targeting is worth around
$2 billion (` 12,700 crore) in Delhi alone,
with around 10,000 transaction opportu-
nities coming up for building and redevel-
opment every year. The company is aim-
ing 1% of this to build 100-plus homes every
year. "This would give us revenue of ` 500
crore in 3-5 years," Dalmia said.
All the homes developed by Prithu will have
GRIHA (Green Rating for Integrated Habi-
tat Assessment) certification. The costing
of homes will vary from ` 2,300 per sq ft to
` 6,000 per sq ft, which will cover approvals,
architectural designing and construction.
Banks, financial services
sector lead Mumbai office
space absorption in
June qtr: CBRE
Banking, financial services and insurance
sector absorbed around 31% of total
transacted space of 1.3 million sq ft in the
country's commercial capital Mumbai
during second quarter ending June,
according to a report by CBRE. The sector
continued as the Mumbai's top corporate
real estate occupier during the quarter.
However, CBRE expects substantial office
space take-up from prominent global
information technology firms, especially
at locations such as the Bandra-Kurla
Complex (BKC) in coming quarters.
Corporate expansion strategies, especially
for back-office space requirements, drove
leasing activity in the city over the last three
months. The trend is likely to continue in
forthcoming quarters. Peripheral locations
constituted approximately 50% of the total
space take-up in Mumbai during the period,
the report said.
 NEWS & EVENTS
CORPORATE
GRFL to set up fourth inland container depot in Gujarat
Logistics player Gateway Distriparks said
that its subsidiary Gateway Rail Freight
Ltd. (GRFL), will set up its fourth inland
container depot (ICD) at Viramgam near
Ahmedabad in Gujarat. It further said
that “this will be a terminal on the con-
fluence of the two double stack routes
between Garhi Harsaru in Gurgaon
(Haryana) and two main ports on the west
coast at Mundra and Pipavav in Gujarat.”
Gateway Distriparks said the terminal
with the railway siding and container yard
will be constructed over 35 acres of land
IRB Infra bags order
worth 2650 Cr from NHAI
IRB Infrastructure Developers Ltd., one of
the largest BOT road developers in India,
declared that it has received Letter of Award
fromNHAI for the project of six laning of
Agra-Etawah bypass section of NH-2 in
Uttar Pradesh under NHDP Phase-V on
build-operate-transfer (BOT) model. The
estimated project cost of the company is
nearly ` 2,650 crores with construction
period of 910 days. The concession period
for the same is 24 years.
Lanco to start port
project work in Australia
The Masterbuilder | July 2015 | www.masterbuilder.co.in
According to a notification issued by the
Department of Environment, Australia,
the Australian subsidiary ofLanco Infratech
is expected to start construction of a port
from the third quarter of 2015. The
Department, said that Lanco Resources
Australia Pty Ltd. has proposed to under-
38
take dredging of approximately 1.9 million
and is expected to be operational within
a year. The company added that all the
necessary regulatory approvals from
Western Railway for this purpose are in
place.
cubic metres as part of the new Berth 14A
located within the Inner harbour of Bunbury
Port in Western Australia. The Bunbury
Port is an existing operating harbour.
Dredging activities are proposed to com-
mence in October and last for up to a maxi-
mum of 40 weeks. With coal resources of
approximately 1.1 billion tonnes, coal from
Griffin caters to the export markets as well.
Production at the mine during the year
2013-14 was 2.93 million tonnes while the
same was dropped to 2.3 million tonnes
during the last fiscal. The Project supports
the export of coal from the proposed
expansion of the Griffin Coal operations in
the Collie Basin through the Project. In
order to process this increased volume of
coal, new transport facilities, a handling
plant and berthing arrangements are
required at Bunbury Port to mobilize the
coal from the mine to the ship.
Holcim Ltd CEO Bernard
Fontana steps down
Swiss cement giant Holcim said in a
statement that its Chief Executive Officer,
Bernard Fontana, will step down from his
position. With the successful public
exchange offer and the expected closing
of the merger with Lafarge, Andreas Leu
and Bernard Terver will also step down
from the Holcim Executive Committee with
completion of the merger. Bernard Terver
currently responsible for Africa Middle
East as well as South Asia will assume the
position as Head of India for Lafarge Holcim
from the date of the closure of the merger.
With this capacity Terver will continue his
mandates in the Boards of Ambuja
Cements and ACC Limited in India. Holcim
has controlling stake in India firms, Ambuja
and ACC. Leu who is responsible for the
Americas, will also leave the Group with
effect from August 1. Holcim and Lafarge
had earlier announced the leadership of
Lafarge Holcim with Wolfgang Reitzle as
statutory Chairman of the Board of Direc-
tors and Eric Olsen as CEO. The mandate
of the new Board of Directors and Execu-
tive Committee will be effective from the
date of the completion of the merger.
SAIL and NSDC sign MoU
for skill development
in steel sector
Steel Authority of India Limited (SAIL) and
National Skill Development Corporation
(NSDC) signed a MoU for skill develop-
ment in steel sector. This has been signed
as a follow up to the MoU signed between
Ministry of Skill Development & Entre-
preneurship (MSDE) and Ministry of Steel
on July 10, 2015. Under the SAIL-MSDC
MoU, five thrust areas have been identi-
fied to support the above initiatives, which
are - Skill Development Centers (SDCs) at
Bhilai, Bokaro, Rourkela and Durgapur,
Skill Development Centre of Excellence
for Iron & Steel in the vicinity of IISCO Steel
Plant at Burnpur, System of Certifying and
Recognizing Prior Learning (RPL) of
workforce, Upgrading SAIL training infra-
structure and aligning with Quality Packs
(QPs)/ National Occupational Standard
(NOS) developed by Indian Iron and Steel
Sector Skill Council (IISSSC) and lastly fresh
skilling of local youth for employability.
The SAIL and NSDC MoU will support skill
development initiatives in the vicinity of
SAIL Plants for meeting the requirement
of skilled manpower and developing
industrial ecosystem of the area. There is
shortage of skilled manpower in the steel
industry particularly in advanced technol-
ogies such as hydraulics, electrics, auto-
mation, bearings, etc., in addition to lack
of skilled manpower in common engi-
neeringskillssuchasweldingandplumbing.
 NEWS & EVENTS

SUSTAINABILITY

City. It will feature environmentally friendly

Nabard to channel fund to fight climate change classrooms and lots of green space, but
its significant feature will be a 250 foot tall,
energy efficient, residential high rise dor-
National Bank for Agriculture and Rural
Development (Nabard), got an accredi- mitory building. Designed to house 520
tation from the Green Climate Fund people when it is completed in 2017, the
(GCF) - a global multilateral fund that is dormitory will be the tallest Passive House
meant to assist developing and poor building in the world. It is expected that it
countries in taking up their respective could change the way buildings are con-
mitigation and adaptation measures to structed in New York City. Meeting Passive
fight climate change. Accreditation to the House standards costs about 5% more
Nabard, means that the national finan- money than normal construction. But the
cial institution will act as a channel dormitory will use as much as 70% less
through which the GCF will deploy its energy for heating and cooling during its
resources in India. It also makes the bank Besides Nabard, the GCF has, so far, lifetime, repaying that initial cost penalty
eligible to identify communities and areas accredited 19 other institutions from many times over. It will save 882 tons of
which are most vulnerable to climate across the globe. It includes the Asian CO2 each year compared to a normal
change and submit proposals to the Development Bank (ADB), the United building. The airtight design, combined with
Fund for financial support. The funding Nations Development Programme a unique ventilator system that brings in
will support a range of activities includ- (UNDP), Germany-based Deutsche fresh air from outside, means the building
ing installation of renewable (solar, wind Bank AG, the United Nations Environ- does not need much energy in the way of a
and bio-mass) energy, enabling farm- ment Programme (UNEP) and the heating and cooling system. In the US,
ers to grow drought-resistant crops and Agence Francaise de Developpement Passive House standards are usually
reducing deforestation. (AFD) of France. reserved for single family homes, but the
Cornell dormitory may lead the way toward
applying them to larger buildings as well.
World Bank wants on a number of developing countries. Two decades ago, LEED standards that are
'substantial' pre-2020 Financing is a key dispute between rich and considered standard procedure today
developing nations, which have been nego- requires many changes to existing building
climate funds
tiating the new pact for years. Developing codes. The new building may pave the way
countries want money, to finance the costly to a more energy efficient urban future.
shift from fossil fuel-based to sustainably-
powered economies, and to strengthen
their defences against climate effects. India’s clean energy
Developing countries insist that rich nations targets ahead of others:
must show how they intend to keep a UN official
promise made in 2009 to boost climate
finance to $100 billion (91 billion euros) per United Nations Under Secretary General
year from 2020. Developing countries are and CEO for 'SE4ALL' initiative, Kandeh K
The Masterbuilder | July 2015 | www.masterbuilder.co.in

According to the Vice President and cli-
mate envoy of World Bank, Rachel Kyte,
putting money on the table for pre-2020
climate adaptation projects in poor coun-
tries, may help unlock an ambitious global
pact in December. Paris, which will host the
UN conference from November 30 to
December 11 for 195 countries to thrash out
and sign the final text on global warming.
The deal will take effect in 2020, seeking to
limit average global warming to 2-degrees
celsius (3.6-degrees Fahrenheit) over pre-
Industrial Revolution levels. According to
Kyte the impacts of climate change are
40
demanding that adaptation be given much Yumkella, said that India can lead the world
more prominence in the Paris pact. in the area of sustainable energy from
renewable sources, as its clean energy
Cornell builds target is way ahead of the UN global goal.
World's Tallest Passive India targets 175 GW of renewable energy
House Building capacity by 2022, which includes 100 GW
of solar, 60 GW of wind power, 10 GW of bio-
mass-fired power and 5 GW of small hydro
power. The UN's 'SEE4ALL or Sustainable
Energy for All' envisages making sustain-
able energy a reality for all by 2030. Power,
Coal and New & Renewable Energy Min-
ister Piyush Goyal said that the partner-
ship of UN with India will certainly lead India
Cornell Tech is building an applied sciences to become world leader in the sphere of

already having a severe economic impact campus on Roosevelt Island in New York clean and affordable energy for all.
 NEWS & EVENTS

INTERNATIONAL

reference design for all other operational

Planning permission given for China’s walking city: Report
A master plan to create a virtually
pedestrianised district of the Yuexiu
International Financial City in China has
received planning permission. Master
Plan Architect, Foster and Partners, said
that the district will have reduced num-
bers of cars and lorries with the major-
ity of vehicles relocated below ground
to create a network of pedestrian streets
above ground. It said road widths will be
kept to a minimum. The scheme includes
a series of office and residential towers,
a hotel, new public spaces, shops, cafes
and restaurants at ground level. Foster
and Partners senior executive partner
and studio head Luke Fox said that the
buildings and structures and will also be
assisting MRT Corp with the tender pro-
cess for the underground construction
package. The latter includes drawing up
tender documents, evaluating technical
submissions from tenderers and carrying
out design and technical reviews.
Poland gets €800m
funding for expressways
new urban model for Wuhan will be a
unique and exciting new destination, with
a sustainable mixture of commercial and
residential uses, but which feels famil-
iar and of its place. He added that the city
will be built in a new model rather than
creating an enclosed ‘city within a city’.

Bam and Volker Wessels win Arup appointed as design

the major Ijmuiden sea consultant for Malaysian
lock project light rail tunnel project

The European Investment Bank

A consortium of the two Dutch contract-
ing giants, was named preferred bidder
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Arup has been appointed as a design con-
sultant for the second line of the Klang Val-
ley mass rapid transport (MRT) project in
(EIB) has agreed loans totalling
€800m for the construction of the
Warsaw bypass and sections of
an expressway in Western Poland.
A €550m long-term loan to Bank
Gospodarstwa Krajowego (BGK)
will enable construction of 162.5
km of the S5 expressway, running
between Nowe Marzy, Bydgoszcz
and Mielno, and between Wronczyn
and Radomicko. The EU bank is
providing a further €250m long-

for the Ijmuiden sea lock. This will replace
the 100-year-old Northern Lock and pro-
vide access from the North Sea to the
canal running from Ijmuiden to Amster-
dam. Consortium OpenIJ – which includes
Bam, Volker Wessels and fund manager
DIF – will be responsible for design, con-
struction, finance and maintenance of the
new lock for 26 years. The lock will be 70m
wide, 500m long and 18m deep. Con-
struction will start early next year and
ships will be able to use the lock by the end
of 2019. Dredging activities will be carried
out by subcontractors Boskalis and Van
Oord. The project is one of six schemes on
42
Kuala Lumpur. The contract for Mass Rapid
Transit Corporation involves the refer-
ence design for the 13.5 underground sec-
tion. The second line, also known as the
Sungai Buloh-Serdang-Putrajaya Line (SSP
Line) will run from Sungai Buloh to Serdang
and Putrajaya, covering a distance of
52.2km. It will consist of 39 stations, 10 of
which will be underground. The elevated
section of the SSP Line is estimated to be
38.7km in length. Arup will be doing the
reference design for the 10 underground
stations and the fitting up of the Tun Razak
Exchange Station – an interchange that
will connect the Sungai Buloh-Kajang
term loan for the construction of
the 18.6 km southern section of
the Warsaw bypass between
Pulawska and Lubelska streets.
Within this project, the EIB will also
support the construction of a new
bridge across the River Vistula,
which will supplement the strained
capacity provided by the eight
existing road bridges. According
to László Baranyay, EIB vice-
president responsible for lend-
ing in Poland, this will strengthen
the economic competitiveness of
Poland and increase the quality
of life of Polish citizens.

theDutchgovernment’slocksprogramme. Line and the SSP Line. It will be producing

 PRECAST BUILDING: DESIGN PROVISIONS
Structural Connections for Precast Concrete
Buildings - Review of Seismic and Other
Design Provisions in Various International
Codes - An Overview
C.A Prasad1, Pavan Patchigolla2
Director, METEY Engineering & Consultancy Pvt. Ltd.
1
1 2 Structural Engineer, METEY Engineering & Consultancy Pvt. Ltd.
2
P
recast concrete is significantly being used in earth-
quake resisting structures in many parts of the world.
Due to the lack of understanding of the basic nature
of seismic behavior, the precast concrete structures were
viewed with scepticism in seismic regions. Some countries
considered the use of precast concrete in earthquake re-
sisting structures with suspicion because of their bad per-
formance in major earthquakes. Examples of poor behav-
ior of precast concrete building structures are during 1976
Tangshan (China), 1985 Michoacan (Mexico), 1988 Armenian,
1994 Northridge and 1999 Kocalli earthquakes due to im-
proper design and detailing of ductile element, inadequate
diaphragm action, poor joint and connection details, inadequate
separation of non-structural elements and inadequate sepa-
ration between structures. These are presented in the state-of-
the-art report by Park and co-workers (fib, 2003).
Countries like Japan, Canada, Italy, Chile, Mexico, New
Zealand and USA, which are well known for high seismici-
ty, adopt precast concrete construction practices. In these
countries, the design and construction practices are usually
supported by the results from experimental investigations.
Recent experimental investigations have mainly focussed
The Masterbuilder | July 2015 | www.masterbuilder.co.in
on developing techniques to reduce damage in structures
using precast elements. For example, with reference to New
Zealand, University of Canterbury conducted tests to design
connection details between hollow-core floors with beams
and walls that could sustain up to 6% of inter-storey-drift.
Perspective of the past:
The evolution of the precast industry in seismically active
regions of the United States and other parts of the world, with
an emphasis on the need to develop technology compatible
with precast concrete construction, are discussed and pre-
sented by Englekirk21. It was reported that precast concrete
construction is extensively used and is being promoted in
Japan on high rise buildings even though Japan is not hav-
ing a specific national design standard on precast concrete
structures. The technical justification for precast systems in
Japan is provided by experimental studies. Further research
46
on the behavior of precast concrete elements and structures
under seismic loading is reported in references 15-19.
To limit the possibility of progressive collapse and to obtain
a monolithic action, structural integrity is taken care of in
precast concrete structures by means of longitudinal and
transverse ties connecting members to a lateral load re-
sisting system. Forces shall be permitted to be transferred
between members by grouted joints, shear keys, mechan-
ical connectors, reinforcing steel connections, reinforcing
topping, or a combination of these means. The adequacy of
connections to transfer forces between members is deter-
mined by analysis or by test. In designing a connection using
materials with different structural properties, their relative
stiffnesses, strengths, and ductilities are considered.
Provisions related to seismic design considerations are
continuously being improved and incorporated in different
international standards. Development in the codal provisions
and guidelines of American and New Zealand construction
practice is discussed.
A brief history of building code provisions for precast /
prestressed concrete in the United States was presented by
D’Arcy, et al.22, in which it was reported that the first set of
specific design provisions ever developed in the United States
for precast concrete structures in regions of high seismicity
appeared in NEHRP17 Recommended Provisions. The NEH-
RP provisions presented two alternatives for the design of
precast lateral-force-resisting systems: one, emulation (same
as) of monolithic reinforced concrete connection and the
other, use of the unique properties of precast concrete el-
ements interconnected predominantly by dry connections
(jointed precast). For emulation of the behavior of monolithic
reinforced construction, two alternatives were provided: struc-
tural systems with “wet” (ductile) connections and those
with “strong” (elastic) connections. The design provisions for
precast structures in high seismic regions were expanded
in NEHRP (FEMA, 2001) Provisions19. The seismic-force re-
sisting system for high seismic regions suggested in NEH-
RP (FEMA, 2001) provisions19 are special moment resisting
frames and special structural walls with superior type dry

connections. The ACI 318-02, introduced design provisions
for precast concrete structures located in regions of moderate
to high seismic risk or assigned to intermediate or high seis-
mic design categories. Provisions for non-emulative (jointed
precast) design of precast wall systems were not included
in ACI318-02.
A perspective on the seismic design of precast concrete
structures in New Zealand is presented by Park14. Trends
and developments in the use of precast reinforced concrete in
New Zealand for floors, moment resisting frames and struc-
tural walls of buildings with aspects of design and construc-
tion, particularly the means of forming connections between
precast concrete elements were discussed and presented
by Park14.
Seismic performance of precast concrete systems-Codal
provisions
Failure of precast concrete buildings in 1964 Alaska, 1976
Tangshan (China), 1988 Armenia, 1994 Northridge, 2001 Bhuj
and 2008 Wenchan (China) earthquake was mainly due to
collapse of floors for some or other reasons.
One of the main reasons of collapse of floors were loss
of seat due to failure of support system, poor connections,
excessive deformation of support system (beam elongation)
and deformation incompatibility between the support and the
floor. A possible solution to avoid these failures can be by
providing the sufficient seating incorporating the effect of all
possible movements into account.
Fig. 1 shows such detail of required bearing length at the
support suggested by NZS 3101: 2006.
Fig. 2 and Fig.3 show the alternative special reinforcing
to transfer the shear force and support precast concrete floor
units in the event of loss of bearing. Continuous beam rein-
forcement will transfer shear force to column in case of loss
Fig. 1Required bearing length at the support of a member in relation to its
clear span
Fig. 2 Alternate continuous reinforcement through the beam at the level of
bottom of floor to support precast concrete floor units.
PRECAST BUILDING: DESIGN PROVISIONS
of seating, the other alternative with hanger stirrups in the
vicinity of support can also help in the transfer of shear force.
Fig. 3 Alternate continuous reinforcement through the beam at the level of
bottom of floor and in the topping of slab floor to support precast concrete
floor units.
Connections and Bearing
The codes permit a variety of methods for connecting
members in plane and out of plane. These are grouted joints,
shear keys, mechanical connectors, reinforcing steel con-
nections, reinforced topping, or a combination of these. Codes
suggest a minimum bearing length after considering for tol-
erances, as the clear span/180 from the edge of the support
to the end of the precast member. However it should not be
less than 50mm for solid or hollow core slabs and 75mm for
beams or stemmed members as per ACI 318-0832. NZS 3101
provides bearing width for hollow core slab as 75mm. Codes
have suggested to have a clear distance of 15mm from the
unarmored edges and make allowances for concrete cover.
Required length of bearing at the support of a member in
relation to its clear span is illustrated in Fig. 3. Connections
that rely solely on friction caused by gravity forces are not
permitted by codes. For hollow-core slabs, the floor should
be mounted on low friction bearing strips with a coefficient
of friction less than 0.7 and a minimum width of 50mm, as
per NZS 3101.
Structural Integrity
Structural integrity is necessary to improve the redun-
dancy and ductility in structures. This also helps to avoid col-
lapse of the structures in the event of damage to major sup-
porting element or an abnormal loading event by maintaining
overall stability. Codes suggest provisions for precast concrete
structures to achieve structural integrity to the same extent
as of monolithic structures. Tension ties are provided in the
The Masterbuilder | July 2015 | www.masterbuilder.co.in
transverse, longitudinal and vertical directions and around the
perimeter of the structure to effectively tie precast concrete
elements together. This will also achieve the diaphragm ac-
tion of the floor and a seismic load path in the structure.
Diaphragm Action
Precast concrete floor could not transmit in plane force
induced by earthquakes to lateral load resisting system ad-
equately and failed during past earthquakes. Codes have
dealt with the design of precast concrete diaphragms similar
to the cast-in-place diaphragms. Design and detailing pro-
visions for both un-topped and composite diaphragms with
topping are given in the codes. Codes have suggested the
minimum thickness of topping to be 50mm for 20mm cover
and 25MPa strength of concrete. It is further needed to be
increased depending on the size of reinforcement and clear
cover to be used.
47
 PRECAST BUILDING: DESIGN PROVISIONS
ACI 318-08 recommends minimum thickness of topping
to be provided on precast concrete or roof elements, acting
as structural elements and not relying on composite action
to be 67.5mm.
NZS 3105 relates the minimum thickness of topping with
the diameter of bars used. Minimum thickness of topping for
6, 10, 12 and 16 mm stirrups, ties or spirals used is 50, 75, 90
and 105 mm respectively. It is also suggested that if the cover
is greater than 20mm then the thickness of topping should be
increased by the amount of additional cover.
Deformation compatibility of flooring systems
Elongation of plastic hinge regions in beams result in the
deformation incompatibility of floors with the support sys-
tem. This phenomena is much observed in the collapse of
hollow-core floors in 1988 Armenian and 1994 Northridge
earthquakes. To overcome this incompatibility issue and
avoid the brittle failure, NZS3101 have suggested for the pre-
cast floor systems to be designed to have adequate ductili-
ty. The code has suggested the connection details that have
performed well in analytical and experimental investigations.
Precast Concrete Frame and Wall Systems
Codes have suggested the design and detailing of these
systems to be same as cast-in-place system with taking
particular care in designing the connection to emulate sim-
ilar behavior. Precast concrete frame systems composed of
concrete elements with ductile connections are expected to
experience flexural yielding in connection regions. ACI /318-
08 has recommended the reinforcement provisions and type
of mechanical splices to achieve the monolithic behavior of
connections.
Design for the structural purpose:
The main purpose of the structural connections is to
transfer forces between the precast concrete elements in
order to obtain a structural interaction when the system is load-
ed. By the ability to transfer forces, the connections should
secure the intended structural behavior of the superstruc-
ture and the precast subsystems that are integrated into
it. This could for instance be to establish diaphragm action
in precast floors and walls, or cantilever action in precast
The Masterbuilder | July 2015 | www.masterbuilder.co.in
shafts. For this reason, the structural connections should be
regarded as essential and integrated parts of the structural
system should be designed accordingly and with the same
care as for the precast concrete elements. It is insufficient
just to consider the connections as details for site erection.
The advantages that normally are obtainable with prefabri-
cation can be lost with an inappropriate design and detailing
of the structural connections.
Ductility
Connections should preferably behave in a ductile man-
ner. Ductility can be defined as the ability to have large plastic
deformations before failure. In structural materials, ductility
is measured as the magnitude of the deformation that occurs
between yielding and ultimate failure. Ductility in building
frames is usually associated with moment resistance. In
concrete members with moment-resisting connections, the
48
flexural tension is normally resisted by reinforcing bars.
Ductile joints can be achieved by giving the brittle parts of the
joint an extra capacity, for example by calculating with re-
duced allowable stress in these components. Typical brittle
components are welds, short bolts in tension, bolts subject-
ed to shear, reinforcement anchorage zones, etc.
Tests are conducted at department of civil engineering,
University of Manitoba on precast concrete shear wall con-
nections. The observations / conclusions thereon are as fol-
lows:
1) All connections tested were capable to withstand large
nonlinear deformations well beyond first yield with very
good energy absorption. Connections with bonded mild
reinforcement had ductility around 5. Post-tensioned
connections had ductility of 6.
2) Debonding of continuity element across the connection
significantly enhanced the response of the connection in
terms of energy dissipation and ductility.
3) Presence of shear keys across joint interface limited the
slip mechanism which is desirable in the overall precast
wall connection response.
4) Seismic response up to a ductility of three could be re-
sisted by all the tested configurations without any appar-
ent damage to the precast wall connection. This level
represents typical seismic demand for low to moderate
seismicity.
Movements
Connections must not hamper necessary movements in
the structure. Necessary movements will in most cases be
the deformation of beams and slabs due to loads and/or pre-
stressing forces. Typically this problem arises when a verti-
cal facade panel is connected to a beam or slab somewhere
in the span (away from the support). If the connection detail
makes the vertical movement of the beam or slab impossible,
this may cause damage to the connection detail itself, or to
the elements. Even if there is no damage, unwanted forces
may be introduced in the elements, causing unwanted de-
formations. The solution is to construct the connection detail
with a sliding arrangement, or it can be made as a hinge.
Types of Joints
The most serious problem facing the precast industry is
finding a reliable and economic method to join prefabricated
members. Connections or locations of high stress concen-
trations are weak points in the structural system; and they
have to withstand high forces and displacements during strong
earthquakes. Thus, to design and properly detail joints is the
most important factor in achieving the safe and economical
precast structures.
Three types of joints are distinguished viz.
1) Embedded steel shapes anchored to the precast members
by studs or rods and the connection completed with site
welding or bolting. They are known as dry connections.
Drawback is the failure of the connections by shearing of
studs, pull out of the anchor rods, splitting of the con-
crete, brittle failure of the welds and bolt threads during
earthquakes indicate that dry or mechanical connections
 PRECAST BUILDING: DESIGN PROVISIONS

are points of high stress concentrations and represent
weak points in the system which can jeopardize its struc-
tural integrity and safety.
Workmanship in field is an important factor of uncertain-
ty and it appears that site welding is very susceptible to
brittle failure.
2) Poured in-situ reinforced concrete joints with dowels
and reinforcement either spliced or lapped or welded, are
known as wet connections. This type of connections show
excellent performance during earthquakes. They tend to
behave monolithically, provide continuity, higher redun-
dancy and add to the structural integrity of the system.
3) Post tensioning the precast elements together with ten-
dons crossing the joints.
Connections in framed structures
Beam column connections are classified as, Rigid, Semi
rigid and Hinge.
Rigid connections are incorporated into framed struc-
tures as moment resistant joints to provide resistance against
the gravity and earthquake loads. They are capable of trans-
mitting the moment, shear and axial forces.
Semi rigid connections are similar to rigid ones, except
that they have lower yield moments and do not develop full
continuity.
Simple supported and hinged joints are designed to re-
sist gravity loads only and have no moment resistance.
Joint types of cast in place and post tensioned, are cur-
rently the most reliable means of connecting precast mem-
bers and are used in ductile moment resistant frames.
Research work in New Zealand indicates these joints
and systems to have good energy dissipation capacity.
Wall panel structures:
Shear connections between floor and wall panels in
precast box type structures may be dry, wet or may be con-
nected by post tensioning. Dry joints are points of high stress
concentrations, which may lead to progressive joint deterio-
ration. Thus wet poured in-situ strips with over-lapped hooks
or dowels are preferred over mechanical devices and they
are more reliable and effective. Tests carried out in japan
showed that precast panels connected by wet joints behave
monolithically and those with dry joints tend to behave inde-
pendently.

Recommendations To Indian (Stan-

S.no Aspect Indian (Is 15916:2010)
dard Is 15916:2010) For Adoption.
Forces may be transferred between members
by grouted joints, shear keys, mechanical
Force Transfer Mech-
1 - connectors, reinforcing bar connections, welded
anism
or bolted connections reinforced topping, or a
combination of these means.

9.1 - The considerations for design of joints are: a) Feasibility, b) Practicability, c) To control cracking due to restraint of volume
2 Design Considerations
Serviceability, d) Fire rating, e) Apperance change, and differential temperature gradients.

To provide resistance against sliding, overturn-

ing and rocking.

Joint/Connection 9.2 (a) - It shall be capable of being designed to transfer the imposed load and mo-
3
Requirements ments with a known margin of safety.

9.2 (c) - It shall accept the loads without marked displacement or rotation and avoid
high local stresses.

9.2 (e) - It shall require little temporary support, permit adjustment and demand only
a few distinct operation to make.

9.2 (g) - It shall be reliable in service with other parts of the building.

9.2 (h) - It shall enable the structure to absorb sufficient energy during earthquakes
so as to avoid sudden failure of the structure.

Type Of Joints In
The Masterbuilder | July 2015 | www.masterbuilder.co.in

4 9.2.1 - Continuous or hinged under lateral loading.

Structure

Water Tightness
5 - Water tightness provisions to be detailed.
Specifications

9.1 (b) - The fire rating for joints of precast components shall be higher or atleast
6 Fire Resistance
equal to connecting members.

Detailing Specifica-
7 Dry or wet joints as specified in cl. 9.3
tions

New Zealand code NZS 3101 part 1 have given

the definitions of equivalent monolithic systems
8 Jointing Systems -
and jointed systems in a detailed manner. These
are recommended for adoption in to IS codes.

The definitions given for connections of limited

IS 13920:1993 suggest that precast and / or prestressed concrete members may be
Seismic Provisions ductility, ductile jointed connections and ductile
9 used only if they can be provided with the same level of ductility, as that of a mono-
(Ductility) hybrid connections as mentioned in NZS 3101 is
lithic reinforced concrete construction during or after an earthquake.
recommended for adoption in to IS code.

8.2 - Details about the requirement of safety against progressive collapse. Tie
provisions horizontally and vertically are detailed with a tensile force of Ft = 60 kN or
10 Progressive Collapse
(20+4N)kN whichever is less, where N is the number of storeys including basement.
Key element identification is also indicated.
50
 Provisions from various international codes, viz., American standards, New Zealand, Euro, British,
Hongkong, Canada, on the structural connections are summarized briefly in the table below.

Comparision of Provisions With Respect To Joints

PRECAST BUILDING: DESIGN PROVISIONS

51 The Masterbuilder | July 2015 | www.masterbuilder.co.in

52 The Masterbuilder | July 2015 | www.masterbuilder.co.in PRECAST BUILDING: DESIGN PROVISIONS
 RMC PLANT: CERTIFICATION

In Quest of Quality Concrete

Vijay Kulkarni
Technical Adviser, Quality Council of India
and Former President - ICI

T
raditionally, construction involving concrete had been
a labour-intensive activity in India. The demand for
higher speed of construction, especially for residential and
commercial housing, and infrastructure projects involving
construction of flyovers, highways, roads, airports, etc. neces-
sitated adoption of mechanized and semi-mechanized tech-
niques of construction. The need for large volumes of concrete
as well as faster speed of concrete construction was felt. This
was conducive for the development of ready-mixed concrete
(RMC) on commercial basis.
Use of batching and mixing plants for producing large
volumes of concrete was in vogue in India for a long time.
However, such use was minimal and restricted to construc-
tion of big jobs like hydro-electric projects, large industrial
complexes, major bridges, etc. It was only since early 1990s
that witnessed the beginning of commercial RMC industry in
India.
The growth of RMC commenced with metropolitan cities,
and then spread to other major cities. No authentic data is
available on the RMC industry in India. However, it is believed
that currently the industry has spread its wings to more than
100 cities of India. Major corporate-sector companies such
as ACC Ltd. Ultratech Cement Ltd, Lafarge Aggregates &
Concrete (P) Ltd., RMC Readymix (India) - Prism Cement Ltd.,
Godrej, etc have set up a large number of RMC plants in
different cities. Again, no authentic data is available on the
number of commercial plants in India; however, the number
The Masterbuilder | July 2015 | www.masterbuilder.co.in
plant audit-based scheme was launched in December 2008
and around 250 RMC facilities at 50-plus locations in India
(mostly belonging to RMCMA member companies) were au-
dited and certified by the RMCMA.
After operating this quality scheme successfully for near-
ly four years, RMCMA decided to raise the quality scheme to
a higher pedestal. For this purpose, RMCMA signed a Mem-
orandum of Understanding (MoU) with the Quality Council of
India (QCI) – a non-profit, national apex organization wedded
to quality facilitation, accreditation and surveillance.
QCI Scheme
QCI took the initiative of setting up three committees,
namely, the Steering Committee, Technical Committee and
Certification Committee. Experts from key organizations
(see box) from the government and private sectors and pro-
fessional bodies were invited to be the members of these
committees. The involvement of these organizations in the
evolution of the scheme ensured that the ownership of the
scheme is broad-based and views and concerns of major
owners and specifiers in the country using large volumes of
concrete are taken into account.
The evolution of QCI scheme took more than one-and-a-
half year. Following painstakingly prepared Scheme Manuals
were finalized by the expert committees after long delibera-
tions.

is believed to be exceeding 1000. In addition equal number of

plants (or even more) is being operated by construction com-
panies in India for captive use.

Quality of Concrete

Quality of concrete being produced and used in construc-

tions - especially those involving use of primitive labour-intensive
site-mixed concrete - has remained one of the major concerns
of owners and specifiers. Unfortunately, till very recently, no
established framework was available to ensure quality.
The Ready Mixed Concrete Manufacturers’ Association
(RMCMA) was the first to initiate efforts to evolve a frame- Fig 1 Three expert committees set up by QCI
work for quality for ready mixed concrete. It was based on two
strong pillars – best practices followed in advanced countries - Criteria for Production Control of Ready Mixed Concrete3
and adherence to provisions in the Indian standards – mainly - Certification Process for Ready Mixed Concrete Produc-
IS 456 and IS 4926. Two Quality Manuals prepared by Experts tion Control Scheme4
Committee contain the details of the RMCMA Scheme1,2. This - Provisional Approval for Certifying Bodies for RMCPCS5.
54

Multi Stakeholder Committees
- Central Government Ministries, e.g. Ministry of Housing
& Urban Poverty Allevation, Ministry of Road Transport and
Highways, MES, etc.
- Key Specifier: Central Public Works Department (CPWD)
- Central PSUs e.g. National Highway Authority of India,
Airport Authority of India, RITES
- User bodies, e.g. Builders Association of India, Construction
Federation of India.
- Professional bodies, e.g. Indian Concrete Institute (ICI),
Association of Consulting Civil Engineers (ACCE), CREDAI.
- Manufacturers, e.g. Ready Mixed Concrete Manufacturers’
Association (RMCMA), Cement Manufacturers’ Association
(CMA)
- Certifying bodies, e.g. Bureau Veritas Certification (I) Pvt
Ltd., ICMQ India Pvt Ltd.
While formulating the scheme it was ensured that the
QCI Scheme conforms to the requirements of the Bureau of
Indian Standards (BIS), Indian Roads Congress (IRC), Indian
Railway Standards (IRS), etc. The Scheme is also made ap-
plicable for:
- RMC plants supplying concrete commercially
- Plants supplying concrete for specific project (captive
plants)
- Plants supplying concrete partly on commercial basis
and partly for captive consumption.
Scheme excludes operations of placing, compaction, fin-
ishing and curing of concrete.
The Scheme documents (Fig 2) are publically available and
can be down-loaded from http://qcin.org/CAS/RMCPC.
Criteria for Production Certification Process for Provisional Approval for
Control of RMC RMCPCS CBs for RMCPCS
Fig 2 QCI Scheme Manuals prepared by multi-stakeholder Committees
Two Options
The QCI Scheme offers two options of certifications, namely
- RMC Production Control Capability Certification
- RMC 9000+ Certification
The Scheme logos are shown in Fig 3.
RMC Capability Certification is the crux of the QCI
Scheme. Comprehensive criterion has been developed by
the Technical Committee which is documented under the
Scheme Manual “Criteria for Production Control of Ready
Mixed Concrete”, published by BMTPC, Ministry of Housing
& Urban Poverty Alleviation, Govt. of India3. Besides the audit of
the plant and machinery and the control mechanism adopted
by the producer, the criteria also embody laboratory testing
facilities, technical skills of the human resources, the controls
RMC PLANT: CERTIFICATION
Fig 3 QCI Scheme: Two options
exercised on the quality of different concrete ingredients, mix
design and the final product.
The production control criteria which can be considered
to be heart of the scheme include the following six main fea-
tures:
1. Resource management: It covers three main areas, name-
ly, plant, equipment and other utilities, laboratory and key
personnel. Main areas under resource management are
diagrammatically presented in Fig 4. Provision of basic
laboratory testing facility is made mandatory under the
QCI Scheme. The minimum testing equipment for the lab-
oratory and the calibration frequency of the equipment are
also specified. Compressive check list items have been
developed so that an auditor is able to have an in-depth
understanding of all key aspects of resource management
having bearing on quality.
2. Control on Quality of Incoming Materials: The ready-mixed
concrete producer needs to verify quality of all ingre-
dients on a regular basis. Various standards of the BIS
have specified the tests to be performed on different ingre-
dients and their frequencies of testing. The QCI scheme
has made it mandatory to perform these tests at BIS
specified frequencies. It is also specified that the physical
and chemical properties of the basic ingredients should be
tested in NABL-accredited laboratory, at least once in six
months or when there is a change in the source of mate-
rials. Such rigorous testing regime would certainly ensure
that ingredients having good quality are used in produc-
tion of ready-mixed concrete.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Fig 4 Resource management under production control criteria
3. Concrete Design: The QCI scheme requires that the ready-
mixed concrete producer should have in-house capabili-
ty to carry out mix proportioning. Plant personnel should
also have the ability to carry out adjustments in the mix
to cater to the variability in the incoming materials – for
55
 RMC PLANT: CERTIFICATION

example, the variations in the moisture contents in ag-
gregates, grading, etc. The competence of the key per-
sonnel who carry out mix design will be judged by the
auditors by going through the old records, interviewing
some key personnel and witnessing few tests in the lab-
oratory.
4. Production and Delivery: The auditor has been given the
freedom to choose any five orders received by the producer
during the past six months and verify from the autographic
records as to whether the supplies have been made ex-
actly as per the orders of the customers. Incidentally, the
tests to be conducted and their frequencies in controlling
the quality of the final product have also been specified in
the QCI Scheme.
5. Control on Process Control Equipment and Maintenance:
Upkeep of plant and equipment, their calibration, etc. play
an important role in determining the quality of the final
concrete. The QCI scheme specifies the frequency of in-
spection, calibration tolerances, etc.
6. Complaints and Feedback: The QCI Scheme has made it
mandatory to have a Nodal Officer, who will be responsi-
ble for complaints and feedback. The scheme also high-
lights the importance of having established procedures
to receive, resolve, review and find out the root causes of
the complaints.
Certification Process
Detailed procedures for carrying out certification under
the QCI Scheme have been evolved and are explained in the
Certification Manual4. The broad aspects covered under the
procedures are as below:
1. Application for certification: It includes application form,
registration of applicant and the information to be furnished
by the applicant to the certifying body.
2. Audit program: The audit program is divided into Stage 1,
Stage 2 and Surveillance audits. While each plant needs
to be audited under RMCPCS, the ISO 9001 audits can be
carried out on sampling basis as allowed under ISO 9001
certification.
3. Audit man-days: Audit man-days under certification and
surveillance audits for both schemes have been fixed by
the Certification Committee.
4. Audit planning: This includes the information to be provided
to the certifying body, constitution of audit team and audit plan.
5. Certification audit: It provides guidance on how RMC 9001+
QMS based certification and RMC capability certification
audits should be performed. Safety measures to be ad-
opted during the audit are also highlighted.
6. Non-conformities: Three types of Non Conformity (NC)
have been specified, namely, Critical, Major and Minor. The
detailed descriptions of each of the NCs and the time
for closure have also been specified (see Table 1). The CBs
need to send the audit report within 7 days from the date
of the completion of the audit.
7. Certification decision: Certificate will be issued by the
CB, only when all raised NCs are closed (critical and major
after on-site verification and minor after off-site verification).
8. Surveillance: Surveillance audits shall be carried out by
the CB every six months, with at least one surprise audit
in a year. The surprise audit will be conducted with a short
notice of 3 days.
9. Complaints: This section covers the complaint handling
process. The need to have a documented process to re-
ceive, evaluate and make decisions on complaints is
highlighted. The CB should audit the complaints received
by the plant from its customers. The manner in which a
complaint received about a certified plant should be han-
dled is described.

Non con-
Description Classification Time frame for closure
formity
Check List items:
3.2.1.1 Storage –Cement only Within 15 days. Corrective ac-
3.2.1.2 Batching and Mixing tions shall be submitted to CB
Non compliance with a requirement which
3.3 Laboratory within 10 days. Onsite verifica-
indicates serious failure of the plant’s ca-
Critical 5. Concrete Mix design tion to be undertaken within 5
The Masterbuilder | July 2015 | www.masterbuilder.co.in

pability to produce and deliver RMC to meet

6. Production and delivery
the customer requirements
6.1 Identification and traceability
7. Control of process control
equipment and measurements
days and decision taken either
to close the NCs or suspend
certification

Non conformity regarding a Management

3.2.1.1 Storage –other than
system requirement which does not allow
cement Within 1 month. Evidences of
the production and delivery process to meet
3.2.1.3 Delivery fleet closure shall be provided to
Major the customer requirements (applicable to
3.4 Key personnel the CB; verification to be done
ISO 9001 requirements only as defined by
4. control of incoming materials on site
CB) or as given in the Criteria for the classi-
8. Complaints
fication in column 3

Non compliance with a requirement which Within 3 months. Evidences of

6.2 Control of non-conforming
does not compromise either the overall closure shall be provided to the
Minor products
management system effectiveness or the CB; verification to be done in
9. Feedback.
production and delivery process the following surveillance audit

Table 1: Non Conformities – Description, classification and time frame for closure
56
 RMC PLANT: CERTIFICATION
10. Certificate: The information to be included in the certificate
as well as its validity are described.
11. Suspension and withdrawal of certificate: It provides de-
tailed guidance when the certificate will be suspended
and withdrawn and the suspension will be revoked.
12. Change of location/ownership/name: The certified plant
needs to inform the CB changes in location, ownership and
name of company. With the change in location, audit of
the new facility becomes essential. In case there is a
change in the name of the company or its ownership, ap-
propriate documents need to be submitted to the CB.
13. Fees: the fee structure of the CB shall be publically ac-
cessible and also provided on request.
Approval System for Certification Bodies
The Certification Bodies (CBs) which would be auditing
and certifying the ready-mixed concrete plants under the
RMCPCS need to primarily comply with the requirements
specified in ISO 17065 and additional requirements specified
by the Quality Council of India. With a view to commence the
operation of the scheme immediately, a Provisional System
for Approval of the CBs was evolved, documented and approved
by the Certification Committee5. Stringent requirements have
been specified the committee for the CBs operating the scheme.
The Minimum Competence Requirements of Auditors audit-
ing the RMCPCS have been specified (see box). Further, the
CBs will be subjected to a through yearly audit. They need to
obtain accreditation from National Accreditation Board for
Certification Bodies (NABCB) under the QCI.
No of Certified Plants under
Company
Plants certification
ACC Ltd 10
Godrej & Boyce 7 0
IJM Concrete 6 0
Lafarge Aggregat &
18
Concrete (I) Pvt Ltd.
RDC Concrete (I) Pvt
11
Ltd
The Masterbuilder | July 2015 | www.masterbuilder.co.in
RMC Readymix (I) -
a Div of Prism 18
Cement Ltd.
UltraTech Cement Ltd. 39
Source: Websites of certifying bodies
Leading RMC producers in India - Current status of QCI Certifcation (July 2015)
Minimum Competence Requirement of Auditors
- Minimum Bachelor’s degree in engineering in related
field(s) with at least 5 years of relevant experience in
RMC/Batching plant; or Diploma in engineering in relat-
ed field(s) with 7 years of relevant working experience in
RMC/batching Plants
- Experience in core technical processes like QA/QC or
production and process control
- Training and experience in auditing.
58
Conclusion
The QCI Quality Scheme provides a comprehensive
framework of controlling quality of concrete from ready-mixed
concrete plants. The Key Benefits of the Scheme to owners/
specifiers, RMC producers, small customers and concrete
industry are highlighted below.
Key Benefits of QCI Scheme
- For Owners and Specifiers (architects, consultants)
- Third-party quality assurance from an independenta-
gency, based on well-defined quality norms evolved
by experts
- Reliable Tool for short-listing of concrete producers
- For RMC/Concrete Producers
- Competitive advantage over non-certified producers
- Top management gets audited data on their plants
- Small Customer (e.g. individual house builder)
- Assurance on QA&QC of concrete, without employing
experts
- Concrete Industry
- Raise the industry standard and bring it on par with those
from advanced countries.
Epilogue
The QCI Scheme is voluntary. However, looking at the ad-
vantages of the QCI Scheme, owners, specifiers, designers, etc.
can make the scheme mandatory for jobs/projects undertaken
by them. The scheme can also be used for short-listing of
concrete supplier. Further, a six monthly third-party audit of
the RMC facility provides crucial information to client/owner
on actual performance.
Some government/semi-government organizations like
3 the PWD-Pondicherry, BruhanMumbai Mahanagarpalika,
Mumbai, CIDCO, Navi Mumbai, have already made the appli-
cation of the Scheme mandatory for concretes procured for
their projects (see enclosures).
References
11
1. Quality Manual Part – I Check List for Certification of Ready
Mixed Concrete Production Facilities, Ready Mixed Con-
0
crete Manufacturers’ Association, India, 2008.
14 2. Quality Manual Part – II Guidelines on Quality Control and
Quality Assurance of Ready Mixed Concrete, Ready Mixed
Concrete Manufacturers’ Association, India, 2008.
0
3. Criteria for Production Control of Ready Mixed Concrete
under Ready Mixed Concrete Plant certification Scheme
(QCI), Building Materials & Technology Promotion Coun-
cil, Ministry of Housing & Urban Poverty Alleviation, Gov-
ernment of India, New Delhi, 2013.
4. Ready Mixed Concrete Plant Certification Scheme
(RMCPCS) – Certification Process, Quality Council of India,
New Delhi, 2013.
5. Ready Mixed Concrete Plant Certification Scheme
(RMCPCS) – Provisional Approval System for Certifica-
tion Bodies, Quality Council of India, New Delhi, 2013. w
 CONCRETE: RECYCLED AGGREGATES
Potential Use of Recycled Coarse
Aggregates in Concrete
Subhash C. Yaragal , Vivek V B , M Padmini , M Jacob,
J Niveditha1, Anil Kumar Pillai2
National Institute of Technology Karnataka, Surathkal
1
The Ramco Cements Limited
2
Abstract: Concrete continues to be the most consumed con-
struction material in the world, only next to water. This fact is
due to its appealing properties of high compressive strength
and the property of mould-ability to any conceivable shape.
Due to rapid increase in construction activities, it is import-
ant to assess the amount of construction and demolition
waste being generated and analyse the practices needed to
handle this waste from the point of waste management and
disposal and also with regard to waste utilization in concrete
from the sustainability aspects. Construction and Demolition
(C&D) waste constitutes a major portion of total solid waste
production in the world, and most of it is used in landfills.
Research by concrete engineers has clearly suggested the
possibility of appropriately treating and reusing such waste
as aggregate once again in concrete, especially in applica-
tions such as bed concrete and in road beds for pavement i.e.
where works are of less importance as regards to the strength.
The use of such waste as recycled aggregate in concrete can
be useful for both environmental and economic aspects in the
construction industry. This study reports some interesting
results of the utilization of recycled coarse aggregates in
concrete from construction and demolished waste.
Due to high demand for construction activities in re-
cent years in India and all over the world, the natural ag-
gregates resources are remarkably waning day by day. On the
other hand, millions of tonnes of C&D residues are gener-
ated. Natural resources are dwindling day by day due to
their extensive use to cope with the increasing demand of
Civil Engineering Projects. Therefore, the use of C&D waste
as an alternative aggregates for new concrete production
The Masterbuilder | July 2015 | www.masterbuilder.co.in
gains importance to preserve natural resources and reduc-
ing the need for disposal, (S Manzi et al. 2013). The amount
of construction and demolition waste has increased enor-
mously over the last decade in the entire world, (Sami W.
Tabsh et al 2009). Disposal of construction and demolition
waste has also emerged as a problem in India. Therefore,
recycling of waste concrete is beneficial and necessary for
the environmental preservation and effective utilization of
natural resources, (Ashraf M. Wagih et al. 2013). The use of
recycled coarse aggregate obtained from construction and
demolition waste in new concrete is a solution for effective
waste utilization, (M. Chakradhara Rao et al.2011).
The management of construction and demolition waste
is a major concern due to increased quantity of demolition
rubble, shortage of dumping sites, increase in cost of dis-
posal and transportation and above all the concern about
environment degradation. Although a substantial portion of
60
construction materials could be substituted by re-processed
construction waste material, these options are not exercised
in developing countries due to lack of knowledge and insuffi-
cient regulatory frameworks resulting in waste getting piled
up causing disposal problems, (R.V.Silva et al. 2014). The in-
creasing problems associated with construction and demo-
lition waste, have led to a rethinking in developed countries
and many of these countries have started viewing this waste
as a resource and presently have fulfilled a part of their de-
mand for raw material, (Shi-Cong Kou et al. 2012).
Many developed countries have been recycling C&D waste
and using it for construction works. In Scotland about 63% of
the C&D waste was recycled in 2000. The Government there is
working out specifications and code of practice for recycling
of C&D waste. U.K uses 49-52% of the C&D wastes and Aus-
tralia reuses 54% of the wastes generated. Belgium has a
higher recycling rate (87%) and uses majority of C&D for re-
cycling purposes. Japan is one of the pioneer countries that
recycle C&D waste. 85 million tonnes of C&D waste was
generated in 2000, of which 95% of concrete was crushed and
reused, (Akash Rao et al. 2007).
Using recycled concrete aggregates, will require
checking the quality of the aggregates, since they are col-
lected from different sources, grades of concrete and age,
(A.K.Padmini et al. 2009). Concrete workability is more influ-
enced by the shape, texture and grain size distribution of the
recycled aggregates than by their total amount, (S. Manzi et
al. 2013). The compressive strength primarily depends upon
adhered mortar, water absorption, Los Angeles abrasion, size
of aggregates, strength of parent concrete, age of curing and
ratio of replacement, interfacial transition zone, moisture state,
impurities present and controlled environmental condition
(Isabel Martínez-Lage et al. 2012). Absorption of RCA is one
of the major contributing factors in the strength of concrete,
(K C Panda and P K Bal 2013).
This study reports some important changes in properties
such as compression strength and absorption of recycled
aggregate concrete.
Materials
Ordinary Portland Cement (OPC) 43 grade was used and
its properties are tabulated in Table 1. Coarse aggregate was
crushed stone with a maximum size of 20 mm. Locally avail-
able natural river sand conforming to zone III (IS 383-1970
grading requirements) was used as fine aggregate. Physical
properties of fine and coarse aggregates are presented in
Tables 2 and 3 respectively. Potable quality water is used.
 CONCRETE: RECYCLED AGGREGATES

Recycled aggregates were obtained from demolished con- % Finer

crete made in the laboratory with maximum size of 20 mm. Sieve size (mm)
NCA RCA
Table 4 shows the properties of recycled coarse ag-
gregates and Table 5 gives mix proportions for OPC based 20 100 100
concrete. The sieve analysis results of natural and recycled 16 68.5 71.5
aggregates are shown in Table 6.
12.5 32.1 27.7
Result ob- Requirements 10 0.7 0.5
No. Property
tained as per IS code (NCA-Natural Coarse Aggregates, RCA-Recycled Coarse Aggregates)
Specific Table 6 Sieve analysis results of natural and recycled coarse aggregates
1 3.12 -
gravity
Normal con- Sources and processing of RCA
2 29% -
sistency
In order to obtain correct assessment of strength of RCA
Not less than 30
Setting times, Initial 65 based concrete, it was thought necessary to produce con-
3 Not more than
minutes Final 270 struction and demolished waste from same quarry virgin
600
coarse aggregates. To achieve C & D waste, about 30 Nos. of
Fineness, Not less than 150 mm concrete cubes were cast and cured for a period
4 330
m2/Kg 300
of 28 days. Later all these were compressed to failure, to
Soundness, Not more than produce C & D waste.
5 2.50
mm 10 mm A common procedure adopted to recover the coarse ag-
Comp. 3d 7d 28d 3d 7d 28d gregates from C & D wastes is as follows. The C & D waste,
6 was fragmented manually further, and then 10 Kg of C & D
strength,Mpa 34 51 61 22 33 43
waste was placed in Los Angeles aggregates testing machine
Table 1 Physical properties of Ordinary Portland Cement with constant charge and the apparatus was run for 5 min-
utes.
Property Result
Later this processed material is removed, and sieve
Specific gravity 2.62 analysis was carried out. After sieve analysis, the obtained
Loose: 1463 Kg/m3
Bulk density
Compact: 1661 Kg/m3
Moisture content Nil
Table 2 Properties of fine aggregates

Property Result
Specific gravity 2.73
Loose: 1360 kg/m3
Bulk density
Compact: 1527 kg/m3
Moisture content Nil
Table 3 Properties of coarse aggregates

Sl. No. Property Results

1 Specific gravity 2.59 Fig. 1 Compressive strength variation of OPC based concrete with RCA
The Masterbuilder | July 2015 | www.masterbuilder.co.in

(Mean data)
2 Water absorption 2.69%
3 Fineness modulus 6.96
Table 4 Properties of recycled coarse aggregates

RCA C FA CA RCA W
Mix
(%) (kg) (kg) (kg) (kg) (kg)
Mix 1 0 400 600 1200 - 200
Mix 2 20 400 600 960 240 200
Mix 3 40 400 600 720 480 200
Mix 4 60 400 600 480 720 200
Mix 5 80 400 600 240 960 200
Mix 6 100 400 600 0 1200 200
(RCA-Recycled Coarse Aggregate, C-Cement, FA- Fine Aggregates, CA-
Coarse Aggregates, W- Water)
Fig. 2 Compressive strength variation of OPC based concrete with RCA
61

Table 5 Composition of various mixes for OPC blended concrete (Full data)
 CONCRETE: RECYCLED AGGREGATES

RCA (%) No. of cubes (no RCA), 20%, 40%, 60%, 80% and 100% (all RCA) by weight
of the total natural coarse aggregates in concrete. So for each
0 3 mix 3 Nos. of 150 mm cubes concrete cubes as stipulated by
20 3 the code were cast. 18 Nos. of 150 mm cubes were cast and
40 3 28 days water cured before testing them for compressive
strengths. Experiments were aimed for achieving workable
60 3
slump between 50-75mm without using super plasticizers.
80 3 Standard slump cone apparatus is used for measuring the
100 3 value of slump. During the slump tests it was found that the
Total 18 workability of fresh concrete made with 100% replacement
of RCA had slump value close to zero mm. With increase in
Table 7 Test matrix for compression on 150 mm cubes
percentage of RCA in concrete the workability was getting
Average Average lower and lower. This was mainly due to the high absorp-
Comp. Relative tion rate (2.69%) of the RCA as compared to the fresh coarse
Comp. Relative
RCA (%) Strength Comp. aggregate (0.2%). Adding water to compensate for this ab-
Strength Comp.
(N/mm2) Strength
(N/mm2) Strength sorption was not a good option as exact amount could not be
Control 40.44 0.96 ascertained. So it was decided to soak the RCA for 24 hours
before use, so that it does not absorb water during the process
0 43.11 42.1 1.02 1.00
of mixing (M. Etxeberria et al. 2007), this method of soaking
42.67 1.01 helped to attain moderate workability of concrete without use of
39.11 0.93 plasticizers. The test matrix for compression test is shown
in Table 7.
20 40.89 39.3 0.97 0.93
The concrete samples with RCA are tested for 28 day
37.78 0.90 strengths and compared with the results of the strengths of
37.78 0.90 concrete made with virgin natural aggregates.
40 37.33 37.5 0.89 0.89 Results and Discussion
37.33 0.89
Compressive Strength
34.22 0.81
Table 8 presents the results of the compressive strength
60 34.22 34.4 0.81 0.81
tests for OPC based concrete specimen. It can be noticed
34.67 0.82 that the compressive strength of the cubes goes on decreasing
33.77 0.80 as the percentage of the RCA replacement gets increased
80 34.67 33.5 0.82 0.79 from 42.1 MPa for the control mix to 30.8 MPa in the fully
RCA replaced cubes. The drop in strength with increase in
32.00 0.76
RCA proportion is attributed to the bond strength becoming
30.22 0.72 weaker and weaker with RCA increase.
100 31.11 30.8 0.74 0.73 From Table 8, it is observed that there is a decrease in
31.11 0.74 strength from 7% to 27%, when 20% of virgin aggregates is
replaced by RCA, to the case when 100% of virgin aggregates
Table 8 Compressive strength of cubes for OPC based concrete specimen is replaced by RCA. These findings are in agreement with
other investigators. S.C.Kou et al. (2012) reports a fall in the
Dry weight Wet weight Absorption compressive strength. Sami W. Tabsh and Akmal S. Abdel-
RCA (%)
The Masterbuilder | July 2015 | www.masterbuilder.co.in

(kg) (kg) (%) fatah (2009) have reported that the decrease in strength is
0 8.232 8.579 4.22 by about 10-25%. Sumaiya Binte Huda and M. Shahria Alam
(2014) have got a decrease in 15-20% when aggregates
20 8.080 8.470 4.83
were replaced. Figure 1 shows the normalized compressive
40 7.844 8.256 5.23 strength variation, with increase in RCA. These findings are
60 8.093 8.485 4.84
80 7.956 8.371 5.22
100 7.963 8.36 4.99
Table 9 Water absorption results for OPC based concrete

RCA, was agitated and washed in a water tank to remove

surface crushed rock fines (dust) and sun dried before their
being used as RCA to cast specimen.

Experimental Methodology

The obtained aggregates are mixed in proportions of 0% Fig. 3 Variation of percentage of absorption for OPC, with RCA
62
 CONCRETE: RECYCLED AGGREGATES
similar to the results of Wai Hoe Kwan et. al (2012). Shi-Cong
Kou and Chi-Sun Poon (2013) have also reported a decline in
their compressive strength. K.K.Sagoe-Crentsil et al (2001)
have similar results with recycled aggregates replaced con-
crete. According to the studies by Isabel Martínez-Lage et al.
(2012) the estimated loss for concrete with 100% recycled
aggregate was 23%, with values ranging from 20% to 31%.
There is a reduction from normalized strength factor
of 1.00 to 0.73, when the natural aggregate was completely
replaced with recycled aggregate. Hisham Qasrawi (2014)
has also reported a reduction in concrete strength when re-
placed with RCA. K C Panda and P K Bal (2013) have reported
that compressive strength, flexural strength and split tensile
strength of concrete decreases with increase in the amount
of RCA.
Figure 2 shows the best fit line, showing the drop in
strength of concrete with increase in percentage of RCA.
The proposed equation can be used to predict the normal-
ized strength of concrete as a function of RCA, with maxi-
mum error in prediction of less than 2.5%.
Normalized Strength = 0.9848-[0.0026Xrca(%)] ..(1)
Water Absorption Test
Water absorption was used to determine the amount of
water absorbed under specified conditions that indicates the
degree of porosity of a material. The results of the water ab-
sorption tests are as shown in Table 9. The results indicate
that the water absorption was higher in all the cases when
there is a replacement by recycled aggregate. The percent-
age of absorption varied from 4.22% to 5.23%. It is clear that
the concrete with RCA has more absorption rate than that of
the control mix. This is mainly due to the high absorption of
the recycled aggregate compared to the natural aggregate
(Isabel Martínez-Lage et al 2012). The residual mortar at-
tached to recycled concrete particles serves as a potential
conduit for moisture transport. Figure 3 shows water ab-
sorption in a graphical form. Hence we can say that the RAC
has more porosity when compared to the normal concrete.
Though this may not have a direct relation with the durability
of the concrete, it is affecting the strength of the concrete.
K.K.Sagoe-Crentsil et al (2001) have got absorption rates
ranging between 5-7%. The absorption rate of this investiga-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
tion ranges between 4-6%.
Conclusions
(1) RCA exhibits similar behaviour like fresh aggregate
in concrete; therefore, RCA could be incorporated into
many concrete structures. However, RCA that has an
unknown origin should be tested to ensure that the RCA
was not from a structure that was suffering from alka-
li-silica reaction, alkali-aggregate reaction, sulphate at-
tack, or some other harmful reaction. Such RCA could
affect adversely the strength and durability of the con-
crete and may be harmful.
(2) A maximum reduction of about 27% was noticed in com-
pressive strength when the entire coarse natural aggre-
gate was replaced with RCA. Moreover, environmental
benefits may be able to compensate for the negative
effect of loss in strength to some extent due to the use
64
of recycled coarse aggregate in concrete leading us to
sustainable development.
(3) Absorption for RCA concrete was more than that for con-
trol mix. This may affect the durability of the concrete.
(4) As the degree of processing gets higher the RA tends to
be more similar to NA. Hence RA after processing shows
better results than unprocessed RA.
References
[1] A.K.Padmini, K.Ramamurthy, M.S.Mathews (2009), Influence of
parent concrete on the properties of recycled aggregate concrete.
Construction and Building Materials, 23, 829-836.
[2] Akash Rao, Kumar N. Jha, Sudhir Misra, (2007), Use of aggregate
from recycled construction and demolition waste in concrete, Re-
sources Conservation and Recycling, 50, 71-81.
[3] Ashraf M. Wagih , Hossam Z. El-Karmoty , Magda Ebid , Samir H.
Okba (2013), Recycled construction and demolition concrete waste
as aggregate for structural concrete, HBRC Journal , 9, 193–200.
[4] Hisham Qasrawi (2014), The use of steel slag aggregate to enhance
the mechanical properties of recycled aggregate concrete and re-
tain the environment, Construction and Building Materials, 54, 298–
304.
[5] Isabel Martínez-Lage, Fernando Martínez-Abella, Cristina Vázquez-Her-
rero, Juan Luis Pérez-Ordóñez (2012), Properties of plain concrete
made with mixed recycled coarse aggregate , Construction and
Building Materials ,37 ,171–176.
[6] K C Panda, P K Bal (2013), Properties of self-compacting concrete
using recycled coarse aggregate, Procedia Engineering, 51, 159 – 164.
[7] K.K.Sagoe-Crentsil, T.Brown, A.H.Taylor (2001), Performance of
concrete made with commercially produced coarse recycled con-
crete aggregate, Cement and Concrete Research, 31 , 707-712.
[8] M. Chakradhara Rao , S.K. Bhattacharyya , S.V. Barai (2011), Be-
haviour of recycled aggregate concrete under drop weight impact
load, Construction and Building Materials, 25 ,69–80.
[9] M. Etxeberria , E. Vázquez, A. Marí, M. Barra (2007), Influence of
amount of recycled coarse aggregates and production process on
properties of recycled aggregate concrete, Cement and Concrete
Research, 37, 735–742.
[10] R.V. Silva, J. de Brito, R.K. Dhir (2014), Properties and composition of
recycled aggregates from construction and demolition waste suit-
able for concrete production, Construction and building materials,
65, 201-217
[11] S. Manzi , C. Mazzotti, M.C. Bignozzi (2013), Short and long-term
behavior of structural concrete with recycled concrete aggregate,
Cement & Concrete Composites , 37 , 312–318
[12] S.C. Kou, C.S. Poon (2012), Enhancing the durability properties of
concrete prepared with coarse recycled aggregate, Construction
and Building Materials, 35, 69–76.
[13] Sami W. Tabsh ,Akmal S. Abdelfatah (2009), Influence of recycled
aggregate concreteon strength properties of concrete, Construction
and Building Materials ,23, 1163–1167.
[14] Shi-Cong Kou, Chi-Sun Poon (2013), Long-term mechanical and du-
rability properties of recycled aggregate concrete prepared with the
incorporation of fly ash, Cement & Concrete Composites, 37, 12–19.
[15] Shi-Cong Kou, Chi-Sun Poon, Hui-Wen Wan (2012), Properties of
concrete prepared with low-grade recycled aggregates, Construc-
tion and Building Materials, 36, 881–889.
[16] Sumaiya Binte Huda, M. Shahria Alam (2014), Mechanical behavior
of three generations of 100% repeated recycled coarse aggregate,
Construction and Building Materials, 65, 574-582.
[17] Wai Hoe Kwan , Mahyuddin Ramli, Kenn Jhun Kam, Mohd Zailan
Sulieman (2012), Influence of the amount of recycled coarse aggre-
gate in concrete design and durability properties, Construction and
Building Materials, 26, 565-573. w
 CEMENT: CSB
Performance of Calcium Silicate-Based
Carbonated Concretes vs. Hydrated Concretes
under Freeze-Thaw Environments
First of a Three-Part Series Exploring the Durability of Solidia Concrete™
in a Variety of Testing Environments
Jitendra Jain, Ph.D.,1, Vahit Atakan, Ph.D.,2, Nicholas
DeCristofaro, Ph.D.,3, HyunGu Jeong4, Jan Olek, Ph.D.,5
Sr. Research Scientist, 2Director, Research and Development, 3Chief Technology
1
Officer, Solidia Technologies®, 4Graduate Student, 5Professor, Purdue University,
3 West Lafayette, Ind.
Abstract: Solidia Technologies® has developed a calcium sili-
cate-based cement (CSC), which emits less CO2 during its pro-
duction as compared to Ordinary Portland cement (OPC). This
CSC is hereafter referred to as Solidia Cement™. Additionally,
Solidia Concrete™ made using Solidia Cement cures and hard-
ens through a carbonation process and consumes CO2 during
this process. The total CO2 footprint associated with cement
manufacturing and use can be reduced by up to 70% when
Solidia Cement replaces OPC. Although Solidia Concrete can
achieve compressive strengths over 10,000 psi, the effect of
freezing and thawing exposure and surface scaling in presence
of salts need to evaluated. This paper presents results for two
types of Solidia Concrete and a reference concrete tested as per
ASTM C666 procedure A. The scaling resistance is evaluated as
per ASTM C672 for air entrained Solidia Concrete and reference
concrete. RDME values for both Solidia Concrete and reference
concrete after 300 FT cycles were about 88%. After extended
FT exposure (~800 cycles) concrete specimens performed well
as RDME values did not reduce further. The scaling resistance
after 50 FT cycles was very good for Solidia Concrete and reference
concrete.
The Cement Sustainability Initiative of the World Business
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Council for Sustainable Development set 2050 CO2 reduction
targets for the global cement industry. To accomplish this goal,
the use of alternative cementitious materials is becoming more
prevalent. Solidia Technologies® has addressed this challenge
through the development of a calcium silicate-based cement
(CSC), which emits less CO2 during its production as compared
to Ordinary Portland cement (OPC). This CSC is hereafter re-
ferred to as Solidia Cement™. Additionally, Solidia Concrete™
made using Solidia Cement cures and hardens through a car-
bonation process and consumes CO2 during this process. The
total CO2 footprint associated with cement manufacturing and use
can be reduced by up to 70% when Solidia Cement replaces
OPC.
Before Solidia Concrete can be used in widespread appli-
cations, its durability must be demonstrated. The durability of
concrete is generally defined as the ability to withstand damaging
effects of the environment without deterioration for a designed
66
duration. The durability of concrete involves resistance to freeze-
thaw, corrosion, carbonation, alkali-silica reaction (ASR) and
chemical attack from sulfates and chlorides, and many more.
Concrete has the potential to be damaged if it is subjected to
freeze-thaw cycles as water expands during freezing. Frost
damage-a progressive deterioration process that starts with
the surface separation (or scaling) and ends up with extensive
cracking of the interior of the element-is a major concern when
concrete is used in cold regions. The deterioration proceeds
as freezing and thawing cycles are repeated, and the material
gradually loses its stiffness and strength. In addition, increas-
ingly irreversible expansion is induced.
Air-entraining agents are recommended for most of the
concretes, principally to improve resistance to freeze-thaw cy-
cles when exposed to water and deicing chemicals in cold re-
gions. This paper reports RDME and mass change for Solidia
Concrete and reference concretes after 300, and 800 freeze-
thaw cycles. Scaling resistance is reported after 50 and 100 cycles
for Solidia Concrete.
Materials, Mixture Proportions and Experiments
Materials, Mixture Proportions and Mixing Procedure
Solidia Cement, sand, coarse aggregates and water were
weighed as per proportions in Table 1. Coarse aggregates
were loaded to the mixer, followed by Solidia Cement and then by
sand. The aggregates, cement and sand were mixed for 1 min-
ute to produce a dry mix. While the mixer was rotating, 50%
of the water was added to the dry mix to produce a wet mix.
All water-reducing admixture was then added to the wet mix,
followed by the remaining amount of water. Finally, all air-en-
training admixture (AEA) was added to the wet mix. This wet mix
was mixed for an additional 3 minutes. The mixer was stopped
for one minute to settle the wet mix. Wet mix was mixed for an
additional 30 seconds and unloaded into a pan.
The air content and the unit weight of fresh concrete were
measured as per ASTM C231. Rectangular concrete beams with
the dimensions of 3 in x 4 in x16 in (75 mm x 100 mm x 405 mm)
and 4 in x 8 in (100 mm diameter x 200 mm length) cylinders
 CEMENT: CSB

Reference ments were done immediately after the completion of the thawing
Ingredients Solidia Concrete cycle.
Concrete
Freeze-thaw durability was calculated using the following
Ordinary Portland
325 equations:
Cement
Solidia Cement 400 -
(1)
Fly ash 0 81
According to ASTM C666, the freeze-thaw test process is
Sand 689 765
continued to 300 cycles or to the point when Durability Factor
Coarse Aggre- (DF) drops below 60%, whichever occurs first. As the number
1134 1032
gates of FT cycles are 300, RDME is equal to DF. As Solidia Concrete
Water 116 170 is a novel concrete, no long-term durability information under
AEA, ml/kg of FT exposure is available. Therefore, while ASTM C666 requires
3 3 testing up to 300 cycles, this testing was continued beyond 700
cement
cycles to evaluate the freeze-thaw potential of Solidia Concrete.
Water reducer,
10 0
ml/kg of cement Procedure to Determine Scaling Resistance
Water to cement-
0.30 0.42 CO2-cured Solidia Concrete and water-cured reference
ing materials
concrete specimens were preconditioned in air (23°C, 50% RH)
Air Content, % 5.5 6.7 for 14 days. A dam was installed using a waterproof material
Table 1: The proportions of raw materials for concrete mixtures, kg per around the perimeter of the specimens. This dam was designed to
cubic meter expose the top surface area of the specimen to a salt solution
consisting of 4% calcium chloride.
were cast in metallic molds in three layers. For the scaling test, For the scaling resistance measurement, the specimen was
concrete slabs of 12 in x 6 in x 3 in (302 mm x 151 mm x 76 at freezing temperature (-18°C) for 11 hours and at thawing
mm) were cast in mold in two layers. With the addition of each temperature (23°C) for 11 hours. Water was added to the sur-
layer, the mold was vibrated on a table vibrator for 30 seconds. face if the solution level dropped below 6 mm during the exper-
All Solidia Concrete specimens were demolded after 4-5 hours. iment. After every freeze-thaw cycle, the solution was changed.
The demolded concrete specimens were placed in a chamber During measurements, the calcium chloride solution was re-
for CO2-curing. The CO2-curing parameters to achieve the de- moved. The surface was flushed with water, pictures were tak-
signed compressive strength were 60oC and 98% inlet CO2 con- en to record changes due to exposure to FT action in presence
centration for 65 hours. of salt solution, and the mass of each specimen was recorded.
Comparable reference-concrete specimens were demold-
ed after 24 hours and submerged in lime-saturated water for Results and Discussions
28 days to achieve designed compressive strength. Reference Freeze-Thaw Test Results
concrete contained 20% fly ash as cement replacement which
is typical in pavement concretes in Indiana. The water to cement Mass Changes: The changes in mass and resonant fre-
ratio for Solidia Concrete was selected such as to obtain similar quencies of all specimens were measured after every 30FT cy-
porosity and compressive strength as that of reference concrete. cles. Figure1 shows the normalized mass (with respect to the
Solidia Concrete specimens were produced at Solidia Tech- initial mass) for Solidia concrete specimens (both air entrained
nologies’ facility in Piscataway, N.J. The freeze thaw resistance and non-air entrained) and for the reference concrete (air en-
test as per ASTM C666 (Procedure A – freezing and thawing in trained). Values higher than 1.00 indicate mass gain whereas
water) and scaling resistance test as per ASTM C672 were per- values lower that 1.00 indicate mass loss. For Solidia Concrete,
The Masterbuilder | July 2015 | www.masterbuilder.co.in

formed at Purdue University, West Layette, Ind. The results of
these tests were already presented at ACI Fall Convention in
2014.
Procedure to Determine Freeze-Thaw Resistance
Prior to initiating the FT testing both, the CO2-cured Solid-
ia Concrete specimens and water-cured reference concrete
specimens were preconditioned by saturating them in tap water
for 48 hours. Initial mass and fundamental transverse frequen-
cies were measured for saturated specimens. Each specimen
was then placed in a container with water surrounding it. The
containers were placed in the freeze-thaw apparatus. Each
freeze-thaw cycle consisted of lowering the specimen tem-
perature from 40o to 0oF and then increasing the temperature
back to 40oF over a time duration of about 5 hours. The mass
and resonant frequencies were measured for each specimen
after the completion of each 30 freeze-thaw cycles. Measure-
the increase in mass is attributed to water absorption during
the test as most of the mixing water is removed from Solidia
Concrete during CO2 curing. Although specimens were soaked
in water for 48 hours before the commencement of test, the
smaller size pores present in Solidia concrete are not expected
to saturate within this time period. It can also be observed from
Figure 1 that the mass gain is greater for air-entrained speci-
men due to the presence of large air voids. For the reference
concrete, continuous mass loss is observed after exposure to
FT cycles. After 500 cycles, air entrained Solidia Concrete has
about 1% mass gain, while air entrained reference concrete lost
about 6% of its mass. Non-air entrained Solidia Concrete lost
less than 0.1% mass. This behavior can also be seen in Figure
2, which shows photographs of Solidia concrete and reference
concrete specimens after exposure to 300 FT cycles. In Figure
2, aggregates are clearly visible on the surface of reference
concrete specimens. This is the result of scaling of the OPC-
67
 CEMENT: CSB
based concrete surface. In contrast, the Solidia Concrete spec-
imens do not show that much scaling and thus do not experi-
ence significant mass loss.
Figure 1: Mass change for reference concrete and Solidia Concrete over
the duration freeze thaw test up to 800 FT cycles
(A) Solidia Concrete (B) Reference Concrete
Figure 2: Concrete specimens made with (A) Solidia Cement and
(B) OPC cement after completion of the FT test (350 cycles)
Relative Dynamic Modulus of Elasticity: The relative dynamic
modulus of elasticity was calculated for all concrete specimens
exposed to freezing and thawing after every 30 cycles using
Equation 1. Figure 3 shows RDME values for Solidia Concrete
(air entrained and non-air entrained) and reference concrete
(air entrained) after exposure to different number of FT cycles.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Figure 3: Relative Dynamic Modulus of Elasticity for Reference and Solidia
Concretes over the duration freeze thaw test up to 800 FT cycles
The RDME values decrease due to the formation of mi-
cro-cracks in concrete specimens when exposed to FT action.
After first measurement, the RDME values were reduced for all
specimens and remained at about 90% or more after 300 cycles for
both air entrained Solidia Concrete and reference concrete. For
non-air entrained Solidia Concrete, RDME values decreased to
about 80% after 100 FT cycles and to about 58% after 300 FT
cycles. These values of RDME indicate very good FT resistance
for air entrained Solidia Concrete but marginal performance for
non-air entrained concrete.
68
(A) Initial 5 cycles 50 cycles 100 cycles
(B) Initial 10 cycles 15 cycles 50 cycles
Figure 4: Solidia Concrete (A) and reference concrete (B) scaling spec-
imens before and after completion of different number of FT exposure
cycles
Scaling resistance test results
Specimens from the Solidia Concrete and reference con-
crete scaling tests are shown in Figure 4A and 4B respectively
before and after different number of FT cycles. The tests were
performed as per ASTM C672, which is described in section 2.3.
Figure 4A shows no surface scaling for Solidia Concrete
after 50 FT cycles in the presence of calcium chloride solution,
which indicates good scaling resistance. The test was contin-
ued further to evaluate long-term performance for Solidia Con-
crete, which shows no visible scaling after completion of 100
cycles.
Figure 4B shows reference concrete specimens after dif-
ferent numbers of FT cycles. After exposure for 50 cycles, the
reference concrete specimen does not show any visible scaling
and, thus can also be considered having good scaling perfor-
mance.
Conclusions
In this study, the freeze-thaw and scaling resistance was
evaluated as per ASTM procedures for Solidia Concrete and
reference concretes. The following can be concluded form the
data collected from the study:
1) Air entrained Solidia Concrete performed extremely satis-
factorily in freeze-thaw testing, retaining 88% of the original
dynamic modulus even after 500 FT cycles and displaying
essentially no mass loss. Even without air entraining, the
performance of Solidia Concrete was judged to be reason-
ably satisfactorily-essentially zero mass loss being record-
ed even after 500 cycles, while the relative dynamic mod-
ulus at 300 cycles (the standard duration of testing) was
reduced to about 60% of the original value.
2) Air entrained Solidia Concrete showed no visible deteri-
oration in the standard scaling test, even after 100 cycles,
i.e. twice the number of cycles usually administered in this
form of testing.
3) Despite the relatively satisfactory performance displayed by
non-air entrained Solidia Concrete, normal air entraining is
recommended where freezing and thawing are anticipated.
 CONCRETE: CURING

Planning for Hot Weather Concreting

Nitin Sreenivasan
Technical Director, Technokotes

H
ot weather creates special chal- water content, Ib/cu.yd 310 14
lenges for pre casters, and tech- 300 12
nically speaking, there are more 10

Initial set, hr.

290
obstacles to overcome when placing con- 8
280
crete in hot weather than in the cooler sea- 6
sons. By understanding how heat, humid- 270 4
3-in (75-mm) slump
ity and wind affect the curing of concrete, 260 1 1/2-in. (38-mm) aggregate 2
you can adjust your mix and compensate 250 0
30 50 70 90 110 40 60 80 100 120
in a variety of other ways to maintain high Concrete Temperature, 0F Concrete Temperature, 0F
quality standards. Effect of temperature on water requirement of concrete (Ref.1) Effect of temperature on conrete setting time (Ref.1)
While you will not likely need to take Figure 1
all of the recommended precautions stated
below, each hot-weather scenario should makes control of air content more diffi- Wind is not customarily associated with
be analyzed individually by qualified per- cult. High temperatures reduce air con- hot weather, for example, but it is an
sonnel, who should find the optimum mix tent, requiring higher dosages of air- important factor because the wind accel-
of quality, practicability and economy. entraining admixtures. erates the curing process in combination
Placing, finishing, and curing concrete Even if more cement is added to com- with temperature, humidity and solar radi-
require extra care in hot weather. When pensate for increased water demand, ation. Efforts to preserve concrete quality
temperatures rise above 30°C, fast setting, quality of the hardened concrete may suf- on windy, sunny days are more critical than
lower strengths, and cracking are all more fer. Concrete cured at high temperatures those required on calm, humid days, even
likely. But these problems can be avoided gains early strength faster but at the if ambient air temperatures are identical.
by recognizing the causes and minimizing expense of 28-day strength. There's also As shown in Fig. 2
weather effects. more cracking due to drying shrinkage and
The key to success in hot weather concreting
a greater possibility of thermal cracking,
Why Hot Weather Can Cause Problems is planning and preparation. By carefully
especially in mass concrete.
When concrete temperature increases,
increased water is required to produce the
slump needed for placing. Typical effects
The Masterbuilder | July 2015 | www.masterbuilder.co.in

for a 75 mm-slump concrete made with

11/2- inch- maximum size aggregate is shown
below in Figure 1. Rate of slump loss
increases as well, increasing the chance
that water will be added at the job site.
Regardless of whether water is added at
the plant or the job site, higher water con-
tent increases shrinkage and a higher water-
cement ratio reduces strength.
Because higher temperatures speed
setting, handling and finishing are more
difficult and cold joints are more likely.
Plastic cracking also may occur during fin-
ishing when humidity is low or wind speed
is high (Figure 2).
70

If concrete is air- entrained, hot weather Figure 2


selecting concreting materials and con-
struction methods, producers and con-
tractors can avoid most problems.
Concrete Production, Delivery, and Dis-
charge
The first steps in controlling concrete
temperature are taken at the batch plant.
Lowering concrete temperature decreases
water demand, slows slump loss, increases
setting time, and reduces the chance of
plastic shrinkage cracking.
- Minimize cement content by using
water reducers and fly ash as a cement
replacement. Also use the largest size
and amount of coarse aggregate per-
mitted by placing conditions.
- Use retarders to control fast setting
and when long haul times are
unavoidable. But carefully control the
dosage, especially for flatwork. If too
much retarder is used in concrete for
slabs, the surface may crust over while
the underlying concrete remains plas-
tic. Finishers may start floating and to
welling too soon, creating a wavy sur-
face or trapping bleed water beneath
the surface.
- If a higher slump is needed, consider
using third generation high range water
reducers instead of water to get the
needed slump. These admixtures pro-
ducehighslumpsthatlastupto2hours.
Table 1: Potential problems during hot weather concreting (ACI 305)
- The high slump also reduces friction
between aggregate particles during
mixing, slowing heat build up in the
mixer drum during transit.
- Consider substituting Type II moder-
ate heat cement for Type I normal
cement. Avoid using Type III cement.
- Shade aggregate stockpiles and wet
them to promote evaporative cooling
that lowers concrete temperature.
Wetting with chilled water is even more
effective, especially when humidity is
high.
- In extremely hot weather or when con-
crete for massive structures is being
produced, use chilled batch water, add
ice as part of the batch water, or cool
the concrete with liquid nitrogen.
- Time deliveries so placing delays don't
cause long truck waiting periods. Dis-
charge concrete as soon as possible
after mixing.
- Limit mixing to 100 drum revolutions
at the mixing speed designated by the
mixer manufacturer. Use agitating
speed for additional revolutions.
- For long hauls during hot, humid
weather, consider delaying mixing
until the truck reaches the job site.
This requires loading the materials into
the drum without rotating it and
charging the cement last. If relative
humidity is low, concrete can some-
CONCRETE: CURING
times be hauled long distances after
mixing even when air temperatures are
high.
- Paint mixer drums white so they don't
absorb as much solar heat. For a 1-hour
delivery time, concrete in a white drum
will be about 2.5°C cooler than con-
crete in a red drum.
- When possible, schedule deliveries to
avoid the hottest part of the day. In arid
climates, concrete poured after mid-
night is exposed to lower temperatures
and less wind. Also, final set occurs
near sunrise when early drying and
cracking are less likely because rela-
tive humidity is highest.
- Don't add water at the job site other
than that required initially to adjust to
the specified slump.
Placing and Finishing
Hot weather concreting requires hav-
ing enough workers and equipment on the
job to handle the unexpected. Anticipating
problems is a part of the planning process.
- Have all forms, equipment, and work-
ers ready to handle concrete, espe-
cially the first delivery of the day.
- Use a thermometer to monitor con-
crete temperature when the mix is
delivered and call for plant adjustments
if needed.
- Have at least one standby vibrator on
The Masterbuilder | July 2015 | www.masterbuilder.co.in
71
 CONCRETE: CURING
hand for every three in use. Vibration
equipment failures are more frequent
in hot weather.
- Keep all equipment that touches the
concrete cool: chutes, conveyors, pump
lines, tremies, enforcement, and bug-
gies. Protect from sunshine if possible
or spray with water.
Figure 3
- If there isn't a vapour barrier under the
slab, dampen the sub-grade before
placing concrete. If there is a vapour
barrier, compact a 1- to 3-inch-thick
layer of damp sand over it before plac-
ing concrete
- Dampen side forms for slabs or walls
withcoolwaterbeforeplacingconcrete.
- Work fast but don't finish concrete while
there's still bleed water on the surface.
When there's danger of plastic
shrinkage cracking, control evaporation
from the concrete surface. Use fog sprays
or spray on a mono molecular film. Under
severe drying conditions, cover all exposed
surfaces after they 're placed and screed-
ed, and then uncover only that part of the
surface being worked. See Figure 3.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
72
Curing and Protection
Curing is an especially critical opera-
tion during hot weather. Poor curing can
cause low strength, cracking, and discol-
oration.
- Start curing as soon as finishing is
completed.
- Cure continuously, preferably with
water. Continuous curing is espe-
cially important during the first day
after concrete is placed.
- Protect all surfaces from drying, even
for a short time, since intermittent dry-
ing can cause pattern cracking. Use
wet burlap or cotton mats, a continu-
ous spray mist, or white-pigmented
curing compound.
- Cure for the specified period but not
less than three days. Seven day curing
is better.
- During curing, spray the outside sur-
faces of forms to keep them cool.
- When forms are stripped before the
specified curing time has elapsed, pro-
vide a wet cover for the newly exposed
surfaces.
Testing and Inspection
During hot weather, contractors and
producers are sometimes penalized for
others' mistakes. If test cylinders are
treated improperly, low tests may result,
with the concrete supplier or contractor
often taking the blame. Careful testing can
eliminate some of the disputes and job
delays that result after low strength test
results are reported.
- Make slump, air tests, and test cylin-
ders immediately after obtaining the
concrete sample.
- Don't leave test cylinders unprotected
in the hot sun. High initial curing tem-
peratures alone can reduce 28-day
strength by as much as 10%. Keep cyl-
inders at 20°C to 27°C for the first 16
to 24 hours after casting. Do this by
storing them in a shady location, a field
curing box, an air- conditioned con-
struction trailer, or wrapped in wet
burlap. Evaporation from the wet bur-
lap helps to keep cylinders cool.
- Prevent test cylinders from drying by
casting them in plastic moulds with a
plastic lid or by covering them with
plastic sheets.
- Make air content tests more frequently
than on jobs at normal temperatures.
Notify the batch plant when air con-
tent approaches the lower specifica-
tion limit.
At frequent intervals record air tem-
perature, concrete temperature, general
weather conditions, wind speed, and rela-
tive humidity. Also record slump loss, water
added on arrival, and corresponding mix-
ing time.w
For More Details:
Technokotes
26-B, Goodwill Sanskruthi, Bhairavnagar,
Dhanori Road, Pune - 411015, INDIA.
Phone: +91 20 27171412 / 27172249
Email: nitin.sreenivasan@gmail.com
Web: www.technokotes.co.in
 SILICA FUME

Silica Fume for High

Rise Buildings

Surendra Sharma
Dy-General Manager (Construction)
Elkem South Asia Pvt Ltd.

Introduction: range 8599% (Figure 1). The ultra-fine 300 to 600kg/m3. In this densified form,
particles improve particle packing and the ultra-fine silica fume particles are
Silica Fumes has been used as a
produce a highly pozzolanic reaction in agglomerated loosely together. The
mineral admixtureto improve concrete
the concrete mixture, leading to: product can then be delivered in bulk or
properties since the 1950s. Commercial
bags to the concrete plant. During mixing
development of the material began in the - Reduced permeability, therefore at the concrete plant, it is important to
1970s with Elkem Microsilica® being a reduced ingress of chloride &other ensure the densified silica fume
registered trademark belonging to Elkem harmful agents and resulting in agglomerates are broken down, reverting
Silicon Materials of Norway. The term greater protection for reinforcing to their primary, ultra-fine condition with
'microsilica' is commonly used in many steel, especially in critical full dispersion throughout the concrete
countries to describe silica fume. infrastructure e.g. marine structures mixture. This is achieved through correct
As a strategy for more sustainable - Higher strength batching sequence, efficient mixing plant
development, it is worthy of considering - Higher abrasion & erosion resistance and adequate mixing time. Due to its high
High Performance Concrete (HPC) which
The benefits of silica fume in high surface area (typically ca. 20,000m2/kg),
due to its high performance in terms of
performance concrete are summarised silica fume concrete requires the use of
strength and durability can reduce
in Table 1 superplasticiser to achieve appropriate
consumption of concrete and thereby
reduces carbon footprint too. Features of silica Reaction in concrete Key concrete benefits Commercial
fume possibilities
Production of silica fume High SiO2 Extremely efficient Reduce size and
Microsilica is an industrial by-product, content (>85%) pozzolanic reaction Optimal high mass of elements
produced during the manufacture of (increased CSH and compressive and with higher
reduced Ca(OH)2), flexural strength strength concrete
metallurgical silicon. Around 350500kg of
improved transition zone
silica fume arises for every tonne of between aggregate and Reduced corrosion of Longer service life
metallurgical silicon produced. paste steel reinforcement for marine
Silica fume can be defined as ultra- Glassy Lubricating, ball-bearing structures
fine particles of amorphous silicon (amorphous) effect Greater abrasion and
dioxide. Each particle is spherical, sub- spherical shape chemical resistance Longer service life
The Masterbuilder | July 2015 | www.masterbuilder.co.in

micron in size and with SiO2 content in the Ultra-small Maximum particle for industrial floors
particle size (less packing, reduced voids Reduced segregation
than 1 micron) and permeability and bleed Easier pumping for
tall buildings
Reduced sprayed
concrete rebound Economical
sprayed concrete
Table 1: Features and benefits of silica fume
water/binder ratio.
Handling and Mixing Silica Fume
Silica fume tends to reduce or eliminate
During production, silica fume initially bleed water; it is imperative that a suitable
takes the form of an ultra-fine (average curing regime must always be enforced at
particle size 0.15 micron) dry powder and the construction site[1].
has very low bulk density. To aid handling,
Current uses of Silica Fume Concrete
the silica fume powder is usually subjected
Figure 1: Silica fume particles are spherical to a 'densification' process, thereby Protection from corrosion for steel
74

and sub-micron sized increasing the bulk density from around reinforcement
 SILICA FUME

Concrete structures requiring strength
and durability in a high chloride
environment, such as harbors and
marine bridges, are a major application
for silica fume. For example, Bandra-
Worli Sea Link Bridge in Mumbai used high
performance silica fume concrete. The
required strength and marine durability
were achieved using M50 grade (with 10%
silica fume) for the piles and M60 silica
fume concrete for the pile caps, piers and
precast segments.
Severe chloride environments, such as
marine structures and projects in the
Middle East, Utilise silica fume for maximum
service life. In the Middle East, it is common
for a maximum chloride permeability of
1000 coulombs to be specified (ASTM
C1202-09 method). Typical silica fume
concrete mixtures supplied to these
projects achieve around 500 coulomb or
less.
Shotcrete and tunnels
M30
Cement , kg/m3 317
Silica fume, kg/m 3 0 10%
Aggregates, kg/m 3 1900
Water, kg/m 3 143
w/b ratio 0.45
Strength 3 days 20.89
Strength 7 days 28.13
Strength 28 days 35.73
% abrasion loss, 72 hrs 6.26
Table 2: Mix Design and Results,
Tehri Dam Laboratory Trials
Silica fume is also specified for
tunnelling projects, both for sprayed
concrete and precast segments. For
sprayed concrete, silica fume improves
both the fresh rheology and the long-term
durability of the concrete. In precast, it is
used to increase both strength and
strength of the matrix and the improved which is typically based on a ternary blend
bond between matrix and aggregates. of binder.The aim of a 'triple blend' is to
Tehri dam, constructed on the Bhagirathi economically optimise strength, durability
river in North India, is a 2000MW and placement. For example, the
hydroelectric power plant with an earth Guangzhou International Finance Center,
and rock fill dam and several chute and designed by Wilkinson Eyre and completed
shaft spillways. The water velocity in the in 2010 is 432m tall with 103 floors and for
spillways has been recorded up to 45- this project a ternary blend silica fume
50m/s with circular motion especially at concrete mix was used to improve
the junction of the vertical and horizontal pumpability and achieve high strength.
shafts of the shaft spillway, creating high The structure is a column-in-column design,
risk of having severe cavitation damage with a reinforced concrete core tube and
along the lining of the spillway. A large an exterior frame of concrete filled steel
amount of fine sand and silt is carried columns. Some 70,000m3 of high strength
in the river, posing a high risk for concrete was supplied, including C90
abrasion-erosion damage to the pumped to 168m height and C80 pumped
hydraulic structure [2]. to 410m. Details of the C80 concrete mixture
For the Tehri dam project, laboratory are shown in Table 3
trials were conducted using various Ultra-high strength concrete
concrete grades, with and without silica
fume. The abrasion-resistance test method Ultra-high strength concrete (UHSC)
used was ASTM C 1138. This method uses technology has been extensively researched
steel balls in water stirred by paddles at by the academic community. There is
growing awareness of the commercial value
of these higher performance concretes. A
M50 M60 M70
typical UHSC mixture could have a water/
340 365 380
binder ratio around 0.150.20 and a 20%
10% 10%
1934 1909 1890 silica fume dosage (of total binder mass).
142 140 130 The silica fume contributes towards the high
strength through (a) highly efficient
0.38 0.35 0.31 pozzolanic reaction and (b) optimised
29.33 43.29 51.16 particle packing. To help design a UHSC
43.82 56.49 60.85 mixture with optimal particle packing,
56.18 68.23 75.4 computer software such as those based
3.06 2.88 2.75
on the Andreassen model can be used [3].
P11 42.5 R
(GB175-
2007 Water/binder
GGBS Silica fume Superplasticiser Consistence
‘Common ratio
Portland
Cement’)
3 3 3
420kg/m 142kg/m 20kg/m PCE 0.26 220260mm
Table 3: C80 mix design, Guangzhou International Finance Center
The Masterbuilder | July 2015 | www.masterbuilder.co.in

durability.
Abrasion resistance
Applications requiring exceptionally
high abrasion resistance, such as heavy
duty industrial floors, coastal sea
defences and military pavements specify
high performance silica fume concrete.
For example, a number of hydroelectric
dam structures in India, e.g. Chamera,
Salal, and Tehri, have utilised high
performance silica fume concrete to
reduce erosion and abrasion damage in
the spillways and stilling basins.
Silica fume will increase the abrasion
resistance of concrete through increased
1200 rpm to simulate the abrasive action
of waterborne particles such as silt, sand,
gravel, and boulders. The results of the
laboratory trials are shown in Table 2. A
high performance M70 concrete mix with
10% silica fume showed least abrasion
loss and was selected for use in the
construction project.
High rise buildings and pumping
Silica fume is routinely used in the
construction of the world's tallest buildings.
Classic examples include the Burj Khalifa
in Dubai and the Petronas Twin Towers in
Kuala Lumpar. This type of structure
Recent research in Norway has
demonstrated that UHSC can successfully
be made using locally available, common
materials [8]. Understanding the synergy
between silica fume and superplasticiser
in the UHSC is critical to achieve the very
low water/binder ratio required by UHSC.
This is an area of research now being
progressed by Elkem.
Self-compacting concrete
Self-compacting concrete (SCC) mixes
can be sensitive to fluctuations in material
properties and batching accuracy,
potentially leading to issues of segregation
or variations in consistence. This can make
75

requires a high performance concrete,

 SILICA FUME

Building Name Location Height, meters Date large-scale supply of SCC from ready-
mixed plants more difficult and onerous.
Tallest structure in To overcome this issue and improve the
BurjKhalifa Dubai 828 the world,
robustness of self-compacting concrete,
completed 2010
a relatively low dose of silica fume (for
International example, 5% silica fume by weight of total
Hong Kong 484 Completed 2010
Commerce Centre cementitious content) is effective.
Below the summary of High rise
Tallest twin
executed in the recent past where
Petronas Twin buildings in the
Kuala Lumpur 452 Microsilica has been used in the project
Towers world, completed
1998 (Table 4).

Completed 2004, Concluding Remarks

Taipei 101 Taipei 508 tallest LEED rating Since first becoming commercially
building
available in the 1970s, silica fume has
Guangzhou West steadily established itself as aversatile
Guangzhou 432 Completed 2010
Tower and reliable material. It is being used to
produce high performance concretein a
Trump Tower Chicago 423 Completed 2009 wide range of projects around the world.
Two International Higher performance concrete can play an
Hong Kong 413 Completed 2003 increasingly significant role in improving
Finance Centre
the sustainability of concrete construction,
One of the world’s by improving the durability and service life
Burj Al Arab Dubai 321 tallest hotels, of infrastructure and by enabling structural
opened 1999
design improvements such as reduced
311 South Wacker column sizes.
Chicago 293 Completed 1999
Drive
References
Trianon Frankfurt 186 Completed 1993 1. SILICA FUME ASSOCIATION. Silica fume
users manual. USA, April 2005, available
World One, Mumbai 442 On going fromhttp://www.silicafume.org/concrete-
manual.html
Royal PolasisWorli Mumbai 320 Completed
2. MANN P P S AND VISHNOI R K.Abrasion
Oasis Reality Worli Mumbai 372 Ongoing erosion resistant high performance concrete
at Tehri dam project – A case study,
Proceedings, Workshop on High
Minerva Tower Mumbai 304 On going Performance Microsilica Concrete &
Shotcrete application in Hydropower Projects,
IREO Victory valley New Delhi 178 Completed 28 April 2006, NCB, Ballabgarh, India
3. EMMA (ELKEM MATERIALS MIX ANALYSER),
Table 4 COMPUTER software available from Elkem.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
76
 ROLLER COMPACTED CONCRETE

Construction of Roller Compacted

Concrete Dam: A Case Study at
Batu Hampar Dam
Assrul Reedza Zulkifli1, Abdul Rahim Abdul Hamid2,
Mohd Fadhil Arshad3, Juhaizad Ahmad4
1
Faculty of Civil Engineering, Universiti Teknologi MARA, Shah Alam Selangor, Malaysia
2
Faculty of Civil Engineering, Universiti Teknologi Malaysia Johor Bahru, Malaysia
3
Institute Infrastructure Engineering and Sustainable Management (IIESM),
Universiti Teknologi MARA, Shah Alam Selangor, Malaysia
4
Faculty of Civil Engineering, Universiti Teknologi MARA, Shah Alam Selangor, Malaysia

Abstract: Rapid and economical construction are among nu-
merous advantages of the construction of roller compacted
concrete (RCC) dam compared to conventional dam. However,
the complex process of RCC dam construction is facing diffi-
culties due to lack of understanding and involvement from the
local construction industry player since this type of construction
in Malaysia is still new. Therefore, this paper presents the pro-
cess of RCC dam construction in Malaysia. Site observation and
the review on literature of RCC dam construction was conduct-
ed to get the real view on the construction process of such proj-
ect. The expert panel interview was conducted to get the view
on RCC dam construction. Panel interview result was analysed
and supported with the literature to gather the process of RCC
dam construction. From the result analysis, the construction
processes which consist of determination of mix design, RCC
production and RCC placement is presented.
The new technology is adopted for the construction of
gravity dam and the technology is known as roller compacted
concrete (RCC). Reference [1] stated that RCC has been rapidly
developing over the past 40 years and now is commonly used
for gravity dam application. Recently, Malaysia started adopting
RCC technology to the gravity dam construction. With the fact
that the construction of RCC dam is still new in Malaysia, the
understanding on such construction is very limited among local
construction industry player. The first RCC dam in Malaysia is
The Masterbuilder | July 2015 | www.masterbuilder.co.in
standing the construction of RCC dam among the local con-
struction industries player.
This paper presents the process of the construction
of Roller Compacted Concrete Dam in Malaysia with Batu
Hampar dam in Rembau, Negeri Sembilan as the case study
since Malaysia has just started to adopt the RCC dam tech-
nology in the construction of the Dam project. The scope of
this study is focused on construction stage of RCC dam proj-
ect. This study involves interview sessions with the profes-
sional and semi-professional construction personnel who
were involved in RCC dam project in Malaysia. Roller Com-
pacted Concrete Dam
Roller Compacted Concrete Dam
Concrete in general are defined as a composite construc-
tion material composed primarily of aggregates, cement and
water. According to America Concrete Institute (ACI), Roller
compacted concrete (RCC) is defines as concrete compact-
ed by roller compaction [3]. RCC is considered for application
where no slump concrete that can be transported, placed
and compacted by using the normal construction equipment
that being used in earthfill and rockfill works [3]. Parallel to
this, [4] defines RCC as no slump consistency concrete that
is placed in a thin horizontal lifts and compacted by vibratory

rollers. The application of RCC is considered when it is eco-

Kinta dam which is situated in Ipoh and constructed by Japa-
nese contractor (Hazama Corporation). It was completed in
2007. In 2008, the construction of Batu Hampar dam is started
which is the second RCC dam project in Malaysia. Dekon Sdn.
Bhd, the local contractor who had no previous experience of
RCC dams was selected to construct the dam. The government
intention to develop local knowledge or expertise of RCC in-
stead of recourse to international contractor is the main rea-
son why Dekon was selected [2].
The understanding and involvement from the local con-
struction player is still at the early stage. Therefore, the
construction personnel such as engineer, the supervisor,
the technician, until the general workers has very limited
knowledge on the RCC dam project that leads to difficulties.
Hence, there is a need to capture the knowledge of RCC dam
construction.
This study will serve as an avenue for further under-
78
nomical competitive with other construction method and in
this case is the application of RCC method for construction
of a gravity type of dam [4].
RCC dam construction requires four basic component
which includes ingredient for the concrete, production of the
concrete, transportation and placement of the concrete to
the dam [5].
RCC Mix Design
The typical RCC mix design contains approximately 5-6
percent water, 5-10 percent cement and flyash, 30-35 per-
cent fine aggregates and 60-65 percent coarse aggregates.
This design possesses the characteristic required by the
gravity dam which is strength and permeability properties
[4]. RCC mixture proportioning procedure is very similar to
conventional concrete. According to [6] the general method-

ology of RCC mixes proportion by used soils approach is:
1) Selection of suitable aggregate.
2) Select range of trial mixes which consist of various ce-
ment and fly ash content.
3) Determine desirable moisture content.
4) Prepare RCC cylinder and specimen for strength testing
and durability testing.
5) Select mix proportion based on laboratory result
RCC Placement
According to [7] the machineries used to construct RCC
dam are similar to the construction of earth embankment
which is dozer, dump truck and roller compactor. Dump
truck used to transport the RCC mixture to the dam site, and
dozer used to spread the RCC material at certain thickness,
then the roller compacter required to compact the RCC ma-
terial [7].
According to [3] RCC lift minimum thickness is ranging
from 150 mm to 1m but in normal practice in United State
is rarely exceeded 0.6m and the thickness is depending on
mixture proportions, plant and transport capability, place-
ment rates, spreading and compacting procedure, and the
size of placement area.
Methodology
The overall view of the RCC dam construction was cap-
tured from the literature review and interview questions
were drafted based on site observation. Interview sessions
were conducted and the statement given by the respondent
was recorded. The interview was recorded using a digital
recorder to record opinions provided by the interviewee and
were converted into a written form. Furthermore, content
Fig. 1: Works Breakdown Structure of RCC Dam Construction
ROLLER COMPACTED CONCRETE
analysis was done on the answer and statement given by ev-
ery respondent during the interview.
Result and Discussion
From the analysis, the processes of RCC construction
works as shown in Figure 1 are listed below:
1) Determination of RCC mix (RCC design mix)
2) Aggregates production
3) Foundation preparation and treatment
4) Diversion culvert and river diversion works
5) RCC mix production
6) RCC placement works
7) Instrumentation works
A. Determination of RCC Mix
Three combined mix aggregates grading namely T1(63-
25)mm size, T2(25-5)mm size and T3(5-0.75)mm size which
is coarse, medium and fine size of aggregates are adopted.
This mix aggregates grading meets the specified grading en-
velope as in specification. Cement with low heat of hydration
is the ideal cement to prevent temperature rise in concrete.
To lower the heat of hydration of RCC, less amount of ce-
ment is used and type F Flyash is used to replace the quan-
tity of cement. It was finalized and approved by RCC dam
specialist as follows:
1) T1-28%, T2-34%, and T3- 38%
2) Cement- 65kg/m3 and Flyash-105kg/m3
3) Moisture content between 4.5% and 5.4%
4) Vebe time with a 12.5kg surcharge was 15 to 30 second
5) Retarder is used to increase the initial setting time, there
by maintaining fresh lift joint
6) Bedding mortar used to treat the cold joint for RCC lift
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79
 ROLLER COMPACTED CONCRETE

B. Aggregates Production of upstream RCC dam where the erection of formworks was
made as the level of RCC increases. Every increasing level
Three types of aggregates produced based on specifi- of RCC, system formworks is lifted up using a mobile crane
cation namely T1 (63-25)mm, T2 (25-5)mm and T3 (5-0.75) and carpenters tied bolt and nut of the formwork. Figure 3
mm which is coarse, medium and fine size of aggregates. shows the formworks at upstream of Batu Hampar dam.
Before RCC placement take place, the aggregates needs to The precast concrete blocks embedded with steel plate are
be stockpiled at least 80% of total amount of aggregates re- arranged by using mobile crane along the area where RCC
quired to complete the project. is to be placed that form a downstream step as shown in
C. Foundation Preparation and Treatment Figure 4 which is the same method used in China 131 meter
high Jiangya Dam, precast concrete block were used to form
Site clearing and removing overburden are the first step the step in downstream face of the dam [8].
in preparing the RCC dam foundation. After site clearing
and removing the soil or overburden was done, rock scal-
ing works are the next step that to be done. Rock scaling
works are to determine the type of rock where the spec-
ification state that, dam are to be sit on grade 2 or better
rock. Foundation grouting are carried out is to strengthen
the foundation and to ensure permeability of the foundation
is high. The concept is to seal of the void, crack and fracture
inside the rock that will strengthen the foundation for the
dam to sit. The granite rock is permeable and as a result,
fewer amounts (volume) of grouting are needed.

D. Diversion Culvert and River Diversion

Diversion culvert is a reinforced concrete structure with

15m diameter x 60 m long, complement with upstream and a
downstream cofferdam. This is to allow the river flow trough Fig. 3: Carpenter Fixing the Formworks at Upstream of the Dam
cofferdam into the diversion tunnel and flow to downstream
of the river.

E. RCC Mix Production

Continuous pugmill type of production plant is used for

RCC production which is able to produce maximum capacity
of 400 m3/hour [2]. This plant control proportion of aggre-
gates component by volumetric, and cement and flyash by
weight control. Due to weather condition in Malaysia, chill
water is used to lower the temperature of RCC mix.

F. RCC Placement Works

At the beginning stage of RCC placement, RCC is to be

placed at a series of 15 meter wide strips from downstream
to upstream in 6 meter section. The thickness of placement
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is 300 millimeter and compacted by vibratory roller com-

pacter. The time allowed from mixing of RCC, transport,
spreading and compaction is 45 minute. Immediately after
RCC has compacted, the field density test (FDT) was carried
out using nuclear density meter to measure the density of
RCC. Then, if the compaction achieved 98% above, the next
layer is continued with the same method and routine. Figure
2 shows the routine of RCC placement works.
Fig. 2: Routine of RCC Placement
1) RCC Placement Preparation
System formworks were used to form 65 m vertical wall
80
Fig. 4: Concrete Block are Arrange to form a 600 m Downstream Step
2) RCC Surface Preparation
When the RCC surface are left more than 8 hour, normal-
ly due to plant breakdown or other issues that RCC place-
ment are needed to be stopped, lift joint treatment needs
to be performed before continuing a new layer of RCC. On
the surface of old RCC layer, roughening was performed by
using high pressure water jet blasting and the time to im-
plement it is determined by hardening time which is 8 hours
after compaction. Immediately after green cutting was done,
bedding mortar is spread and the new layer of RCC place-
ment is continued. This method was carried out to ensure
the good bonding between joint lift which is between the lay-
ers of RCC.
 ROLLER COMPACTED CONCRETE

3) Transporting, Spreading and Compacting ens, and prior to the placement of the next layer. Transverse
joint were cut by a vibratory blade machine and galvanized
In the early stage of RCC placement works, RCC was thin plates were installed in the cutting plane to prevent
transported by dump truck directly from the RCC mixing closing that has shown in Figure 7. Figure 8 shows the loca-
plant. The usage of dump truck was recognized as inefficient tion of water stop, drainage hole and transverse joint.
due to the site was at narrow steep side that lead to frequent
needs to change and erect the temporary access for place- 6) RCC Curing
ment works. Therefore, the conveyor system is essential to
transport RCC directly to dam site. After placement, if the commencement of next layer of
Conveyor system is required to transport RCC. However, RCC is more than 24 hour, the concrete is cured by water
due to the unavailability of technology in Malaysia, cost and ponding.
other management issues, the conveyor system was not ap- 7) Laboratory Testing and Quality Control of the RCC Dam
plied at the beginning of the placement works. The convey-
or system was used only when the RCC reached level 95 m Various quality control measures were executed at RCC
(lowest level was RL 75m). Figure 6 shows conveyor system dams so that the quality of materials is monitored carefully.
that has been apply at Batu Hampar dam. Quality control methods that were applied at Batu Hampar
RCC that was deposited from dump truck at the dam site dam is as below:
was spread with 300 mm thickness by tracked dozer. Single
drum vibratory roller compacter was used to compact the
RCC. Single Vibratory rollers compacter makes one round
trip over the concrete without vibration and continued with
at least three round trips with vibration. Practically five (5)
to seven (7) passes with vibration is enough to achieve the
98% compaction density. This method is fast and sufficiently
accurate which contributes to uniformly compacted RCC [9].
Immediately after compaction was sufficiently carried
out, density of the RCC or field density test was tested us-
ing nuclear density meter. Figure 5 shows RCC Transporting
and spreading and compacting process.

4) GERCC Application

Grout enriched RCC (GERCC) is produced by adding 3:1

or 4:1 water-cement ratio grout to the uncompacted RCC
and then concrete vibrator used to compact the concrete.
Grout was mixed using mixer and spread manually using
bucket that as shown in Figure 4.7. The concept of using
GERCC in RCC dam is to be applied at location of RCC place-
ment where difficult to access by vibratory roller compacter.
By applying GERCC it fills the void in RCC and create the Fig. 5: RCC Transporting, Spreading, and Compacting, Nuclear Density
smooth surface especially for upstream and downstream Meter used to Check the Density Every Layer of RCC Placement Completed
portion where it can be seen clearly after formworks have
been dismantled. According to [10] at Kinta dam, GERCC are
applied at the entire upstream and downstream faces (in-
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cluding the stepped spillway), the transition zone between

RCC and rock abutments, drainage gallery walls, as well as
encasement of waterstops, drains, and reinforcing steel.

5) Transverse Joint, Drainage Hole and Water Stop

At the upstream and downstream edges of the dam, Fig. 6: Conveyor System Apply at Batu Hampar Dam when the RCC Level
Reach Higher Level
galvanized steel plates were installed in advance as a con-
traction joint at 15 m spacing. Then, water-stop and drainage
holes were set in the upstream face of the dam. The drain-
age hole and water stop were set at the upstream face of
the dam prior the increase of RCC. Drainage hole function is
to collect and convey the water that seep thru the dam and
the water are drain out from drainage gallery to downstream
river.
Transverse joints are installed to prevent temperature Fig. 8: Water Stop, Drainage Hole
Fig. 7: Transverse Joint were Cut and and Transverse joint Location,
cracks in the concrete [11]. The installation took place after Installed a Galvanize thin Plate at from left, Workers apply GERCC at
the completion of RCC placement layer and before it hard- Batu Hampar Dam
82

Upstream Face of the Dam

 ROLLER COMPACTED CONCRETE

1) Concrete Strength Instrument Type Application

Concrete strength is being monitored according to date Measure the pore water
Vibrating wire piezometer
the cylinder sample was taken and compressive strength pressure
test is conducted 7, 14, 28, 56, 96 and 180 day. It was carried Combine biaxial
out from the determination of RCC mix process until RCC Ground lateral movement &
Inclinometer/magnetic
settlement
placement works are completed. To monitor the compres- extensometer
sive strength of RCC, compressive strength test and indirect Thermocouple Temperature of the dam
tensile strength test is carried out at the stated days.
Measuring strain in mass of
Vibrating wire strain gauge
2) Density of RCC RCC dam
Measure the internal stress
Nuclear density meter is used to check the density of the Vibrating wire pressure cell
of RCC
RCC after compaction is carried out. The number of passes
of the vibratory roller is manually counted to ensure the ad- Surface settlement/ deflec- Vertical and horizontal dis-
equate compaction of RCC layer. tion point placement of the dam
Table 2: Instrument Installed at Batu Hampar Dam
3) Vebe Consistency Test of RCC Mix
Conclusions
RCC concrete is dry and lean, the slump test cannot be
used to measure its consistency [12]. The Vebe test with the The process of RCC dam construction in Malaysia start-
standard container is conducted to monitor the consistency ed from determination of RCC mix until RCC placement
and workability of RCC mix. The test is conducted once every works. Before RCC placement started, it requires the prepa-
batch of RCC production. Optimum Vebe time is between 15 ration process which involves the preparation of RCC mix,
to 25 second, where it is the optimum in workability of RCC. foundation preparation, and diversion works. Preparation
of RCC mix includes finalizing the RCC mix and production
4) RCC Material Testing of RCC. Further to RCC placement works, it requires the
complex of construction method in order to place a large
RCC material testing is carried out in the early stage of
amount of mass concrete to form a gravity type of dam. The
RCC construction until the end of RCC construction works.
instrumentation is installed at the dam during construction
The RCC material are tested to ensure the consistency of the
stage to monitor overall performance of the dam structure
RCC material. Table 1 shows the major material testing for
to ensure dam safety.
Batu Hampar dam project.
References
Material Test Frequency
[1] Warren, T., Denoyer, A., and Ulas, A., (2011). Taking advantage of RCC:
Chemical composition, Ted Warren discusses the history of roller compacted concrete (RCC)
Every delivery
Cement moisture content, specific dam construction and its various applications and advantages to gravity
to site
gravity, finess, temperature dam design and construction. International Water Power and Dam Con-
struction, 63(7), 20-23.
Every delivery [2] Wagner, C. (2011). Batu Hampar dam - design and construction of an
Flyash Same with cement testing
to site RCC dam. Dams and Reservoirs, 21(2), 77-90.
Flakiness test, sieve analy- 1 per day and [3] Department of The Army, U. S. A. C. o. E. W., DC. (2000). Engineer Man-
ual-Engineering and Design Roller-Compacted Concrete. [Engineer
sis, specific gravity, sound- every new Manual]. EM 1110-2-2006
Aggregates ness, and others testing production of [4] Bass, R. P. (1991). Alternative Dam Construction Techniques. Proceed-
that related to aggregates. aggregates ings of the 1991 Georgia Water Resources Conference, March 19-20,
Instructed by engineer stockpile 1991, Athens, Georgia.
The Masterbuilder | July 2015 | www.masterbuilder.co.in

Table 1: Material Testing at Batu Hampar Dam
E. Instrumentation
According to [11], the instrumentations installed in dams
are for the purpose of:
1) Monitoring overall performance of the dam structure to
ensure dam safety.
2) Monitoring the behaviour of the RCC dam.
Different instrumentation, monitors different character
or behavior of the dam. The instrument that has been in-
stalled at Batu Hampar dam are as stated in Table 4.2 below:
Every 10 m height of RCC dam, the instrumentation was
installed by slotting the instrument in the RCC lift and the
cable was laid inside the RCC by trenching it to cable riser
pipe, before continuing RCC placement as usual.
84
[5] Uribe, L., & Bosshart, D. (2002). Challenging RCC dam construction for
the Ralco project in Chile. International Journal on Hydropower and
Dams, 9(4), 95-99.
[6] Choi, Y., & Groom, J. (2001). RCC Mix Design—Soils Approach. Journal
of Materials in Civil Engineering, 13(1), 71-76.
[7] Bass, R. P. (2003b). Rehabilitating Dams with Roller Compacted Con-
crete Bridging the Gap (pp. 1-9)
[8] Forbes, B. A (2003), Using Sloped Layers to Improve RCC Dam Con-
struction. Civil structures, Hydro Review Worldwide (HRW). Vol 11:
Number 3.
[9] Nawy, E. G. (2008). Concrete construction engineering handbook Sec-
ond Edition: Chapter 20 Roller Compacted Concrete, Salem USA: CRC
LLC. Chapter 20 page 1-72
[10] Forbes, B. A, Hansen, Kenneth, D., Kitzgerald, Thomas, J. (2008) State
of the Practice – Grout Enriched RCC in Dams.United States Society on
Dams Annual Conference. April/May 2008. Portland Oregon, 1-17
[11] Shaw, Q. H. W. (2011). Chapter 2 : RCC Construction, RCC Mixes, RCC
Instrumentation & RCC Dams Study. University of Pretoria: Ph.D. Thesis
[12] Nagataki, S., Fujisawa, T., & Kawasaki, H. (2008). State of art of RCD
dams in Japan. Paper presented at the 50º Congresso brasileiro do con-
creto, Salvado (1st Brazilian RCC Symposium september 2008)w
 CONCRETE: AGGREGATE REPLACEMENT

Study on Mechanical Properties of

Concrete with Various Slags as
Replacement to Fine Aggregate
Ramagiri Anudeep1, K.Venkata Ramesh2, V. SowjanyaVani3
1
Post Graduation Student, Master of Technology
(Structural Engineering and Natural Disaster Management), GITAM University, Visakhapatnam
2
Professor, Department of Civil Engineering, GITAM University, Visakhapatnam
3
Assistant Professor, Department of Civil Engineering, GITAM University, Visakhapatnam

Abstract: An experimental programme is planned to study the
effect of using copper slag (CS), granulated blast furnace slag
(GBFS) and silicomanganese slag (SiMn) as fine aggregate on
the properties of concrete. Sixteen concrete mixtures are pre-
pared with different proportions of CS, GBFS respectively rang-
ing from 0% to 100% and SiMn ranging from 0% to 50%. These
sixteen concrete mixes are evaluated for mechanical proper-
ties and durability. Addition of 60% CS and GBFS respectively
as sand replacement yielded comparable or higher strength
than control concrete and there is reduction in strength at all
replacement levels of SiMn.
India, in recent years is witnessing a rapid growth and inno-
vative development in construction industry. The extended use
of concrete and its materials involve use of available natural re-
sources. Natural resources in India are depleting, contrasting-
ly, there is substantial increase in generation of wastes from the
industries. The sustainable development in concrete technol-
ogy and construction involves the use of waste and innovative
materials in order to replace the depletion of natural resources
and find alternative ways for conserving the environment. The
materials like - slags, quarry dust, manufactured sand, munic-
ipal incineration waste ash, bottom ash, recycled sands from
construction and demolished waste, etc are used as alternative
materials for replacement or full substitution of sand.
Aggregates are considered as one of the main filler con-
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in the country from iron and steel industries.2 Silicomangane-
seis smelted in electric or a blast furnace, the process creates
ferromanganese and silicomanganese. The slag is then fur-
ther processed by crushing and washing to remove as much
of the remaining metal as possible. The remaining ore is then
screened and sold for use in cement manufacture as an ingre-
dient, and concrete production as a cementitious, reactive ag-
gregate. SiMn often contains 15% manganese oxide that is the
most common by-product of the process.
The objective of this research program is to identify the al-
ternative sustainable materials which replace the natural riv-
er sand without morphing its strength and durability aspects
of concrete and this investigation presents the results from
planned experimental tests conducted on concrete replacing
CS, GBFS and SiMn as fine aggregate at constant w/c ratio.
Materials
Cement: The cement used in this study is Ordinary Portland
Cement (OPC), 53 grade.
Fine aggregate :The fine aggregate used in this investiga-
tion is clean river sand, from Srikakulam.
Copper slag :Copper slag used in this project is from Hin-
dustan Copper Limited, Kolkata.
Granulated blast furnace slag: Granulated blast furnace
slag used in this project is from Vizag Steel Plant, Visakhapa-

stituents of concrete as they occupy 50 – 80% of concrete vol- tnam.

ume. The concrete industry globally consume over 8-12 billion Silicomanganese slag: In this project Silicomanganese slag
tonnes of natural aggregates annually. 1Recently natural sand is from Vizag Steel Plant, Visakhapatnam.
is becoming scarce in availability and costly, because of its de-
mand by the construction industries. In this context, construc- Major Com-
CS GBFS SiMn
tion industry and researchers are looking for easily available, ponents
cheap and sustainable alternative materials to natural sand. SiO2 (Com-
Latest trends and growth in concrete technologies are focusing bined as 33 – 35% 36.67% 43.49%
on sustainable development by using industrial by-products as Silicate)
ecological raw materials in concrete. FeO 40 – 44% 2.2% 0.61%
Various types of industrial slags, such as CS, GBFS are ex-
tensively used in concrete as fine aggregate. In duration about Al2O3 4.0 – 6.0% 15.36% 18.50%
33 million tonnes of copper slag is being generated annually CaO 0.8 – 1.5% 37.08% 17.61%
worldwide, among which, India is contributing 6 – 6.5 million MgO 1.0 – 2.0% 9.21% 6.49%
tonnes. Replacement with copper slag may result 20% high-
MnO - - 11.52%
er strength to that of control concrete for 50% replacement.
Around 10 million tonnes of GBFS is currently being generated Cu 0.6 – 0.9% - -
86
 CONCRETE: AGGREGATE REPLACEMENT

S 0.8 – 1.2% - - test results showed that there is comparable particle size dis-
tribution with the gradation requirements for concrete sand as
Free Silica < 0.5% - - shown in Fig. 1. CS, GBFS and SiMn have comparable grada-
Ni 0.01- 0.03% - - tions.
Pb 0.01 - 0.03% - - Coarse aggregate: In this present investigation, locally
available crushed stone aggregate of size 20mm and down are
Zn 0.2 – 0.3% - -
used.
Bi 0.01 - 0.02% - - Water: In this investigation, potable water is used.
Co 0.04 - 0.13% - -
Experimental Programme
Others - - 1.78%
Table 1 – Chemical composition of slags The mix proportion chosen for this study is shown in Table
3. Sixteen concrete mixtures with different proportions of CS,
Major Com- GBFS ranging from 0% to 100% and SiMn ranging from 0% to
CS GBFS SiMn
ponents 50% are considered as shown in Table 3. The effect of slags as
Angular, Angular, replacement to sand on workability is studied. The specimens
Particle Glassy, Mul- are demoulded after 24 hours and cured in water for 7 and 28
Roughly Medium
size, Shape tifaceted days.
Cubical rough
Blackish Light green- Testing Procedure:
Appearance Gray, Glassy
gray, Glassy ish gray
> 5-7
After curing the concrete samples, the following tests are
> 5-6 conducted:
Hardness Mohr’s -
Mohr’s scale - 7 and 28 day cube compression strength test, accordance
scale
with IS: 516-1959 using a loading rate of 400 Kg/min.
Bulk density
- 7 and 28 day cube split tensile strength test, accordance
at 250C (gm/ 1.8-2.2 1.2 – 1.5 Approx 3
cm3) with IS: 5816-1999 using a loading rate of loading 2.4 N/min.

pH 6.5 8 – 10 8.80
Coarse
Conductivity Nil Nil Nil Cement Sand aggre- Water
w/c ratio
Weight loss 1.75-2.0 (kg/m3) (kg/m3) gate (kg/m3)
on ignition at 9000C 1.8 1.8 (kg/m3)
(%) 400 667 1140 180 0.45
Moisture
< 0.1 6% - Table 3 - Concrete design mix proportions
content (%)
Specific Results and Discussion
2.78 2.15 1.57
gravity
Effect of CS, GBFS and Simn Substitution as Fine Aggregate on
Grading
Zone I Zone II Zone I Concrete Properties
limit
Table 2 – Physical properties of slags Workability

From Table 4, the workability of concrete increases signifi-

cantly with the increase in CS content as sand replacement.
The considerable increase in the workability with the increase
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of CS quantity is attributed to the low water absorption charac-

Fig 1: Particle size distributions of CS, GBFS, SiMn and sand
The chemical composition and physical properties of CS,
GBFS and SiMn are presented in Table 1 and Table 2.
Gradation test is conducted in accordance with IS: 383 –
1970 on all the samples -CS, GBFS and SiMn and sand. The
teristics of CS and its smooth, glassy surface. There is surplus
quantity of free water even after the absorption for hydration
process when compared to sand. The increase in the workabil-
ity may have a beneficial effect on concrete where the concrete
mixes with low water-to-cement ratios are considered, such
that concrete can improve workability, greater strength and
improve durability than the conventional concrete mix.
The workability of concrete decreases remarkably with the
increase in GBFS and SiMn content in the concrete mixes indi-
vidually. The considerable decrease in the workability with the
increase of GBFS and SiMn respectively quantity can be accred-
ited to the high water absorption and its high surface area.
Compressive Strength
From Table 4, the compressive strength of concrete in-
creased as CS replaced to sand increased up to 60%. Beyond
87
 CONCRETE: AGGREGATE REPLACEMENT

that the compressive strength reduced noticeably due to in-
crease in the excess free water in the mix. The optimum com-
pressive strength is achieved at 60% replacement level of CS.
The compressive strength of concrete increased as GBFS
reached 60% replacement level. Beyond that the compressive
strength reduced considerably due to the increase in water ab-
sorption characteristics of slag and its high surface area since
finer than sand and the compressive strength of concrete de-
creased for all replacement levels of SiMn. The compressive
strength reduced significantly due to the increase in water
absorption characteristics of GBFS and SiMn individually. The
water absorption of GBFS and SiMn at higher replacement lev-
els made the water content of the mix crouched than actually
required. This reduced the binding of the constituents, thereby,
reducing the strength characteristic within hardened concrete.
Split Tensile Strength
From Table 4, the split tensile strength of concrete in-
creased as CS replacement to sand increased up to 60%. Be-
yond that the split tensile strength reduced prominently due to
the increase in the free water which is excess in the mix. The op-
timum split tensile strength is achieved at 60% replacement of
CS, which is 19.86% compared to the control mix. The split ten-
sile strength of concrete increased as GBFS quantity increased
up to 100%. The highest split tensile strength achieved by 100%
replacement of GBFS; there is an increase in the strength to
35.30% when compared to control mix. Split tensile strength of
concrete decreased for all replacement levels of SiMn. The split
tensile strength reduced due to the increase in water absorp-
tion characteristics of slag and its high surface area.
Effect of slag substitution as fine aggregate on carbonation of
concrete
The effect of CS, GBFS and SiMn replacement as fine ag-
gregates on the CO2 effect is presented in Table 4, The Ca(OH)2
of concrete is unaffected by CO2 penetration and the colour
turned out to be purple for all the sixteen mixes adopted.
Table 4 – Average strength results of concrete at 7 and 28
days of curing.
Cost Comparison of Fine Aggregate
Many cities in India are experiencing scarcity in the supply
of sand for the constructional use. For instance in a place like
Visakhapatnam, (A.P) one cubic meter of sand costs ` 1200.

Mix Nota- Slump Density Average strength (kN/m2)

Mix no. Mix type
tion (mm) (kg/m3) (fcu)a (fcu)b (fcs)a (fcs)b
1 Control (100% S) Control 50 2517.03 35.62 47.84 2.80 3.20

2 20% CS + 80% S CS20 20 2569.18 31.84 45.18 2.73 2.89

3 40% CS + 60% S CS40 30 2575.40 33.92 45.62 2.80 3.46
4 50% CS + 50% S CS50 30 2592.59 35.55 48.74 3.18 3.53
5 60% CS + 40% S CS60 50 2652.74 39.40 53.77 3.41 3.84

6 80% CS + 20% S CS80 Collapse 2734.81 37.77 51.99 3.53 3.77

7 100% CS CS100 Collapse 2798.81 34.14 47.84 3.25 3.65

20% GBFS +
8 GBFS20 30 2478.22 28.88 45.77 2.85 3.20
80% S
40% GBFS +
9 GBFS40 20 2471.11 29.47 46.66 2.99 3.58
60% S
50% GBFS +
10 GBFS50 15 2427.85 31.84 53.62 3.08 3.72
50% S
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60% GBFS +
11 GBFS60 5 2409.77 32.29 55.11 2.82 3.72
40% S
80% GBFS +
12 GBFS80 0 2370.07 33.17 43.55 2.85 3.84
20% S
13 100% GBFS GBFS100 0 2362.96 37.10 43.69 2.66 4.33
20% SiMn +
14 SiMn20 35 2434.96 27.25 36.63 3.01 3.30
80% S
40% SiMn +
15 SiMn40 10 2295.70 19.84 28.51 2.31 2.54
60% S
50% SiMn +
16 SiMn50 0 2283.55 17.47 27.03 2.02 2.54
50% S

S – Sand, CS – copper slag, GBFS – granulated blast furnace slag, SiMn – silicomanganese slag.
(fcu)a – Average cube compressive strength at 7 days, (fcu)b – Average cube compressive strength at 28 days
(fcs)a – Average tensile strength at 7 days, (fcs)b – Average tensile strength at 28 days

Table 4 – Average strength results of concrete at 7 and 28 days of curing.

88
 CONCRETE: AGGREGATE REPLACEMENT
Fig 2: Compressive strength of concrete replacing different slags as fine
aggregate at 7 days and 28 days
Fig 3: Split tensile strength of concrete replacing different slags as fine
aggregate at 7 days and 28 days
Due to the existence of steel plant this place has availability of
different slags in abundance. One cubic meter of granulated
blast furnace slag costs about ` 400 – 500, one cubic meter of
silicomanganese slag costs about ` 250 – 350. Copper slag be-
ing imported from Kolkata the slag costs about ` 1700 – 1800.
At other places, where sand is available at reasonable costs,
slag is availableat cheaper rates or at comparatively lower pric-
es. Using of slag in constructions can minimise the depletion of
natural sand resources and can improve concrete properties.
Conclusions
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Based on the literature review and the results from the
experimental work the following conclusions can be made.
Aggregate replacements have a significant effect on the per-
formance of the fresh concrete mix and also the strength char-
acteristics. One of the objectives of aggregate replacement is
to produce sustainable concrete which is economical, needs
relatively low amount of natural resources and makes use of
the industrial by-products.
- The workability improved with increase in the replacement
of CS percentage due to smooth nature, there isadecrease
in the workability to higher GBFS replacement due to its an-
gular nature, fineness and high water absorption property.
For SiMn replacement the workability decreased with the
increase in the replacement levels.This is due to angular
nature and high water absorption property.
- The density of the concrete incorporating sand with the CS
90
increased with increase in the replacement due to high
CS density.The density of concrete incorporating GBFS
decreased with increase in replacement levels due to low
GBFS density. Replacing sand with SiMn in concrete ob-
served reduction in the density since SiMnhas low density.
- There is more than 12% improvement in the compressive
strength of concrete with 60% replacement of CS in con-
crete. It is observed, about 15% improvement in the com-
pressive strength of concrete with 60% replacement of
GBFS in concrete. Thus 60% replacement of CS, GBFS re-
spectively is optimum to improve strength characteristics.
There is a reduction in strength of concrete at all replace-
ment levels with SiMn to sand.
- Split tensile strength of concrete is increased by 20% at
60% CS replacement and 35% at 100% GBFS replacement.
There is reduction in split tensile strength of concrete re-
placed with SiMn at all replacement levels.
- Replacing sand with CS, GBFS and SiMn in concrete has no
effect towards CO2.
Comparative Discussion
GBFS may be adopted as replacement to fine aggregate
compared to CS and SiMn to enhance the concrete strength,
durability and iseconomical.CS can be adopted where the con-
crete mix has low water-to-cement ratio. Considering cost fac-
tor CS is not economical compared to GBFS and SiMn.
References
- Khalifa S. Al-Jabri, Makoto Hisada, Abdullah H. Al-Saidy, S.K. Al-Or-
aimi.,Performance of high strength concrete made with copper slag
as a fine aggregate,Construction and Building Materials, 2009,Vol.
23,pp. 2132–2140.
- Akshay C. Sankh, Praveen M. Biradar, Prof. S. J Naghathan, Man-
junath B. Ishwargol., Recent trends in replacement of Natural Sand
with Different Alternatives,International Conference on Advances in
Engineering & Technology – 2014 (ICAET-2014).
- Dr. KodeVenkata Ramesh, D. SreeRamachandraMurty, P. Swarna
Kumar., Appraisal of Crushed Stone Dust, as fine aggregate in struc-
tural concrete,Concreting;CE&CR,July 2007.
- Khalifa S. Al-Jabri, Makoto Hisada, Salem K. Al-Oraimi, Abdullah H.
Al-Saidy., Copper slag as sand replacement for high performance
concrete,Cement& Concrete Composites, 2009,Vol. 31, pp. 483–488.
- Khalifa S. Al-Jabri, Abdullah H. Al-Saidy, RamziTaha., Effect of cop-
per slag as a fine aggregate on the properties of cement mortars
and concrete,Construction and Building Materials, 2011, Vol. 25, pp.
933–938.
- Bipra Gorai, R.K. Jana, Premchand., Characteristics and utilisation
of copper slag - a review,Resources, Conservation and Recycling,
2003, Vol. 39, pp. 299-/313.
- Mostafa Khanzadi, Ali Behnood., Mechanical properties of high-
strength concrete incorporating copper slag as coarse aggregate,-
Construction and Building Materials, 2009,Vol. 23, pp. 2183–2188.
- Isa Yuksel, TurhanBilir., Usage of industrial by-products to produce
plain concrete elements,Construction and Building Materials,2007,
Vol. 21, pp. 686–694.
- Liu Chunlin, ZhaKunpeng, Chen Depeng., Possibility of concrete pre-
pared with Steel Slag as Fine and Coarse Aggregates: A Preliminary
Study,Procedia Engineering, 2011, Vol. 24, pp. 412 – 416.
- Omer Ozkan, Isa Yuksel, OzgurMuratoglu., Strength properties of
concrete incorporating coal bottom ash and granulated blast fur-
nace slag,Waste Management, 2007, Vol. 27, pp. 161–167.w
 CEMENT: UFNSP
Influence of Ultrafine Natural Steatite
Powder on Setting Time and Strength
Development of Cement
K. Sudalaimani1 & M. Shanmugasundaram2
1
Department of Civil Engineering, Thiagarajar College of Engineering,
Thiruparankundram, Madurai
2
Department of Civil Engineering, Kalasalingam University,
Srivilliputhur
Abstract: This paper deals with the setting time and pozzola-
nic activity of cement when ultra fine natural steatite powder
(UFNSP) is used as replacement for cement. Initial setting time,
final setting time, and mortar cube strength were studied, due
to the replacement of ultra fine natural steatite powder with
cement at 5%, 10%, 15%, 20%, and 25% by mass of cement.
The setting time of fresh cement-binder paste and compressive
strength of mortar cubes are observed. Scanning electron mi-
croscopy (SEM) and X-ray diffraction (XRD) were applied to in-
vestigate the microstructural behaviour and chemical element
distribution inside cement-binder matrix. Results indicate that
the length of dormant period is shortened. The replacement of
ultra fine natural steatite powder with cement reduces initial
setting time, and final setting time and increases mortar cube
compressive strength.
Steatite is a type of metamorphic rock, largely composed of
talc ore, rich in magnesium. It is composed of hydrated mag-
nesium silicate: Mg3Si4O10(OH)2. Steatite is the softest known
mineral and listed as 1 on the Mohs hardness scale. It is already
used in paint industry, particularly in marine paints and protec-
tive coatings. This is used in ceramics due to its high resistivity,
very low dielectric loss factor, and good mechanical strength.
Addition of steatite powder increases the viscosity and mechan-
ical properties of feed stock. The thermal properties of steatite
are also good [1]. Massive steatite cut into panels is used for
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switchboards, for acid proof tabletops in laboratory, laundry, and
kitchen sinks, and in tubs and tanks, as well as for lining alkali
tanks in paper industry. Due to its high melting point (1630°C)
[2], steatite can be used in refractory and fire places. It is also
quite useful in sculpturing. When fabricated by a combined
method of high energy ball milling, cold pressing, and sintering,
it improves thermal properties of ceramics [3, 4]. Cement mor-
tars prepared with steatite particles have been investigated for
restoration of sculptures and other craftworks. It was observed
that the highest compressive strength (43 MPa) and lowest ap-
parent porosity (0.19%) are achieved when steatite particles are
coarser (ranging from 1.41 mm to 0.42 mm), and 40% of poly-
meric phase is employed [5]. A special cement-based mortar
containing additions of fine powder waste from mineral ex-
traction of steatite has been developed in Brazil, as a composite
material for restoration of steatite elements [6]. The steatite is
mostly used in electrotechnics. Stabilization of protoenstatite in
92
steatite body is achievable by the development of small crystals
[7]. Improper selection of parameters led to undesired problems
such as separation of the powder-binder mixture and formation
of collapses and cracks on the structure of the moulded parts.
The optimum moulding parameters of the feed stocks for the
zigzag shaped mold are determined to be at an injection pres-
sure of 80 to 140 MPa at barrel temperature of 190 to 230°C [8].
When a property of powder injection moulded steatites is inves-
tigated, sintered at 1300°C for 4 hours, a theoretical density of
98%-99% is achieved. Three-point bending and tensile test was
performed on the samples sintered at 1200°C to 1300°C. The
maximum three-point bending and tensile strength values are
found to be 154 MPa and 47 Mpa, respectively [9]. Indian steatite,
mined in Rajasthan and Andhra Pradesh, is comparable with
the best quality available in other countries. The steatite mined
in India, with more than 92% brightness, less than 1% Fe2O3,
and less than 1.5% CaCO3, is preferred for exports [2]. Indian
steatite is considered to be the second best in the world next to
“Italian steatite.” The UFSP used in this experiment develops
M-S-H gel; hence the comparative study of C-S-H and M-S-H is
vital. On account of the basic structural difference between the
two gel types, M-S-H and C-S-H are essentially immiscible [10].
Magnesium hydroxide (Mg(OH)2 aka brucite) is a good starting
point for the development of low pH cements. pH value of ex-
cess brucite in equilibrium with water is calculated to be around
pH 10.5 [11]. Hence, in principle, cement based on the hydration
of MgO powder, calcined at low temperature to ensure fast hy-
dration, should yield the desirable pH. According to Zhang et
al. [11] high MgO contents do not affect the pH, whereas high
silica fume content results in a pH closer to 9.5. Both MgO and
silica fume composition have potential applications for the en-
capsulation of wastes containing heavy metals [11]. In the pres-
ent research work, effect of UFNSP powder on setting time and
strength development on cement is investigated.
Materials and Experimental Methods
Raw Materials
Cement. Ordinary portland cement conforming to IS: 8112-
1989 (Indian Standard Designation, IS: 8112-1989) is used for
mortar mixtures; the cement used in this study belongs to type
I of ASTM. The physical and chemical properties are given in
Table 1.
 CEMENT: UFNSP

Fine Aggregates. Standard natural sand having hard, clean, Cement UFNSP
strong, durable, uncoated particles and meeting the require-
ments of the specifications (ASTM C144-11) with specific gravity Physical properties
of 2.65 is used as fine aggregate. Blaine surface area (m2/Kg) 380 750
Water. In the present investigation, potable water is used Particle mean dia. (μm) <32 <5
for mixing and curing. Density 3.1 2.7
Mineral Admixture. UFNSP obtained from UltraFine Miner-
Loss of ignition 2% 3.33%
al Pvt. Ltd., India, is used as natural admixture. UFNSP is man-
ufactured by using high quality crushers and superfine grind- Chemical properties
ers. UFNSP is finer than cement. The physical and chemical SiO2 23% 62.67%
properties are given in Table 1. Al2O3 4.20% 0.24%
Consistency of Cement MgO 0.20% 33.26%
Fe2O3 1.20% 0.30%
The basic aim is to find out the water content required to
CaO 63% 0.20%
produce a cement paste of standard consistency as specified by
the IS: 4031 (Part 4)-1988. The principle is that standard consis- Table 1: Physical and chemical properties of cement and UFNSP
tency of cement is that consistency at which the Vicat plunger
point 5.0 0.5 mm measured from the bottom of the mould. Ini-
penetrates to a point 5–7 mm from the bottom of Vicat appara-
tial setting time is the period elapsing when water is added to
tus, conforming to IS: 5513-1976. Approximately 400 g of cement
the cement and the needle fails to pierce the test block by 5.0
is mixed with a weighed quantity of water. The time of gauging
0.5 mm measured from the bottom of the mould.
should be between 3 and 5 minutes. Fill the Vicat mould with
Final Setting Time (FST). Replace the above needle by the
paste and level it with a trowel. Lower the plunger gently till it
one with an annular attachment. The cement is considered to
touches the cement surface. Then release the plunger to sink
finally set, when the gentle application of the needle makes an
into the paste. Note the reading on the gauge and repeat the
above procedure taking fresh samples of cement and different
quantities of water until the reading on the gauge is 5 to 7 mm.

Initial and Final Setting Time (IST and FST)

How to calculate the initial and final setting time as per IS:
4031 (Part 5)-1988 by Vicat apparatus conforming to IS: 5513-
1976? Prepare a cement paste by gauging the cement with 0.85
times the water required to give a paste of standard consisten-
cy. Start a stopwatch the moment water is added to the cement.
Fill the Vicat mould completely with the cement paste gauged
as above. With the mould resting on a nonporous plate, smooth
off the surface of the paste making it level with the top of the
mould. The cement block thus prepared in the mould is the test
block.
Determining Initial Setting Time (IST). Place the test block
under the rod bearing the needle. Lower the needle gently in
order to make contact with the surface of the cement paste.
Release quickly, allowing it to penetrate the test block. Repeat Figure 1: Scatter plot on strength of mortar cubes with standard
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the procedure till the needle fails to pierce the test block to a deviation.
93
 CEMENT: UFNSP

% replacement of % consistency of
S.No Mix IDs IST in minutes FST in minutes
UFNSP water for binder
1 C0 0 24 30 360
2 C5 5 28 25 330
3 C10 10 29 20 300
4 C15 15 31 20 300
5 C20 20 34 25 330
6 C25 25 37 40 450
Table 2: Consistency, IST, and FST

3-day 7-day 28-day

SD in CO-VAR SD in CO-VAR SD in CO-VAR
S.No Mix IDs strength in strength strength in
MPa in % MPa in % MPa in %
MPa in MPa MPa
1 C0 29.00 2.39 8.23 37.00 2.19 5.29 45.00 2.00 4.44
2 C5 33.00 1.90 5.75 40.00 1.79 4.47 49.00 1.38 2.78
3 C10 42.00 1.10 2.61 47.00 1.10 2.33 52.00 1.10 2.11
4 C15 44.00 1.10 2.49 49.00 0.89 1.83 52.00 0.84 1.59
5 C20 37.00 2.37 6.40 45.00 1.79 3.98 48.00 1.67 3.49
6 C25 23.00 3.90 16.95 30.00 2.45 8.16 39.00 2.10 5.38
Table 3: Compressive strength of mortar cubes

impression therein, while the attachment fails to do so. Final
setting time is the period elapsing when water is added and the
needle makes an impression on the surface of the test block.
Compressive Strength on Mortar Cubes
Mortar cubes used in this investigation were 70.6 mm
70.6 mm 70.6 mm confirming to IS 10080-1982. The specimens
were prepared in ratio of cement  : sand as 1 : 3 and W/B ratio as
0.47. These specimens are cast in three layers, in accordance
to IS 10080-1982. Each layer is well compacted by a tamping
rod of 12 mm diameter. After the compaction the top surface is
leveled using a trowel and left for 24 hours to dry in room tem-
perature of 28°C with 60% humidity. On the next day, at room
temperature of 29°C and 54% humidity, the mortar cubes are
kept inside a curing tank filled with portable water. The speci-
mens are tested with a 2000 kN capacity hydraulic compression
testing machine, as per IS: 4031-1982 (Part 6). Altogether 108
mortar cubes (6 Mix IDs x 18 specimens) were cast and were
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Scanning Electron Microscopy and X-Ray Diffraction Studies
The specimen is studied by Scanning Electron Microscopy
and XRD Patterns. Samples for scanning electron microsco-
py (SEM) analysis are taken near the surface (0-1 mm depth)
of specimens. Micro structural studies utilized SEM (HITACHI
S-3000H, Japan) equipped with EDAX analyzer for micro struc-
tural observations of the surfaces, which is coated with evapo-
rated copper for examination. SEM analyses is done at a max-
imum magnification of 20,000 x with energy 15 keV and a high
resolution of 3.5 nm. For this analysis, samples of size 10 mm
cubes are cut with a saw cutter on 28th day. The XRD analysis
is carried out with a Siemens D-5000 X-ray diffractometer with
Cu K-beta radiation and 2 scanning with a step size of 0.02° and
a measuring time of 10.00 Deg/minute. A voltage of 40 kV and
current of 15 Ma is used. Samples are collected from the cubes
after 28 days of water curing and powdered in ball mills to pass
through the sieve size of 90μ.

tested for compressive strength.

94
 CEMENT: UFNSP

Figure 2: SEMimages of specimens with 20000 x magnification: (a) C0

specimen, (b) C5 specimen, (c) C10 specimen, (d) C15 specimen, (e)
C20 specimen, and (f) C25 specimen.

Results and Discussions

Consistency of Cement

From Table 2 the consistency of binder material is ob-

served. The consistency is found to continuously increase as
the percentage replacement of cement with UFNSP increases.
The water consistency increases for C5, C10, C15, C20 and C25
at 4%, 5%, 7%, 10%, 13% when compared with C0. This may be
due to higher fineness of UFNSP and higher water absorption
property.

Setting Time

From the experimental design, the maximum, minimum

and average values of IST and FST are shown in Table 2, togeth-
er with the main effects and UFNSP interactions. The values
are reported as relative values with respect to ordinary Portland
cement paste, 30 and 360 minutes for IST and FST respectively.
The IST for C5, C10, C15 and C20 decreases by 5minutes, 10
minutes, 10 minutes, and 5 minutes respectively and for C25
IST increases by 10 minutes when compared with C0 mix. Sim-
ilarly the FST for C5, C10, C15 and C20 decreases by 30 min-
utes, 60 minutes, 60 minutes, and 30 minutes respectively and
for C25 FST increases by 90 minutes when compared with C0
mix. From the above results it is observed that IST and FST de-
creases when percentage of UFNSP replacement increases up
to 20%, but there is a sudden increase in IST and FST on C25
specimen which may be due to excess UFNSP.

Compressive Strength of Mortar Cubes

The Masterbuilder | July 2015 | www.masterbuilder.co.in

The strength attained during 3 days, 7 days and 28 days on

mortar cubes are experimentally tested for 6 specimens on
98

Figure 3: XRD patterns of C0, C5, C10, C15, C20, and C25 mortars. Q:
quartz; C: calcite; P: portlandite; B: brucite.
each age and their average results are shown in Table 3 and
Figure 1. The strength of mortar cubes of C5, C10, C15, C20 and
C25 are compared with C0 mix. The compressive strength on 3
days for C5, C10, C15 and C20 increases by 13.8%, 44.8%, 51.7%
and 27.5%. The strength of C25 decreases by 20.7%. On the 7th
day for C5, C10, C15 and C20 increase by 8.1%, 27.02%, 32.43%
and 21.6%. The strength of C25 decreases by 18.9% and on the
28th day for C5, C10, C15 and C20 increases by 10%, 15.6%,
16.7% and 6.7%. The strength of C25 decreases by 13.3%. Thus
the above results show the Mix C5, C10, C15 has a considerable
increase in terms of strength and also the strength is easily
attained on its early ages like 3 days and 7 days. Data on the
variation in compressive strength of mortar cubes is shown in
Table 3 and Figure 1. The Standard Deviation (SD) and Coef-
ficient of Variation (CO-VAR) of the compressive strength on 3
days, 7 days and 28 days shows decrease in SD and CO-VAR
with increase in ages. The maximum SD is observed in C25, the
lowest SD is observed at C10 and C15. The SD for C0 and C20
shows almost equal values. C5 shows lesser SD than C0 but
more than C10 on all age. The CO-VAR fell from maximum val-
ue on 3 days to the lowest on 28 days for all specimens. The data
shows that C15 is the specimen having Lowest SD and CO-VAR,
with maximum strength, which also ensures that C15 mix is the
most reliable of all mix IDs. The C25 specimens have highest
SD and CO-VAR and lowest strength and are identified as the
inferior specimen of all other specimen.
CEMENT: UFNSP
Microstructural Analysis
The results obtained in SEM and XRD analysis are shown
in Figures 2 and 3.
The analysis shows that the best results are obtained from
adding 15% of UFNSP. The images obtained in SEM are shown
in Figure 2. Figure 2(a) shows the micrograph of C0; it consists
of fine particles, which appear to have agglomerated into larg-
er groups of particles. Figure 2(b) shows the micrograph of C5
specimen; the extent of coverage is substantial but not enough
material has formed to create a continuous film on the surface
of the particle. Some regions show the traces of no hydration
products and absence of deposition of hydration products. Fig-
ures 2(c) and 2(d) show the micrograph of C10 and C15 speci-
mens, respectively. This shows that due to the abundance of the
hydration products the appearance has changed from small
isolated particles to tangled web of flake-like crystals. The hy-
dration products consist of a mixture of phases as is typical for
portland cement. For example, portlandite is visible at some
regions, intermixed with reticulated C-S-H (or) M-S-H gel.
Figure 2(e) shows the micrograph of C20; it is similar to that of
C0; but there are no empty regions without hydration products,
and hence this C20 specimen mechanical behaviour is similar
to that of C0. Figure 2(f) shows the micrograph of C25 speci-
men; this shows that the flake-like crystals start disappearing
and form into cloudy disintegrated form. This also confirms the
loss in bonding effect. A study on microstructure of samples C0,
C5, C10, C15, C20, and C25 is made. The results show that the
UFNSP particles have been covered in a continuous pattern for
C5, C10, and C15 specimens and pattern of very small parti-
cles is identified for C20 and C25 specimens. The patterns for
C20 specimen are similar to C0 specimen. The C25 specimen
shows lack of bonding and formation of independent particles
without bond, which may be the cause of reduction in strength.
Figure 3 shows the X-ray diffrograms of C0, C5, C10, C15,
C20, and C25 mortars, respectively. The main compounds are
quartz (SiO2), calcite (CaCO3), portlandite (Ca(OH)2), and bru-
cite (Mg(OH)2). The X-ray diffrograms show increase in quartz
when UFNSP is added. The calcite is similar in all specimens.
The intensity of brucite increases as percentage replacement
of UFNSP increases. The peaks for all specimens indicate
the presence of quartz, calcite, and portlandite and very small
quantity of brucite. The intensity of portlandite peak is slightly
The Masterbuilder | July 2015 | www.masterbuilder.co.in
higher in C10 and C15 when compared to other specimens.
99
 CEMENT: UFNSP
The increase in C15 strength is due to the right combination
of portlandite, calcite, and brucite. The SEM image and X-ray
diffrograms (Figures 2(d) and 3) of C15 show the wider pres-
ence of dense portlandite and brucite which supports faster
hydration reaction. The reduction in calcite leads to decrease
in carbonation process. Hence maximum strength is attained
in C15. Figure 3 shows that the intensity of portlandite is very
low for C25. The increase of brucite (Mg(OH)2) in combination
with reduction of portlandite leads to the conclusion that port-
landite most probably reacted with magnesium. The very low
solubility of brucite favours the consumption of calcium hydrox-
ide (Ca(OH)2) [12]. The reduction in strength of C25 specimen
is attributed to the pozzolanic activity and pore structure. Since
replacement of UFNSP reduces the content of portlandite, the
hydration reaction and pozzolanic activity decreases. Hence the
strength contribution from this process is lower than C0.
Conclusion
From the present study it can be concluded that replace-
ment of UFNSP with cement results in decrease of IST and FST,
but the consistency of binding material increases. This shows
the increase in requirement of water to produce cement paste.
The compressive strength of mortar cube increases during its
early stages. The maximum compressive strength in 3, 7, and
28 days is observed at C15. The improvement in strength in C5,
C10, C15, and C20 is nominal at all stages and normalizes in 28
days. The C25 shows decrease in strength and increase in IST
and FST. It is also observed that replacing UFNSP with cement
results in improvement of microstructure of cement mortar.
The C5, C10, and C15 specimens show denser microstructur-
al bond when compared to other specimens. The availability of
denser hydration product (portlandite) in C15 specimen is iden-
tified. The C20 specimen shows micro structural similarity to
control specimen. The reduction in strength of C25 specimen
is attributed to the pozzolanic activity and pore structure. C25
shows disintegrated microstructure and very low intensity of
portlandite. From all the above discussion it is concluded that
the suitable UFNSP replacement percentage should not ex-
ceed 20%.
Conflict of Interests
The authors declare that there is no conflict of interests re-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
garding the publication of this paper.
100
Acknowledgments
The authors of this paper express their gratitude to the
management of Thiagarajar College of Engineering (TCE). The
authors wish to express their thanks to the department for fa-
cilitating this work.
Publishers Note: This paper was first published in - Advances
in Materials Science and Engineering
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acterization of microstructural and thermal properties of steatite/cordierite
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es, vol. 34, no. 2, pp. 131–143, 2010. w
 DRY MIX MORTAR

Ramco Drymix Range:

Innovative Solutions for Non-Structural Applications

R
amco Cements has an annual
capacity of 16.5 million tones
through five state-of-the-art inte-
grated cement plants and four grinding
units. The plants are equipped with the lat-
est world class technology and each of
them is reputed for its energy efficiency
along with captive thermal power genera-
tion. 'Ramco Supergrade' is the single
largest brand of cement in the South.
The company formerly known as
Madras Cements Ltd was started way
back in 1958 at Ramasamy Raja Nagar in
the southern part of Tamil Nadu. The com-
pany is among the first cement compa-
nies in India to introduce Fuzzy Logic Soft-
ware System for process controls, deploy
pre-calciner technology, operate with the
most modern Programmable Logic Con-
trollers, install Vertical Roller Mills for
cement grinding and introduce Surface
Miner for limestone excavation. In fact the
company had installed the first electro-
static precipitator for manufacturing
cement through dry process at RR Nagar
as early as 1976.
Dry Mix Division
In 2002, Ramco Cements established
a 0.75 lakh tonne capacity dry mix mortar
plant for manufacturing tile fixing com-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
of the leading brands of Tile Adhesives
specified by many leading builders, archi-
tects. The company offers a wide range of
products from T2 to T6 which will ensure
the right product for the right application
Ramco Super Fine Putty
This is a cement based putty which
ensures better bonding to substrate and
excellent resistance to moisture. It is an
all season player and does not flinch under
any weather condition. It is thermal insen-
sitive and the long lasting finish that this
cement based putty provides will make
your wall a real winner. As a matter of fact,
Ramco Super Fine Putty provides the
ideal foundation for the modern day high
quality wall coatings.
Blocks. The product ensures the most
economical way to lay AAC blocks, fly-ash
blocks, concrete blocks etc. A 3 mm thin
bed application substitutes the traditional
15 mm thick bed application.
Ramco Super Plaster
Another exciting product in the Dry
Mix range is the Ramco Super Plaster, a
ready mix cement sand plaster, which has
begun to revolutionize the conventional
plastering at construction sites. The fre-
quent issues engineers and contractors
face with regard to availability of good qual-
ity river sand, Plastering related cracks,
and difficulties in maintaining the correct
mix proportion from batch to batch, throw
the biggest challenges in the conventional
cement sand plastering. The Dry Mix Divi-

pounds, cement based wall Putty and plas- sion found the right balance by offering a
tering materials, required for the housing product far superior in quality than con-
industry. Located at SIPCOT Industrial ventional plaster keeping the cost afford-
Estate, Sriperumpudur, about 40 KM able.
from Chennai, the company's dry mix
plant was among the first of its kind in
India established in technical collabora-
tion with Germany's M-Tec, the world
leader in dry mixes technology.
Ramco Tile Fix
This is a cement based polymer modi-
fied tile adhesive with a wide range rec-
ommended for fixing ceramic/vitrified Ramco Block Fix
tiles, glass mosaic, granite swimming Ramco Block Fix is a polymer fortified
102

pool tiles etc. Ramco Tile Fix is today one block adhesive suitable for all kinds of
 DRY MIX MORTAR

Ramco Plastering Compound
This is a cement lime mix with high
purity Hydrated lime which is a superior
alternative to ordinary cement for Plas-
tering and non-structural applications.
Ramco plastering compound is the only
product of its kind in the country that
offers the advantages of a cement and
lime plaster specifically designed for plas-
tering and all non-structural applications
in general.
New Product - Ramco Thick Bed Mortar
In a constant endeavor to offer cus-
tomers total wall and floor solutions and
maximize on the opportunities in the mar-
ket, the company has come up with a thick
bed mortar for fixing tiles where undula-
tions in floor exceed 8 mm. This thick bed
mortar will be an underlayment to level
the existing floor (where a deep bed is
required), to maximize the coverage of
Ramco Tile Fix, which will be applied over
the same. The thick bed mortar will also
be useful in projects where conventional
cement sand mortar is used. Earlier new
products introduced in the range like Poly-
mer Modified Plaster (for the Reserve
Bank of India project), Ramco Block Fix,
New General Purpose Plaster have been
successful, and hence the company is con-
fident that the new Ramco Thick Bed Mor-
tar will also be received well by the cus-
tomers.
For details customers can visit the
website www.ramcocements.in where
customer testimonials of the company's
Dry Mix Products have been published for
reference.w

THE CEMENT LIFE

-Rudrabir Ghanti
This is an autobiography of cement in its own words. In this poem, it compares itself with humans and talks
about its long journey it has undertaken.

My legacy is as old as 3000 BC when I was used in the Great Pyramid of Giza,
The romans used me to build Colosseum and
loved me more than the Italian Pizza.
Back then I was weak as I was mainly made of lime,
But further addition of clay at 1200C made my quality even more sublime.
I thank Joseph Aspdin who gave me recognition and discovered my identity,
Among materials, my concrete form is second only to water as the
heaviest used entity.
My forefather was named Portland after the famous building stone,
However, the current generation is named after blending with
composites and pozzolon.
My nutrition is provided by C3S, C2S and water causing
my strength to increase,
But too much of C3A may cause me to heat & expand and
make me look obese.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
I may be exposed to hot weather and sometimes I am cold,
I may be a bridge, dam or a dome depending on the shape in which
you mould.
I may need strength, be sprayed resist free-thaw or repel water,
But thanks to admixture, a few doses of which make me energized like
harry potter.
Excessive amount of large particles may cause me to bleed,
My skin may develop shrinkage cracks if evaporation is allowed to exceed.
I need to work out for 28 days in order to develop my strength,
I disagree with Uncle Hooke on extension as I can’t get my original length.
I may experience stress and strain which often gives me tension,
Luckily, my friend rebar can share the sorrows during times of
apprehension.
Too much of fast food like sulphate & chloride may result in acidity,
This causes my friend rebar to corrode in presence of O2 and humidity.

My embodied energy is low when you compare me to steel,

As I grew up, I took sand, gravel and water as additional supplements
which made my performance discrete,
Even biggest rival ‘steel’ became jealous of me as I popularly began to
be known as “concrete”.
I dislike using poorly graded particles as it causes me to segregate,
My workability gets badly affected by too much porosity in aggregate.
When produced on-site, mix me thoroughly before starting with decant,
However, I prefer off-site production in a well controlled batching plant.
My skin can dry out too quickly and I may need a moisturizer,
In order to maintain my flow and moist look luckily, I have a plasticizer.
This may improve my workability and ability to compact easily,
If you still don’t trust my consistency,
A slump test can be used readily.
104
I am durable whether I support a plane or an automobile.
Humans raise questions about me by calling me unsustainable,
But don’t forget without me your civilisation would be unattainable.
About the Author: Rudrabir Ghanti, a recent graduate in
structural engineering from Imperial College London, is a
concrete enthusiast and has a keen interest in concrete
technology. He is current providing consultancy at
construction chemicals company named Dura Build Care
Pvt. Ltd. He intends to pursue further industrial research in
the field of concrete durability studies and foresees himself
as a future entrepreneur (he has also completed his MBA
from Cardiff University) in concrete- related sector. He likes
to be creative during free time and has a tremendous affinity towards poem writing and
technical write-ups. He is currently settled in New Delhi, where he is pursuing his PhD in
concrete durability at IIT-Delhi. He can be reached at rudrabir.ghanti@yahoo.com.
 ???????????????
DRY MIX MORTAR

Dry Mix Mortar:

A Trend that's Catching On
Dinesh Chandran K.P
Head –Technical Services & R&D of Building Products Division,
UltraTech Cement Limited.

integration business model through dry

I
n the construction industry, mortar is a
general term related to mixture of
cement and sand in different proportions
along with water. Mortar is used for
masonry construction, flooring, plastering,
and finishing, which will be in a wet state
for application. In contrast to site mixed
mortar, dry mix mortar is a term for readily
mixed raw materials in dry form which may
also have additives and polymers added
for specific usage in construction. Dry mix
products provide excellent technical prop-
erties to meet the stringent performance
requirements which are common in the
current construction scenario. The use of
dry mix mortar products will be cost
effective by reducing the potential con-
struction problems with long-term integ-
rity of structures with a simple materials
approach.
Dry mix mortar has a wide category of
products that includes dry mix products
and construction chemicals in dry form.
Globally, manufacturers of construction
chemicals have the entire dry mix mortar
product range. However, they are not spe-
cifically categorised as dry mortar manu-
facturers as they also have liquid and resin
based products.
The concept of dry mix mortar was
conceived as dry mix factory-made prod-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
ment from a durability perspective for lower
maintenance. Dry mortar industry has a
large role to play in this regard by develop-
ing quality assured products with hassle
free application even with machines. Auto-
mated plants, sophisticated lab tests and
analysis, and scientific formulations of
products have made adapting to the local
raw materials and standards easier.
In India, the trend of dry mix mortar is
catching up for the past 6-7 years and is
showing a good prospect for future in the
construction industry. By using dry mortar
products, the quality and speed of con-
struction increases. The non-availability of
river-sand and the increase in labour cost
and non-availability of skilled labour have
necessitated the requirement of ready
made building products. This scenario was
well understood by major cement manu-
facturers globally and in India for a forward
mix plants.
Considering cement volumes and the
percentage cement volume for masonry
applications, higher rate of conversion of
conventional cement mortar system to
factory made dry mortar is possible in the
near future.
The advantages for dry mix mortar
include:
1. Factory made dry mortar with quality
certification as per standards
2. Usage of quality raw materials as per
the applicable standards
3. Green products for environment
sustainability
4. Educating the users on good con-
struction practices and quality of the
contents
5. Pursuing the industry to deliver struc-
tures with good standards

ucts which are used for plastering, masonry,

tile adhesives, flooring screed, and repair
products which are based on cement being
the main binder. The dry mix mortar prod-
ucts are available in pre-bagged form and
can enable significant enhancement on
building quality based on simple mix and
apply operations. As a result, the adapta-
tion of these products will be faster in the
years to come.
Population growth is on the rise and
non-availability of natural resources as raw
materials to meet the demand in infra-
structure activities is a concern. Also, green
building certifications are an emerging
106

trend and there is an increasing require-


6. Testing of products for all technical
parameters and creating awareness
about the technical attributes to users
for choosing the right product
7. Proper quantification of materials and
reduction in wastage
8. Speed
9. Hassle free and ease of application and
usages
The aspect of non-availability of few
Indian standards for dry mix mortars is
also discussed elaborately among acade-
micians, engineers and consultants.
Adoption of EN/ASTM/ISO standards for
manufacturing and testing of dry mix mor-
tars is also discussed. The testing labs are
also gearing up for testing these products
by improving their skill set of technicians
and equipment.
We can clearly see an engineering trend
setting up for the need of factory made dry
mortars, and its mechanized usages. The
usage of additives/polymers in dry mix
mortar also plays a very effective role in
the quality of product. The additive / polymer
manufacturers along with dry mortar
manufacturers are conducting meetings
and workshops to propagate the need and
advantage of dry mix mortars.
A well-established dry mix mortar pro-
duction plant is normally equipped with
computer controlled batching, dosing,
mixing and packing along with sand drying
and grading facilities. The annual output
production capacity will range from 20,000
tonne to 2,00,000 tonne.
Some of the Dry Mix Mortar Products
Include
Jointing Mortar
DRY MIX MORTAR
???????????????
1. Plastering – internal / external
2. Thin joint mortars
3. Floor screeds
4. Stuccos
5. Cement grouts
6. Tile adhesives
7. Tile joint fillers
8. Waterproofing products
9. Crack fillers and repair materials
UltraTech Building Products Division
Plastering caters to dry mix mortar product category,
and also have autoclaved aerated concrete
(AAC) lightweight block plants in Wada and
Hyderabad.
The product range of UltraTech Build-
ing Products Division includes:
UltraTech Readiplast - Ready mix
cement plaster/ render with high quality
polymer additives. It can be used on inner
and outer walls.
UltraTech Power Grout - is a cement
based material consisting of additives and
Waterproofing graded sand. It is a ready-to-use powder
designed to provide high early strength in
a short span of time by mixing optimum
quantity of water.
UltraTech Seal & Dry - is a cement-
based single component, polymer modified,
flexible, elastomeric, waterproof coating
for concrete and masonry surfaces. Seal
& Dry has high water impermeability under
hydrostatic pressure up to 7 bar.
UltraTech Fixoblock is a versatile thin
jointing material with superior adhesion
strength for joining AAC blocks, fly ash
Grouting bricks, concrete blocks, etc.
UltraTech Xtralite – is a lightweight
Autoclaved Aerated Concrete block, lighter
than standard size bricks and blocks.
UltraTech Super Stucco - is a facing
material that can be applied to any flat or
The Masterbuilder | July 2015 | www.masterbuilder.co.in
undulating surface and can be used as a
base coat for interiors or as final finish for
exteriors.
With the emergence of East Asia Dry
Mix Mortar Association (SEADMA) and
Middle East Dry Mix Mortar Association
(MEDMA) and the recent increment in
number of dry mix mortar manufacturers
in India, technocrats are demanding more
dry mix mortar products to be introduced.
Dry mix mortar business is in the way for-
ward for growth, with the involvement of the
government to regulate the building mate-
rial industry with adequate standards as a
whole. 
107
 PLASTER SYSTEM

Mechanized Spray Plaster System -

Perlcon Giema - The Only Way Forward

Shri Shreyas C Sheth

Chairman, Perlcon Premix Pvt. Ltd.

C
ontemporary construction indus-
try is searching Solutions for en-
suring smooth execution of mega
projects, in particular the real High Rise
Structures which are invariably stum-
bling with
- Lack of Mechanized Systems at work
places
- Multiple Material Handling engaging
scarce man power at project site
- Speedier, Consistent Execution with
Minimum Wastage of Resources
- Enhanced work feasibility at higher
elevationshavingrestrictedworkspaces
- Higher Control over project execution
time, eliminating “Activity Lag Time
Intervals”
Consistency and higher Accuracy at spaces
The only way forward to eliminate the work places - Offers total control over project exe-
above mentioned adversities is to opt for - Enhancedwork Quality, irrespective cution time, eliminating several
technology driven project execution mo- of higher elevations, restricted work activity cycles
del using Dry Mortars and versatile ma-
chines, tools and plants. Mechanized con- Perlcon Giema Spray Plaster system “Blitz” TP 18
struction work execution adopted by the Brief Mechanical parameters and “Real Time” machine efficiency data are as follows;
Construction industry till now are;
Discharge at Nozzle : Up to 30 Lit/Min i.e. Approx. 0.75 Cum/Hr.
- Earth work in excavation and filling
- Concrete mixing, transporting & pla- Mixing Hopper : 40 Lit Capacity
cing Electrical Connection : 3 Phase 400 V/50Hz (Ideal for Indian Conditions)
The Masterbuilder | July 2015 | www.masterbuilder.co.in

- Curing water drawing and spraying
- Material handling (partially)
- Tiling, plumbing, fabrication activities
(partly)
Perlcon Giema Spray Plaster system,
with its unique features is indeed, a way
forward for mechanized plastering work
at site;
- Perlcon - Giema Spray Plaster system
effectively reduces Manpower need to
1/5th
- Perlcon - Giema ensures material
handling at project siteto 2/5th by
weight and also eliminates wastage
and pilferage
108
Dimensions / Weight : 1400 mm L x 620 mm B x 1020 mm H
(Overall Weight 114 Kg Approx.)
Basic Components : Premix Mortar Mixer, Spray Pump, Water Pump,
Water / Green Mortar /Compressed Air Hose pipes
(3 Nos, 10 Mt Each), Spray Nozzle & Air Compressor
Max Grain Size : Dry Mortar shall have maximum grain size 3.0 mm
Supply Pressure/Reach : 30 Bar (Max), Maximum up to 30 Rmt
Spray nozzle output : 3.00 cum
Dry mix mortar/4 hrs. : 3300 kg
12-15 mm thick plaster
area covered per Shift : 1800-2000 Sq.Ft. for Internal Plastering work
1000-1200 Sq.Ft for External Plastering work
Average spray plaster
Application Manpower : Operator + 3 Skilled + 2 Unskilled workers

- Maximizes speed with better work

 PLASTER SYSTEM

Perlcon is receiving enthusiastic
responses from various segments of Con-
struction Industries; leading promoters in
particular. Industry is as such on serious
look out for Spray Plaster Solution because
of several collateral benefits it offers. We
strongly feel that such systems will only
help India to finish projects much faster
which would help close in the current sup-
ply demand gap.
Indian construction industry has now
to be proactive for factoring in “Value of
Time” during the project execution stage.
The industry has to be ready with proper
methodology to buttress itself against
“Time Over-runs”. Perlcon Spray Plaster
Solution finds itself well placed to meet
this challenge successfully.
However, equally important is to cre-
ate awareness amongst the conventional
applicators about the Spray Plaster oper-
ations. The applicators must be given logi-
cal introduction and formal training of
Spray Plaster systems. Perlcon proactively
offers systematic training as well as initial
on site supports to its esteemed custom-
ers. Perlcon has undertaken a vital pro-
gram through which several Approved
Applicators will be offered to the indus-
tries for Spray plaster Applications.
Finally, Perlcon sees enormous po-
tential for Spray Plaster Solution. Within a
couple of years, it sees the Industry re-
placing conventional manual plastering
activity with mechanized plastering con-
cept. It has happened with RMC / Pump con-
crete operation and the same will be repea-
ted for Spray Plaster Systems too– sooner
is always better for all stake holders. 
For further details:
Perlcon Premix Pvt. Ltd.
302 Akshay, 53 Shrimali Society,
Navrangpura, Ahmedabad
Mob: +91 99250 25109 / +91 78019 32666
E-mail: info@perlcon.com
Web: www.perlcon.com

Tesla Co-founder Ian Wright:

Transforming Garbage Trucks into Electric Green Machines
Ian Wright who left Tesla, a company he founded is back. His latest venture, Wrightspeed, is doing some-
thing not entirely dissimilar to Tesla, and commercial trucks are his focus. Wrightspeed does not make the
whole truck, rather just a clean, electric powertrain specially designed to meet the needs of industrial
trucks, such as garbage trucks and large delivery vehicles. Commercial trucks, like those used for delivery
or for garbage pickup, are noisy, smelly, and guilty of a lot of carbon emissions. Wright hopes the prospect of
converting fleet vehicles to electric powertrains will be attractive to business owners, because it can repre-
sent a significant cost savings in the long term. There's a pretty hefty up-front investment, though, as an elec-
tric powertrain costs between $150,000 and $200,000 to install, while a brand-new garbage truck, for exam-
ple, costs $500,000. Convincing fleet owners to shell out that much cash will be a challenge, especially if
they feel their current trucks are doing just fine.
Wrightspeed's first clients are 25 FedEx trucks and 17 garbage trucks for the Ratto Group, a Santa Rosa-based
waste management company. The electric powertrains being installed in these trucks feature a lot of famil-
iar traits, like an electric engine, battery system, and an on-board power generator that can run on diesel or
natural gas to recharge the battery when it runs low on juice. It may not seem like big business, starting with
just 52 vehicles, but Wrightspeed has plans to grow. The company is moving into a new headquarters in
Alameda, and plans to expand their headcount from roughly 25 to 250 employees over the next few years.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
110
 COMMUNICATION FEATURE

Gandhi Automations
Loading Bay Equipment

G
andhi Automations Pvt Ltd is
India's No.1 Entrance Automa-
tion and Loading Bay Equipment
Company. This widely recognized posi-
tion has been achieved over years of hard
work, innovation, commitment to quality
and reliable customer service. The com-
pany is also proud to be certified to ISO
9001 : 2008. Since its inception in 1996 we
have been manufacturing, importing, dis-
tributing and installing products that are
problem free and easy to operate.
The company offers complete logistics
solutions by providing Dock Levelers,
Dock Shelters, Sectional Overhead Doors
and Dock Houses.
Electro-hydraulic, mechanical and air-
powered Dock Levelers offered by Gandhi
Automations are not only “a bridge for con-
necting a vehicle”, but also facilitate fast,
smooth and safe transition by compen- Dock Leveler
sating the difference in heights between
elers offered by the company ensure load- out moving the vehicle. The vehicle then
the loading bay and the vehicle. This con-
ing and unloading with lesser effort and departs at the end of the process.
tributes to minimizing energy used and
minimal cost. Radius Lip Dock Levelers allow the dock
savings on heating and chilling costs
It is possible to load and unload your to connect with the truck-bed, thus mak-
resulting in maintaining the quality of the
products in a safe way and in the process ing it possible to drive directly on and off
transported goods. Dock Levelers offered
obtain remarkable energy savings. The with fork-lift trucks, roll containers etc.
by Gandhi Automations are designed as
loading bay remains with the Dock Lev- Loading and unloading operations
per EN 1398 standard for the most
eler in rest position and the Sectional Over- become quick, safe and economical.
demanding loading and unloading opera-
head Door closed, until the vehicle is posi-
tions. Telescopic Lip Dock Levelers are ideal for
tioned. The driver drives back centring to
Efficient loading & unloading the goods: connecting vehicles that cannot travel to
the Dock Shelter and stops the vehicle the
the dock (e.g. sea containers, side loading
The Masterbuilder | July 2015 | www.masterbuilder.co.in

The importance of efficient loading the
goods has always been evident, and it has
increased over the years, essentially for
two reasons: the lesser availability and
the higher cost of manpower. Conse-
quently lesser qualified manpower is
being utilised which leads to damage in
the goods.
The cost of loading and unloading the
goods can be calculated precisely and is
exactly definable, which allows for a sci-
entific approach to find out the investment
that goes into the process. Gandhi
Automations has always designed solu-
tions based on such scientific approach
112
moment it gets in contact with the bump-
railway wagons etc.), These types can be
ers.
supplied with a lip extending up to 1 m.
The Sectional Overhead Door is then
Gandhi Automation's Dock Levelers
opened only when the vehicle is posi-
are equipped with the most secure safety
tioned, brakes applied and engines shut
devices and accessories. w
off .This eliminates the exit of hot air,
intake of cold air (or the opposite in hot
and inside conditioned places) and intake
of exhausting gases in the warehouse. For further details:
After the Sectional Overhead Door opens, Gandhi Automations Pvt Ltd
the lip of the Dock Leveler connects to the 2nd Floor, Chawda Commercial Centre,
Link Road, Malad (W), Mumbai – 400064, India.
truck bed for loading / unloading to take Tel : +91 22 66720200 / 66720300
place. Fax : +91 22 66720201
At the end of the loading/unloading the Email : sales@geapl.co.in
Website : www.geapl.co.in
Dock Leveler is put in rest position and the

and feedback from clients. The Dock Lev- Sectional Overhead Door is closed, with-

Costa Concordia Salvage Operation
The Project
To safely remove the ship, the salvage plan involved first
securing and stabilizing the wreck, using anchor blocks
attached to the seabed. This was to prevent the ship from slip-
ping along the steep incline of the seabed into deeper water.
The next step was preparing a false flat bottom using a com-
bination of piled platforms and grout-filled fabric formworks, on
which the wreck could rest after it had been rotated to an upright
position (parbuckling).
Airtight tanks, or sponsons, would be attached to either side
of the hull to help with the parbuckling and refloating opera-
tions.
Once the parbuckling and refloating was completed, the
ship would be towed away to be dismantled.
“It was estimated that this exercise would
3 ranging in size and shape, weighing up to 100kg in air before fill-
use approximately 20,000 tonnes (18,000m )
of cement.”
Ambico FoundOcean was awarded the scope to supply and
install approximately 2,000 custom designed fabric formwork
grout bags and grout mattresses.
The grout-filled formworks were required to act as a false
seabed which would take the ship's load once the parbuckling
was complete.
Wall of formworks
In order to construct an artifical seabed to create a stable
base for the hull, a construct of grout bags will be placed to
occupy the empty space between the two spurs of rock (one in
the stern area and the other in the bow of the hull – some 90m
apart) on which the wreck was resting.
The Concordia resting in its capsized position on the seabed
FABRIC FORMWORK: CASE STUDY
Fabric mattresses measuring seven meters by four mete-
rs were laid on top of the wall of formworks and subsquently
filled with grout to provide an even surface onto which the ship
will be rolled. This ensure that the weight of the ship’s hull is
evenly distributed so as not to create stress points that could
damage the hull.
Formwork Design
Ambico FoundOcean designed and manufactured the grout
bags in its manufacturing facility in Navi Mumbai according to
the project requirements. They were made from a flexible, high-
strength synthetic woven fabric which is permeable to water but
not to grout. The wedge-shaped bags were designed with sturdy
partitions so that they would fill evenly to produce a stable
formwork.
Eight different types of grout bags were designed for this job
ing. The large rectangular formworks were seven meters long,
three meters wide and two meters high, with a 42 m3 grout vol-
ume and weigh approximately 55 tonnes when filled. Smaller
wedge-shaped bags were also used: these were 3.5 meters
long and had an 8.1 m3 grout volume and weigh 10 tonnes when
filled.
Various other shapes and sizes were designed to account
for the variable topography of the seabed, and to accommodate
the huge parbuckling chains which were later laid on top of the
formwork-bed.
Grouting Procedure
The shallow water depth allows the formworks to be
installed by divers, who connected the hoses to the fabric bags
to fill them with grout.
The Masterbuilder | July 2015 | www.masterbuilder.co.in 113
 FABRIC FORMWORK: CASE STUDY
Once the formwork construct was complete, grout mat-
tresses were placed over them. These mattresses were manu-
factured using the same high-quality fabric as the formworks,
and provided a flat and stable base for the ship to rest on once it
has been pulled upright.
Mixing System
Cement was stored in multi-tonne vertical silos, and was
mixed on deck using a FoundOcean Recirculating Jet Mixer
(RJM).
Grout samples were taken from the mixer, which set as
Grout equipment onboard the work vessel
A Building
Inspired by
Underwater
Spiderwebs
114 The Masterbuilder | July 2015 | www.masterbuilder.co.in
Images: www.icd.uni-stuttgart.de
grout cubes in a curing tank. This was to demonstrate that the
compressive strength of the grout met the requirement for the
project.
“When built in 2005, the Concordia was to be
the largest Italian cruise ship, measuring
951m in length and weighing over 114,000
in gross tonnage.”
Ecosystem Safeguard
In order to meet the environmental requirements of the sal-
vage project, the seabed was to be returned to its original condi-
tion.
The Ambico FoundOcean fabric formworks, which weighed
up to 50 tonnes each when filled, were designed to be lifted out of
the sea when the salvage operation was complete. They were
later taken ashore for processing and recycling. w
For further details:
Ambico Group
#701-702 Shri Sai Corporate Park, Next to Polaris Tower,
Opp. Laxmi Nagar Industrial Estate, Goregaon Link Rd.,
Goregaon (West), Mumbai – 400 090, India.
Tel: +91 22 2876 6641 / 42 | Fax: +91 22 2876 9473
Email: info@ambicoindia.com | www.ambicofoundocean.com
The ICD/ITKE Research Pavilion 2014-15 demonstrates the architectural potential of a
novel building method inspired by the underwater nest construction of the water spi-
der. Collaboration between the University of Stuttgart's Center for Computational
Design and the school's Institute of Building Structures and Structural Design has
resulted in a pavilion that draws from the web-spinning habits of the diving bell spider.
Through a novel robotic fabrication process an initially flexible pneumatic formwork is
gradually stiffened by reinforcing it with carbon fibers from the inside.
The ICD/ITKE Research Pavilion 2014-15 demonstrates the architectural potential of a
novel building method inspired by the underwater nest construction of the water spi-
der. Through a novel robotic fabrication process an initially flexible pneumatic
formwork is gradually stiffened by reinforcing it with carbon fibers from the inside. The
resulting lightweight fiber composite shell forms a pavilion with unique architectural
qualities, while at the same time being a highly material-efficient structure.
These building prototypes explore application potentials of novel computational
design, simulation and fabrication processes in architecture. The pavilion was devel-
oped at the intersection of the two institute's research fields and their collaborative
teaching in the context of the interdisciplinary and international ITECH MSc program.
This prototypical project is the result of one and a half years of development by
researchers and students of architecture, engineering and natural sciences.
The design concept is based on the study of biological construction processes for fiber-
reinforced structures. The web construction process of water spiders was examined
and the underlying behavioral patterns and design rules were analyzed, abstracted and
transferred into a technological fabrication process.
The water spider spends most of its life under water, for which it constructs a rein-
forced air bubble to survive. First, the spider builds a horizontal sheet web, under which
the air bubble is placed. In a further step the air bubble is sequentially reinforced by lay-
ing a hierarchical arrangement of fibers from within. The result is a stable construct
that can withstand mechanical stresses, such as changing water currents, to provide a
safe and stable habitat for the spider. This natural production process shows how adap-
tive fabrication strategies can be utilized to create efficient fiber-reinforced structures.
 FABRIC FORMWORK: CASE STUDY

Perdido Norte Pipeline Separation

Introduction lines to achieve separation while also providing the required sup-
port.
The Perdido Norte large-diameter pipeline is 312.3km long
The pipelines cross at a water depth of 1,370m (4,500 ft).
and is tied back to the Williams Seahawk gas gathering system
in the Gulf of Mexico. The project involved separation of the two Project Description
18 inch pipelines that crossed at a depth of 1,370m to prevent
The separation was achieved by installing a grout-filled
each one’s cathodic protection being affected by the other.
crossover formwork between the two pipelines, which sup-
Cathodic protection is a technique used to control the corro-
ported the upper pipeline and gave protection to the lower.
sion of a metal surface. For pipelines, a sacrificial metal anode is
To enable Found Ocean to install the 1.2m (4ft) tall, 7.3m
normally used which corrodes instead of protected metal.
(24ft) long formwork, a jack was deployed to the worksite to raise
About Pipeline Rehabilitation the upper pipeline 18” above the top of the lower pipeline.
The specialist fabric formwork deployment sled has been
Pipelines may require separating for a variety of reasons;
developed by Found Ocean to be operated by ROV, so that install-
during installation as a preventive measure, and post-installa-
ing and filling formworks can be done safely and swiftly when
tion as a curative course of action.
divers cannot be used.
Where pipelines cross they are subject to forces that can
cause them to bend: sagging is where it bends down slightly, and
depending on the level of bend, may cause the pipeline to snap or
crack; and hogging where the pipe could bend upwards.
Material flowing through the pipeline can cause it to move
slightly. As this persists, crossing pipelines can rub together
causing friction and eventually lead to thinning of the walls, mak-
ing them more susceptible to corrosion.
As fields become entwined with new installations, this type Side view of the pipeline crossing
of remedial work will become more common.
Grouting Procedure
“At 2,514m the Perdido Norte is one of the
On deck, the form work bags were folded and fastened to the
deepest export pipelines in the world.” deployment frame using soft harnesses. The grout line between
Ambico Found Ocean was awarded the scope to supply and the sled and the form work was also connected atthis stage.
install a custom designed fabric form work between the two pipe- Once at the worksite, the ROV removed the formwork from
118 The Masterbuilder | July 2015 | www.masterbuilder.co.in

Standard and custom designed formworks for various subsea applications

 FABRIC FORMWORK: CASE STUDY

the sled and maneuvered it into position between the pipelines.

The grouting technician on board the vessel mixed the grout and
pumped it down the specialist deep-water grout umbilical.
The ROV continuously monitored the orientation and posi-
tion of the bag to confirm that its compartments were filling
evenly. Mixing and pumping stopped when the formwork was
completely filled.
The ROV detached the formwork grout line from the deploy-
ment sled allowing the self-sealing valve to operate, and guided
the sled and main grout line back to the surface.
ROV footage of formwork installation
Mixing Systemand Quality Control
“The Perdido project marks another milestone
Found Ocean mixed ordinary Portland cement (OPC) using for Ambico Found Ocean, as it once again
its 12V grout mixer. Cement was stored in bulk pressurized
silos, and pneumatically delivered to the mixer through a hose.
breaks the record for the world’s deepest
The grout was mixed and then stored in a holding tank and deployed fabric formwork.”
pumped to the formwork.
Grout density was controlled by mixing fixed volumes of For further details:
seawater and cement from the top-mounted surge tank on
Ambico Group
the mixer. Material samples were taken from each compart- #701-702 Shri Sai Corporate Park, Next to Polaris Tower,
ment of the formwork and cured as grout cubes, in accordance Opp. Laxmi Nagar Industrial Estate, Goregaon Link Rd.,
with specification BS EN 12390-2:2009. They were tested to Goregaon (West), Mumbai – 400 090, India.
Tel: +91 22 2876 6641 / 42 Fax: +91 22 2876 9473
ensure that the compressive strength met the requirements for Email: info@ambicoindia.com www.ambicofoundocean.com
the project.

The 2.2 mile San Francisco-Oakland Bay

San Francisco-Oakland Bay Bridge New East Span that was completed
and opened to traffic on September 2, 2013,
Bridge New East Span bags has been declared as the Outstanding Pro-
ject Award (OPA) winner for 2015 by The
DFI's 2015 Outstanding Deep Foundations Institute (DFI). The East
Span is the world's longest, single‐tower
Project Award self-anchored suspension span (SAS) and
the world's widest bridge at 259 feet. It is
located in a high seismic zone, situated
between two major faults capable of produc-
ing large earthquakes. Anchoring the SAS
tower foundation was accomplished by the
T.Y. Lin International/ Moffatt & Nichol Joint
Venture using the rock socketing process.
The lower, heavily‐reinforced concrete por-
The Masterbuilder | July 2015 | www.masterbuilder.co.in 119

tion of each pile was cast in rock sockets in

bedrock. The upper, permanent steel shell
was filled with more heavily reinforced con-
crete and welded to the concrete‐encased
steel footing box of the tower foundation at
water level. Bay Area geology also varies
along the length of the bridge, and presented
immense challenges for the design and con-
struction of the foundations.
The award will be presented to representa-
tives of the T.Y. Lin International/ Moffatt &
Nichol Joint Venture at the DFI 40th Annual
Conference on Deep Foundations in Oak-
land, Calif., October 12-15, 2015.
 MANUFACTURED SAND
Manufactured Sand
Dr. Aswath M U
Professor and Head Department of Civil Engineering,
Bangalore Institute of Technology
R
iver sand is a widely used construction material all over the
world, especially in the production of concrete, cement-sand
mortar and concrete blocks. Various Government, Non
Governmental Organisations and Research Institutes are striv-
ing to identify alternative materials to supplement river sand.
There is a strong need for research on river sand substitutes for
concrete production and cement sand mortar production. The
research should aim to identify suitable river sand substitutes for
practical applications in the local construction industry and also
focus on formulating practical solutions for using river sand
substitutes. The development of standards / specifications and
incorporating in the BIS codes will reduce the pressure on us-
ing river sand. The standards and codal specifications will assist
to select and use the alternatives by the various stake holders.
Quality certification of the alternate aggregates and quality cer-
tification of the concrete manufacturing process plays a vital role in
ensuring the durability of the concrete.
Researchers are in continuous search for the alternatives
to sand. Fine aggregate is one of the important constituents
of concrete. River sand is becoming a scarce material. Sand
mining from rivers has become objectionably excessive. It has
reached a stage where it is killing all our rivers day by day. So
sand mining has to be discouraged so as to save the rivers.
As natural sand deposits become depleted near some areas
of metropolitan growth, the use of alternatives to sands as a
replacement fine aggregate in concrete is receiving increased
attention. The National Green Tribunal also imposed ban and
restrictions on the sand mining.
Some of the Alternatives to River Sand are
The Masterbuilder | July 2015 | www.masterbuilder.co.in
- Manufactured Sand
- Fly Ash/ Bottom Ash/Pond Ash
- Copper Slag - Filtered Sand
- Sea Sand, Slag Sand
- Crushed Waste Glass
- Recycled Aggregate/C&D Waste Aggregate etc..
Manufactured Sand:
Manufactured sand is popularly known by several names
such as Crushed sand, Rock sand, Green sand, UltraMod Sand,
Robo sand, Poabs sand, Barmac sand, Pozzolan sand etc. IS
383-1970 (Reaffirmed 2007) recognizes manufacture sand as
‘Crushed Stone Sand’.
Crushed stone sand is produced by crushing boulders.
Manufactured sand is produced by rock-on-rock or rock-on-
120
metal Vertical Shaft Impactor (VSI) in which the process that
produced alluvial deposits is closely simulated. Particle size
reduction and achieving equidimensional shape is critical to
get desired properties. If rock is crushed in compression lot of
inherent properties exhibited by natural river sand are lost. If
proper technique of manufacturing is not adopted aggregates
are bound to become flaky and elongated. Improvements to
sand by way of washing, grading and blending may have to be
done before use at the consumer end. In case of manufactured
sand all the processes mentioned above can be done at manu-
facturing plant itself and controls are much better in producing
quality fine aggregates.
Fine aggregates manufactured sand proposed to be used
shall be produced from a Vertical Shaft Impact (VSI) crushers
and shall conform to the requirements of Zone-II (in most of the
cases) as per IS 383-1970 (Reaffirmed in 2007) and particles fin-
er than 75 µm shall not exceed 15 %. Special efforts on the part
of M-sand manufacturers (such as washing of sand by water
or dry washing by air) is required to restrict particles finer than
75 µm to 15%. The global trend is to utilize dry classification
solutions to produce manufactured sand. The dry separation
process separates fine and coarse particles. This allows a re-
duced percentage of super fines in manufactured sand, thereby
meeting specifications and achieving quality products.
M-sand can also be used for making masonry mortar and
shall conform to the requirements of IS 2116-1980 (Reaffirmed
1998) - “Specification of sand for Masonry mortars”.
Issues and General Requirements of Manufactured Sand
The Civil engineers, Architects, Builders, and Contractors
agree that the river sand, which is available today, is deficient in
many respects. It does content very high silt fine particles (as in
case of Filter sand).Presence of other impurities such as coal,
bones, shells, mica and silt etc makes it inferior for the use in
cement concrete. The decay of these materials, due to weathering
effect, shortens the life of the concrete.
Now-a-days, the Government have put ban on lifting sand
from River bed. Transportation of sand damages the roads. Re-
moving sand from river bed impact the environment, as water
table goes deeper & ultimately dry.
General Requirements:
1. All the sand particles should have higher crushing strength
2. The surface texture of the particles should be smooth
3. The edges of the particles should be grounded
4. The ratio of fines below 600 microns in sand should not be
less than 30%
 MANUFACTURED SAND

5. There should not be any organic impurities
6. Silt in sand should not be more than 2%, for crushed sand
7. In manufactured sand the permissible limit of fines below
75 microns shall not exceed 15%
Manufactured Sand Quality
Manufactured Sand should adhere to the highest standards
and must undergo the following quality tests
1. Sieve analysis
2. Optical Microscopic Study to check the particle shape
3. Workability (slump test by slump cone method)
4. Cube test for compressive strength
5. Tests for Silt and clay
The artificial sand produced by proper machines can be a
better substitute to river sand. The sand must be of proper gra-
dation (it should have particles from 150 microns to 4.75 mm in
proper proportion). When fine particles are in proper proportion,
the sand will have fewer voids. The cement quantity required
will be less. Such sand will be more economical. Demand for
manufactured fine aggregates for making concrete is increas-
ing day by day as river sand cannot meet the rising demand of
construction sector. Natural river sand takes millions of years
to form.
Technical Specifications for Sand as Per BIS:
The Indian Standard IS: 383; “Specification for Coarse and
Fine Aggregates from Natural Sources for Concrete” covers the
requirements for aggregates, crushed or uncrushed, derived
from natural sources, such as river terraces and riverbeds, glacial
deposits, rocks, boulders and gravels, for use in the production
of concrete for normal structural purposes including mass
concrete works.
Before choosing any alternative one should check the tech-
nical specifications as per the BIS codes. Sand is mainly used
for the preparation of mortar and concrete. It is also required to
manufacture the building blocks. The standard terminology used
for sand is fine aggregate. We all know that sand is a natural-
ly occurring granular material composed of finely divided rock
and mineral particles. The composition of sand is highly variable,
depending on the local rock sources and conditions, but the most
common constituent of sand is silica (silicon dioxide, or Si O2),
usually in the form of quartz. Fine Aggregate( Sand and/or
crushed stone) are less than 4.75 mm in size and F.A. content
usually 35% to 45% by mass or volume of total aggregate.
Aggregates shall comply with the requirements of IS 383.
As far as possible, preference shall be given to natural aggregates.
Other types of aggregates such as slag and crushed over burnt
brick or tile, which may be found suitable with regard to strength,
durability of concrete and freedom from harmful effects may be
used for plain concrete members, but such aggregates should not
contain more than 0.5 percent of sulphates as SO, and should
not absorb more than 10 percent of their own mass of water.
IS:383 classifies sand in to; Natural Sand - Fine aggregate
resulting from the natural disintegration of rock and which has
been deposited by streams or glacial agencies, Crushed Stone
Sand - Fine aggregate produced by crushing hard stone; and
Crushed Gravel Sand - Fine aggregate produced by crushing
natural gravel.
Quality of Aggregates
Aggregates shall consist of naturally occurring (crushed or
uncrushed) stones, gravel and sand or combination thereof. They
shall be hard, strong, dense, durable, clear and free from veins
and adherent coating; and free from injurious amounts of disin-
tegrated pieces, alkali, vegetable matter and other deleterious
substances. As far as possible, flaky, scoriaceous and elongat-
ed pieces should be avoided.
Deleterious Materials -Aggregates shall not contain any
harmful material such as pyrites, coal, lignite, mica, shale or
similar laminated material, clay, alkali, soft fragments, sea
shells and organic impurities in such quantity as to affect the
strength or durability of the concrete.
Aggregates to be used for reinforced concrete shall not
contain any material liable to attack the steel reinforcement.

Fine Aggregate Coarse Aggregate

Sl. No. Deleterious Substance Method of Test
Percentage by Weight, Max Percentage by Weight, Max
Uncrushed Crushed Uncrushed Crushed
1 2 3 4 5 6 7
The Masterbuilder | July 2015 | www.masterbuilder.co.in

i Coal and Lignite IS: 2386 (Part II)-1963 1.00 1.00 1.00 1.00
ii Clay lumps IS: 2386 (Part II)-1963 1.00 1.00 1.00 1.00
Materials finer than 75-µ
iii IS: 2386 (Part I)-1963 3.00 15.00 3.00 3.00
IS Sieve
iv Soft fragments IS: 2386 (Part II)-1963 - - 3.00 -
v Shale IS: 2386 (Part II)-1963 1.00 - - -
Total of percentages of
all deleterious materials
(Except mica) including Sl.
vi - 5.00 2.00 5.00 5.00
No. (i) to (v) for Col 4,6,7
and Sl. No. (i) and (ii) for
Col 5 only.
Table1: Limits of Deleterious Materials, IS:383-1970 Reaffirmed 2007 Clause 3.2.1
[Note: Aggregates petrographically similar to known reactive types or aggregates which, on the basis of service history or laboratory experiments, are suspect-
ed to have reactive tendency should be avoided or used only with cements of low alkalies {not more than 0.6 percent as sodium oxide (Na2O )} after detailed
121

laboratory studies. use of pozzolanic cement and certain pozzolanic admixtures may be helpful in controlling alkali aggregate reaction.]
 MANUFACTURED SAND

Aggregates which are chemically reactive with alkalies of ce- Size and Grading of Aggregates
ment are harmful as cracking of concrete may take place.
Limits of Deleterious Materials: The maximum quantity of IS 383 defines Fine Aggregates as aggregate most of which
deleterious materials shall not exceed the limits specified in Ta- passes 4.75-mm IS Sieve and contains only so much coarser
ble 1 when tested in accordance with IS: 2386-1963. However, material as permitted in cl.4.3. [Cl. 4.3 Fine Aggregates -The
the engineer-in-charge at his discretion may relax some of the grading of fine aggregates, when determined as described in IS:
limits as a result of-some further tests and evidence of satisfac- 2386 (Part I)-1963 shall be within the limits given in Table 4 and
tory performance of the aggregates. shall be described as fine aggregates, Grading Zones I, II, III and
Aggregate Crushing Value: The aggregate crushing value, IV. Where the grading falls outside the limits of any particular
when determined in accordance with IS: 2386 (Part IV)-1963 grading zone of sieves other than 600-micron IS Sieve by a total
shall not exceed 45 percent for aggregate used for concrete amount not exceeding 5 percent, it shall be regarded as falling
other than for wearing surfaces, and 30 percent for concrete within that grading zone. This tolerance shall not be applied to
for wearing surfaces, such as runways, roads and pavements. percentage passing the 600-micron IS Sieve or to percentage
Aggregates Impact Value: As an alternative, the aggregate passing any other sieve size on the coarse limit of Grading Zone
impact value may be determined in accordance with the meth- I or the finer limit of Grading Zone IV.]
od specified in IS: 2386 (Part IV)-1963. The aggregate impact value NOTE 1-For crushed stone sands, the permissible limit on
shall not exceed 45 percent by weight for aggregates used for 150-micron IS Sieve is increased to 20 percent. This does not
concrete other than for wearing surfaces and 30 percent by weight affect the 5 percent allowance permitted in 4.3 applying to other
for concrete for wearing surfaces, such as runways, roads and sieve sizes.
pavements.
Is Sieve
Aggregate Abrasion Value: Unless otherwise agreed to be- Percentage Passing for
Designation
tween the purchaser and the supplier, the abrasion value of ag-
gregates, when tested in accordance with the method specified Grading Grading Grading Grading
in IS: 2386 (Part IV)-1963 using Los Angeles machine, shall not Zone 1 Zone II Zone III Zone IV
exceed the following values: 10 mm 100 100 100 100
4.75mm 90-100 90-100 90-100 95-100
a) For aggregates to be used in concrete for wearing surfaces:
30 percent 2.36 mm 60-95 75-100 85-100 95-100
b) For aggregates to be used in other concrete: 50 percent 1.18mm 30-70 55-90 75-100 90-100
Soundness of Aggregate: For concrete liable to be exposed, 600 micron 15-34 35-59 60-79 80-100
the action of frost, coarse and fine aggregates shall pass a sodium 300 micron 5-20 8-30 12-40 15-50
or magnesium sulphate accelerated soundness test specified 150 micron 0-10 0-10 0-10 0-15
in IS: 2386 (Part V)-1963, the limits being set by agreement be-
tween the purchaser and the supplier, except that aggregates Table 4: Fine Aggregates, IS:383-1970 Reaffirmed 1997 Clause 4.3)
failing in the accelerated soundness test may be used if they pass
a specified freezing and thawing test satisfactory to the user. NOTE 2 - Fine aggregate complying with the requirements
[Note: - As a general guide, it may be taken that the average loss of of any grading zone in this table is suitable for concrete but the
weight after 5 cycles shall not exceed the following: quality of concrete produced will depend upon a number of fac-
tors including proportions.
a) For fine aggregate: 10 percent when tested with sodium NOTE 3 - Where concrete of high strength and good dura-
sulphate (Na2 SO4), and 15 percent when tested with mag- bility is required, fine aggregate conforming to any one of the
nesium sulphate (Mg SO4) four grading zones may be used, but the concrete mix should
b) For coarse aggregate 12 percent when tested with sodium be properly designed. As the fine aggregate grading becomes
The Masterbuilder | July 2015 | www.masterbuilder.co.in

sulphate (Na2 SO4), and 18 percent when tested with mag-
nesium sulphate (Mg SO4)
NOTE 1 -The presence of mica in the fine aggregate has
been found to reduce considerably the durability and compres-
sive strength of concrete and further investigations are underway
to determine the extent of the deleterious effect of mica. It is ad-
visable, therefore, to investigate the mica content of fine aggre-
gate and make suitable allowances for the possible reduction in
the strength of concrete or mortar.
NOTE 2- The aggregate shall not contain harmful organic
impurities [tested in accordance with IS: 2386 (Part II) - I963] in
sufficient quantities to affect adversely the strength or durabil-
ity of concrete. A fine aggregate which fails in the test organic
impurities may be used, provided that, when tested for the effect of
organic impurities on the strength of mortar, the relative strength
at 7 and 28 days, reported accordance with 7 of IS : 2386 (Part VI
)-1963 is not less than 95 percent.
122
progressively finer, that is, from Grading Zones I to IV, the ratio
of fine aggregate to coarse aggregate should be progressively
reduced. The most suitable fine to coarse ratio to be used for any
particular mix will, however, depend upon the actual grading,
particle shape and surface texture of both fine and coarse ag-
gregates.
NOTE 4- It is recommended that fine aggregate conforming
to Grading Zone IV should not be used in reinforced concrete
unless tests have been made to ascertain the suitability of pro-
posed mix proportions.
The percentage passing 600μm sieve will decide the zone
of the sand: Zone-I Coarse Sand; Zone-II; Zone-III and Zone-IV
Fine Sand. Grading Limits can also be represented through a
graph of sieve size on the x-axis and % passing on the Y-axis
(Semi log sheet).
Fineness Modulus (FM): The result of aggregate sieve anal-

ysis is expressed by a number called Fineness Modulus. It is

 MANUFACTURED SAND

Illustration Of Characteristic
Classification Description Example
Specimens
1 2 3 4
River or seashore gravels;
Fully water worn or com-
Rounded Fig. 1 desert, seashore and wind-
pletely shaped by attrition
blown sands
Naturally irregular, or partly
Pit sands and gravels; land or
Irregularly or partly rounded shaped by attrition, and hav- Fig. 2
dug flints; cuboid rock
ing round edges
Possessing well- defined
edges formed at the in- Crushed rocks of all types;
Angular Fig. 3
ter-section of roughly planar tullus; screes
faces
Material, usually angular, of
which the thickness is small
Flaky Fig. 4 Laminated rocks
relatively to width and/or
length
Table 6: Particle Shape, IS:383-1970 Reaffirmed 1997 Clause C-3.2

FM is an index of fineness of an aggregate. The fineness

Figure1: Particle Shape:rounded
Figure 2: Particle Shape:irregular
modulus of the fine aggregate is required for mix design since
sand gradation has the largest effect on workability. Fine sand
(low FM) has much higher effect paste requirements for good
workability. It is computed by adding the cumulative percentages
of aggregate retained on each of the specified series of sieves,
and dividing the sum by 100 [smallest size sieve: No. 100 (150
μm)]. The higher the FM, the coarser is the aggregate.

Sampling and Testing

Sampling: The method of sampling shall be in accordance

Fig.3 Particle Shape:Angular Fig.4 Particle Shape:flaky with IS: 2430-1969. The amount of material required for each
test shall be as specified in the relevant method of test given in
Significance of Grading IS: 2386 (Part I)-1963 to IS: 2386 (Part VIII)-1963.
Is Sieve Testing: All tests shall be carried out as described in IS:
Percentage Passing by Weight Grading 2386 (Part I)-1963 to IS: 2386 (Part VIII)-1963. Unless otherwise
Designation
stated in the enquiry or order, duplicate tests shall be made in
Zone-I Zone II Most Zone-IV
all cases and the results of both tests reported.
(Coarse Suitable/ Zone-III (Fine
Sand) Desirable Sand) Information to be furnished by the Supplier:
10 mm 100 100 100 100
Details of Information: When requested by the purchaser
4.75mm 90-100 90-100 90-100 95-100 or his representative, the supplier shall provide the following
The Masterbuilder | July 2015 | www.masterbuilder.co.in

2.36 mm 60-95 75-100 85-100 95-100 particulars:

1.18mm 30-70 55-90 75-90 90-100
a) Source of supply, that is, precise location of source from
600µm 15-34 35-59 60-79 80-100 where the materials were obtained
300µm 5-20 8-30 12-40 15-50 b) Trade group of principal rock type present
c) Physical characteristics
150µm 0-10 0-10 0-10 0-15
d) Presence of reactive minerals
Fineness 2.78- 2.25- e) Service history, if any. Subject to prior agreement, the sup-
4.0-2.71 3.37-2.10
Modulus 1.71 1.35 plier shall furnish such of the following additional informa-
Fine-Aggregate Grading Limits tion, when required by the purchaser:
f) Specific gravity, g) Bulk density, h) Moisture content
obtained by adding the sum of the cumulative percentages by i) Absorption value
mass of a sample aggregate retained on each of a specified se- j) Aggregate crushing value or aggregate impact value
ries of sieves and dividing the sum by 100. The specified sieves k) Abrasion value,
are: 150 μm (No. 100), 300 μm (No. 50), 600 μm (No. 30), 1.18 mm l) Flakiness-index, m) Elongation-index, n) 3 Presence of del-
(No. 16), 2.36 mm (No. 8), 4.75 mm (No. 4), 9.5 mm , 19.0 mm , eterious materials
37.5 mm , 75 m , and 150 mm. o) k) Potential reactivity of aggregate
Fineness modulus = 283 ÷ 100 = 2.83
124

p) m) Soundness of aggregate
 MANUFACTURED SAND

Percentage of Cumulative chemically stable sands provides greater durability and higher
Percentage strength to concrete by overcoming deficiencies like segrega-
individual frac- Percentage
Sieve size passing, by tion, bleeding, honey combing, voids and capillary.
tion retained, retained by
mass
by mass mass
Greater Workability
10 mm 0 0
100
4.75 mm 2 2 The crusher dust is flaky and angular in shape which is
98
2.36 mm 13 15 trouble some in working. There is no plasticity in the mortar
85
1.18 mm 20 35 which makes it even difficult for the mason to work, whereas
65
600 µm 20 55 the cubical shape with grounded edge and superior gradation
45
300 µm 24 79 gives good plasticity to mortar providing excellent workability.
21
150 µm 18 97
3
Pan 3 - Offsets Construction Defects
0
Total 100 283
Manufactured sand has optimum initial and final setting
Results of Sieve Analysis and calculation of FM of Sand
time as well as excellent fineness which will help to overcome
the deficiencies of concrete such as segregation, bleeding, honey-
combing, voids and capillary.

Economy

Usage of manufactured sand can drastically reduce the

cost since like river sand, it does not contain impurities and
wastage is NIL. In International Construction Scenario, no river
sand is used at all, only sand is manufactured and used, which
gives superior strength and its cubical shape ensures signifi-
cant reduction in the cement used in the concrete
Eco-Friendly

Fine Aggregate for Concrete: FM Range 2.3 to 3.1

Greater Durability
Manufactured sand has balanced physical and chemical
properties that can withstand any aggressive environmental
and climatic conditions as it has enhanced durability, greater
strength and overall economy. Usage of manufactured sand
can overcome the defects occurring in concrete such as honey
combing, segregation, voids, capillary etc.
Manufactured sand is the only alternative to river sand.
Dredging of river beds to get river sand will lead to environmen-
tal disaster like ground water depletion, water scarcity, threat to
the safety of bridges, dams etc.
Beside with the Government contemplating ban on dredg-
ing of River beds to quarry river sand, as part of the growing
concern for environment protection, manufacturing sand will
be the only available option.
Conclusion

High Strength Keeping the demand in mind and all the technical specifi-
cations mentioned above, we need to use Manufactured Sand
The superior shape, proper gradation of fines, smooth in all construction works. Many manufacturers are producing
surface texture and consistency in production parameter of quality M Sand using latest technologies ensuring the quality

Comparison between Manufactured Sand and Crusher Dust

The Masterbuilder | July 2015 | www.masterbuilder.co.in

Manufactured Sand Crusher Dust

Grey Grey
Colour Cubically Shaped Flaky
Particle Shape Manufactured as per IS, BS, ASTM Elongated (Shapeless)
Product Standards a) It is fractured dust of jaw crusher
Manufacturing International technology con- b) A waste product in production process of stone crusher
Process trolled manufacturing process No controlled manufacturing process as it is the
through imported machines by-product of stone crusher
Gradation As per IS 383 - 1970 Zone-II Does not adhere to IS 383 - 1970 or any other standards
Recommended for usage in con-
Suitability for crete & masonry works worldwide Not recommended for use in concrete or masonry
concreting by the concrete technologists. works. Does not have quality.
Confirms international standards
125

Comparison And Advantages: (Source: Poabs M Sand & Besto)

 MANUFACTURED SAND

Sieve Analysis River Sand Vs M-Sand

% Age passing for single sized aggregates
Is Sieve River Sand % Age Passing M-Sand % Age Passing
of Normal Sand (IS 383 - 1970) Zone II
4.75 mm 99.25 99.75 90 to 100
2.36 mm 93.50 78.25 75 to 100
1.18 mm 48.00 52.00 55 to 90
600 Microns 21.00 38.00 35 to 59
300 Microns 04.00 21.00 08 to 30
150 Microns 0.05 5.00 0 to 10

Comparison of Impurities - River Sand Vs M-Sand

River Sand M-Sand
Marine Products 2-4% Nil
Oversized Materials 6 - 10 % Nil
Clay & Silt 5 - 20 % Nil

Natural Sand Manufactured Sand

- Excessive and illegal quarrying of Natural sand at
river beds , resulting into soil erosion and danger to
the reservoir structures
- Scarcity due to ban on quarrying activities near the
river bed by the Govt. to prevent depleting of natural
resource
- No control on silt content
- Very long distance transportation resulting into vol-
ume loss on the quantity of sand received at site.
- Adulteration with filter sand (Unfit to be used in con-
crete)
- No guarantee on gradation
- Huge inventory cost during monsoon for non avail-
ability
- Fear of not getting sand, if rejected for quality
- Additional manpower for removal of pebbles & boul-
ders while loading into batching plant to avoid pump
choke ups
- No mechanism on pricing
Courtesy:Besto
- 100% replacement to Natural sand & It is One of the bi-product of
aggregates
- No scarcity , as the Govt. is encouraging the business to garner
un-tapped revenue
- Govt. has identified the places and accorded the sanction for carrying
out quarrying and crushing activities without compromising on any
environmental issues
- Sand washing machine to ensure 0% silt content, benefiting best
economized concrete with possibilities of reduction in cement content.
- Uninterrupted supply even during rainy season, which in turn facili-
tating timely completion of the project.
- No adulteration
- World class Machine is employed to get the Top-Quality-Graded ag-
gregates meeting both BIS and Customer requirement, the Consis-
tency on the required gradation is guaranteed.
- No fear, the quality is the main focus.
- No additional manpower is required to remove boulders or pebbles,
which is again cost saving
- Transparency in pricing , as the manufacturing facility is legal and
ethical

as per BIS specifications at affordable costs compared to river 8. IS: 383-1970, [Reaffirmed 1997], Specification for coarse and fine aggregates from
natural sources for concrete, Bureau of Indian Standards, New Delhi.
sand. As natural sand deposits become depleted, the use of al-
9. Nichols, F.P (Manufactured sand and crushed sand in Portland cement concrete
ternatives to sand as a replacement for fine aggregate such as INTERNATIONAL, NO. 8, PP 56-63, 1982).
Manufactured Sand is receiving increased attention.
The Masterbuilder | July 2015 | www.masterbuilder.co.in

10. POBAS MSAND-http://www.msand.in/poabsmsand.php

Acknowledgement: The content of the paper is sourced from
various organisations for knowledge dissemination. All logos
and images are property of the respective owners listed in the
references
References
1. Elavenil, S., Nagabhushana Rao, Bh., Radhakrishnan, R and Hariharan, K
(2005)“Comparative Study of Steel and Polypropylene Fibre Concrete Plates for
Bridges and Roads”, Journal of Current Science, Vol.7, No.1, pp. 19-24
2. Elavenil.S,Saravanan.S,Akarsh.M.R,(2012)‘Studies on Plastic mixed concrete
with Conventional concrete’,i-managers Journal on Structural Engineer-
ing,Vol.1,N0.2,pp- 11-17
3. Guide to the specification and use of manufactured sand in concrete CCAA – T60
(Cement Concrete and Aggregates AUSTRLIA).
4. Guide to the specification and use of manufactured sand in concrete CCAA – T60
(Cement Concrete and Aggregates AUSTRLIA).
5. Hudson BP – (Manufactured sand for concrete).
6. Hudson BP – (Manufactured sand for concrete).
126
11. Reference manual for field engineers on building construction, Task Force for
Quality Assurance in Public Constructions, Govt. of Karnataka
12. Research on River Sand Substitutes for Concrete Production and Cement Sand
Mortar Production by Professor Albert K.H. Kwan, Department of Civil Engineer-
ing, The University of Hong Kong
13. Sand matter the sand saga… an overview of sand scenario- Built Expressions
Vol:2 Issue:9 September 2013
14. Singapore’s sand shortage “The hourglass effect”- Oct 8th 2009 | SINGAPORE
15. Technical data and potential use of fly ash, bottom ash and pond ash of APNRL
Plant 2012
16. Use of Manufactured Sand in Concrete and Construction an Alternate to River
Sand by G. Sreenivasa, General Manager (Business Development), UltraTech Ce-
ment Limited, Bangalore
17. VTU e-learning Notes for UNIT-II (Aggregates used for concrete making)
18. RoboSand The perfect substitute for river sand-http://www.robo.co.in/home.htm
19. www.robosilicon.com
20. www.vsicrushers.com
21. http://en.wikipedia.org/wiki/Sand
22. http://www.artificialsand.com/faqs.html
23. http://www.msand.in/
24. http://www.msand.in/

7. ICOMAT Report 25. http://www.oregrinder.com/ w

 INTERACTION
Manufactured to Perfection:
Engineered Sand Delivered On-Site
Prof. M.S. Shetty
Renowned Concrete Technologist
T
he rapid pace of construction wit-
nessed over the last couple of de-
cades has placed enormous strains
on available sources of natural sand. The
harmful effects on the environment due to
rampant sand mining is an issue that has
been affecting the construction industry
in recent times. However, all is not lost
when it comes to the environment as Man-
ufactured Sand had come as a boon to the
construction industry. One company that
had taken a lead in this specialized area is
MAAD Sand & Minerals Pvt. Ltd. with
‘UltraMod Sand'.
The strong R&D focus of the company
has been behind this outstanding solution.
In a detailed interaction with MAAD Sands
& Minerals Pvt. Ltd. Managing Director,
The Masterbuilder | July 2015 | www.masterbuilder.co.in
128
Sandesh Mahale
Managing Director
MAAD Sand & Minerals Pvt. Ltd.
Mr.Sandesh Mahale and renowned con-
crete technologist Prof.M.S.Shetty gave
valuable insights into the various advan-
tages offered by Engineered Sand and the
importance of the right method of manu-
facturing. Here are excerpts from the
interaction.
Do you feel that the focus around manu-
factured sand has increased in recent ?
Sandesh Mahale: India is embarking
on an unprecedented infrastructure dev-
elopment spree. Concrete is the backbone
material for such developments. Today we
are producing 90 crore cubic meter of con-
crete. For this we need approximately 6
crore truckloads of sand (one truck load is
15 ton). Collection of 6 crore truckloads of
sand from river and stream beds pres-
ents a very serious environmental prob-
lem. Having foreseen this serious envi-
ronmental problem our government has
banned dredging from natural sources.
To keep up trend of infra-structure devel-
opment unabated it has become neces-
sary to use manufactured sand.
In our country quarrying industry is in
the hands of the unorganized sector. Sand
is produced in an unscientific manner and
supplied to construction sites. Being help-
less concrete industry has to accept such
nonstandard crushed sand. With the result
the production of concrete has not only
become difficult but also necessitated the
use of extra cement- a national waste.
Other countries in the world also faced
 INTERACTION

similar issues but they solved the prob- 3. UltraMod sand is manufactured to that the presence of a small quantity
lem by using modern science and tech- have good shape and surface texture. of (say 6% of minus 75 micron) mate-
nology for producing manufactured sand, The technology is inbuilt in the manu- rial resulted in reduced water demand,
which is suitable for any type and grade of facturing process for attaining good cement demand, while at the same
concrete. shape and surface texture. No doubt time improved workability. Whereas
In our country also a few quarry own- natural sand has some advantages in the natural sand very fin particles are
ers and entrepreneurs established mod- with respect to shape factor but with not permitted because such fine par-
ern equipment for producing manufac- respect to texture the surface being ticles can be only in the form of mud
tured sand in some of the big cities like smooth it suffers from reduced bond and clay.
Mumbai. But they are not fully exploiting strength. 5. The uncompacted voids in all-in agg-
the potential of the modern equipments 4. UltraMod sand being screened by dif- regates of the UltraMod sand pro-
that they are using. They are going for short- ferent vibrating screens and scientifi- duced by V.S.I crushers using rock-on-
cut methods to produce cheap sand. Quite cally washed it contains all size parti- rock technology was found to be 34%
a number of them are supplying manu- cles including particles smaller than as compared to 36% of uncompacted
factured sand of inconsistent quality. 75 microns. Extensive studies showed all in-aggregate from natural source.
Prof.M.S.Shetty: I have used Manu-
Case Study made under the guidance of Prof. M.S. Shetty-Renowed Concrete Technologist
factured Sand at many sites in Mumbai
Optimization Achieved with ULTRAMOD SAND as compared to all other Fine Aggregate
even M 80 grade of self compacting con-
Ultramod Concrete Sand
crete without any problem. As a matter of
fact good quality of Manufactured Sand MATERIAL
facilitated the production of good quality
of concrete. Many others in Mumbai have
also produced even grade M 95 concrete.
But suppliers of such quality material are
few and far between.
What are the various advantages offered
by UltraMod sand vis-à-vis natural sand?
Plaster Sand: Plaster Sand Comparative with other Plaster Items
Prof.M.S.Shetty: One of the big advan-
tages with UltraMod Sand is that since it is
produced using selected rock mass, it is
free from impurities like mud, silt, clay,
decayed organic matter, chlorides and
sulphides, as compared to natural sand,
which contains several, if not all these
impurities. The scientific technology and
equipment that is used by MAAD Sand &
Minerals in the manufacturing process
also ensures good shape and surface tex- PrePlast: Cost Comparative with others
ture, factors which enable production of
top quality concrete.
I am of the opinion that the right qual-
The Masterbuilder | July 2015 | www.masterbuilder.co.in

ity of Manufactured Sand is superior to nat-

ural sand in many respects. Let us take a
look at these advantages one by one.
1. UltraMod sand derived from selected
rock mass is free from impurities like
mud, silt clay, decayed organic mat-
ters, chlorides and sulphides. Whereas
by nature natural sand contains many if
not all the above mentioned impurities.
2. UltraMod sand is produced in any
desired grading. Good grading is the
most important property of aggre-
gates for making workable, economi-
cal and durable concrete. Natural
sand is rarely well graded.
129
 INTERACTION

What are the various steps involved in the
manufacturing process of engineered
sand?
Sandesh Mahale: The manufacturing
process is divided into five different
stages. These include:
The primary circuit:
The boulders quarried from selected
rock mass of size about 750 mm are
crushed to about 200 mm size by a jaw
crusher.
The secondary circuit:
The secondary circuit consists of a
cone crusher which reduces 200 mm sized
stones to about 25mm to 30 mm size.
The tertiary circuit:
The tertiary circuit consists of a verti-
cal shaft impactor (V.S.I) which uses rock-
on-rock collision technique for sizing and
shaping of particles. The tertiary circuit is
the most important of modern techniques
to modify the shape and surface charac-
teristics of both coarse and fine aggregates.
Tertiary circuit also has provision of recir-
culation to obtain ideal shape and surface
texture. The oversize is then send further to
ConeCrusherforreshapinginfourthstage.
Fourth stage
Oversize above 5 mm is circulated in
Cone Crusher ideally 7 to 9 times to get de-
sired gradation and shape. Recirculation
helpsitgetting'neartonaturalsand'shape.
Fifth Stage Evowash
Excessive dust is not only a nuisance
but also makes the sand unsuitable for
making good concrete. The so called Man-
ufactured Sand available in market con-
sists of 18 to 22% of 150µ. In and around
this region there are hardly any suppliers
who have hi-tech sand washing system to
limit the dust content consistently. UltraMod
sand is manufactured using hi-tech
'Hydrocyclic' sand washing system by
trade name 'Evowash system' used in con-
junction with V.S.I crusher equipment. The
Manufactured Sand is washed in a scien-
tific manner to remove dust to a predeter-
mined level. We limit 150 µ to 10 to 12%
and 75 µ up to 5% by weight.
Ideally Evowash needs 60,000 liters of
water per hour. But because the group is
green product concious we recycle 75% of
water in Evowas system improvisation.
Further to this we have installed a Fil-
ter Press which also removed water from
sleudge and we almost recycle 90% of
watr used in Hydrocycle Evowash pro-
cess, Thus making it green plant.
What products you manufacture under
UltraMod Sand brand its features ?
Sandesh Mahale: The company offers
three variants of UltraMod Sand - (a)
UltraMod Sand- Concrete, (b) UltraMod
Sand- Plaster and (c) UltraMod Sand-Pre
Plast, all of which have taken the construc-
tion industry by storm, thanks to their
numerous advantages that they offer.
Some of the unique features of UltraMod
Sand- Concrete include :
- 150 µ content limited to 12% and 75 µ
below 3%-5% by weight.
- Delivered in SSD condition resulting
in no additional correction for water
absorption.
- Free water content at par with best
available natural sand.
- Tested for High Performance Con-
crete (HPC) and Self Compacting Con-
crete(SCC).
- Consistent gradation.
The unique features of UltraMod Sand-
Plaster include:
- Shape comparable to natural sand.
- 1:5 instead of 1:4 results in lower ce-
ment consumption.
- No oversize particles.
- Rich cement mortar upto 35 Mpa can
be achieved.
- Delivered in SSD condition resulting in
no additional correctio for water ab-
sorption.
- Consistent below 3mm gradation.
Similarly, the unique features of UltraMod
Sand- PrePlast are as follows:
- Available in 40 kg bag, easy to store,
easy to handle (almost 0% wastage).
- Added with glass fibre for better per-
formance.
Around 25% savings as compared to
nearest replacement, i.e., natural sand.w

th 1st Announcement and

World Congress on Joints, Bearings and
8 Seismic Systems for Concrete Structures
Call for Papers
The Masterbuilder | July 2015 | www.masterbuilder.co.in

THE IJBRC has issued a call for papers for the Eighth World Congress on Joints,
Bearings and Seismic Systems for Concrete Structures being held in Atlanta, Geor-
gia, USA on September 25-29, 2016 at The Atlanta Marriott Buckhead Hotel and Con-
ference Center.
Deadline:
Solicited: Papers are sought for presentation at the conference and inclusion in the Abstracts by September 1, 2015
proceedings on all topics related to Expansion Joints, Bearings and Seismic Sys-
Submit to:
tems including methods for measuring and predicting structural movements; prop-
Email: ijbrc@rjwatson.com
erties and test procedures; movement, rotation and load capacity and case studies.
Fax: 716‐901‐7015
The list is not intended to be restrictive and all papers related to the subject matter
will be considered. Dec. 1, 2015 - Authors Notified
Apr. 1, 2016 - Manuscript Due
Requirements: Potential papers will be selected on the basis of a peer review of a
200 word abstract before authors are invited to submit the full paper for acceptance Official Language: English
review. The abstract and papers shall be submitted in MS Word or PDF format in For more information visit:
accordance with ACI standard procedures. The full name and email addresses of all www.ijbrc.org
130
 CASE STUDY
Post Earthquake Findings of
Damaged Buildings in Nepal
J Srinivas Prasad
Managing Director, La Green
Bangalore
Introduction
This article is based on experience and
observations in the recent earth quake at
Nepal made by more hundreds of site
visits. Such heavy loss due to the struc-
tural damage has sparingly noticed in
modern times.
The article is aimed at to understand
manmade mistakes that caused such de-
vastating effect of the seismic move-
ments on the structures, the nature of
distress, pitfalls, remedial measures and
suggested measures to avoid repetition of
such failures caused by earth quakes.
Types of Structure studied
The observations made on building
having different functionality- Hospitals,
Hotels, Commercial building, mercantile
buildings, government authority buildings,
residential bungalows & private houses
and residential complexes in around the
capital city of Kathmandu.
Modern Kathmandu city was originally
a lake and has liquidifaction problems
and many discrete locations, more prone
in the newly developing areas.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Mainly three different types of founda-
tion being noticed in Kathmandu- load
bearing brick walls mostly noticed in buil-
ding more that 20 years old, RCC frame
structure and sometimes a combination
of brick and RCC. Deep foundations are
only found in very recent and few buil-
dings.
The building on consolidated soil are
less effected that the ones at uncon-
solidated areas.
Types of distress noticed:
- Ductile failure beam column junction
- Shear Failure in Columns
132
- Delaminating of RCC Brick Wall joint
Ambarish Ghosh
- Column Bulging
- Slant Shear Cracks on Wall- Cross
Shear
- Horizontal Shear cracks in Walls
The severe extend of the damage may
be attributed to the following:
Authority Check Absent
- No provision for checking the struc-
tural design
- No provision to maintain minimum dis-
tance between two adjacent buildings.
- No provision to make soil test report
mandatory
- No Provision for completion certifica-
tes.
Defect in Prevalent Construction System
- There is no efficient construction
Monitoring System
- Nothing called PMC exist in Nepal
- Quality Control & Quality Assurance
is highly neglected.
- Focus is more to economizing and not
on safety
Maternity Hospital in Kathmandu-
No Linter provided above the opening
The Structural designer are using old
version of the design software without
considering the latest consideration of IS
code which is being followed there and
commoner are living with the impression
that IS code is not sufficient to adapt for
Nepal seismic Conditions.
On the contrary please note the following:
Newly costruncted Residential
BungalowRings are missing in the columns
- Foundation designed but no soil in-
vestigation report
- Poor detailing
- Design not following ductility dealing
IS:13920
- Not following basic Design – Guide-
line As per IS:456
- Poor construction Practice
- Improper QC & QA.
- Old structure not designed as per
latest code and not retrofitting as per
Seismic Requirement.
Thus all of the above leading to such
catastrophic failures.
The need to improve the ability of an
existing building to withstand seismic
forces arises usually from the evidence of
damage and poor behaviour ring a recent
earthquake. It can arise also from cal-
culations or by comparisons with similar
buildings that has been damaged in other
places. While in the first case the owner
can be rather easily convinced to take
measures to improve the strength of his
building, in the second case dwellers that
have much more stringent day-to-day
needs are usually reluctant to invest
money in the improvement of seismic
 CASE STUDY

safety. The problems of repairs, res- of concrete and reinforcement details are
toration and seismic strengthening of not available for most of the sites. First of
buildings are briefly stated below: all an as build structural drawing need to
be made before taking up and redesign or
1] Before the occurrence of the
retrofitting work.
probable earthquake, the required
strengthening of seismically weak Some of the method and retrofitting
buildings is to be determined by a philosophies are already adopted world
survey and analysis of the structures. wise. Some of them are as some below:
2] Just after a damaging earthquake, Suggestion for Implementation by Gover- Using Steel Section
temporary supports and emergency nment authorities at Nepal
repairs are to be carried so that
precariously standing buildings may 1. Separate design cell to check for de-
not collapse during aftershocks and sign before sanctioning and PMC to
the less damaged ones could be
quickly brought back into use.
3] The real repair and strengthening
problems are faced at the stage after
the earthquake when things start
settling down. At this stage distinction
Using Steel Section
has to be made in the type of action
required, that is, repairs, restoration
and strengthening, since the cost,
time and skill required in the three
may be quite different.
The decision as to whether a given
building needs to be strengthened and to
what degree, must be based on calcula-
tions that show if the levels of safety de-
manded by present codes and recom-
mendations are met. Difficulties in esta- Strenegthning of brick pillar by MS angles

blishing actual strength arise from the

considerable uncertainties related with
material properties and with the amount
of strength deterioration due to age or to
damage suffered from previous earth-
quakes. Thus, decisions are frequently
based on gross conservative assum-
ptions about actual strength.
The method of repair and strength-
ening would naturally depend very largely
Retrofitting by micro-concrete & Rebar
on the structural scheme and materials
used for the construction of the building in
the first instance, the technology that is
The Masterbuilder | July 2015 | www.masterbuilder.co.in

feasible to adopt quickly and on the

amount of funds that can be assigned to
the task, usually very limited.
Retrofitting philosophy that can be
adopted by use of the following systems:
- Using Steel Frames & Stiffeners
- Using Reinforcement & micro-
concrete
- Using FRP Systems
- Steel wires & mesh
- Use of Modern chemicals
- Combination of the above
After conducting NDT and based on
Using FRP to increase the ductility beam- Retrofitting by micro-concrete & Rebar
the NTD results & Soil test. The strength
133

column junction
 CASE STUDY

correct implementation
2. Use of RMC or designmixed concrete
mandatory for all public building &
high rise ( above 3 storied)
3. Soil test report should be made man-
datory as Kathmandu has liquefac-
tion problem.
4. Stability certificate from structural
engineer should be made mandatory
after completion.
5. Completion Certificate should be made
compulsory for use of the building to
check built as designed.w

For further details:

Email : jsprasad@lagreensindia.com
Using FRP to increase the ductility beam- column junction

In order to identify an alternative solution to protect mul-

Researchers from tiple existing buildings from damages due to earthquake
without altering them using a single device, researchers
University of Brighton from the University of Brighton, have designed a novel
vibrating barrier ViBa. The device can reduce the vibra-
come up with a new tions of nearby structures caused by an earthquake's
anti-earthquake technology ground waves. ViBa would be buried in the soil and
detached from surrounding buildings, and should be
able to absorb a significant portion of the dynamic energy
arising from the ground motion with a consequent
reduction of seismic response (between 40-80%).
The idea behind this is to look at buildings as an integral
part of a city model, which also includes the soil under-
neath and the interaction between each element, rather
than as independent structures. Each ViBa can be de-
signed to protect one or more buildings from an earth-
quake but also it forms part of a network of devices placed
at strategic locations in order to protect entire cities.
The ViBa itself is essentially a box containing a solid cen-
tral mass held in place by springs. These allow the mass
to move back and forth and absorb the vibrations created
The Masterbuilder | July 2015 | www.masterbuilder.co.in

by seismic waves. The entire structure is connected to

the foundations of buildings through the soil to absorb
vibrations from them. The position of box underground
would depend on how deep the surrounding foundations
went and could even be placed on the surface.
As the ViBa is designed to reduce all vibrations in the soil,
it could also be used to insulate buildings against ground
waves from human activities such as road traffic, high-
speed trains, large machinery, rock drilling and blasting.
In this way, the technology would be able to absorb a
larger quantity of energy than traditional measures used
to insulate railways such as trenches or buried sheet-
pile walls.
134
 CUSTOMER TESTIMONIAL

Successful Waterproofing
of Flat and Domed Roofs

N R Ashok
Chief Consultant
Ace Technologies, Bangalore

W
aterproofing is a very complex
subject and requires extensive
knowledge of construction
materials, structural behavior and the
construction process to enable a watertight
structure.
Water Leakage is ultimately a symptom
just like fever is indicative that something
is wrong with our body. A proper
understanding of the application area and
the conditions the system will be subjected
to is very crucial for giving desired results .
There I no magic and there is no one and
all product which will solve all water leakage
problems. The choice of product or
combination of products will depend on
various factors.
Leakage can occur due to various
factors which contribute to deflection and
cracking of members . It will lead to
corrosion and affect the serviceability of
building
- Inadequate propping of slab/beam
- Early removal of shuttering
- Inadequate curing – Less strength
- Inadequate steel using in the structure
- Inadequate concrete member
The Masterbuilder | July 2015 | www.masterbuilder.co.in
above will help in designing and checking
the structure during construction to ensure
that water leakage does not occur.
It is obvious that such mistakes occur
at various parts of the building and hence
the solution to each should be tackled
independently.
Typical Parameters and characteristics
of the Product will be helpful for selection
of appropriate system for relevant
application.
- Elongation %
- Tensile Strength
- Bond Strength
- Adhesion Strength ( wet / dry areas)
- Water impermeability
- Weather resistance
- Shore A Hardness
It is obvious that an entire treatise on
waterproofing will constitute a book.
Hence we will concentrate on
waterproofing of areas like flat terraces
and Domed structures since this is the
most common type of leakage that most
people face (other than basements).
The options for flat areas are
waterproof coatings, membranes and
capillary based waterproofers. Each has
its own advantages based on the situation.
However the challenge is for Large roof
spans and for Domed Structures . Choices
are plenty in elastomeric range from Two
component Cementitious Acrylic , Single
component Pure Acrylic systems to
Single component Polyurethane
waterproofing coating systems . While
every system has its own advantages and
differentiation can be drawn , it is very
important to choose the right system
balancing the Service life expectancy with
Economics.
In this particular Structure in Bangalore,
a two component high performance
elastomeric flexible cementitious coating
system was recommended considering the
requirements of waterproofing and
structural aspects . La Fibreflex ULTRA , a
new generation two component
cementitious acrylic waterproof coating
system from Lagreens has been used
which has around 400 % elongation and
has good adhesion and bond strength to
old and new Cementitious substrates .

thickness
- Design which uses lower strength
concrete than required
- High water cement ratio leading to less
than specified concrete strength
- Inadequate compaction of concrete
leading to honeycombs
- Overloading of structure during
construction
- Overloading of structure by owner due
to storing heavy materials after
construction
- Fire damage
- Making openings after construction
and not sealing it effectively
Hence adequate knowledge of the
138
 CUSTOMER TESTIMONIAL
The bond strength has been further
improved with an intermediate
impregnation repellent acrylic polymer
coat for ensuring the interface adhesion
between concrete and coating which is
the key for success in waterproofing of
exposed terraces .
Important guidelines that we need to
consider while waterproofing roofs :
1. It is critical to make the mother slab
itself completely waterproof. Hence the
heart of waterproofing a roof slab is to
apply a strong, fiber filled, tough,
breathable, elastomeric waterproof
coating over the entire mother slab
including below the parapet wall. This is
very important since every parapet wall
will crack. Water enters these cracks,
reaches the slab below and any
uncoated portion of slab will be prone to
leakage in many cases. And now a few
guidelines regarding coatings.
2. The first defence against water leakage
is an adequate slope to drain out water
from flat terraces before it penetrates
the slab and leaks below. Water
ponding should be avoided at all costs.
It is strongly advisable to give 1:100
slope . Note that this can be achieved by
brick batcoba or kappi or Integral
cement based waterproofing using well
burnt brickbats. Please note that this
treatment may develop cracks in
certain places if not done correctly.
However, it will still perform its stated
function of draining away most of the
water from the slab.
3. The waterproof coating should be
coated over the entire slab and should
be done in two parts. The first part is
coating the area below the proposed
parapet wall the day after concreting.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Two coats shall be applied 600 mm
wide (like a band) from the edge of the
roof slab all round the perimeter of the
building. During this time, the slab shall
be cured by placing thick gunny bags or
straw over the entire roof slab and shall
be sprayed with water to keep the slab
continuously wet. The usual practice of
building cement bunds the next day and
filling up with water shall be postponed
for a day until the waterproof coating
has been applied. After that, one brick
high parapet wall shall be built all
around the edge and inside mortar
bunds shall be built, all the while taking
care to see that gunny bags are kept
140
wet. After that, water shall be ponded
for minimum 15 days. The second part
of coating is to be applied over the rest of
the slab anytime after 15 days, but
should be protected immediately by
brick batcoba or integral cement based
waterproofing. While laying the
protective brick batcoba, utmost care is
to be taken to ensure that the coating is
not damaged. Personal supervision is
required at this stage.
4. Note that many engineers recommend
a concrete screed on top of the slab due
to the fact that it can be applied quickly.
This is not recommended. One, the
density of regular concrete is much
more than brick bat coba and hence
adds to weight on the slab. Two, a
uniform thickness of screed will not be
able to provide a 1:100 recommended
slope for primary water drainage. If at
all brick bat coba is difficult to execute,
then vermiculite concrete, foam
concrete, or any other such material
can be used in place of brick bat coba for
weatherproofing. However, all other
specifications regarding waterproofing
will not change.
5. Most engineers/contractors build the
parapet wall first and then insist that
while coating is being done, they will
provide a coving of mortar at the wall
floor junction. Firstly, the coving is
never cured correctly. Second, masons
typically use very rich mortar to do the
coving which invariably leads to
enormous number of cracks because
of high cement content. Water will
invariably leak through this, enter the
space below the parapet wall and then
leak into the slab.
6. If at all the parapet wall has already
been built, then the second, less
desirable choice would be to build the
coving (maximum 75 mm wide) and
cure it with wet gunny bags for 10 days
before applying the waterproof coating.
The waterproof coating shall be applied
on the mother slab and extended over
the coving and onto the parapet wall for
a minimum height of 300 mm. While
coating over the coving, a nonwoven
polyester mesh or geotextile mesh 150
mm wide shall be applied after the first
coat and then two more coats shall be
applied on it to ensure that the wall floor
joint is watertight.
7. Finally, the importance of surface
preparation before waterproof coating
cannot be overstressed. High pressure
water jetting is strongly recommended
to remove dust and open up the surface
so that the mother concrete slab
surface shall be able to hold the
waterproof coating perfectly. Basically
the porous nature of concrete has to be
exposed for improving the
performance of any coating system . A
strong penetrating film forming primer
is a must.
8. Quality skilled application from mixing
and applying the waterproof coating
within its recommended setting time is
very important. It is no use selecting the
right material and trying to save on
application cost by giving the job to a
person who does not have adequate
training. Company trained and
authorized applicators are normally the
best bet. Such trained applicators will
also ensure that the right amount of
material is used in grid pattern to
ensure that the coating thickness
remains uniform.
In conclusion , apart from selecting
the right product , following good
practices of application it is equally very
important to have a site representative
during construction who will supervise
the work and is very crucial to ensure
successful waterproofing. Progress
photographs must be made part of the
submittal process. A properly discussed
waterproofing program involving the
manufacturer, applicator and owner can
ensure good waterproofing which will last
for a long time.
Last, but not least, the advice of a good
waterproofing consultant can make all
the difference between a watertight
structure and a structure that is saddled
with problems of leakage. Note that
prevention is always better than cure.
Trying to solve water leakage issues after
a few years invariably costs much more
than doing it right in the first place. Plus, it
avoids the hassles associated with
repairing of the structure while the
structure is in use.w
For further details:
Ace Technologies
Email: nrashok100@yahoo.co.in
 INTERACTION

Hilti TE800-AVR is a Tool Made for India

- Nitin Katyal, Sales Director, Hilti India

T
he Hilti Group is a globally leading
manufacturer and supplier of qual-
ity, innovative and specialized tools
and fastening systems for professional
users in a variety of trades. The group's
Indian arm- Hilti India has made rapid
inroads into the market with its wide range
of products which includes drilling and
demolition, diamond coring and cutting,
construction lasers and sensors, passive
fire resistance, screw fastening, adhesive
and mechanical anchoring, and gas fas-
tening systems. In an exclusive interview
with The Masterbuilder, Nitin Katyal, the
company's Sales Director gave detailed
insights into the Hilti Group's history, its
India presence, its new launches and future
plans.Hereareexcerptsfromtheinterview.
Hilti has a global reputation for customer
focus and innovation. Please take us
through your journey in India till date.
Hilti was founded in 1941 in Schaan,
Liechtenstein. In India, Hilti started oper-
ations in 1997 in Delhi. Today, we have 22
offices across India with more than 500
employees who serve customer needs
across job sites and offices. Our direct sales
force acts as value added technical advi-
sor to our customers. In addition we have
a dedicated team of engineers to support
customer design needs for fastening &
The Masterbuilder | July 2015 | www.masterbuilder.co.in
across markets. Tell us about this out-
performer.
We are proud to say that the TE 800
AVR is a tool made for India. This tool was
designed after taking feedback from our
customers in India and hence takes into
account multiple job site conditions that
our customers face every day. For exam-
ple, TE 800-AVR has an electronic control
Nitin Katyal
switch that protects the motor from volt-
age surge which are common on job sites
mechanical parts. The 3 chambered
in India. To protect the tool from heat and
lubrication systems ensures that the
dust, the tool has been designed to have
dust is kept out & heat that is gener-
an intelligent airflow which helps in cool-
ated because of moving mechanical
ing the mechanical parts. Each internal
parts is absorbed quickly.
part of the tool (such as rotor, guide tube,
- Electronic power steering: This en-
carbon brush) has been designed to
sures a steady performance under
ensure that the tool outperforms and out-
lasts. As a result TE 800-AVR offers 21 tough site conditions. It protects the
Joules of impact energy at a low vibration tool against voltage spikes and en-
of only 9m/s2. sures constant high performance even
when long cords are used. In addition,
The breaker comes with a unique HI Drive the Electronic Restart Interlock pro-
Technology. Can you throw some light on tects the user in case of un-planned
the technology? power off & on scenarios and hence it
assists in driving safety on job site.
Hilti's innovative HI Drive technology
is the outcome of decades of experience What are the key advantages and appli-
in developing power tools. cations of the TE 800-AVR?
HI Drive has three key features: TE 800-AVR has a very strong set of
- Efficient engine: It consists of an 1850 product and service features. The top fea-

Watt HPD motor that offers the best tures are:

controlled demolition. In 2012, Hilti in India
was recognized as a 'Great Place to Work'.
Hilti in India has regularly launched
differentiated products and services
across demolition, fastening and passive
fire protection sectors. Today we have a
portfolio of more than 500 products that
are regularly used by our customers in
some of the most prestigious projects in
India. In 2015 we have already launched 6
new products and we will continue to ex-
cite our customer with great products and
services.
The recently launched Hilti TE 800-AVR
142
performance to weight ratio, a smart
carbon brush that offers double the
service interval and an intelligent air
flow design that keeps the engine cool
& minimizes the dust entry. Finally, a
solid epoxy coating protects the rotor
from debris hits and hence increases
the life of the rotor.
- Excellent transmission: This consists
of a perfectly aligned transmission with
a large ram and connection end to effi-
ciently transmit 21 Joules of impact
energy. The tool consists of a three
chambered lubrication system for en-
- High power to weight ratio
- Enhanced working comfort which
ensures higher productivity
- Versatility for all applications (floor
demolition as well as wall breaking)
- Premium Tool Service that offers best
in class service on the tool
TE 800-AVR is a versatile breaker and
the key applications are:
- Slab demolition & wall demolition
- Corrections at construction site like
widening of space around doors &
windows

medium breaker has been making waves suring effective lubrication of moving - Making new cutouts on wall or floor
 INTERACTION

Tell us about the unique AVR feature of
your breakers
When the chisel impacts the con-
crete, the breaking force of the chisel on
concrete leads to a return force on the
operator in form of tool vibrations. Expo-
sure to high tool vibrations has two side
effects. First, the vibrations in tool lead to
operator fatigue which reduces operator
productivity. Second, prolonged exposure
to vibration leads to Hand Arm Vibrating
Syndrome (HAVS). Hilti's Active Vibration
Reduction technology significantly
reduces the vibration in the tool and the
vibration on TE 800-AVR is only 9m/s2. The
AVR technology hence significantly
improves operator productivity and also
reduces risk of HAVS.
How has been the response for the prod-
uct in India?
TE 800-AVR has received excellent
response from our customers across the
India and our product launch expecta-
tions are being met. Our customers
clearly see a strong value with TE800-AVR
because they are able to do their demoli-
tion work faster and with higher safety.
Our Premium Tool Service also helps
them manage their project costs as we
offer free repair services in the first year of
tool purchase.
What are the other new launches you
have lined up?
Hilti will continue to bring innovative
products and services to India for satisfy-
ing customer needs in the market. Our
new 'Premium Tool Service' offers 3
advantages- free first year repair, an
upper limit on the repair cost for upto 3
years and a 15 day repair warranty on our
repair service. The Premium Tool Service
has created lot of excitement with our cus-
tomers as it offers them complete peace
of mind on the tool ownership. w

LCSs panel designed at

Eindhoven University of Technology
being tested in Netherlands
On a highway stretch near Den Bosch, The Netherlands, a new duced in any desired, regular colour, is robust, and the LSCs
form of solar technology is being tested on a noise barrier that will even work when the sky is cloudy. That means it offers tre-
are often used to dampen the loud sounds of highway traffic mendous potential.” A year-long test project was launched on
for housing units and businesses establishments located June 18 on two sections of noise barriers, each 5 meters wide
The Masterbuilder | July 2015 | www.masterbuilder.co.in

alongside busy roads. Engineers at the Eindhoven University
of Technology have come up with a solution that makes the bar-
riers an attractive part of the landscape as well as a source of
clean energy. The technology that is behind these new solar
noise barriers is called luminescent solar concentrators
(LSCs). LSCs are coloured panels that receive light and direct
it to the edges of the panels where there are traditional solar
cells that harness the solar energy.
“Thanks to their many colours the LSC are visually very attrac-
tive, which makes them ideal for use in many different situa-
tions in the built environment”, said Michael Debije of the
Department of Chemical Engineering and Chemistry, who
has carried out years of research into these panels. “Further
benefits are that the principle used is low cost, they can be pro-
144
and 4.5 meters high. The barriers are partially covered in the
LSCs and partially covered in semi-transparent panels hold-
ing conventional solar cells, so that they can compare the per-
formances of the two technologies.
The test will evaluate how much electricity the LSC panels can
generate under various conditions as well as how well they
stand up to any vandalism, as often happens with any outdoor
infrastructure. The researchers are hopeful that the solar
noise barriers will prove to be a beneficial new approach to a
typically boring structure. Initial research shows that 1 km of
the solar noise barriers can generate enough electricity to
power 50 homes. The success of this test could show how
solar cells can be used to both power and beautify urban envi-
ronments.
 CONCRETE: REPAIR & REHAB
Sulphate Attack in Concrete & Mortar
Nitin Sreenivasan
Technical Director, Technokotes
Sulphate attack can be 'external' or 'in-
ternal'.
External: due to penetration of
Sulphates in solution, in groundwater for
example, into the concrete from outside.
Internal: due to a soluble source being
incorporated into the concrete at the time
of mixing, gypsum in the aggregate, for
example.
External Sulphate Attack
This is the more common type and typ-
ically occurs where water containing dis-
solved Sulphate penetrates the concrete.
A fairly well-defined reaction front can often
be seen in polished sections; ahead of the
front the concrete is normal, or near nor-
mal. Behind the reaction front, the com-
position and microstructure of the concrete
will have changed. These changes may vary
in type or severity but commonly include:
- Extensive cracking
- Expansion
- Loss of bond between the cement paste
and aggregate
- Alteration of paste composition, with
mono sulphate phase converting to
ettringite and, in later stages, gypsum
formation. The necessary additional
The Masterbuilder | July 2015 | www.masterbuilder.co.in
calcium is provided by the calcium
hydroxide and calcium silicate hydrate
in the cement paste
The effect of these changes is an over-
all loss of concrete strength.
The above effects are typical of attack
by solutions of sodium Sulphate or potas-
sium Sulphate. Solutions containing mag-
nesium Sulphate are generally more
aggressive, for the same concentration.
This is because magnesium also takes part
in the reactions, replacing calcium in the
solid phases with the formation of brucite
(magnesium hydroxide) and magnesium
silicate hydrates. The displaced calcium
precipitates mainly as gypsum.
146
Other sources of Sulphate which can
cause Sulphate attack include:
- Seawater
- Oxidation of sulphide minerals in clay
adjacent to the concrete - this can pro-
duce sulphuric acid which reacts with
the concrete
- Bacterial action in sewers - anaerobic
bacterial produce sulphur dioxide which
dissolves in water and then oxidizes to
form sulphuric acid
- In masonry, Sulphates present in bricks
and can be gradually released over a
long period of time, causing Sulphate
attack of mortar, especially where
Sulphates are concentrated due to
moisture movement
Figure 1 Scanning electron microscope image of
Sulphate attack in concrete. Ettringite (arrowed) has
replaced some of the calcium silicate hydrate in the
cement paste; the darker areas of paste have been
partly decalcified. As a consequence of these
alterations, the paste will be weakened. Although
much of the cement paste here remains apparently
unaltered (eg: top right), if widespread within the
concrete (which in this instance it was) Sulphate
attack can significantly weaken the concrete.
Internal Sulphate Attack
This occurs where a source of Sulphate
is incorporated into the concrete when
mixed. Examples include the use of Sul-
phate-rich aggregate, excess of added
gypsum in the cement or contamination.
Proper screening and testing procedures
should generally avoid internal Sulphate
attack.
Delayed Ettringite Formation
Delayed ettringite formation (DEF) is
a special case of internal Sulphate attack.
Delayed ettringite formation has been
a significant problem in many countries. It
occurs in concrete which has been cured
at elevated temperatures, for example,
where steam curing has been used. It was
originally identified in steam-cured con-
crete railway sleepers (railroad ties). It can
also occur in large concrete pours where
the heat of hydration has resulted in high
temperatures within the concrete.
DEF causes expansion of the concrete
due to ettringite formation within the paste
and can cause serious damage to con-
crete structures. DEF is not usually due to
excess Sulphate in the cement, or from
sources other than the cement in the con-
crete. Although excess Sulphate in the
cement would be likely to increase expan-
sion due to DEF, it can occur at normal lev-
els of cement Sulphate.
A key point in understanding DEF is
that ettringite is destroyed by heating above
about 70C.
ADefinitionofDelayedEttringiteFormation
DEF occurs if the ettringite which nor-
mally forms during hydration is decom-
posed and then subsequently re-forms in
the hardened concrete.
Damage to the concrete occurs when
the ettringite crystals exert an expansive
force within the concrete as they grow.
In normal concrete, the total amount
of ettringite which forms is evidently limited
by the Sulphate contributed by the cement
initially. It follows that the quantity of
ettringite which forms is relatively small.
Ettringite crystals form widely-dispersed
throughout the paste. If expansion causes
cracking, ettringite may subsequently form
in the cracks but this does not mean the
ettringite in the cracks caused the cracks
initially.

Figure 2 Diagram showing how paste expansion
produces a small gap around small aggregate
particles and a bigger gap around larger particles.
Figure 3 Scanning electron microscope image of
limestone aggregate particle. The cement paste has
expanded and a gap has formed between between
the aggregate and the cement paste. This is
characteristic of damage to concrete due to DEF.
The aggregate is no longer contributing to concrete
strength, since it is effectively detached from the
cement paste. Often, these gaps become filled with
ettringite.
DEF causes a characteristic form of
damage to the concrete. While the paste
expands, the aggregate does not. Cracks
form around these non-expanding 'islands'
within the paste - the bigger the aggregate,
the bigger the gap.
Conditions necessary for DEF to occur
are:
- High temperature (above 65-70 degrees
C approx.), usually during curing but not
necessarily
- Water: intermittent or permanent sat-
uration aftercuring
- Commonly associated with alkali-silica
reaction (ASR)
In laboratory tests, limestone coarse
aggregate has been found to reduce
expansion.
DEF usually occurs in concrete which
has either been steam cured, or which
reached a high temperature during curing
as a result of the exothermic reaction of
cement hydration.
As the curing temperature of concrete
increases, ettringite normally persists up
to about 70 C. Above this temperature it
decomposes. In mature concrete, mono
Sulphate is usually the main Sulphate-
containing hydrate phase and this persists
up to about 100C. DEF could occur in con-
crete which was heated externally, eg: from
fire.
An ettringite molecule contains 32
molecules of water; ettringite formation
therefore requires wet conditions.
DEF and ASR appear to be closely linked;
in one study (Diamond and Ong, 1994) a
mortar made using limestone aggregate
was cured at 95 C. Subsequent ettringite
formation within the paste was scarce and
expansion was minimal. However, if
aggregate susceptible to ASR was used
instead of limestone, ettringite formation
and expansion were both much greater.
This, and other studies, suggests that ASR
is,orcanbe,aprecursorforDEFexpansion.
The effect of cement composition on
DEF is not well understood. Some factors
correlate strongly but the causes are not
clear. In laboratory tests, DEF expansion
was shown to correlate positively with
cement-related factors, including:
- high Sulphate
- high alkali
- high MgO
- cement fineness
- high C3A
- high C3S
DEFisstillbynomeansfullyunderstood.
Thaumasite form of Sulphate attack (TSA)
The thaumasite form of Sulphate
attack (often abbreviated to TSA) requires
a source of Sulphate and also of carbon-
ate. Thaumasite can occur rarely as a nat-
ural mineral as an alteration product of
limestones.
Thaumasite can form in concrete and
in mortar. The cement hydration products
normally present, mainly calcium silicate
hydrate and calcium hydroxide, are
decomposed as a result of both Sulphate
attack and of carbonation. Since it is the
calcium silicate hydrate in concrete that
provides most of the strength, thaumasite
formation results in severe weakening.
Thaumasite has the chemical for-
mula:
[Ca3Si(OH)6.12H2O] (SO4)(CO3)
or
CaSiO3.CaCO3.CaSO4.15H2O
It tends to form at low temperatures,
typically about 4 C - 10 C. As it forms, the
concrete or mortar converts to a friable
material often described as a 'mush.' Con-
crete severely affected by thaumasite for-
mation can easily be broken with the fin-
gers and the coarse aggregate lifted out.
A source of additional water is also
required for thaumasite formation. Damp
CONCRETE: REPAIR & REHAB
cementitious render over brickwork, espe-
cially where the render is cracked, and con-
crete and masonry in cool, damp cellars
are typical examples of where thaumasite
may occur.
Normal Sulphate attack usually results
in the formation of ettringite. This uses alu-
minium provided by the cement and clearly
this is limited in quantity in normal con-
crete. However, thaumasite formation does
not involve aluminium; given an adequate
supply of Sulphate and carbonate,
thaumasite can continue to form until the
calcium silicate hydrate is completely
decomposed. Consequently, while the use
of Sulphate-resisting Portland cement
provides some defence against normal
Sulphate attack, it does not give any par-
ticular protection against thaumasite for-
mation.
Sulphate can be supplied from a range
of sources; groundwater or bricks are
common examples. Carbonate can be
supplied from atmospheric CO2 or from
limestone present in the concrete or mor-
tar.
Figure 4 Polished section of degraded concrete
from a highways structure in the United Kingdom.
Thaumasite has formed around coarse limestone
aggregate (large dark particles) and in cracks.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Examples of thaumasite are arrowed. This polished
section was 40mm in diameter but thaumasite
formation is so extensive that it requires little
magnification to be clearly visible.
Serious damage to concrete or
masonry due to thaumasite formation is not
a common occurrence, even in cool, damp
climates. w
For More Details:
Technokotes
26-B, Goodwill Sanskruthi, Bhairavnagar,
Dhanori Road, Pune - 411015, INDIA.
Phone: +91 20 27171412 / 27172249
Email: nitin.sreenivasan@gmail.com
Web: www.technokotes.co.in
147
 FOCUS: ADMIXTURES

Creating Durable Concrete

with Admixtures

Anandita Kakkar
DGM, Marketing & Advertising,
Kryton Buildmat Co. Pvt. Ltd.

A
s we move into an uncertain future wrought with en-
vironmental concerns and the call to build more re-
sponsibly not because it is good to do, but more be-
cause it is a must. In order to do so we must build wisely.
This is especially true in countries like India that are looking
at a growth and development spurt. With the government
opening up the floodgates for foreign investment and work-
ing closely with international firms to set up manufacturing
hubs in India, the country is realizing the need for responsi-
ble and durable construction.
Concrete is the most used man-made material in the
world, used twice as much as all other materials combine,
including steel, wood, and aluminum. Taking a look at our
major cities and the buildings and infrastructure that en-
compasses them you will see just how much concrete is used.
In fact, according to a 2007 United States Geological Survey,
‘Minerals Commodity Summary – Cement’, over 3,000 kg’s
of concrete is used annually for each man, woman, and child
on the planet. In India alone the cement industry grew by
12% in 2014 and is expected to grow 8% until 2016, to under-
stand the extent of concrete consumption in India and the
subcontinent alone.
Ensuring the environmental and sustainable factors are
accounted for is vital to the preservation of our societies and
for future generations. To do so, we must use innovative ma-
terials that can stand up to the rigors of Mother Nature, whilst
also limiting the harm to the environment. In countries with
The Masterbuilder | July 2015 | www.masterbuilder.co.in
than other major building materials. Concrete is also easy
to procure, as in its simplest form is made of three main in-
gredients: water, Portland cement and aggregates. Water
is all-around us, coarse and fine aggregate can be found in
numerous locations and cement is easy to come by as well.
Concrete is also known as a durable material; meaning
its qualities can resist whether action, chemical attack while
maintaining its desired engineering properties. However, as
evidenced by deteriorating buildings across the world and
repairs becoming common practice, concrete structures are
not living up to their desired lifespans, which is to say; our
structures are not durable enough.
Concrete can deteriorate under certain circumstances,
such as:
- Chloride attack/Corrosion of steel reinforcement;
- Sulfate attack;
- Alkali Aggregate Reaction (AAR); and
- Freeze/thaw cycles.
However, without question the greatest cause of con-
crete deterioration is the ingress of water and water borne
chemicals. Water, one of the essential components of a con-
crete mix design is the biggest issue facing the durability of
concrete today.
Concrete Admixtures
Methods to protect concrete from water without surface

vast and dynamic environmental and population differences,

applied barriers have been evolving for several decades. To-
these materials can make a sea of change in living conditions.
For concrete, the best and most efficient method in en-
suring this is to create sustainable structures by using the
most durable concrete possible. In most cases, the reason
behind concrete deterioration is the ingress of water. Water
breaks into the concrete moisture through cracks and pores,
infiltrating the matrix and effectively limiting the durability of
the structure. When concrete durability is compromised, the
sustainability and resilience of the structure is also

Concrete Durability

The reason concrete is used so readily is that no other

building material can match it in terms of effectiveness, price,
and performance for most purposes. Furthermore, concrete
can be durable, is rather easy to ‘install’, but first and fore- PRAs are chemical admixtures used to protect concrete from the damaging
148

most, it limits the negative environmental effects further effects of water and water borne chemicals.
 FOCUS: ADMIXTURES
The ICW admixture starts crystallization and develops its needle like crystals
in concrete as defense against water damage.
day, there are several approaches to designing and installing
durable, water resistant concrete, such as proper mix pro-
portioning; minimizing the water-cement ratio; ensuring the
concrete is well consolidated, and employing good wet cur-
ing practices to maximize the concrete’s properties, as well
as using concrete admixtures.
Additionally, Supplementary Cementitious Materials
(SCMs) such as fly ash, ground granulated blast furnace slag
and silica fume have become common for the range of ben-
efits those materials provide.
Permeability Reducing Admixtures
Increasingly, Permeability Reducing Admixtures (PRAs)
are being used to provide an additional level of protection from
within. PRAs are chemical admixtures used to protect con-
crete from the damaging effects of water and water borne
chemicals. These particular kinds of admixtures are distinct
tools for making durable concrete, and compliment rather
than replace other tools such as the previously mentioned
SCMs.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
150
Same as above – side by side
With proper selection and use, PRAs (Often referred to as
“integral systems”) have been used to replace surface applied
sealers, water repellents and membranes. They provide in-
tegral protection against water and chemicals throughout
the full depth of a concrete element, and can eliminate the
labor needed to apply surface protective systems.
Further to these advantages, PRAs are not vulnerable to
surface damage, and the installation of these integral sys-
tems is less affected by environmental factors (particularly
rain). Altogether, these advantages bring a concrete structure
the best of both worlds: Being cost efficient and saving time
during construction; and providing quality, lasting support
against water damage to enhance the entire structures du-
rability.
PRAN/PRAH
The selection of an appropriate PRA depends on the
service conditions, and how water is expected to enter the
concrete. A document from The American Concrete Insti-
tute (ACI), ACI 212.3R-10 Report on Chemical Admixtures for
Concrete, subdivides PRAs into two categories based their
performance properties:
- PRAN (Permeability Reducing Admixture for Non-Hy-
drostatic Conditions) admixtures are intended for appli-
cations that are not subject to hydrostatic water pressure
and are sometimes called damp roofing admixtures. Most
PRAN’s contain water repellant chemicals that shed wa-
ter and reduce water absorption into the concrete.
- PRAH (Permeability Reducing Admixture for Hydrostat-
ic Conditions) are primarily intended for use in concrete
that is exposed to water under pressure and are some-
times called waterproofing admixtures. They are able to
withstand the high hydrostatic pressure for applications
such as basements, tunnels and water containment
structures.
A comprehensive educational document has been re-
cently published by ACI. ACI’s Educational Bulletin, E4-12 –
Chemical Admixtures, describes the basic types and uses of
these admixtures, and works as a valuable introduction to
this complex topic. E4-12 is a free resource and can be found
on ACI’s website www.concrete.org. (Source: E4-12 Chemi-
cal Admixtures for Concrete)
Conclusion
Resilient and durable structures are a result of effec-
tive construction practices, efficient minds and innovative
product technology. Moreover, it requires finding solutions
to problems faced in the construction industry. The world is
moving away from traditional and sometimes ineffective
methodologies and accepting thoroughly tested and proven
technologies that have a track record of success.
PRAH, crystalline technology is one example. This ad-
mixture drastically reduces the ingress of water by using the
concrete itself as a water barrier, thereby increasing the du-
rability of the completed structure. It’s easy to apply, saves
on time and money and also has no negative impact on the
environment, while providing quality, lasting support against
water damage to enhance a structures durability. w
 CONCRETE: FLOORING SYSTEM
Innovative Flooring Systems
B M Nagarajan
Director, Neocrete Technologies Pvt. Ltd.
E
poxy and Polyurethane floorings
have become common in most of
the industries as they offer great
advantages in terms of seamlessness,
cleanability, aesthetics, and chemical re-
sistance and so on. But they still do not
find favour in many of the commercial
applications as well as exterior areas due
to various issues of scratch resistance, UV
resistance etc. But with the advent of
new-age raw materials in polymers,
additives, fillers and pigments as well as
awareness towards environmental pro-
tection and green buildings had led to a
plethora of new floorings and concepts
and we will take a peek at them.
SuDS compliant flooring systems
(Based on technical information pro-
vided by Ronacrete Limited, Essex, UK.
References are also drawn from
www.defra.co.uk, www.netregs.org.uk,
www.susdrain.org )
What is SuDS?
Sustainable Drainage Systems (SuDS)
is designed to reduce the potential impact
of new and existing developments with
respect to surface water drainage dis-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
charges. The idea behind SuDS is to try to
replicate natural systems that use cost
effective solutions with low environmental
impact to drain away dirty and surface
water run-off through collection, storage,
and cleaning before allowing it to be
released slowly back into the environment,
such as into water courses. This is to
counter the effects of conventional drai-
nage systems that often allow for flooding,
pollution of the environment – with the re-
sultant harm to wildlife – and contami-
nation of groundwater sources used to
provide drinking water. The paradigm of
SuDS solutions should be that of a system
152
that is easy to manage, requiring little or
no energy input (except from environ-
mental sources such as sunlight, etc.),
resilient to use, and being environmentally
as well as aesthetically attractive.
(Information sourced from Wikipedia.)
In short, a city like Mumbai goes
through a nightmarish seasons of flooding
year after year due to long spells of rain
and funnily a season of water shortage
may be after about 6 to 7 months. Thus all
the water that pours in the land goes
straight to drains and sewers and onto the
sea. All the concrete buildings, concrete
roads and concrete pathways add to the
woes of the common man as well as
scores of city-planners and admini-
strators. SuDS compliant walkways,
drive-ways, pool surrounds, access
roads, hard landscaping areas etc can be
a boon to these people by improving the
ground water situation significantly that
would mitigate the problems of country-
wide metro cities.
How does SuDS work?
SuDS is an approach to managing
rainwater falling on roofs, floors and
other surfaces through a sequence of
actions. The key objectives are to manage
the flow rate and volume of surface runoff
to reduce the risk of flooding and water
pollution. SuDS also reduce pressure on
the sewerage network and can improve
biodiversity and local amenity
Sustainable drainage is a departure
from the traditional approach to draining
sites. There are some key principles that
influence the planning and design pro-
cess enabling SuDS to mimic natural
drainage by:
- Storing runoff and releasing it slowly
(attenuation)
- Allowing watertosoakinto the ground
(infiltration)
- Slowly transporting (conveying) water
on the surfaceFiltering out pollutants
- Allowing sediments to settle out by
controlling the flow of the water
Permeable pavement
Permeable Overflow
sub-base to discharge
or further
treatment
if required
Infiltration
In this scenario, the first line of
responsibility lies on the type of out-door
flooring surrounding the residential,
commercial and other buildings. Typically
concrete, tiles or paver blocks are being
used to provide this flooring surface.
Though paver blocks do allow some water
to drain through joints, other surfaces
directly conduct the water to the drain
pipes.
Alternately, the new genre of floorings
offer an ideal path for rain water directly
towards the surface underneath after
filtering the unwanted pollutants, at the
same time offering a strong surface for
pedestrian and light vehicular traffic.

A schematic drawing of the flooring
system is given below
This flooring system is a resin bound
aggregate surface using a specially for-
mulated UV resistant, non-yellowing resin
and hardener system mixed with natural
recycled aggregates in order to provide a
highly porous, but decorative, strong and
functional flooring surface.
The open matrix structure allows
water to drain through into the substrate,
feed any surrounding trees and plants
and avoid any change of or damage to the
natural water table. This open matrix
construction is in line with the require-
ments of Sustainable Drainage Systems
(SuDS), designed to reduce the potential
of flooding on new and existing urban
developments.
Technical data:
Mix Ratio 7.5kg resin: 106.25kg
Yield 4.675m2@ 15mm
Pot Life 15-20 mins
Anti-slip Aggregate 0.1kg per m2
(optional)
Permeability > 850 litres
water/m2/min
Foot Traffic After 4 hours cure
@ 20OC
The major application area of this
flooring system are : Decorative natural
aggregate surfacing, Footpaths, walkways,
corridors, cycle paths, Playgrounds, pool
and pond surrounds, Driveways, car park
bays, Showrooms, offices, reception
areas, art galleries, Patios, conservatories,
gardens, gazebos.
This concept is being used in tree-pit
system wherein the porous tree-pits offer
ease of maintenance, decoration and
allow the tree to feed through the resin
bound gravel system
Polymer-Epoxy Hybrid coatings
Epoxy coatings, for over 30 years are
being used in variety of industries suc-
cessfully. Though epoxies offer excellent
properties of adhesion, strength, che-
mical resistance etc, suffers from few dis-
advantages such as non-UV resistance,
susceptible to moisture, rigidity of film,
typically having solvents that affect
environment and long curing time. Thus
epoxy coatings cannot be used in:
- Exterior areas subjected to exposure
to sunlight
- Where high impact resistance is
required
CONCRETE: FLOORING SYSTEM
- Where quick turn-around 3 to 4 hrs is
a pre-requisite
- Where water usage is continuous
such as food-processing plants,
abattoirs, dairies etc
Though solvents are being eliminated
or reduced in most of the formulations,
zero VOC can only be obtained by using
water-borne systems. Typical water-
borne epoxies do not offer the same level
of performance in terms of abrasion re-
sistance, durability, strength etc and this
led to the emergence of new-age tech-
nologies of polymer- epoxyhybrid floor-
ings.
Advantages of polymer- epoxy hybrid
coatings
- Easy use and cleaning
- Long potlife
- Fast drying
- Early hardness establishment
- Good water resistance and also can
be used on floors having higher
moisture content
- Good chemical resistance
- Significantly improved UV resistance
compared to conventional epoxy
dispersion
Various applications include:
- Exterior sports floors for tennis
courts, basketball courts etc
- Exterior drive-ways, parking bays,
walk ways
- Exterior loading bays
- Warehouses, logistic centres
- Food processing plants, dairies
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Staircase Safety Systems (SSS):
Why does a staircase need SSS?
Staircase in a high-rise tower is the
most important, but most-neglected part
of the building. Most people do not need to
use the staircase in normal times, but in
case of unlikely fire, the staircase be-
153
comes the most important life-saving
 CONCRETE: FLOORING SYSTEM
conduit to transport the people to safety.
Hence there are guidelines that were
drawn for construction as well as main-
tenance of staircases in high-rises so that
they are absolutely safe in times of dire
need.
The National Building Code, which is
a document containing standardized re-
quirement for the design & construction
of most types of building in the country
specifies minimum guidelines for pro-
tection of life and property
Guidelines for Fire Protection and Means
of Exit Requirements (Including High
Rise Buildings )
Internal Staircases
- Shall be composed of non-combust-
ible materials throughout.
- Externalwall of building shall constit-
ute one of its sides.
- Shall not be arranged around a lift
shaft.
- Minimum flight width=1000mm,
Maximum flight width=2000mm.
- Minimum tread =250mm, Maxim-um
riser=190mm, Minimum Head
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Room=2200mm. (varying slightly
based on classification of buildings)
Fire Protection Requirements for High
Rise Buildings – 15m in Height or Above
Construction
- All materials of construction in load
bearing elements, stairways and cor-
ridors and facades shall be non-
combustible.
- The interior finishes should not have a
flame spreadability rating exceeding
Class 1.
- The internal walls or staircase shall be
of brick or RCC with minimum of 2H
154
fire rating.
- The staircase shall be well ventilated.
- The roof of the shaft shall be one met-
er above the surrounding roof with
fire resistance rating of 2h.
- The above is the minimum specific-
ations for a staircase in India.
Image Courtesy: www.shilpaarchitects.in
However, in developed world, there are
more stringent requirements for stair-
cases and these changes and additions to
the means of egress requirements have
been introduced in the International
Building Code for high-rise buildings.
One requirement was an additional
stairway for buildings more than 420 feet
in height (IBC Section 403.5.2).If a building
exceeds 420 feet in height, then a third
stairway would be required. This is to
overcome the problem encountered at
the WTC in 2001, when occupants were
egressing down the stairs while firefigh-
ters were trying to work their way up the
same stairs.
Stairways serving high-rise buildings
are required to be constructed as smoke-
proof enclosures per IBC Section 403.5.4
Photoluminescent (Anti-slip Fire
resistant Epoxy Coating) Anti Slip stair
nosings Stair nosings with anti slip and
photoluminescent strips serve as the
built in core of the system. These nosings
provide the benefits of both low level
visual egress and slip prevention. Slips
and falls are the second largest cause of
accidental injuries in the United States.
When quickly evacuating (Fire-retardant
staircase nosing) a large number of
people from a tight stairwell; slips and
falls are known to be a major hazard and
cause of injury. While tape, paint and
guidance treads will meet the new code
Image courtesy: www.safetystep.com
they don't provide anti slip protection. Also
high traffic stairwells subject tape, paint
and guidance treads to abuse and more
frequent replacement. Stair nosings with
profiled grooves, anti-slip and photo-
luminescent inserts provide a more
complete and durable solution.
Spatial guidance on steps, handrails,
floor landings and wall and exit enclosu-
res Imagine walking down an unfamiliar
unmarked stairwell in total darkness or
smoke. Photo luminescent anti slip stair
nosings give fleeing occupants both visual
and spatial guidance to allow them to
swiftly and safely descend the stairs.
Combine this with photoluminescent
markings on handrails, floor landings and
the perimeters of wall and exit enclosures
and occupants are guided safely to the
exit. This advance guidance system pre-
vents many injuries due to tripping and
falling and also provides fleeing occu-
pants with an added feeling of confidence
and control.w
For further details:
Email: bmnagarajan@gmail.com
 RETROFIT: CASE STUDY
Development of Retrofit Scheme for Deficient
Post Tensioned Flat Slab by Using Post
Tensioned Carbon Laminates for Large
Commercial Premises
Abstract: Post tension flat slab construc-
tion is very popular to cover large areas
with economy and speed, especially
for commercial type of buildings like IT
Parks. Even though post tension slab is
popular system if proper quality is not
maintained during execution it may lead
to major structural stability issue. This
case study presents one such typical ex-
ample attributed to poor workmanship at
site and bad quality control at site. When
this particular building was given for long
term lease, just before fit out large de-
flections were observed in slab panels.
On closer look and after cleaning through
cracks were observed from top around
the column capital. Prime reason for
this was the bad quality at site and wrong
profile placement of post tension tendons
inside the slab. Because of this slab was
behaving like a regular RCC flat slab,
leading to excessive sagging and cracks
The Masterbuilder | July 2015 | www.masterbuilder.co.in
on top. Sanrachana Structural Strength-
ening Pvt. Ltd. (SSSPL) team was roped in
to provide most efficient solution in terms
of both time and cost as structure was to
be handed over to tenants. After weigh-
ing all the available options it was decided
to make use of high strength pre-cured
carbon fiber reinforced polymer (CFRP)
laminate system with anchor plate by us-
ing both post tensioned and non-postten-
sioned CFRP Laminates. The material
systems was provided by Specialty Rein-
forced Polymer Composite Pvt. Ltd. After
successful completion of the work, full
scale load test conforming to IS 456 was
conducted at site before handover. The
158
load testing was carried out by Vijna Con-
Dr. Mangesh Joshi1, Sagar Patil2,
Manish Yadav3
1
CEO
2
Structural Design Engineer
3
Project In-charge(Execution)
1,2,3
Sanrachana Structural Strengthening Pvt. Ltd.
(SSSPL), Thane, India
sulting Engineers Pvt. Ltd. The structural
performance of the particular strength-
ened structure was satisfactory under the
actual load test and it successfully met all
the structural requirements with gener-
ous safety margin. Over 1.00 lac sq.ft of
area was successfully retrofitted by using
12000 RMT (12KM) CFRP laminates in 30
days. The paper presents the evolution
of the structural strengthening system,
its application at site and details of load
test conducted. Pre-cured Carbon fiber
laminate have emerged as very efficient
construction material systems, especial-
ly in the field of structural strengthening/
retrofitting of existing structures. While
there are many reasons why structures
need strengthening/retrofitting, change
in use, poor workmanship at site, errors
during design or subsequent increase in
imposed load demand is one of the ma-
jor reasons for structural strengthening/
retrofitting.
Introduction
Number of new building structures
are deficient because of poor workman-
ship at site, bad quality or because of er-
ror in the design. This paper present one
such case study.
Post tension flat slab construction
is very popular to cover large areas with
economy and speed, especially for com-
mercial type of buildings like IT Parks.
Even though post tension slab is popular
system if proper quality is not maintained
during execution it may lead to major
structural stability issue. When this par-
ticular building was given for long term
lease, just before fit out large deflections
were observed in slab panels. On closer
look and after cleaning through cracks
were observed from top around the col-
umn capital. Prime reason for this was
the bad quality at site and wrong profile
placement of post tension tendons inside
the slab. Because of this slab was behav-
ing like a regular RCC flat slab, leading
to excessive sagging and cracks on top.
It was observe that major cracks are at
top of the slab along the periphery of the
column capital and also the same cracks
are propagating between columns in lon-
gitudinal as well as in transfer direction.
It was also observe that there is a per-
manent sag in the slab which is around
40mm (minimum) to 120mm (Maximum).
This was the alarming signal to the client.
This type of cracks were observed
over on 2 floors having area of around
50000.00 sq.ft each. So it was decided
to retrofit total area of 1 lac sq.ft. As the
property was to be given on lease and
fit out period was of 60 days, the biggest
challenge was to complete the project in
30 days and handed over to client. This
would avoid loss of revenue to the client.
Different options for retrofitting like
addition of structural steel, span short-
ening and stiffening were considered.
However, it would have reduced the head
room in addition to adding extra dead
load on already weak structure and time
required for completion was very high.
Considering these limitation of traditional
system it was decided to use CFRP Lami-
nates for structural retrofitting by passive
as well as active systems. CFRP systems

are light weight, its profiles are thin so
there is no loss of head room and its ap-
plication is fast. Use of CFRP is now well
establish in various field in construction it
Figure 1: Use of composite in con-
struction
can be used by different methods as de-
scribed in figure 1
Initail Condition of Slab
As discussed above post tensioning
cable placement was wrong so although
slab was designed as Post tensioned slab
it was behaving as regular RCC flat slab.
And in absense of lesser top reinforce-
ment cracking was obsered around the
column capital and parallel to column
strip. This is can be more clearly seen in
Figure 2 a and 2b.
Figure 2: (a)-Initial condition
Figure 2: (b)-Initial condition
Rerofitting Approch
First slab was analysed by using FEM
based sofwares for its designed load and
to find the forces on section. It was found
that if we don’t consider contribution of
post tension forces there was defficien-
cy of top steel. The same diffiecincy was
compensated by applying CFRP lami-
nates at deisgned spacing and loaction
the details of the same are given in fol-
lowing section and figures. Prior to ap-
RETROFIT: CASE STUDY
plication of CFRP laminates all crackes
were opened with V-Cut and are grouted
with low viscosity monomer by gravity
pouring at many locations grout could
be seen dropping from bottopm of the
slab. After this slab was supported from
bottom to release the load partially and in
that state laminate application was done.
Slab Bending Moment At Column Drop In X Di-
The pannels where excessive deflection
rection
was there were strengthened usning
post-tenstioned laminate sysytem and
balance with regular anchoring.
The strengthening system was de-
signed in reference to ACI 440.2R-08.
Pre-cured CFRP laminates being pro-
duced in the factory under stringent qual-
ity norms, consistent and relatively higher
mechanical properties are ensured. Ends
were fixed in position by MS plate to avoid
Slab Bending Moment At Column Drop In Y Di-
peeling.
rection
Figure 3: FEA Analysis of flat slab
Defficient Top Reinforcement / Steel
As per input data provided by client,
a model is prepared on FEM based soft-
ware.
Input Data
Grade of slab= M35 N/mm2
Grade of Steel = Fe 415 N/mm2
Depth of slab = 230 mm
Load considerations on the slab Slab bending moment contour
Self-weight of Slab = 5.75 KN/m2 at column drop in x direction
Floor Finish = 2KN/m2
Imposed Load = 5KN/m2
Slab bending moment contour at column drop in
The Masterbuilder | July 2015 | www.masterbuilder.co.in
y direction
Figure 4: FEA analysis results and proposed loca-
tion of CFRP Laminates
3d Model
Figure 5: Strengthening with cfrp plate at deficient
159
Deformed Shape area
 RETROFIT: CASE STUDY
Figure 6: Floor plate showing location of laminates
FEM Analysis Results and Proposd
Crack along The Periphery of Column Cap
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Crack after Opening Crack filling with Monomer
(By Gravity
160
Grout Leaked through Slab
The objective of the load test was to
verify the structural performance of ret-
rofitted slab, which was strengthened us-
ing pre-cured carbon laminate strength-
ening system as per the approved design.
Monopol Leakage through Slab Thus, with the load test, the structural
performance of the strengthened slab
was thoroughly verified as per Clause No.
17.6 of IS:456 2000.
Test Parameters
The test parameters were set as per
Surface Preparation the input data received from consultants
as follows:
Design imposed load of 500 kg/m2.
Note: Since the displacements to be
measured in the proposed load tests, the
test conformed to limit state of service-
ability. The imposed test load considered
as per IS456 clause 17.6 as follows.
Dead Load + 1.25 times imposed load
Therefore actual imposed test load =
Primer Application 200+ (1.25 x 500) = 825 kg/m2.
Test Specimen
Load test was carried out on the
strengthened slab panel of typical 10.8 m
wide x 10.8 m long patch, which was mu-
tually selected by the consultants as per
the test arrangement described herewith.
To apply design imposed load a
Laminate Fixing
water tank was constructed with brick
block. The height of water level is fill upto
825mm (0.825m) to get the imposed load
of 825Kg/m2
Test Equipments
The test facility consists of the following:
Fixing of MS Plate Test specimen 10.8 m wide x 10.8 m
long patch of slab clearly demarcated.
Strengthening Scheme And specially devised data acquisition
system- TC-1600 FD in order remotely
Actual Site Photograph of Execution
acquire the test reading with the help of
Material Specification used in Project 6 numbers of LSC 100 mm range linear
STR Strong Lam 100X1.4 displacement sensors.
Tensile Strength: 2800 MPa Test Schedule
Tensile Modulus: 165 Gpa Following are the steps to be followed for
Elongation: 1.7 % load testing.
Width 100mm
1. Initially a tank had been made with
Thickness 1.4 mm
brick block so that water can be
Full Scale Load Testing stored over the selected slab panel
Upon completion of the strengthen- and a measuring scale was fixed at
ing work, as per the project specifications, center of the slab as shown in fig. no.
full scale load test was carried as per the 2. Load increment will be 25%, 50%,
details below- 75% and 100% of the calculated im-
posed load.
Objective of the Test
3. First a water level is fill till 150mm
 RETROFIT: CASE STUDY
and reading was recorded
4. Water level is filled till 400mm and
reading was recorded
5. Water level is filled till 600mm and
reading was recorded
6. And at last water level is filled till
825mm and reading was recorded.
Experimental Setup
System Arrangement
Sensor Location Position of sensor
at Site
Water Level in tank = 825mm
Structural Performance Test
a) Displacement sensors were placed
on the soffit of the slab panel to mea-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
sure the displacements at predeter-
mined locations. Each sensor was
checked and initial reading was noted.
b) Load was applied gradually.
c) Displacement and residual dis-
placements at the predetermined
locations were captured by the data
acquisition system and the deflection
values were calculated by using in-
house software.
d) The test specimen was loaded to
100% design load in specific intervals.
Each load interval was maintained for
specific time interval.
Results of Load Testing
162
- In the load test, it was found that with-
Load-deflection curve for Sensor 1
Load-deflection curve for Sensor 2
in 24 hours of removal of the imposed
load, much more than 75% of the re-
covery observed in the structure as
described in the graphs presented
above.
- As per the Indian standard IS456:
clause 17.6.3.1 If the maximum de-
flection in mm, shown during 24hr
under load is less than 40l2/D, where
is the effective span in m and D the
overall depth of the section in mm, it
is not necessary for the recovery to
be measured and the recovery provi-
sions of clause 17.6.3 shall not apply.
In the load test, the recovery of the
structure took place with the gener-
ous margin as mentioned above. The
maximum deflection observed in the
slab panel = 22.1 mm, The test slab
was subjected to a load equal to full
dead load of it plus 1.25 times the
imposed load for a period of 24 hours
and then the imposed load were re-
moved. It was found that the maxi-
mum deflection during 24 hour load
period is 22.1 mm which is greater
than the limit value of 40l2/D i.e. 20.28
mm. The recovery observed in the
load test is 75% after unloading.
Thus, the strengthened structure
suitably met the IS code requirements as
per clause 17.6.3 of IS 456:2000.
Concluding Remark:
Over 1.00 lac sq.ft of area was suc-
cessfully retrofitted by using 12000 RMT
(12KM) CFRP laminates in 30 days.
Pre-cured Carbon fiber laminate have
emerged as very efficient construction
material systems, especially in the field
of structural strengthening/retrofitting of
existing structures.
Acknowledgements:
Specialized Retrofit Designer & Con-
tractor –Sanrachana Structural Strengt-
neing Pvt. Ltd.
Material Supplier- Specialty Rein-
forced Matrix Pvt. Ltd.
Load Testing Agency- Vijna Consult-
ing Engineers Pvt. Ltd.
Third Party Consultant- IIT Bombay
References
1. KATSUMATA, H., KOBAYASHI, K., MORITA,
S. and MATSUZA, Y. Japanese state of the
art on seismic retrofit by fibre wrapping
for building structures: Technologies and
research development activities, Fourth in-
ternational symposium on fibre reinforced
polymer reinforcement for reinforced con-
crete structures, ACI International, SP 188-
74, 1999, pp. 865-878.
2. MANCARTI, G. D. Strengthening of Califor-
nia steel bridges by pre-stressing, Trans-
portation Research Record No.950, Trans-
portation Research Board,1984, 3-187.
3. DUNKER, K. F., KLAIBER, F. W., BECK, B.
L. and SANDERS, W. W. Jr. Strengthen-
ing of existing single span steel beam and
concrete deck bridges, Report No. ISUERI-
Ames-85231, Civil Eng, Iowa State Univer-
sity, Ames, 1984, pp.102.
4. SWAMY, R. S., JONES, R. and BLOXHAM,
J. W. Structural behavior of reinforced con-
crete beams strengthened by epoxy bond-
ed steel plates, The Structural Engineer,
65A(2), 1987, pp. 59-68.
5. MEIER, U. Carbon fibre-reinforced poly-
mers: Modern material in bridge engineer-
ing, Structural Engineering International, 1,
1992, pp. 7-11.
6. MUKHERJEE A. Repair and rehabilitation
of structures- Strategies with nonmetal-
lic fibres. Proceedings of the 1st National
workshop on ageing and restoration of
structures, IIT Kharagpur, 2001,13, pp.
1-12.
7. GIBSON, R. F. Principles of composite ma-
terial mechanics. McGraw Hill Internation-
al edition, engineering mechanics series,
1994.
8. Maitra, S. R. -2001 ‘‘Fiber-reinforced poly-
mer composites in the rehabilitation and
strengthening of reinforced concrete col-
umns.’’ M.Tech. thesis, Dept. of Civil Engi-
neering, Indian Institute of Technology, Bom-
bay, Mumbai, India.
9. Manfredi, G., and Realfonzo, R. - 2001
‘‘Models of concrete confined by fiber com-
posites.’’ Proc., 5th Int. Symp. on Fiber-Re-
inforced Polymer Reinforcement for Con-
crete Structures (FRPRCS–5), C. Burgoyne,
ed., Thomas Telford, London, 865–874w
 COMMUNICATION FEATURE

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 HIGHWAY REPAIR
Highway Repair Systems
Sameer Bhore, Project Manager – Multichem Industries Pvt. Ltd. Multichem Group, Mumbai
R
oads, and means of transport, make
a crucial contribution to economic
development and growth and bring
important social benefits. Poorly main-
tained roads constrain mobility, signifi-
cantly raise vehicle operating costs, in-
crease accident rates and their associ-
ated human and property costs, and agg-
ravate isolation, poverty, poor health, and
illiteracy in rural communities.
This note highlights the economic and
social importance of regular road main-
tenance and recommends ways to achieve
sustainable road maintenance with scarce
public resources. Its audience is not spe-
cialists but rather people who need to
understand road maintenance enough to
discharge their responsibilities effectively:
government policy-makers, mayors, min-
istry staff, new World Bank staff and staff
in sectors such as rural development and
social funds.
Causes of the Failures of the Highways
The Masterbuilder | July 2015 | www.masterbuilder.co.in
There are many different causes of road
defects. Some of the causes on roads are:
1. Poor Design and Construction
Failures like cracking in rigid pave-
ment are caused by inadequate curing of
166
concrete, settlement, movement or re-
straint at joints may also lead to the devel-
opment of cracks and subsequent failure.
Most of the roads in the country are
designed in the ministries or by consul-
tants are poorly executed. This leads to a
situation where preliminary studies of the
environment that will help the design and
construction decisions are not done. This
leads to poor understanding of the road
environment which subsequently leads to
poor road design and construction.
2. Heavy Traffic
All road surfaces wear under the
action of traffic, particularly during the
very early life of the road. But within a
short time the micro texture reaches an
equilibrium level and thereafter the low
speed skidding resistance remains rea-
sonably constant. However, the action of
traffic continues to wear the macro sur-
face texture and thus gradually reduces
the high speed skidding resistance.
Increase of traffic loads both in terms of
numbers and axle loads due to increased
economic and developmental activities in
the country. One of the defects caused by
heavy traffic on the road is the deforma-
tion of the road way which is the change in
a road surface from the intended profile.
This results due to the application of over-
load that is beyond what the roadway is
designed and constructed for.
3. Poor Maintenance Culture
Even if the roads are well built they
need adequate maintenance for sus-
tainability. One of the main problems of
highway development in India is mainte-
nance. The roads are rarely maintained
and whenever maintenance is attempted
it is done haphazardly. The road network
is therefore left to deteriorate to the extent
that portions of the roads become im-
passable. Roads worldwide were consid-
ered critical infrastructure in any nation's
life and were paid premium attention.
There is lack of local government pres-
ence in these areas in the area of road
maintenance. It has become an open
truth that roads under the local govern-
ments are generally in a state of total dis-
repair. Checks over the years have re-
vealed that on record, crores of rupees
had been allocated for repair works on the
country's roads only for minor repair
works to be effected.
4. Poor Highway Facilities
Highway facilities like drainages when
not in use or lacking in performance result
in some of the environmental related
defects like roadway deformations and
pot holes. Every part of main roads is not
spared the onslaught of deadly potholes
that have inflicted both physical and emo-
tional torture on motorists. The situation
degenerates by the day aided by the rains
and failed drainage filled with silts.
5. Poor Laboratory and in Situ Tests on Soil
Since most of the construction com-
panies in the country could not afford ade-
quate laboratory facilities they should
make use of the laboratories in the uni-
versities and polytechnics that have better
facilities in the country for the test of their
construction materials.
 HIGHWAY REPAIR
6. Use of Low Quality Materials
Use of low quality aggregate adversely
affects the quality of the roads. This some-
times occurs in the form of the improper
grading of aggregates for sub base and
poor sub grade soil. The use of extreme
cohesive and expansive soil as sub grade
soil results in prolonged consolidation and
unnecessary settlement of the roadway.
The use of soil of low bearing capacity leads
to the failure of the sub grade soil.
7. Poor Workmanship
Most of the workmen in construction
sites are not well trained. This is especially
among the artisans and the craftsmen.
Some times the technicians, the technol-
ogists and even the engineers are not
given adequate practical training. Inap-
propriate application of materials by the
workmen is mostly due to low knowledge
of the works by the workmen. Operations
like soil compaction and stabilization are
inadequately done due to low knowledge
of the workers. An most important, lack of
feel of the ownership of national property.
8. Poor Supervision
Most of the super visions of construction
work are done by the engineers and other
middle level supervisors like the foremen.
Some of these supervisors who have low
knowledge of the work find it difficult to
deliver adequate supervision at the site.
Some of the faults on the roadway like
depressions, cracks and even pothole can
occur due to improper workmanship that
resulted from wrong supervision. Wrong
supervision could result to improper app-
lication of the material and operation of
the works. Operations like the application
of bituminous material, compaction of the
The Masterbuilder | July 2015 | www.masterbuilder.co.in
soil etc could be messed up because of
improper supervision.
9. Not Co-opratting Local Professional
Bodies in Highway Design, Construction
and Maintenance
As earlier mentioned, the profes-
sional bodies have a lot of contribution to
make to the construction of highways in
this country. At present the professional
bodies have not been given adequate
chance to contribute to road construction
and maintenance in the country. The whole
work of road construction and mainte-
nance in the country is left at the mercy of
168
expatriate companies that need to under-
stand the local terrain and situation of our
roads to enable them construct appropri-
ately. This information can be provided by
the local professional bodies that have
more knowledge of the local environ-
ment. The professional bodies can even
act as checks and monitors to the con-
struction firm on road work in the country.
New Construction Techniques
Several relatively new techniques make
it possible for concrete contractors to re-
habilitate and resurface highways effi-
ciently with minimum traffic interruption.
Among these is fast-track concrete pave-
ment technology, in which high-early-
strength concrete (e.g. UltraFill Fast Track
Repair and KwikFix) is used to allow re-
constructed roads to open more quickly.
While conventional concrete mixes might
require a curing time from five to 14 days,
fast-track concrete can meet roadway
opening strengths in 12 hours or less. Al-
though combinations of ingredients vary,
high-early-strength concrete commonly
includes a higher proportion of the stan-
dard cement to water or contains high-
early-strength cement. The smaller ce-
ment particles increase the surface area,
allowing more cement contact with the
water in the concrete mix, meaning faster
hydration is achieved. Generally, fast-track
concrete provides good durability be-
cause most of these concretes are air
entrained and have a relatively low water
content—factors that improve strength
and decrease the chloride or salt perme-
ability that damages steel reinforcement
and contributes to deterioration.
Another relatively new technology is
to use sealers on the existing roads to
enhance the life to another 5 years. These
products penetrate deep into road sur-
face thus avoiding water to go inside.
Some of the products are RhinoShield
and SiliCoShield.
Modern Products and Methods of Repair:
HiWayCrete System
Multichem has developed 4 systems
to repair damaged roads without affecting
vehicle transport.
1. HiWayCreteUltraPatch: Asphalt ba-
sed concrete to patch up potholes, sets
in 2 hours
2. HiWayCreteUltraFill: Special cement,
with setting time 3 mins to 30 minutes
3. HiperCrete: Special cement based
repair product with setting time 3 mins
to 2 hours.
4. HiWayCreteRhinoShield: Special As-
phalt road sealer to increase the life of
road.
1. UltraPatch
UltraPatch is a cold applied ready to
use asphalt based pot hole repair mate-
rial. It can be used by municipalities, con-
tractors and business owners to fill pot-
holes and repair roads. Cold patch asphalt
is a preferred method for patching pot-
holes today because it is easy to use and
does not require any heavy machinery. In
fact, you need only a shovel and a tamping
tool. Another benefit of our UltraPatch is
that it can be used year round on high-
ways, roads, driveways, and more. Winter,
Spring, Summer, Fall – UltraPatch keeps
on working and stays workable!
It has the following properties:
- It can be used in wet or dry weather con-
ditions. Very much suitable in rainy sea-
son.
- The material sets in 1 to 2 hours, hence
restores to original surface instantly.
- Technically superior hence unmatched
performance with each pour.
- Used under any extreme weather con-
ditions.
- Comes in easy to carry, 25kg bag.
- Shelf Life more than 12 Months.
2. UltraFill
UltraFillis made of special cemen-
titious materials with proprietary addi-
tives to give fast setting properties. The
product is popularly used for repairing or
patching cracks, holes and spalled areas
of highways, airfield pavements, bridge
decks, as well as a variety of commercial
and industrial applications.
Special Properties:
Setting Times: 2-10 minutes
Compressive Strength: 3000 psi (20
N/mm2)
3. HiperCrete
HiperCreteis manufactured from ce-
 HIGHWAY REPAIR

mentitious products with proprietary addi-
tives to give very high strength and fast set-
ting time. It comes in different categories
to be used as per requirement of site con-
ditions. Some of the products are
HiperCreteHighWay Patch,
HiperCreteFlowWay Patch,
HiperCreteKwiKFiX, HiperCrete PY and
HiperCrete MC
4. HiWayCreteRhinoShield
RhinoShieldis a proven sustainable
maintenance product, for roads and high-
ways, runways etc. Treatment of
RhinoShield will increase the life of asphalt
roads and highways by more 5- 7 years of
normal life. Product come in 25 lit drum
and can be sprayed or brush applied.w
For further details:
Multichem Industries Pvt. Ltd.
2, MatoshreeKunj, M.D. KiniMarg,
Near RBI Colony, Bhandup (E), Mumbai-400042
Ph: 022-25669137, 02225664890, 09323890199
Email: info@multichemgroup.net,
Web: www.multichemgroup.net

Abu Dhabi Urban Planning Commission

Unveils New Al Reem Island Plan
The Abu Dhabi Urban Planning Council (UPC) recently unveiled a
new master plan for Al Reem Island, which will have 10,000 hotel
rooms, 11 schools, light rail transit, and will house 210,000 residents
on completion.
The integrated concept master plan covers a total land area of nine
million square meters, with a total gross floor area (GFA) of almost
20 million square meters of which 1.4 million square meters is allo-
cated for office space, 873,576 square meters for retail and 10,000
hotel and serviced apartment rooms. It will also have 11 private
schools accommodating 20,000 students, six nursery/kindergarten
centers, one university (Paris Sorbonne), three new private hospitals
and a number of clinics, nine mosques, transit hub, and 500,000
The Masterbuilder | July 2015 | www.masterbuilder.co.in
170
square meters of parks and open spaces, including pedestrian
promenades for the island's coastline.
The plan was submitted by Bunya, incorporated by the island's three
master developers, Tamouh, Reem Developers, and Aldar Proper-
ties, in December 2014, after working closely with the UPC and the
three master developers over the past seven years to create the new
plan. The UPC gave its nod on the proposal in April 2015. Tamouh is
developing 60 percent of Al Reem Island, Aldar 20 percent, and
Reem Developers 20 percent. Only 15 percent of the master devel-
opment has been completed or is under construction since its
launch in 2005, but the island is already home to 20,000 residents.
 ???????????????
REPAIR AND RESTORATION
Heritage Conservation:
It's Not Only About Architectural Conservation
Chetan R Raikar
Chairman, Structwel
B
uilt Heritage, or in other words
heritage structures, is a part of
the cultural heritage of any society
and it provides a continuity and meaning
to the society. Heritage conservation is
necessary as it helps protect and maintain
the Built Heritage in its current state, pre-
venting further damage/ deterioration.
Conservation requires the understanding
of architectural details, structural aspects,
material science & its early construction
technique.
Conservation / restoration of Built
Heritage, hence, require a multi-
disciplinary effort. Usually a team of experts,
based on the type and the extent of the
problem, should work together in con-
serving heritage structures.
Philosophy
Heritage Conservation requires
understanding of the history of the struc-
ture, its cultural significance as well as the
structural and material characteristics.
Understanding the styles of architecture
in a heritage structure is critical in case of
adaptive reuse. In short, heritage structures
provide an excellent opportunity to sharpen
The Masterbuilder | July 2015 | www.masterbuilder.co.in
the skills of structural engineering, mate-
rials science, forensic engineering and
building design along with its architectural
features.
Any kind of conservation requires an
in depth knowledge of the original matrix
of the structure, which includes the type of
building materials used, type of construc-
tion and construction techniques adopted
etc. It's also utmost vital to understand the
historical back ground of the structure
including its usage pattern through its life
span, any previous structural interven-
tions. We also need to assess the present
state of the structure including damage or
172
distress & its structural behavior. In order
to gather and assimilate all these infor-
mation several activities like research of
historic records, survey and inspection of
the structure, site & laboratory testing of
materials, non destructive testing, under-
standing the structural framework and
seismic behavior of the structure etc are
required to be conducted.
The varied types of activities, as illus-
trated, will require the services of profes-
sionals like architects, structural engineers
and material scientists. The present sce-
nario of heritage conservation is such that
architects dominate the field. Structural
Engineers and material scientists are either
not involved or if involved they seldom get
the freedom to put into effect their sug-
gestions.
The role of structural engineer in the
structural evaluation process and condition
assessment of historic structures is
indispensable. The structural engineer has
a major role to play in studying and under-
standing the structural behavior of differ-
ent components of the structure, assess-
ing the strengthening requirements with
particular reference to seismic behavior,
assessing the structural safety etc.
The damages to the structure can be
of two categories, namely structural dam-
age or material damage. The damages need
evaluation as to which category the dam-
age pertains to. For ex: the cracks in
structure may be due to either material
deficiency or structural deterioration. In
such cases, cracks will have to be carefully
examined to understand their cause.
Structural appraisal of a building, hence,
is vital in evaluation of historic buildings. It
may include inspection, structural analysis
and testing of materials or even load test-
ing of various structural components.
In historic structures, damage or dis-
tress may be the result of inadequate design
and/or construction, decay and unplanned
alterations. During inspection, it is impor-
tant to note the deficiencies in original
design, deterioration of structural ele-
ments and the damage done to the struc-
ture during its life, to understand the cause
of structural deficiencies. There can be
structural movements like subsidence,
settlement, sway, bulging of walls, cracks
etc. Deformations and cracks due to
movements which may threaten the use
or safety of the structure will have to be
carefully distinguished. Careful examina-
tion can reveal whether the movement is
ongoing and the direction of its propaga-
tion.
The ancient period construction mate-
rials like lime mortar and the type of con-
struction like vaulted roofs, arches, huge
walls and wooden frames may have an
inbuilt ability to withstand some structural
movements (flexibility) which may have to
be understood clearly while deciding the
retrofitting measures. Water ingress can
also be the culprit behind decay of most
structural materials like masonry damages,
timber decay, sulphate-attack on cement
and concrete or rusting of steel or iron which
will have to be identified and taken care of.
It is equally important to study the type
of materials involved in construction and
its ingredients and the extent of erosion or
decay. There are several organic materials
like horse hair, belgiri fruit, jiggery, linseed
oil etc used in ancient construction mate-
rials like lime mortars. The study of the
building materials to understand its
ingredients and composition is essential
to arrive at proper repair techniques. The
contribution of material scientists in this
field is significant.
In short, assessment of the gravity of
any particular structural distress or symp-
toms and the causes mainly needs an
 ???????????????
REPAIR AND RESTORATION ???????????????

understanding based on practical experi- D E

Extra Bar to be Added
ence of the performance of historic struc- 100 Curved bars Reinforcement
M25 Grade Shortcrete 75MM THK.
Grid 80@300C/C
tures, and the contribution of the non- Bolts 16MMf @ 900 C/C
structural fabric in the performance rather Bothways ISMC 75

than calculations.
Case study

600
In order to explicate the structural
aspects underlying conservation of heri- Typical opening
tage structures, the project of conserva- in wall

tion of a 151 years old heritage structure in

Pune is enumerated here. The structure Ismc 75
900 c/c
had undergone several distresses like Through Bolts R.C.C. Beam
12MMf @ 600 c/c
partial collapse in the east elevation and
south west corner portions, profuse leak-
age from the clay tiled roof of the structure Rubble Packing
Earth Filling
and cracks in the stone masonry etc. Orig- D E

inally built as a Governor's monsoon resi- Typical Wall Elevation

75Mm. THK.
dence, the structure had undergone change M:25 Shortcrete
Reinforcement Bolts 12f
of ownership and usage over the years and Grid 8f@300c/c 900 c/c
Bolts 12MMf @ 900 c/c 10 THK. Plate
was subjected to some interventions and 10MM. THK M.S Plate
ISMC 75
150MM.x150MM.
additions/alterations due to the same. Expoxy Grout Ground LVL Ground LVL.
Ground LVL. Ground LVL
The earlier investigations, conducted M.S. Base Plate
300x400x16THK.
by a local architect, to the building had con-
firmed usage of gold leafing work in the 4 Nos. 12f
External Stone Bolts 300 Deep
interiors of the rooms which substantially Masonary

increased the conservation cost. Sam-

ples were taken of the alleged gold leafing
work and tested in UICT, Mumbai. The
results revealed no traces of gold and con-
firmed the usage of gold paint. This exper-
imentation brought down the cost of con-
struction substantially. This is an explicit
example to impulsive conclusions which
would have been avoided in case of detailed
investigations by involving material experts
& engineers.
One of the major lacunas in earthquake
resistance of the structure was identified
as the asymmetry in plan and elevation of
the structure. Two dimensional analyses
of individual walls were carried out using
suitable soft-wares. Nominal load carry-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Typical details of strengthening of walls
bearing walls on both the sides of the
existing wall using either shortcrete or
jacketing technique. Through bolts were
provided to effectively hold these two walls
together which were necessary for effec-
tiveness. Since all the internal walls have
been rendered with lime mortar, the same
finish was redone over the shortcrete. This
increased the thickness of the internal
walls by 150 mm and external wall by 75 mm
and the flooring in certain areas which were
disturbed were re-laid. Suitable founda-
tion for effective load transfer was con-
structed and shortcrete was taken right
up to the roof level and effectively tied up at
the end of the wall. This ensured improved
bearing to wooden trusses and joists
throughout the structure.
Endoscopy of wood was another method
which saved enormous quantity of wood
during conservation. It was used exten-
sively to identify erosion in wooden mem-

bers at the roof level and at the plinth level

ing capacity of the walls was assumed for in dance floor. The eroded wood and those
the structural analysis since it was observed infested by white ants could be identified
that the in-fill material used in the load and replaced and the rest could be salvaged
bearing walls included construction debris, thus saving tremendous cost during con-
broken brick bat etc. Slenderness of the servation
wall was checked in both the directions. The roof of the building has clay Man-
The reason of collapse of load bearing galore tiles over wooden trusses and bat-
walls was identified as over stressing of the tens in some areas and flat terraces hav-
walls due to ageing and original poor qual- ing cement / lime concrete water proofing
ity construction. Since the material used for in the rest. The flat terrace water proofing
construction of the walls was greatly vary- wherever leaking was tested using ebo-
ing throughout the structure, it was rec- nite hammer for debonding. The debonded
ommended to enhance the load carrying water proofing was redone using brick bat
capacity of the walls substantially. This was lime mortar over laid with lime concrete.
carried out by providing structural load
174

Wall strengthening by Shortcreting Clay tiles of the entire sloping roof were
 ???????????????
REPAIR AND RESTORATION
Wooden trusses of roof after repairs Sloping roof under repairs
removed and replaced after cleaning. The
broken tiles were replaced with new tiles.
Eroded wooden members like rafters,
purlins etc were repaired. Localized areas
and minor cracking in structural wooden
members were made good by filling the
cracks and voids with a mixture of epoxy
and saw-dust. Partial replacement of
wooden members was done where major
portion of the section could be salvaged.
This technique was implemented typically
in wooden beams and joists which were
eroded towards the ends buried in the
walls. Complete replacement of wooden
sections was resorted to where the wooden
The Masterbuilder | July 2015 | www.masterbuilder.co.in
176
Sloping roof after repairs
members were infected by termite and /
or have been eroded beyond serviceabil-
ity. Steel plate flitching was done at the
junctions of beams and columns to improve
the earthquake resistance of the structure.
Conclusion
The safety and stability aspect of the
building is of utmost importance in any
conservation effort along with maintain-
ing the aesthetics and the historic value of
the building. The limited knowledge or
experience of conservation architects, in
the structural aspects of building conser-
vation & also in material engineering, is an
important factor failing the conservation
initiatives in several cases. Hence, the con-
tribution of more and more experienced
structural engineers and material scien-
tists in this field is vital to make the con-
servation efforts more effective.w
For further Details:
Contact: Mr. Faiz Rahman
Structwel Designers &
Consultants Pvt. Ltd.
Plot No.15, Sector 24, Off Sion - Panvel
Highway, Turbhe, Navi Mumbai-400 705.
Ph: 022- 27841010 / Mob: 098196 42087
Email: faiz.rahman@structwel.com
Website: www.structwel.com
 REPAIR & REHAB
Fiber Reinforced Polymers
Muralee Balaguru
President, Green NanoFinish LLC
Advancements in Inorganic Systems
Fiber Reinforced Polymers (FRP) is an evolving type of ex-
ternal reinforcement widely used in the construction industry.
FRP systems create a high-strength composite that consists
of using high-strength fibers in conjunction with polymer resin
to attach the fibers to the applicable surface. There are many
different types of FRP systems, depending on the type of fibers
and type of polymer resin being utilized.
Carbon fibers are the most commonly used for strengthen-
ing concrete structures, typically as a woven fabric, due to their
high tensile strength. Additionally glass fibers and basalt fibers
can also be used for various FRP applications as well. When
evaluating polymers resins they fall into two distinct categories:
organic polymers and inorganic polymers. Organic polymers
are currently the industry standard for FRP systems, while inor-
ganic polymers are moving from the development phase into de-
ployment for construction. Inorganic polymers offer some dis-
tinct advantages based on their unique properties, including fire
resistance, utilization of industrial byproducts, and resistance to
UV degradation. The most important advantage that inorganic
FRP systems offer, specifically when applied to concrete, is that
it will from both a chemical bond in addition to the mechanical
bond formed with organic polymers. This dual bonding virtually
eliminates the interface between the inorganic FRP and con-
crete, creating a permanently reinforced structure.
Fiber Reinforced Polymers can be used for many different
applications. This article focuses on three areas: strengthening,
crack repair, and confinement.
Strengthening
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Concrete is an excellent building material for its versatili-
ty and longevity. However just like any building material it will
deteriorate over time due to do corrosion, overloading, weath-
ering, and external damage. There are essentially two ways to
deal with these issues: replace the structural elements that have
deteriorated, or repair them to their original strength. Replacing
the structural elements is an expensive and time consuming
option and depending on the structure may not even be feasible.
In these cases Fiber Reinforced Polymer repair is typically the
best option for cost effective and rapid repair. Structures that
typically need repair over time include bridges and parking decks.
Bridges consist of several important structural elements
that wear out over time and lose strength due to various fac-
tors, including corrosion, overloading, and vehicular damage.
Possibly the most important parts of a bridge are the support
beams, which allow for large spans and have to endure through
178
millions of loading and deflection cycles. These support beams,
typically constructed from concrete or steel, must be kept in
good condition to ensure the bridge does not fail. The most
economical and time efficient way to perform repairs on these
beams is to perform FRP repairs. These repairs entail bonding
high tensile strength fabric to the face of the beam that expe-
riences tension forces. With proper bonding the fabric can in-
crease the strength of the beam back to its original condition,
preventing bridge failure.
Parking garages are another structure that often needs
repair due to exposure to the elements and normal use wear-
ing. These structures are almost exclusively made of reinforced
concrete or pre-stressed concrete and contain large spans to
allow for easy traffic flow. Due to these large spans the concrete
experiences relatively large deflection loading that the con-
crete must compensate for. Similar to the way FRP is used for
beams, FRP can be adhered to the tension side of these con-
crete spans to increase their strength. This type of repair can
greatly increase the lifespan for a structure, negating the need
for costly construction and replacement.
Crack Repair
Cracks occur in concrete structures for many different
reasons, including structural cracking due to the corrosion of
steel reinforcement, settlement cracks, and cracks caused by
structural movement such as earthquakes. When these cracks
occur they must be filled to prevent more serious deterioration
from occurring due to water intrusion. To fill these cracks the
most commonly used repair system is to seal the surface with
an epoxy adhesive and then inject the crack with an organic
polymer. This repair does a good job of sealing the crack and
preventing further deterioration at the crack interface. Howev-
er these organic polymers do not “re-join” the concrete from
a structural standpoint. This is an application where inorganic
polymers can provide superior performance because they not
only fill the crack but also create a linked system. Inorganic
polymers have a chemistry very similar to that of concrete, so
using them as a crack filler essentially fixes the wall back to its
original strength and load transfer characteristics. This is es-
pecially important for load bearing concrete elements, such as
concrete walls.
One of the main causes of cracks to concrete walls are
earthquakes. During earthquakes the foundations of concrete
structures move rapidly and erratically, putting large strain on the
concrete elements. Once these cracks occur in load bearing
elements they can have dangerous consequences by compro-
mising the structural integrity of the entire structure. By using
 REPAIR & REHAB
an inorganic polymer to fill concrete cracks these structural
concerns can mitigated by returning the structure to its original
load bearing capacity.
Another aspect of crack repair, particularly in cracks that are
anticipated to continually move, is adhering a high strength fab-
ric over the crack surface. This fabric is used to seal the surface,
and even more importantly to “bridge” the crack to prevent
further movement. Again this is very important for structur-
al elements that have been damaged by earthquakes. These
structures that are located in “earthquake zones” will continue
to experience aftershocks and foundation movement even after
the initial earthquake event. Using a Fiber Reinforced Polymer
repair to bridge these cracks will work to prevent these cracks
from becoming larger and more damaging to the structural in-
tegrity of the concrete.
Milled Crack in Concrete (left) that has been Bridged with Inorganic FRP
(right)
Confinement
Confinement is an increasingly used Fiber Reinforced
Polymer method and entails wrapping a concrete element in
high-strength fabric impregnated with polymer to adhere it to
the concrete surface creating a durable shell. Confinement is
a useful for both repairing concrete elements, as well as retro-
fitting structures for seismic events. Typical concrete elements
that have utilized FRP confinement include utility poles, load
bearing columns, and concrete piles.
Concrete utility poles used for electrical wires, phone wires,
and lights are often damaged due to corrosion, extreme weather
events, overloading, and vehicular traffic collisions. Replacing
these poles would not only be costly but would also disrupt the
services associated with the wires attached to the pole. The
The Masterbuilder | July 2015 | www.masterbuilder.co.in
best alternative to replacing these poles is to repair them using
FRP confinement. For this type of repair high strength fabrics
are adhered to the concrete surface using an epoxy resin and
are wrapped around the entirety of the pole, either in sections
or a continuous loop to form a protective shell. By using FRP
confinement the concrete utility pole is protected from further
deterioration due to weathering. This is particularly important
for concrete poles that have exposed reinforcement rebar with
significant corrosion. By wrapping the column fully a water bar-
rier is created that will inhibit further corrosion from occurring.
Additionally for concrete poles that have experienced significant
reinforcement corrosion there may also be loss of structural
strength. Using FRP repair can increase the structural strength
and return it to its original state.
Fiber Reinforced Polymer column confinement is an ex-
cellent way to repair load bearing concrete columns. Replacing a
180
concrete column, whether it is on a bridge, building, or other
structure would be extremely difficult if not impossible without
replacing the entire structure. FRP confinement is an econom-
ical and timely repair method that can be used to enhance load
carry capacity as well as increase shear capacity. This is partic-
ularly important for structures that are expected to experience
earthquake damage. FRP confinement can be used on columns
as a seismic retrofit by increasing their loading capacity and
ductility for lateral forces to ensure these structures can better
withstand an earthquake.
Before (left) and After (right) Pictures of Concrete Bridge Column Wrapped
in Carbon Fabric Impregnated with Inorganic Polymer FRP
Concrete piles tend to experience significant deterioration
because of their constant exposure to water. This exposure to
water, especially salt water, accelerates the corrosion that the
steel reinforcement experiences. When this steel reinforcement
corrodes it begins to expand causing the concrete around it to
expand laterally, which in turn causes the concrete to crack in
tension. Once the concrete cracks the corrosion process accel-
erates even more as the reinforcement is fully exposed to the
elements. FRP confinement is an excellent repair method for
these piles by creating a shell around the piles, shielding them
from the elements. To further improve the repair, this shell cre-
ates a cast-in-place form that can be filled with grout to recreate
the concrete cover for the reinforcement that has disappeared.
Additionally this type of repair benefits greatly from the use of
inorganic Fiber Reinforced Polymer. Inorganic materials will
not degrade from exposure to water, even saltwater, and will last
longer than conventional organic polymers. Inorganic polymers
will also form a chemical bond with the concrete piles ensuring
that they will not delaminate over time and will remain in place
to protect the pile.
Fiber Reinforced Polymer repairs are increasingly being used
for concrete structures as they can be rapidly applied and are
more economically feasible than alternative systems or struc-
ture replacement. This increase in use has made them a more
widely accepted for repairing a wide variety of concrete struc-
tures. Furthermore their increased use has unearthed the lim-
itations that conventional organic FRP systems have based on
their chemistry and durability. These shortcomings create an
opening for better products, specifically inorganic polymer FRP
repair systems. Inorganic polymers offer superior bonding to
concrete and steel by creating both chemical and mechanical
bonds, ensuring the FRP does not de-bond from the surface
they are repairing. Furthermore inorganic systems offer supe-
rior durability compared to any other system available on the
market. The merging market for Inorganic Fiber Reinforced
Polymers will continue to grow as structures continue to age
and durable repairs become increasingly necessary around the
world. w
 COMMUNICATION FEATURE
Setting New Standards in Precast
Products with SFRC Technology
S
teel fibre reinforced concrete (SFRC)
is a technology that is fast finding
an increasing number of takers in
India. Fibre reinforced concrete is being
widely used in the precast construction,
pavements, tunneling, flooring, etc. One
company that has emerged a key player in
the field of precast products using the
technology is Precision Wire Industries,
headquartered at Kamleshwar, Nagpur.
The company is manufacturing, TUSKRETE
BRAND Steel Fibres and precast products
made from SFRC including, compound
walls, industrial drains, highway drains and
lentil beams and Check dam gates (K.T
Weir Plates). Precision Wire Industries has
been on the forefront of the industry with
several unique product innovations, which
are a result of a strong R&D focus. It has
also added another unique precast prod-
uct 'thin walled' compound walls, to its
impressive product portfolio.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
According to Devendra Balasaria, the
dynamic proprietor and driving force behind
the company's rapid growth story, the
182
products manufactured using the SFRC
technology offer several advantages over Numerous Industrial/Warehouse
conventional materials. One of the biggest floorings have been done successfully and
benefits offered by the products is the fact the client base is increasing day by day.
that they are cheaper as compared to
material used in conventional construction
methods. While being economical in cost,
they are also extremely tough, durable and
long lasting. Moreover, since they are all
precast products, except for the digging for
the construction of the wall or laying the
drain, there are absolutely no hassles at
the construction site. This factor also adds
to their sustainability quotient since there
is minimal environmental disruption at the
construction site. Another major advan-
tage offered by the method is quicker con-
struction time, which in turn helps sav-
ings on overall project costs and also
reducing carbon footprints, adding to the
green house points and National saving.
We have used this SFRC technology
with 300mm concrete spun pipes, 3600 mm
long beams. with excellent results.
 COMMUNICATION FEATURE
The company's products are enjoying
wide popularity and have been used in sev-
eral prestigious projects. The Highways
drains have been used at Jamtha 4 lane
Ring Road project in Nagpur. Lintels man-
ufactured by Precision Wire Industries have
been used in the construction of an engi-
neering college at Sakoli, as well as a new
unit of Haldiram at Kapsi near Pardi Naka,
and in the construction of a compound wall
in Mul and recently by a franchise unit of
Coca Cola.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
184
of 40 MT loaded trucks are plying on this
pavement.
With this success, we have also been
able to convince Nagpur Improvement
Trust to use Steel Fibres in their concrete
road pavement and they have agreed to
use this technology.
Sounding optimistic Devendra Balsaria
added that the precast products made using
SFRC technology have huge growth
potential in the Indian market.
Suspended Slab with only Steel Fibre
The suspended slabs of thickness 75 mm and
size 2mt x 2mt and 3mt x 3mt were successfully
tested under load upto 10KN/m2 super imposed
load of 10kN/m3
These suspended slabs were casted at
The company has also successfully Shree Baburao Deshmukh college, Wardha by
Mr. Bais under guidance of Dr. R.K Ingle,
executed a pavement of 8 km length at a Professor, VNIT Nagpur.
residential township in Nagpur. The first
project for pavement was with PMGSY, Solar Power Plant Precast Foundations
which was successfully executed for their
trialpurposeandafterbestresults,thesame
was used for a upcoming biggest township
at Nagpur. The total length of pavement
with 9 mts wide road is around 8 KM.
Even after lapse of 3 years the concrete
pavement has no damages and heavy loads
SFRC Pavement for PMGSY:
SFRC Pavement for PMGSY were done successfully
by replacing 40% cement with Fly-Ash. The thickness
was only 120mm instead of 180mm.
Fibres Quantity was only 25Kg per MCU be and a
Trial stretch of 50 meters length was layed.
The design was done by Dr. R.K. Ingle
The industry is also exploring poten-
tial of using this technology for low cost
housing and other critical precast prod-
ucts. Continuous R&D and best results have
opened more avenues to be explored. w
For More Details:
Precision Wire Industries
303, Gomti Apartment, Law College Square,
Nagpur-440010.
Mob: 09823170062/09372391456
Email: devendrabalasaria@hotmail.com
Web: www.tuskrete.com
 WATERPROOFING

Waterproofing Products for

Complete Protection of Home
Sameer Bhore, Project Manager, Multichem Industries Pvt. Ltd., Multichem Group, Mumbai

D
amp is merely unwanted mois-
ture in a building. Kitchens and
bathrooms are common places
where we introduce un-wanted moisture
into our homes as a by product of the activi-
ties we carry out, namely showering and
cooking. But we have systems in place to
reduce the effect such as extracts and
opening windows.
What do we do, then, when moisture
is getting in of its own accord. Two of the
common routes in houses are through
damp ingress in verticle surface and roof
areas. It's essential to protect your wall
and roof against the passage of water.
Leaving these areas without suitable
waterproofing could exposing your house
to a number of dangers as well as missing
out on a number of key benefits.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
surface and the water molecules. Once
the building materials come in contact with
water, they absorb water through their
pores by the capillary action. You may call
concrete 'Hard Sponge'.
Strength of Concrete& Waterproofing
The strength of concrete is very much
dependent upon the hydration reaction of
cement with water. Water plays a critical
role, particularly the amount used. The
strength of concrete increases when less
water is used to make concrete. The hy-
dration reaction itself consumes a spe-
cific amount of water. Concrete is actually
mixed with more water than is needed for
the hydration reactions. This extra water
is added to give concrete sufficient work-
ability.
Flowing concrete is desired to achieve
proper filling and composition of the forms.
The water not consumed in the hydration
reaction will remain in the microstructure
pore space. These pores make the con-
crete weaker due to the lack of strength
forming calcium silicate hydrate bonds.
Some pores will remain no matter how
well the concrete has been compacted.
There pores become source of leakage in
concrete.
How Water Can Harm?
Normally we would be expecting a
90% of all Water Intrusion
Problems Occur within 1% of
the Total Building or Struc-
ture's Exterior Surface Area
- Health problems due to dampness,
which may lead to respiratory prob-
lems, growth of micro-organisms and
exposure to gas like radon.
Water in the building can also be a big
threat to health and happiness, it contrib-
utes to environmental pollution especially
in big cities where very large population
concentrated in a small space, creates
carbon dioxide, sewage, smoke from
motorized vehicles, etc. This is a very com-
plicated problem with no single solution.
Waterproofing Benefits
You Must Protect Your Building's Interior
from Water Damage
For most of the time during construc-
tion, you may find the inner parts of your
building exposed to the elements. Things
like the frames, the foundations, wiring
and insulation, as well as the floors. If
you're using concrete and steel the haz-
ard is less prominent, although those metal
parts may still rust, and concrete can still
suffer damage, but it's with wooden mate-
rials that the dangers of water really set in.

building to be watertight but there are al-

Is it Swimming Pool cum Bed Room?
Why Need Waterproofing at All?
Concrete Absorb the Water
Concrete, bricks, stones and mortars
are composed of crystals of carbonate, sili-
cate, aluminates or oxides, whose sur-
faces are rich in oxygen atoms, which carry
negative electrical charge of hydroxyl
groups, which carry both negative and pos-
itive charges. Such surfaces are polar and
are also called hydrophilic. When water
comes into contact with these surfaces,
186
If exposed to water for prolonged periods,
ways ingress points on the concrete, in other
the wood may begin to rot or become
parts of the building because of variety of
infested with mold, rendering the entire
reasons and water can enter through these
structure unsound and unfit for habitation.
points to cause the following damages.
Waterproofing your building materi-
- Corrosion of metals such as steel rein- als during construction will help prevent
forcement in concrete structures
causing malignancy.
- Swelling of plaster boards and subse-
quent debonding of ceramic tiles.
- Possible short circuit of lighting and
power points.
- Blistering of Paint.
- Damage to structures and finishes such
as floor joints, beams, floors, studs,

hydrogen bonds are formed between the skirting, and frames.

 WATERPROOFING
this from occurring, promoting in your
fledgling building a healthy, strong start.
As you'll be better protecting your materi-
als from damage, it also prevents expen-
sive delays and replacements, as you will
not need to be repairing continuous dam-
age either during construction or after it
has been completed.
It Prevents Flooding in Basements
Basements in particular are vulnera-
ble to moisture seeping within them.
Water soaks through the soil and quickly
leaks through cracks and fissures within
the concrete, which can lead to flooding
as well as mold and mildew. During the
winter, this moisture will then freeze,
causing it to expand and force the cracks
open wider and making the problem
worse. Eventually, the entire basement
could be rendered unsafe.
As the basement is being built, it is
essential to take steps to keep them water-
proof and seal them off from moisture. Be
sure to protect the foundations of the
building as well, as doing so will promote
the long-term stability of the structure.
It Saves Money
While the costs of waterproofing may
initially seem like a severe blow to your
The Masterbuilder | July 2015 | www.masterbuilder.co.in
budget, it is best to think of it as a long-
term investment that makes money dur-
ing the building's lifetime. Much like in-
stalling insulation or double-glazed win-
dows, waterproofing your new construc-
188
tion is a measure undertaken for the future,
and will quickly save you money in the
long run.
Think about things in this way: would
you rather invest money now in a strong,
secure house that requires minimal re-
pairs from water damage caused by leak-
ing basements or walls, or have to fork out
cash for those repairs continuously for
the rest of your time in it?
It Promotes Long-Term Comfort
Waterproofing your new construction
site early helps you to start sealing it off
more efficiently than trying to it after buil-
ding has finished. The measures taken
help reduce moisture in the interior of the
building, which makes it more comfort-
able to live in, while also providing a foun-
dation for further work later on.
Some permeability is desirable in the
building to let humidity building up inside
the structure to escape, however the trick
is allowing this while still keeping the
moisture out. Such measures are easier
to achieve as the building is being con-
structed. After the fact, you'll probably
require expensive reconstruction work to
fit it all in properly. Thinking about this
early can help prevent headaches about
the matter later.
Waterproofing Materials
Various waterproofing products are
available in the market to protect your buil-
ding, rooms or property. Some of them
are listed here:
- Integral Waterproofing Compounds:
e.g. Multiguard IW+, Contite 125,
Powershield 500, Multiguard IWP
- Acrylic Based Polymer Coating: e.g.
Multicrete CM, Multicrete SBR, Mix-
crete, Powercoat
- Mineral Based Polymer Modified Coat-
ings: e.g. Multiguard A, Leakshield,
Aqua Stop
- Protective and Decorative Coatings:
e.g. Roof Mate Roofshield, Ultraroof,
Rainshield, Heatshield
- Chemical DPC for Rising Dampness:
e.g. Aqua Block, Nano Sil
- Waterproofing Coatings and Adhe-
sive for Tiles, Marble and Granite: e.g.
Multifix, Surefix, Prime Fix, Fusion-
crete, Nano Fix, Perma Flex
- Silicon based Water Repellent Mate-
rial: e.g. Silico Shield
- Injection grout for cracks: e.g. Prime
Grout Super Add 250
- Joint Sealants: e.g. Multi Flex AC,
Crackfix
Integral Waterproofing Compounds
The integral waterproofing compounds
have been in the use from the last 4 5
decades. They were used as admixtures
to make concrete waterproof. These con-
ventional waterproofing admixtures are
now more advanced, as either pore fillers,
workability agents, crystallization based
or water repellents, and as such they are
useful to protect structure with most eco-
nomical way. In situations where con-
crete is not continuously in wet or in damp
condition, integral water proofing will be
most suited. These products are used dur-
ing the construction of structure.
Acrylic Based Polymer Coatings
Structural inadequacy or failure to
adhere to the proper detailing of rein-
forcement, or the unequal settlement,
variation in temperature and long term
drying shrinkage with age etc are some of
the additional reasons for development of
cracks in concrete members.
In such situations a membrane form-
ing waterproofing materials are ideal. The
membrane should be tough, water resis-
tant, solar reflective, elastics, elastomeric
and durable. They allow the movement of
the concrete members, but keep the qual-
ities of the membrane intact.
 WATERPROOFING
Mineral Based Polymer Modified Coatings
Waterproofing of concrete, brick ma-
sonry and cement bound surfaces can be
achieved by a specially made slurry coat-
ings. Slurry consists of specially processed
hydraulically setting powder component
and a liquid polymer component. These
two materials when mixed in a specified
manner forms brushable slurry. Two coats
of this slurry when applied on roof surface
or on any other vertical surface in base-
ment, water tank or sunken portion of
bathroom etc. forms a long lasting water-
proofing coat. This coating requires cur-
ing for a week or so. The coating so formed
is elastic and abrasion resistant to some
extent. To make it long lasting, the coating
may be protected by mortar screeding or
tiles.
Protective and Decorative Coatings
RCC members such as sun breakers,
louvers, facia, facades, sun shades and
chajjas, crack and spall off within a matter
of a few years, particularly when the cover
provided to these thin and delicate mem-
bers are inadequate. Water seeps into
these members and corrodes the rein-
forcement in no time. Corrosion is also
accelerated by carbonation. To enhance
the durability of such thin member is to
The Masterbuilder | July 2015 | www.masterbuilder.co.in
make them waterproof, carbonation re-
sistant coating is given. Incidentally it will
present a aesthetic and decorative look.
Chemical DPC for Rising Dampness
Often old buildings are not provided
with damp-proof course. The water from
the ground rises by capillary action. This
rising water brings with the dissolved
salts and chemicals which result in peel-
ing of plaster affecting the durability of
structure, and also make building unhy-
gienic. Now we have materials that can be
injected into the wall at appropriate level
to seal the capillaries and thereby to stop
190
the upward movement of the water
Waterproofing Coatings & Adhesives for
Tiles, Marble and Granite
The normal practice followed for fix-
ing glazed tiles in bathroom, lavatory,
kitchen and other places is the use stiff neat
cement paste. The existing practice, though
somewhat satisfactory in the indoor con-
ditions from the point of fixing, such prac-
tice is unsatisfactory when used in out-
door conditions and also from the point of
view of waterproofing quality. The cement
paste applied at the back of tiles do not
often flow towards the edges of the tiles
and as such water enter at the edges, par-
ticularly when white cement applied as
joint filler become ineffective. In large
number of cases it is seen that paintings
and plasters get affected behind these
glazed tiles supposedly applied to prevent
moisture movement from wet areas.
Silicon Based Water Repellent Materials
Sometimes, in buildings, brick works
are not plastered. Bricks are exposed as
they are. If good quality, well-burnt bricks
are not used in such constructions, the
absorptive bricks permit the movement of
moisture inside. Old heritage buildings
built in stone masonry may suffer from
minute cracks in mortar joints or plastered
surface may develop craziness. In such sit-
uations one cannot use any other water-
proofing treatment, which will spoil the
intended architectural beauty of the struc-
tures. One will have to go for transparent
waterproofing treatment. For this pur-
pose silicon based water repellent mate-
rials are used by spraying or brushing.
Injection Grout for Cracks
Injection grouting is one of the power-
ful methods commonly adopted for stop-
ping the leakages in dames, basements,
swimming pools, construction joints and
even in the leaking roofs. A few years
back, cement was used for grouting pur-
poses. Cement is not a ideal material for
grouting, as it shrinks while setting and
hardening. Non-shrink or expansive ce-
menting is the appropriate material. We
have quite a few materials available in the
market for filling up cracks and crevices in
concrete structures to make them water-
proof or for repair and rehabilitation of
structures. The grouts are produced with
selected water repellent, silicifying chem-
ical compounds and inert fillers to achieve
varied characteristics like water imper-
meability, non-shrinkage, free flowability
etc. They are suitable for gravity grouting
as well as pressure grouting.
Joint Sealants
Joints in buildings, bridges, roads and
airfield pavements are inescapable. They
may be expansion joints, construction joints
or dummy joints. Such joints must be ef-
fectively sealed to facilitate movement of
structure, to provide waterproofing qual-
ity or to improve the riding qualities. While
providing large openings and windows in
buildings there exists gap between wall
and window frames, through which water
flows inside. Such gap in window should
be effectively sealed. The gaps resulting in
installation of sanitary appliances are also
required to be sealed.w
For further details:
Multichem Industries Pvt. Ltd.
2, MatoshreeKunj, M.D. KiniMarg,
Near RBI Colony, Bhandup (E),
Mumbai-400042.
Phone: 022-25669137, 02225664890,
09323890199,
e-mail: info@multichemgroup.net
www.multichemgroup.net
 AWARDS
Tata BlueScope Steel's DURASHINE®
Brand Recognised as Asia's Most
Promising Brand
D
URASHINE®, the flagship retail
brand of Tata BlueScope Steel,
has been accredited with the Asia's
Most Promising Brand Award at the 'Asian
Brand and Leadership Summit - 2014'
held in New Delhi earlier this year.
Asia's Most Promising Brand is the
first ever project on brands involving
leading brands from Asian countries
across 50 industry categories. The award
is a result of a survey conducted by World
Consulting and Research Corporation.
The process is evaluated & audited by
KPMG in India.
Launched in the year 2008, DURASHINE®
is India's largest Colour Coated Sheets
brand today. The brand is backed by the
strong parentage of Tata Steel and
BlueScope Steel, Australia, where quality
and commitment have always been held
paramount. DURASHINE® offers a range
of world class colour coated steel roof and
wall sheets, structural products and
accessories specially designed for the
residential, commercial and industrial
segments.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
192
Vikas Pundir, Chief, Channel Sales, Tata BlueScope Steel receiving the award
Speaking on the occasion Mr. Vikas
Pundir, Chief, Channel Sales, Tata
BlueScope Steel said "DURASHINE® has
been a pioneer in this segment. Its range
of products are built on strong market
knowledge, continuous market research
and advanced manufacturing technology
that help us deliver benchmark solutions
tomatchthelocalconsumerrequirements."
A large part of the success of
DURASHINE® has been attained due to
extensive marketing activities that help
develop a connect with consumers. This
includes a balanced media mix of
promotional activities and a robust service
management system that helps retain
confidence across the entire value chain.
Mr. Riten Choudhury, Managing
Director, Tata BlueScope Steel says "This
prestigious award validates the success of
AMPB Certificate
DURASHINE® and the excellence in quality
of our products and services. DURASHINE®
is the market leader in its category and
this award will aid in further strengthening
the brand."
DURASHINE® is marketed through
a wide network of distributors and
dealers with a footprint is 565 districts
across India. w
For More Details:
Tata BlueScope Steel Limited
Regd. Office: The Metropolitan,
4th Floor, Final Plot No.27,
Survey No.21, Wakdewadi,
Shivaji Nagar, Pune – 411005
Tel.: +91 20 6621 8000
www.tatabluescopesteel.com
 CONCRETE: UHPC

Ultra-high Performance Concrete

(UHPC) Premix

M N Ramesh
Director, Talrak Construction Chemicals Pvt. Ltd.

Ultra-high Performance Concrete

1 2
The growing challenges in construc-
tion industry has led to several advances in
material science in general and concrete in
particular. The performance specifications
have paved way to innovative approaches
for accomplishing target attributes of con-
crete resulting in development of a new
class of cementitious composites, namely-
ultrahigh performance concrete (UHPC).
The combination of mechanical and dura-
bility properties of UHPC makes it an ex- 3 4
clusive material for using in design and con-
struction of infrastructure projects in-
volving challenging designs and perfor-
mance requirements.
The UHPC is developed through cha-
racterization of the Nano-mechanical pro-
perties of the phases governing the UHPC
micro structure. These Nano-scale pro-
perties are then up scaled to the macro
1. Synthesizes cementitious nanoparticle. 2 & 3. Nano tubes bridging cracks in a cement composite.
level for engineering applications. This pro- 4. Nano- layer of calcium aluminate particle.
cess involves development of algorithms
through which a defective free matrix tran- allows drastic reduction in the sheer rein- Extreme properties of UHPC
sition zone achieved. Based on the perfor- forcement in simple span bridges and
UHPC can be designed to get the pro-
mance requirements the combination of buildings
perties as per required specifications. Fol-
various constituent materials are chosen UHPCs have demonstrated exceptional
lowing are the properties achieved by in-
performance when used as a field-cast clo-
The Masterbuilder | July 2015 | www.masterbuilder.co.in

and a development of multiscale model corporating the patented Quantz ® tech-

with defect free interfaces allows to accu-
rately determine the composite stiffness
from the measured Nano-mechanical prop-
erties for optimizing the packing density of
cement-based engineered composites.
Applications
Of late UHPC isconsidered for use in a
wide variety of infrastructure applications.
The high compressive and tensile strengths
allow for the redesign and optimization of
structural elements. Concurrently, the en-
hanced durability properties facilitate ex-
tension of design life and allow for potential
use as thin overlays, claddings, or shells.
194
sure pour or grout material in applications
requiring the onsite connection of multiple
prefabricate elements
UHPC also finds its application in a vari-
ety of other applications. These applica-
tions include precast concrete piles, seis-
mic retrofit of structures, thin-bonded over-
lays on deteriorated bridge decks, and se-
curity and defence application for blast re-
sistant structures. In a general with UHPC
any designed performance specification
can be met.
Replacement
nology.
- High Strength up to 350 MPa
- High Flexural Strength up to 75MPa
- High Tensile Strength
- High Thermal Resistance
- High Thermal Isolation
- Range of workability, from very stiff to
extreme fluid
- Low carbon foot prints
Optimizations of section with UHPC
Following illustration shows the level of op-
timisation possible using UHPC
Availability

The enhancement of the tensile strength Development of concretes within the


Reduction: 80 %
1 m2 1,5 m2
1,0 m
1,2 m
Quantz High Strength steel:
C 190-220 without 20 % SAS 670/800 and
reinforcement concrete C 50-60
Optimizations of section
UHPC class are currently taking place
worldwide. In Indian context there are
have been very few examples of using con-
cretes of 100MPa commercially. But the
reproducibility of the mix at sites has re-
mained as a great task. Now this material,
commercially will be made available in
the country by a Bangalore based com-
pany - Talrak Construction Chemicals Pvt.
Ltd., in the most readily available form of
UHPC product. It is basically a dry mix
which will be supplied in the form of a pre-
packed powder, to which only addition of
specified quality of course aggregate with
recommended particle size distribution
and water are added and mixed in a bat-
ching plant to get a concrete mix of strength
M100 and above. It is a proprietary prod-
uct – TalrakreteUltra™ Drymix manufac-
tured using Quantz® technology from Ger-
many.
Mixing and casting
Any conventional concrete mixer will
mix UHPC using the proprietary drymix.
However, it must be recognized that UHPC
requires increased energy input com-
pared to conventional concrete, so mixing
time will be more than that required for
normal concrete. This increased energy
input, in combination with the recom-
mended coarse aggregate and low water
content, necessitates the incorporation of
special additives into the Drymix to ensure
that the UHPC does not overheat during
mixing.
The placement of UHPC may imme-
diately follow mixing or be delayed while
additional mixes are completed. Although
the transit time prior to the initiation of the
cement hydration reactions can be influ-
CONCRETE: UHPC
method is generally appropriate, but com-
pressive strengths as high as 150 MPa
may necessitate smaller specimen sizes,
different specimen shapes, higher test
machine capacities, or different speci-
men preparation techniques. All the tests
such a compressive strength, flexural
and tensile strengths, flow tests, chloride
2 ion permeability tests etc. need to be car-
4,9 m ried out on the UHPC for its proper as-
sessment.
Structural design considerations
Analysis of UHPC structural compo-
2,2 m nents is not necessarily more complex
than analysis of conventional reinforced
C 50 - 60 with 5% normal steel concrete structures. However, it is imper-
reinforcement
ative that the analysis be carried out ratio-
nally without allowing preconceived con-
cepts of reinforced concrete behavior.
enced by factors such as temperature
the setting and time before the workability
bc
loss can be extended by using proper ad-
mixture in the Drymix. E1
UHPCs tend to exhibit rheological be-
1 2 0
haviours similar to normal self-compac- tension
1%

Compression
ting concretes, thus requires similar form ftj
bt
preparation. Internal vibration of UHPC is
Stress Strain
not recommended due to the fibre rein-
forcement. For example, the compressive stress-
strain response of conventional concrete
Curing
has a parabolic shape that is sometimes
Applying appropriate curing methods modeled through a rectangular stress
is essential to the performance of any con- block. Such a stress block would only be
crete, especially UHPC. Like all concretes, appropriate for UHPC if appropriate fac-
UHPCs require hydration water, but un- tors were applied to adjust the block to
like other concretes, UHPCs have been en- match the stiffer and more linear UHPC
gineered to require very little additional response. Moreover, it is frequently desir-
water, instead facilitating appropriate rhe- able to include the sustained tensile ca-
ological behaviours through the use of an pacity of UHPC in an analysis. Although
optimized gradation of granular materi- this extra stress block may increase the
als. The reduced water content in a UHPC complexity of the calculation, it does not
mix necessitates careful attention to cur- introduce new theory and should be able
ing practices so as not to allow the inclu- to be computed appropriately.
ded water to escape prior to hydration. Im-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Concluding remarks
mediately after casting, any exposed UHPC
surface needs to be sealed with an imper- Be it a fast track construction,or to in-
meable layer as curing is very critical in crease the span ranges, or retrofit the
UHPC. On critical members it is a good structurally inadequate infrastructure,
idea to keep the surface remain sealed in UHPC can provide of unique solutions to
the formwork until it has attained suffi- existing challenges. As with any new mate-
cient properties to allow it to self-support rial, utilization will grow as innovative ap-
and not self-desiccate. A compressive plications are developed and market de-
strength of 97 MPa is frequently used as a mand intensifies. Research has demon-
substitute value to indicate the attainment strated that UHPC is a material both capa-
of an acceptable level of hydration. ble of and emerged as a material for fu-
ture deployment in infrastructure scale
Testing
applications. The UHPC premix can elim-
In general, well-established testing inate lots of problems associated with vari-
procedures for conventional concrete are ations due to the quality and consistency
195
applicable to UHPC. The conventional test of material available at site. 
 COMMUNICATION FEATURE

Portland Slag Cement (PSC)

P
ortland Slag Cement, commonly
known as PSC, is blended cement.
Slag is, essentially, a non-meta-
llic product comprising of more than 90%
glass with silicates and alumino-silicates
of lime. JSW Cement, users superior qual-
ity slag produced at it's steel manufactur-
ing plant, conforming to IS: 12089 stan-
dards for producing PSC. It is created with
a combination of upto 45- 50% slag, 45% –
50% clinker, and 3-5% gypsum. PSC has
been voted as the most suitable cement
for mass construction because of its low
heat of hydration.
The multi-fold advantages of PSC
PSC's inherent chemistry gives it sev-
eral advantages over ordinary cement.
Apart from being more environment-
friendly, it offers.
- Ultimate compressive strength
- Excellent resistance to Chloride & Sul-
phate attacks
- Low risk of cracking
- Improved workability
- Better compatibility with all types of
admixtures
- Superior finish
- Ease of pumping
- Better resistance against alkali-silica
reaction
- Minimised shrinkage cracks
Where PSC can be used?
- All types of residential, commercial
and industrial projects
- Dams and other mass concrete works
- Water retaining structures
- Concrete roads and flyovers
- Most suitable for marine construc-
tions
- Pre-cast concrete products
- Foundations and piles construction 

Making Rapid Inroads into the Indian Market

& epoxy system, along with total stone solutions like
stone cleaners & impregnators, surface treatment prod-
ucts (polishers and colour enhancers).
The company's products are supplied in wide range of
packaging sizes suited to varied consumer require-
ments. The high level of quality of AKEMI products is
ensured by the company's State-of-art production and
filling plants, as well as its continual most stringent
inspection and testing processes to ensure interna-
tional standard quality.
The Masterbuilder | July 2015 | www.masterbuilder.co.in

AKEMI is a name that is well-known globally for its

Mr.Torsten Hamann (M) and Dr.Dirk Hamann (L) receiving the award
Akemi, head quartered in Nuremberg, Germany has been manu-
facturing chemical products for the treatment of natural and engi-
neered stones for more than 75 years now. The company is a leading
partner globally for stone processing enterprises. In 2011, Akemi
Technology India Pvt Ltd. established a state-of-the-art manufac-
turing facility in Bengaluru and since then has made rapid inroads
into the growing Indian market.
AKEMI formed a JV with Silicone Concepts, New Delhi in 2013 to
offer the full range of fillers & adhesives based on polyester system
196
strong R&D focus. The company's product range is
being continuously optimized and expanded. Some of
AKEMI's numerous innovations are being protected by
international patents, such as its Marmorkitt with stone
structure, as well as the popular AKS polishing line adhe-
sive. Numerous AKEMI fillers are also certified by exter-
nal certifying institutions. As a company in the chemical
industry, AKEMI is very conscious of the importance of
environmental protection and product safety. Accord-
ingly AKEMI products meet all legal requirements with
regard to health protection, work safety and labeling.
AKEMI has recently been received the prestigious 'Bavaria's
most Innovative Company Award' from the association
of family owned enterprises- ASU, Berlin, Germany.
 INTERACTION
Keeping Tiles Damage Free
D
URAfloorprotector-xf, by Supreme
Industries Ltd. protects expensive
tiles from damage during reno-
vation or interior work.
DURAfloorprotector-xf is an innovative,
cost effective, new generation product
introduced by Supreme Industries Ltd. for
protecting different types of floors. Ajay
Mohta, General Manager Construction
Accessories Division spoke to The
Masterbuilder about the development of
this product and what makes it a must-have
for those looking to renovate their interiors.
DURAfloorprotector-xf is very well
accepted in the market and the proof to
which is that the company has success-
fully sold over 50 lacs sq.ft. material in the
firsttwoquartersofitslaunch.
Excerptsfrom the interaction:
What were the reasons for the introduc-
tion of this floor protection product?
While doing the interiors of any pro-
ject, flooring is completed prior to electri-
cal or plumbing work. During these works,
scratches can develop even resulting in
breaking of tiles or flooring due to dragging
of heavy equipment. As 25% of the interior
cost involves modern floorings, it is nec-
essary to protect the floors till the total
interior work is completed. Traditionally,
The Masterbuilder | July 2015 | www.masterbuilder.co.in
198
Plaster of Paris (PoP) was used for this
particular application, but not only is lay-
ing and removing of PoP a time consum-
ing and a tedious activity, but it also gener-
ates harmful dust.
What are the salient features of
DURAfloorprotector-xf?
DURAfloorprotector-xf is an innovative
technology that provides universal cush-
ioned flooring protection for wood, ceramic
and vinyl floors. It is a closed-cell, polymer
based microcellular foam composed of
thousands of cells trapped in the foam with
the reinforcement of high performance
polymer which helps to resist all types of
pressure imparted. The product offers
hassle-free application process compared
to PoP, rosin paper, plastic runners or drop
cloths. It does not absorb paint, oil, grease
or any cleaning agents.
DURAfloorprotector-xf is flexible, can
be cut to fit in any space and works well on
either side- vacuum or sweep clean and is
reusable. It is environment friendly, inert and
does not promote growth of bacteria and
fungi.
What are the possible applications and
advantages of the product?
DURAfloorprotector-xf keeps floors
Ajay Mohta
General Manager, Construction Accessories
Division, Supreme Industries Ltd.
safe from damage and debris and its anti-
slip properties provide a safe work envi-
ronment. It is a reusable, reversible surface
protection for concrete, marble, granite and
other counter surfaces. It also provides
cushioned universal floor protection dur-
ing construction for hardwood, ceramic tile,
linoleum and carpet floors as well as sinks
and tubs, walkways and decks during
building or remodeling. It is already very
well accepted by the leading architects,
interior decorators, contractors, develop-
ers and builders as there has been an
urgent need for an alternative to PoP and
DURAfloorprotector-xf now offers the most
appropriate solution.
S i n c e i t s l a u n c h ,
DURAfloorprotector-xf has been the num-
ber one choice for temporary floor protec-
tion in the construction industry. This heavy-
duty, reinforced product is engineered to
protect new and existing floors from the
heavy demands of the jobsite.
DURAfloorprotector-xf is non-staining
and reusable. It provides the perfect solu-
tion when protecting new or existing wood,
tile, stone, linoleum, vinyl composition tile
and most other floor types.
What is the marketing approach that the
company will be using for the product?
Supreme Industries already has a vast
distribution network all over India for other
DURA range of products related to civil
industry. A lot of new distribution networks
have been created with the launch of this
product to make it easily available. These
include people involved in trading or retail-
 INTERACTION

ing of flooring tiles, plywood and other
products related to interior decoration
industry.
Some of the other products under the
DURA range include DURAmembrane:
High performance waterproofing mem-
brane; DURAboardHD100: Compressible
filler board for expansion joints; DURArods:
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Closed-cell, polymer based foam filler
material with a circular profile; DURAshield:
Material for spandrel insulation in glass
façade buildings; DURAroofil: Light weight,
resilient, soft, polymer based closed-cell
foam closure profile used as gap filler in
roofing systems; DURAblockfiller: Special
purpose, high density filler board; DURA
vapourbarrier: High performance water
vapour barrier material and DURA pro-
tector: Membrane Protection Board.
Contact:
Mr. Ajay Mohta
Mob: +91-9831020808 / 9810495550
dura@supreme.co.in
www.supreme.co.in

Description: Call for Presentations from ACI Committee 120, History of Concrete.
Meeting: Technical session at the ACI Fall 2016 Convention. This will be held
Call for Presentations: October 23-27, 2016, in Philadelphia, PA. Solicited: Due to the history of cement
production in the Lehigh Valley, presentations on cement powders such as lime
HISTORY OF CONCRETE mortars, natural cement, “early” masonry or Portland cement are sought however
January 15, 2016 to January 15, 2016 presentations on other topics related to the history of design, construction,
cementitious powders, , and concrete practices would also be considered .
Presentations would be 15-20 minutes in length. Any type of physical artifact is also
The Concrete Convention and
encouraged. Requirements: 1) Presentation title; 2) author/speaker name(s), job
Exposition, FALL 2016
title, affiliation, and contact information; and 3) a one-page abstract. Deadline:
Philadelphia , PA United States
Abstracts are due by January 15. 2016 Send to: Ryan Scott, Essroc Italcementi
Sponsor(s): ACI Committee 120,
Group E-mail: ryan.scott@essroc.com
History of Concrete
For more information, contact: Ryan Scot, Essroc Italcementi Group,
United States, Email: ryan.scott@essroc.com
200
 COMMUNICATION FEATURE
Gandhi Automations
Working Towards A Green Tomorrow
G
andhi Automations Pvt Ltd –
India's No.1 Entrance Automa-
tion& Loading Bay Equipment
Company organized Green Drive for its
employees at its head office in Mumbai on
occasion of 'World Environment Day' on
5th June 2015. On this occasion the Direc-
tors of the company Mr. Samir Gandhi &
Mr. Kartik Gandhi personally presented
each of their employees with a sapling for
planting. The Director's promoted this
green drive as they firmly believe in Envi-
ronment Protection and leaving behind a
Clean Environment for the future genera-
tions.
This is not the first time that Gandhi
Automations has worked towards a
Green tomorrow, in fact Gandhi
Automations is a proud member of the 'In-
dian Green Building Council'. Gandhi
The Masterbuilder | July 2015 | www.masterbuilder.co.in
High Speed Doors
202
Automations product range comprises of
Dock Levelers, Dock Shelters, Sectional
Overheard Doors, Insulated Rolling Shut-
ters, High Speed Doors and Fire Rated
Rolling Shutters which helps in energy
saving and provide healthier personal and
professional spaces.
Our below product range used for dif-
ferent applications in Buildings contrib-
ute to the Green Movement:
Insulated Rolling Shutters/ Fire Rated
Rolling Shutters:
Our Insulated Rolling Shutters stop
substantial heat and cold from enter-
ing the room. They also maintain the
temperature (heat/ cold) within the
room. By keeping the temperature
stable, We can reduce the power con-
sumption and save huge amount of
electricity.
We also manufacture Insulated
Rolling Shutters having Vision Win-
dows, Where sufficient amount of out-
side natural sun light directly enters
the room / work area hence saving
substantial electricity.
High Speed Doors:
High Speed doors are used for
application of quick open and close at
entry and exit points where the room
temperature need to be maintained.
With this quick operation of door, we
can maintain the temperature within
the area and lower energy costs sub-
stantially. We also manufacture High
Speed Doors having Vision Panels
where the outsidenatural sun light
directly enters the room / work area.
The installation of Vision Panelsin the
above doors saves electricity.w
For further details:
Gandhi Automations Pvt Ltd
2nd Floor, Chawda Commercial Centre,
Link Road, Malad (W), Mumbai – 400064, India.
Tel : +91 22 66720200 / 66720300
Fax : +91 22 66720201
Email : sales@geapl.co.in
Website : www.geapl.co.in
 CONCRETE: WATERPROOFING
Waterproofing as a System - Practical
Considerations and Waterproofing with
Cementitious Systems
Sunny Surlaker
Head - Admixtures Division
MC-Bauchemie India Pvt. Ltd.
I
n today’s construction scenario, due to extreme require-
ments, we put tremendous stress on speed, economy and
construction practices. A combination of these factors affects
the durability of concrete in several ways. In Indian conditions,
where waterproofing is very important more often than not. It
is not executed in a technically correct manner. Due to these
construction and/or material problems, structures both above
and below the ground are susceptible to waterproofing prob-
lems. Dampness entering the living space (especially through
ceilings and walls) is an indication that the structure has failed
in durability and that structural elements have already begun
deteriorating.
Waterproofing is important in protecting the structure and
ensuring that it is usable over its service life. The forces exerted
by water are enormous and its effects are unpredictable. Water
enters the structure through the weakest route. Therefore the
best possible way to ensure waterproofing is to place “multiple
barriers” between water and the living space. A reliable water-
proofing system installed by professionals is essential to achieve
lasting protection from water damage. Much is demanded here
from both the material and its applicators.
The most important aspect for any waterproofing treatment
is its performance. Materials and systems should be tested for
capillary absorption as well as penetration under hydrostatic
The Masterbuilder | July 2015 | www.masterbuilder.co.in
pressure. Such tests are available internationally and materials
can be tested anywhere in the world to adhere to ASTM/EN
standards. In India IS 3085 can be used to test water penetration
under pressure.
Why Waterproofing?
Concrete is a wet table material and has affinity to water.
Water enters the body of concrete through hydrostatic pressure
or capillary action or both. The capillary suction of dry or par-
tially dry concrete can be equivalent to a hydrostatic pressure
through cracks and crevices. Water passes end to end through
concrete, either in the liquid or vapor phase, through intercon-
nected voids. In the concrete, there are gel pores, capillary pores
and entrapped air. Permeability is a function of capillary poros-
ity and water-cement ratio. Permeability of concrete to liquids,
ions and gases is of direct relevance to both its durability and to
204
it sleak - resistance. The basis of waterproofing is thus, to mini-
mize permeability and / or wet table characteristics of concrete.
Concrete by and large offers good resistance to moisture
penetration if recommended procedures were followed in mix
design, workmanship, mixing, transporting, placing, vibration,
and curing. However, conditions may nevertheless, develop
where concrete may further need protection against water in-
gress.
Consequences of Dampness / Leakage
There are several harmful or undesirable effects of leakage
in a building. When water penetrates the structure, corrosion
begins in the reinforcement and cracks develop in the con-
crete. This may cause structural failure later in the life of the
structure. Dampness in floors also leads to health and safety
problems. Unsightly marks appear on the walls due to dampness
and seepage causing discoloration, shedding of plasters and
efflorescence. Dampness attracts and breeds termites or oth-
er biological organisms. With deterioration of concrete and the
reinforcement, the durability of the structure is endangered.
Dampness causes short circuits from electrical installations,
which may act as possible fire hazards. Dampness in labo-
ratories or technical workshop may cause failures or damage
sophisticated equipment.
Waterproofing Principles
Waterproofing is the treatment of a surface or structure to
prevent passage of water into it or out of it. There are various
forces that can act alone or in combination, to force water into
concrete. These forces include hydrostatic pressure, capillary
action, wind-driven rain, difference between vapor pressure
between two sides of concrete or some combination of these.
Waterproofing differs from damp proofing in that the former
consists in the positive prevention of movement of water under
pressure. Water enters the concrete structure through inter-
connected voids and pores, cracks, structural defects or through
faulty joints.
Here it is important to consider, in many projects damp
proofing is expected of the waterproofing system. There is a
clear difference between the two. As per ACI Committee 515
report, waterproofing is a treatment of a surface or structure to
prevent the passage of water under hydrostatic pressure while

damp proofing 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 con-
ditions are to be borne in mind and the material to be selected
accordingly.
Requirements of a Good Waterproofing System
The latest trend in waterproofing will be “Prevention is bet-
ter than cure”. With high demands on durability, the thought
process should turn to preventing water ingress through the
concrete, either by provision of an external membrane or by
manipulating the properties of concrete itself. This method en-
sures that the concrete is protected against water and aggres-
sive media and the structure is protected from failure through
its design life.
This approach also follows the logic that “Waterproofing can
only be as good as the Base Concrete”. Therefore, for new con-
structions, this entails making good watertight concrete and for
restoration projects, the substrate should be brought back to its
initial state. This methodology also follows the Diktat “Put Mul-
tiple Barriers” between the water and the living space / structural
elements for best protection against water. This can be done by:
- Use of Watertight concrete
- Liquid Applied Membranes
Though waterproofing problems are serious and at times
look unsolvable, it has never been a difficult task to ascertain the
reasons for waterproofing failures. Once the investigation is
complete and after proper diagnosis, the waterproofing treat-
ment passes through three distinct phases:
a. Selection of waterproofing systems and materials.
b. Repairs to the existing structure and surface and surface
preparations.
c. Application of specified waterproofing systems or treatments
The steps are intentionally formulated to include repairs
and surface preparation as independent operations, as it has
been observed that this very important step does not receive the
attention it deserves. Many systems involving proper specifi-
cations and proper selection of materials have failed only on
account of improper pretreatment repairs and negligence of prop-
er surface preparation. It is unlikely any waterproofing system
properly applied under efficient supervision cannot guarantee
the desired performance.
The dampness and water seepages are mostly from the
following weak spots and zones:
a. Concrete or masonry constructions of high permeability.
b. Weak spots on account of honeycombing and segregation
in concrete.
c. Cold joints and construction joints.
d. Improper pointing of brickwork or block work.
e. Not providing water stops, water bars etc., wherever necessary
f. Not providing or improper sealing of expansion joints.
g. Cracks during construction due to faculty concreting, faulty
design or natural settlements.
h. Improper bonding at the interface of two different materials
of construction.
i. Non-provision or failure of Damp proofing courses.
CONCRETE: WATERPROOFING
j. Improper surface treatment and wrong selection of coating
materials.
k. Improper provisions of slopes and drainage.
l. Improper sealing of plumbing and sanitary joints.
To address these weak spots, waterproofing materials
should possess following basic requirements:
a. The material should provide water tightness(a combination
of hydrophobicity and impermeability) to the system.
b. The material should have flexibility and elasticity to combat
thermal and other stresses.
c. The material should have excellent bonding and adhesion
properties both to the substrate as well as to ensuing treat-
ments.
d. The material, as far as possible, should retain the breathing
properties of concrete.
e. The material should have abrasion resistance if used as a
topcoat.
f. The material should be easy to apply, preferably free from
solvents, etc.
g. The material should be cost effective.
h. The material should be resistant to algae, fungus and other
microbial attacks.
However, in the actual practice it is quite difficult to locate a
material possessing all above requirements. The fact therefore
becomes quite evident that there can be no universal material
to solve all the problems and only a combination of materials
can be fruitful. Judicial compromises are necessary but the
problems become simpler when the waterproofing treatment
is viewed as system and not as a material.
Stages of Waterproofing
There are four major components to the waterproofing system:
a. Impermeable Base
b. Treatment of Joints
c. Repairs and Surface Preparation
d. Application of Surface Barrier (Cementitious Systems)
a. Impermeable Base
For any kind of structure and especially for structural ele-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
ments like foundations, slabs and shear walls, the main aim of
waterproofing is to prevent the passage of water through the con-
crete. Waterproofing can only be as good as the base. If the base
itself is of very poor quality, no matter what treatment or the most
modern material is applied, the waterproofing is bound to fail.
Quite simply this can be achieved by good concrete technology and
blocking the capillaries in concrete, using the following thought
process:
- Having a dense aggregate gradation using available mate-
rials
- Using high performance PCE polymers, to reduce permea-
bility and Capillarity
- Use of materials like Silica-fume or Aluminosilicate slurries in
concrete
- Use of highly specialized latest generation Integral water-
proofing compounds that work on process of Dynamic Syn-
205
Crystallization® (DySC) technology
 CONCRETE: WATERPROOFING
b. Treatment of Joints
A major impediment to water tightness of concrete is the
drying shrinkage cracks developed if control joints are not pro-
vided. Also there would be random cracking in concrete due to
temperature contractions. If waterproofing is done at very early
stages the cracks will be transferred to rigid surface barriers
and would be major conduits for leakage. Therefore control
joints should be well designed in addition to the unavoidable
construction and expansion joints. Principally each joint is to be
sealed by suitable joint sealants in addition to providing the wa-
ter stops or water bars. Passage of water through joints can
only be arrested by preventing migration or by forming water
seals.
The joints should be properly prepared and the opposite
faces should be parallel. Joint sealing material should be able
to resist the joint movement. Joint covers are usually neoprene
or silicone and should be installed giving due weight age to in-
tersections. It should be remembered that in case of negative
side waterproofing, the water stops and joint sealants are pri-
mary defenses to water tightness.
c. Repairs and Surface Preparation
The surface to be coated must comply with the principles of
building construction and should fulfill the structural require-
ments, including properly designed slopes and drainage system
to avoid stagnation of water. Before carrying out any repairs the
basic principles of civil and structural engineering should be
thoroughly adhered to.
Cracks: First it should be ascertained whether the cracks
are structural or non structural. Secondly it should be estab-
lished whether there is moisture ingress through the cracks
and whether the cracks are moving or non-moving type. The
width and depth of the crack plays a major role in deciding the
material for repairing the cracks. Wider cracks can be cut open
and filled with non-shrink materials having bonding properties.
For finer cracks, injecting and grouting techniques with ep-
oxies, polyurethanes and ready to use polymer grouts can be
used. For leaking cracks, the Primary injection is carried out
with foaming polyurethane resins and the secondary injection
is carried out by low viscosity and flexible polyurethane resin.
Figure 1 shows addressing Cracks by Injections (cementitious
or resin-based)
The Masterbuilder | July 2015 | www.masterbuilder.co.in
206
Figure 1: Injections
Grouting: As a precautionary measure, low permeability
concrete can be cast with low water cement ratios. Cement
grouting techniques can be resorted to densify the concrete.
It is advisable to use a non-shrink admixture in conventional
cement grouts to impart the grout non-shrink characteristics.
Ready to use, polymer modified grouts which are workable at
low water cement ratios develop strengths of about 35 N/mm2
are very suitable for grouting even where the strengths are the
criteria. All joints / voids should be neatly grouted.
Honeycombing: The techniques adopted for repairs of hon-
eycombed patches will depend upon the extent of honeycomb-
ing. If the areas are large, the concrete of same grade as of base
concrete is fully suitable, when the concrete is still green. The
aim should be to make the concrete or mortars non shrink and
incorporate a bonding agent in the system for effective bonding
of old substrate to new repair material. Prepacked, polymer
modified repair compounds, which combine non-shrink, bond-
ing as well as high strength characteristics are more suitable
on account of price considerations as compared to epoxy mor-
tars. Figure 2 shows Filling of afftected / honeycombed areas.
Figure 2 - Repairing Voids
Leakage and seepage spots and zones: Using polymer
modified Quick Setting Plugging mortars can stop leakages.
If water is leaking through cracks, releasing the pressure and
re-routing of water is required before using quick setting plugs
might be necessary. Figure 3 shows application of Quick-Set-
ting Plugging Mortars.
These measures should stop the leakages completely before
application of surface barriers. If leakages are still observed,
PU injections should be resorted to. Water compatible PU in-
jections can also be undertaken as Grid Injections if larger ar-
Figure 3: Quick setting plugging mortar
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 CONCRETE: WATERPROOFING
eas show leakage due to bad and porous concrete. Only after
the leakages are controlled, surface barriers can be applied. In
case of negative waterproofing the repairs should be total. The
repairs should be followed with proper surface preparation de-
pending upon the type of treatment foreseen.
The surface preparation plays a key role in success of any
waterproofing system, whether the materials are conventional
or new generation. Prior to waterproofing it should be ensured
that the surfaces are totally free from remnants of form oils or
curing compounds. The surfaces should be totally free from
loose materials, dust, oil, grease and other contaminations.
Bonding of surface barrier materials has to be ensured. De-
pending upon selected barrier materials, degree of surface water /
moisture content of the substrate is to be checked.
d. Surface Barrier Materials
One of the major parts of waterproofing is the selection and
application of surface waterproofing barriers. The main function
of these barriers is to arrest the passage of water through the
body of concrete either by capillary action or hydrostatic pres-
sures. The surface applied barrier materials are not a substitute
to joint sealants, which are to be applied in the third dimension.
Only few of these materials can be applied both for Positive side
and Negative side waterproofing. The performance of barrier
materials for Waterproofing and Damp proofing should also be
checked for exposure to aggressive soil contaminants.
Though several materials are available as surface protec-
tive systems, the concept of waterproofing has remained the
same, which is the tanking system. Waterproofing acts as pro-
tective envelope to arrest entry of water into the concrete. Built
up bituminous waterproofing membranes were very popular
few years back and they were bonded to the surface either by
self-adhesion cold application or heat welding. Major difficulty
in the application of bituminous or polymeric bituminous mem-
branes was covering the geometry of the structure, overlap-
ping joints and use of moisture sensitive adhesives to bond the
membrane to the substrate.
Liquid Applied Membranes became more popular in the
last decade on account of their ease of application and mould-
ability to form seamless membranes over any curvature. Some
Liquid Applied Membranes are of the non-breathable type and
this would give rise to blisters and craters, which would eventu-
ally affect the barrier performance.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Waterproofing by cementitious slurries is becoming more
popular on account of ease of application, compatibility with
substrate as well as competitive pricing. The slurries are avail-
able in rigid and flexible types. Cementitious slurries are man-
208
Figure 4: Equivalent cover
ufactured by incorporating acrylic polymers either in powder or
liquid form depending upon flexibility required. Old generation
Waterproofing slurries were rigid and therefore were not suit-
able for Waterproofing because of transference of cracks from
base concrete to the Waterproofing system. Availability of new
acrylic raw materials made the formulations of flexible water-
proofing slurries possible to counteract the rigidity factor.
Crack bridging characteristics is one of the most important
criterions for the flexible slurries as well as chloride diffusion
is an added feature for underground structures. These slurries
are of breathable type, which contribute to better waterproofing on
account of no blistering and bubbles. There are other properties
imparted to waterproofing slurries like crystallization. However,
some data of testing available concludes that this property is not
established with respect to permeability testing. The crystalline
and chemical coatings react chemically with the free lime in ce-
ment in presence of moisture and provide capillary repellency.
Small shrinkage cracks are also autogenously healed. Careful
surface preparation is the key to success of these cementitious
waterproofing slurries. The biggest advantage of waterproofing
slurries is its ability to adhere to damp, wet or moist surfaces.
Another benefit, these waterproofing membranes provide is
equivalent cover to concrete. For e.g. MC’s 2-Component Flex-
ible Cementitious Elastic Material at 2mm thickness provides a
cover equivalent to 72 cm of well-compacted M30 Concrete. This
feature allows these materials to be used in repair and protec-
tion projects apart from waterproofing applications.
Some Additional properties / advantages of 2 component
cementitious Liquid applied Membrane Forming Systems include:
- Crack bridging
- Breathable
- Thermal resistance
- Water tight
- Easy application to both dry and moist surfaces
- Good bonding to the substrate
- Resistant to aggressive waters, chlorides, sulphates, etc.
One disadvantage of this material is resistance to abrasion,
which can be very easily addressed by means of a waterproof
plaster, screed or tiling system.
Applications for these kind of membranes are multifold, in
basements, wet areas, swimming pools, tanks, dead walls, ter-
races, terrace-gardens, structural elements and so on. The main
point to remember while using a slurry-applied membrane is
the correct detailing of joints, water stops and interfaces (cov-
ings) between horizontal and vertical surfaces.
Figure 5: Bathroom Detail
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 CONCRETE: WATERPROOFING
Figure 6: Basement detail
Figure 7: Swimming pool detail
Flexible 2 component cementitious systems, when used in
conjunction with injection grouting, crystallization based water-
proofing slurries, waterproof plasters, tile adhesives, etc. and
applied over good concrete fortified with a Dynamic SynCrys-
tallization Based Integral Waterproofing Additive, has shown
tremendous success over the last decades. As always, detailing
is the key to successful application. Figures 4, 5 and 6 show in-
depth detailing for basement structures, wet area bathrooms
and swimming pools. Using the same material systems with
varied detailing can help enhance durability of waterproofing on
The Masterbuilder | July 2015 | www.masterbuilder.co.in
key-projects.
210
Figure 8: Importance of WP detailing
Conclusion
Today’s specifier or constructor has innumerable materi-
als at his disposal, each claiming to be the best. Most of these
materials are characterized by generic properties. These prop-
erties are suitable for Quality Control to produce batch certifi-
cates, but do not address the waterproofing system as a whole.
The best waterproofing system is made of Good Base, Good
Material and Good Application.
The success of waterproofing system depends not only on
the materials alone, but also more on application and under-
standing limitations of the materials in question. Rather than
asking for Guarantees from applicators, which has not stopped
failures, the adherence to Quality Assurance systems should be
reverted to. Guarantees can only be asked from bonafide, qual-
ified and authorized applicators. There are quasi-governmen-
tal institutions abroad, e.g. BZB in Germany, which issues IRP
certificates to trained, qualified applicators. Such qualifications
should form a part of specifications. Under most circumstanc-
es the concrete cast should be Waterproof High Performance
Concrete, keeping in mind the “prevention is better than cure”
motto. Even for such materials test certificates conforming to
international codes and certified by bonafide agencies must be
procured.
Finally, it is the best practices to be followed in construction,
which will ensure that the longevity of the structure is main-
tained and the structure is cost effective over its design life. w
 GROUND REPORT
SDLG Wheel Loaders:
Enhancing Productivity of Gangavarm Port
F
or centuries ports have played an
extraordinary role in the growth of
International trade, which in turn
has boosted numerous economies. Inter-
estingly, the words export and import too
are incomplete without port.
The scenario is the same in India where
ports have a predominant existence.
Located along the 7000 plus km peninsu-
lar coastline, these are hubs of growth.
Efficient handling of cargo to the tune of
almost 500 million tonnes annually sub-
stantiates the same. Also, investments to
the tune of $10 billion in various port pro-
jects are an indicator of the major trans-
formation and upgradation this industry is
undergoing. And with the Government of
India inviting private sector participation
in development of port infrastructure, this
growth trend is augmenting manifold.
That brings us to Gangavaram Port, a shin-
ing example of how a private sector player
can take port infrastructure to the next
level.
Excellence in the Making
Gangavaram Port is situated in
Visakhapatnam, Andhra Pradesh along-
side the Bay of Bengal. With a depth of 21
meters, this is the deepest port in India.
The Masterbuilder | July 2015 | www.masterbuilder.co.in
214
Ship unloader at Gangavaram Port
The port was awarded toa consortium led
by Mr. DVS Raju through an international
bidding process in the year 2003. It began
construction in 2005 and commenced
operations in 2008. Mr. V Janardhana
Rao, Director of Operations, Gangavaram
Port says “It's been 7 years since we
began our journey. With our technological
advancement and state-of-the-art facili-
ties today we are operating at par with the
best in the world. Together as a team of
highly dedicated professionals and
experts today we strive to be the leading
port in South East Asia.” Emphasizing on
the same, he says “Each day comes with
its share of challenges and opportunities.
And I can proudly say that we've managed
to convert more and more challenges into
opportunities. Growing and excelling in
the process.”
Running a Tight Ship
With the rich experience of Mr. V
Janardhana Rao and staunch support
from all the employees, Gangavarm Port
has progressed substantially. Mr. V
Janardhana Rao says “Being the deepest
port in the country comes with its own
share of responsibilities. We handle more
than 60 cape size vessels of upto 200000
DWT annually. Only a few ports in the coun-
try can claim to do the same.” He contin-
ues, “In 2014-15, the port started it's func-
tioning with 5 berths and extended to 9
berths on which we handled around 20.75
MMT with a growth rate of 31% over 2013-
14. Though the tonnage represents an
admirable performance, it does not
depict the entire picture. Considering that
we achieved these numbers despite being
pulled back due to Cyclone Hudhud, it is
remarkable.” When asked more about
the hardship they went through.
“It's been 7 years since we
began our journey. With our
technological advancement and
state-of-the-art facilities today
we are operating at par with the
best in the world. Together as a
team of highly dedicated
professionals and experts, we
strive to be the leading port in
South East Asia.”
Mr. V Janardhana Rao
Director of Operations, Gangavaram Port
Mr. V Janaradhan Rao says “It came to
a point where our port was expected to be
shut down for 3-4 months. But we turned
the tide. The entire team was here and you
could feel more energy inside the port
than outside. With sheer dedication of our
employees and support of the contrac-
tors, we were up and running in just 19
days after Cyclone Hudhud.”
He continues “This was one of the many
reasons that propelled us to expand. And
so we did. Today we have 9 ultra modern
berths. Out of which there are three mech-
anized berths equipped with ship
 GROUND REPORT

unloaders & loaders and closed conveyor

systems. Now our tonnage handling ca-
pacity is 45 million tonnes. Which means
we will depend even more on our contrac-
tors to deliver results. Just like how they
have been doing uninterruptedly in the
past.”
Talking more about the role of contrac-
tors he says “We at Gangavaram Port treat
contractors like our shareholders. We
believe we cannot achieve our goals with-
out their backing. And from the time we
began operations all of our contractors
have continued to do business with us till
date. That is how much we value our rela-
tionship with them.”
Unloading in progress at the port

Responsible work culture

SDLG wheel loader in action at the prot
On time, Every time
V Janardhana Rao says “At Gangavaram
Port we value the time factor most. Whether
it is pre-berthing, unloading/loading or
discharging of goods we are always on our
toes to ensure they happen efficiently. This
results in a lot of savings on freight costs.
And it has been the trend since the begin-
ning. Gangavaram Port is one of the few
Greenfield port projects in India to have
been implemented on schedule. Consid-
ering the magnitude of this sector it is a
commendable feat.”
Further he says “Timely delivery and
efficiency are the main ingredients for suc-
The Masterbuilder | July 2015 | www.masterbuilder.co.in
Ship loader at the port
cess in our field. This is the prime reason
why we got associated with SDLG. The
SDLG team provides us equipments,
spare parts and support at the right time,
which is very critical in our work. Their
effort to serve us the best always is appre-
ciable. Their machines and services are a
reflection of the same. Currently we use
15 SDLG Wheel Loaders which include
LG979 & LG958 - models that deliver
great performance and enhance produc-
tivity every time.”
Talking about the role of Gangavaram
Port for the betterment of society and envi-
ronment Mr. V Janardhana Rao says “We
consider it as our duty to give back to the
environment and society. Employment
opportunities for villagers in and around
our port, continuous air quality, Marine
water /sediment, noise & ground water
quality monitoring and tree plantation
drives are some of the activities we under-
take at regular intervals. Also, we ensure
healthy work environment at the port.” He
continues “We have sprinklers to ensure
cleanliness all around. These cover a
radius of 120 meters and are 50 meters in
height. The mist technology ensures a
long lasting effect.”
Here is where growth is.
Mr. V Janardhana Rao concludes by
saying “At Gangavaram Port there are growth
opportunities for everyone associated and
we aspire to create more in the future.”

BASF Researcher, Roberta Magarotto Honoured for her

Contribution to Concrete Research
R oberta Magarotto, Director of Development at BASF Construction Chemicals Europe, has received an
award of the Committee for the Organization of International Conferences for her outstanding contribu-
tions in the area of concrete technology and chemical admixtures. The award was presented at the International
Conference on Superplasticizers and Other Chemical Admixtures in Concrete in Ottawa, Canada, on July 15.
The award recognizes internationally known scientists, engineers and researchers who have made significant
and sustained contributions in the subject area of the current conference. Roberta Magarotto started working
for BASF in 1994 after her graduation in Industrial Chemistry from the University Ca’Foscari in Venice. From the
beginning her focus was on concrete additives, especially on the development of new water-reducing polymers
and on new technologies for the construction industry. Her team was first to develop water-reducing additives
for concrete based on polycarboxylate ether – a technology with a demand which is still growing worldwide.
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