JCB India Ltd

JCB India Ltd

Cover
Tac System Formwork Sdn Bhd
Tac System Formwork Sdn Bhd
Vimtech corporation
JSW Serverfield Structures Ltd
Metecno India Pvt.Ltd
Hyundai Construction Equipment India Pvt.Ltd
Fayat India
Gandhi Automations Pvt.Ltd
EDITOR'S COMMENT
Your feedbacks are welcome and
should be sent to: The Editor,
The Masterbuilder, 102/11
(New No. 46/11), Tripti Apartments,
Marshalls Road, Egmore, Chennai,
In Carnival Mode India. Phone: +91 44 28555248
Telefax: +91 44 28586703

T he global construction industry's output is all set to reach a

phenomenal US$ 12 trillion by 2020, a 70% increase from this
year's figure of US$ 7.2 trillion, according to a recent report by Global
Editor-in-Chief
K.P. Pradeep
editor@masterbuilder.co.in
Vice-Chairman
Construction Perspectives and Oxford Economics. It comes as no K G K Moorthy
kgk@masterbuilder.co.in
surprise to many to find India amongst the big boys of global
Director Editorial, Construction Chemicals
economy vis-à-vis China and the US to be partly responsible for half Dr. Y P Kapoor
of the US$ 4.8 trillion increase in output. Editor-in-Charge
Ravi Damodaran
Not in awe for the reason that it is perceptible to the world that the Sub-Editor
Indian Infrastructure sector is passing through one of its most exciting Nigel Narayan
Head - Content Development CE,
periods in history. The need for world class infrastructure, which is so Infrastructure & Environment
crucial for growth and development has never been felt so strongly Sadagopan Seshadri
before by policy makers. Infrastructure projects such as nuclear Contributors
Bhavani Balakrishna, Saadat Ali, Sanjay
plants, mass public transport systems, expressways, highways,
Staff Correspondent
flyovers, and world class airports that will empower our dreams are M.K. Prabhakar
being envisioned keeping in mind the long term perspectives. Vice President Marketing
H. Usha Devi
Expansion in areas of rural infrastructure, irrigation, water resource Head-New Media Initiative
management and environmental engineering is expected to get top Pradeep Nair
Credit Controller
priority in the 12th five year plan, as the UPA realigns itself to make G.B. Muralidharan
growth truly inclusive by reaching out to rural areas. India's water Finance
market is one of the largest in the world with an annual growth rate R. Prema
nearing 20%. The PPP model will be critical to accelerate growth and Manager Digital Production
K. Sravanthi Kiran
increase output and efficiencies in this sector. In addition, significant Manager Digital Media
steps to foster infrastructure growth in our country are innovative Lakshmi
measures like long term contractual partnership between private and Creative Head
S. Nithiyanandam
public sector agencies, specifically financing, designing,
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Printed By
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H & K Rolling Mill Engineers Pvt.Ltd
Contents

Editor's Comment.......................14
News & Events............................20
CE: Road Construction E-Scape.....................................228
Extreme Utility Machines In Large Earthmoving Projects
M.K. Prabhakar 144 Classifieds.................................207

36 Building Information Modeling

The Battle to Bring Buildings Back to Basics
94 Infrastructure: Nuclear Plants
India's Ambitious Plan Electricity Production
Emma Stewart, Ph.D. By Nuclear Reactors
Dr. Prabhat Kumar,Distinguised Scientist & Project Director, Bhavini
L. Swamy Raju, Additional Chief Engineer (Civil), Bhavini
V. Manoharan, Additional Chief Engineer (Civil), Bhavini

44 Seismic Retrofit: Case Study

Seismic Rehabilitation of Historic Concrete Structure
with Fluid Visco-Elastic Dampers 116 Infrastructure: Nuclear Power Plants
Opting for Nuclear Power ? Be Clear & Design Smart
Kit Miyamoto, M.S., S.E., President & CEO, Lon M. Determan, S.E., Project Sadagopan Seshadri, Chief - Content Development,
Manager Amir Gilani, PhD, P.E., Project Engineer, Marr Shaffer & Miyamoto, Inc. CE - Infrastructure - Environment
West Sacramento, CA, Robert D. Hansen, PhD, P.E.,
Professor Emeritus University of Michigan Walnut Creek, CA

124 CE: Events

CONEXPO-CON/AGG
56 Corrosion Resistance: Marine Structures
Design Considerations for Durability of Reinforced Concrete
Show Lifts the Spirits of US Construction Industry
Amith Indurthi, Resident Correspondent, USA

Structures in Marine Environments

Atef Cheaitani,Chief Technology Officer Savcor Group Ltd, Sydney, Australia
M N Ramesh,Chief Executive Officer Savcor India Private Limited, Bangalore, India 128 Road Construction Equipment: Industry Analysis
Road Construction Equipment Sector Ready for the Bull Run
Bhavani Balakrishna

64 Repair : Polymer Modification

Flexible Polymer-Cement Repair Materials and their
Applications
138 In Conversation
Executive Briefing' A Chat with JCB's Chief Alchemist Vipin
Ivan Razl, Ph.D., P.Eng. Gemite Products Inc., Mississauga, Ontario, Canada Sondhi

74 Corrosion Control: Technologies 142 New Roll Out

JCB Rolls Out New Diesel Engine for Off-Highway Vehicles
Emerging Corrosion Control Technologies for Repair and
Rehabilitation of Concrete Structures*

144
Dr. Qiu Jianhai, BEng PhD CEng MIMMM FICorr, NACE Certified Corrosion
Specialist (#5047) WebCorr Corrosion Consulting Services CE: Road Construction
Extreme Utility Machines in Large Earthmoving Projects
M.K. Prabhakar

90 Post Event Analysis

2nd International Conference on Construction Chemicals
Speakers Highlight Role of Construction Chemicals for a
150 CE: Technology
High-tech Road Building Intelligent Compaction Shows the Way
Sustainable Tomorrow Special Correspondent

94 150

44 128
14 The Masterbuilder - April 2011 | www.masterbuilder.co.in
PNP Polytex Pvt.Ltd
Contents

156 Earth Moving Equipment: New Technology

Automatic Navigation Control Systems in Earthmoving
200 CE: Company Focus
Mobile Crushing, Screening and Washing Equipment
Equipment Breaking New Ground from Powerscreen
Special Correspondent

204 Spotlight
162 Infrastructure: Highways
Paving the Way to the Future
Gmmco-Caterpillar Celebrate 25 Years of Partnership

M.K. Prabhakar

208 CE: Finance

170
Analysing Asphalt Plants' A Key Ingredient to Success
Heavy Engineering Blesson Varghese, Director, Marini in India
Hoover Dam Bypass An Engineering Marvel
Bhavani Balakrishna
212 Profile
Liugong India Eyes US$ 175 Million Annual Revenue by 2012
176 Modular Building: Rating
Modular Building and the USGBC's LEED™
Special Correspondent 214 Industry Interaction
TIL Introduces Double Barrel Technology to India
R Nandagopal, Vice President Equipment & Project Solutions, TIL Limited

183 Awards
Design of Place Lalla Yeddouna in Fez - Competition Winners
[A part of material handling solutions division]

Announced
218 Profile: Shoring System
STAXO 40 The Lightweight, Economical, Safe and Efficient

184 Flooring
One Day Flooring
Shoring System

Subash Cipy, Managing Director, Cipy Polyurethanes Pvt. Ltd

220 Construcion Chemicals: Company Focus
Don Construction Chemicals India Ltd now

190 Face to Face

Industry Interaction “DURAmembrane is a versatile material”
Part of DCP International

222
Mr. Ajay Mohta, General Manager Construction Accessories Division,
The Supreme Industries Ltd. Automated Doors
Smart Reset Self-Repairing Automatic Flexible Door

194 Disaster Management

Putzmeister @ Fukushima Nuclear Plant
223 Equipment: New Roll Out
New High Pressure Concrete Pump from REL
196 Buzz
Construction Chemicals Industry Captains See
Happy Days Ahead
Akhil Kakkar, General Manager, Kryton Buildmat
224 Viewpoint
ERP for SMEs
Kunal Mehta, Managing Director, SKG Equipments Pvt. Ltd.

198 Technology: E-Surveying

E Surveying Solutions Simplifying
Survey Engineering Drawings
226 Site Report
Putzmeister M32 at work in Alakhnanda Hydro Project

162

156 194 212

16 The Masterbuilder - April 2011 | www.masterbuilder.co.in
 Contents

Advertisers Index___________________________
A Hess Concrete Machinery Rockwool (India) Ltd 173, 175
India Pvt.Ltd Back Cover
Action Construction S
Equipment Ltd 137, 139, 141 Hormann India Pvt.Ltd 199
Savcor India Private Limited 55
Ajax Fiori Engineering (I) Pvt.Ltd 81 Hyundai Construction Equipment
India Pvt.Ltd 9 Schwing Stetter (I) Pvt.Ltd 45
Amogha Road Equipment 203
J SEC-RJMT Engineering Pvt.Ltd 187
Asons Enterprise 131
JBA Concrete Solutions Pvt.Ltd 159 Seven Hills Safety Equipments
Apollo Infratech Pvt.Ltd 31,39 and Systems (P) Limited 207
B JCB India Ltd Flap
Silicone Concepts Int'l.Pvt.Ltd 101
JSW Serverfield
Bridge Seminar 121
Structures Ltd Front Cover- 2 Simpson & Co.Ltd 119
Bomanite India 147
K SKG Equipments Pvt. Ltd. 225
C
Kamaz Vectra Motors Ltd Back Inner Sleek Boards India Ltd 111
Case Construction Equipment 21
Kryton Buildmat Co.Pvt.Ltd 29 Soilmec Foundation Equipment
Cemseal System & Sales Pvt.Ltd 27
L
(Webac) 187 Speedcrafts Ltd 161
Lipi Polymers Pvt.Ltd 61
Cico Technologies Ltd 59 SSA Techno Construction Pvt. Ltd. 207
Liugong India Pvt.Ltd 85
Cipy Polyurethanes Pvt.Ltd 53
Lucky International 91 STP Ltd 107
Chetra Machinery India Pvt.Ltd 63
M T
Columbia Pakona Engineering
Machines & Engineering Company 113 Tac System Formwork
Pvt.Ltd 203
Sdn Bhd Gatefold
Cosmos Construction Machineries Maco Coporation India Pvt.Ltd 173
& Equipments Pvt.Ltd 179 Terex India Pvt.Ltd 71
MB subscription form 211
Cosmos Sales Corporation 153 TIL Ltd 73
Metecno India Pvt.Ltd Front Inner- 2
D The Supreme Industries Ltd 41
MM Castings (P) Ltd 127
Dextra India Pvt.Ltd 197 Tunnel Design & Construction
N (IQPC -Singapore) 215
Doka India Pvt.Ltd 19 Nicomac Doors Pvt. Ltd 175 Toshniwal Systems & Instruments
Don Construction Chemicals P
India Ltd 49 Pvt.Ltd 193
Partnership Contracting U
E (Hongkong) 217
E Surveying Solutions 199 Unipave Engineering Products 103
Pidilite (Dr.Fixit) 77
Ermotec International Pvt.Ltd 203,225 Universal Construction Machinery
PNP Polytex Pvt.Ltd 15
& Equipment Ltd 155
Esquire -CMAC Pvt.Ltd 123, 165,197
Putzmeister Concrete Machines
Unisteel Engineering Works 97
F Pvt.Ltd 23
Unitech Exhibitions - Roof India 221
Fayat India 10 R
G Ramtec 207
V
Gandhi Automations Pvt.Ltd 11 RD Mining Equipments Pvt.Ltd 89 Viki Industries (P) Ltd 135

Greaves Cotton Ltd 67 Reliance Industries Ltd 169 Vimtech Corporation Front Inner- 1

H Revathi Equipment Ltd 93 W

H & K Rolling Mill Engineers Pvt.Ltd 13 Relyon Facility Services 207 Wirtgen India Pvt.Ltd 35

The Masterbuilder - April 2011 | www.masterbuilder.co.in 17

Contents

Advertisers Index / Classification_______________

Concrete Block Making Machinery Terex India Pvt.Ltd 71
Hess Concrete Machinery India Pvt.Ltd Back Cover Roofing
Machines & Engineering Company 113 Doors-Automatic Metecno India Pvt.Ltd Front Inner- 2
Columbia Pakona Engineering Pvt.Ltd 203
Gandhi Automations Pvt.Ltd 11 Lipi Polymers Pvt.Ltd 61
Hormann India Pvt.Ltd 199 Lucky International 91
Concrete Pipes
Nicomac Doors Pvt. Ltd 175
Apollo Infratech Pvt.Ltd 39
Roofing Fastners
Dozers Asons Enterprise 131
Concrete Pump Manufacturers
Putzmeister Concrete Machines Pvt.Ltd 23 Chetra Machinery India Pvt.Ltd 63
Rubber MDF
Schwing Stetter (I) Pvt.Ltd 45
Sleek Boards India Ltd 111
Facility Services
Construction Chemicals Relyon Facility Services 207 Scaffolding
Don Construction Chemicals India Ltd 49
Cosmos Sales Corporation 153
Cemseal System & Sales (Webac) 187
Fire and safety Equipments
Seven Hills Safety Equipments and Systems (P) Software
Construction Equipment
Limited 207 E Surveying Solutions 199
Greaves Cotton Ltd 67
Splicing Systems
Flooring Dextra India Pvt.Ltd 197
Construction Equipment &
Machinery Bomanite India 147
Steel Structures
Action Construction Equipment Ltd 137, 139, 141 Cipy Polyurethanes Pvt.Ltd 53
JSW Serverfield Structures Ltd Front Cover - 2
Ajax Fiori Engineering (I) Pvt Ltd 81 JBA Concrete Solutions Pvt.Ltd 159
Amogha Road Equipment 203 Reliance Industries Ltd 169
Tensile Membrane
Apollo Infratech Pvt.Ltd 31 Lucky International 91
Case Construction Equipment 21 Formwork
Chetra Machinery India Pvt.Ltd 63 Doka India Pvt.Ltd 19 Thermal Insulation
Cosmos Construction Machineries & Tac System Formwork Sdn Bhd Gatefold Rockwool (India) Ltd 173, 175
Equipments Pvt.Ltd 179
Fayat India 10 Foundation Equipment TMT
Hyundai Construction Equipment India Pvt.Ltd 9 Soilmec Foundation Equipment P.Ltd 27 Viki Industries (P) Ltd 135
JCB India Ltd Flap Green Building Materials
Liugong India Pvt.Ltd 85 Ramtec 207 TMT-Technology Suppliers
Machines & Engineering Company 113 H & K Rolling Mill Engineers Pvt.Ltd 13
Revathi Equipment Ltd 93 Material Handling Equipments
Schwing Stetter (I) Pvt.Ltd 45 Esquire - CMAC Pvt.Ltd 123, 165,197 Truck Manufacturers
SEC-RJMT Engineering Pvt.Ltd 187 Maco Coporation India Pvt.Ltd 173 Kamaz Vectra Motors Ltd Back Inner
SKG Equipments Pvt. Ltd. 225
Speedcrafts Ltd 161 OEM Suppliers Turbine Ventillators
TIL Ltd 73 Ermotec International Pvt.Ltd 203,225 PNP Polytex Pvt.Ltd 15
Toshniwal Systems & Instruments Pvt.Ltd 193 MM Castings (P) Ltd 127
Unipave Engineering Products 103 Simpson & Co.Ltd 119 Waterproofing
Unisteel Engineering Works 97 Cemseal System & Sales (Webac) 187
Universal Construction Machinery & Particle Board Don Construction Chemicals India Ltd 49
Equipment Ltd 155 Sleek Boards India Ltd 111 Kryton Buildmat Co.Pvt.Ltd 29
Vimtech Corporation Front Inner- 1 Pidilite (Dr.Fixit) 77
Wirtgen India Pvt.Ltd 35 Repair and Rehabilation Silicone Concepts Int'l.Pvt.Ltd 101
Cico Technologies Ltd 59 SSA Techno Construction Pvt. Ltd. 207
Crushing Equipment Pidilite (Dr.Fixit) 77 STP Ltd 107
RD Mining Equipments Pvt.Ltd 89 Savcor India Private Limited 55 The Supreme Industries Ltd 41

18 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Doka India Pvt.Ltd
News & Events
CONSTRUCTION EQUIPMENT
Indian Market Helps in
World Construction
Equipment Market
Upturn
The increase in construction equip-
ment sales in India, China, North
America, Western Europe, and Japan
has attributed to the world construc-
tion equipment market being on the
upturn to the levels of 2007.
The market for construction
equipment in these regions is expected
to grow + 8.5 percent in 2011 and
touch 8, 07,665 units, according to
the research done by Off-Highway
Research. The previous high witnessed
by the market was in 2007 when a
volume of 7, 82,661 units were sold all
over the world.
According to the research the
resurgence is being led by the remark-
able growth in the India and Chinese
markets. The two markets are
expected to account for not less than
70 percent of the construction equip-
ment sales in 2011. This is a substan-
tial increase compared to the figure of
40 percent in 2007.
The Indian market enjoyed a
growth rate of + 4.5 percent with
59,322 units being sold. While the
growth rate of the Indian market is
expected to zoom to + 19.3 percent, it
is expected to remain a more modest
+6.7 for the Chinese market.
20 The Masterbuilder - April 2011 | www.masterbuilder.co.in
The research survey indicated that
the Indian market would become a
potentially 11, 00,000 units market
by 2015. The survey also pointed out
to the fact that India is the third
largest equipment market in the world
after China and the United States.
Testing Times for
Japanese Construction
Equipment Majors
The recent devastating earthquake
in Japan has caused extensive damage
to some of the country's major
construction equipment factories. Big
names including Hitachi and
Komatsu have seen their production
being disrupted.
With India being one of the
dependent markets on Japanese
exports when it comes to construction
equipment, the impact is also likely to
be felt here in a few days' time. Five of
Hitachi's factories are said to have
suffered damage in the quake.
Komatsu is also reported to have
suffered damage to its heavy equip-
ment plants located in various parts of
the country. Kubota is another big
name that has a presence in the
affected region, but the company has
not come out with any official reports
about any damage.
CNH Acquires Full
Ownership of Indian
Construction Equipment
Joint Venture
CNH, which is the parent of Case
and New Holland, two leading brands
in the construction equipment domain
has now consolidated its position in
the growing Indian market with the
buyout of Larsen & Toubro's (L &T)
stake in their joint venture.
The joint venture includes a wide-
spread distribution network of 56
dealers and 144 outlets, apart from a
modern production facility in
Pithampur, near Indore in Madhya
Pradesh. The company has announced
that it would rename the business
'Case New Holland Construction
Equipment India', hitherto and would
continue to come out with new
product offerings apart from strength-
ening its presence in the country.
Speaking on the development,
CNH Global President and CEO Mr.
Harold Boyanovsky remarked “This is
an important step in our long term
commitment to consolidate our
construction equipment business in
India and in other export markets and
to develop a manufacturing base in
India fully integrated in the CNH
worldwide industrial footprint.”
Mr.Boyanovsky further added that
"The Pithampur plant will be in a posi-
tion to make the most of the opportu-
nities for growth that the sector offers
today and in the future.” The plant is
currently being used for the manufac-
ture of vibratory compactors and
backhoe loaders. The new venture
now joins CNH's agricultural equip-
ment base in India, New Holland Fiat
India.
Terming the development of the
company's decision to exit the joint
venture Mr.J.P,Nayak, President of L
& T said that it is part of the stream-
Case Constructions Equipment
News & Events
CONSTRUCTION EQUIPMENT
lining process. "We have an excellent
relationship with our partner, and wish
them all success in India”, he added.
Ashok Leyland Aims Big
Vinod Dasari- MD- Ashok Leyland Ltd.
"We will adopt a multi-pronged stratergy."
Ashok Leyland's new Managing
Director Mr.Vinod Dasari has told
media personnel that the company
will strive for doubling its sales of
trucks in the next five years and also
aim for a slot in the top ten truck
companies in the world.
The company put up an impressive
performance with sales of 94,100 vehi-
cles in 2010-11. The target achieved
by the company gives it a rank “close
to 20” among global truck makers.
The company's board has set ambi-
tious targets for attaining a position
among the top ten truck makers in the
world.
“This will effectively mean
doubling our current sales,” said Mr
Dasari, who took over as the
Managing Director from
Mr.R. Seshasayee. Mr. Dasari also said
that the company would be launching
the “Avia' medium duty vehicles in the
country in a year's time.
Among other observations,
Mr. Dasari said that the company,
apart from aggressively promoting the
Ashok Leyland brand is also consid-
ering an entry into the boat building
industry.
22 The Masterbuilder - April 2011 | www.masterbuilder.co.in
SC Notice to
Indo-Italian JV
The Supreme Court has issued
notices to Italian firm Ansaldo Caldaie
Boilers and its Indian partner
Gammon India over an appeal , that
was filed by power major, NTPC,
seeking restriction of the joint venture
from participation in a Rs.15,000
crore tender for super-critical power
equipment.
A Delhi High Court verdict earlier
had permitted the joint venture to
participate in the bidding process for
the supply tender. A bench consisting
of Justices Cyriac Joseph and Altamas
Kabir remarked that it would pass
orders only after proper hearing of all
the parties concerned.
Solicitor General Gopal
Subramanium, appearing for NTPC
said that the joint venture was formed
for supply of super-critical power
equipment to the state-run company.
However, the bid was rejected by
NTPC since the Italian firm did not
have the capacity to design the partic-
ular equipment and did not fulfil the
minimum criteria that were stipulated
as part of the techno-commercial
tender.
Senior Advocate, Gopal Subramanium
Senior Counsel Mukul Rohatagi,
appearing for the Italian firm argued
that the firm had all the requisite expe-
rience and had fulfilled all the parame-
ters to participate in the bidding
process. NTPC would maintain status
quo on the tendering process till the
issue was resolved according to the
Solicitor General.
Chennai-based ACB India is a JV
between Ansaldo Caldaie, an Italian
boiler manufacturer, and Gammon
India, which holds a 73.4 per cent
stake.
Industry Majors Demand
Environmentally Positive
Regulations
Environmentally positive
construction equipment by 2020 is
what has been demanded through new
regulations by leading players in the
domain. With increasing focus on emis-
sion control norms, manufacturers are
now under pressure to come out with
machines that are compatible with the
seemingly ever-changing norms.
A new set of tough regulations has
been demanded by the industry to
ensure that construction machines
make a positive contribution to envi-
ronment, carbon dioxide emissions,
and noise pollution. There has been
growing demand for construction
machines that emit fewer pollutants.
The new regulations are aimed at
producing construction equipment
that will mandate zero emission of
particulates, carbon monoxide and
hydro carbons from 2020.
Similarly, the regulations are
sought to make the machines not only
quiet, but also ensure that they absorb
any extraneous noise from their imme-
diate environment. The regulations
also aim to ensure that radical new
laws are implemented in order to
ensure that machines are built using
low carbon materials.
Putzmeister Concrete Machines Pvt.Ltd
News & Events
INFRASTRUCTURE
POWER
Tata Power
JV Bags 236 MW
Hydropower Project
Anil Sardana, MD, Tata Teleservices,
“this project further contributes to our
clean fuel portfolio and reinforces
our sustainability agenda.”
Tata Power has announced that its
consortium with SN Power, a Norway-
based firm, has won the rights to build
a 236 MW hydroelectric power plant
in the northern part of India.Tata
Power and SN Power Norway entered
into an exclusive partnership in 2009
to develop hydro-power projects to
meet the increasing demand in India
and Nepal through the provision of
clean energy.
The company in a statement said
that the Dugar Hydroelectric project
in Himachal Pradesh would be devel-
oped through a special purpose vehi-
cle. A detailed exploration and design
study will then be taken to plan and
finalise the project implementation.
The pre-implementation agreement
will be signed with the Directorate of
Energy, Himachal Pradesh govern-
ment. It however, did not disclose the
financial details of the project.
Tata Power's managing director,
24 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Anil Sardana,said "this project further
contributes to our clean fuel portfolio
and reinforces our sustainability
agenda. Our association with SN
Power has been fruitful and rewarding
and is in line with our growth strategy
to build global relationships and part-
nerships with the organisations which
are leading performers in their field."
` 6, 000-cr Thermal
Power Project Beginning
to Take Shape
A 6,000 crore thermal power plant
project is going to come up in
Adilabad district of Andhra Pradesh.
The project will mark the stepping
into the power generation domain by
state-owned Singareni Collieries Co
Ltd (SCCL), which was till now
majorly in coal mining projects.
Financial closure for the project has
been achieved according to media
reports. The total debt component of
Rs.4,000 crore for the proposed 2 x
S NarsingRao, Chairman & MD,
Singareni Collieries
600 MW power project will be
provided by the Power Finance Corpo-
ration (PFC), according to Mr. S
NarsingRao, the Chairman and
Managing Director of the company.
The project is likely to be
completed and be operational by April
2014.
RAILWAYS
US$ 250 mn ADB Loan
for Bangalore Metro
The Asian Development Bank
(ADB) has loaned an amount of
US $ 250 million for the Bangalore
metro project to the Indian government.
The project which is scheduled for
completion in 2013 will consist of 42.3
km of track, equipment, sleek new
stations, and rolling stock for the two
key routes that it will cover in the
Indian IT capital.
Bangalore Metro Rail Corporation
is the special purpose vehicle which has
been formed to carry out the project.
Japan International Cooperation
Agency has also provided funds for the
project. Loans from commercial
sources are also being utilized for the
project.
New Hurdle for
Hyderabad Metro Project
A new hurdle seems to be crop
from seemingly nowhere for the
Hyderabad Metro Rail (HMR) project,
almost every passing day. If it was shop
owners who didn't want the line to be
passing close to their buildings some
time ago, it is now the time of founda-
tion stone ceremony, which could
potentially delay the project.
 News & Events

INFRASTRUCTURE

During FY11, around 5,000 km of

road construction was awarded, which
was much below the targeted 9,000
km mark. “However, this is the
highest awarding done so far in the
history of NHDP. This translates into
approximately 14 km per day, versus
the initial target of 20 km per day,”
says a Sharekhan report offering some
optimism to the beleaguered sector.

With the state government keen to Industry experts believe that

invite the Prime Minister
Dr. Manmohan Singh or UPA Chair-
person Mrs. Sonia Gandhi for the foun-
dation stone laying ceremony, officials
fear that they would need to wait at
least for two months since it is tough to
secure the appointment of the VVIPs.
Incidentally the concessionaire L & T
had achieved the financial closure for
`16,375 crore in a record six month's
time for the project.
The project has been facing delays
right from the time the contract was
awarded to Maytas in 2008 and subse-
quently terminated resulting in fresh
bids and the award of the project to
L & T in 2009. There were recently
protests against the metro project
from some sections which were of the
view that the line would mean the
demolition of some heritage buildings.
ROADS
Road Projects set
to be Focus Area in FY'12
The road sector is showing sure
signs of revival, thanks to the criticism
of the government on that front from
all quarters, according to industry
experts. The signs are visible from the
fact that bidding for new road projects
by the National Highway Authority of
India (NHAI) has gained momentum
recently, after the lull experienced last
year.
though tough, it is possible to achieve
the much touted target of executing
20 km a day by FY 13. Although a
Herculean task, it is believed that with
better handling of land acquisition
issues, the required pace can be main-
tained.
Aggressive bidding is expected
once the process for awarding road
projects starts in the next few months.
This is considered a turnaround for the
sector which had come in for harsh crit-
icism for lack of initiatives for driving
ahead the progress of projects.
Quality; the Sufferer in
Highway Projects
Quality seems to have taken a back
seat when it comes to highway projects
in the country. Highway engineers
have been reportedly quoted saying
that increasing pressure from the Plan-
ning Commission and the Finance
Ministry has meant that safety has
taken a beating in highway projects.
It is interesting here to note that
around 60 percent of the fatalities in
road accidents take place in National
and State Highways, even though they
Chief Engineer, A.P Bahadur
constitute only about 6 percent of the
total road network in the country.
Industry analysts feel that more often
than not, safety features such as
flyovers and underpasses are the first
to become a casualty, right at the
design stage.
In a recently held seminar on road
safety to highway engineers and
design consultants Mr. A.P Bahadur,
former Chief Engineer, Ministry of
Road Transport and Highways had
said “ The original (proposed) project
cost for building that stretch ( Delhi
and Agra) was an estimated `8.56
crore a km. We were told to reduce the
cost”. The cost was bought down to
`3.6 a km.
Mr. Bahadur further added “To do
this, the features that were knocked off
included 15 minor bridges, 29 vehic-
ular underpass, 59 pedestrian under-
passes, 25 flyovers, and stretches of
service roads.” Mr. Bahadur wanted
engineers to put their foot down and
insist on safety features and make sure
that they record on file that they had
suggested safety features but had to
comprise to reduce costs.
NHAI Chief's Term
Extended
The tenure of the National high-
ways Authority of India (NHAI)

The Masterbuilder - April 2011 | www.masterbuilder.co.in 25

News & Events

INFRASTRUCTURE

Chief, Mr. R.S Gujral, has been The Centre is planning

extended till June 30th the govern-
ment said in an announcement.
Mr. R.S Gujral
It also said that the process for
appointing the regular Chairman is
going on. Mr. Gujral, Road Transport
and Highways Secretary, was given the
additional charge of NHAI Chairman
for three months with effect from
January 1 this year.
“We have given extension to Mr.
Gujral for another three months.
Meanwhile, the process is on for selec-
tion of a regular Chairman for NHAI,”
the Road Minister, Mr. C.P. Joshi has
reportedly said on the issue.
Expressways to Link
constructing two new expressways
linking Jaipur and Chandigarh with
the national capital. The construction
cost of the projects would be around an
estimated US $3 billion.
"The Centre has decided to build
Delhi Jaipur and Delhi-Chandigarh
expressways. Ministry officials will
take up the issue with states of Delhi,
Rajasthan, and Haryana. Once they
come on board, we will get the detailed
project report," Road Transport and
Highways Minister Mr. C.P Joshi has
been quoted saying in media reports.
The Centre is also re-examining a
proposal that envisages setting up of
an Expressway Authority of India
(EAI) on the lines of the National High-
ways Authority of India (NHAI).
There are plans to build over 18,000
km of expressway entailing an invest-
ment of ` 4, 50,000 crore.
The minister reportedly told that
there was a need for the new express-
ways in view of the increased traffic
between the cities.
Four Laning of
Kota-Teendhar
Highway Approved
The four laning of the Kota
Teendhar Highway has been approved
for the speedy industrial development
of the two districts. The corridor
connects important cities in Rajasthan
with those in Madhya Pradesh.
Six Laning of
Ahmedabad-Vadodara
Highway Cleared
The Cabinet Committee on Infra-
structure has cleared the six laning of
the Ahmedabad-Vadodara section in
NH-8. The total stretch of 102.3 km
will be built on Design, Build,
Finance, Operate and Transfer
(DBFOT) basis in BOT (toll) mode of
delivery.
The cost of the project is estimated
to be ` 2,37.76 crore, with the conces-
sion period being 25 years, which
includes the construction period of 36
months. The stretch is strategically
important since it covers the industrial
districts of Ahmedabad, Kheda,
Anand, and Vadodara.

Delhi to Jaipur, by the Cabinet Committee on Infra-

structure. The 88.9 km stretch on
Chandigarh National Highway -12 will be devel-
oped on Design, Build, Finance,
Operate and Transfer (DBFOT) basis
on BOT (toll) mode of delivery.
The total project cost is pegged at The section is an important stretch
in the Golden Quadrilateral (GQ)
` 580.79 crore, with the concession
network, which links the two major
period being 25 years, including the
cities in Gujarat with Mumbai. Apart
construction period of 30 months. The
from further improving trade and
project covers the districts of Jhalawar
commerce in the cities, the project is
and Kota in Rajasthan.
also expected to provide employment
The project is considered crucial to thousands of labourers in the region.

26 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Silicone Concepts Int'l.Pvt.Ltd
News & Events
INFRASTRUCTURE
PORTS
Paradip Port Plans
Expansion
The Paradip Port Trust (PPT) is
chalking out ambitious expansion
plans and intends to raise capacity over
three times to 237 million tonnes by
2020. Interestingly this is despite the
1.72 percent decline in cargo
throughout 2010-2011.
“The port will increase its capacity
from 76 million tonnes to 237 mt by
the year ending 2020 to become the
number one port in the country,
elevating its position from fifth place,”
PPT Chairman, Mr. G.J. Rao told
media persons recently.
There are plans to establish an oil
jetty and a multipurpose berth with
15mt capacity added Mr.Rao. The
port also intends to undertake massive
dredging works to handle large sized
vessels. The capacity expansion is
being undertaken at the port keeping
in view the future requirements.
Mormugao Port
Expansion Plans
The Mormugao Port Trust (MPT)
has crossed the 50 million tonnes cargo
figure during 2010-11 and is now one
of the most important ports in the
country. The port has secured the 7th
position among the 12 major ports of
28 The Masterbuilder - April 2011 | www.masterbuilder.co.in
India, according to Mr.P.Mara
Pandiyan, Chairman of MPT.
The Chairman said that the
construction of a berth, mainly for
berthing of non-cargo vessels,
including cruise ships, is scheduled to
be completed by August. The plan also
envisages the development of a
4MTPA mechanized coal import
terminal at existing berth No.11 on
design, build, finance, operate and
transfer (DBFOT) basis.
Mr. Pandiyan also added that the
development of coal handling
terminal at berth No.7 on DBFOT
basis is under progress with the sched-
uled date of commencement of opera-
tion pegged at May 2013.
Govt Mulls Tax-Free
Bonds from Major Ports
to Fund their Infra Projects
Mr. K Mohandas,
Secretary Shipping Ministry
The government is reportedly
considering allowing major ports to
raise Rs.5, 000 Crore from tax-free
bonds. The highlight however, is that
it is planning to allow the ports to raise
the amount themselves.
“We are yet to take a final decision.
Major ports are one of the options for
raising the money,” Mr. K Mohandas,
Secretary in the Shipping Ministry has
been quoted saying in press reports.
“They will need some agency to
raise this money, like National High-
ways Authority of India (NHAI) does.
It doesn't seem very feasible for port
authorities to raise the money,”
Mr.Vishwas Udgirkar, senior director,
Deloitte, has reportedly said in media
reports.
According to industry sources the
ministry is also planning to set up a
Maritime Finance Corporation (MFC).
The money that will be raised will be
used to finance the infrastructure
requirements and dredging operations
of the various major ports.
URBAN
Rural Infrastructure
Development Activities
on the Rise
There has been a spurt in rural
infrastructure development activities
around the country. With the govern-
ment launching the Bharat Nirman,
its flagship program for boosting rural
infrastructure, there has been definite
positive effects that are visible in
several areas.
Infrastructure including, water,
irrigation facilities, housing, electrifi-
cation, telecommunication and roads
are now the areas of focus in several
parts of the country in rural areas. The
Pradhan Mantri Gramin Sadak Yojana
(PMGSY) has been instrumental in
the increase in good quality roads
around the country in rural interiors.
Similarly, the Rajiv Gandhi
Kryton Buildmat Co.Pvt.Ltd
News & Events
INFRASTRUCTURE
Grameen Vidyuttikaran Yojana
(RGGVY) which had targeted to cover
over 175 lakh below poverty line
households in one lakh villages has also
been a success. Another 42 lakh houses
are to be covered under the scheme by
the end of this fiscal year.
Govt Mulls Mega
Manufacturing Hubs
Shri Anand Sharma,
Union Minister for Commerce and Industry
The government is mulling setting
up of mega manufacturing hubs in
various parts of the country, in order to
make the country a manufacturing
powerhouse. The move is seen being
inspired by China's success story in the
field of manufacturing.
The Department of Industrial
Policy and Promotion (DIPP) is said to
be putting on fast track the National
Manufacturing Policy, which would
help in the creation of what is being
termed as the National Manufacturing
and Investment Zones (NMIZs).
Typically these zones would be
30 The Masterbuilder - April 2011 | www.masterbuilder.co.in
spread over around 8 sq km and would
offer all facilities needed for setting up
manufacturing units. The DIPP is
seeking sops including, flexible labour,
tax incentives, refinance facility,
simpler exit norms for foreign inves-
tors, etc, for these facilities, according
to industry sources.
Five Key Water Supply
Projects in Trouble
Five key water supply projects that
are intended to quench the thirst of
Mumbaikars have run into trouble
with locals' opposing them tooth and
nail. It is the demand of the locals that
the projects should first of all provide
water to locals and the tribal popula-
tion in the area before water reaches
Mumbai.
Most of the projects that are facing
stiff opposition are being executed by
the Mumbai Metropolitan Region
Development Authority (MMRDA).
Dams are proposed to be build over
Kalu and Shai Rivulets as per the plan.
Similarly there is an ambitious plan to
bring water from Surya Dam in Thane
to the western suburbs in the city.
At present only Mumbai and the
Navi Mumbai Municipal Corporations
have dams. With the population of the
city increasing quite literally by the
day, there is an urgent need for
augmenting the water supply capacity
through additional projects.
DAMS
Construction Works at
Kutch Branch Canal
(KBC) Project to Begin
Hon'ble Chief Minister, Gujarat,
Shri Narendra Modi
The construction works related to
the Kutch Branch Canal (KBC)
project, which is part of the Sardar
Sarovar Project, is all set to begin. The
Chief Minister of Gujarat,
Mr.Narendra Modi will lay the foun-
dation stone for the five major
construction works related to the
project in a few days time.
Speaking about the Sardar Sarovar
project, the State Water Supply
Minister Mr.Nitin Patel said that the
project would ensure gravity-based
flow of Narmada water in the entire
Kutch district. He also said that three
pumping stations would be set up at a
cost of `518 crore for the purpose. The
pumping stations will lift water to a
height of 60 metres, which is equiva-
lent to the height of a 20 storied
building said the Minister.
The parched land in Kutch is
expected to be turned into a 'fruit
bowl' once Narmada waters begin to
flow through the region. According to
experts the KBC , which would be a
man made 360 km long river, would
be the only perennial source of water in
the district once it is completed.
Apollo Infratech Pvt.Ltd
News & Events
INTERNATIOAL
Manitowoc Exhibits Top
of Line Cranes at
Intermat Trade Show
(L - R) Carina El Rkaiby and David Semple of
Manitowoc Cranes, Nabil Al Zahlawi, od NFT,
Ahmed Talhimet of Manitowoc
and Fadi Daher of NFT.
Two of the latest innovations from
Manitowoc stood side-by-side on the
company's booth at Intermat Middle
East. The company showed the Grove
GMK6300L all-terrain crane, that
combines 300 t of lifting power with a
long-reaching80 m boom, and the
Potain MDT 268, one of the most
recent additions to the company's
range of high-capacity topless tower
cranes, with a capacity of either 10 t or
12 t. Both cranes are new to the
Middle-East market within recent
years.
David Semple, vice president of
sales for Manitowoc in the Middle East
and Africa, said the two cranes demon-
strate the company's industry-leading
engineering and ability to adapt to
changing market needs.
With an Allison transmission, the
GMK6300L has a powerful, reliable
and cost-effective drive-train that
offers unmatched performance. Its elec-
tronic controls allow it to adapt to its
surroundings and it has self-
diagnostics for easier maintenance.
When combined with Grove's
Megatrak independent suspension
system, the Allison transmission
provides optimum travel both on and
off the road.
32 The Masterbuilder - April 2011 | www.masterbuilder.co.in
The MDT 268 is one of the recent Yet another Super
introductions in the Potain topless
MDT crane line. It offers fast erecting Heavy Lifter Tested
and dismantling times without Sarens, a leading name in lifting
compromising capacity. NFT, an Abu solutions, has tested a new 120,000
Dhabi-based Potain dealer and one of tonne metre SGC 120 super heavy
the largest tower crane owners in the lifting ring type crane in its facility in
world, has many Potain MDT 268 Belgium recently.
cranes which it has used on some of
Saudi Arabia's most prestigious recent The 3,200 tonne capacity super
construction projects. heavy lift crane is among the largest in
the world. The lattice boom giant
This crane, along with Potain's comes with 130 metres of main boom.
larger model, the MDT 368, were The crane boasts of a capacity of 1,000
lifting leaders during the construction tonnes at 80 m radius. The crane is
of the Princess Nora bint designed to meet both European and
Abdulrahman University in Riyadh, US standards for lift cranes.
the world's largest women-only
university. There were 150 cranes used
on this $11.5 billion project, the
majority from Potain.
The MDT 268 has a topless design,
with no cathead and tie-bars, which
means contractors can place them in
close proximity on job sites, without
needing to erect them too high. This
saves both time and money and
provides an optimized working envi-
ronment. The versatility and speed of
erecting and dismantling the MDT
268 allowed main contractor Saudi
Oger to not only meet but exceed the
extremely tight build schedules on the
university project. The new crane's application areas
One interesting feature on the include nuclear power plants, refiner-
MDT 268 is its folding jib an industry ies, mining, and construction. The
first for topless cranes. The patented design also boasts of features that
folding jib helps with one of the reduce cost of transporation and oper-
biggest problems in the construction ation. The crane can be shipped in 135
of cooling towers dismantling the standard containers in standard boom
crane once construction is complete. condition.
Because the jib's radius is greater than
the cooling towers, contractors are CAT's New CT Series,
often faced with a problem when Vocational Trucks
'climbing down' the crane. But the
folding jib offers an innovative solu- Caterpillar, one of the leading
tion to this problem. Another construction equipment manufactur-
standout feature is the counter jib that ers, will unveil its newline of voca-
can be folded for transport. tional trucks during the forthcoming

ConExpo show in Las Vegas. The
machine on display at the company's
booth would be the Cat CT660.
According to the company, the
trucks are suited to a wide variety of
work and have been designed using
customer feedback. Also on show
would be the company's 64 tonne
capacity G Series 775 rigid dump
truck.
The company will also display five
new models in the K Series of mid-
sized wheeled loader range. This new
line features an improved cab, apart
from featuring a fuel efficient engine.
New Flat Top City
Crane Launch
Liebherr, a market leader in lifting
solutions, is all set to launch its 85 EC
B 5 tronic flat top city crane soon. The
company will be launching the crane
during the SMOPyC exhibition that is
going to be held in Spain this month.
The crane can lift 1.3 tonnes at the
jib, with its compact dimensions
ideally suited for work in urban areas
where space is at a premium. The
highly versatile climbing tower section
of the crane is 3.9 m long and can be
used both inside and outside a build-
ing.
The crane is also easy for carrying
around in urban centers since its unit
weigh less , the heaviest component
weighing less than 3 tonnes. Another
interesting feature of the crane is that
it can be operated either with or even
without a cabin.
Solar-Powered Wind
Turbine for Ultimate
Energy Generation
Scientists have now come out with
a new set of spinning solar blades that
will enable both solar energy and wind
energy to be produced together. A
team led by Dr. Joe King has come out
with the innovation solution in the
UK.
Dr. King, while speaking about
the project said, “While we are no
strangers to windy weather in the UK,
it can be intermittent in other regions.
Solar panels may only be useful here
during our ten days of summer or an
occasional heat wave, but in countries
such as Morocco, Italy, and Spain they
could make a real difference.”
The team had to face several
The Masterbuilder - April 2011 | www.masterbuilder.co.in 33
News & Events
INTERNATIONAL
hurdles such as the potential problem
that could be caused to air craft pilots
whose visibility could be disturbed due
to the beams of light that shoot out
from the turbines. There was also the
concern about the turbines generating
solar rays that could set surrounding
buildings on fire, if they are concen-
trated.
Shantui Launches
First Product in
US Market
Shantui Construction Machinery
Co., a multinational based in
Shandong, China, announced today
the launch of its SD10YE bulldozer,
the Company's first product to enter
the U.S. market. The SD10YE is certi-
fied by TÜV SÜD America as Tier III
emissions compliant, and is the
smallest dozer in Shantui's arsenal.
The SD10YE runs on hydrostatics,
comes standard with a Cummins
engine, and has horsepower rated at
100, or 74kW.
Like other Shantui offerings, this
dozer packs in value for the price.
Intelligent GPS service, automatic
alarm system, and auto-diagnostic
functions keep uptime at a maximum.
The SD10YE also doesn't skimp on
operator comfort,. The fully enclosed
hexahedronstyle cabin provides for
low noise and vibration, and a high-
capacity climate control system circu-
lates air and defrosts.
The SD10YE is designed for smaller
projects, but has Shantui's hallmark
toughness and durability, along with
being environmentally friendly and
highly economical.
“This is our first product that
meets the stringent emission stan-
dards of Europe and the USA. It is on
the vanguard of a whole line of new
products that we will be introducing in
the coming years,” said Richard Li,
News & Events
INTERNATIONAL
Vice President for International at
Shantui. “Our aggressive investment
in R&D these past few years is starting
to show handsome results with the
launch of the SD10YE,” he added.
At Conexpo, Shantui is also
demonstrating its wide diversity of
product lines. In addition to the
breakthrough SD10YE dozer, Shantui
is also displaying its workhorse
SD32W bulldozer, SL60W wheel
loader, SR12P-5 road roller, SG18-3
motor grader, JCM 921C excavator,
HJC5270THB truck mounted boom
concrete pump and the HBT8016R
concrete trailer pump at booth G-200.
Visitors down by 16
percent in ConExpo but
Rise in the Number of
International Delegates
The ConExpo construction equip-
ment exhibition which concluded last
week attracted around 120000 visi-
tors, figures which are about 16
percent lower than the 2008 show.
According to industry experts, the
show's attendance pattern in a way
reflects the difficulties that are being
faced by the construction industry in
the US.
34 The Masterbuilder - April 2011 | www.masterbuilder.co.in
However, there has been an
increase in the number of overseas visi-
tors, which was about 24 percent of
the total number. The figure was
about 19 percent in the previous
edition of the show in 2008. The orga-
nizers of the show, the Association of
Equipment Manufacturers (AEM)
have claimed that the exhibition has
been a success with the exhibitors in recent weeks include that of Pace
reporting strong purchases, as well as University, Verizon Tower and New
sales leads. York Downtown Hospital.
According to Mike Haberman,
Chairman of ConExpo 2011, “it was Truck Mounted Concrete
really great to see our industry look Pump Helps Cool Down
ahead with some enthusiasm after the
recession.” The exhibition was spread Japanese Nuclear Reactor
over 2.34 million net square feet of
exhibit space and attracted more than
2400 exhibitors.
The next edition of the show would
be again held at the Las Vegas Conven-
tion Center in Las Vegas, US on 18-22
March in 2014.
Iconic Building Workers are using an M 58-5
Turns Dangerous Putzmeister truck mounted concrete
pump for cooling down the
A building which was hailed as a Fukushima nuclear reactor. The
masterpiece is now being admonished concrete pump that has been produced
by virtually all and sundry. Critics had in Aichtal near Stuttgart comes with a
raved and ranted about Frank Gehry's vertical reach 58 m.
iconic tower at 8 Spurce Street in New The concrete pump also has a 5-
York City. arm boom to support the cooling of
The very same critics are now the damaging cooling pools. With the
tearing down the famous architect for concrete pumps the advantage is that
the glimmering steel façade of the cooling water can be fed over great
iconic building. The façade is so distances. Water can be fed to exactly
incredibly reflective that it has set on where it is required using the concrete
fire on more than one occasion, some of pump.
the surrounding buildings. The pump has an output of 160
cubic metres per hour at a pressure of
If reports from the New York Fire
85 bar and is driven by the truck's
Department are to be believed that the
diesel engine. This means that the
concentrated reflections from the
concrete pump does not have to rely on
stainless steel façade of the building
external power supply. The machine is
are causing the fire on the roofs of
operated using remote control, which
several nearby buildings.
allows the distributor arm to have flex-
The buildings that have caught fire ible movement.
Wirtgen India Pvt.Ltd
Building Information Modeling

The Battle to Bring

Buildings Back to Basics

O ur global society is
simultaneously experiencing an
economic and environmental
crisis. Economically, signs of a feeble
recovery mask fundamental flaws with
and the necessary leadership too
wanting.
Those of us in the building space now
find ourselves at the front line of the
battle against these two crises. And as
the way capital and currencies are
with many in the front lines, we are both
managed worldwide. Environmentally,
in the “cross-hairs” of new regulation but
world energy demand is predicted to
luckily newly equipped with an
Emma Stewart, Ph.D. double by 2030 and water shortages are
“armament of tools” to respond.
predicted to hit every major city in the
next couple decades. The combination of Buildings are in the crosshairs for new
two such complex and seemingly regulation because, in most economies,
intractable challenges has led many to they represent the biggest guzzlers of
defeatism. The numbers are too large, the energy, outpacing even vehicles. The
causes too many, the data too expansive, reasons are simple.

36 The Masterbuilder - April 2011 | www.masterbuilder.co.in


a. H u m a n s h a v e b e c o m e
primarily an indoor species, and we've
also become a “plugged-in” species. So
the majority of our thirst for electricity,
heating and cooling manifests in
buildings.
b. Hundreds of years ago our
buildings were designed based upon
local climactic zones, weather, and
future adaptive reuse. Today, buildings
are built so rapidly and at such scale
that they tend to be cookie-cutter
structures that bear no relevance to
the buildings, climate, or energy source
around them.
So when policy-makers scour the
economy for the most promising areas
to reduce waste and increase jobs, they
typically land squarely on building
retrofits.
One can find evidence of this in any
part of the world. The European Union
has committed to cut energy use from
buildings by 20% by 2020 and the UK's
national climate legislation requires
existing buildings to be net zero energy
by 2020. China's 12th Five Year Plan,
released this March, dictates a 16%
reduction in energy intensity nation-
wide, with a strong emphasis on
improving buildings to achieve that
goal. All US federal agencies, including
the largest portfolios in the world, the
General Services Administration and
Department of Defense, must
implement energy efficient practices
for at least 15% of their inventory by
2015, alongside annual reductions
targets for energy, water, and
greenhouse gas reductions. In part due
to these mandates, Pike Research
predicts a $400 billion US market in
energy retrofits by 2030, which one can
extrapolate to a global market of
roughly $1 trillion by that same date.
The sheer number of existing
www.masterbuilder.co.in | The Masterbuilder - April 2011
Building Information Modeling
buildings roughly 728 billion square
feet worldwide - can make conducting
comprehensive building performance
analysis and implementing energy-
saving projects a daunting task. Dated
or nonexistent building plans and
incomplete energy consumption
histories make it difficult to predict
future performance throughout the life
of a proposed renovation project or to
evaluate and compare proposals from
energy service companies (ESCOs).
There are also the political challenges
of garnering stakeholder support and
building consensus between legal,
procurement, and finance departments
during contract negotiations.
So herein commences the battle to
bring buildings back to the basics -- but
this time, with new tools. The linear
design-build process embraced for so
long with questionable returns is
finally being forced to compete with a
renaissance of new industry practice,
integrated project delivery (IPD) and
building information modeling (BIM).
The first contractually realigns the
famously disjointed incentives
between owner, architect, and
engineer, towards a given outcome
(e.g. LEED or energy per square foot)
rather than simply lowest time and cost
to delivery. The second offers a 3D
technology-based process to support
decision-making throughout the
retrofit and build process.
37
Building Information Modeling
For existing buildings, BIM enables
the team to more quickly and easily to
create a basic building model to
simulate the performance and cost of
renovations. The digital model includes
data components that represent
building elements and
characteristicssuch as materials,
weight, thermal resistance, and other
physical propertiesthat contribute to
building performance. With BIM, one
can analyze and assess the energy
performance of individual buildings --
for example, what generates a better
economic and energy-efficient return
for our headquarters, installing higher
R-value wall insulation, or modifying a
heating system? One can then scale up
to multiple buildings to evaluate, and
rank the environmental and financial
impact of proposed renovations for
example, which buildings within the
portfolio would benefit the most from
an HVAC upgrade? With a more
comprehensive understanding of the
relative performance of the property
portfolio, one can craft a strong
inventory modernization program, and
focus detailed design efforts and
construction on the projects with the
38 The Masterbuilder - April 2011 | www.masterbuilder.co.in
greatest impact. So BIM helps to tackle
the issue of scalability, because it is just
as applicable at the level of thousands
of buildings as it is at the level of one
building.
The basic steps are as follows:
1. Get Pickin': Collect basic building
informationincluding wall, floor, roof,
and ceiling dimensionson each building
within the portfolio. This can be done
the old-fashioned expensive way (i.e. a
walk-through audit), but more recently
software has come about that allows
you to stitch together the model from
digital photos and satellite images from
the web.
2. Get Sketchin': Create basic BIM
m o d e l s fo r e a c h b u i l d i n g ( o r
“prototype” for commercial stores) in
the portfolio. You can generate a
comprehensive BIM modelincluding
floor plans, elevations, sections, and
3D views from the most basic building
dimensions in just a few hours so don't
over-do it here. Even with minimal up-
front effort, you can generate a basic
model that represents the form and
geometry of the building and begin
analyzing and prioritizing building
improvements with a surprisingly high
level of accuracy. Also at this stage, one
can begin selecting building materials
from within the BIM tool itself, perhaps
prioritizing recycled, renewable, or
locally sourced materials.
3. Get Testin': Analyze multiple
attributes to improve environmental
and economic performance. For
example, use Revit to analyze heating
and cooling load for a typical schedule
of operation. Then explore creative
options to shed that load through
natural ventilation (uses weather
data), shading (uses sun path data),
onsite renewable generation potential
(uses wind and sun data), and water
catchment potential (uses
precipitation data). A water catchment
system may inspire the use of non-
potable water for irrigation or even a
plant-based gray water filtration plant
on site, reducing wastewater service
costs. With sister civil engineering
tools, the building site can be evaluated
for storm-water system needs and to
maximize the water returned clean to
the aquifer.
Apollo Infratech Pvt.Ltd
Building Information Modeling

4. Get Busy: Compare and then prioritize

projects or investment alternatives based on
conservation objectives, such as water or fossil
fuel usage, or financial goals. Before signing an
Energy Service Performance Contract, use BIM
to perform internal reviews of the service
provider's proposals to confirm key
predictions and assumptions. Not only will this
keep them honest, you will also likely unearth
additional savings opportunities they missed T-box
because BIM optimizes for the entire building,
not its component parts.
All of these steps are increasingly enabled
through the power of cloud computing, where
general contractors, MEPs, and architects can
yank from the cloud the key data points they
need to assess a building's potential for net
zero energy or carbon neutrality. In addition to
acting like a huge data repository in the sky,
cloud computing has brought down the price
of computing to the point where design
Exposed portion of T box, once layed
software will soon iterate on your behalf, until
it lands on the optimal design based on the
parameters you set.
So with our new armament of tools,
Device to Capture
Integrated Project Delivery and Building Wind from Trains
Information Modeling enabled by cloud Trains, as they run, are known to generate quite a bit of wind
computing, we're finally well equipped to face energy. Scientists are now researching the possibilities of
the cross-hairs of regulators, and beyond using this wind energy as a potential source of power. A
them, the dual crises of economic and device developed by the industrial designer duo of Qian
environmental decline. Jiang and Alessandro LeonettiLupariniwill aim at doing just
that. The device was designed to fit in-between the sleepers
i International Energy Agency (2010) “World Energy
of the tracks to funnel the wind generated by the train onto a
Outlook”
turbine which can be turned to generate power.
ii Pike Research (2009) “Energy Efficiency Retrofits for
Commercial and Public Buildings” The device, aptly coined the “T-box”, can be placed
alongside railway or metro lines to harness the otherwise
iii Lux Research (2010) “Diamonds in the Rough:
wasted wind generated by these trains. T box, unlike other
Uncovering Opportunities in the Green Buildings
Market” conventional devices, makes use of artificially generated
wind instead of depending on natural sources.
Author's Bio The device contains of a vent showing on the surface, with a
Emma Stewart, Ph.D., is currently the Senior majority of its working taking place underground. The blades
Manager for AEC Sustainability at Autodesk where in the device are designed to rotate along a central axis
she leads the design software company's efforts to within a cylindrical housing. The device was made popular
make sustainable design easy, cost-effective and rou- when it won the silver medal at the Lite-On awards, last year.
tine across the building and infrastructure industries. With the number on rail projects packing by the double,
Emma holds a Ph.D. in Environmental Science and coupled with the number of trains already running, one could
Management from Stanford University and a B.A. only imagine the amount of power that could be generated
Honors degree in Human Sciences from Oxford using this device.
University.

40 The Masterbuilder - April 2011 | www.masterbuilder.co.in

The Supreme Industries Ltd
Seismic Retrofit: Case Study
T
his paper presents the nonlinear seismic
analysis, development, and implementation of
an innovative seismic retrofit strategy for a
six-story nonductile reinforced concrete 145,000-sf
(13,470 m2) historic building. Dynamic and
nonlinear static analytical results verified that the
building had a weak soft-story with inadequate post-
yield capacity, and large torsional response. The
analysis indicated that the existing building is not
seismically adequate to withstand anticipated lateral
forces generated by earthquake excitations at the site.
A "collapse prevention" performance upgrade for a
475-year return event was desired. Nonlinear fluid
viscous dampers were placed at the first story level to
reduce the seismic demand and obtain a more
uniform response. Visco-elastic fluid viscous dampers
44 The Masterbuilder - April 2011 | www.masterbuilder.co.in
were strategically placed at one side of the building
to reduce the torsional irregularity of the building.
The proposed cost effective, state-of-the-art retrofit
will improve the seismic performance of the building.
This paper presents the performance-based
evaluation and retrofit design of the Hotel Stockton.
The 145,000-sf (13,470 m2) reinforced concrete
building, built in 1910 in Stockton, California, is a
torsionally irregular structure comprised of a six-story
portion connected to a two-story portion. There was
significant concern that the building will not be able
to withstand the level of earthquake shaking
expected at the site for two reasons: a weak and soft
lateral force resisting system at the first floor level,
and the inadequate confinement of reinforcement in
the first story columns. To assess the performance of
Schwing Stetter (I) Pvt.Ltd
Seismic Retrofit: Case Study
the structure, a detailed mathematical model of the
building was prepared based on FEMA 273
guidelines. Dynamic and nonlinear static analytical
results verified the presence of the soft-story
response, inadequate post-yield capacity, and large
torsional response. The analyses indicated that the
existing building is not seismically adequate to
withstand anticipated lateral forces generated by
earthquake excitations at the site. The existing
structure will suffer substantial damage and possible
collapse in the event of a major earthquake.
To address the above-mentioned inadequacies, the
Owner decided to undertake a voluntary seismic
upgrade of this building. The focus of the seismic
rehabilitation was to address the major deficiencies of
the structure, namely the soft-story and torsional
response of the building. The main objective was to
provide a "collapse prevention" performance goal
during a 475-year return event. Nonlinear fluid
viscous dampers were placed at the first story level to
reduce the seismic demand and obtain a more
uniform response. Visco-elastic fluid viscous dampers
were strategically placed at one side of the building
to reduce the torsional irregularity of the building.
Finally, the first story interior columns supporting
the six-story portion of the building were wrapped
with a fiber-reinforced polymer composite (FRP). A
new mathematical model was prepared incorporating
the seismic upgrades, and was subjected to nonlinear
time history analyses using three sets of
twocomponent, independent acceleration histories
derived from a site-specific acceleration spectrum.
Evaluation of the analytical results of this model
showed that the story drift for the first floor was
significantly reduced, the torsional response was
nearly eliminated, and all structural members
remained elastic.
Description of Structure
The Hotel Stockton, built in 1910 as a 252-guest
room hotel, is a historic landmark building in
Stockton, California. The building, also referred to as
The Stockton, measures approximately 300 ft (91.4
m) in the E-W direction and 100 ft (30.5 m) in the
N-S direction. In elevation, it is comprised of a six-
story portion on the east side and a two-story portion
on the west side, and has a full basement. The first
46 The Masterbuilder - April 2011 | www.masterbuilder.co.in
story is 18 ft (5.5 m) high and the remaining floors
have a story height of 10'-3" (3.1 m). Figure 1 below
shows a south elevation of the eastern portion of the
building.
In the E-W direction, the building consists of 15
bays at approximately 20-ft (6.1-m) spacing. In the
N-S direction, there are five bays at approximately 20
ft (6.1m) per bay, see Figure 2. The structure is a
cast-in-place reinforced concrete building. Reinforced
concrete columns, beams, and shear walls comprise
the gravity and lateral load resisting system. The
basement columns are 18- and 20-in. (457 and 508
mm) square for the twostory and six-story segments
of the building, respectively. At the ground floor and
above, column sizes vary from 18-in. (457 mm)
square at the first story to 14-in. (356 mm) square at
the fifth story. There is a full 9-in. (229 mm) thick
concrete perimeter wall between the basement and
the first floor, and there are numerous 6-in. (152
mm) thick concrete walls between the floors above
the second floor. However, there are no structural
walls between the ground and the second floor levels.
Typical floors consist of 4-in. (102 mm) concrete slabs
with a 2-in. (51 mm) topping slab supported by EW
concrete beams, and N-S concrete girders.
Although the as-built plans of the structure are
not available, field investigations have shown that the
columns typically have four and eight longitudinal
reinforcing bars around the perimeter of columns at
the two-story and six-story segments, respectively.
Typical minimum concrete cover for the
reinforcement is approximately 2 ½ to 3 in. (64 to 76
mm). The groundto- first story columns have eight
1-in (25 mm) square bars. Typical transverse ties
consist of 1/8-in (3.2 mm) thick by 1-in (25 mm)
wide bars at 8 in. (203 mm) spacing.
Analytical Model of Existing Structure
Figure 2: Plan View at 2nd Floor

The computer program ETABS (CSI 2001) was
used to prepare a mathematical model of the
building, see Figure 3 for a schematic of the model.
Key features of the mathematical model are
summarized below. o Material properties. A concrete
Ø Parameters for nonlinear analysis. For this softstory
compressive strength of 3 ksi was used. This value is
consistent for concrete strength of buildings
constructed in the early part of the last century
(FEMA 273), and corresponds to the values obtained
from field investigations. Tensile testing of sample
reinforcement indicated yield and tensile strengths of
approximately 65 and 72 ksi (450 and 500 MPa),
respectively. Field studies indicated that the column
longitudinal reinforcement splice lengths varied from
26 to 28 inches (660 to 711 mm) for 1-in (25 mm)
square bars. Therefore, the yield properties of the
longitudinal bars were reduced to 42 ksi (290 MPa),
per FEMA 273. A yield value of 36 ksi (250 MPa)
was used for the column ties.
Ø Frame elements. All columns were modeled as
square sections with longitudinal bars in a circular
pattern. Girders and beams were modeled as
rectangular sections with the section depth
measured from the top of the topping slab. T-
beam action from the floor slab was neglected. All
dimensions were specified as centerline-to-
centerline - (i.e. no rigid end offsets were
specified). The perimeter basement walls and wall
segments between the floors were modeled as
shell elements. Similarly, the floor slabs at all
levels were modeled as shell elements. FEMA 273
recommends using a value of 50% of the gross
Figure 3: Schematic of The Mathematical Model of The Building
www.masterbuilder.co.in | The Masterbuilder - April 2011 47
Seismic Retrofit: Case Study
moment of inertia (Ig) for the cracked moment of
inertia (Icr) of the flexural members. This
reduction factor was applied to the beams,
columns and shearwalls.
structure, the nonlinear behavior will be entirely
limited to the first story columns. As such,
nonlinear hinges were defined and placed on these
columns. To capture the complete nonlinear
response of these columns, two types of hinges
were used: shear hinges placed at mid-height of
Figure 4: Response Spectra
the columns, and biaxial-force (PMM) hinges near
the top and bottom of the columns. The location
of the PMM hinges was determined by assuming
that the plastic hinges would form at a distance of
2b/3 (where "b" equals the width of the column)
from the top and bottom of column-to-floor
connections. For the PMM hinges, interaction
curves based on ACI 318-99 were used to
determine the axial forcebiaxial moment yield
surface. For the nonlinear analysis, the column
plastic hinge properties are a function of column
slenderness, transverse reinforcement (size,
spacing, and anchorage), and axial and shear
demand. For the columns under consideration,
the axial force ranges between 10-15 percent of
the nominal compressive strength, and flexure is
the controlling response. The shear force is less
than three times the nominal shear strength, and
the columns have poor confinement (transverse
reinforcement). Since the lap splices for the
longitudinal reinforcement are not fully
developed, sudden strength degradation may
occur after the onset of the nonlinear behavior.
Therefore, hinge formation (yielding) should be
Seismic Retrofit: Case Study
avoided, and subject columns should remain elastic.
Ø Gravity loading. Gravity loads used in the model
consisted of the self-weight of the structure, 0.02
ksf (0.96 kPa) for partitions, 0.025 ksf (1.20 kPa)
for weight of the 2-in. (50-cm) topping slab, and
0.005 ksf (2.40 ksf) for miscellaneous (e.g., fans,
vents, plaster). Live loads consisted of typical code
prescribed floor loads.
Ø Inertial mass. The mass of the structure consisted
Figure 5: Acceleration Record & Spectrum
of all structure dead loads and one half of the
partition loads. The code-mandated 5-percent
eccentricity was achieved by offsetting the floor
mass. The total inertial weight (mass) of the
structure is approximately 14,000 kips (64,050
kN).
Earthquake Histories
Site investigations were used to determine the
sitespecific acceleration spectra. The Design Basis
Earthquake (DBE) spectra (10% probability of
exceedence in 50 years) used for the studies presented
herein is shown in Figure 4. In the same plot, the
response spectrum for the Maximum Considered
Mode Period (sec) Principal direction
1 1.2 Transverse (N-S)
2 1.0 Longitudinal (E-W)
3 0.9 Torsion
Table 1
Earthquake (MCE) (2% probability of exceedence in
50 years) is also shown. Three sets of time histories
were prepared by J. P. Singh (Singh 2002) by
matching the response spectra derived from the
horizontal components of each of the three recorded
48 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Figure 6: Modes 1 & 2 (Elevations)
earthquake records to the target spectra, and then
base-line correcting in the time domain. The records
were derived from the 1989 Loma Prieta earthquake
(0- and 90-degree components recorded at Agnews,
0- and 90-degree components recorded at Gilroy, and
270- and 360-degree components recorded at San
Marino). Figure 5 shows the DBE acceleration record
and the computed acceleration spectrum for the
xcomponent of the Agnews record. The y-component
of this record and the x- and y-components of the
other two records have similar acceleration spectra.
Analytical results of the existing b building
Dynamic analysis. A modal analysis of the
building was conducted to determine the
fundamental period and mode shapes of the
structure. Table 1 summarizes the results for the first
three modes obtained. The first two mode shapes of
the building are shown in Figure 6a and 6b. It is
noted that the response is that of a soft-story
structure with nearly all the deformation
concentrated in the first story columns.
Figure 7 shows the deformed shape of the second
floor in plan for the first mode. It is noted that due to
the lack of symmetry in the N-S direction, there is a
large torsional component to this mode. In particular,
the largest deformation occurs at the far right (east)
side of the building. This torsional response will place
additional demand on the columns at this side of the
structure.
Nonlinear pushover analysis. To asses the
Figure 7: Mode 1 (Plan)
Don Construction Chemicals India Ltd
Seismic Retrofit: Case Study
performance of the building to seismic loading, a
nonlinear static analysis was conducted. The
structure was initially loaded to a gravity loading
equal to 110% of the dead load and 27.5% of the
unreduced live load. Next, step-by-step lateral
loading in the x- and y- directions were applied to
the structure. Two separate and independent lateral
load patterns were considered: (1) a force pattern
matching the mode shapes with 100% and 30%
loading in each direction and (2) uniform force
pattern with 100% and 30% loading in each
direction. for the governing load case, the demand
and capacity curves do not intersect. Therefore,
collapse of the structure is predicted.
Two particular events of interest were studied: (1)
when does the first plastic hinge form in each
direction, and (2) what is the ultimate configuration
of the plastic hinge? (The plastic hinges are identified
by circles on the columns.) The displaced shape of
the structure at the formation of the first column
plastic hinge is shown in Figure 8. The frame
elevation on the left corresponds to the formation of
the first plastic hinge when the structure is pushed
along the longitudal-direction. This yielding response
occurs at a displacement of 0.84 in. (21 mm),
measured at the second floor level. The frame
elevation on the right corresponds to the formation of
the first plastic hinge when the structure is pushed
along the transverse-direction. This yielding response
occurs at a displacement of 1.44 in. (37 mm),
measured at the right (east) side of the second floor
level. In summary, as long as the second floor
displacements are limited to the values specified
above, it is expected that the column response for the
critical first story columns will remain in the elastic
range.
The displaced structure at a story displacement of
1.5 in. (38 mm) for loading along the longitudinal-
Figure 9a & 9b: Progressive Hinge Formation (elevations)
50 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Figure 10: Progressive Hinge Formation (Plan)
axis (Figure 9a), and 2.5 in. (64 mm) for loading
along the Transverse-axis are shown (Figure 9b).
Note that many of the first story columns have
formed plastic hinges atthe top and bottom. The
soft-story behavior of the building is made clear in
the figures; all the floors above the second floor have
a nearly rigid behavior, while the first story columns
experience substantial deformation.
Figure 10 shows the second floor plan view of the
structure at the deformation level of 2.5 in. (64 mm)
as the structure is pushed in the transverse-direction.
It is noted that all the nonlinear behavior is
concentrated at or close to the right (east) side of the
building. As previously noted, the building is
torsionally irregular in the transverse direction.
Linear time history analyses. To investigate the
performance of the building during a 475-year return
Figure 11: Displacement History of Existing Structure (Linear Model)
event (DBE), the structure was subjected to
acceleration time histories. Study of the three
motions revealed that the San Marino record
produced the most severe test for the structure (i.e.,
the largest values of column stress and story drift). As
such, this record will be used for the remainder of
this paper for comparison purposes.
The three dimensional linear model was subjected
to this accelerogram. Figure 11 shows the second
floor displacements as measured at the lower-right
 Seismic Retrofit: Case Study

(S.E.) corner of the building. Using equal capacity of the columns along the right (east) side
displacement assumption, a comparison of the time of the structure. Addition of steel columns for the
history response of the existing building with that of FVD braces adjacent to all the columns along this
the nonlinear pushover analysis indicates that the gridline met this goal.
story drifts will cause significant plastic rotation in
Ø Increase ductility of all the interior first story
the hinge regions of the columns, and cause probable
columns for the 6-story segment of the building.
collapse of the building. Performance Goal. Since this
To meet this criterion, fiber-reinforced polymer
is a voluntary seismic upgrade, the focus of the
composite (FRP) was wrapped around the hinge
seismic rehabilitation is to address the major
regions (top and bottom) of the columns.
deficiencies of the structure, namely, the soft-story
and torsional response of the building. The retrofit Device No. DBE Capacity, c, k-sec/in K, k/in
will limit the response of the structure to linear kip (kN) (kNsec/ mm) (kN/mm)
elastic behavior; that is, limiting the maximum xand FVD 16 210 (934) 100 (35) 0.5 100 (35)
y-components of the second floor displacement to FVED 4 300 (1334) 125 (44) 0.5 125 (44)
0.85 in. (22 mm) and 1.44 in. (37 mm), respectively. Table 2: Damper Properties
This will give an adequate level of confidence against Structural upgrade
collapse of the structure. The main performance goal
is to provide a cost-effective "collapse prevention" FVDs have been extensively researched
performance upgrade during a 475-year return event (Constantinou and Symans, 1992) and implemented
(DBE).
Retrofit method
To meet the selected performance goals for the
upgrade of this structure, a retrofit approach
combining several state-of-the-art strategies was
utilized.
Ø Reduce the soft-weak story effects by increasing
the effective damping of the structure. This
objective was achieved by employing Fluid
Viscous Dampers (FVD) at the first floor.
Ø Reduce the torsional response of the building
without increasing acceleration demand of the
super structure. This was achieved by adding fluid
viscoelastic dampers at the east side of the
structure.
Ø Provide a more redundant story shear capacity in
the upper floor transverse direction. In the
transverse direction, the building has structural Figure 12: Damper Frame Elevation
walls at the exterior walls only. Therefore, wood
in the upgrade of many structures, including the
shear walls were added for the upper six story
seismic retrofit of the historic Hotel Woodland
portion of the building. These walls will act in a
(Miyamoto and Scholl 1996). FVDs provide an
fashion analogous to cross-walls in an
economical way of improving the structural response
unreinforced masonry (URM) bearing wall
without losing any floor space. This was the chosen
building.
seismic improvement method for this building for
Ø Provide redundancy for the gravity load-carrying two reasons: (1) it reduces the second floor

www.masterbuilder.co.in | The Masterbuilder - April 2011 51

Seismic Retrofit: Case Study
displacement by increasing viscous damping, and (2)
it reduces the seismic demand of the superstructure.
Damper selection. FVDs were strategically placed
in the structure to optimize their effectiveness
without blocking access to the architecturally
sensitive areas of the ground floor. A total of 20
damper bays were utilized. Initially, only linear fluid
viscous dampers were considered for the upgrade,
however, this approach necessitated using relatively
large devices to meet the performance criteria. In
addition, this did not address the torsional
irregularity of the building. To mitigate these
problems, two types of devices were utilized:
nonlinear fluid viscous dampers were used in 16
braced bays, and a combination of nonlinear fluid
viscous dampers in parallel with elastic elements
(herein referred to as fluid visco-elastic dampers, or
FVEDs) was utilized in four braced bays. The table
below summarizes the pertinent properties of the
devices.
Additional columns at either end of the diagonal
devices will prevent the transfer of the damper forces
to the existing building columns. Figure 12 shows a
typical damper frame elevation.
Fluid Visco-Elastic Damper
A combination of fluid viscous dampers and
Figure 13: FVED & FVD Devices
52 The Masterbuilder - April 2011 | www.masterbuilder.co.in
polyurethane elastomers have been successfully used
in the aerospace industry. The mechanical
characteristics of this elastomer are as follows:
(Gallagher Corporation, 2002)
Ø Urethane Elastomers provides consistent
mechanical properties through a temperature
range of 0ºF to 225ºF (-18ºC to 107ºC).
Ø Urethane exhibits compressive capacity of 80 ksi
(552 MPa) without molecular damage and
Figure 14: Displacement History of Damped Structure
elasticity.
Ø Aging under static stress has no effect on
mechanical properties if protected from ultraviolet
light.
Ø Flame resistance is sufficient to meet
Federal Aerospace Regulation 25.853B.
See Figure 13 for FVED and FVD
construction. Prototype testing per FEMA
273 will be conducted to verify response
and durability.
Response of the retrofitted structure
To assess the effectiveness of the proposed
building upgrade, nonlinear time history
analyses of the structure incorporating the
dampers were performed. The mathematical
model of the existing building was modified
by adding the sixteen FVDs and the four
FVEDs. Two time history cases were
considered. In one case, the mathematical
model was preloaded by a static load equal to
90% of the total dead load prior to being
subjected to the lateral accelerations. In the
Cipy Polyurethanes Pvt.Ltd
Seismic Retrofit: Case Study
Figure 15: Typical FVED response
second case, the preload equaled 110% of the dead
load and 27.5% of the unreduced live load. The
envelope of response quantities was then obtained by
selecting the maximum values from the two load
cases.
Response evaluation. To evaluate the seismic
response of the upgraded structure, the displacement
response of the second floor was examined and a
stress check of all first story columns was performed.
Figure 14 shows the second floor displacement
responses for the lower-right (S.E.) corner. It is noted
that the maximum computed displacements are
approximately 0.56 in. (14 mm) and 0.85 in. (22
mm) in the longitudal transverse directions,
respectively, which is well below their target values.
This corresponds to story drift ratios of
approximately 0.003 and 0.004, respectively. A
comparison of the displacement response for the
original structure and this figure shows that the
maximum response was reduced by more than a
factor of five by the addition of FVD and FVED
elements.
Finally, the computed axial force in the columns
was examined. No net axial tension was found in the
existing columns. The maximum force in the FVD
was less than 200 kips (890 kN). As such, the 200-
kip (890 kN) dampers used are adequate for these 16
damper bays. Figure 15 depicts the response of a
typical FVED. It is noted that the maximum damper
and spring forces are approximately 250 kips (1112
54 The Masterbuilder - April 2011 | www.masterbuilder.co.in
kN) and 90 kips (400 kN), respectively.
Spectra acceleration of this structure
was 0.17g.
Conclusion
Analytical studies of the Hotel
Stockton revealed that the structure
would not be able to withstand the
seismic loading resulting from the
anticipated site-specific earthquakes. To
mitigate this seismic deficiency, the
structure was upgraded with a
combination of sixteen nonlinear fluid
viscous dampers, four nonlinear fluid
visco-elastic dampers, and fiber
reinforced polymer wrap at selected columns. The
analytical studies predict that the retrofitted
structure will have a significantly improved
performance when compared to the existing
structure. In particular, the upgrade will limit the
response of the existing members to the linear range
by limiting the expected seismic demand on the
structure. This upgrade will reduce the risk of
building collapse. Total seismic upgrade cost was
$1.3 million ($9/ft2, $96/m2), which was about 5%
of total construction budget ($24 million, $165/ft2,
$1780/m2).
References
Ø Computer and Structures, Inc., 2002, "ETABS 7.2.2, Linear and
nonlinear static and dynamic analysis and design of building
systems," Berkeley, CA
Ø FEMA 273, October 1997, "NEHRP Guidelines for the Seismic
Rehabilitation of Buildings," Building Seismic Safety Council,
Washington, D.C.
Ø Miyamoto, H.K. and Scholl, 2002, "Seismic Rehabilitation of an
Historic Non-Ductile Soft-Story Concrete Structure using Fluid
Viscous Dampers," Proceedings of the 11th World Conference
on Earthquake Engineering
Ø Constantinou, M. and Symans, M., 1992, "Experimental &
Analytical Investigation of Seismic Response of Structures with
Supplemental Fluid Viscous Dampers," State University Of
New York at Buffalo, Buffalo, New York, NCEER-92-0032
Ø Sing, 2002, Site Specific Time Histories for Hotel Stockton,
Richmond, CA
Ø Gallagher Corporation, 2002, "The Engineering Properties of
Urethane Elastomers," Gurnee, IL
Savcor
Corrosion Resistance: Marine Structures

Design Considerations for

Durability of Reinforced
Concrete Structures in Atef Cheaitani M N Ramesh

Marine Environments Atef Cheaitani

Chief Technology Officer Savcor Group Ltd
Sydney, Australia
M N Ramesh
Chief Executive Officer
Savcor India Private Limited, Bangalore, India

I
n recent years, durability requirements are often means that the electrochemical potential of the steel
specified for new reinforced concrete structures locally becomes more negative and forms anodic
especially for those to be built in marine areas, while the other portions of the steel which have
environments. It is evident today that the use of high the passive layer intact will act as catchment areas for
performance concrete, good concrete cover, corrosion oxygen and will form cathodic areas.
inhibitors and protective coating is not sufficient to
In spite of the development of high performance
provide corrosion prevention for reinforced concrete
concrete from the early 1970s until today, it is
structures in severe conditions of marine
evident that the application of high performance
environments. Various corrosion prevention measures
concrete in conjunction with measures such as
such as the use of corrosion resistant reinforcement
protective coating, thick concrete cover and corrosion
and cathodic prevention have been used in the past
inhibitors is not necessarily good enough for ensuring
20 years to reduce the corrosion of reinforcement for
high durability of concrete structures in marine
new reinforced concrete structures in marine
environments. For this reason, various corrosion
environments. This paper will provide a brief review
prevention measures have been used and specified for
of these measures and highlight their applicability
new reinforced concrete structures to be built in
under various circumstances.
marine environments. This paper will provide an
Reinforced concrete is a composite material that overall review of these measures.
relies on the high compressive strength of concrete
Corrosion Prevention Measures
and the high tensile strength of steel for its
mechanical performance. Steel has poor corrosion Corrosion prevention measures in vogue include:
resistance and concrete has good anti-corrosion modifying the concrete mix design to decrease
properties. The hydration process of concrete leads to concrete permeability and provide an adequate cover
the formation of hydroxides which raises the pH level to reinforcement; coating application to limit
of the cement to around 12.5 and provides a stable
oxide layer on the steel surface, which
prevents the anodic dissolution of the
steel. Reinforced concrete failure is caused
by the corrosion of the steel reinforcing
bars as a result of the destabilisation of the
oxide layer. When the passivity of the
steel partly or completely breaks down,
either as result of carbonation or
chlorides, the corrosion will start. This Fig.1. Mechanism of chloride induced corrosion

56 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Corrosion Resistance: Marine Structures
chloride ingress into the concrete; use of corrosion-
resistant reinforcement; addition of inhibitors to the
fresh concrete; and cathodic prevention by impressed
current.
Mix design, concrete cover and coating
application
The quality of concrete is of major importance in
determining the durability of reinforced concrete
structures. Although concrete is a dense material, it
contains pores and many of these pores are
interconnected to form a network of channels that
allow water and oxygen, both important to steel
corrosion, to penetrate into the concrete. For this
reason, a low water/cement ratio will lead to either a
lower number of pores or smaller pores in the
concrete, both of which can lead to a reduction of
concrete permeability and to conductivity of the
concrete. In addition to selecting a lower cement
ratio in the concrete, the selection of the cement type
and the addition of mineral admixtures such as silica
flume, fly ash and slag will play a significant role in
reducing the corrosion rate of reinforcement in
concrete.
An adequate layer of concrete to the first layer of
reinforcing steel may under some circumstances,
delay the ingress of chloride ions. The adequate
depth of concrete cover is normally stated in various
standards, subject to the exposure condition of the
structure. The minimum depth of concrete cover
must be adjusted to allow for tolerances caused by
construction practices.
For dense, high quality concrete with adequate
concrete cover, carbonation induced corrosion of the
embedded steel is not considered to represent a major
problem, however, for concrete structures in marine
environments, regardless of the quality of concrete
and the thickness of the concrete cover, it appears
that it is only a matter of time before detrimental
amounts of chloride reach the embedded steel
through the concrete covers or concrete cracks and
cause reinforcement corrosion and concrete spalling.
The penetration of chloride takes place through
uncracked concrete mainly by capillary absorption
and diffusion. When a relatively dry concrete is
www.masterbuilder.co.in | The Masterbuilder - April 2011 57
exposed to salt water, the concrete will absorb the
salt water relatively fast and wetting and drying of
the concrete especially in tidal zones can accelerate
the accumulation of high concentration of salt in the
concrete. Furthermore, similar areas of concrete with
similar exposure conditions will have variation in the
concrete deterioration process as it is very difficult to
ensure homogeneity of concrete after being placed.
In certain applications where a 100 year design
life requirement is specified for structures located in
marine environments, the use of various chloride
diffusion modelling, carbonation modelling and
durability assessment of other deterioration
mechanisms may lead to the theoretical development
of concrete mixes and design covers that may provide
theoretically a 100 year design life. Typical concrete
used for such applications is 50MPa compressive
strength concrete with, for example, a binder
combination of 52% Shrinkage Limited (SL) cement,
25% fly ash, 23% blast furnace slag, 600Kg/m3
cement content, 0.38 W/C ratio, 75 mm concrete
cover and 500 microstrain drying shrinkage at 56
days. There is no doubt, that the use of such concrete
will lead to a substantial increase in the design life of
a structure in a harsh marine environment, however
there are many other factors that could not be
considered in the modelling process, such as concrete
cracking; wetting and drying effect in accelerating
the rate of chloride penetration; early-age exposure
to seawater before the concrete has gained sufficient
maturity and density; high temperatures during
concrete placement; homogeneity of the concrete;
workmanship problems especially in relation to
concrete cover; and finally, the nature of the
formation of the corrosion cell due to chloride ingress
within the structure which only requires ingress of
chloride to the steel level at various crack locations to
start the development of unlimited numbers of
corrosion cells within the concrete itself.
Coating the external surfaces of concrete may in
some circumstances, assist in delaying the onset of
reinforcement corrosion. In a marine environment,
especially in the tidal and splash areas, it is unlikely
that such a measure will be effective in preventing
reinforcement corrosion.

Corrosion resistant reinforcement
The final and most important line of defence
against corrosion is the reinforcing steel. As a
measure for preventing the corrosion of steel in
building concrete, various types of corrosion resistant
reinforcement have been used in the past.
Epoxy coated reinforcement
Epoxy coated rebars are carbon steel coated with
stable organic coatings (epoxies) to serve as a barrier
for isolating the steel from moisture, chloride ions
and oxygen to prevent corrosion.
Epoxy coated rebars were introduced in the mid
1970s in the United States as means of extending the
useful life of reinforced concrete bridge components
by minimising concrete deterioration caused by
corrosion of the reinforcing steel. The epoxy coatings
are intended to prevent moisture and chlorides from
reaching the steel.
There are various documentations regarding this
subject with some of the documents showing
favourable performance of epoxy coated rebars
especially when used in areas of low corrosion risk.
When epoxy coated rebars have been used in
substructures that are exposed to a severely corrosive
environment, the epoxy coated rebars did not
perform well. Significant premature corrosion of the
epoxy coated rebars was observed in many structures
after 5-10 years from the date of construction.
The main reasons for the failure of the epoxy
coated rebars are:
† Under-film corrosion because of the migration of
water, oxygen and chlorides through the concrete
and epoxy to the steel surface;
† Wet adhesion loss resulting in the separation of
the coating from the substrate; and
† Disbondment of the epoxy coating from the
reinforcing steel which starts at coating defects.
It is the authors' opinion that the use of epoxy
coated rebars for corrosion prevention should not be
considered under any circumstances. In areas of low
corrosion risk, the use of carbon steel with high
58 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Corrosion Resistance: Marine Structures
performance concrete and good concrete cover is
sufficient to prevent any corrosion from occurring. If
the oxide layer which forms around the steel is not
damaged due to carbonation or chloride ingress,
there should be no issues with corrosion. For the
areas of high corrosion risk in marine environments,
the use of epoxy coated rebars will not under any
circumstances provide the adequate corrosion
prevention to extend the life of the structure.
Galvanised steel reinforcement
Steel reinforcing bars can be protected with a
coating applied by dipping properly prepared steel
bars into a molten bath of zinc.
Hot-dipped galvanised coatings for reinforcing
bars have been used over the last fifty years in many
countries to improve the service life of concrete
structures.
Galvanising constitutes a means to extend the
service life of rebars in concrete structures that will
be subjected to carbonation. A substantial increase of
the service life of the structure can be achieved by
using galvanised steel.
For marine structures, where the primary
problem is chloride-induced corrosion, the increase in
service life could be too short to justify the extra cost
required for the use of galvanised reinforcement.
Rapid corrosion will occur when galvanised and black
steel is used in the same structure and is electrically
connected in chloride-contaminated structures.
Stainless steel reinforcement
The term stainless steel refers to a group of
corrosion resistant steels containing a minimum of
12% chromium. Various alloying additions (nickel,
titanium, nitrogen.etc) can be added to provide
different mechanical and corrosion properties. The
use of stainless steel in concrete is related to its
capacity to resist corrosion in chloride-contaminated
structures.
Stainless steel reinforcement has been used in
various countries in structures that are located in
aggressive environments. Stainless steel has been
used in construction joints or critical gaps between
Cico Technologies Ltd
Corrosion Resistance: Marine Structures
columns and decks. There are no extensive
performance data available from long-term use of
stainless steel as reinforcement in concrete.
Because of the very high cost of stainless steel
reinforcement, it is not likely that the entire
reinforcement for a large marine structure would be
made from stainless steel. A more likely use of
stainless steel would be for the outer rebar layer of a
reinforced concrete element in the tidal/splash zone.
Galvanic corrosion in this case between stainless steel
and carbon steel should be investigated.
Corrosion inhibitors
Corrosion inhibitors are chemicals that can be
added to the concrete to decrease the corrosion rate.
The inhibitors can be subdivided into three
categories, anodic inhibitors, which are used to
reduce the anodic reaction rate, cathodic inhibitors,
which are used to reduce the cathodic reaction rate,
and mixed inhibitors which are used to reduce
cathodic and anodic reaction rates.
The inhibitors are used as a preventive measure
for new reinforced concrete structures in aggressive
environments with a known future risk of chloride-
induced corrosion. Corrosion inhibitors are marketed
separately as admixtures or they are present in the
repair product used for conventional patch repair.
There are various questions in relation to the
application of corrosion inhibitors as admixtures to
reinforced concrete. Some of these questions are
www.masterbuilder.co.in | The Masterbuilder - April 2011 59
related to the long-term experience with corrosion
inhibitors, the effect of corrosion inhibitors on
concrete properties, the acceleration of corrosion
when the corrosion inhibitors are used with
inadequate dosage, and other issues related to the
leaching out and evaporation of the inhibitors from
the concrete.
In general, it appears that if inhibitors are used in
suitable concentration, they may delay the initiation
of corrosion, however there is no established evidence
that the commercial inhibitors available at present
are able to reduce the corrosion rate after the
initiation of corrosion.
Cathodic prevention
Steel embedded in alkaline-free chloride concrete
is in the passive condition. This passivity breaks
down when the level of chloride content exceeds the
threshold and pitting corrosion can initiate.
Cathodic prevention is an electrochemical
technique that involves the application of a small
electrical current using anodes that have been
embedded in the concrete during construction. This
system can be applied to an entire structure or to
selected elements of a structure with the aim of
preventing reinforcement corrosion when chloride
penetration from the environment takes place during
the service life of the structure. The basic philosophy
of cathodic prevention is that a much smaller
cathodic prevention current is required to prevent
pitting corrosion compared to a higher current
requirement to suppress ongoing corrosion.
The cost of the application of cathodic
prevention is substantially lower than the
cost of the application of cathodic
protection.
The conditions for pitting initiation and
propagation were pointed out by Pourbaix
who during the 1970s introduced the
concept of "imperfect passivity" and "perfect
passivity" intervals. The different domain of
potentials is shown below. As can be seen
from the graph, for cathodic prevention, a
modest lowering of the steel potential can
produce a significant increase in the critical
Lipi Polymers Pvt.Ltd

chloride level. The free corrosion potential of steel
ranges from -200mV to 0mV versus saturated
calomel electrode (SCE). Pitting corrosion can take
place if the chloride level exceeds 0.4%w/w cement.
If a cathodic prevention current is applied to steel
in chloride-free concrete, this will allow the steel to
remain passive even when the chloride reaches a
considerably high content. The cathodic prevention
current produces hydroxide ions at the steel surface
and causes the chloride ions to move toward the
anode away from the steel.
When cathodic prevention is applied, the
initiation of a new pit is prevented but pitting can
propagate. For this reason cathodic prevention has to
be applied before corrosion initiates and must be
maintained throughout the service life of the
structure. If pitting corrosion has initiated, the
current capacity typical for cathodic prevention will
no longer be sufficient and cathodic protection
current would be required.
Graph showing: cathodic prevention (1-2-3-);
cathodic protection restoring passivity (1-4-5-); and
cathodic protection reducing corrosion rate (1-4-6-)
The use of cathodic prevention for prestressed
steel will eliminate the risk of hydrogen evolution
because a lower current is required to prevent the
initiation of pitting corrosion. A typical operating
current for cathodic prevention ranges from 1-2mA/
m² of steel. The cathodic prevention design current
density is normally 10mA/m² of steel surface. The
design for a cathodic prevention system, system
monitoring and operation is similar to cathodic
protection. The main difference is related to the
lower current density requirement and the ease of
installation during construction.
Conclusion
In order to improve the corrosion resistance of
reinforced concrete structures to be built in marine
environments, it is essential to undertake durability
assessment, durability design and durability planning
as a part of the design phase and construction phase
in order to minimise the risk of long term
deterioration of the structure.
For any structure located in a marine
60 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Corrosion Resistance: Marine Structures
environment, the exposure conditions should be
established and the elements of the structure should
be classified based on corrosion risk.
It is the authors' opinion that for any elements of
the structure that are classified in the low corrosion
risk category, a combination of the use of high
performance concrete, good concrete cover and
external coating can be used to ensure long term
durability of the structure and to increase its life with
minimal maintenance.
For any elements of the structure that are
classified as high corrosion risk areas, such as the
tidal and splash zones, the only economically viable
option that can be considered is the use of high
performance concrete combined with the use of good
concrete cover and the installation of a cathodic
prevention system. It is important to note that any
cathodic prevention system should be maintained for
the life of the structure as an integral part of the
maintenance program of the structure.
The use of a suitable type stainless steel
reinforcement can also be considered to improve the
corrosion resistance of reinforcement. However, this
should only be considered only if stainless steel is
used for the entire structure and no stainless steel is
used in conjunction with carbon steel in order to
avoid potential galvanic corrosion problems.
References
† Tettamanti, M., Rossini A., and Cheaitani, A., "Cathodic
Prevention and Cathodic Protection of New and Existing
† Concrete Elements at the Sydney Opera House", Corrosion/97,
Paper No.255, NACE, 1997.
† Cheaitani, A., "Corrosion Prevention for Marine Structures",
Coast and Ports Australasian Conference 2003, New Zealand.
† Cheaitani, A., Karajayli, P., and Chun-Ni, J., "Application of
Cathodic Prevention to Sea Cliff Bridge, Lawrence Hargrave
Drive", Corrosion & Prevention 2006, Paper 006.
† Cheaitani, A., Pedeferri, P., Bazzoni, B., Karajayli, P., and Dick,
R., "Performance of cathodic
† prevention system of Sydney Opera House underbroadwalk
after 10 years of operation", Paper No. 06342, NACE 2006.
† Zhou,H., and Cheaitani, A., "Corrosion prevention of new
reinforced concrete structures", Chengdu Conference, China
2006.
Chetra Machinery India Pvt.Ltd
Repair : Polymer Modification
P
olymer modification of cement paste increases
the tensile and flexural strength of mortars and
concrete and reduces their brittle nature. Since
the polymer-modified cement is a composite of two
entirely different types of materials, the
characteristics of the key components, cement and
polymer, will be briefly described. Classification of
the polymers used in modification is followed by a
description of the main characteristics of flexible
polymer-modified cement composites and their
applications in concrete repair.
Portland cement based concrete and mortar are
among the most widely used construction materials.
Low cost, high stiffness, high compressive strength,
non-flammability and ease of fabrication are the most
obvious advantages of concrete, whilst low tensile
strength, brittleness and, to some extent, long term
durability represent its most serious limitations.
Reinforcing the concrete with steel provides the
necessary tensile strength and the incorporation of
64 The Masterbuilder - April 2011 | www.masterbuilder.co.in
fibres increases its toughness (resistance to crack
propagation). Polymer modification of cement paste
increases its tensile and flexural strength and reduces
its brittle nature by increasing toughness of mortars
and concrete. In this presentation we will briefly
review the field of polymer modified concrete and
mortars. Since the polymer modified cement is a
composite of two entirely different types of materials,
the characteristics of the key components, cement
and polymer, will be briefly described. Classification
of the polymers used in modification is followed by a
description of the main characteristics of polymer-
modified cements and their applications in concrete
repair. The presentation will then describe
performance characteristic and applications of novel
highly flexible, polymer modified cement composites.
We will conclude by showing that future use of
polymer modified cement composites will likely be in
the area of durability and performance improvements
of cement materials applied in thin sections.

Brief History
The ancient history of using natural polymers
including asphalt to modify lime and clay mortars
goes back to the Babylonians, Egyptians and ancient
India. Europeans in the Middle Ages knew how to
use ox blood and egg white to increase the toughness
and durability of lime mortars. The modern history
of man-made modifiers starts in the late fifties with
the development of butadiene styrene,
polychloroprene and acrylic latex and their use in
modifying mortars and concrete. The main
application of latex polymer modified cements at that
time was in concrete repair. The use of polymers in
the fabrication of bridge and parking garage overlays
was developed in the USA and Canada in the early
seventies. The function of the polymer was mainly to
reduce concrete permeability and to increase
resistance to chloride penetration, toughness and
adhesion. Dry polymer modifiers, so called
redispersable powders, based on ethyl-vinyl acetate
(EVA), polyvinyl acetate-vinyl carboxylate, (VA/
VeovVa), acrylics, styrene-acrylics and others were
introduced in the early eighties. Dry polymer
modifiers allow the formulation of one-component
systems. Initially dry polymer modifiers were inferior
in many aspects to polymer emulsion (latex) but
more recently the dry polymers are becoming as
effective as their chemical equivalents in the latex
form.
Classification
Polymer modified Portland cement paste is a
composite material consisting of an inorganic cement
paste and polymer. Each material is different and it is
beyond the scope of this presentation to discuss the
individual characteristics of these two components.
We will only define Portland Cement, Polymer and
Composite Material (Encyclopedia Britannica).
"Portland cement is a binding material in the form
of a finely ground powder, usually gray, that is
manufactured by burning and grinding a mixture of
limestone and clay or limestone and shale. When
mixed with water, the anhydrous calcium silicates
and other constituents in the Portland cement react
chemically with the water, combining with it
www.masterbuilder.co.in | The Masterbuilder - April 2011 65
Repair : Polymer Modification
(hydration) and decomposing in it (hydrolysis),
hardening and developing strength".
"Polymer is any of class of natural or synthetic
substances composed of very large molecules, called
macro-molecules, that are multiples of chemical units
called monomers".
"Composite Material is a solid material that
results when two or more different substances, each
with its own characteristics, are combined to create a
new substance whose properties are superior to those
of the original"
For the purpose of this paper we are using the
word "cement" to describe "mortars" based on
Portland cement binder, but the word "cement" does
not exclude other cement binders and pozzolanic or
other inorganic admixtures, that can be used as part
of the mortar composition. The performance
characteristics of polymer-modified cement are
controlled by the characteristics of its individual
components. The main characteristics of hydrated
Portland cement paste and polymer are summarized
in Table 1.
Polymer Hydrated Cement Paste
Organic Inorganic
Low modulus of elasticity High modulus of elasticity
High tensile strength Low tensile strength
High elongation Low elongation
High fracture toughness Low fracture toughness
Temperature sensitive Temperature insensitive
Table 1. The basic characteristics of polymer and hydrated Portland
cement paste.
The type of cement, the type of polymer and their
respective quantities mainly control the properties of
polymer-cement composites. Other influences
controlling the final properties of the composite
include the type of surface-active agents used,
mixing, curing, etc. There are a large number of
polymer (monomer) types that are used in
modification of Portland cement paste. Figure 1,
(Chandra & Ohama 1994), shows the main classes of
materials available. For the purpose of this
presentation we will direct our attention primarily to
polymer latexes. These types of polymers can be
further classified by their chemical nature. Since we
Repair : Polymer Modification

paste particles start to hydrate and cement gel

begins to form on the surface of the cement
particles.
Ø The mixture of cement gel covered un-hydrated
cement particles is enveloped with a close-packed
layer of polymer particles.
Ø In the third step, the removal of water by
hydration and evaporation, the closely packed
polymer particles start forming polymer films
(membranes).
Ø Properties of Flexible Polymer Modified Cement
Figure 1. Classification of polymer (monomer) modifiers of cement (FPMC)
paste.

are mainly interested in flexibility of polymer cement Polymer modification of cement paste changes the
composites, we need to introduce the term "glass properties of mortar and concrete. These effects
transition temperature "Tg" of a polymer. Below the depend mainly on the polymer content, expressed as
Tg temperature, polymers exhibit "glassy" behavior polymer/cement ratio, the type of polymer and also
and are relatively brittle with limited flexibility. At the design of the mortar or concrete. Typical effects
temperatures above Tg, the polymer is more flexible are summarized in Table 2.
and tough and exhibits a larger elongation in tension. Property Effect
At Tg properties such as specific volume, specific Compressive strength Decreased or increased
heat, dielectric coefficient, rates of gas/liquid Tensile strength Increased
diffusion through the polymer and conductivity Fracture Toughness Increased
change as shown in Figure 2. Adhesion Increased
Modulus of Elasticity Decreased or increased
Drying shrinkage Decreased or increased
Water vapor permeability Decreased
Hydraulic permeability Decreased
Creep Decreased of increased
CO2 permeability Decreased
Chloride penetration resistance Decreased
Chemical resistance Increased in some chemicals

Table 2. Typical effects of polymer modification on perform-ance of

Figure 2. Glass Transition Temperature (Tg) of an amorphous (non-
crystalline) polymer.
Polymer Modification Mechanism
The mechanism of polymer modification of
Portland cement paste is complex but can be
schematically described in three separate steps:
Ø Immediately after mixing with water, the cement
Portland cement mortars and concrete.
The first commercially available latex modifiers
for Portland cement exhibited Tg in the range of 10-
20 oC. This relatively high Tg of the modifier results
in an increase in the compressive, tensile and bending
strengths as well as increase adhesion and impact
strength of Portland cement based mortars and
concrete up to a certain level of polymer cement
ratio. The tensile elongation is also increased, but the
ultimate tensile strain does not increase much over
1%. The typical relationship between the polymer
content, expressed as polymer/cement ratio (meaning
the weight of polymer solids divided by the weight of

66 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Greaves Cotton Ltd
Repair : Polymer Modification
cement solids), is shown in Figure 3. The Tg of the
acrylic polymer used in the study presented in Figure
3, was +13 oC.
Figure 3. Compressive and flexural strengths of polymer modi-fied
mortars vs polymer cement ratio (p/c).
Tensile Properties
Decreasing the Tg of polymer modifier and
increasing the polymer content in the mortar
increases the tensile elongation. The ultimate tensile
elongation may vary anywhere from 5% to 100%
depending on the level of polymer modification, the
type of the polymer used (even for a given Tg), and
the type of mortar used. The ultimate tensile stress
may vary from 1 MPa to 6-7 MPa and more, but
Figure 4. Tensile stress/strain curves of non-reinforced and re-inforced
FPMC.
typically with increasing tensile strength the tensile
elongation decreases and vice versa. The addition of
fibres or use of reinforcing fabric affects the tensile
stress/strain behaviour of flexible polymer cement
composite. Figure 4 shows the stress/strain
68 The Masterbuilder - April 2011 | www.masterbuilder.co.in
relationship of a non-reinforced and a polypropylene
fabric reinforced, proprietary FPMC. The addition of
short fibre reinforcement generally increases the
tensile strength but may reduce the tensile
elongation. The reinforcing fabric increases the
tensile strength properties without significantly
reducing the tensile elongation. The type of fibre or
fabric, their moduli of elasticity, fabric design and
volume fractions will affect the tensile stress/strain
behaviour of such a composite, but it is beyond the
scope of this presentation to cover this area. The
tensile stress/strain properties and other mechanical
properties of FPMC composite are affected by
temperature. With decreasing temperature the
flexibility of the FPMC composite decreases and this
decrease becomes critical around temperatures below
the Tg of the polymer used. The tensile stress/strain
behaviour is also affected by the wet or dry state of
the composite material. A non-reinforced composite
will exhibit lower ultimate tensile stress and ultimate
elongation in a wet (water saturated) state than those
of dry material. Tensile properties of flexible polymer
modified cements may decrease with time but this
decrease is also dependent on the type of exposure
such as continuous "wet", continuous "dry" or "wet
and dry". The decrease in tensile elongation is usually
accompanied by an increase in tensile strength but it
can be to some extent controlled by the formulation
of the cement mortar.
Compression properties
The compressive strength of polymer-modified
Figure 5. Compressive strength of mortars modified with polymer
latexes of varying Tg. (w/c=0.6, p/c=0.3, sand/cement ratio =2, the
control compressive strength of unmodified mortar 41.6 MPa, test
temperature 180C).

mortar is also affected by polymer modification.
Figure 5 shows the ultimate compressive strength
values of mortars modified with polymers of varying
Tg temperature.
Modulus of elasticity in tension
The tensile modulus of elasticity of flexible
polymer cement will vary considerably depending on
the polymer content, Tg of the polymer and the
composition of the cement matrix. Thus the moduli
of elasticity may reach values as low as 300-500 MPa
for highly flexible composites.
Crack Spanning
One of the reasons for using FPMC is their
flexibility, allowing waterproofing of concrete
structures with "moving cracks". The crack bridging
capacity of a non-reinforced and fabric reinforced
proprietary product in a thickness of 2.5 mm at
different levels of polymer modification is shown in
Figure 6.
Figure 6. Crack-bridging capability of reinforced and non-reinforced
proprietary FPMC as a function of polymer content.
Hydraulic Permeability
FPMC exhibit very good hydraulic
impermeability. A relatively thin layer, 1.6-2.00 mm
thick, applied to concrete will resist water head
pressure in excess of 30-40 meters on both negative
and positive sides.
Water vapor transmission
Depending on the polymer/cement ratio, type of
polymer and formulation of the modified mortar, the
FPMC will exhibit a wide range of water vapour
transmission. When expressed in terms of
www.masterbuilder.co.in | The Masterbuilder - April 2011 69
Repair : Polymer Modification
permeance, a thin 2 mm layer may act as a very
efficient vapour retarder with permeance around 50-
60 ng/Pa.s.m2 (or approximately 1 perm). On the
other hand, flexible polymer modified cements can be
formulated at the same thickness of 2 mm to exhibit
permeances, in excess of 500-600 ng/Pa.s.m2, (or 10
Perms), thus providing a highly "breathable"
waterproofing and protective layer.
Carbon dioxide and chloride penetration
resistance
Data available from technical information on
commercial products show that polymer modified
cements, including flexible cements, exhibit excellent
resistance to carbon dioxide penetration and are very
effective protection for reinforced concrete structures
against carbonation and consequent corrosion of the
reinforcing steel. Similarly the resistance to chloride
penetration of these materials is also very good
(Coppola et al. 1997).
Abrasion resistance
Properly formulated FPMCs exhibit very good
abrasion resistance mainly because of their toughness.
Figure 7 shows "wet" abrasion resistance of several
materials: conventional sand cement/mortar, high Tg
polymer modified mortar, a "dry" polymer modified
proprietary repair mortar, a proprietary FPMC and a
polyurethane membrane - the type used in protection
of balconies. The Taber Abrader was used to
determine the abrasion rate and the results show that
the polymer-modified cement with low Tg is superior
to conventional and polymer modified mortars and
has similar abrasion resistance to that of polyurethane
membrane. The testing was carried out under both
dry and wet conditions. Under wet (water saturated)
conditions the abrasion is higher for all the materials
tested in very similar proportions.
Salt Scaling Resistance
The salt scaling resistance of FPMC is generally
very good, most likely due to the flexibility of the
materials.
Chemical Resistance
Due to their high polymer content, FPMC exhibit
Repair : Polymer Modification
Figure 7. Abrasion resistance of various mortars in wet state - Taber
Abrador Model # 503, abrador wheel, Calabrase H-22, mass on each
arm =500g.
a considerably higher chemical resistance, even in
acidic environments, than conventional Portland
cement mortars or concrete.
Applications of FPMC Composites
Repair of Concrete Digester Tank, Bedford, Nova
Scotia, Canada
In 1993 the concrete roof of a digester tank in
Bedford, Nova Scotia, Canada collapsed. The
concrete roof was replaced with a "gas holding" steel
roof. Over the years and due to excessive pressure the
reinforced concrete tank, which measured 10 m in
diameter and 7 m high, had developed vertical and
horizontal cracks. The repair required long term
sealing of the cracks in the reinforced concrete wall as
well as concrete protection. The designer selected
two materials for the repair: alkaline resistant glass
fibre-reinforced, micro-silica enhanced mortar as the
primary waterproofing layer and a FPMC as the
secondary waterproofing and protective layer. Tests
and practical experience with the fibre-reinforced
mortar had shown that if the crack telescoped
through the layer it would be only hairline. But since
it was difficult to accurately determine the movement
of the cracks in the reinforced concrete wall of the
tank under the fully loaded condition, it was
conceivable that the primary waterproofing layer
would develop fine through cracks due to movement
of the substrate cracks. Therefore an additional
protective coat of FPMC was applied as a secondary
waterproofing and protective layer. The high
flexibility allowed crack spanning of fine cracks and
the high polymer content provided improved
chemical resistance. After cleaning the tank by
sandblasting the vertical and horizontal cracks were
70 The Masterbuilder - April 2011 | www.masterbuilder.co.in
covered using a galvanized welded fabric (1.7 mm
wire diameter, 30 cm wide strip with opening 5 cm
by 2.5 cm) mechanically fastened to the concrete.
After the placement of the welded wire fabric, a 12
mm thick layer of fibre-reinforced mortar was
applied to the concrete surface of the tank. The
material was mechanically applied using the wet
process shotcrete method. The following day the
surface of the primary layer was thoroughly cleaned
with high-pressure water. Then an approximately 3
mm thick layer of FPMC was rolled on in two coats.
The waterproofing, protective system was air cured
for approximately one week before the tank was put
back into use. The performance of the repair has been
excellent. The interior of the tank was inspected in
1997, 4 years after the installation, and no leaks or
deterioration of the waterproofing system was found.
Further inspections in 2000 and 2003 also revealed
no leaking.
Municipal and Industrial Land-fill sites,
Chemical Protection of "Dry" Pre-Cast Manholes,
Brantford, Sarnia, Ontario, Canada
Extensive investigation of concrete manholes and
concrete drainage pipes of a municipal land-fill site in
Ontario using robotic TV camera investigation
showed that after 25 - 30 years of service, there is
approximately 12-15 mm deep concrete deterioration
in many areas due to chemical attack. Since the
specified design life of such structures is presently
being changed from 30 to 100 years, the design
engineers have been looking for various methods to
increase the chemical resistance of wet or dry cast
concrete pipes and manholes. The commonly used
epoxy coatings exhibit high chemical resistance but
in negative side applications where the water is also
getting behind the coating the epoxy coatings de-
bond. FPMC with a high content of a low Tg
polymer provide considerable improvement in
chemical resistance to that of Portland cement
mortar. This improvement is sufficient to increase the
service life of the pre-cast concrete components to
presently specified levels and beyond. In addition
they do not exhibit the problem of de-bonding as in
case of epoxy coatings. They are easier to apply and
less expensive than the epoxies. The dry-cast concrete
pipes were cleaned using high-pressure water. The
Terex India Pvt.Ltd
Repair : Polymer Modification
FPMC layer was applied by spraying and brushing.
A brush was used to provide a pin-hole free coating
approximately 1 mm thick. The second coat was
applied in the same manner and thickness and air-dry
cured.
Underground, reinforced concrete tanks, Port of
St. John's, Newfoundland Canada
Large volume underground reinforced concrete
tanks were built during the Second World War and
used for storage of bunker oil. In 1997 it was decided
to refurbish the tanks and use them as storage tanks
for drilling "mud" used in off shore oil drilling in
Newfoundland. The tanks had extensive cracking
but. the most serious problem was the contamination
with oil residues and an originally applied bituminous
protective coating. The surface of the concrete was
cleaned using high-pressure water with sand in
combination with industrial degreasers. The
degreasing of the surface was carried out several
times. The cracks were treated with a FPMC layer,
reinforced with approximately 15 cm wide
polypropylene reinforcing fabric. The remaining areas
were coated with a different type of FPMC designed
to provide long-term chemical resistance to the
drilling mud.
Cooling tower interior, Bishan, People's Republic
of China
The cooling towers at a thermal power plant in
Bishan, China, were built in the mid Eighties. The
original coal tar epoxy applied to the interior side of
one of the cooling tower wall had failed after
approximately 10 years of service. In 2000 the
original epoxy coating had been removed and another
epoxy coating had been applied to the interior. This
application failed completely, by severe delamination
of the epoxy, in about three to four years. In 2004 it
was decided to use FPMC as waterproofing. There
were a number of reasons for changing the widely
used very low permeability epoxy system but the
main reason was the historically poor performance of
epoxy systems in these types of applications
throughout northern China and elsewhere. A
thorough computer analysis of the moisture content
in the concrete wall, the climatic conditions and all
modes of moisture and heat transfer, showed that
72 The Masterbuilder - April 2011 | www.masterbuilder.co.in
having a very low water vapor transmission coating
(vapor barrier) on the interior was not necessary, since
its water vapor permeability has relatively little effect
on the overall moisture content in the concrete wall
of the cooling tower. The lower cost of the polymer-
modified cement versus the epoxy coating and the
ease of application were also important considerations
is selecting the FPMC over the epoxy. The total
interior area was approximately 8,000 m2. The most
difficult task was to remove the existing epoxy
coating since only some of the epoxy was completely
de-bonded and considerable areas of the epoxy
remaining well adhered. Rotating, mechanical, hand
held grinders were used to remove the epoxy. Due to
time and economic constraints, well-adhered epoxy
was not removed. The FPMC was brush applied in
two coats to a total thickness of 2 mm.
Conclusions
Polymer modification of mortars or concrete
increases the toughness and, to some extent, the
tensile and bending strengths of these materials. By
using a higher level of polymer modification with a
polymer exhibiting a low Tg, a high flexibility in
such composites can be achieved. The main use of
these materials is in thin section applications, in
waterproofing and protection of concrete structures.
The high flexibility allows the spanning of substrate
cracks and provides waterproofing and protection
that cannot be achieved using conventional mortars
or high Tg polymer modified mortars.
References:
Ø Chandra, S. & Ohama Y. 1994, Polymers in Concrete, Boca
Raton, CRC Press
Ø Coppola, L. at al. 1997, Properties of Polymer-Cement Coatings
for Concrete Protection, Fifth Canmet/ACI Conference,
Superplasticizers and other Chemical Admixtures in Concrete,
ACI SP - 173: 267-286
TIL Ltd
Corrosion Control: Technologies
Emerging Corrosion Control Technologies
for Repair and Rehabilitation
of Concrete Structures*
T
echnology always advances faster than the
development of codes, specifications, and
standards. Recent innovations in materials,
processes and corrosion control technologies have
enabled designers and architects to meet
performance-based specifications at lower life cycle
cost. This paper focuses on the recent developments
and applications of state-of-the-art emerging
technologies for repair and rehabilitation of
reinforced concrete structures. These technologies
include: press-on zinc hydrogel anode CP system,
snap-on zinc mesh anode CP system, pre-packaged
zinc sacrificial anode system, conductive concrete,
electrochemical chloride extraction (CE) or
electrochemical chloride removal (ECR),
electrochemical realkalisation (ER), duplex/stainless
steels and alloys reinforcements. Most of these
emerging technologies are also increasingly used for
corrosion prevention in new concrete structures.
Some application examples are also cited to
demonstrate the potentials of these promising
technologies in the new millennium.
Primer on Concrete Corrosion
General
Reinforced concrete is the most versatile and
potentially one of the most durable materials that a
designer can choose to build almost any type of
structures. Under normal conditions, the reinforcing
steel is in a passive state - it is protected from
corrosion by a rather inert oxide film (passive film) on
its surface. The formation and the subsequent
breakdown of such an oxide film are mainly
determined by the pH and the chloride content of
the concrete. When the local environment at the
74 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Dr. Qiu Jianhai, BEng PhD CEng MIMMM FICorr
NACE Certified Corrosion Specialist (#5047)
WebCorr Corrosion Consulting Services
rebar/concrete interface cannot maintain the passive
state of reinforcing steel, active corrosion in either
uniform or localized form (pitting) will occur.
Because of the widespread use of reinforced concrete,
today corrosion of reinforcing steel is rapidly
becoming a major problem throughout the world.
Bridges, marine structures, buildings and other
concrete structures are being severely damaged by
corrosion.
Carbonation
Carbonation refers to the interaction of carbon
dioxide in atmosphere with the hydroxides in the
concrete. Carbonation is detrimental to the corrosion
resistance of reinforcing steel as it destroys the
passive film.
Ca(OH)2+CO2=CaCO3+H2O
CaCO3+CO2+H2O=Ca(HCO3)2
soluble bicarbonate
Leaching of Ca(OH)2 due to carbonation causes
the pH of the concrete to fall below 9 and this leads
to the depassivation of the reinforcing steel surface.
Chlorides
Chlorides are well known for their ability to
penetrate and destroy passive films on steels and
alloys.
Fe => Fe2+ + 2e-
FeCl2+2H2O=2HCl + Fe(OH)
Chlorides may come from an external source such
as seawater or exist as mixed-in. The local
acidification due to the hydrolysis of metal chloride

creates an auto-catalyzing situation for the corrosion
of steel. Chlorides either alone or combined with
carbonation are the primary cause of concrete
corrosion.
Corrosion Products
As corrosion continues, corrosion products build
up around the reinforcing steel. Corrosion products
commonly observed when concrete cores containing
corroding rebar were broken open were ferrous
hydroxide (Fe(OH)2), hydrated ferrous chloride
(FeC12H2O), and black ferrous oxide (Fe3O4).The
exact product formed depends on the availability of
oxygen, water, and chloride ion, but the result is
essentially the same. These corrosion products occupy
from 2 to 14 times the volume of the original steel,
creating an expansive force that is sufficient to cause
the concrete to crack. Propagation of the cracks leads
to staining, spalling and delamination of concrete.
Innovative Cathodic Protection Systems for
Concrete Repair and Rehabilitation
Introduction
Zinc, as a sacrificial anode, has been used to
catholically protect ship's hulls for more than a
century now. It has become a common practice to use
cathodic protection either alone or in combination
with coatings for buried pipelines, storage tanks and
offshore structures. It has been well established both
in theory and in practice that the process achieves an
immediate reduction in corrosion rate by making the
reinforcing steel the cathode, inhibiting its tendency
to oxidize. In addition, the cathodic reactions at the
steel/concrete interface increase the alkalinity (raise
the pH) by hydroxyl ion (OH-) generation and drive
chloride ions (Cl-) away from the steel as a result of
the negative charge on the ions being repelled by the
negative polarity of the reinforcement and attracted
to the positive polarity of an installed anode. Thus
Cathodic Protection of steel in concrete has always
incorporated some degree of Realkalisation (increase
in pH) and Chloride Extraction (redistribution of
chlorides). Both these processes reduce the risk of
corrosion of steel in the concrete and also achieve
further protection. Recent innovations in materials
and design have made CP, - the old remedy, ever
www.masterbuilder.co.in | The Masterbuilder - April 2011 75
Corrosion Control: Technologies
more attracting and promising today.
Pressure-sensitive Zinc-Hydrogel Anode
For conventional CP systems (SA or ICCP) to
function properly, it requires the presence of a
continuous conductive electrolyte between the anode
and the cathode. This is to form a closed circuit such
that the reinforcing steel is indeed made the cathode.
In areas of electrical discontinuity, reinforcing steel
would not be cathodically protected. One of the
recent innovations is the self-adhesive and conductive
zinc-hydrogel anode that provides a continuous
electrolyte contact between the anode and the
reinforcing steel embedded in the concrete structure.
The pressure-sensitive zinc-hydrogel anode is
essentially a sheet of zinc foil coated with an ionically
conductive hydrogel pressure-sensitive adhesive
(Figure 1), which serves as the electrolyte between
the anode (zinc foil) and the cathode (reinforcing steel
in concrete). The hydrogel is covered with a liner to
help protect it from contamination. At time of
installation, the protective liner is removed from the
hydrogel by hand, and the zinc-hydrogel anode is
adhered to the clean, bare concrete surface.
This zinc foil anode coated with hydrogel is
provided in roll form for coverage of the concrete
surface to be protected. The ionically conductive
hydrogel performs two functions: (1) to enable the
anode to be securely adhered to the exterior surface
of the concrete structure, and (2) to serve as a
continuous conductive electrolyte between the anode
and the concrete structure.
How It Work
As illustrated in Fig. 2, the zinc foil is applied to
the surface of structurally sound concrete structure.
The pressure sensitive adhensive (conductive
hydrogel) bridges the gap between the zinc anode
(foil in this case) and the concrete surface - making
possible the electrolyte continuity across the anode
and cathode (rebars).
The zinc foil must be electrically connected to the
rebar network by wires so that electrons can flow
through the wire from zinc (anode) to rebars
(cathode). Conventionally, current flows in the
opposite direction of electrons, i.e., from cathode to
Corrosion Control: Technologies
Fig. 1 Pressure-Sensitive Zinc-Hydrogel Anode
(Illustration copyrighted by 3M)
Fig. 2 Installation of Zinc-Hydrogel Anode
(Illustration copyrighted by 3M)
anode. Ionic current is carried by charged species
such as Cl-, Na+, OH-, Ca2+ etc. across the
electrolyte (concrete + hydrogel). The potential of
rebar and the current flowing between the zinc foil
and the rebar can give some indication about the
degree of cathodic protection.
Why It Works
Corrosion of rebar is the process involving the
following oxidation reaction:
Fe ==> Fe2+ + 2e
A neutral iron atom lost 2 electrons and became a
positively charged ion. The tendency of a metal to
lose electrons can be considered as the tendency of
metal to corrode.
When zinc foil is applied to the concrete surface
but not connected by wire to the rebar network, the
steel rebar continues to corrode at a normal rate.
When zinc foil is electrically connected to the rebar
76 The Masterbuilder - April 2011 | www.masterbuilder.co.in
network, ELECTRONS flow from zinc foil into steel
rebars, thus reducing the steel's tendency to lose
electrons and hence reducing the rate of corrosion
(oxidation). This is because zinc is a much more
reactive metal than steel, it has a much greater
tendency to lose electrons than that of steel. Since
electrons carry negative charges, the accumulation of
electrons within steel rebar makes steel more
negatively charged, leading to cathodic polarisation, -
the shift of rebar potential in the negative direction.
In general, the greater the tendency for the anode to
donate electrons to the cathode, the greater the
degree of protection rendered to the "cathode" (the
steel rebar network). However, one must remember
that when an anode donates electrons to the cathode,
the anode material "sacrifices" itself. What this means
is that the useful life of the anode is both limited by
the chemical/electrochemical surface reactivity and
the amount of physical material available.
Potential Applications
The nature of the zinc hydrogel anode makes it a
perfect rehabilitation option for structures or certain
sections of structures exposed to atmospheres. The
conductive hydrogel ensures the continuity of
electrolyte across the rebar-concrete-hydrogel-anode,
and hence cathodically protects the rebar network.
Tips: It is a good idea to paint the zinc surface to
preserve the anode material by reducing corrosion of
zinc from external atmosphere.
Pre-packaged Zinc Sacrificial Anode
Conventional patch repair of corroded concrete
structures inevitably introduces "incipient anode"
effect due to the different electrochemical behavior of
the "new" and "old" rebar/cement. The newly patched
area has a higher potential than the neighboring area
(which may still be contaminated with chloride) and
is the cathode in the corrosion process, while the
rebars in the neighboring areas become the anode
and start to corrode. Conventional patch repair treats
only the symptoms not the cause and the incipient
anode effect makes this repair a never-ending process.
One innovative product that uses pre-packaged
zinc sacrificial anode (commercially known as
Pidilite (Dr.Fixit)
Corrosion Control: Technologies

Galvashield XP - registered trademarks of Fosroc

international) can provide solution to the incipient
anode induced corrosion (Fig.3). Since zinc is pre-
packaged in a specially formulated mortar that
maintains the surface reactivity of zinc, electrons
released from zinc will be readily transferred to the
neighboring steel rebar network. The effective
protection distance by such an embedded unit is
sufficient to suppress the incipient anode effect.
Installation of such an integrated system is easy and
flexible. There are no special techniques required.
The self-contained wire ties allow attachment to
vertical, horizontal and overhead positions (Fig.4).
The effectiveness of the pre-packaged zinc sacrificial
anode on the preventing rebar corroison is
demonstrated in Figure 5.

Fig.5 Effectiveness of pre-packaged zinc sacrificial anode on the

corrosion of rebar
Photo copyrighted by FOSROC International

cathodic protection system. The principle behind the

Fig.3a Zinc encased in special mortar 3b Cross-sectional view the zinc
anode
Photos copyrighted by FOSROC International
Fig4. Installed zinc anode (Galvashield XP)
Photos copyrighted by FOSROC International
Laboratory experiments showed that the zinc
anode can suppress the formation of incipient anodes
around the repair (Fig.5).
Field applications include car parks, buildings,
bridges and any other reinforced concrete structures
where conventional patch repairs can not provide
acceptable performance.
Snap-on Zinc Mesh Anode CP system
System Description
This is yet another innovation in sacrificial anode
system is exactly the same as that used by the zinc
hydrogel anode system and the pre-packaged zinc
anode system. This product was originally developed
as "Lifejacket" by Alltrista Zinc products Company in
North America and is marketed by FOSROC
International as "Galvashield LJ". The all-in-one
system (Fig.6) is based on the installation of 2-piece,
snap-together jackets (Fig.7) lined with expanded
zinc mesh (Fig.8).
Each jacket assembly is supplied with a minimum
of 8 non-conductive standoffs per face. These
standoffs secure the zinc mesh in place while
achieving the optimum position of the jacket in
relation to the piling.The self-contained system
provides an innovative solution to the corrosion
problems of both new and existing concrete
structures subject to periodic wetting and drying as
experienced in the splash and tidal zones (Fig.9).
Life Expectancy
As in any other sacrificial anode CP system, the
life expectancy can be calculated if current output of
the anode is known. It is mainly determined by the
amount of zinc anode material and the rate (current

80 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Ajax Fiori Engineering (I) Pvt.Ltd
Corrosion Control: Technologies
output) at which zinc "sacrifices" itself (in order to
protect the cathode):
Manufacturer's data sheet suggests that the zinc
mesh embedded in the snap-on fibreglass jacket has a
projected life of 46 years.
Fig.6 Snap-on Zinc Mesh Anode CP System (Galvashield LJ) (Photo
copyrighted by FOSROC International and Alltrista Zinc products
Company)
Fig 7 & 8 The two-piece fiberglass jackets snap together (Photo
copyrighted by FOSROC International and Alltrista Zinc
products Company)
Fig.9 Zinc Mesh Anode Installed on Bridge Pilings (Photo copyrighted
by FOSROC International and Alltrista Zinc products Company)
82 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Major Attractions and Applications
Compared with conventional CP system, the
snap-on zinc mesh anode jacket has the following
attractions:
† All-in-one, self-contained sacrificial anode CP
system
† Snap-on type quick, easy installation
† Low cost effective repairs
† Maintenance-free
† No need for external power
† Long life protection
† Jackets are available in a wide range of sizes and
can accommodate both square and round pilings
(Fig.10)
Major applications include splash and tidal zones
of steel reinforced concrete structures. Optional Cast
bulk zinc anode can be used on fully submerged
structures.
Electrochemical Treatment
Principles
In all electrochemical restoration techniques a
direct current is applied between the reinforcement
(cathode) and an external anode in electrolytic
contact with the concrete. Cathodic protection (CP) is
a permanent installation with design currents below
10 mA/m2, electrochemical chloride extraction (or
removal, - EC or ECR) and electrochemical
realkalisation (ER) are applied only on a temporary
basis and use currents up to 1 A/m2. In all three
cases the electrochemical reactions at the cathode (the
rebars) produce hydroxyl ions leading to an increase
of the pH near the rebar. This facilitates passivation
of the steel. Reaction (1b) is possible at very high
current densities and produces hydrogen and
especially high tensile steels under load could suffer
hydrogen embrittlement.
2 H2O + O2 + 4e ==> 4OH- (1a) (at low
current density)
2 H2O + 2e- ==> 2OH- + H2 (1b) (at high
current density)
At the anode the possible oxidation reactions are

Fig.10 Jackets for square and round pilings
(Photo copyrighted by FOSROC International and Alltrista Zinc products
Company)
oxygen evolution, chlorine evolution or water
decomposition:
2 H2O ==>O2 + 4H+ + 4e- (2a)
water is used)
4OH- ==> O2 + 2H2O + 4e- (2a') (if
alkaline solution is used)
2 Cl- ==>C12 + 2e- (2b)
H2O + C12 ==>HCl + HClO (2b')
These reactions lead to an acidification of the
electrolyte around the anode (OH- ions are converted
into O2; H2O is converted into H+). The decrease in
pH value in the electrolyte around the anode depends
on the current density applied.
Anode and Electrolyte Selection
Electrochemical Realkalisation:
Anode material: Steel mesh
Electrolyte: 0.5M ~ 1.0M LiOH solution
Chloride Extraction:
Anode Material: Platinum-coated titanium wire
(chlorine gas is prevented by using ion exchanger
impregnated with saturated Ca(OH)2 solution. The
ion exchanger is placed between the concrete surface
and the anode, Cl- ions escaped from the concrete
into the electrolyte are exchanged for OH- ions);
Copper wires (copper dissolves on the anode and
combines with Cl- to form CuCl2; Aluminum foil
Electrolyte for CE: Saturated calcium hydroxide;
Sodium borate; Sodium hydroxide; Tap water
Due to reactions on the anode (equations 2a, 2a',
2b), the pH of solution around the anode will
Corrosion Control: Technologies
decrease. The acidification of electrolyte and
formation of chlorine gas are considered to be
undesirable. An acidic solution may attack the
concrete and chlorine gas is toxic. Using alkaline
electrolyte such as saturated calcium hydroxide
solution or a sodium borate solution can prevent acid
attack on concrete and chlorine gas formation. At pH
above 7, practically no chlorine gas is formed as the
reaction on the anode is predominated by reaction
indicated by equation (2a').
Summary
(if tap Electrochemical chloride removal and
electrochemical realkalization lead to an increase in
pH at the rebars and to repassivation of corroding
steel. The durability of ECR has been proven on
different site jobs with a track record between five
and eight years if further chloride ingress is avoided
by applying a coating on the concrete surface. Several
reinforced concrete structures treated with ER
showed good performance over several years without
applying a coating. To avoid adverse side effects the
current density during the treatments must be
limited to < 2 A/m2 steel surface. Methods and
quantitative criteria to assess the efficiency and
durability of the electrochemical repair methods
should be improved and defined in an international
standard.
Conductive Concrete
The Nature of Conductive Concrete
Conventional concrete is excellent in durability
and mechanical properties but is a poor electrical
conductor, especially under dry conditions. Durable
concrete that is excellent in both mechanical and
electrical conductivity properties may have important
applications in the electrical, electronic, military and
construction industry (e.g. for CP system, de-icing
road from snow).
Conductive concrete may be defined as a
cementitious composite which contains a certain
amount of electronically conductive components to
attain stable and relatively high electrical
conductivity. The principle behind it is the use of
cement to bind together electrically conductive
www.masterbuilder.co.in | The Masterbuilder - April 2011 83
Corrosion Control: Technologies
materials such as carbon fiber, graphite and 'coke
breeze' - a cheap by-product of steel production - to
make a continuous network of conducting pathway.
The design formulation is based on the 'electrical
percolation' principle by which the composite
conductivity increases dramatically by several orders
of magnitude when the content of the conductive
phase reaches a critical 'threshold' value. Further
increases in the conductive phase content boost
composite conductivity only slightly. The design
specifies an amount just over the threshold content,
assuring high conductivity and mechanical strength
as well as good mixing conditions.
Concrete bridge decks are prone to ice
accumulation. The use of road salts and chemicals for
deicing is cost effective but causes damage to
concrete and corrosion of reinforcing steel in concrete
bridge decks. This problem is a major concern to
transportation officials and public works due to rapid
degradation of existing concrete pavements and
bridge decks. The use of insulation materials for ice
Sydney Opera House
Type 316 stainless steel rebar and mesh replacing carbon steel
reinforced concrete which failed after about 25 years of service
(Photo copyrighte dby NiDI)
84 The Masterbuilder - April 2011 | www.masterbuilder.co.in
control and electric or thermal heating for deicing
have been attempted and met limited success. Based
on the results of a transient heat transfer analysis, a
thin conductive concrete overlay on a bridge deck has
the potential to become a cost effective deicing
method. When connected to a power source, heat is
generated due to the electrical resistance in the
cement admixture with metallic particles and steel
fibers. Small-scale slab heating experiments have
shown that an average power of about 520 W/m2
(48 W/ft2) was generated by the conductive concrete
to raise the slab temperature from -1.1oC (30oF) to
15.6oC (60oF) in 30 minutes. This power level is
consistent with the successful deicing applications
using electrical heating cited in the literature.
Applications of Conductive Concrete
The conductive concrete can be used as a
structural material and bonds well with normal
concrete. The conventional mixing type is
lightweight, with only 70 per cent of normal
concrete weight. Thermal stability is comparable to
normal concrete, production employs conventional
mixing and casting equipment, and application of the
conductive concrete is similar to that of conventional
concrete. The conductive concrete could be used
along with specially configured electrodes and an
electric power supply to provide de-icing on roads,
sidewalks, bridges and runways. Placed as an overlay,
conductive concrete with very low resistivity can be
used as a secondary anode in existing cathodic
protection systems, providing uniform current
distribution over its large surface area and reduced
anodic current density. At the same time, it provides
excellent mechanical stability due to its load-bearing
capacity and its bond strength as an overlay. And
because conductive concrete attenuates
electromagnetic and radio waves, it can be used to
shield computer equipment from eavesdropping
efforts and protect electrical installations and
electronic equipment from interference.
The Benefits
Conductive concrete has excellent mechanical and
electrical conductivity properties.
† It is much lighter in weight than conventional
Liugong India Pvt.Ltd
Corrosion Control: Technologies

concrete. achieve certain required properties. The properties of

a stainless steel are determined by it structure which
† It can be produced easily, without special
is in turn determined by its alloying composition.
equipment.
There are three types of stainless steels according to
† It will reduce the need of salts and save millions in the structure: ferritic, austenitic and martensitic.
dollars in snow removal costs. Austenitic grades 304 and 316 are the widely used
† It warms by power taken off-line, it uses an AC reinforcing material.
current. It is also safe for a person crossing a It has long been well established that stainless
charged concrete pathway. steels have superior corrosion resistance than carbon
† It can also be used for protecting structures steels. Stainless steels and alloys can maintain their
against static electricity and lightning, and natural passivity in seawater or 3.5% NaCl solution.
preventing steel structures and reinforcing layer of In comparison, the passive behaviour of carbon steel
steel in concrete structures from corroding. rebars observed in concrete will be totally lost when
carbon steels are immersed in seawater or 3.5% NaCl
† It absorbs over 90% of the electromagnetic solution, leading to active dissolution and hence
energy and it is cheaper and more convenient continuous loss of material. Research has shown that
than the existing ways of blocking out when the pH of concrete pore water falls below 9,
electromagnetic energy. carbon steel rebar will depassivate. Stainless steels
Stainless Steels and Alloys Reinforcements can even maintain their passivity in acidic
environment. Carbonation and/or chloride ingress
The Difference Between Black Rebar and would not be able to destroy or depassivate stainless
Stainless Steel Rebar rebars as the chromium oxides (the passive film on
Stainless steel differs significantly from carbon
steel in its composition, structure and properties. As
its name suggests, stainless steel is stainless and has
superior corrosion resistance when compared with the
carbon steel. The most fundamental difference lies in
the composition. By definition, steel is considered to
be stainless when it contains at least 12% chromium.
This is the minimum amount of chromium required
in an alloy/steel to maintain its "stainless" surface
appearance. The superior corrosion resistance of
stainless steel is due to the stability of an ultra thin
surface oxide (mainly chromium oxide) - the passive
film. If the passive film is broken or damaged due to
chemical or mechanical actions, the chromium
element in the steel substrate can almost instantly
repair the damaged area by re-oxidization (re-
passivation). It is this unique self-healing process that
makes stainless steel "stainless".
Type of Stainless Steels and Alloys
Chromium is the essential element in all types of
stainless steels and alloys. Other alloying elements 140 tonnes of Type 304 stainless steel rebar being installed in an
such as nickel and molybdenum are also used to addition to the historic Guildhall, London (Photo copyrighte dby NiDI)

86 The Masterbuilder - April 2011 | www.masterbuilder.co.in


Type 316LN rebars being installed in a bridge deck on highway 407 just
north of Toronto, Canada (Photo copyrighte dby NiDI)
stainless steel surface) is much more stable and hence
has much greater resistance to corrosion than the iron
oxides (the passive film on carbon steel surface). In
recent years, more designers and engineers have
realised that solid stainless steels offer highest
protection against corrosion in concrete structures.
With many other alternative CP systems and coated
products, the ultimate failure has often been due to
over-reliance on that lowest common denominator at
construction site level, namely the unskilled labour.
This is particularly so for coated/galvanized rebars -
which, unlike solid stainless steels, are not
homogeneous. Careless handling and installation
(cutting, bending) can serously impair their corrosion
resistance. With solid stainless steel rebars, however,
the integrity and durability will not be affected at all.
Intelligent Use of Stainless Rebars
Stainless steels offer almost maintenance-free
solution to the problem of long-term durability of
concrete structures and can be used within existing
design codes and practice in two ways. The simplest
but more expansive option would be to use 100%
stainless rebar to replace existing carbon steel rebar.
This would eliminate corrosion and enable a design
life in excess of 120 years. The total cost can be
competitive when life cycle costing is taken into
account. To reduce the cost, stainless steel rebar can
be used intelligently in areas of a structure such as
bridge joints, splash zones, support structures and
column heads where carbon steel rebars are judged to
be at high risk of corrosion. If stainless rebars are
used in vunerable areas where cracking occurs and
water enters, there will be no significant corrosion
www.masterbuilder.co.in | The Masterbuilder - April 2011 87
Corrosion Control: Technologies
and the structure will remain sound. It has been
estimated that the stainless steel content on
prestigious structures would be as little as 7~20%.
The same concept can be used in other structures
such as general building where peripheral or external
walls could be constructed from stainless steel rebar
linking in to carbon steel rebar for the internal
structures where corrosion is not a problem.
Applications
Ranking Of The Emerging Technologies For
Corrosion Control In Concrete Structures
Based on the effectiveness in reducing or stopping
the corrosion of steel reinforcement, the following
ranking is suggested:
Conclusions
The emerging technologies are increasingly used
for the repair and rehabilitation of reinforced concrete
structures due to their effectiveness and ease of
installations. For long-lasting cost effective structures
and facilities, these emerging technologies are already
used for corrosion prevention in new concrete
structures exposed to more corrosive environments.
If you want to know more about this topic
presented here, there is a short course entitled
"Emerging Corrosion Control Technologies for the
Repair and Rehabilitation of Concrete Structures". It
can be taken as in-house training course, online
course or distance learning course at
www.corroosionclininc.com
Acknowledgement
The author wishes to thank the following
organizations and companies for the permission to
use copyrighted photographs, drawings and
illustrations in this paper: The Nickel Development
1 Impressed Current Cathodic For repair /rehabilitation
Protection (ICCP) For new structures
2 Stainless steel / duplex stainless For repair /rehabilitation
steel For new structures
3 Sacrificial Anode (SA) system For repair/rehabiliation
4 Electrochemical Treatment For repair/rehabiliation
ER/ECR (or CE)
5 Conventional patch repair Base for comparison
Corrosion Control: Technologies
Institute, 3M Company (S) Pte Ltd, Fosroc
International.
References
Ø Peter Pullar-Strecker, Corrosion Damaged Concrete,
Butterworths 1987
Ø Corrosion of Steel in Concrete, Eds P. Schiessl, Chapman and
Hall, 1988
Ø Corrosion of Reinforecment in Concrete Construction, Eds Alan
P. Crane, Ellis Horwood, 1983
Ø Corrosion Rate of Steel in Concrete, ASTM, STP 1065, 1988
Ø Cathodic Protection of Reinforcement Steel in Concrete, Eds K.
G. C. Berkeley, Butterworths, 1990
Ø Controlling Concrete Degradation, Proc of the International
Seminar, University of Dundee, Scotland, 1999
Ø Corrosion of Reinforcement in Concrete, Eds C. L. Page, K. W.
J. Treadaway and P. B. Bamforth, 1990
Ø Corrosion of Reinforcing Steel in Concrete and Its Prevention by
Cathodic Protection, J. Bennett, 1986
Ø Corrosion of Reinforcement in Concrete Construction, Eds C. L.
Page, P. B. Bamforth and J. W. Figg, 1996
Ø C. J. Abbott, Concrete, May 1997
Ø A. Lewis, Concrete, September 1997
Ø B. Elsener, M. Monila and H. Bohni, Corrosion Science, Vol.35,
p1563 (1993)
88 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Ø J. Parker, Concrete, September 1997
Ø P. Whiteway, Nickel, Vol.14, September 1998
Ø R. J. Kessler, "Zinc Mesh Anode Cast into Concrete Pile
Jackets", Materials Performance, December 1996
Ø G. Sergi and C. L. Page, Sacrificial Anodes for Cathodic
Protection of Reinforcing Steel Around Patch Repair Applied to
Chloride-Contaminated Concrete", EuroCorr' 99
Ø J. Flis et al, Corrosion, Vol.49, 1993
Ø "Concrete Conductor", Construction Materials, Chemistry &
Industry News, 17 March 1997
Ø P. Xie, P. Gu and J. Beaudoin, Electrical Percolation Phenomena
in Cement Composites Containing Conductive Fibres", Journal
of Materials Science, Vol. 31, 1996
Ø Renderoc Galvashield XP - Sacrificial Anodes for Sustaining
Localised Concrete Repairs, system guide of FOSROC limited.
Ø Galvashield LJ for Marine Structures, Product Guide of
FOSROC limited.
Ø Rob W. Lambe and Nigel Davison, Enhancing the Durability of
Concrete Repair Systems, Concrete' 99, 6th International
Conference on Concrete Engineering and Technology, 29 June -
1 July 1999, Kuala Lumpur, Malaysia.
Ø Zinc-Hydrogel Anode 4727, Product Guide, 3M.
Ø R. B. Hartman and J. E. Wehling, "A Galvanic Zinc-Hydrogel
System for Cathodic Protection of Reinforced Concrete
Structures", 3M Company
RD Mining Equipments Pvt.Ltd
Post Event Analysis

2nd International Conference on

CONSTRUCTION CHEMICALS
Speakers Highlight Role of Construction Chemicals for a Sustainable Tomorrow

T he importance of construction
chemicals can never be
overemphasized, especially in a
developing country like India where
awareness levels about them is
comparatively lower. The 2nd
International Conference on
Construction Chemicals “ Construction
Chemicals Conclave -2011 , organized
by FICCI and the Dept. of Chemicals &
Petrochemicals, Govt. of India, was
therefore an important event, with
several industry luminaries
highlighting the advantages of
construction chemicals and the way
forward for the country in the field. The
conference was held at Hotel Le
Meridian, Bengaluru, from March 17-18.
The conclave featured high profile
speakers from both and abroad talk on
the entire spectrum of topics
connected to the construction
chemicals industry. Going into the
current status of the industry,
Mr.R .K.Bhatia, Head-Chemicals
Division, FICCI, observed “Construction
chemicals is estimated to be an Rs.1,
800 crore industry in the country.
About 85 percent of contractors aren't
aware of the advantages of
construction chemicals,” a fact that
was agreed to by almost all the
speakers.
However, there is no denying the
fact that awareness levels about
construction chemicals is on the rise in
the country. The rapid advancements
in building technology owe a lot to the
d eve l o p m e nt s i n t h e f i e l d o f
construction chemicals in the last two
decades. Surging construction activity,
spurred on by the continued impetus
to infrastructure development
activities and the booming real estate
market are giving fillip to the
construction chemicals market in the
country today. Talking about the
challenges ahead Mr.R.Mukundan,
Managing Director, Tata Chemicals Ltd,
in his welcome address said “The
construction chemicals market is right
now small but we can expect rapid
growth rate of 25-35 %. This is not
going to be sufficient. Why can't we
think of making it a ` 10,000 crore
industry? This conference has been
organized to address such challenges.
For instance, how can we improve
quality standards, etc.”
The growth potential for the
construction chemicals industry is huge
in India to say the least. To put things
into perspective, one just needs to look
at the market in comparison with that
of a development nation like the
United States where the market is
valued at US $ 7.7 billion.
While the overall market is fairly
consolidated, there is considerable
fragmentation when it comes to
application areas. While admixtures
form the largest selling products at 35
percent, flooring chemicals follow
second with a 15 percent market share.
Another interesting fact is that the top
five players account for about 50
percent of the market, while the rest of
it is taken care of by the smaller,
unorganized players.
Speaking further about the
challenges faced by the industry, guest
speaker, Dr.Paul J.Tikalsky, Chairman &
P ro fe s s o r, D e p t . o f C i v i l a n d

90 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Lucky International
Post Event Analysis
Environmental (Nuclear) Engineering,
The University of Utah, USA, remarked
in his address, “Development of
infrastructure in a sustainable way is
the challenge for the construction
industry. We must therefore find
inorganic and organic chemicals for a
sustainable environment.”
Dwelling on the way forward for the
industry, Mr.Sanjay Bahadur, CEO,
Pidilite Industries, said in his keynote
address that diminishing natural
resources, demands of mass housing,
high-rise construction, high speed
construction, etc, are all challenges for
the construction chemicals industry.
“Propagation of the multiple benefits
of construction chemicals is the need of
the hour,” added Mr.Bahadur,
emphasizing the role that major brands
have to play in this industry, which is
still at a nascent stage in India.
As part of the vision statement,
M r. D . S i t a r a m i a h , E x p e r t a n d
Consultant, spoke about history of
construction chemicals in India, its
current status and where it is headed.
This was followed by the inaugural
92 The Masterbuilder - April 2011 | www.masterbuilder.co.in
address by Mr.S.C.Gupta, Joint
Secretary, Dept. of Chemicals and
Petrochemicals, GoI, who during his
speech observed that the construction
chemicals industry is potentially a US $
1 billion industry by 2020.” According
to estimates, construction chemicals
cost less than 2 % of the total
construction cost, but offer immense
benefits,” Mr.Gupta quipped, speaking
about the advantages of construction
chemicals and the lack of awareness
about them in the country. He also
pointed out that things are changing
for the better and it is only a matter of
time before the country catches up
with the rest of the world in the field.
The session on “Overview of
Construction Chemicals” was chaired
by Dr.Y.P.Kapoor, a doyen in the
construction chemicals industry and
Director, Editorial, Construction
Chemicals, The Masterbuilder. The
eight sessions saw over 30 eminent
speakers from the industry speak on an
entire gamut of topics pertaining to the
construction chemicals industry. A key
undertone in almost every speaker's
address was the emphasis on
sustainability and how construction
chemicals can contribute towards a
green tomorrow.
Under the topic of “Role of
Construction Chemicals in making
S u s t a i n a b l e S t r u c t u r e s ”,
Dr.S.K.Manjrekar, Chairman and
Managing Director, Sunanda Specialty
Coatings Pvt Ltd, highlighted the crucial
role of construction chemicals in
today's world, where sustainable
structures are the norm. Giving an
architect's perspective on the issue,
Ms.Meghana Dutta, Principal
Architect, Studio Decode, observed
that, “Every building presents an
opportunity for sustainability.” The
session on “Green Chemistry of
Construction Chemicals for
Sustainability” also saw speakers
including, Mr.K.Padmakar, Head-
P ro d u c t M a n a ge m e nt , P i d i l i te
Industries, and Mr.Ravindra Babu,
Marketing Manager, Fosroc India speak
on the relationship between
sustainability and construction
chemicals.
Revathi Equipment Ltd
Infrastructure: Nuclear Plants
I
ndia has an ambitious target of power production
by Nuclear Power Reactors to meet future energy
needs of the country. Two Indian companies,
Nuclear Power Corporation of India Limited (NPCIL)
and Bharatiya Nabhikiya Vidyut Nigam Limited
(BHAVINI) are responsible organization to construct
thermal reactors and fast breeder reactors respectively
in the country. NPCIL is currently operating
seventeen nuclear reactors and constructing five
reactors. Many more reactors are at anvil. Bharatiya
Nabhikiya Vidyut Nigam Limited formed as a
94 The Masterbuilder - April 2011 | www.masterbuilder.co.in
company and registered under Companies Act, 1956
on 22nd October 2003 under the administrative
control of Department of Atomic Energy is presently
involved in construction and commissioning of 500
MWe Prototype Fast Breeder Reactor (PFBR) at
Kalpakkam. Kalpakkam is an important nuclear
establishment of Department of Atomic Energy of
India and this coastal site is situated 70Km south of
Chennai. The PFBR is the forerunner for the future
Fast Breeder Reactors to be constructed in various
parts of our country including two more reactors at

Kalpakkam to meet the future energy needs of India.
BHAVINI is constructing Mega Project PFBR and
the reactor is now in advanced stage of construction.
Preface:
PFBR is situated on the south of existing twin
units of Madras Atomic Power Station (MAPS). The
centre lines of MAPS unit 2 and PFBR are only 500
meter apart. PFBR and MAPS locations on the beach
of Bay of Bengal, is shown in Figure-1.
www.masterbuilder.co.in | The Masterbuilder - April 2011 95
Infrastructure: Nuclear Plants
Fig-1: Location of PFBR and MAPS at the beach of Bay of Bengal
The entire PFBR plant is divided into nuclear and
power islands. The reactor location with respect to
MAPS is governed by minimum recirculation of
water discharge from condenser to sea. The PFBR
plant located on the shore takes condenser cooling
water from sea. Sand transportation and littoral drift
are large at sandy beach profile and at sea bed near
PFBR. The intake structure in PFBR was therefore
required to be engineered to avoid the sand entering
the pump house and clogging the intake passage to
condenser cooling water. The intake structure was
Fig 2(a) Integrated layout of shore protection &PFBR Intake &Outfall
designed to draw sea water from off-shore location
above sea bed, where depth of water is approximately
10 metres. Central Water and Power Research
Station (CWPRS) has developed the scheme of
drawing condenser cooling water, the length of
intake submarine tunnel, position of intake shaft, the
depth at which the water should enter the intake
shaft, and has finalized the hydraulic parameters of
intake. CWPRS finalised these parameters based on
extensive study of several factors including the height
Infrastructure: Nuclear Plants
of tide, Highest Water Level (HWL) and Lowest
Water Level (LWL), wind velocity and sea current in
different months of the year, effect of outfall water on
the temperature of intake water for Madras Atomic
Power Station and for the intake water temperature
of PFBR. The integrated layout of the Intake and out
fall structures of MAPS and PFBR is given in Figure-
2(a) and 2(b).
Fig 2(b): Intake / Outfall Arrangement for MAPS and PFBR
General Features of Intake Structures:
The PFBR Intake structure consists of:
Ø Outlet Shaft on the shore
Ø Intake Shaft off the shore
Ø Submarine Tunnel
Ø Approach Jetty for the Offshore intake shaft
Fig 3: General layout of sea water intake system
Fig 3 above shows general layout of sea water
intake structure. The off shore intake shaft is of
4.25m dia, Tunnel is horse shoe shaped submarine
tunnel of 3.6m dia and on the shore out let shaft is of
6.0m diameter. The horse shoe shape tunnel size has
been arrived based on the adequacy of cross section
even after 40 years of barnacle growth on the tunnel
96 The Masterbuilder - April 2011 | www.masterbuilder.co.in
surface.
The intake is designed to draw 29m³/sec sea water
for condenser cooling for the 500 MWe PFBR. This
has been computed from the _T of 7° C across
condenser of PFBR. The approach jetty is provided to
facilitate approach to intake shaft.
For coastal sites, the Ministry of Environment and
Forest has the following guidelines:
"Temperature Limit for Discharge of Condenser
Cooling Water from Thermal Power Plant:
New projects in coastal areas using sea water.
The thermal power plants using sea water should
adopt suitable system to reduce water temperature at
the final discharge point so that the resultant rise in
the temperature of receiving water does not exceed
7oC over and above the ambient temperature of the
receiving water bodies.
Existing thermal power plants.
Rise in temperature of condenser cooling water
from inlet to the outlet of condenser shall not be
more than 100C.
Guidelines for discharge point:
The discharge point shall preferably be located at
the bottom of the water body at mid-term for proper
dispersion of thermal discharge.
In case of discharge of cooling water into sea,
proper marine outfall shall be designed to achieve the
prescribed standards. The point of discharge may be
selected in consultation with concerned State
Authorities/NIO.
No cooling water discharge shall be permitted in
estuaries or near ecologically sensitive areas such as
mangroves, coral reefs/spawning and breeding
grounds of aquatic flora and fauna".
(Source: Ministry of Environment & Forest,
Notification, New Delhi dated 22nd December
1998)
Since MAPS is the old unit, the system is
maintained in such a way that the resultant water
temperature at the final discharge point for the
Unisteel Engineering Works
Infrastructure: Nuclear Plants

combination of MAPS and BHAVINI outfall is

maintained at 10° C.
Outlet Shaft on the shore:
This is 6m diameter vertical shaft at the shore
which is 55m deep.

Fig 6a: Submarine tunnel

Fig 4: outlet shaft

Intake Shaft off the shore:

This is 4.2m diameter which has a depth of 50m.

Fig 6b: Top view of the tunnel

Fig 5: Sectional elevation of intake structure

Submarine Tunnel
The submarine tunnel has a length of 556m and a
diameter of 3.6m
Fig 6c: Inner view of the tunnel
Approach Jetty for the Offshore intake shaft
Intake Submarine Tunnel
Approach jetty has the length of 567m width is
3.52m and diameter 7.1m Exploratory bore holes were drilled along the
centre line alignment of the proposed submarine
Geotechnical Investigation along the length of tunnel well before the tunnel construction was taken

98 The Masterbuilder - April 2011 | www.masterbuilder.co.in


Fig 7a: Construction of approach jetty
Fig 7b: overall view of Construction of approach jetty
Fig 7c: View of construction of approach jetty from shore side
up. Geotechnical Investigations were carried out on
core samples from these bore holes taken along the
central line of the proposed tunnel alignment by
drilling of the 13 numbers of boreholes of 76mm dia
(NX) at 50m intervals. Boreholes were drilled upto a
www.masterbuilder.co.in | The Masterbuilder - April 2011 99
Infrastructure: Nuclear Plants
depth of 65m below the sea bed for fixing the tunnel
Invert level for safe tunneling. Further, tests were
also carried out for finalizing the design of tunnel
supports, lining thickness etc. These 13 numbers of
bore holes were drilled from fore bay location to
offshore intake location (600m length). Out of 13
core samples collected along the length of the tunnel,
five boreholes namely TBH-1 to TBH-5 were on
shore boreholes and eight boreholes namely TBH-6
to TBH-13 are off shore boreholes. The intake well is
located at the bore hole No.13. The bore holes drilled
at 50m intervals indicate that the hard rock levels
closely follow the sea bed profile (expect bore hole
No.7).
Apart from these, 13 bore holes for geotechnical
evaluation, two numbers of receiver boreholes were
also drilled which are on shore bore holes, for cross
hole tests.
All the fifteen boreholes including on shore and
offshore were plugged using grout material
consisting of cement and bentonite in 1:1 proportion.
Fig 8: Original layout sea water intake structure, approach jetty, seal pit
& outfall structure
The jetty runs parallel to the submarine tunnel
and is located 15m towards north of the tunnel. Thus
the jetty axis is 15 meters north of the 13 number of
borehole alignment.
The jetty is supported on 36 sets of piles located
at 15m intervals. The piles have been taken into the
hard rock upto 2m depth for socketing. The profile of
rock encountered along the jetty alignment confirms
generally the profile similar to the bore holes along
Infrastructure: Nuclear Plants
the centre line of the tunnel and this is true even at
TBH-7 where the hard rock was found at much
deeper depth.
M/S Design Group Project Consultants (P)
Limited, Bangalore have provided the entire design
and construction detailing for the submarine tunnel
after analyzing the geotechnical investigation data.
They have also analysed the rocks, produced
geological mapping, decided on rock anchoring,
taken decision on geological issues encountered
during construction and have produced detailed
reports of the incidents.
Geological Characterisation of the Lithological
Units:
All boreholes reveal similar stratification. Four
distinct layers were noted in all the bore holes, these
are Sandy soil, Clay layer, Weathered rock and Hard
rock. Geological characteristics of the lithological
units encountered was analysed by experts and the
detailed description of the lithological units are given
below:
Upper Brown Granular Zone
This is upper most zone which comprises of fine
to medium to coarse grain brown sand, with angular
/ assorted grains of transparent and opaque quartz,
minor specks of mica flakes (biotite) and mafics
(hornblende, etc). There is a strand line close to the
shaft. This indicates that it is an area of regression.
The grain size variation is not uniform. Thickness of
this lithological unit ranges between 5.5 - 10.5 m.
Argillaceous Horizon
This lithological unit has a thickness of 2 to 9.7 m
(approx.) and its color is greyish / greenish. This clay
is highly sticky and plastic, with rare shell fragments.
This horizon can be taken as a marker horizon. It can
also be considered as an aquiclude and groundwater
below this unit is likely to occur under semiconfined
and confined conditions. This clay occurs like a plug
and its origin is not confirmed as there is no zone of
transition above and below in its spatial distribution.
This shows a break in sedimentation and deposition
environment. Because of its pale green color,
chemical composition study, plasticity, engineering
100 The Masterbuilder - April 2011 | www.masterbuilder.co.in
property etc., were planned to be conducted.
Weathered Rock
This zone is encountered immediately below the
clay horizon. This zone consists of broken core of
garnetiferous charnockite and chloritised charnockite
/ migmatite. Thickness of the weathered zone ranges
from 0m to 15.6 m (approx.).
Hard Basement Rock
This zone occurs immediately below the
weathered rock zone without any transition to fresh
rock. The hard basement rock has been encountered
in all the Bore holes between 10.5 m to 18 m depths
from ground level except for Borehole 7 (TBH-7),
where hard rock is encountered at a depth of 29 m
below ground level. Depth persistence and lateral
prevalence of the hard rock has been established as
seen from the correlation of the sub surface
lithological data.
Hard basement rock encountered in this strata
belongs to the Archean Charnockite group of rocks
and Migmatite complex comprising igneous intrusive
rocks and metamorphic rock. The charnockite group
of rocks is made up of quartz, pyroxene, feldspar, and
garnet. The charnockite group of rocks is also
migmatised to varying degrees resulting in
retrogression and conversion into migmatite complex
comprising different types. (Reference Geological
Survey of India (GSl) map,1998). The migmatite
complex comprises of different types of gneiss, such
as garnetiferous, biotite gneiss, hornblende gneiss,
augen gneiss and garnetiferous quartzo-felspathic
gneiss. The magmatite are generally grey coloured.
In addition to this the mineralogical composition
and its assemblage manifested in the form of micro
joints, slips, shears, slickensides, rock alteration,
fracture filling, confined only to zones of thin
partings, foliation and joints at different depths.
Excepting for these thin weak zones, the host rock /
country rock appears to be homogeneous, medium to
coarse grained, migmatitic at places; as such there is
no major zones showing any effect of intense
shearing. A deeply weathered zone encountered in
TBH-7 is an exception.
Silicone Concepts Int'l.Pvt.Ltd
Infrastructure: Nuclear Plants
Geotechnical Stratification
All the thirteen boreholes (TBH-1 to TBH-13)
revealed similar stratification but thickness of layers
vary depending on the location. Ground water was
encountered at 2.5 to 9 m below ground level at
different borehole locations during the investigation.
General stratification of the site and its characteristics
area as follows:
Stratum 1: Loose to medium yellowish Sand
This layer is present in all boreholes. This layer
extends upto 2.5 m depth in TBH-1 & 2 to
maximum 7.0 m in TBH-7. In some boreholes this
layer is again encountered at 5.5 m and 6.75 m after
dense to very dense sand layer. SPT values vary 11 to
30. This range of N values shows loose to medium
dense relative density of cohesionless soil. The soil is
classified as SM-SP, SP and grain size distribution
shows gravel 0 to 6%, sand 88 to 98% and silt +
clay 1 to 10%.
Stratum 2: Dense to very dense Sand
This layer is present in all bore holes except TBH-
7. Thickness of the layer varies from 1.25 to 4.8 m.
SPT values varies from 30 to 71. This range of N
values shows dense to very dense relative density of
cohesion less soil. This soil is classified as SP-SM, SM,
SC, SP.
Stratum 3: Yellowish brown Silty Clay of medium
to Stiff
This is present in some bore holes like TBH-2 and
TBH-3 at depth 7.2 and 8.5 m respectively below
ground level. Thickness of the layer is varying from
1.8 to 4.0 m. SPT values vary from 9 to 12. Soil is
classified as CH. Grain sizes are gravel 0 to 4%, sand
1 to 37%, silt 23 to 41%, clay 37 to 64%.
Stratum 4: Very stiff to hard Yellowish brown
Silty Clay
This layer is present except in TBH-8. Thickness
of the layer varies from 1.1m to 9.75m. N value
ranges from 18 to 57. Soil is classified as CH. Grain
sizes are gravel 0 to 1%, sand 2 to 50%, silt 17 to
45%, clay 33 to 66%.
102 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Stratum 5: Highly Weathered rock
This is moderate to highly weathered rock.
Thickness of this stratum varies from one meter to
15.6 m. N-value exceeded 100 and in some cases
rebound of SPT hammer was observed.
Stratum 6 : Moderately Weathered rock
A small layer of moderately weathered rock is
present below highly weathered rock. It varies from
0 to 5.5 m.
Stratum 7 : Charnockite Bedrock
This stratum is medium to coarse grained hard
rock comprising of Charnockite and gneiss with
garnet crystals. Generally between 10 m to 18 m
depths, from ground level the hard basement rock
has been encountered in all the boreholes except
Borehole BH-7 where hard rock is encountered at a
depth of 29 m below ground level. The Rock Quality
Designation in this layer is generally in the range of
40 to 100. Weighted average of RQD in each
borehole varies from 71 to 85. Core recovery varies
81 to 90. The Rock Mass Rating of this bed rock is
63.8 and it is classified as Class II (good) rock as per
Bieniawski 1979 & IS: 12070- 1987 (Table 7).
Compression wave velocity for the rock strata varies
from 3659 m/sec to 4762 m/sec. Value of shear wave
velocity for this layer ranges from 2000 m/sec to
2300 m/ sec. Dry density and bulk density varies
from 2.66 to 2.99 gm/cubic cm and specific density
varies from 2.69 to 2.99.
Outlet Shaft on the Shore:
The excavation of the onshore shaft and the
submarine tunnel was commenced by the M/S
Gammon India Limited at PFBR site in February
2008. 3D geological log of the same was carried out
to confirm the parameters for design of lining and to
decide upon the reach where consolidation grouting
is required. The log indicated that generally the bed
rock met was Charnockite / Garnetiferous
Charnockite Gneiss with joints tight and incipient,
while the prominent joints were continuous for 5 to
10m in length in some places. These joints got
exposed as a result of blasting while excavation.
Unipave Engineering Products
Infrastructure: Nuclear Plants
Seepage was noticed at the contact of overburden
and excavated rock surface. However, necessary
precautions were taken which included channelizing
the seepage water and monitoring of seepage in the
shaft.
The outlet shaft construction was incidence free
and was completed without major difficulty with all
the temporary supports.
Submarine Tunnel:
The horizontal horse shoe shaped excavation in
rock for submarine tunnel of size varying from 3.6m
to 4.2m is 560 meter long with Chainage 0.00
starting from centerline of vertical outlet shaft.
Conventional blasting using controlled charge was
deployed for the tunnel boring.
Fig 9: Photos of Submarine tunnel
Two incidences were encountered during the
submarine tunnel construction.
Incidence-1:
Observation:
On completion of CH11500 on 13th Jan 2009 it
was noted that the grout in TBH-4 collapsed and
crumbled into the excavated tunnel. It also was noted
that while carrying out the rock excavation for tunnel
only 3 boreholes TBH-1, TBH-2 and TBH-4 have
been encountered within the alignment of tunnel but
not in centerline of the tunnel; rather they were away
from central axis to varying extent; from 0.5 m to
1.5m. TBH-3 could not be traced inside the tunnel.
This lead site to reach a conclusion that the boring
tool might not have taken exact gravity line while
drilling and/or the position of the drilling rig might
104 The Masterbuilder - April 2011 | www.masterbuilder.co.in
not have been closely maintained to submarine
tunnel axis. This conclusion governed decision
making process for further commencement of tunnel
boring.
TBH-4 was encountered during blasting on
previous day of the incidence i.e on 12.01.2009.
Small quantity sand had fallen down into the tunnel
from the hole when the zone of TBH-4 was blasted.
On 13-1-2009 at 4am further blast of 3m length was
taken up. De-mucking operation of excavated rock
was completed around 11am. At 11.15am subsidence
of sandy soil occurred at grade level (GL) exactly
above the bore hole No.TBH-4. People working on
the grade level noted that sinking of ground over
TBH-4 location and formation of a funnel shaped
chimney at the grade level, and people working in
the tunnel informed that certain slush along with
sand is falling through TBH-4 hole. On further
inspection of the tunnel it was observed that 76mm
dia TBH-4 bore has got unplugged of grouted
material (cement and bentonite in 1:1 proportion).
The slurry of grouted material along with about
12meter cube of sand has fallen down from the hole
on to the invert level of tunnel. Slight water too was
found dripping through the hole. A rod of 25mm dia
and about 4m length could be easily penetrated into
the unplugged hole of TBH-4 from inside the tunnel
bore.
Immediate action taken by BHAVINI after the
incidence-1:
Ø As a safety precaution the tunnel rock excavation
work was stopped forthwith.
Ø The matter was also referred to the experts who
arrived at site for assessment within hours of the
incident.
Decision making process following the incidence:
Ø The tunnel site was inspected by various experts.
Several rounds of reviews and discussions were
held. Experts expressed apprehension that minor
water seepage from TBH-1 and unplugged of
grouted material from TBH-4 does not provide
enough confidence that such incidence (seepage
from grout or unplugging of the grout borehole)
will not happened

Hence:
Ø Either the tunnel should be diverted in further
span to avoid encountering grouted before bore
holes during the further tunnel construction.
Ø Or the grouting should be improved before
further blasting for tunnel bore.
Ø The bore hole size is only 76mm diameter and the
over burden over the roof of the tunnel is about
50m. In case of unplugging of borehole below the
sea water, the pressure of sea water that could
gush into the bore hole will be 5Kg.cm2, the
velocity of water will be about 25m/sec and the
discharge will be in the order of 7000LPM. If
dewatering pump capacity is augmented to suit
above as well as if the bore holes are re-grouted
from 3m before reaching such boreholes location
by injecting appropriate cement / chemical grouts
like polyurethane through horizontally or upward
inclined holes towards the roof of tunnel, it is
possible to maintain the same alignment of tunnel
in the further construction too.
However this proposal was dropped for the
following reasons:
Ø Out of balance nine bore holes yet to be
encountered during tunnel construction, one is on
the shore edge and eight are below sea water.
Ø Since no casing pipe has been left while drilling
the boreholes, it may be difficult to identify the
location of the drilled boreholes from the top
surface and take measures to grout the area
around the bore hole. Technologies / methods to
identify the borehole in advance where casing pipe
is not left are not well established.
Ø In this case, the location of borehole can be
identified exactly only after blasting and
excavating the underground tunnel.
Ø Even if the grouted bore holes are identified when
the tunnel excavation is approaching the bore hole
location using radar technology, grouting the
already plugged borehole may poses complexity.
Ø The pressure grouting from consolidation of areas
around the bore hole may not be effective as the
www.masterbuilder.co.in | The Masterbuilder - April 2011 105
Infrastructure: Nuclear Plants
grouting is to be done in hard rock strata under
higher pressure than the tunnel consolidation
pressure (grouting prior to excavation of tunnel is
being done for strata to plug fissures, water
leakage etc). Therefore, tackling the situation if
the borehole in the sea location gets unplugged
during blasting for the tunnel excavation is
complex.
Ø The experience of tackling the flooding of sea
water in the tunnel is not readily available. It is
possible that more than one borehole may give in,
during the blasting / de-mucking in which case
dewatering of tunnel may become difficult.
Ø The project does not have cushion of time to face
a situation of flooding of tunnel which will involve
complex remedial measures.
Ø Keeping safety of workmen into as prime
consideration in decision making, it was decided
to take diversion for further course of tunnel.
Deviation of the alignment of the Tunnel:
Factors that were considered for deciding the
extent of deviation of tunnel are as follows:
Ø The deviation of TBH-1, TBH-2, TBH-4 opening
in tunnel from axis of the tunnel and non
detection of TBH-3 suggests that the deviation of
the axis of the tunnel should be large enough to
avoid meeting the TBH-5 to TBH-13 during
further tunnel construction.
Ø The deviation should be as small as possible to
reduce additional length of jetty required to
approach the new intake shaft.
Ø Further for the shifted location of the intake
structure, sea conditions such as littoral drift,
current etc. considered for the study for the
original design has to remain unaltered.
Ø Irrespective of the uncertainty of the bore hole
alignment (deviation from verticality) and
positional tolerance, the distance of the existing
bore hole from the blasted contour of the tunnel
should be minimum two meters (cover rock
between bore and blasted surface should be min
two meters).
Infrastructure: Nuclear Plants
Ø The tunnel has to be deviated to south-east and
after certain distance made parallel to existing
alignment as jetty on north of tunnel prevents
deviation of alignment to north.
Ø The rock profile in deviated contour should be
predictable from already completed geo-technical
studies.
Ø The water pressure drop should have only
marginal increase even after addition of two bends
in the tunnel. The existing sea water pump
supplying cooling sea water to the condenser
should be checked for its capability to cope up
with the increase flow path resistance.
Ø The bio-fouling concern should not enhance due
to the deviation in the flow path of the tunnel.
It was decided to divert the tunnel towards south-
east from the location of borehole No.TBH4 which is
at a distance of 115m towards east from the fore bay
shaft which is located on land. The straight line
lengths of the tunnel upstream and downstream of
the bends were checked for compliance to Bureau of
Indian Standard, IS 2951. Based on the requirement
of straight length between the bends as per standard
IS 2951, it was decided to deviate the alignment of
the tunnel keeping the angle of deviation as 11º from
TBH-4 and incline length to be maintained to 110m.
The tunnel bore will be again diverted by 11º at the
end of 110m diversion to make it parallel to the
original alignment. The southward
shift in the tunnel alignment thus works out to
21m. With the deviation of tunnel from the location
of borehole No.4, involving horizontally shifting the
tunnel by 21m southwards at the end of an inclined
length of 110m, the increase in total tunnel length
will be around 2m in addition to introduction of two
bends. For deviated alignment of submarine tunnel -
plan (general arrangement please refer Annexure - 1).
CWPRS that estimated the head loss due to
shifting of the tunnel by 21m and two angular
deviations of 11º and at two end of an inclined length
of 110m as 0.023mwc (meter of water column). Thus
the head loss due to change in the layout of the
submarine tunnel is insignificant compared to the
106 The Masterbuilder - April 2011 | www.masterbuilder.co.in
total pressure drop computed for the original layout
which is 1.9mwc. Hence, the additional drop in
pressure because of two bends and increase in length
of the tunnel by two meters does not change the
pumping head requirement of the cooling water
pumps. The pressure drop calculations were based on
IS 2951 (Part-II). Since, the pressure drop due to the
deviation in tunnel alignment is insignificant,
increase in head loss does not result in lowering of
water level in the forebay sump. Therefore, the water
level in the forebay would not fall below the designed
minimum water level. Hence, the submergence
required for the pumps is not altered. This was also
confirmed by DCPL who had carried out initial
design of the tunnel.
M/s IGCAR assessed and confirmed that there is
no impact on biofouling due to the proposed change
in the tunnel alignment by deviation.
M/s CWPRS, Pune has confirmed that for the
shifted location of the intake structure, sea conditions
such as littoral drift, current etc. considered for the
study for the original design will remain unaltered.
With the above deviated alignment of the tunnel,
the new axis of the tunnel with perfect drilled TBH-5
would be about 10.5 meter. Even after considering
TBH-5 alignment shift by 5.5 meters towards south,
the northern boundary of the deviated tunnel will be
2.5 meter from TBH-5. Therefore any opening of
TBH-5 in the deviated tunnel path and consequent
grouting of TBH-5 was not envisaged.
The geologists confirmed that the hard rock
profile at PFBR site generally follows the natural
ground profile. The slope is only form west to east
and the rock profile follows the ground profile as
proved by the TBH bore holes. With the decision of
shifting the tunnel by 21 meter towards south
beyond TBH-5, no change is expected in the hard
rock strata or the profile compared to initial
prediction based on geotechnical investigation. It
may be noted that for the original geotechnical
investigation itself the bore holes were taken at
distance of 50m; each borehole representing the
strata over a radial distance of 25m. The new
alignment is adjudged to be safe and the deviated
alignment of tunnel will also have adequate hard
STP Ltd
Infrastructure: Nuclear Plants
rock cover. The available rock cover for the tunnel
from the crown is expected to be 4D on south of
TBH-7 as at this location, the hard rock level is
comparatively at a lower level than the other bore
holes. Whereas at the other borehole locations
indicate rock cover of more than 6D.
Internal pressure due to water at submarine
tunnel level is about 5kg/sq.cm. (50m water
column), where as external pressure due to weight of
rock and over burden soil is about 11.4kg/sq.cm. As
per IS standard 4880 Part-IV, maximum rock cover
required is H i.e. 5Kg/Sq.cm. With this 21m shift of
the off-shore Intake structure towards south from the
original location, the jetty length has also to be
increased by another 21m towards south. The
grouting of already exposed boreholes i.e. TBH-2 &
4 located on land was also undertaken and effected
successfully.
Depth (in m) Lithological Details
0.0 – 7.0 Medium grained yellowish brown sand
7.0 – 13.40 Very stiff to hard brown sandy clay
13.40 – 25.05 Yellowish grey completely weathered rock
25.05 – 26.0 Highly weathered Charnockite. Poor recovery. RQD
Nil.
26.0 – 29.0 Highly weathered grey fractured Charnockite. Poor
Recovery. RQD Nil.
29.0 – 30.0 Moderately weathered Charnockite. Poor Recovery.
RQD 20%
30.0 – 60.0 Slightly weathered Charnockite. Recovery good,
RQD Fair to good.
Incidence-2 (Shear Zone Encountered between
Ch243 and Ch264)
(Rock condition at TBH-7)
From the analysis of borehole log details of 13
numbers of boreholes it was evident that low rock
will be encountered while tunneling at TBH7 and
site will have to take cautious approach during tunnel
excavation between TBH-6 and TBH-8. Rest other
bore log predicted trouble free construction while
advancing blasting for creation of submarine tunnel
bore. The following are the lithological, core recovery
percentages and RQD details of TBH-7 core samples
as prepared by M/S Geotechnics & Constructions
Pvt. Ltd.
108 The Masterbuilder - April 2011 | www.masterbuilder.co.in
From 13.4 m to 25.05 m the rock is highly
weathered. Further from 25.05 m to 30.0 m the rock
is highly weathered to moderately weathered
Charnockite with poor core recovery and nil RQD
had been obtained. From 30 m to the end of the hole
(65 m) slightly weathered Charnockite with good
core recovery and fair to good RQD had been
recorded.
The occurrence of deep weathering in a single
lithologically similar hole is intruguing. In view of
the completely weathered to highly weathered rock
with very poor core recovery, shattered rock and zero
RQD in TBH-7 alone, it was inferred that the reason
for this may not be lithological but structural
infirmity. With only scanty subsurface data available,
the experts took recourse to the regional geology and
also the geotechnical investigation done for Madras
Atomic Power Station (MAPS) tunnel bore holes
which is existing 500meter north of PFBR submarine
tunnel and was constructed around forty year back.
The absence of dolerite in any of the PFBR boreholes
and the occurrence of dolerite in the MAPS tunnel
bore holes was had suggested to the possibility of an
east-west fault between the two tunnels before actual
tunneling work started. Since, the dolerite rock is
now encountered after the shear zone this possibility
is now ruled out.
Possibility-1
Regionally the foliation trend in the gneissic rock
is N25º to 50º ES25º to 50º W with a dip of 60 to
80 degree in easterly direction. N30º E - S30º W
joints (Foliation joints) are dominant. Hence,
probably the shear zone encountered in TBH-7 could
be a foliation shear.
Possibility-2
Dolerite with sheared contact is reported in the
off shore bore holes drilled at MAPS. The dip of the
dyke is estimated to be 70º close to Kalpakkam, at
Punjeri a N.W.-S.E. dyke is traceable for about 1 km.
In the area around Anaikattu about 15 km south
west of Kalpakkam several WNW-ESE dykes are
reported. In MAPS Reactor I pit a N60º W - S60º E
dyke was reported. It could be seen that the dykes in
the area trend WNW-ESE to NW-SE direction with
 Infrastructure: Nuclear Plants

www.masterbuilder.co.in | The Masterbuilder - April 2011 109

Infrastructure: Nuclear Plants
a dip of 65º to 75º towards S30º W. The contacts of
many dykes are sheared; the shear zone trend is also
in the same trend. If the structural infirmity in TBH-
7 could also have the same trend and dipping
towards SW. Strike trend and apparent dip were
projected on to the new alignment. Thus it was
predicted that rock in the shear zone and adjacent
area will be closely jointed and could render the
crown of the tunnel weak where it intercepts.
A horizontal diamond drill hole was planned to be
drilled with double tube core barrel as tunnel
advanced. It was planned in advance that if drilling
data confirms the prognosis, tunneling in this
hazardous zone has to proceed cautiously. The zone
may be under a hydrostatic head. A similar zone in
Naptha Jhakri HEP in Himachal Pradesh (Himalaya
range) was tackled through DRESS Methodology i.e
Drainage, Reinforcement, Excavation and Support.
The method consists of drainage beyond the
heading by drilling holes with simultaneous insertion
of partly perforated steel pipes, improving the
heading by grouting and shotcreting. Before starting
the work supports (as dictated by design
considerations) was planned to be kept ready and
placed as soon as possible taking care to provide
laggings between the supports and crown. The above
details were brought to the notice of the field staff
and they were kept in readiness to face the situation.
To conform this and take precautionary measures,
a horizontal diamond drill hole was drilled with
double tube core barrel as tunnel advanced. Great
precaution and cautious approach was taken from
Ch.250 to Ch.290.
Observation during sub marine tunneling
operation:
As predicted earlier, during the excavation of
tunnel the shear zone was encountered at Ch.245
continued up to Ch.257.5. The material in the shear
zone consists of highly crushed leucocratic
Charnockite. Although most of it is granular and
non-cohesive, in places it is completely clayey. No
water seepage was notice in the shear zone portion.
From Ch: 257.5 onwards and up to the face of the
excavation at Ch.270 Dolerite was encountered. The
110 The Masterbuilder - April 2011 | www.masterbuilder.co.in
dolerite Dyke although hard and fresh was found to
be blocky and seamy. To the left of the crown damp
surface and dripping conditions prevailed.
The absence of dolerite in any of the bore holes (as
per data provided) and the occurrence of dolerite in
the MAPS tunnel bore holes was referred to and the
possibility of an east-west fault between the two
tunnels was predicted earlier, even before start of
tunnel excavation boring. Since, the dolerite rock is
now encountered after the shear zone this possibility
is now ruled out.
In the MAPS tunnel boreholes, the dolerite is
found to be at least 54 m wide. As per bore hole
details, dolerite was not encountered even in TBH-7,
the logs of TBH-8 also indicate only charnockite and
not dolerite. Hence, it is probable that the dolerite
now encountered is less than 50 m wide.
Remedial measures taken in PFBR tunnel in the
shear zone.
Ø The entire excavation was geologically mapped
Ø From Ch. 243m to Ch 264m (in the shear zone
and blocky and seamy dolerite portions), 75 mm
thk. shotcrete of M35 grade with wire mesh was
applied.
Ø Wherever dolerite was found blocky, it was
stitched by 10mm thick plate anchored 3m deep
into the rock using 25mm diameter rebar.
Ø ISMB 600 @ 600 c/c with steel lagging was
provided in this stretch of submarine tunnel. The
entire inner surface (top, sides and bottom
surfaces) of this dolerite region was supported
with the above referred structural members.
Ø After the 3D geological logging of the submarine
tunnel, consolidation grouting was carried out
between Ch.15m to 30m, Ch.75m to Ch.85m and
Ch 240m to Ch 270m.
Ø Before any blasting for the tunnel, probe holes,
6m deep were drilled from the blasted face to
determine the rock strata ahead of tunnel face.
This was done either by diamond drilling or jack
hammer drilling.
The work of tunnel excavation is under progress
and as of 15th September, 2009, 515 meter out of
Sleek Boards India Ltd
Infrastructure: Nuclear Plants
560 meter of tunnel was already excavated.
Concluding Remarks:
The PFBR intake structure is a design and
construction marvel. True to the type of activity, the
construction has met several surprises which were
quickly addressed with the help of experts within
India. The job has progressed well as per schedule
despite the above mentioned difficulties.
Acknowledgement:
This detailed technical paper is prepared after
drawing technical contents from various reports
prepared by experts and organizations engaged by
BHAVINI for intake structure design, construction,
trouble shooting and remedial actions. This report
has also major inputs from the agencies who have
carried out geo-technical investigation, construction
and inspection activities. The authors thankfully
acknowledge them.
The credit of this report goes to:
Ø Dr. S.K. Jain, Chairman and Managing Director,
M/s Nuclear Power Corporation of India Limited
& M/s Bharatiya Nabhikiya Vidyut Nigam
Limited
Ø Dr. Baldev Raj, Distinguished Scientist and
Director, Indira Gandhi Centre for Atomic
Research, Kalpakkam
Ø Shri S.C. Chetal, Director, REG, Indira Gandhi
Centre for Atomic Research, Kalpakkam
Ø M/S IGCAR who have conceptualised and
conceived entire scheme. Carried out bathymetric
studies, analysed the results produced by various
experts
Ø The entire civil team of M/S BHAVINI Ltd
Ø M/S CWPRS, Pune have designed and done
model studies of Intake Structures and finalised
blasting charge
Ø M/S Gammon India Limited who have finalized
construction and inspection schemes and done
field construction of Intake Structures
Ø M/S DGPCL, Bangalore who have provided the
entire design and construction detailing for the
submarine tunnel after analyzing the geotechnical
112 The Masterbuilder - April 2011 | www.masterbuilder.co.in
investigation data. They have also analysed the
rocks, produced geological mapping, decided on
rock anchoring, taken decision on geological
issues encountered during construction and have
produced detailed reports of the incidents
Ø M/S DBM Geotechnics and Constructions Pvt
Ltd., Bombay who carried out Bore Hole drilling
and Geotechnical Investigations
Ø M/S Anna University, Chennai who gave expert
analysis on geotechnical analysis.
Ø M/S NGRI who carried out cross hole tests
Ø M/S Indian Institute of Technology, Chennai
Ø M/S National Institute of Ocean Technology,
NIOT, IIT, Chennai who have done HWL and
LWL studies
Ø Dr. D.N. Seshagiri, an experienced Engineering
Geologist and Dr. S.R. Gandhi, a Senior Geologist
and Professor at IIT Chennai, who have
contributed significantly in preparation of this
paper. Few names of organisations and experts
have been brought out above. The contribution of
those whose names do not appear is also not less
and is thankfully acknowledged.
References:
Ø Geotechnical Investigation Report for Sea Water Intake
Structure at Kalpakkam in Tamilnadu State for FBR-Project,
BHAVINI-DBM Geotechnics and Construction Pvt.Ltd.
Ø Report from Design Group, Bangalore Titled Paper on
Geotechnical Problems faced during execution of Submarine
Tunnel and Remedial measures carried out.
Ø Physical Thermal Model Studies for Locating Intake/ Outfall of
500MWe Fast Breeder Reactor Project (PFBR)-CWPRS
Ø Mathematical Model Studies for Location of Intake/ Outfall of
500MWe Fast Breeder Reactor Project (PFBR)-CWPRS
Ø Flow Model Studies for Intake Structure of Fast Breeder
Reactor Project (PFBR)- CWPRS
Ø "Supplementary Mathematical Model Studies for Littoral Drift
and Thermal Recirculation for Sea Water Intake/ Outfall of
500MWe Fast Breeder Reactor Project (PFBR)-CWPRS"
Ø Physical Wave Model Studies for Sea Water Intake/ Outfall of
500MWe Fast Breeder Reactor Project (PFBR)-CWPRS
Ø Field Data Collection and Analysis for Condenser Cooling Sea
water System (CCWS) of 500MWe Fast Breeder Reactor
Project (PFBR)-CWPRS
Machines & Engineering Company
Infrastructure: Nuclear Power Plants

Opting for Nuclear Power ?

Be Clear & Design Smart
Sadagopan Seshadri,
Chief - Content Development, CE - Infrastructure - Environment

O ne of the greatest challenges

facing our planet is how to
supply electricity to a rapidly
growing population with ever increasing
need for electric power. Limited
resources and irreversible changes to our
climate threaten catastrophic
consequences unless intelligent decisions
are made. The need of the hour is to
gather a proper perspective to make
appropriate choice of resources and
develop technologies in order to generate
safe, clean and optimal cost energy.
A Double-Whammy Predicament
The renewed focus on the nuclear
industry world over subsequent to the
earthquake-tsunami double-whammy in
Japan is understandable. India is no
exception where on one hand its
proponents are vehemently trying by all
means to convince all and sundry that
nuclear power is safe and clean, while
environmentalists are crying hoarse
predicting doomsday.
The safety credentials of nuclear
Figure 1 Indian Nuke Map: NPP Location & Seismic Zone Identification
power plants (NPPs) once again have
come to the global platform for each Russia) both of which had neither The design takes into account the
one's introspection. earthquake nor tsunami. s afety, d eliver y, eff icien cy an d
N u c l e a r ex p e r t s m ay a s s e s s Safe and Cheap Energy? And the economics of delivery. Thus, a complex
probability of an earthquake-tsunami trade-off! number of elements enter the design
striking a nuclear facility as perhaps just matrix with numbers to be chosen and
The industry says nuclear power is
once-in-a-million-years. It offers no frozen. These numbers decide the fate of
safe, clean and cheap. But as in every
solace as this once event can even unfortunate incidents being contained or
design, construction and operation, here
happen tomorrow! ending up in disasters. Some fundamental
too an economically feasible choice is to
elements that figure are:
If the theory of a Fukushima be made which gets translated as the
occurring because of a earthquake- right choice. This is the “trade off”. In the § Structural safety in NPP is ensured by
tsunami combo is bought, then what is nuclear case if the trade off taken in design appropriate design and quality
the take on accidents at Three Mile falls short of what is demanded by an construction. In reality it is
Island (USA) and Chernobyl (USSR/ unfortunate event, it could spell a disaster! accomplished by a trade-off between

116 The Masterbuilder - April 2011 | www.masterbuilder.co.in


structural safety; higher initial cost of the
NPP (meaning higher cost of power
generated).
Operational safety is a function of
periodic preventive maintenance
that involves shutting down the
reactor. This warrants a trade-off
against the plant load factor (PLF)
and thereby escalating cost of power
generated.
Routine operations involve removal
and storage of spent fuel rods, which
need be cooled by air and water in
heavily shielded buildings for around
50 years so as to prevent over-
heating and fire.
Then they are re-processed in a
separate facility for separating
plutonium, and encased in glass for
deep geological burial.
These steps are essential but
increase cost of power generated.
And risks & costs continue well
beyond their useful life:
Nuclear plants after their useful life
cannot be simply abandoned. They
have to be decommissioned,
spending as much or more money
than their construction cost itself.
This includes cost of keeping facility
Lighting
Aircraft
Crash
Chemical
Explosion
Reactor
Meteorology
Hydrology
Earthquake
Figure 2 External Events
Infrastructure: Nuclear Power Plants
7 Major
Accident
ACCIDENT
6 Serious Accident
5 Accident with
wider consequences
4 Accident with
Local consequences
3 Serious Incident
INCIDENT
2 Incident
1 Anomaly
Below Scale / Level 0
No SAFETY SIGNIFICANCE
The INES Scale is a worldwide tool for communicating to the public in a consistent way the safety
significance of nuclear and radiological events. Just like information on earthquakes or
temperature would be difficult to understand without the Richter or Celsius scales, the INES Scale
explains the significance of events from a range of activities, including industrial and medical use of
radiation sources, operations at nuclear facilities and transport of radioactive material. Events are
classified on the scale at seven levels: Levels 13 are called “incidents”and Levels 47 “accidents”.
The scale is designed so that the severity of an event is about ten times greater for each increase in
level on the scale. Events without safety significance are called “deviations” and are classified
Below Scale / Level 0.
Figure 3 INES
perennially beyond human access decommissioning, its life was
because it continues to be radioactive. “extended”. The Three Mile Island costs
of decommissioning or entombing
For instance, India's Tarapur NPP life
Chernobyl NPPs must have been
was long since over but instead of
colossal. The costs of decommissioning
the five Japanese NPPs are tentatively
estimated at around Japan's GDP!.
Power
Failure Realize real needs then Customize
As tragically seen in Japan, a system is
no better than its weakest flaws.
Cyclone
§ Sure, the containment shell worked
well past its design parameters, but
still not well enough to handle the
loss of coolant. It remains to be seen
Flood
if it indeed worked well enough to
prevent a major disaster, or if it
merely delayed a major disaster.
Geotechnical
As rightly said:
§ The lesson is not that "most of the
design worked, so we're safe", nor is
it "nuclear power is fatally flawed, no
www.masterbuilder.co.in | The Masterbuilder - April 2011 117
Infrastructure: Nuclear Power Plants
matter what we do", the lesson is
that “things happen that we don't plan
for in ways that we do not anticipate”.
The nuclear power industry is one
where each country sets its own detailed
quality and safety specifications within a
framework of chosen consultants, safety
bodies, main contractors and other
stakeholders.
For an energy technology to be
viable, it must be economical and satisfy
the policies that have been established
by government to address social and
environmental concerns. Only those
technologies that lie in the nexus of the
three disciplines - technology, policy and
economics - can be deemed viable.
Depending on location, each of these will
va r y a n d t h e o p t i m u m e n e rg y
technology for a given location will vary
accordingly.
Be clear about nuclear
There are different designs doing the
rounds. A lot of Pros & Cons on their
absolute safety & workability beyond
doubt persist. Structural safety has once
again raised its head ominously in
conjunction with our inability to have the
foresight needed to choose the needed
“factors of safety” prudently, justify it as
essential to avoid “incidents” and work
the costs based on these numbers to study
feasibility of nuclear options. India should
not become testing ground for others!
Starting from the concrete
containment (A), each of the areas in the
nuclear facility (see view at Figure 4)
becomes risk prone depending on where
and how an incident occurs and
develops. A look at events unfolding at
Fukushima is an eye opener:
Japan raised the severity rating of the
crisis at the Fukushima No. 1 nuclear
power plant to the same level as the
Chernobyl disaster, weeks after it was
criticized for downplaying the seriousness.
Pointing to the large amount and
wide dispersion of radioactive material
from the stricken facility, the Nuclear and
118 The Masterbuilder - April 2011 | www.masterbuilder.co.in
View inside the Nuclear Power Plant
A
1
2 3
B
D 6
14
9 11
E C 12
5 8 10
7
4 13
1 Concrete containment 6 Steam generator 11 Generator A Containment
2 Steel liner 7 Reactor main coolant pump 12 Transformer B Machine house
3 Steel pressure vessel 8 High-pressure turbine 13 Condenser C Control room
4 Reactor pressure vessel 9 Reheater 14 Feedwater tank D Fuel store
5 Control rod drive 10 Low-pressure turbine E Fuel storage basin
Figure 4
Industrial Safety Agency (NISA) and the amount of radioactive materials
Nuclear Safety Commission of Japan released had levels of iodine between
raised their accident assessment to level 370,000 and 630,000 terabecquerels.
7, defined as a "major accident" on the That is above the standard of several tens
International Nuclear and Radiological of thousands of terabecquerels that is
Event Scale. used to define a level 7 accident on the
International Nuclear and Radiological
Junichi Matsumoto, an official with
Event Scale.
the plant's operator Tokyo Electric Power
Co., said: "Discharge (of radioactive The explosions and fire at the
materials) has not been completely Chernobyl plant spread about 5.2 million
stopped and there are concerns that the terabecquerels across several countries.
amount released could equal or exceed
At Fukushima, radioactive material
that for Chernobyl."
has been released into the environment
Earlier however just after the March in a series of separate incidents.
11 earthquake, NISA had rated the Radioactive steam was initially
situation at Fukushima as a level 4 deliberately vented into the atmosphere
accident, meaning that radioactive to reduce pressure within the core
materials had been released outside of containment vessels. Subsequent
the Fukushima nuclear plant. Then on hydrogen explosions at the buildings
March 18, the assessment was raised to housing the No. 1 and No. 3 reactors
level 5, the same as the 1979 accident at blew away part of the ceilings and
the Three Mile Island nuclear plant in the dispersed radiation.
United States. An explosion near the suppression
One standard used for a level 5 pool for the No. 2 reactor and a fire at a
accident is the emission of radiation storage pool for spent fuel rods at the
levels equivalent to several hundreds to No. 4 reactor are also believed to have
several thousands of terabecquerels of released radioactive material.
radioactive iodine. One terabecquerel is
Keiji Kobayashi, a former lecturer of
a trillion becquerels.
nuclear engineering at Kyoto University's
Subsequent estimates of the total Research Reactor Institute, said: "From
Simpson & Co.Ltd
Infrastructure: Nuclear Power Plants
the time when a dry boil at the reactor
core and hydrogen explosions occurred,
it became difficult to stop the discharge
of radiation. It was clear the accident was
more than a level 6. There are also
elements not found in the Chernobyl
accident such as the release of
radioactive materials into the ocean."
A fresh Evaluation by revisiting is the
minimum that decision makers owe the
nation before finalizing the country's
nuclear road map. It goes for all: GE,
AREVA, WESTINGHOUSE and any other.
Assurances
The Indian heads in the nuclear
establishment giving account of each
facility have aired their assurance of
design & operational safety of India's
nuclear reactors besides their right siting
too which is claimed to be reason for
terming them as not vulnerable.
The Nuclear establishment in India
has assured that our systems are robust.
Out of the 20 reactors, only two in
Tarapur are based on the boiling water
principle as the ones in Japan. Going by
the statements of the Department of
Atomic Energy, diesel power backups for
our nuclear power plants, particularly in
tsunami prone areas, have been
constructed at high altitudes to avoid
flooding by tsunami.
Currently, very bold marked thrust is
being seen in the country's nuclear
programme, with the big nuclear power-
generating parks in five locations, all
coming up with foreign technology. After
the Japan event, India needs further
reassurance in respect of proven
technologies of partners, timely
deliveries, operational safety, fail proof
I&C before mega plans are put on track in
the nuclear domain.
BHAVINI
The indigenously-developed PFBR is
at an advanced stage of construction
under the aegis of state-owned Bhartiya
Nabhikiya Vidyut Nigam (BHAVINI)
and is expected to be commissioned by
2011 end.
120 The Masterbuilder - April 2011 | www.masterbuilder.co.in
From L to R: Managing Director of Nuclear Power Corporation of India S K Jain,
Chairman, Atomic Energy Commission Srikumar Banerjee,
and Chairman, Atomic Energy Regulatory Board S S Bajaj
W e will not jump to say that our power
reactors will not suffer a similar kind of
situation but we are planning to revisit all the
Jain said, “The uniqueness of Indian system is
that NPCIL has got centralized online
monitoring system of all the power stations
safety aspects of our plants after doing a which are operating in Mumbai. We have all
complete analysis of the Japanese incident the emergency control centre where plants
and share the entire safety means with the live parameters are online through satellite,”
public in a transparent way,” chairman and he said.
Managing Director of Nuclear Power
“Parameters are available for various safety
Corporation of India S K Jain said on Mar13.
and reactor systems where safety experts can
Jain said, out of the 20 operating Indian assemble within few minutes can do the entire
reactors, 18 are Pressurised Heavy Water parallel analysis and also in continuous
Reactors, two are Boiling Water Reactors. The contact with the stations,” he said.
two reactors of 1000 MW of Russian VVER-
“Design safety, safety analysis capacity are
1000 type under construction at Kudankulam
available as a back up of operating plants
in Tamil Nadu have Generation-3 plus designs.
which is unique to India,” Jain said adding “it is
Between BWR (Tarapur units 1 and 2 and the a big strength.”
Japanese reactors at Fukushima Daiichi) and
Inspite of all these, with open mind we will be
PHWR there is a big difference as the PHWR
revisiting the safety aspects and share them
(Pressurised Heavy Water Reactor) reactor
with the public, Jain stressed.
has 100 to 200 tonne of cold moderator which
surrounds all the coolant channels. Calendrias Meanwhile, seismologists (earthquake
submerged in a cool water of canlendria vault specialists) here said, all Indian reactors are
(1000 tonnes). not on coast and the Indian coastline is more
than 1,200 miles away from Sunda trench
There is a very big heat sink available in
where mega earthquakes can occur.
PHWRs and secondly, unlike the BWR
(Boiling Water Reactor), the PHWR is also “Hence, similarity analysis of reactor
cooled by naturally occurring siphon accidents incidents between Japanese
mechanism.Since the steam generator reactors which are few hundred miles away
located at a higher elevation, directly injecting from mega subduction zones and Indian
water from the firefighting system into the coastal reactors which are few thousand miles
generator is also available as a supplement, away from Sunda trench should be done
he said. objectively,” they said.
"Our anxiety about technological “470,000 MWe” - a pie in the sky?
challenges for the construction of the
Physicist and research scholar at
country's first 500 MW Prototype Fast
Princeton University M V Ramana's
Breeder Reactor (PFBR) is over and we
are at the closure for technology deliv- guess is that India will see one set of twin
ery," said IGCAR Director Baldev Raj. The reactors from the big players, France,
500 MWe reactor, being developed by Russia and the US, at each of the sites
the Indira Gandhi Centre for Atomic allotted to these countries although the
Research (IGCAR) here, uses a unique US gets two sites because of the civilian
mix of uranium and plutonium which sig- nuclear agreement it pushed with India.
nificantly enhances the capability to gen- “It is plausible that the 20,000 MWe by
erate electricity per tonne of fuel utilised. 2020 might materialise, but I doubt if one
Bridge Seminar
Infrastructure: Nuclear Power Plants

Power Station Operator State Type Units Total Capacity (MW)

Kaiga NPCIL Karnataka PHWR 220 x 4 880
Kakrapar NPCIL Gujarat PHWR 220 x 2 440
Kalpakkam NPCIL Tamil Nadu PHWR 220 x 2 440
Narora NPCIL Uttar Pradesh PHWR 220 x 2 440
100 x 1
Rawatbhata NPCIL Rajasthan PHWR 200 x 1 1180
220 x 4
Tarapur NPCIL Maharashtra BWR 160 x 2 1400 Figure 5 Prototype Fast Breeder Reactor,
(PHWR) 540 x 2 Kalpakkam, Indira Gandhi Centre for
Total 20 4780 Atomic Research

Table I : 20 nuclear power reactors produce 4,780.00 MW (2.9% of total installed base)

Power Station Operator State Type Units Total Capacity (MW)

Kudankulam NPCIL Tamil Nadu VVER-1000 1000 x 2 2000
Kalpakkam NPCIL Tamil Nadu PFBR 500 x 1 500
Kakrapar NPCIL Gujarat PHWR 700 x 2 1400
Rawatbhata NPCIL Rajasthan PHWR 700 x 2 1400
Figure 6 Kundankulam Project in Tamil Nadu
Banswara NPCIL Rajasthan PHWR 700 x 2 1400
Total 8 6700
up nuclear power projects in the country
want to pass on part of the liability to the
Table II The projects under construction suppliers and are thus stalling the
passage of the nuclear liability bill.
March 1993: Fire in Narora Atomic PP brought reactor core almost to partial fuel meltdown. The Among the companies that have
fourth level safety protection in design saved. Similar fires had occurred in Rawatbhata and expressed interest in entering the field
Kakrapar plants. The 1993 fire occurred when two steam turbine blades broke. The blade fault had
been detected by turbine designer GEC UK which had given revised blade design to the Indian are Reliance Industries and Tata Power.
manufacturer who, in turn, prepared drawings for new blades. DAE action: nil. True, India does have a strong
May 1994: The Kaiga project delayed as containment dome collapsed during construction. appetite for electricity but by no means
Reasons: design deficiencies and lack of quality control (AERB had ordered stress tests in each reactor
before start-up and complete simulator installation for operator training. The conditions were not met). at the risk of a la Chernobyl, TMI or
Fukushima!!!!!!
June 1994: Flood water entered condenser pit and turbine building basements in the Kakrapar reactor
Reasons: Absence of sealing arrangements. Similar flooding had occurred twice at other stations.
Tsunami waves, five-metres high hit the power reactors at Kalpakkam in Tamil Nadu. A minor water
Author's Bio
leak was reported in the plant. Walls collapsed but were repaired by 2007. The author leads our Delhi bureau. An
Table III. Let's not forget : Close calls Engineer and qualified ADR professional
(NALSAR alumnus), Sadagopan Seshadri has
can have the targeted 40,000 MWe by time is close to nine years. In most cases, been a senior Contract Management
2020,” predicted Ramana. As of now PM the anticipated construction time was Professional in large national &
International Companies. His domain expe-
Manmohan Singh's target seems a pie in about five years,” he said.
rience is in Building Products, Cement plants
the sky. and Mega Power project execution. He is
The liability aspect: who foots the
disaster bill expert visiting faculty for Contract
“Construction of nuclear reactors
Management at the SSAA, IP University,
has always taken much longer than, say,
Issues such as who bears the liability New Delhi.
natural gas-based power plants,” said
make the Areva project and those by Being passionate about Environment he
M V Ramana, physicist and research
Americans shaky. The issue is not just the has now turned to Landscape Projects
scholar at Princeton University. “The
amount of compensation to be paid in design teamed with likeminded architects &
time period increased significantly after engineers for sustainable landscapes devel-
the event of an accident but as to who
the mid-1980s following the Three Mile opment He is vocal with his views on these
will be landed with bill, the operators or
Island and Chernobyl accidents. As per areas through his writings.
the suppliers, and to what extent.
the International Atomic Energy He can be reached at design2xcel@gmail.com
Agency's data the average construction Private Indian players who wish to set

122 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Esquire -CMAC Pvt.Ltd
CE: Events

CONEXPO-CON/AGG
Show Lifts the Spirits of US Construction Industry
Amith Indurthi
Resident Correspondent, USA

P erhaps no other trade show had

been so eagerly anticipated in US
in the recent times, than the
CONEXPO-CON/AGG, which was co-
organized along with the IFPE 2011
exposition, from March 22-26 in Las
Vegas. The continued uncertainty in the
US construction market had meant that
the exposition had a heightened
curiosity factor, around the world, given
the global reverberations of success or
failure of the event. The
overwhelmingly positive mood at the
exposition meant, that the pale of
g l o o m t h a t h a d e n g u l fe d t h e
construction industry in the US had
been lifted. The success of the show
came as a shot in the arm for global
construction equipment manufacturers.
The CONEXPO-CON/AGG and IFPE
2011 attracted nearly 120,000
registered attendees. It was the largest
gathering in North America since 2008
for the construction, construction
materials, and fluid power/power
transmission/motion control industries.
The CONEXPO-CON/AGG show
organizers officially opened the show
with a ribbon cutting ceremony led by
its Chairman of Managing Committee of
the event, Mr. Mike Haberman and the
Institute of Fluid Pipe Education (IFPE)
Chairman Mr. Al Carlson.
“Conexpo is the largest construction
equipment show in the western
hemisphere with more than 2000
exhibitors and the industry support
makes it the great event that it is while
the co-location with IFPE and ICON
enhances the experience,” Mr.
Haberman reportedly said in his
opening speech.
Dubbed the “American Bauma”, the
show laid claim to being the largest
trade show that is held in the US. Over
2,000 exhibitors are displaying latest

124 The Masterbuilder - April 2011 | www.masterbuilder.co.in


construction equipment in the
show. Mr.Haberman during his
inaugural address touched upon the
fact that no longer can the US be not
affected by what he termed as
“crumbling infrastructure”. He went on
to add that the “show promises an
entire host of new product launches,” a
promise which was fulfilled by a vast
majority of construction equipment
manufacturers, who had lined up
several new products and technologies,
for launch during the show.
Record International Participation
According to the organizers, the
international registrations accounted
for a record 24 percent of the total. The
i nte r n at i o n a l b u s i n e s s v i s i to rs
represented over 150 countries. The
show also hosted 42 official
international customer delegations
from 37 countries, which were
organized by the U.S.Department of
Commerce, as well as by other
associations and related groups.
The quality of attendees was
evident from the fact that around 44
percent of the business visitors had top
titles of president/owner and vice
president/general manager/chief
financial officer. Exhibitors on their part
have reported strong purchases and
sales leads, apart from enhanced
networking opportunities for
technology sharing initiatives because
of the show.
The all pervading atmosphere of
optimism was bought out aptly by
Mr.Megan Tanel, Association of
Equipment Manufacturers (AEM), Vice
President of Exhibitions and Events,
who has been quoted in the official
website of the show stating "The
construction industry has been through
some very tough times, with record
u n e m p l o y m e nt , s i n c e t h e l a st
CONEXPO-CON/AGG and IFPE in March
2008. With these positive numbers and
the industry support of the shows,
we're optimistic about the future and
looking forward to seeing these new
sales orders fulfilled, “ before adding
"The increased global participation by
attendees and exhibitors underscores
the importance of world markets to our
industry. The U.S. economy is slowly
improving and we have a ways to go,
especially in construction, but after 18
to 24 months there is more pent-up
Aerial View of the Venue
www.masterbuilder.co.in | The Masterbuilder - April 2011 125
CE: Events
demand for equipment to be ready
for the upturn.”
More than 860 co-located events,
educational programs and pre-planned
meetings, were held along with the
show. ICON Expo for concrete products
industry was among the key co-
locations that took place during the
show. The expositions also saw the
conduct of several annual conferences
of national industry associations, which
assume significance, given the
buoyancy in the U.S construction
i n d u s t r y, e s p e c i a l l y a f t e r t h e
announcement of the infrastructure
stimulus package by the Obama
administration.
The event saw more than 2,400
exhibitors taking more than 2.34 million
net square feet of exhibit space. While
IFPE 2011 was the largest ever,
CONEXPO-CON/AGG's exhibit space
was the second largest in its history,
according to the organizers.
The global nature of the event was
evident from the 10 international
exhibit pavilions that were part of the
shows. Pavilions from China, Finland,
Italy, Korea, Spain, and United Kingdom
CE: Events
were major attractions in CONEXPO-
CON/AGG, while IFPE had pavilions
from China, Italy and Taiwan.
The growing importance of the software
industry in the field of construction
equipment came to the fore in the show
with it featuring IT & Business Solutions
pavilion, which was sponsored by the
Associated General Contractors of
America.
Industry Focused Education
One of the key components of the
show was the record number of
education, training, and certification
programs that were on offer. There has
always been criticism of lack of trained
manpower to operate construction
e q u i p m e nt e ve n i n d e ve l o p e d
countries. The focus in this show
The Event Saw Numerous Industry- Client Interactive Sessions
126 The Masterbuilder - April 2011 | www.masterbuilder.co.in
A Grand Inaugural Function
therefore of specific training program
for construction equipment, was
therefore welcome by the entire
construction fraternity. A record 126
sessions across nine fields, were a
unique feature of the show. Some of the
most interesting sessions were on
management and applied technology
and industry trends. There was also a
Green Roads Summit and a Crane and
Rigging Conference that were held as
part of the show.
There was a specific program held
during the show that focused on safety
in crane and other aerial lift equipment.
As part of the Crane and Rigging
Conference, visitors were provided with
training on safety and hands-on
operational experience. The International
Mixer Driver Championship organized
A Record International Participation was another Highlight of the Show
by the National Ready Mixed Concrete
Association (NRMCA) was another
highlight of the show.
Although the construction
equipment show attracted around
120000 visitors, figures which are about
16 percent lower than the 2008 show,
the increase in the number of overseas
visitors was a positive that organizers
could take out of the event. Overseas
visitors constituted about 24 percent of
the total number of attendees, which
was a significant 19 percent jump over
the figures of the previous edition of the
show held in 2008.
The organizers have also announced
that the next edition of the show would
be again held at the Las Vegas
Convention Center in Las Vegas, US on
18-22 March in 2014.
MM Castings (P) Ltd
Road Construction Equipment: Industry Analysis

ROAD CONSTRUCTION
EQUIPMENT SECTOR
Ready for the Bull Run
Bhavani Balakrishna

A n efficient road network

system is a pre-requisite for a
burgeoning economy like India.
Hence, it does not come as a surprise
that road construction and
maintenance has been one of the
major thrusts of the UPA government
in its current and past stint.
Our country has the third largest
road network across the globe
consisting of National Highways, State
Highways, Major District Roads and
Village and Other District Roads. While
the National Highways comprise only
2% of the total length of roads, they
carry over 40% of the total traffic across
four different corners of our country.
Starting with the 9th Five Year Plan
(1997-2002), road sector expenditures
have gone up from 3% of the total Plan
expenditure to almost 12% today.
These expenditures were primarily for
national highway and rural road
development programs. The Eleventh
Plan indicates a total planned
investment of about INR 2, 09,400
Crores in road infrastructure and road
construction equipment contributes
about 21-23 per cent of the total
project cost in road projects. This
should be ample evidence about the
growth potential for road construction
equipment industry in India. However,

128 The Masterbuilder - April 2011 | www.masterbuilder.co.in


the industry relies on the efficient
and timely allocation of funds to
national road development projects.
Delays in the implementation of these
projects will inevitably result in slowing
down or delaying the expected
industry growth.
Road Construction Equipment Market
From Evolution to Present
The road construction equipment
Road Construction Equipment: Industry Analysis
since its early days. The 1960s
heralded the mechanization of the
entire process. The globalization of the
Indian economy in 1991 also brought
about the much required impetus to
the road construction equipment
industry. Indian manufacturers tied up
with foreign partners for R&D and
improvisation of their products. The
modification of specifications as
required by MORT&H also gave a boost
to R&D, innovations and collaborations.
Previously, while a single static road
roller was used for the compaction of
the sub grade, sub base, base and black
topped layers, the practice is now to
use a different type of road roller for
each layer, like soil compactors,
ta n d e m v i b ra t o r y ro l l e rs a n d
pneumatic tyred rollers. The demand
for hot mixed plants has moved from
small capacities like 20-30 TPH to 120-
400 TPH in road projects. Conventional
rigid paves are increasingly being
substituted with slip form pavers in
concrete roads. The market is already
familiar with technology and machines
like wet mix plants, cold and hot milling
machines, pavers for the construction
of base course and cold and hot re-
cycling machines that can reduce the
thickness of the road crust and also
have the ability to recycle the used
material during road construction.
Here is a brief description of the
road construction process. Any heavy
infrastructure project begins with site
clearance. Then, a motor grader makes
the sub-base flat to a certain extent.
The motor grader also helps in profiling
the sub-base. After this, a soil
compactor or a single drum compactor
is used to compact the soil. This also
helps in increasing the load bearing
capacity. Generally, a smooth drum is
used for non-cohesive soils and a
padfoot drum with feet for soils such as
clay or silt. Specially graded aggregate
is then brought in to form the unbound
www.masterbuilder.co.in | The Masterbuilder - April 2011 129
INDIAN ROAD NETWORK
(Length in Kilometers)
National Highways (NH) 58,112
State Highways (SH) 1,37,119
Major District Roads (MDR) 4,70,000
Village and Other Roads 26,50,000
(ODR & VR)
Total Road Length 33,15,231
Source: National Highways
Authority of India (NHAI)
base course. The next step involves
laying the first bituminous base course
a carefully designed and manufactured
mixture of asphalt and aggregate - hot
with an asphalt paver. It is essential that
the asphalt remain at high
temperatures up to the point of being
laid. After this, a tracked or wheeled
paver is used to put down multiple
binder layers based on the traffic loads
the road is expected to carry. The
thickness of the first binder layers may
vary from 100-150 mm. A tandem roller
then follows behind the paver to
compact each layer before the final
wearing course of about 50mm of
asphalt is put down.
“The market share for excavators as
compared to all construction &
earthmoving equipment is on the
rise every year. With big projects
coming in contractors are opting for
specialized machinery like tracked
excavators. Currently the market
size is about 7500 machines”
Amit Gossain
AVP- Marketing & Business
Development, JCB India
Road Construction Equipment: Industry Analysis

2009 2010 2011 2012 2013 2014

Units Rs. Crs Units Rs. Crs Units Rs. Crs Units Rs. Crs Units Rs. Crs Units Rs. Crs
Asphalt 920 322 1150 402.5 1350 472.5 1500 525 1600 560 1650 577.5
Finishers
Compaction 2787 418.1 3400 510 3800 570 4200 630 4500 675 4800 720
Equipment
Crawler Dozers 562 505.8 700 630 800 720 900 810 1000 900 1050 945
Motor Graders 342 212 600 372 700 434 800 496 900 558 950 589
Total Road
Construction 4611 1100 5850 1915 6650 2197 7400 2461 8000 2693 8450 2832
Equipment

Demand for Road Construction Equipment as per Off-Highway Research

Industry Structure and Players
The key players in the industry
include JCB, Gujarat Apollo, Wirtgen,
CNH International, Volvo, Greaves
Cotton, TIL, Fayat India, Ammann and
DMI.
“The construction equipment
industry in India has had several
years of strong growth, in the range
of 15-20% per year, and we see great
potential for the future. There is no
doubt that backhoe loaders and
excavators will continue to represent
the core products for the Indian
market in the coming years. CNH,
through its brand Case Construction
Equipment, holds the market
leadership for vibratory compactors
and is the second player in the local
backhoe loader market. CNH's
objective is to consolidate both its
leadership positions in the vibratory
compactor and in the backhoe
loader segments through product
enhancements and improved
service coverage.”
Mario Gasparri
General Manager, CNH International
According to Mr. Amit Gossain, is growing at a rate of 5 10%. We
AV P - M a r ke t i n g & B u s i n e s s expect the market to grow at a similar
Development, JCB India, “The market rate for the next five years.”
share for excavators as compared to all
The competition is certainly intense
construction & earthmoving
with global construction equipment
equipment is on the rise every year.
majors eyeing India as one of the
With big projects coming in contractors
potential markets. This may put some
are opting for specialized machinery
pressure on the profit margins of
like tracked excavators. Currently the
existing players. Also, the recent
market size is about 7500 machines. “
budget initiative that allows for resale
According to Mr.Mario Gasparri, of specified machinery imported
General Manager of CNH International, (under 0% import duty) for road
“The construction equipment industry construction before 5 years on
in India has had several years of strong payment of import duty at depreciated
growth, in the range of 15-20% per value may have a negative impact on
year, and we see great potential for the the domestic construction equipment
future. There is no doubt that backhoe players as the contractors who
loaders and excavators will continue to
represent the core products for the
Indian market in the coming years.
CNH, through its brand Case Construction
Equipment, holds the market leadership
for vibratory compactors and is the
second player in the local backhoe
loader market. CNH's objective is to
consolidate both its leadership
positions in the vibratory compactor
and in the backhoe loader segments
through product enhancements and “At present, the road construction
improved service coverage.” equipment market in India stands
at an industry volume of 2500
Commenting on the industry's machines per year and is growing at
m a r k e t p o t e n t i a l M r. A . M . a rate of 5 10%. We expect the
market to grow at a similar rate for
Muralidharan, Managing Director,
the next five years.”
Volvo India Pvt. Ltd states, “At present,
the road construction equipment A.M. Muralidharan
market in India stands at an industry Managing Director, Volvo India Pvt. Ltd
volume of 2500 machines per year and

130 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Asons Enterprise
Road Construction Equipment: Industry Analysis
“The typical Indian customer is no
longer making buying decisions only
based on the price. Customers are
now looking for reliability, quality,
prompt after-sales technical support
and lesser downtime.”
Rolf J.Jenny
Ammann Group
preferred the domestic equipment or
hiring of such equipment over the
imports can now avail the choice to
import the specified machinery at 0%
customs duty and move to other
similar projects in order to ensure full
utilization.
However, most industry players
acknowledge the evolving maturity of
the Indian customer. According to
Mr.Rolf J.Jenny of the Ammann Group,
“the typical Indian customer is no
longer making buying decisions only
based on the price. Customers are now
looking for reliability, quality, prompt
after-sales technical support and lesser
downtime.”
There have been concerns among
the industry and its stakeholders that
there is a huge gap between demand
and supply for improved roads and the
domestic construction industry is still
in its initial stage to meet the future
demand. Most industry experts also
agree that timely execution and
completion of projects is another
aspect of concern, the underlying
reason being undue delays made by
the Government while making
decisions.
132 The Masterbuilder - April 2011 | www.masterbuilder.co.in
C o m p a n i e s a r e p ro a c t i v e l y
addressing issues like unavailability of
spare parts and lack of skilled
manpower that have plagued the
industry for long. There is also a major
thrust on increasing production
capacities, R&D and innovation with
more and more players introducing
world class technology for Indian
contractors.
The Wirtgen Group which has “With the Hamm 311, we have
maintained a strong presence in India developed a model that is designed
since 1995 with local sales and service specifically for the Indian market.
This single drum compactor
centres in Mumbai, Ahmedabad, New corresponds to the high standards of
Delhi, Hyderabad, Bangalore, Chennai quality of the Wirtgen Group, but is
and Calcutta recently commenced the manufactured locally so that the
licensed production of Hamm single- pricing allows us to prevail on this
highly competitive market,”
drum compactors in Pune last year. In a
press release accompanying the news, Ramesh Palagiri
Ramesh Palagiri, Managing Director of Managing Director, Wirtgen India
Wirtgen India says “With the Hamm
311, we have developed a model that is
designed specifically for the Indian accommodate a Wirtgen surface miner
market. This single drum compactor or a large asphalt paver from Vögele.
corresponds to the high standards of Case New Holland (CNH) operates a
quality of the Wirtgen Group, but is production facility in Pithampur,
manufactured locally so that the Madhya Pradesh. This facility currently
pricing allows us to prevail on this builds backhoe loaders and vibratory
highly competitive market,” The compactors. According to the
company has also built a new training company, the full acquisition of the
centre in the same facility that can even Pithampur operations represents an
HAMM 311 Single Drum Compactor
 Road Construction Equipment: Industry Analysis

CASE 752 Tandem Vibratory Compactors Greaves Bomag Single Drum Compactor

important step in CNH's strategy aimed amplitude and dual frequency to meet efficie ncy and thus
at creating a strong manufacturing requirements of asphalt and soil resulting in precision finish of roads.
base for our construction business and compaction and, dual drum driven by The range comes in 1 to 2 metres. The
at further consolidating their presence hydraulic motors. JCB has invested Paver offers 9.2 metres of paving width
in the country. CNH also plans to several crores in its Pune plants and and comes with enhanced screed
strengthen its Case dealer network in Ballabhgarh in order to meet the ever features offering superior compaction,
line with the growth of the market to growing demand for construction resulting in high quality finish and
further improve the level of the service equipment in India. It has also invested undulation effect on roads.
for the construction industry in the in some of the largest and best parts, TIL has recently entered into an
country. warehouse and training centers. agreement with Astec Inc to introduce
Mr.Gaspari further elaborates that Greaves Cotton which has a equipment meant for the road
the R&D facilities for the construction formidable presence in the road construction industry, including cone
equipment business in India will be construction industry recently unveiled crushers, high frequency screens, and
further enhanced, as they benefit from a new range of milling machines, hot mix asphalt plants.
CNH worldwide investments, pavers, loaders and twin shaft batching Mr.R.Nandagopal, TIL-ASTEC, Vice
resources and expertise in equipment plants at BC India, 2011. The state-of- President, Equipment & Project
and innovations. CNH will devote art BOMAG milling machines is Solutions, explains, “India is currently a
particular focus to fuel consumption, equipped with features like front batch mix country. But with increase in
operational ease and precision, cab loading, track mount & steering and road project size, you will need hot mix
comfort and maneuverability. auto control & auto engine power a s p h a l t p l a n t s w h i c h fe a t u r e
regulation to enhance operator continuous mix or double barrel
JCB, one of the leading construction
equipment manufacturers in India, has
a complete range of excavators,
backhoe loaders and compaction
e q u i p m e nt to m e e t t h e ro a d
construction demands in India. In 2008,
i t i n t ro d u c e d t w o m o d e l s o f
compactors - Vibromax VM115 and
VMT 850. The VM115 soil compactor
has high amplitude of 1.95 mm, best in
class centrifugal force, maintenance-
friendly with a lifetime lubricated
centre joint, comfortable operator
station with weight adjustable seat,
and zero greasing points. The 8.5 tonne
tandem roller VMT 850 has dual CASE 770 Loader Backhoe

www.masterbuilder.co.in | The Masterbuilder - April 2011 133

Road Construction Equipment: Industry Analysis

technology. “. TIL's Hot Mix Asphalt

Plant is used to properly proportion,
blend and heat aggregate and asphalt
to produce an HMA that meets the
requirements of the job mix formula
(JMF). There are Batch Type and Drum
Type HMAPs.
The Ammann Group which has
already made its mark in countries like
China, Malaysia, Vietnam, Thailand,
Australia and New Zealand now has
been making rapid inroads in the Indian
market with its array of road
construction equipment, ranging from
high quality asphalt plants to compactors.
Ammann S 240-400 t/h Stationary Asphalt Mixing Plant
worldwide. Ammann also offers paving traditional specification mixes. The
machinery, state-of-the-art compactors plant is configured to work on the
including single drum rollers and highly acclaimed heavy/waste oil firing
pneumatic tyre rollers. system of MARINI to help customers
realize huge savings on production costs.
Fayat India's MARINI MAC Series of
hot mix asphalt plants is aimed at DMI Engineering and Manufacturing
improving productivity and at the same (DMI E&M) Co Ltd offers asphalt mix
time reduce fuel consumption. It plants ranging in capacity from 40 TPH
recently received recognition from a to 400 TPH. The entire asphalt plant
“India is currently a batch mix client due to erection and commissioning can be erected within a week. The
country. But with increase in road of the plant in 20 days' time instead of company's mobile asphalt mix plants
project size, you will need hot mix
asphalt plants which feature the usual 45-60 days. have also been very successful in India.
continuous mix or double barrel The plant is capable of producing Singapore Technologies Engineering
technology.“
futuristic and low carbon emitting Ltd (ST Engineering) recently announced
R. Nandagopal mixes; recycled asphalt mixes with up that its land systems arm, Singapore
Vice President -Equipment & to 35 percent RAP content with Technologies Kinetics Ltd (ST Kinetics),
Project Solutions, TIL-ASTEC

The company has already installed over

3,000 asphalt mixing plants globally,
being a pioneer in the field, with its
strong R & D focus. The company's
R & D Center in Switzerland has been
successful in introducing technology
with which asphalt can be produced at
115 degrees Celsius, instead of the
usually 170 degrees Celsius translating
to lesser energy consumption.”
Ammann offers a range of asphalt
mixing plants, ranging from mobile to
semi-mobile and stationary high
performance units, with capacities
Marini MAC Hot Asphalt Plant
ranging from 80 TPH to 400 TPH

134 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Viki Industries (P) Ltd
Road Construction Equipment: Industry Analysis
JCB VM115D Compactor
has established a wholly owned Indian
subsidiary, LeeBoy India Construction
Equipment Pvt Ltd to market,
manufacture and support a range of ST
Kinetics' CE products, from road
construction and maintenance
equipment to excavators and off road
dump trucks, to meet the growing
needs of the Indian CE market.
The acquisition of Ingersoll Rand's
Road Development division in May
2007 allowed Volvo Construction
Equipment to offer highway-specific
equipment, as well as traditional
construction equipment that are also
needed in the road building process.
Volvo Construction Equipment owns
the RASTA (Resource Centre for Asphalt
and Soil Training Academy) Center for
DMI Asphalt Mix Plant
136 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Volvo - EC360BLC Excavator
Road Technology in India that provides
training and knowledge about the
latest technology for road building and
maintenance.
In the road construction equipment
market in India, Volvo has a market
share of 22 24%. Volvo offers a range of
products especially for road
construction. This includes pavers,
large asphalt compactors, small
asphalt compactors, large soil
compactors, small soil compactors, and
milling equipment. To cater to the
needs of customers in India, Volvo
offers 5.5 meter pavers that are
manufactured at its facility in Peenya
Bangalore while pavers that are 9m and
above are imported from Germany.
Throughout the business cycle Volvo
consistently dedicated substantial
sums to research and development. Mr
A. M. Muralidharan further elaborates,
“New technology doesn't have to mean
complex systems sometimes the best
ideas are the simplest.”
Volvo is also ensuring that they
meet all environmental standards set
by the government of India including
Tier 3 emission requirements. Volvo
takes a holistic approach to fuel
efficiency and is aiming at delivering
fuel efficiency across all elements of
their machines via engines, systems,
operator behaviour and future
technologies, while increasing the
productivity for its customers. Hybrid
technology is one part of this wider
range of fuel saving solutions.
Future Outlook
The current UPA government had
earlier set itself an ambitious target of
developing 20 kilometers of new roads
per day and building 35,000 km of new
roads by the year 2014. However
former surface union transport Minister
Mr. Kamal Nath acknowledged openly
that this may not be the case. Issues
relating to land acquisition and
awarding of contracts have marred the
target reducing it to 12-13 kilometers
per day as of Mar 2011. But the road for
construction equipment market
remains bullish.
Action Construction Equipment Ltd
????: ????
Executive Briefing
A Chat with JCB's Chief Alchemist
Vipin Sondhi
T he Masterbuilder recently spoke
to JCB's MD & CEO Mr.Vipin
Sondhi on the company's latest
launch the ecoMax BSIII engine and
future plans. An alumnus of Indian
Institute of Technology, Delhi and the
Indian Institute of Management,
Ahmadabad Vipin Sondhi is the face
behind JCB India's transformation to
becoming the country's market leader
for construction equipments. His
business acumen have come to the fore
in making JCB India much more than
just a backhoe loader manufacturing
company, as it was perceived before, to
a company today, that offers an entire
range of construction equipment.
Matching his passion for heavy
construction equipments is his
penchant for playing the violin and his
138 The Masterbuilder - April 2011 | www.masterbuilder.co.in
enthusiasm for teeing off. This business
strategist has played a key role in
ensuring the growth of the company,
which has now sold over 100,000
machines in India. Here are excerpts
from the interview.
How does the BS III emission
compliant engine that you have
recently launched in India compare
with your range of other similar
engines that you are producing
elsewhere in the world?
Worldwide over 150,000 JCB
machines with JCB engines are proving
their worth. The JCB Dieselmax engine
which is built in UK is a Tier IV compliant
state of the art engine which powers
JCB UK's world beating range of
construction equipment. The JCB
Engine ecoMAX has been built on the
same platform as the Dieselmax
engine. However the engines are
customized for Indian conditions and
emission norms. It has the same block,
bedplate design and crankshaft
dimensions and almost similar valve
train. The fuel injection system was
modified to suit Indian conditions.
What are the features in the ecoMAX
engine that help in maximizing its
'green' quotient?
The engine is optimized for our
construction equipment, to offer a
package that produces maximized fuel
efficiency while enhancing productivity
and operating efficiency solutions. JCB
respects the environment and designs
all its products in a way that helps
Action Construction Equipment Ltd
In Conversation
maximize the green quotient. 4
valves per cylinder ensure better
mixing of fuel hence better combustion
and lower emissions.
Has the engine been specifically
designed to suit Indian conditions?
The JCB engine ecoMAX is based on
the same platform as the JCB
Dieselmax, the record breaking Engine
that powered the car which holds the
world's land speed record. It is also the
first engine designed specifically for
off-highway applications. A JCB
m a c h i n e wo r k i n g i n s u b ze ro
temperatures building roads in Leh
might also be called on to work in the
searing heat in the deserts in
Rajasthan. Plus there are difficult off
highway fuel conditions to deal with.
The usage pattern in India is different
from the American or European
markets and the engine has been
adapted specifically considering these
factors.
Will you be using the engine only for
India or are you exploring export
opportunities?
The engine will be utilized only for
JCB machines manufactured in India.
Give us an overview about the
production facility for these engines
that you have in place.
Our new engine plant at its Indian
headquarters in Ballabgarh takes lean
manufacturing to its finest levels. The
engines produced by the plant ensure
Unveiling of 100,000 JCB machine in India
140 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Track excavator : JCB JS360LC
that they have zero defect levels
across its life cycle so that the customer
gets maximum equipment uptime on
the capital investment made. The
manufacturing process of the engines
works on the 'no fault forward'
production model. In accordance with
this, the machine is minutely inspected
at its every stage of production
encompassing cutting edge technology
providing optimum engineering value
to the manufactured product. The in-
process verification of the engine
during the production process includes
a range of stringent tests. The engine
being assembled is passed to the
second stage only after it has qualified
all the test parameters at first stage.
The entire chain of in-process
verification is completely computerized.
The vital element of the assembly plant
is its air conditioning. This is in order
to maintain high cleanliness levels so as
to adhere to BS-III norms. Appropriate
air quality would neutralize chance of
foreign particles entering into the
assembly plant. It's a state of the art
facility which produces world class
engines.
How widespread is your service
network, with respect to the new
launched ecoMAX engine?
JCB in India has the best network of
over 370 dealer outlets which together
cover India across its length and
breadth. Nobody covers India like we
do in the construction equipment
sector. Secondly, we have highly trained
personnel and a lot of focus on training
and development of our employees.
There are continuous hours of training
for our dealer personnel. Extensive
trainings were planned and executed
for JCB engines. Over 1100 service
engineers across all 370+ outlets have
been trained on the new engine to
serve our customers. It's an ongoing
process and training continues. Thirdly,
all engine related spare parts are
stocked at our large JCB warehouses
across India in Chennai, Ballabgarh,
Faridabad, Kolkata, and Pune and at
dealerships/outlets.
Action Construction Equipment Ltd
New Roll Out
JCB Rolls Out
New Diesel Engine
for Off-Highway Vehicles
I t is one thing to be known as the
best construction equipment
manufacturer in the country and
quite another to continue to live up to
that reputation and still another to
better the reputation time and again.
This is where JCB India Limited proves it
has what it takes as the company
launches their diesel engine, the
ecoMax.
As the name suggests, the engine is
fuel efficient and powerful, both.
Difficult, one would think given the
terrain, fuel quality and pollution levels
machines used for construction
purposes battle. But that's where the
JCB team worked hard on the design
142 The Masterbuilder - April 2011 | www.masterbuilder.co.in
and technological
innovation to sculpt an
engine especially suited for
Indian conditions.
Speaking at the launch
of the engine in Pune on
March 31, JCB India MD &CEO,
Vipin Sondhi said, “Diesel engine
technology is a major step for us.
EcoMAX, for use on off highway
vehicles has a 16 valve engine which
means better combustion. Added to it
is the fact that we have designed this
BSIII compliant engine to suit Indian
conditions. It means we have world
class machines with world class
engines tailored for Indian work
The EcoMax: Snapshot
76 hp to 150 hp range | naturally
aspirated | High pressure rotary pump |
Block bedplate and crankshaft
dimensions similar to JCB Dieselmax
engine
Cold Side Features
14.5 psi cooling system | Fan belt auto
adjuster | 6000 hours of belt
life | State-of-Art Delphi fuel system
Hot Side Features
Heavy duty cylinder block | Aluminum
alloy pistons | Centralized location of fuel
injectors | Four cylinder 16 valves |
Deep bed plate design|Low noise and
improved sealing
What you get as a customer
High torque at lower rpm for better
performance | Better operator comfort
due to reduced noise and vibration levels
| Low maintenance cost | Fuel efficiency
| High reliability for longer life | One
year unlimited hours warranty on
Backhoe Loaders | The all important
support from the JCB sales and service
network

“Diesel engine technology is a
major step for us. EcoMAX,
for use on off highway vehicles
has a 16 valve engine which
means better combustion.
Added to it is the fact that we
have designed this BSIII
compliant engine to suit Indian
conditions. It means we have
world class machines with
world class engines tailored for
Indian work conditions.”
Vipin Sondhi
MD & CEO JCB India
conditions.” Teams from India and the
UK worked on the ecoMax design
together to perfect it.
Explaining further, Sondhi said, “If
you look at the areas where our
machines work, you will note that the
fuel they get is not of the best quality,
the dust is also a concern. Our team has
worked on building and design
optimization specifically to meet such
difficult environments.” Powered by a
high pressure rotary pump, with state
of the art Delphi fuel system its range is
impressive from 76 hp to 150hp.
What also adds value to the
ecoMAX is the fact that the oil and filter
change window is of 500 hours each
while the main filter change period is of
1000 hours. These, automatically
reduce maintenance cost. Also in its
favour is the attribute that you can put
the engine on full load immediately.
Low vibrations and noise make it an
even more attractive proposition.
Immediately, (April 1 onwards) all JCB
backhoe models will be powered by
ecoMAX.
To be produced at their world class
premises in Ballabgarh, they have a
capacity to produce 40,000 engines
Www.masterbuilder.co.in | The Masterbuilder - April 2011 143
New Roll Out
however they will produce 20,000
units initially. Understandably, the
engines will be used only on JCB
machines. Since this is a different
design, it cannot just be installed in
older JCB machines.
Choosing Ballabgarh as the
production hub for the engines was
essential simply because the facility
there is better equipped to match the
workflow. “We have invested Rs.135 Cr
in the building, setting up of the
assembly line and the plant
equipment” adds Sondhi.
True to their dedication to
customers, service support is in place.
Their 370 outlets across the country
are already trained to meet customer
requirements for machines using these
engines.
Currently, JCB India imports only
crankshafts from the parent company
JC Bamford Excavators Limited UK. On
the export front, JCB is happy with their
figures for 2010. “We exported 200
machines in 2010, besides our
components are being exported,”
stated Sondhi.
JCB widely acknowledged in India
as a largest construction equipment
manufacture with a range of products
including Backhoe Loaders, Excavators,
Compaction Equipment, Wheeled
Loading Shovel, Telehandelers, Liftall
and Skid Steer Loaders, Lift and Carry
Cranes among others.
Speaking about JCB India, Amit
Gossain, Vice President Marketing and
Business Development said, ''It is
important to keep our network
expanding so customers do not need to
go far to service machines.” Over the
next few months, Sondhi confirms, “we
have an exciting product plan.” Watch
this space as they say in JCB, “where
the best gets even better.”
????: ????
Extreme Utility Machines in LARGE
Earthmoving Projects
A fter a relatively quiet period
witnessed during 2008-09, the
infrastructure development
activities have picked up steam.
Perhaps in no other area is it more
evident than in the case of road
construction projects. The National
Highway Authority of India (NHAI) is
targeting around 100 road projects
totaling a length of 11,000 km for
144 The Masterbuilder - April 2011 | www.masterbuilder.co.in
M.K. Prabhakar
bidding during this fiscal. While road
projects have been in the news for the
past decade, one particular trend is
hard to miss. The size of road projects,
or for that matter other infrastructure
projects such as bridges, flyovers, dams,
etc, is getting bigger by the day. Aiding the
process is the presence of construction
equipment that is specifically meant for
large earthmoving projects.
Leading manufacturers are coming
out with bigger, tougher, and meaner
machines that can take up the strain of
large earthmoving projects, which are
so typical of infrastructure projects,
particularly in the road construction
sector. These extreme utility machines
category consisting of crawler
excavators, wheel loaders, crawler
dozers, motor graders and off highway

dumpers are playing a crucial role in
the fast progress of large infrastructure
projects. Let us take a look at these
various types of equipment that are
available, their key features and the
technology behind , which makes them
so very crucial for the success of large
earthmoving projects.
Trend towards Biggies
Perhaps in no other product
segment is the shift towards higher
capacity more evident than in the case
of crawler excavators. Today the higher
capacity excavators with engine power
ranging from 128 hp to over 200 hp
have become the norm. The 'biggies'
ranging from 14 to 20 tonnes and
above are the preferred choice in large
infrastructure projects. Excavators as a
whole have witnessed rapid growth
with figures released by Off-Highway
Research stating that the country had
seen sales of 11,300 units in 2010. A
very large percentage of this sale is
attributed to the increase in mega
projects, with higher capacity
machines being in demand.
Some of the best examples for
power-packed crawler excavators are
ideally suited to take on large
earthmoving projects can be found in
Large Crawler Excavators are
Vital for Mega Highway Projects
“Our machines are suitably
reinforced structurally to cater to the
arduous Indian working conditions
and high usage cycles in India as
compared to other parts of the
world. All JCB excavators have the
JCB Patented PLEXUS filtration
system “
Amit Gossain
AVP- Marketing & Business
Development, JCB India
the form of Hyundai India's 140 LC-
7, 140-LCD-7 and 140 LCM-7 models.
These mean machines come equipped
with a special Computer Aided Power
Optimization System (CAPO) which
enables them to take on tough jobs
with relative ease. Another biggie from
Hyundai stable is the 210-LC-7 long
reach excavator with an operating
weight of 24,500 kg. The machine
comes with a maximum reach at
www.masterbuilder.co.in | The Masterbuilder - April 2011 145
CE: Road Construction
ground level of 15,120mm and a
digging depth of 11,760 mm.
Another leading name in the field
that offers a range of powerful crawler
excavators is JCB India. The company's
JS Auto range features some of the
meanest machines for large
earthmoving projects. A good example
is the JS 140 model which develops 92
hp of net power and offers a bucket
tearout force of 7985 kgf and a dipper
tearout force of 7404 kgf for high
productivity and performance.
Another model from the company that
comes with power packed features is
the JS 360, with maximum dipper tear
out of 254kN. The boom in the model is
available with a choice of dipper
lengths 2.1, 2.63, 3.23 and 4.03, to suit
the requirements of reach, so very
crucial in large infrastructure projects.
LiuGong India's 225 is another model in
the range with its 21,500 kg operating
weight and 108 kW of rated power,
which makes it a preferred choice for
huge earthmoving projects. Displaying
similar powerful characteristics is the
Volvo 210 B Prime, which was in fact on
display in the recently concluded bC
India 2011 show. The model from Volvo
in the operating weight category of
over 20 t, with a maximum digging
CE: Road Construction
reach of over 9 m and featuring the
boom , arm and swing priority options ,
is ideally suited for a multitude of
functions including site grading,
trenching and backfilling. Another
leading name that offers an excavator
in this range is CHETRA Machinery India
Pvt Ltd, whose EGP 230, with an
operating weight of 23.6 t, features an
engine that develops 7.5 hp power.
Leading manufacturers have been
coming out with specific technology
features to suit the rigors of the Indian
working conditions. Explaining the
technology, Mr.Amit Gossain, AVP-
Marketing & Business Development of
JCB India says, “Our machines are
suitably reinforced structurally to cater
to the arduous Indian working
conditions and high usage cycles in
India as compared to other parts of the
world. All JCB excavators have the JCB
Patented PLEXUS filtration system.
“The specially designed system filters
the entire tank every 4 hours and the
entire system every 8 hours prolonging
hydraulic oil life to upto 5000 hours.
Going into detail about technology
features in their range of crawler
excavators Mr.Sunil Sapru, President of
LiuGong India observed, “The USP of
“The market is crying out for a new
leader and we target to get to that
position. The market size for dozers
in India is around 500 to 600 nos per
year and we hold its 10 % share now”
Ben Callow
CEO of Chetra Machinery India Pvt Ltd
146 The Masterbuilder - April 2011 | www.masterbuilder.co.in
“The USP of LiuGong crawler
excavators lie in the simplicity,
durability, and fuel efficient
Cummins engine. Our excavators
feature a unique bypass electrical
system that allows continued machine
operation in the unlikely event of a
main CPU maintenance issue”
Sunil Sapru
President, LiuGong India
Liugong crawler excavators lie in the
simplicity, durability and fuel efficient
Cummins engine. Our excavators
feature a unique bypass electrical
system, that allows continued machine
operation in the unlikely event of a
main CPU maintenance issue,” a
feature that makes the right choice for
large infrastructure projects in remote
areas. Besides this, Liugong crawler
excavators also feature power boost
The Importance of Dozers in Large Earthmoving Projects is Proven
and heavy lift options for increasing
lifting capacity, another important
feature for projects which involve
moving large amounts of material.
Dozing their Way into the Market
Crawler dozers have a crucial role to
play when it comes to removing large
amounts of material in earthmoving
projects. The emphasis on increased
power is evident from the range of
crawler dozers that are available from
different manufacturers in the country.
BEML for instance offers the BD 475
model, which can develop 860 hp @
2000 rpm, which makes it ideally suited
for mega road projects. One name
which offers a wide range of crawler
dozers is CHETRA. Some of its models
that are ideally suited for large
earthmoving projects include the
T-20.01, where the engine is capable of
developing 397 hp and the T-25.01
where the corresponding figure is 419
hp. The company also offers the even
more powerful T40.01 model that can
develop 540 hp of power. Speaking
about the growing relevance of dozers
in large infrastructure projects in India,
Ben Callow, CEO of Chetra Machinery
India Pvt Ltd, had remarked during an
interaction with The Masterbuilder,
Bomanite India
CE: Road Construction
Wheel Loaders for Clearing Large Amounts of Material
“The market is crying out for a new
leader and we target to get to that
position. The market size for dozers in
India is around 500 to 600 nos per year
and we hold its 10 % share now.” The
market is dominated by unorganized
players, with the vast majority of the
machines being used Chinese dozers
finding its way into India.
Fully Loaded on Features
Just as in the case with China in the
80s and 90s, where wheel loaders quite
“After deliberate investigation into
the market we have arrived at a
conclusion that Indian customers
tend to follow international trends, in
the use of heavier and stronger trucks”
Denis E.Trifonoff
CEO, Kamaz Vectra
148 The Masterbuilder - April 2011 | www.masterbuilder.co.in
literally ruled the roost, it is now their
time to be immensely successful in
India. The trend that the wheel loader
market has witnessed perfectly reflects
a rapidly maturing market with
demand for higher capacity machines
being on the rise. LiuGong's ZL50CX is a
perfect example for a model that can
take on the rigors of large earthmoving
projects. The machine from the world's
largest producers of wheel loaders
comes with a rated load capacity of
5,000 kg and a bucket capacity of 3.0
Articulated Haulers are the key to Tackling Tough Terrain
cubic metres. Speaking about the
benefits of using their wheel loaders,
Mr. Sunil Sapru of LiuGong India says,
“One of the key advantages with them
is the simplified hydraulic system, apart
from the efficient and effective cooling
system. We have developed a state of
the art product line with various
attachments sufficing multiple
applications, therefore enhancing the
efficiency and value for money”.
Volvo had showcased its L 120F
model in the recent bC India show. This
model features the Automatic Power
Shift (APS) feature, a system which
adapts to the operator's operating style
and saves fuel, by selecting the right
gear.” The automatic system in our
wheel loaders ensures optimum fuel
efficiency, said Mr.A.M.Muralidharan,
Managing Director of Volvo India
Private Limited and Head of Volvo
Construction Equipment Business in
India.
In Top Gear
The increase in the number of mega
highway and airport projects has mean
that off highway heavy commercial
vehicles are in great demand today.
These heavy haulers could make all the

difference in timely completion of
projects today. A good example for a
power packed off dump truck model is
the KAMAZ -6540 (8x4) which belongs
to the family of heavy duty trucks with
19t legal payload, GVW up to 31t and
comes with a host of attractive
features, besides being well known for
its productivity and efficiency. The
KAMAZ-6540 is equipped with KAMAZ
V8, 260 hp Euro 2 engine and the
Cummins 285 hp Euro 3 engine. In
addition, two fuel tanks of 210 litres
displacement each allow for lengthy
truck operation without the need for
refueling. Speaking about the truck,
Mr.Denis E.Trifonoff, CEO, Kamaz
Vectra explained “After deliberate
investigation into the market we have
arrived at a conclusion that Indian
customers tend to follow international
trends, in the use of heavier and
stronger trucks.” Man Force Trucks
Private Limited is another name that
offers a full range of heavy duty trucks
with its 49 tonnes GVW version, ideally
suited for large earthmoving projects.
Asia Motor Works (AMW) is
another company that offers its range
of on and off highway tippers that are
suited for the rough and tumble of the
Volvo G710B Grader
construction and infrastructure
industries. The 2523 TP models on offer
by AMW come with a host of features
including, Euro III engines that deliver
180/235 HP and 800 maximum torque.
Heavy duty double acting shock
absorbers and integral power steering
with double UJ ensure a smooth and
stable ride. Ashok Leyland is another
leading name that offers tippers and
tractor trailers for the construction
sector in the 16 to 49 tonne segment. A
good example from its range is the
'Hippo' tipper model with a GVW of
25,000 kgs and 16 cubic metres loading
”The Auto Power Shift feature in our
wheel loaders ensures optimum fuel
efficiency”
A.M.Muralidharan
Head of Volvo Construction Equipment
Business in India
www.masterbuilder.co.in | The Masterbuilder - April 2011 149
CE: Road Construction
capacity. Another good example for a
real heavy duty model is Volvo's
A40EFS, from its E-Series of articulated
haulers. The truck with a loading
capacity of 39,000 kgs is just about the
perfect choice for large earthmoving
projects.
Making the Grade
Mega highway projects have also
pushed the demand for heavy duty
motor graders. A typical example for a
heavy duty motor grader is the G990
model from Volvo, the biggest from its
range of G900 motor graders. The
mean machine comes with an extra 3
855 kg (8 500 lbs) of blade pull and
high-speed capability and can develop
a net engine power of 225-265 hp.
LiuGong India's 418 model too packs a
punch with its rated power of 160 kW
and maximum traction force of 86 kN.
The model also features the largest
grading blade in its class according to
the company. TIPL, which is the wholly
owned subsidiary of TIL Limited, offers
the robust 658 B model, a wheel loader
with a payload of 5,000 kg. The
machine comes with a ZF Axle and
SDEC engine for enhanced productivity
and is ideally suited for large
earthmoving projects.
????: ????
HIGH-TECH
ROAD BUILDING
Intelligent Compaction Shows the Way
Special Correspondent
S pecifications for road building are
becoming increasingly
sophisticated, corresponding to
the heavy increase in the number of
automobiles globally. Compounding the
pressure on governments is the fact that
road project sizes are also becoming
bigger by the day. Nowhere are these
two aspects more visible, than in India,
which is now in the midst of its biggest
road building spree. Faced with the
challenges of lowering project costs,
environmental protection and still
obtain desired results, contractors today
are looking at technology to bail them
150 The Masterbuilder - April 2011 | www.masterbuilder.co.in
out of the tight situation. Intelligent
Compaction (IC) is one such technology
that has come to their rescue with its
double advantage of helping in the
avoidance of premature road failure due
to insufficient compaction, while
enabling low-cost compaction process.
To put it in simple terms, the intelligent
compaction system allows drivers to
virtually 'see' key compaction data on a
display screen, thereby dispensing off
with the guesswork. This in turn means,
unnecessary passes are avoided, leading
to savings of both money and time.
Pavement performance is
dependent on a variety of factors
including, mix temperatures, mix
designs, type of equipment used and
most importantly rolling methodology
being employed. Although proper
asphalt rolling techniques and proper
mix ratios can help build quality roads,
any major improvement on the road
surface is possible, only before the first
layer of asphalt is laid. A uniform sub
base forms the basic element so very
essential for maximizing pavement
performance. A uniform and well laid
base enables to decrease permeability,
reduce settlement and increase

coded map of ground compaction
properties. The location of compaction
value and roller passes are mapped and
recorded by using GPS. A typical IC
system can collect and analyze data for
execution at the rate of approximately
1,700 to 4,000 times per minute.
How do IC Rollers Work?
The rollers featuring IC systems are
equipped with comprehensive
instrumentation which is fed to a
documentation and feedback control
system. These systems process data in
real time, which is then utilized by the
operator. GPS is used to map the precise
location of the roller, speed and the
number of passes over a given location.
Additionally, instruments known as
'accelerometers' are mounted near the
drum to monitor the applied
compaction effort, the response from
the material being compact and the
frequency of the passes that the roller
makes over the surface that is being
compacted. The readings are taken into
consideration for determining the
compaction process. In the case of an
asphalt surface, the additional
temperature instrumentation is used to
monitor the surface temperature. This is
important since vibratory compaction in
strength, aspects, which are crucial
for highway projects. Globally a lot of
research has been going in the field, with
leading road construction equipment
manufacturers with strong R & D focus
such as BOMAG, Sakai America,
Dynapac and Ammann, to mention only
a few, doing pioneering work in the
emerging field.
Control systems and machine
integrated systems that provide a record
of machine-ground interaction form the
key components of IC technology. The
output is linked to GPS position and
'Intelligent' Rollers Help Cut Down Costs and Time
provides roller operators with a color-
www.masterbuilder.co.in | The Masterbuilder - April 2011
CE: Technology
different temperature ranges can
vary, sometimes leading to very poor
compaction. Feedback controls are a key
feature of the IC system which
continuously adjust the force and
frequency of the drum in order to
maximize the efficiency and
effectiveness, with the graphic display
alerting the operator when desired
compaction is obtained.
The Technology behind the System
Correct operation and handling of
vibratory rollers involves the operator
having knowledge of compaction
equipment and 'compactability' of the
asphalt mix, apart from experience.
Vibratory rollers are also not often
operated in a targeted manner, with
vibration being continued for too long or
on a mix that has already cooled down.
With the result, too many passes with
vibration and excessive amplitudes can
happen leading to aggregate crushing or
loosening of the base layer. Intelligent
compaction systems are designed to
support the operator with specific
optimized output, giving an indication of
the compaction process.
Explaining the intricacies that are
involved in the IC system, Mr. Hans-Josef
Kloubert, Head of Application provide a
151
CE: Technology
“Intelligent compaction consists of
continuous compaction control
using rollers with adjustable
compaction energy in order to
achieve optimum and uniform
compaction, continuous compaction
measurement and monitoring of the
roller generated material modulus
as the roller proceeds over the layer
and an integrated global
positioning system to provide a
complete recording of the job site”
Hans-Josef Kloubert
Head -Application Technology, BOMAG
Technology, BOMAG observed “
Intelligent compaction consists of
continuous compaction control using
rollers with adjustable compaction
energy in order to achieve optimum and
uniform compaction, continuous
compaction measurement and
monitoring of the roller generated
material modulus as the roller proceeds
over the layer and an integrated global
positioning system to provide a
complete recording of the job site.”
Stating that the IC system developed
by BOMAG involved continuous
research and is a result of teamwork,
Mr.Kloubert dwelt into the technology
behind the system, explaining that the
company has introduced intelligent
rollers such as VARIOCONTROL single
drum rollers for soil and rockfill
applications and Asphalt Manager
tandem rollers for asphalt applications.
The VARIOCONTROL and the Asphalt
Manager roller are equipped with a
directed vibrator exciter system which
152 The Masterbuilder - April 2011 | www.masterbuilder.co.in
consists of counter rotating eccentric
masses. The system is generating
directed vibrations which can be varied
automatically from vertical to horizontal
and therefore continuously can modify
the compaction energy with the control
system based on the material stiffness.
I n a t y p i ca l I C syste m t wo
accelerometers are mounted on the
vibrating mass of the roller drum. The
accelerometers record the drum
acceleration continuously. The soil
contact force, the energy delivered to
Vibratory Energy from the Compacted
the compacted material and the
Material is measured by the IC System
displacements are all calculated in a
process taking into consideration the reduced, and if the specified maximum
roller parameters, such as masses, fo rc e / m o d u l u s i s re a c h e d , t h e
amplitude, frequency, and centrifugal amplitude is changed so that applied
force. By plotting the force settlement force does not exceed the maximum
curve of the roller drum for one drum limit. This control criteria is what makes
oscillation, the slope of the curve on the the IC technology allow for optimized
loading portion can be calculated as the compaction and consequently, uniform
dynamic stiffness of the soil or asphalt compaction.
surface being compacted.
Going into the principle behind the
Further calculations are done in technology Mr. Kloubert explains “The
order to determine the dynamic principle of the intelligent roller is based
modulus of the material being on the analysis of the interaction
compacted. The data is then transmitted between vibrating drum and the
to an integrated control system, which stiffness of the material being
manages the intelligent rollers compacted.” According to Dr.Iris von
automatically, based on two conditions, Kirschbaum, Head of Communications,
if the roller drum is entering an BOMAG, these systems are being
undesirable bouncing mode the offered in India, by their company,
compaction amplitude is immediately considered one of the pioneers in the
Ground force [KN]
B
150
Compression 100 Expansion F
B max
50
Drum
axle load F
3 2 1 -1 -2 stat
-3
Vibration path (mm)
Theoretical amplitude Compaction amplitude
Force settlement curve of vibrating roller drum
Cosmos Sales Corporation
CE: Technology

“The principle of the intelligent roller

is based on the analysis of the
interaction between vibrating drum
and the stiffness of the material
being compacted”
Hans-Josef Kloubert
Head -Application Technology, BOMAG

benefits of the technology, given that it

IC Display inside Cab
field. The technology can play a key role
in the country since an IC system takes
care of uniformity in road construction,
which in turn helps in avoiding costly
pavement failures, often an issue in
India, resulting in obvious improvements
in long term performance of roads.
A Technology Whose Time has Come
The advent of the system has led to a
debate among industry experts, as to
whether IC is a new trend or just a
product innovation that has enhanced
an existing method of work. While the
jury is not yet out on the long term
has only recently made its appearance,
there is no denying the potential of IC,
both in its ability to cut down on road
construction cost and maximizing
accuracy by eliminating human error.
Moreover, the data collected as part of
the system, can also become design
tools for future projects of road
contractors. With further breakthroughs
expected, the technology is all set to go
places, one of which is India where it has
already made an entry, what with the
massive road building spree that the
country has embarked on. The next few
years could see several leading global
compaction equipment brands coming
to the Indian market with their own
versions of compaction equipment
featuring intelligent compaction.

The WaterShed is a design from the Solar Decathlon

WaterShed Marks its Entry
into the Solar Decathlon 2011
T he 2011 Solar Decathlon, from the Department of
Energy (DOE), US, is all set to kick off later this year.
Scheduled for September 2011, at the National Mall's
West Potomac Park in Washington D.C., the event
challenges 20 collegiate teams to design, build and
operate solar-powered houses that are cost-effective,
energy-efficient, and attractive. Marking one of the
earliest entries into the competition was the WaterShed,
a structure designed to capture more than just energy
from the sun.
team of the University of Meryland. It uses two
rectangular units joined by a central bathroom that is
capped by a split butterfly roof that serves the dual
purposes of capturing both sunlight and rainwater.A
rooftop photovoltaic array harvests enough energy from
the sun to power the building all year-round, while the
green roof also retains rainwater to cool the house. Water
captured from the roof is also used in an interior waterfall
to provide humidity control.
The University of Maryland's Associate Professor of
Architecture, Amy Gardner was quoted saying, "This will
be a lot more than just a great house think of it as a mini-
ecosystem." In an effort to create a house that has the
same effect on the environment as native wetlands the
WaterShed's sustainable features extend beyond the
structure's walls and are designed to protect and make
the most of its Chesapeake Bay location. Constructed
wetlands surrounding the building are designed to filter
storm water and "greywater," which is a significant source
of Chesapeake Bay pollution, while "edible landscapes"
create support for community-based agriculture.

154 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Universal Construction Machinery & Equipment Ltd
 Automatic Navigation Control Systems
in Earthmoving Equipment
Breaking New Ground
Special Correspondent
T he critical role being played by
GPS in the earthmoving industry
is something that is making
contractors sit up and take notice. GPS
when used in close tandem with
earthmoving equipment has proven to
be a viable asset, increasing overall
jobsite efficiency, apart from helping cut
down costs. GPS guidance systems or
automatic navigation control systems
have been gradually becoming part of
heavy equipment since the late 1990s,
when they first made their advent. The
equipment operator can now use GPS
position data to make decisions based
156 The Masterbuilder - April 2011 | www.masterbuilder.co.in
on actual grade and design features. In
fact, some of the guidance systems are
so advanced that they can even operate
the machine's attachments
automatically from a preset design that
was created for the particular job.
With tolerance levels as minimal as
two to three centimeters, GPS guidance
systems can be extremely accurate.
Globally Trimble, Caterpillar, and Topcon
are some of the companies that have
been doing pioneering work on
automatic guidance systems. Automatic
navigation control systems can be
installed on virtually every type of
earthmoving equipment including,
diggers, dozers, excavators, scrappers,
etc. and help in improving construction
efficiency manifold.
Types of Systems
Automatic navigation controls
systems that are used in conjunction
with earthmoving machines can be
broadly classified into two types (1)
indicate only and (2) fully automatic. In
the case of the former, the GPS
positioning information is used as a
guide by the operator. The earthmoving
machine's position is displayed over a
specific design site that is created for the
 Earth Moving Equipment: New Technology
two metre range. In the case of the
presence of a base station, Real Time
Kinematics (RTK) enables site specific
corrections that can be transmitted to
the machine, which increases the
accuracy of the system to a mind
boggling, two to three centimeters.
Indicate only type of automatic
guidance systems are usually used in
earthmoving equipment like motor
graders, soil compactors, and track- type
tractors.
Whenever precise levels of material
need to be moved on a predetermined
design or grade, fully automatic systems
are used. These typical fine grading
applications need the machine's
implements to be controlled by the
automatic navigation control system.
Fully automatic systems rely on an
onsite base station for their accuracy
and consist of one or more GPS receivers
that are mounted on a machine's blade.
Typically, two receivers are used when
the machine has to be controlled in a
three dimensional design. While kits are
available to retrofit fully automatic
systems in existing machines, these days
leading manufacturers also sell
machines that have fully automatic
particular earthmoving project. The
operator then relies on the site design
on display in order to steer and move the
machine's implements.
In the case of indicate only type,
typically a single GPS receiver which is
mounted on the machine, apart from an
angle sensor is used. A base station that
relays site specific corrections is another
important component of the system. In
certain cases, in the absence of a base
station, satellite information is utilized
by the machines. However, in the case of
use of satellite information the accuracy
usually suffers and is only in the one to e.
www.masterbuilder.co.in | The Masterbuilder - April 2011 157
guidance systems integrated in the
machine's implement controls.
Giving examples about advanced
GPS guidance systems, Mr. K.K.Sajan,
Divisional Manager, Sitech India - South
& West, which is Gmmco's dealership for
Trimble Technology Solutions in South,
Central and Western India, pioneering
them in the country, states “Trimble and
Cat 3D machine control systems are the
most versatile grading technologies
available and can be used on a wide
range of machine types including
excavators, dozers, motor graders,
c o m p a c t o rs , m i l l i n g m a c h i n e s ,
trimmers, pavers and more. By putting
design surfaces, grades and alignments
inside the cab, the system gives
operators unprecedented control over
grading, excavating, compaction and
paving applications, significantly
reducing material overages, and
dramatically improving productivity and
profitability. The 3D systems can be
operated in manual or auto mode and
leverage of components that are fully
portable and can be easily moved from
machine to machine.”
Output
Generally speaking there are two
methods in which the output from the
automatic navigation control
system is interpreted by the
machine. In the first type,
the machine's electronic
control module is used
by the operator for
moving implements
fo r t h e d e s i r e d
result. The second
method
invol
Earth Moving Equipment: New Technology

“Trimble and Cat 3D machine

control systems are the most
versatile grading technologies
available and can be used on a wide
range of machine types including
excavators, dozers, motor graders,
compactors, milling machines,
trimmers, pavers and more. By
putting design surfaces, grades and
alignments inside the cab, the
system gives operators
unprecedented control over
grading, excavating, compaction
and paving applications,
significantly reducing material
overages, and dramatically
improving productivity and
profitability. The 3D systems can be
operated in manual or auto mode
and leverage of components that
are fully portable and can be easily
moved from machine to machine.”
K.K.Sajan, Divisional Manager
Sitech India- South & West
GPS guidance systems Enable Accuracy in Earthmoving Projects
GPS guidance systems are finding
increasing use. Typically indicate only
type of GPS guidance systems are
installed in hydraulic excavators. The
angle sensors are integrated in the
bucket, stick, and boom of the machine.
The operator can find out how deep the
bucket is digging by comparing the
bucket location with the site design on
the control module inside the cab.
Indicate only GPS guidance systems
are also the choice
when it comes to
scrappers and
motorgraders
that are used in
road construction projects. Operators
can compare the depth of cut and the
actual site design using the inputs
provided by the GPS antenna mounted
on the machine. The process saves time
and money since the operator knows the
exact amount of material to be moved.
Compactors are another piece of
equipment where GPS guidance systems
are now being used extensively.
Typically the display will have various
colors indicating the areas where
compaction has to be done and the ones
where it has been completed.
Accuracy of the site design is another
key to using GPs guidance systems. The

valve parallel to the machine's pilot

hydraulic valve. The automatic
navigation system then controls the
second valve.
Application in Tandem with Earthmoving
Equipment
While automatic navigation control
systems can be used with almost any
type of earthmoving machine, track-
type tractors are the most popular
machine platform where they are
extensively used. One area where they
are extensively used, especially smaller
sized models, is in road construction
projects.
Hydraulic excavators are another
Operator Friendly GPS Display in the Cab Ensures Increased Productivity
type of earthmoving equipment where

158 The Masterbuilder - April 2011 | www.masterbuilder.co.in

JBA Concrete Solutions Pvt.Ltd
Earth Moving Equipment: New Technology

design can be imported into the

earthmoving machine's GPS display. The
latest versions of GPS guidance systems
also have the ability to define a specific
grade angle or elevation, even without a
site design.
The Indian Scenario
With winds of change blowing across
the Indian construction scene, it is only a
matter of time before automatic
navigation systems become a part and
parcel of earthmoving equipment here.
The encouraging response to these
solutions is aptly summed up
Mr.K.K.Sajan, who when asked about Automatic navigation guidance system mounted on the blade of the dozers
the market response to the products and
machinery especially the Motorgraders, largest ever infrastructure building
solutions that Sitech India- South & West
for the final grading operation to derive spree, global players in the field of
offers, observed , “The going so far has automatic navigation control systems is
maximum benefits. Also here it is very
been very encouraging with most Heavy eyeing the booming Indian earthmoving
imperative to mention the wide
& Highway contractors eager to try and equipment market. With rising
acceptance for the Asset & Fleet
see the application benefits . The awareness levels about the technology
management solutions and we are
application benefits in terms of time and and with India already being a hub for
closely working with a few big fleet
cost has been a driving factor when it software development, it is one area
owners to take this forward.”
comes to Contractor's willingness to try expected to grow exponentially in the
and use technology on their earthmoving The country being in the midst of its coming few years.

and Mr.Kulbir Singh. The glittering award ceremony was held at Imperial Hotel on
8th April 2011.
The Indian Institute of Economic Studies does research on various aspects of
economic growth and industrial activities in the country and based on the data
collect, select the awardees. The Hess Group's considerable experience in the
concrete industry and its success in this field has led to this achievement. The
group has enjoyed major success in India, implementing major industrial
projects with industrial majors like Jindal, Ahluwalia, JK Lakshmi, Ecologic, A & P
Group, etc.
The use of latest technology and quality material in the construction industry
helps in the completion of projects within the time frame and offers benefits in the
form of thermal insulation, sound insulation, more usable area and in structural
HESS GROUP BAGS and foundation loads. Moreover, it also helps in reducing pollution, being an
UDYOG RATTAN AWARD environment friendly process.
Fly ash is an industrial by product, a small percentage of which is used by the

T he prestigious 'Udyog Rattan' awards are given to individuals

and institutions for their contribution to national growth by the
Indian Institute of Economic Studies. This year the awards were
given for contribution to the construction, and in particular
concrete industry. The Hess Group, which is a globally renowned
concrete machinery manufacturing company, has bagged the
prestigious award this year.
The award was presented by Dr.BhishmaNarain Singh (former
Governor of Tamil Nadu and Assam). Present in the dais along
with him were Mr.Virender Singh, Dr.ReetikaKohli,
Ms.SujathaDev, Mr.S.P.S.Bakshi (Chairman & MD EPI India Ltd)
cement and readymix industry. This ash can create a lot of environmental issues
if left unutilized. Hess equipment and technology can convert fly ash into building
material. The entire conversion, production, and transportation process is done
in a scientific manner using the latest technology to avoid any hindrances.
It is time government agencies and firms like NTPC and others, look at these kind
of systems to convert the massive amounts of ash for a better tomorrow for the
country. More needs to be done by the environment ministry on the issue.
Similarly, universities and other educational institutions need to spread
awareness about the subject, in collaboration with international experts in the
field. A professional approach from concerned agencies holds the key to the
success of the government's 5 year plans.

160 The Masterbuilder - April 2011 | www.masterbuilder.co.in

SpeedCrafts Ltd
 PAVING THE WAY
TO THE FUTURE
M.K. Prabhakar
T he progress made by a country
can be gauged from the
condition of its roads they say.
Perhaps nowhere is this statement
more suited than to India. While the
country has made rapid progress with
respect to the development of road
infrastructure, a lot still needs to be
done. The country now has the world's
second largest road network
aggregating over 33 lakh kilometers,
with 70,548 km of National Highways,
1,31,899 km of state highways,
4,67,763 km of major district roads and
26,50,000 km of rural and other roads.
162 The Masterbuilder - April 2011 | www.masterbuilder.co.in
The National Highways Authority of
India (NHAI) has after a period of lull
experienced last year, which also saw a
change at the helm of affairs in the
Ministry of Road Transport & Highways,
reportedly planned aggressive plans,
and is targeting 100 road projects
during the fiscal.
The authority is planning awarding
road projects totaling a length of
11,000 km for bidding, out of which
2,000 km are expected to be awarded
during the first quarter of the financial
year. The authority had awarded
around 5,000 km of road projects in
the last financial year, which though
below the targeted 9,000 km mark, was
the highest during the history of
National Highway Development
Program (NHDP).“ This is the highest
awarding done so far in the history of
NHDP. This translates into approximately
14 km per day, versus the initial target
of 20 km per day,” said a Sharekhan
report recently on the progress made
during the last financial year. The
government targets to construct
35,000 km of highways in the next 12th
Plan period under the National
Highways Development Programme
 Infrastructure: Highways

under increasing criticism for the

mechanism of awarding road projects,
with allegations of rampant corruption
from all quarters.
The ministry had been blamed for
the unholy nexus between corrupt
officials and contractors which had
resulted in inordinate project delays.
"What worries the committee the most
is the general sense of helplessness in
“Making quality roads and greater
fighting out this unholy nexus and the
transparency in the functioning of
consequent alarmingly high 'delivery the ministry will be my main priority.
leakages'. The committee did not find It is a challenging portfolio”
any serious attempt made or proposed
C.P.Joshi
against such a nexus in the road sector," Union Minister for
said a Parliamentary Standing Road Transport & Highways
Committee on Transport said in its
quality highways. The much needed
163rd report, a damning indictment of
momentum to the growth story of the
the state of affairs.
road sector is being provided by the
However, it is not all gloom and continued interest in mega highway
doom, with the things taking a turn for projects that promise to transform the
the better and the NHAI now seemingly road network in the country.
in the fast track mode. With the
Mega Highway Projects
country's infrastructural development
at a crucial juncture, where it is Mirroring the developments in
entering the next 'growth ' stage from several other developed countries, the
the earlier 'beginning', stage, all eyes country is gearing up to meet its
are on the authority and the road increased traffic through mega road
ministry, since the government's projects. Generally speaking, road
ambition of attaining double digit GDP projects costing around US $1 billion
growth or at least sustain the existing 8- are classified under the mega projects
9 percent growth rate depends on category. It was in December 2009 that

(NHDP).This endeavour would

require an estimated investment of
about $60 billion (around 2.75 lakh
crore), of which $40 billion (Rs 1.83 lakh
crore) is expected to come from the
private sector.
The pace also seems to have picked
up with the Union Minister for Road
Transport and Highways Mr.C.P.Joshi,
clearly spelling out his priorities by
stating that, “Making quality roads and
greater transparency in the functioning
of the ministry will be my main priority.
It is a challenging portfolio,” a statement
Mega Highway Projects hold the Key to Sustained Economic Growth
he issued while assuming office, a few

www.masterbuilder.co.in | The Masterbuilder - April 2011 163

Infrastructure: Highways
the Lok Sabha was informed about ten
key mega highway projects. These
projects according to industry analysts
will hold the key to speedy economic
growth of the country.
In a press release issued by the
Ministry of Road Transport and Highways,
it was stated that the National
Highways Authority of India (NHAI) had
made initial identification of 10 mega
highway projects , costing an estimated
Rs.45,000 crore in nine states for
implementation in a phased manner.
The press release went on to give
details of the stretches these projects
would be implemented in. These
include:
1. Six laning of Kishangarh-Udaipur-
Ahmedabad section of NH-79A,
NH-79, NH-76, and NH-8, totaling a
distance of 557 km in the states of
Rajasthan and Gujarat.
2. Six laning of Ichapuram - Srikakulam
- Vishakapatnam Ankapalli -
Rajahmundry section of NH-5,
totaling a distance of 436 km in the
state of Andhra Pradesh.
3. Four laning of Gujarat-Maharashtra
border - Dhule - Jalgaon - Akola -
Amravati section of NH-6, totaling a
distance of 485 km.
4. Four laning of Gwalior-Shivpur-
Biaora-Dewas section of NH-3,
covering a distance of 450km in
Madhya Pradesh.
5. Two laning with paved shoulder of
AmristsarGanganagar Bikaner
Nagaur - Jodhpur Pali section of NH-
15, 89 & 65, totaling a distance of
700km in the states of Punjab and
Rajasthan.
6. Two laning with paved shoulder of
Kolhapur Sangli Sholapur Latur
Nanded Wardha Nagpur section of
NH-7 & State Highway the state of
Maharashtra, covering a distance of
475 km.
164 The Masterbuilder - April 2011 | www.masterbuilder.co.in
"What worries the committee the
most is the general sense of
helplessness in fighting out this
unholy nexus and the consequent
alarmingly high 'delivery leakages'.
The committee did not find any serious
attempt made or proposed against
such a nexus in the road sector"
Parliamentary Standing Committee
on Transport in its 163rd Report
7. Four laning of Panvel Goa /
Maharashtra Border section of NH-
17, totaling a distance of 475 km.
8. Fo u r l a n i n g o f A h m e d a b a d
Bamanbore Samakhiali &
Bamanbore - Rajkot Gondal section
of NH-8A & B totaling a distance of
425 km.
9. Six / Four / 2 Lane with Paved
Shoulders of Bhavnagar Pipavav
Porbandar - Dwarka section of NH-
8E, in Gujarat, with the stretch
covering a distance of 445km.
10. Six laning of Aurangabad Barwa
adda Panagarh - Dhankuni section
of NH-2 .totalling 475 Km, in the
states of Bihar & West Bengal.
The formulation of the projects and
the process of invitation of bids of
these projects are based on the
preparation of Feasibility Reports and
their appraisal for implementation on
World-Class Roads in India are no Longer a Mirage
the public private partnership (PPP)
basis, based on the procedures that are
laid down for the purpose.
Change in Bidding Norms
There seems to a distinct shift in the
bidding patterns, with the government
trying to actively expedite the
construction of major infrastructure
bottleneck in the country's progress.
The spate of criticism that the road
transport ministry had faced in recent
times meant that rules were modified
so as to allow only major players to bid
for these mega highway projects
costing over US $ 1 billion. The NHAI
modified some of the norms in 2010
during the term of Mr.Kamal Nath, as
the Union Minister for Road Transport
and Highways, for the bidding process.
The authority modified some of the
norms in model documents for Build-
Operate-Transfer-(BOT) Projects and
Request for Qualification and Request
for Proposal (RFQ/RFP) in order to
address issues which had been
blocking projects. The changes to the
bidding norms had been done in
acceptance of recommendation of the
B.K. Chaturvedi Committee's first
report set up to recommend ways to
implement road projects faster and
more efficiently. To cut the long story
short, the new norms are an obvious
attempt to keep non-serious and less-
Esquire -CMAC Pvt.Ltd
Infrastructure: Highways
“The NEC (North Eastern Council) is
committed towards channelizing
similar quantum of funds for
improving the road sector in the
region”
Bijoy Krishna Handique
Minister of Development of
North Eastern Region
creditworthy players out of the bidding
process with respect to mega highway
projects.
International Interest
One of the interesting facts to
emerge from the growing opportunities
in the Indian road construction sector
was the increasing presence of
international companies. A consortium
of 20 UK companies had for instance
formed the British-India Roads Group
to participate in the sector. Similarly,
news reports suggest that Canadian
firms are likely to invest over Rs.20, 000
crore in the road sector in the next five
Expressways on the fast lane
166 The Masterbuilder - April 2011 | www.masterbuilder.co.in
years, much of it in the mega projects.
This is apart from enthusiastic
participation from majors such as
Larsen & Toubro, GMR, Reliance Infra,
IRB Infrastructure, etc, being in the fray.
North- East Focus
The government has in a bid to
improve the infrastructure for speedy
development of the backward North
East region of the country, approved
road projects worth Rs.434.23 crore, as
part of the ongoing 11th Plan Projects
for the North Eastern Council (NEC).
Mr.Bijoy Krishna Handique, Minister of
Development of North Eastern Region
has been quoted in press reports
stating “The NEC is committed towards
channelizing similar quantum of funds
for improving the road sector in the
region.” The projects would include
improvement of the Jowai-Nartiang-
Khanduli-Biathanlangsu Roads, a
crucial link between Assam and
M e g h a l ay a . C o n s t r u c t i o n a n d
improvement of Simchuthang-Pabong-
Yangyang Roads in Sikkim and Kangokpi
-Tamei Road in Manipur are the other
important projects that can have a
major positive impact on the economic
development of the region.
Expressway Scene
The countr y could also be
witnessing the completion of a few
”The size of the road projects has
been growing under PPP / BOT etc
and this has translated into higher
capacity and the better mobility of
the plant and machineries to fully
optimize the investment cost.“
R.Nandagopal,
Vice President, Equipment &
Project Solutions, TIL
expressways in the next five years. The
Centre had recently in the month of
April 2011 announced plans for
building two new expressways linking
the national capital to Jaipur and
Chandigarh. The ventures are likely to
entail a cost of nearly US $ 3 billion.”
The Centre has decided to build Delhi
Jaipur and Delhi-Chandigarh
expressways. Ministry officials will take
up the issue with states of Delhi,
Rajasthan, and Haryana. Once they
come on board, we will get the detailed
project report," Road Transport and
Highways Minister Mr.C.P.Joshi had
been quoted saying in media reports
o n t h e p ro j ec t s . T h e Ya m u n a
Expressway, in Uttar Pradesh, with the
draft phase-I masterplan finalized by
the Yamuna Expressway Industrial
Development Authority (YEIDA), is
another key expressway project that
could set the trend for similar projects
elsewhere in the country.
The government is reportedly
examining a proposal to set up a
Expressway Authority of India (EAI) on
the lines of NHAI for facilitating the
construction of over 18,000 km of
expressways which would need an

”Once the roads are built, they need
to be maintained, and this is where
the 100 % recycler, which we
launched has a role to play”
Rolf Jenny
Senior Vice President,
Corporate Development, Ammann Group
estimated Rs.4,50,000 crore, according
to industry experts.
Role of Road Construction Equipment
One of the key driving factors
behind the rapid growth witnessed in
the road construction industry is the
availability of a wide range of road
building machinery. While the density
of India's road network at 0.66 km of
highway per square kilometre
compares favourably with other
countries such as China and Brazil, the
major difference lay in the fact that
most of our highways were narrow,
congested, and was infamous for the
poor surface quality. With the advent
of world-class road building machinery,
things have taken a turn for the better
now. The pace of growth has been such
that in the next five years the market
for road construction equipment is
expected to touch US $ 8 billion.
Entry of New Technology
The evolution of the Indian road
construction equipment market makes
for fascinating reading. The market has
gradually evolved from one that was
driven by cost to one that is now being
driven by technology. The typical
Indian client is taking into
consideration factors such as the type
of transmission, controls, hydraulics,
safety, even aesthetics, before making
a purchase decision. With rising
awareness levels newer technology is
now being accepted with respect to
road construction equipment.
One such technology that has been
in the news in recent times is the
double barrel or continuous mix
technology in asphalt mix plants. The
technology is particularly suited for
mega road projects, with the mix not
being limited to particular batches, as
in the case of batch mix plants. What
this means is continuous supply of
asphalt mix for the project, which is
crucial for the timely completion of
mega road projects. Explaining the
technology in detail Mr.R.Nandagopal
of TIL ,which is offering batch mix
plants featuring the technology in India
says” The size of the road projects have
been growing under PPP / BOT etc and
this has translated into higher capacity
TIL-Astec Double Barrel Hot Mix Asphalt Plant
www.masterbuilder.co.in | The Masterbuilder - April 2011 167
Infrastructure: Highways
“Recycling is going to be the future”
Parag Shah
Managing Director, Vimtech Corporation
and the better mobility of the plant and
machineries to fully optimize the
investment cost. “The double barrel
plant with portable options up to
400TPH and stationary options up to
600TPH will meet up with the growing
demands of infrastructure.
Double Barrel is a combination
aggregate dryer and mixing unit
separated from each other uses
sequential mixing to produce larger
volumes of consistent and
homogeneous hot mix in shorter time
than any other plant. It is equipped to
provide multiple job mixes at a very
short notice.
Road Recycling
The increased emphasis on road
recycling is another heartening aspect
that is being seen in the country today.
The driving force behind this emphasis
Infrastructure: Highways
Road recycling will play a critical role in the mega highway projects of tomorrow
is again the availability of specialized
equipment for asphalt recycling.
Commenting on the technology Mr.
Parag Shah of Vimtech Corporation,
which represents DMI Engineering, a
global leader in asphalt mix plants,
said, “Recycling is going to be the
future.” The company offers a recycling
plant that offers a unique advantage of
being attached to plants of any other
make.
Ammann is another global leader
which has recently come out with its
100 % recycler.” Once the roads are
built, they need to be maintained, and
”Our asphalt plant designs represent
the latest innovations in asphalt
plant design. Customers in India are
now beginning to realize the
importance of productivity and
green technology.”
Blesson Varghese
MARINI Fayat India's National Director
168 The Masterbuilder - April 2011 | www.masterbuilder.co.in
this is where the 100 % recycler, which
we launched in Bauma Munich, has a
role to play,” said Mr. Rolf Jenny, Senior
Vice President, Corporate Development,
Ammann Group in an interaction with
The Masterbuilder. According to
Mr.Jenny, the company may launch the
product in India too if demand picks up.
The MARINI MAC Series of green
asphalt plants are another example for
plants that are ideally suited for
aggregate recycling. Explaining the
advantages of these machines,
Mr.Blesson Varghese, MARINI Fayat
India's National Director, quipped,” Our
asphalt plant designs represent the
latest innovations in asphalt plant
design. Customers in India are now
beginning to realize the importance of
productivity and green technology.”
Road recycling, with a slew of
players offering specific equipment for
the same, looks likely to be a major area
of focus in the country's road
construction sector in the near future.
Most Exciting Phase Ahead
After the period of lull and
subsequent period of uncertainty
witnessed during the time of change at
the helm of affairs, things seem to be
moving in the right path, as far as the
Union Ministry for Road Transport and
Highways and the NHAI go.
“Infrastructure is critical for our
development,” Finance Minister
Pranab Mukherjee had said while
tabling the Budget 2011-12 in the
Parliament. The government proposes
to spend Rs 2.72 lakh crore on the
transport and the energy sectors out of
Rs 5.92 lakh crore earmarked in the
Central Plan for 2011-12. The allocation
for the sectors account for 45.95 per
cent of the plan outlay. Increased
allocation to the transport sector
automatically entails huge investments
in the road sector. Similarly, the
government had also spelt that the
“Infrastructure is critical for our
development”
Pranab Mukherjee
Union Finance Minister
infrastructure investment envisaged in
the 12th plan period would be to the
tune of US $ 1 trillion, a major part of
which would be on road projects. All
these factors point out to the
impending massive growth phase that
the road sector is expected to undergo
in the near future.
The positive sentiments, a buoyant
economy, the proactive policies of the
Centre, streamlined bidding for road
projects and availability of world-class
road building machinery, plus the
famed pool of engineers, for which the
country is known for; the road
construction industry is heading
perhaps towards its most exciting
phase ever in India.
Reliance Industries Ltd
????: ????

Hoover Dam Bypass

An Engineering Marvel
Bhavani Balakrishna

T he Hoover Dam Bypass has the

fourth largest concrete arch in
the United States and is the
longest arched concrete bridge across
the globe. It is also considered to have
the world's tallest concrete columns of
their kind. However, what adds to the
significance of the construction of this
magnificent steel and concrete
structure is its location. The Hoover
Dam Bypass is almost 900 feet above
the Colorado River and lodged between
rock cliffs that form the Black Canyon
spanning the states of Nevada and
Arizona.

170 The Masterbuilder - April 2011 | www.masterbuilder.co.in

 Heavy Engineering

Hoover Dam bypass bridge Contractor:

Daily Vehicle Traffic Obayashi
NEVADA Hoover Dam: 11,500 in 1997 ARIZONA Corp./PSM Steel:
Hoover Dam bypas: 21,100 forecast for 2017 Construction USA Approximately
Inc. Joint Venture. 4 million pounds,
Bridge: $114 enough for 32 M1
million Abrams tanks
(left).
Total bypass
cost: Towers: Hold up
$240 million. the bridge roadway.
1,060 ft.
They will be made
860 ft. Concrete: of 440 individual
Arches:
Approximately concrete blocks.
Each is made Hoover Dam
of 53 concrete 9,000 cubic yards, The tallest will be
segments enough to bury a 280 feet tall with
poured in place Statue football field more 28 segments.
from hoses of Liberty than 4 feet thick.
running from the 305 ft. THE ARIZONA
canyon walls. Sources: Google maps, federal Highway Administration REPUBLIC

The Hoover Dam bypass is a fully
fixed, 323 meters in length under arch
supporting the central span of 580
meters length and continuous beam
deck via vertical piers at 35 meter
intervals. Four form travelers advanced
to the crown of the cast-in-place arch
supported by 88 carefully tuned stay
cables, while precast segmental
construction was used for the tallest
precast columns.
The objective behind the Hoover
Dam Bypass project, also known as the
Mike O'Callaghan-Pat Tillman Memorial
Bridge, is to alleviate the traffic
congestion on the U.S. 93 highway in the
vicinity of Hoover Dam. The U.S. 93 is
also has an important economic role to r
play as it is on the North American
Free Trade Agreement (NAFTA) route
between Mexico and Canada. It is also
the major commercial route between
the states of Arizona, Nevada, and Utah.
The design and construction budget
allocated for the entire project was USD
240 million and the bridge was built in a
budget of USD 116 million.
Mike O'Callaghan-Pat Tillman
Memorial Bridge
After completing the environmental
impact analysis in 1998, the contract
was awarded in the year 2001. While
the project's initial timeline had a
deadline of 2008, in September 2006,
the project suffered a major setback
when the contractors' tower cranes,
located on opposite sides of the
Colorado River Bridge, fell. While there
was minimal damage, the timeline was
revised to Oct 2010. The bridge was
opened to general public on Oct 20,
2010.
Major Design Features
During the design phase, a feature
impact analysis was carried out to
understand which bridge type would
suit the most. Factors like structural
redundancy, height and mass on
Viewscape, rock excavation/canyon
impact, engineering cost, technical
stability for site, construction cost,
construction wind risk, inspection and

www.masterbuilder.co.in | The Masterbuilder - April 2011 171

Heavy Engineering
Mike O'Callaghan-Pat Tillman Memorial Bridge
Owner
Bridge Design
Contractors
Construction Engineer
Form Travellers for Cast In Place Segments
Post Tensioning Materials
Stay Cables
maintenance requirements and
architectural potential were considered
across bridge options like truss, box
guides, cable stayed, suspension, deck
arch and thru arch. Spanning the canyon
or arching against the canyon walls
came out as a favorite. However, since
the clear spanning suspension choice
could suffer from structural
vulnerability and high life cycle cost, it
was decided to proceed with the deck
arch option.
The design team then settled upon
the Concrete Composite solution based
on the cost, schedule and architectural
and technical criteria to address the
specific design issues inherent to the
Hoover Dam site. Some of the key
advantages of the concrete composite
alternative were:
§ It combines the best of both
concrete and steel, the concrete
being effectively used in
compression for the arch, and
lighter steel for the upper structure.
Concrete can also be efficiently
placed using a form traveler system
that is a proven construction
technology for this type of work.
172 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Central Federal Lands Highway Division
T.Y.Lin International with HDR
Obayashi/PSM Construction USA. Inc ( JV)
OPAC and McNary Bergeron & Associates
NRS-USA
Schwager Davis Inc
Schwager Davis Inc
§ Since the concrete arch can follow
on an early foundation excavation
contract without the wait for
fabrication of arch steel, schedules
can be accelerated.
§ Not only does the concrete
composite alternative has the
lowest projected cost for the
favored solid rib alternatives, the
blend of concrete and steel design
detail provides greater flexibility to
design for cost efficiency.
§ The composite distributes
construction risks in terms of costs,
quality control and schedule.
Concrete casting is completed in a
confined form, and runs in parallel
with steel fabrication. The steel
superstructure reduces the risk of
delays and eliminates many quality
control issues inherent with a cast-
in-place concrete superstructure in
the open environ over the gorge.
The composite structure utilizes
concrete where it is most efficient
and steel where it is most efficient.
§ The composite structure allows
progress to occur in parallel on site
during arch erection and in the shop
for superstructure steel fabrication,
with relative independence between
these operations.
The design team then arrived at the
twin rib framed structure. The unique
topography of the site led to a project
specific probabilistic seismic hazards
analysis and a 1000 year return period
was selected. Wind was considered as
on one of the significant environment
factors from the outset of design. Two
factors favored the twin rib layout vis-à-
vis the typical single box section for the
arch. Since the latter would have a width
of 20 meters and also weigh almost 30
tones per meter, precast segmental
option was ruled out. Also, the twin
ribbed frame was expected to perform
better under extreme lateral forces.
The composite superstructure was
selected for girder erection and to lower
weight on the arch. An open spandrel
crown was selected instead of an
integral crown. Integral concrete pier
caps were selected over steel box cap
sections in order to develop the
diaphragm action of the deck used to
avoid lateral bracing of the spandrel
columns. This would also provide
ultimate stability to the flexible columns
along station through direct diaphragm
action. Concrete was chosen instead of
steel since a fracture critical steel
diaphragm generally has a higher
maintenance and inspection costs
despite having a lower first cost.
Construction
Construction began on-site and in
 Rockwool (India) Ltd

Maco Coporation India Pvt.Ltd

Heavy Engineering
the contractor's pre-cast yard set up in
the outskirts of Boulder City, Nevada.
Trucks carried column sections to the
site as and when required for erection.
High line cranes and conventional
cranes were used to set them into place.
The arch was closed in August of 2009
within an impressive 20mm tolerance at
closure. Spandrel columns were
erected using the high line crane. On
both sides, the arches were
concurrently built up in cast sections
with the concrete being pumped
directly from either side. Traveling
formwork was used to maximize speed
of construction. A sky cable was used to
supply the workforce with reinforcement
and other significant materials that
could not be pumped.
In view of the financial and schedule
consequences, the Obayashi/PSM JV
construction team decided to setup a
portable batch plant incorporating a 5-
cubic-yard pan mixer onsite. While pan
mixers are generally used in precast
yards, they were suitable for this
application as quality was priority over
volume per hour. The proximity of the
plant also made it easy to adjust flow
rates during a pour.
The team had to choose between
delivery by buckets or a pumping system
174 The Masterbuilder - April 2011 | www.masterbuilder.co.in
for delivering concrete. The team chose
a pumping system as the cableway hook
would become a critical bottleneck if it
was used for hauling buckets of
concrete. However, the pumping system
had its own challenges. The team had
not only to work around the large
aggregate size of the mix but also find
the means to place in the restricted
pour windows because of high
temperatures, and delivering concrete
to the pump. A typical arch segment
pour took four to five hours.
Consolidation of the concrete in the
forms was a major concern. The
geometry of the arch (many segments
were poured at 45-degree angles)
required the use of top surface forms for
all pours. Pour windows were
established in the forms not only for
placement, but also to allow use of high-
cycle concrete vibrators. In addition,
external vibrators were mounted under
the bottom soffit form and along the
side forms to ensure good consolidation.
Concrete placement was critical and
Putzmeister, the pump manufacturer
helped their team determine how and
where to mount the placing booms and
position the trailer pumps for all
portions of the project. The placing
system they chose to maximize their
concrete placement for the arch was MX
32/36Z and MX 36/38Z placing booms
and BSA 2107 HP-E and BSA 2109 H-E
trailer pumps.
For construction of the twin arches,
one trailer pump was positioned near
the base of the Nevada arches and one
on top of the arch footing in Arizona. A
placing boom was also positioned on
each the Nevada and Arizona side of the
twin arches. The separate placing
booms and their pedestals were flown
via crane to each of the twin arches for
mounting on their specially-designed
platforms.
All of the concrete mixes used for
the arch were advanced concrete mix
designs using harsh aggregates. Liquid
nitrogen was used extensively for pre-
cooling of the concrete in order to
reduce the temperature the concrete
reaches during curing. For the arches, a
high-strength 10,000-psi concrete mix
was used, and for the columns and pier
caps a high-strength 6,000-psi mix was
used. In order to avoid the intense heat
and avoid traffic congestion, most of the
concrete placements occurred at night.
About 8199 cubic yards of 10,000-psi
concrete in the arches, 8364 cubic yards
of 6000-psi concrete in the pier columns
and caps, 5484 cubic yards of 4500-psi
concrete in the bridge deck, 6679 cubic
yards of 4000-psi concrete in the
footings and abutments and 2060 cubic
yards of 3000-psi for the column infill.
On April 1, 2011 the TYLI received
the Grand Conceptor award, the
competition's highest honor, at ACEC's
45th Annual Engineering Excellence
Awards (EEA) Gala held in Washington,
D.C. The EEA awards is known as the
“Academy Awards” of the engineering
industry, recognizing engineering firms
for projects that demonstrate a high
degree of innovation, technical
complexity, achievement, and value.
The Hoover Bypass Dam certainly
deserves to be one of them.
 Rockwool (India) Ltd

Nicomac Doors Pvt. Ltd

Modular Building
and the USGBC's LEED™
Special Correspondent
Continuarion from March 2011 Issue, Page No. 74
Materials and Resources and Modular
Building
LEED rewards projects for recognizing
where materials come from, how they
are used on site, whether or not they are
salvaged during renovations, and how
the residual waste stream is managed.
Special recognition is given to using exist-
ing buildings, materials with recycled con-
tent and those that are mined, harvested,
extracted and assembled within 500
miles of the construction site. Finally
LEED rewards projects that use products
grown using good stewardship practice,
and are lightly processed or have low
embodied energy. LEED wishes to con-
firm that
§ There are no LEED certified products
§ A product cannot give a LEED project
points
§ A product can contribute toward
or comply with LEED credit require-
ments
In LEED products fall into two catego-
ries:
176 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Part - 2
Contribution Credits and Compliance
Credits
Contribution Credits require a calcu-
lation to determine what percentage of
the project materials meets the require-
ment set forth by the LEED rating system
that the project team is applying for cer-
tification. Compliance Credits require all
related materials to meet a certain
requirement set forth by the standard. All
products related to the credit must all
pass the standard. These credits are pass
or fail.
The Prerequisite and LEED Credit
opportunities in the Materials and
Resources section are:
MR Prerequisite 1 Storage and Collection
of Recyclables
The project team must illustrate how
glass, aluminum, paper, corrugated card-
board, and plastic are collected, stored
and then removed from the project site
whether or not a municipal waste collec-
tion program is in place. This is typically
the responsibility of the design team.
§ MR Credit 1.1 Building Reuse, Main-
tain 75% of Existing Walls Floors and
Roof
§ MR Credit 1.2 Building Reuse, Main-
tain 95% of Existing Walls Floors and
Roof
§ MR Credit 1.3 Building Reuse, Main-
tain 50% of Interior Non Structural
Elements
These credits only apply to LEED pro-
jects that involve existing buildings that
may be a modular building or involves
adding modular buildings or new con-
struction that contains modular compo-
nents to an existing building. In each case
an inventory of the building(s) is con-
ducted to calculate the percentage of
each involved. These credits stay in play
unless the new construction being added
to the existing building (if any) exceeds
the size of the existing building by two
hundred percent, at which point these
credits drop out and the existing building
materials segue into MR Credits 2.1 and
2.2, Construction Waste Management.

§ MR Credit 2.1 - Construction Waste
Management, Divert 50% from Dis-
posal
§ MR Credit 2.2 - Construction Waste
Management, Divert 75% from Dis-
posal
One of the significant economies asso-
ciated with modular construction is the
ability to manage construction waste.
LEED rewards construction waste man-
agement at the construction site by being
able to account for the materials, by
weight or by volume, that are diverted
from landfills. This includes all non-
hazardous materials excluding cut and fill
and organic material removed from the
site. One direct benefit of reducing the
overall waste stream is the simplification
of construction waste management at
the site and the attendant reduction in
dumpster costs and hauling fees. In the
case of modular building overall con-
struction waste generated at the site can
be reduced significantly.
§ MR Credit 3.1 - Material Reuse, 5%
§ MR Credit 3.1 - Material Reuse, 10%
LEED rewards incorporating used
building materials in new construction
and major renovation. To date this prac-
tice is very limited in the manufacture of
new modular building components or
MARKETS CURRENTLY SERVED BY COMMERCIAL MODULAR CONSTRUCTION
Manufacturers: Major Markets Served
Kiosks, guardhouses,
and Communication shelters 4%
Healthcare 5%
Military, emergency
and government 10%
Retail, restaurant
and Commercial
10 %
Education 24%
modular units. However, it is quite
possible that modular building practices
could be used in LEED projects where
other aspects of the overall construction
could feature these materials. The
percentages listed refer to the per-
centage of Divisions Two through Ten
material costs of that are represented by
reused materials.
§ MR Credit 4.1 Recycled Content, 10%
(post consumer + ½ pre consumer)
§ MR Credit 4.2 Recycled Content, 20%
(post consumer + ½ pre consumer)
Modern modular building construc-
tion uses a full range of materials with
high recycled content. These materials
are recognized for there relatively high
strength to weight ratios, moisture resis-
tance and cost effectiveness. LEED recog-
nizes the contribution of material manu-
factures that use both post consumer and
pre consumer recycled content.
§ MR Credit 5.1 - Regional Materials,
10% Extracted, Processed and Manu-
factured Regionally
§ MR Credit 5.2 - Regional Materials,
20% Extracted, Processed and Manu-
factured Regionally
These Credits recognize the eco-
nomic and environmental benefits of
building with materials that are found in
Dealers: Major Markets Served
Healthcare 4%
Industrial or Workforce
housing 2%
Military, emergency
and government 8%
General Office Commercial, retail,
(includes construction restaurant and
site) 46% convenience stores 23 %
www.masterbuilder.co.in | The Masterbuilder - April 2011 177
Modular Building: Rating
proximity to the construction site.
The percentages listed refer to the por-
tion of the total material cost less labor
and transportation of materials in Divi-
sions Two through Ten. In order to qualify
for these points, the modular building
manufacturer must then be able to iden-
tify what building products used in the
construction of the component or modu-
lar building unit were extracted, pro-
cessed, manufactured and purchased
within that same 500 mile radius.
MR Credit 6 - Rapidly Renewable Materials
Rapidly renewable materials and
products are those which are derived
from raw materials that come to market
in a ten year cycle or less. These are typi-
cally such materials as bamboo, Agrifiber,
linoleum, cork, wool and cotton. LEED
awards a point to LEED project teams that
can identify and quantify that at least
2.5% of the cost of the materials in Divi-
sion Two through Ten in the entire project
is represented by materials that have
these attributes.
MR Credit 7 - Certified Wood
Certified wood is that which comes
from sources certified by the Forest Stew-
ardship Council's Principles and Criteria.
These include but are not limited to struc-
tural framing, sub-flooring, wood doors
and finishes. In order to qualify for this
Kiosks, guardhouses,
and Communication Industrial or Workforce
shelters 4% housing 3%
General Office (includes
construction site) 35%
Education 24%
Modular Building: Rating
Credit and the point, the modular build-
ing supplier should be able to identify and
quantify that 50% of the value of the
wood based products in the completed
project that are permanently affixed are
FSC certified. If the FSC certified source is
within 5oo miles of the construction site
credit can be taken for MR Credit 5.1-
Regional Materials.
Indoor Environmental Quality and Mod-
ular Building
Next to overall energy efficiency,
effective daylighting and natural ventila-
tion, superior indoor environmental qual-
ity is one of the most desirable and
important attributes of high perfor-
mance green buildings. The following is a
discussion of modular building as it
relates to the LEED Indoor Environmental
Quality category.
EQ Prerequisite 1: Minimum IAQ Perfor-
mance
This prerequisite is based on ASHRAE
6 .1- 2007, Ventilation for Acceptable
Indoor Air Quality with separate consid-
eration of paragraph 5.1 for buildings
that are naturally ventilated. Generally
ASHRAE 6 determines the amount of ven-
tilation air required as well as standards
for the quality of ventilation air and how
it is best distributed.
178 The Masterbuilder - April 2011 | www.masterbuilder.co.in
EQ Prerequisite 2: Environmental
Tobacco Smoke (ETS) Control
The Prerequisite to eliminate or
strictly control environmental tobacco
smoke is applicable to all building types.
The LEED reference guide gives specific
requirements for the design, construc-
tion, commissioning and control of smok-
ing areas inside LEED certified buildings if
they are to be included.
EQ Prerequisite 3: Minimal Acoustical Per-
formance (LEED for Schools only)
LEED for Schools contains this prereq-
uisite which is intended to provide mini-
mum acoustic performance in core learn-
ing spaces in academic buildings. Attain-
ing the credit is based on designing class-
rooms and other learning spaces to meet
the Reverberation Time (RT) require-
ments of ANSI standard S12.60-2002,
Acoustical Performance Criteria, Design
Requirements and Guidelines for
Schools. Also, classrooms and other core
learning spaces must meet Sound Trans-
mission Class (STC) requirements except
for windows which must meet an STC rat-
ing of at least 35.
In addition a background noise level
of 45 dBA must be met using the method-
ologies described in annexes B through D
of ANSI Standard S1 .60- 00 . Or, class-
rooms and other core learning spaces
must achieve an RC (N) Mark II level of 37
with HVAC equipment and installations
as defined in the 2003 HVAC Applications
ASHRAE Handbook, Chapter 47.
Modular building units can be optimized
to meet these criteria as they are seldom
fabricated of heavy masonry construc-
tion or massive materials that reflect
sound. The strategy for meeting this Pre-
requisite and the associated EQ Credit 9:
Enhanced Acoustical Performance can be
formed around materials and construc-
tion techniques commonly used in the
modular building industry.
EQ Credit 1: Outdoor Air Delivery Moni-
toring
This Credit is intended to insure occu-
pant comfort by monitoring the amount
of air mechanically delivered to spaces
with a density of 5 people per 1000
square feet or less, keeping it within 10%
of designed air flow rates. 15% must be
maintained in spaces that are not defined
as high density. Spaces that are naturally
ventilated must have CO sensors in each
space located between three and six feet
above the floor. Modular building manu-
factures must confirm these rates are
achievable and install the proper sensors
and associated limit indicators to inform
building operators and occupants when
design conditions are not being met.
EQ Credit 2: Increased Ventilation
LEED rewards project teams for providing
a minimum of 30% additional ventilation
air to the regularly occupied areas of the
building. The benefit is additional fresh
air and increased assurance that any
residual pollutants will be removed with
additional ventilation and, hopefully,
effective filtration. This credit can be
applied to modular construction the
application of which must be modeled in
EA Credit 1: Optimum Energy Perfor-
mance.
EQ Credit 3.1 Construction IAQ Manage-
ment Plan During Construction
Obtaining this Credit requires under-
standing the Credit intent with respect to
Cosmos Construction Machineries & Equip.Pvt.Ltd
Modular Building: Rating
modular building manufacturing envi-
ronments and conditions. The criteria for
maintaining acceptable IAQ during con-
struction are based on the Sheet Metal
and Air Conditioning Contractors
National Association (SMACNA) IAQ
Guidelines for Occupied Buildings Under
Construction, 1995, Chapter 3. In modu-
lar building manufacturing plants the con-
ditions are often ambient, reducing the
need for supplemental space condition-
ing during construction.
EQ Credit 3.2 Construction IAQ Manage-
ment Plan Before Occupancy
LEED rewards project teams that
build with allergy free non toxic material
and building practices as defined in EQ
Credits 4.1 through 4.6 described below.
As an extra precaution EQ Credit 3.2 Con-
struction IAQ Management Plan Before
Occupancy is available to insure that any
residual indoor air pollutants are
removed. This is done by either flushing
out the completed building or measuring
the same using IAQ testing procedures
focused on the following:
1. Formaldehyde (HCHO) not to exceed
50 parts per billion
2. Particulates not to exceed 50 microns
per cubic meter
3. Total Volatile Organic Compounds
(TVOC) not to exceed 500 micro-
180 The Masterbuilder - April 2011 | www.masterbuilder.co.in
grams per cubic meter
4. Carbon Monoxide (CO) at 9 parts per
billion and no greater than parts per
million above outdoor levels
5. 4-phenylcyclohexane (4-PCH) not to
exceed 6.5 micrograms per cubic meter
EQ Credit 4: Low Emitting Materials
In LEED 2009 the following four Low
Emitting Materials Credits are contained
in this Credit grouping in LEED for New
Construction and Major Renovations:
§ EQ Credit 4.1: Low Emitting Materials
Adhesives and Sealants
§ EQ Credit 4.2: Low Emitting Materials
Paints and Coatings
§ EQ Credit 4.3: Low Emitting Materials
Flooring Systems
§ EQ Credit 4.4: Low Emitting Materials
Composite Wood and Agrifiber Prod-
ucts
In LEED for Schools these Credits are
also available:
§ EQ Credit 4: Option 3 Flooring Sys-
tems
§ EQ Credit 4: Option 5 Furniture and
Furnishings
§ EQ Credit 4: Option 6 Ceiling and Wall
Systems
Each of the above material categories
are governed by organizations that set
maximum allowable limits for VOCs in the
products eligible for credit consideration.
In essence LEED project teams are chal-
lenged to use only benign products with
low or zero VOC content.
The modular building industry has
two unique situations that impact achiev-
ing LEED points for these credits. The first
is by assembling modular building com-
ponents and units in controlled environ-
ments it is possible to critically meter and
effectively apply only the amount of mate-
rial necessary. Material off gassing and air-
borne overspray can be controlled. The
second is technically these credits only
consider materials applied on site. As in
all credit categories only the finished
LEED project is considered. If none of the
materials evaluated in EQ Credits 4.1 -
4.4: Low Emitting Materials are applied
on site then the Credits and associated
points are not available. Conversely, if
even small amounts of the subject mate-
rials are applied in the field, perhaps in
touching up or final installation, then the
entire application of the material in ques-
tion must be evaluated.
EQ Credit 5: Indoor Chemical and Pollut-
ant Source Control
This Credit recognizes the impor-
tance of keeping finished buildings clean
and uncontaminated during their service
life. To obtain this credit and the associ-
ated point the following features and
products must be in place:
1. Walk off grates or removable mats in
the main entrances
2. Code based solutions to properly
venting hazardous gases out of the
building
3. The inclusion of Minimum Efficiency
Reporting Value (MERV) 13 filters in
the permanent HVAC system(s)
EQ Credit 6.1: Controllability of Systems -
Lighting
This credit requires individual lighting
controls for 90% (minimum) of the build-
ing occupants and lighting system con-

trols for all shared multi-occupant
spaces. Modular building manufacturers
simply need to be aware of the lighting
system design requirements and be sure
they are incorporated into the finished
project.
EQ Credit 6.2: Controllability of Systems
Thermal Comfort
Thermal comfort system control, for
the purpose of this credit, is defined as
the provision of control over at least one
aspect of thermal comfort air tempera-
ture, radiant temperature, air speed and
humidity. The influence of these vari-
ables and acceptable strategies for con-
trolling each are set forth in ASHRAE 55-
004. To obtain this credit at least 50% of
building occupants must have access to
comfort controls and be able to control at
least one of the variables. All shared occu-
pancy spaces must have accessible con-
trols. This consideration also extends to
operable windows if the parameters set
forth in ASHRAE 6 .1 007, paragraph 5.1
are met.
EQ Credit 7.1: Thermal Comfort Design
The point for this credit is attained if
the LEED project team can illustrate the
building envelope and space condition-
ing systems can meet the comfort stan-
dards set forth in ASHRAE 55- 004. The
comfort parameters temperature,
humidity, radiant comfort and air velocity
- are the same as those in EQ Credit 6.2.
EQ Credit 7.2: Thermal Comfort Verification
Project teams can obtain this credit
and point by agreeing to conduct an anon-
ymous survey six to eighteen months
after occupancy to determine whether
the comfort goals of the project have
been met. It is typically conducted by the
Owner or the Owner's agent.
EQ Credit 8.1: Daylight and Views Day-
light 75% of the Spaces
Effective daylighting is one of the sig-
nature characteristics of high perfor-
mance green buildings. LEED rewards
effective daylighting through its inclusion
in the calculations for EA Credit 1: Opti-
mum Energy Performance. This credit
acknowledges the importance of daylight
in reducing the dependence on electric
lighting and its positive influence on the
psychology of space.
LEED permits three different calcula-
tion methodologies to determine
whether a minimum daylighting contri-
bution has been made to a sufficient num-
ber of spaces. In essence project teams
must balance the relationship of properly
selected and placed glazing, and provide
effective shading and glare control to
meet minimum daylighting requirements.
EQ Credit 8.2: Daylight and Views Views
for 90% of the Spaces
LEED recognizes the importance of
connecting building occupants with exte-
www.masterbuilder.co.in | The Masterbuilder - April 2011
Modular Building: Rating
rior environment. This point is obtained
by providing views to the exterior from
90% or more of the regularly occupied
spaces. This is a matter of room configu-
ration, or shape, and the strategic place-
ment of vision glazing assumed to be
between 2'-6” and 7'-6” above the floor.
EQ Credit 9: Enhanced Acoustical Perfor-
mance (LEED for Schools only)
EQ Credit 9 builds on the foundation
of EQ Prerequisite 3 Minimum Acoustical
Performance and rewards a point to LEED
project teams that can achieve a higher
level of acoustic performance in primary
learning spaces. Essentially, teams must
follow the design goals and criteria set
forth in ANSI Standard S12.60 2002 to
achieve more stringent acoustic perfor-
mance goals than those associated with
the Prerequisite.
It must be noted that windows with a min-
imum STC rating of 35 may be required in
the modular unit or incorporate acoustic
ceiling tile or other sound attenuating
material for the overall unit to qualify.
EQ Credit 10: Mold Prevention (LEED for
Schools only)
Modular buildings used for class-
rooms and other similar purposes will
continue to be the subject of reviews
regarding IAQ issues in general and mold
in particular. LEED rewards finished build-
ing projects that address Mold preven-
tion by doing the following:
1. Earning EQ Credits 3.1: Construction
IAQ Management Plan During Con-
struction, EQ 7.1: Thermal Comfort
Design, and EQ Credit 7.2: Thermal
Comfort Verification
2. Provide HVAC Systems and controls
designed to limit space relative
humidity to 60%
3. Develop and implement on an ongo-
ing basis an ISAQ management pro-
gram for buildings based on the EPA's
“Building Air Quality: A guide for
Building Owners and Facility Manag-
ers”, EPA Reference Number 40 .F-91-
102 , December, 1991.
181
Modular Building: Rating
Innovation and Design Process and LEED
Perhaps the best feature of the LEED
building rating system is the invitation to
be innovative. In LEED 2009 The Innova-
tion & Design Process includes five credit
opportunities to score points in what are
called ID Credit 1.1 through 1.5. These
credits can be achieved by accomplishing
exemplary performance in the pursuit of
any credit that is eligible for that
approach. In LEED Version 3 2009 those
three ways are:
1. Exemplary performance. This means
the project team has gone beyond
the last increment of the credit's grad-
uated requirements by the next full
increment.
2. Repeat a previously awarded Innova-
tion in Design Credit.
3. Be truly innovative.
The LEED team using modular build-
ing components or modular units is
encouraged to explore ways to achieve
Innovation and Design process points
both in the manufacturing facility and in
the field. Lastly, LEED projects that
involve LEED Accredited Professionals,
LEED APs, are also eligible for a point in
this category. The GBCI has implemented
a two-tiered LEED 2009 exam structure.
182 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Those who pass with the LEED AP Plus
accreditation will be able to claim ID
Credit LEED AP. Those holding a LEED AP
Associate status will not be eligible for
the ID Credit 2 LEED AP ID Point.
New Category: Regional Priority
The Regional Priority Credits category
is new to LEED 2009. The category was
introduced in response to the USGBC
members who felt LEED should evolve
toward something that could address
local issues. The Regional Bonus Credit
Category contains four possible Regional
Specific Environmental Priority credits. A
database of Regional Priority credits is
available on the USGBC website
www.usgbc.org. Each is indexed to the
project location via zip code.
Conclusions
In conclusion, the evolution of LEED is
a reflection of the paradigm shift under-
going in the green building movement in
terms of innovation, creativity and mar-
ket opportunities. The modular building
industry should note the increased
sophistication embedded in the evalua-
tion of the credits and their associated
point scores in LEED 2009. In order for the
Modular Building Industry to capitalize
on these trends a number of issues must
be addressed. Among these are:
1. The ability to embrace change and rec-
ognize how the qualities and attrib-
utes in modular building can be used
to gain market share.
2. The need to overcome the negative
impressions many design profession-
als have regarding the limits to cre-
ativity and adaptability of modular
building techniques by positively pro-
moting the unique qualities and
attributes of modular building, espe-
cially as they relate to green building.
3. Continue current practices and activi-
ties such as conferences and design
competitions in a way that positively
promotes the modular building
industry. The ability to speak with a
unified voice to the AIA, ASHRAE,
BOMA, the US Green Building Coun-
cil, the Collaborative for High Perfor-
mance Schools, and the Association
of School Board Officials is critical to
promoting the interests of the Modu-
lar Building Industry.
It is in the best interest of the mem-
bers of the Modular Building Industry and
the environment at large that we work
together to promote energy, material
and resource efficient buildings that are
optimized for the health and productivity
of building occupants and users.

Design of Place Lalla Yeddouna
in Fez - Competition Winners Announced
M ossessian & Partners and
Yassir Khalil Studio were
declared the winners of
'Design of Place Lalla Yeddouna in Fez',
a two stage competition, launched
with the support of the International
Union of Architects.
Mossessian & partners (London,
United Kingdom) with Yassir Khalil
Studio (Casablanca, Morocco) walked
away with the first prize in the
competition for the 'Rehabilitation of
Place Lalla Yeddouna in the Median of
Fez, Morocco.
The location is a vibrant community
hub and a central tourist point of the
Medina. The competition was
conducted by the Agency of
Partnership for Progress (APP) with its
implementing partner, the Agency for
the Development and Rehabilitation of
the city of Fez (ADER-Fes).
The competition site was approx
7,400 sq m located in the Medina of
Fez, which has been listed as a UNESCO
world heritage site since 1981. Place
Lalla Yeddouna is a strategic location at
the nucleus of this oldest part of Fez.
The Medina is a mosaic of small-scale,
modest, sand-colored houses, and its
endless labyrinth of narrow streets,
where we can find still preserved as a
living museum, an antique mode of life,
full of history and shrouded in mystery.
The Place of Lalla Yeddouna is
expected to be a vibrant mixed-use
urban hub for the community as well as
visitors to the Medina in the future. The
site is expected to be a major catalyst
for artisan development, with exclusive
space available for educational
p ro g ra m s , re s i d e n c e s , a r t i s a n
workshops, retail outlets, cafes, and
other services.
The competition task comprised of
urban design for the Place Lalla
Yeddouna, the preservation of historic
buildings, as well as design of new
buildings. Close to 1,400 architects
registered in the competition and 175
www.masterbuilder.co.in | The Masterbuilder - April 2011 183
Awards
projects were submitted to the jury at
the end of the first stage. Among them
eight projects which showed the
greatest development potential were
selected for the second phase.
While Michel Mossessian with Yasir
Khalil were the first prize winners,
Laura Valeria Ferretti, Maurizio
Marcelloni and Valeria Botti (Rome,
Italy) with Bahia Nouh (Fez, Morocco)
got the second prize and Moxon
Architects, Benn Addy ( London, United
Kingdom) with Aime Kakon (Casablanca,
Morocco) got the third prize.
The international jury comprised of
eminent personalities representing
architects including Marc Angelil,
Switzerland-USA, Meisa Batayneh
Maani, Jordan, Stefano Bianca,
Switzerland, David Chipperfield,
United Kingdom, Omar Farkhani,
Morocco, Rodolfo Machado, USA-
Argentina and Matthias Sauerbruch,
Germany. Bruno Sauer, Spain, and
Mohamed Habib Begdouri Achkari of
Morocco sat as deputy jurors.
Flooring
One Day Flooring
Subash Cipy, Managing Director, Cipy Polyurethanes Pvt. Ltd
T he word concrete comes from the
Latin word "concretus" (meaning
compact or condensed), the
perfect passive participle of "concresco",
from "com-" (together) and "cresco" (to
grow). Concrete solidifies and hardens
after mixing with water due to a chemical
process known as hydration. The water
reacts with the cement, which bonds the
other components together, eventually
creating a robust stone-like material.
Concrete has been used for
construction in various ancient
civilizations. An analysis of ancient
Egyptian pyramids has shown that
concrete may have been employed in
their construction centuries ago. Also
during the Roman empire, Roman
concrete (or opus caementicium) was
made from quicklime, pozzolana, and an
aggregate of pumice. Modern tests show
that opus caementicium had as much
compressive strength as the modern
Portland-cement concrete (20 N/mm2).
184 The Masterbuilder - April 2011 | www.masterbuilder.co.in
However, due to the absence of steel
reinforcement, its tensile strength was
far lower than the present concrete. Like
today, concrete additives have also been
used since Roman and Egyptian times,
when it was discovered that adding
volcanic ash to the mix allowed it to set
under water. Similarly, the Romans knew
that adding horse hair (polypropylene
fibres,today)made concrete less liable to
crack while it hardened, and adding
blood made it more frost-resistant.
In 1756, a British engineer, John
Smeaton made the first modern concrete
(hydraulic cement) by adding pebbles as
coarse aggregate and mixing powered
brick into the cement. In 1824, an English
mason, Joseph Aspdin invented the first
true artificial cement by burning ground
limestone and clay together and
patented as Portland cement, which was
named because of its similarity in colour
to Portland limestone, quarried from the
English Isle of Portland.
Concrete that includes imbedded
steel is called reinforced concrete, which
was invented by Joseph Monier, a
Parisian gardener who made garden pots
and tubs of concrete reinforced with an
iron mesh. Reinforced concrete
combines the tensile or bendable
strength of metal and the compressive
strength of concrete to withstand heavy
loads. Today reinforced concrete is used
more than any other man-made
materials in the world and more than 10
cubic kilometres of concrete are made
every yearmore than one cubic metre for
every person on Earth. Like concrete
structures we see everywhere in the
world, concrete floors are all also
incredible investments that are meant to
last for decades under tough working
conditions.
Concrete floors create dust with fork
lift traffic or even human traffic because
of its rather poor tensile and flexural
strengths, which we call as concrete

dusting. This dust can be harmful to
today's computerized equipments and
may aggravate health conditions of the
people and more over, it settles down on
the finished goods. Concrete dust is
concluded to be the major source of
dangerous air pollution and in order to
get rid of this undesirable concrete dusting,
the surfaces need to be sealed or coated.
The natural porosity of even well-
cured high-strength concrete allows the
absorption of liquids and adhesion of
stains and dust, creating an unsightly
appearance. Uncoated concrete also
presents great difficulties for cleaning
and maintenance, as its porous nature
makes the complete removal of spills and
stains from the substrate, practically
impossible.
The concrete deficiencies like dusting
and the porous capillaries are overcome
by sealing the porous surface and filling
the profile of the concrete floor, thus
creating a smooth, easily cleaned and
maintained floor. The untreated or
uncoated concrete generally has a low
light reflectance value, absorbing light
energy and emitting little and the
application of a smooth, light-coloured
floor coating increases the light
reflectance value of the floor and
increases lighting efficiency and
improving visibility, creating a brighter,
safer working environment. Clean, shiny
floors have a dramatic impact on
employee morale, customer confidence,
and are more enjoyable to work on than
the dull, dirty, bare concrete floors.
There are many different kinds of
concrete sealers, densifiers and coatings
in the market place today, all with specific
advantages and disadvantages. Sealers
are generally classified as a thin coating
which is of 5-10 microns in thickness and
designed to inhibit absorption of liquids
into the concrete. Acrylic sealers are the
most common type of sealers that are
very economical and easy to install.
Hardeners or densifiers are classified as
products that penetrate into the
concrete to create a more watertight
surface and strengthen the concrete.
Concrete hardeners are usually sodium
silicate, potassium silicate, metallic
fluorosilicates and Lithium silicate, being
the latest entrant in this segment. The
densifier reacts with the free lime
available in the concrete and gets
crystallized in the pores. Over the time,
these floors develop a very attractive
gloss and are excellent for warehouse
areas where cost is the first priority but
appearance is also important. A new
method emerging in the industry is the
polished concrete where the concrete
substrate is ground and polished to
expose the aggregates, thus giving a
terrazzo look.
Coatings impart more dry film
thickness than sealers and deposit a thick
film on the concrete that is hard,
chemical and abrasion resistant. The
coating thickness varies from 50 microns
to a few mm thicknesses. Although there
are a myriad of technologies employed in
the floor coatings, the most traditional
and widely available products include
acrylic, MMA, epoxy, polyurethane, vinyl
ester, polyurea and the most latest of all,
polyaspartic coatings .
Acrylic co-polymers based
waterborne coatings have excellent
water, weather and UV resistance, but
having lesser mechanical strength,
chemical resistance, and adhesion.
MMAs are fast curing acrylic coatings e in
www.masterbuilder.co.in | The Masterbuilder - April 2011 185
Flooring
that are resistant to weak acids and
alkalis, but have moderate resistance to
solvents. Fast curing is the big advantage
of MMAs, especially at low
temperatures. At room temperature
MMA has a working time of 10 to 15
minutes and reaches a full cure in 1 to 2
hours. Vinyl esters are a type or subset of
polyester resin, in which the pre-
polymers are formed by reaction of
epoxy resin with acrylic of methacrylic
acid. Vinyl ester resins provide the best
performance in chemical / corrosion
resistance among all other coatings
available today.
Epoxies are the industry's workhorse
floorings in India today. 99 % of the floor
coating companies provide epoxies, as
the epoxy flooring technology is provided
by the resin manufacturers and thus
there is a mushroom of epoxy formulators
in the market. The standard formulation
is based on Bisphenol A type resin, reactive
diluent, defoamers and other additives
with cyclo-aliphatic amine as the curing
agent. Many of the formulators do not
think beyond this standard chemistry.
Epoxy polymer has an open molecular
structure and hence higher amount of
filler loadings is possible than any other
polymer, thus filler-rich varieties are
flooded in the market.
Epoxy-urethane coatings have made
a big impact in the Indian flooring
industry, where hybrid polymer
technology is employed. These products
are either called urethane modified
epoxies, EPU or EPPU where epoxy
polymers are modified by incorporating
urethane linkages to provide elongation
in addition to the normal properties.
Water borne epoxies are used as self
levelling floorings as well as thin-micron
coatings. Breathable self levelling
compositions are formulated with these
types of emulsified resins and hardeners,
imparting a matt finish. Novalac epoxy is
fast curing and offers excellent protection
to strong alkalis, acids, and solvents.
Novalacs have a higher cross-linked
density than conventional epoxies which
Flooring
makes them more rigid and chemical
resistant, and allows them to withstand
higher service temperatures. desirable
properties, including fast cure times, high
a b ra s i o n re s i s t a n c e , f l ex i b i l i t y,
toughness, and good chemical
resistance. Urethanes perform best
when placed on dry concrete as moisture
inhibits the cure of two-component
systems and can cause blistering because
of its undesirable reaction with water,
ge n e rat i n g ca r b o n d i ox i d e ga s .
Polyurethanes, both aromatic (yellowing)
and aliphatic (non-yellowing) are used as
thin coatings as well as self levellings. The
moisture cured urethanes are single
components and dry through reaction
with the moisture or humidity in the air,
forming polyurea linkages. They perform
exceptionally well because of their
remarkable properties such as abrasion
resistance, flexibility, toughness and
chemical resistance. “Odorless”
urethanes have come about as a result of
the restrictions on solvent use in
manufacturing facilities and are based on
polyurethane dispersions, one
component and more recently two
component where the -OH groups of PUD
are reacted with hydrophillic isocyanates.
Urethane mortars combine cement
with water based urethane technology to
produce a mortar product exhibiting
properties of both. Designed to exhibit a
high cross-linked density, urethane-
concrete systems are non-toxic, non-
hazardous, highly chemical resistant,
thermal shock resistant and are the most
preferred systems for the most
demanding applications. This has the
similar modulus of elasticity to that of
concrete, which eliminates differential
flexing that is prevalent with most other
resins.
Polyurea is a subset of polyurethane
when isocyanates are made to react with
amines to form fast setting polyurea
linkages. They have tremendous
advantages over other flooring systems
due to their rapid cure (usually in less
than a few seconds). Higher elongation
(>300%), abrasion resistance (<10mg loss
186 The Masterbuilder - April 2011 | www.masterbuilder.co.in
in a Taber abrasor test), excellent shear
strength (>50N/mm) are some of its
pertinent properties. Rapid setting
polyurea, and more over, due to its
extremely fast cure, sophisticated plural
component spray equipment is needed
for application and hence the need for a
coating having the properties of polyurea
which can be applied by conventional
methods has arisen and hence the birth
of a third generation (3G) coating, called
Polyaspartics.
Polyaspartic polyurea (or simply
polyaspartics) overcomes many of those
difficulties, while retaining the
advantages by combining the best
properties of polyurea and aliphatic
urethanes. Polyaspartic is a type of
polyurea (actually a polyaspartic
aliphatic polyurea) where the NCO
terminated prepolymer is reacted with
secondary or hindered aliphatic
diamines, resulting in polyurea linkages,
but giving ample time (20-30 minutes) for
application by conventional methods like
brushing or rolling. Polyaspartics
generally have very low viscosity,
equivalent to water, which gives it
outstanding wetting ability to apply a
high build in one coat, UV stability, and
excellent chemical and abrasion
resistance thus providing some of the
best properties of epoxy resins and
urethane resin technology. This material
can be applied at nearly any
temperature, bonds easily to nearly any
concrete surface, cures to full strength
within half an hour, is flexible enough to
bridge small cracks, can withstand high
temperatures when cured, has superior
stain and UV resistance and impart
bubble-free, high gloss films.The
tremendous advantage of polyaspartic is
its fast cure time which means that there
is virtually no down time and reduces the
number of trips to and from the job site.
When comparing polyaspartics to
epoxies, polyaspartic coatings are far
superior. Polyasartics have almost three
times the abrasion resistance of epoxies,
they are more flexible, have better
adhesion properties, and are UV stable.
When comparing polyaspartics to
urethanes, polyaspartics have the
advantage in high build properties, they
are not as sensitive to moisture as
urethanes and are far less likely to bubble
and impar a high glossy like epoxies.
Polyaspartic coatings replace can replace
the two component system of applying
an epoxy base coat and a urethane top
coat with a one coat system which is both
faster to apply a provides a superior
product over any concrete flooring or
concrete overlay surface. So we have a
myriad of coatings to choose from. All
have advantages and disadvantages and
so the perception and expectations of the
customer are of paramount interest in
selecting the right product for the right
application. Let us review the coatings
one by one. Acrylic sealers do not offer
long term protection. Liquid floor
hardeners or densifiers will definitely
give sheen over a period of time, but at
the same time the closed pores of the
concrete will get opened up due to traffic
impacts and the oils and chemicals will
start penetrating into the floor, posing
grave risks. Dry shake floor hardeners,
metallic and non-metallic, offer just
temporary protection offered normally
by the civil contractors which later
creates big head aches to polymeric
overlays. MMA and Vinyl ester are very
fast curing having very good mechanical
SEC-RJMT Engineering Pvt.Ltd

Webac (Cemseal)
Flooring
properties, but do not offer good
aesthetics. Moreover, they give away
obnoxious order while application.
Epoxies are better in aesthetics, but poor
in properties, especially the very low %
elongation (<3%) and they take a very
long time to cure and the return to
service takes more than 3 days.
Urethanes are fast curing, have all the
desirable properties needed, but are not
good self leveling and are very sensitive
to moisture. Polyurea, due to its rapid
curing, has a tendency to follow the
contours of the surface to which it is
applied without leveling or filling in
depressions or ridges, thus giving a
textured look. Polyaspartics overcome all
these deficiencies. It is rapid setting, but
has enough pot life to do application by
brush/roller/trowel comfortably, return
to service within a few hours, aesthetic
looking like self leveling epoxy, but the
price is the major discerning factor.
The entire focus of the floor coating
industry today is to provide the
customers and contractors with a user
friendly, dependable multi component,
multipolymer coating system that they
can install with consistency and speed.
Concrete floors are notorious for cracks
and joints. This presents a unique
188 The Masterbuilder - April 2011 | www.masterbuilder.co.in
problem to rigid polymer floor systems
when continued movement either from
thermal factors or load transfer factors
cause reflective cracking in the polymer
floor systems. These cracks are then
subject to increased wear from
mechanical traffic and serve as a
collection point for liquids, dirt and
debris leading to undercutting and
progressive damage to the flooring
system.several factors are important in
determining the proper design. Among
those factors are floor thickness, joint
design, and termination details.
Although polyurea elastomeric
characteristics are capable of bridging
1/8” movement at cracks, construction
joints and contraction joints, there are
often isolation and expansion joints in
concrete slabs that are capable of
movement far in excess of 1/8”. A
professional engineer should design
isolation and expansion joint treatment.
Recoat windows are a concern when
applying multiple coats. As would be
expected for rapid curing products the
recoat window will be relatively short
and dependent on time, temperature,
humidity, and formulation.
Employing various polymer
technologies and combining three
distinct polymer groups, one will now be
able to install a full coating system
comprising of primer, screed and top coat
within a day with the obvious
performance benefits of the fast cure
times, improved abrasion and chemical
resistance, high flexibility, UV stability,
and terrific gloss retention. That is the
brand new concept in the flooring
industry today : 1day flooring.
Today, the facility owners do not have
sufficient time to allot to the flooring
contractors because of the fear of the
slow return to service, which ends up in
production losses and so are wary of the
contemperory floorings which take a
minimum 3 days to return the coated
floors back into service. They are all
looking towards an effective flooring
solution which has the least time
consumption. 1 day floors are the answer
to their prayers : Install the floor today,
use it next day.
1 day floors are the 3G floorings
employing multi-polymer networks to
achieve amazing floor coating results
with minimal down time. A modified
epoxy prime coat, polyurethane screed
and a polyaspartic top coat form the
three key ingredients of this wonder 1
day flooring. After proper surface
preparation, the fast curing epoxy primer
is applied and within 30 minutes, the
ultra fast polyurethane screed is laid with
a thickness ranging from 1-6 mm. The
screed is allowed to cure for 6 hours over
which the rapid setting Polyaspartic self
levelling is laid. The whole system is
returned to service within 6 hours and
the total installation and usage time is
within 24 hours. A site handed over to the
applicator in the evening hours can be
installed and returned back to the facility
owner next day morning, thus saving
valuable process hours, which means
that there is virtually no down time.
Traditionally, either epoxies or
urethanes or a combination of both have
been the sealer of choice for most
commercial or industrial applications.
The unique and adjustable reactivity

of the polyaspartic esters allows for the
design of fast-curing coatings tailored to
the needs of the application. The fast
curing feature of these coatings can
provide significant, money-saving
productivity improvements, along with
high-build, low-temperature curing, and
abrasion and corrosion resistance.
Aesthetics of flooring systems are
usually an important factor to consider in
designing a polymer system. There is
one key feature of polyurea that defines
the essence of the benefits derived from
this technology. For almost every benefit
we can think of, there is a polymer
flooring technology that can provide
similar benefits. However, none can
provide the rapid return to service that is
provided with polyurea. Once it has
been established that a polyurea floor
system has been chosen, Typical ranges
are 1-16 hours.
Alwa Polyurea is relatively new to the
polymer flooring business and the
polymer flooring business is relatively
new to the construction industry.
Advances in polyurea formulations have
led to advances in application equipment
technology. Jointly, these advances have
helped By following existing industry
guidelines that define the “Design,
Installation, and Maintenance of
Protective Polymer Flooring Systems for
Concrete”8, the success of polyurea
flooring systems can be assured.
Concrete floors are an incredible
investment that's meant to last for
decades under tough working
conditions. Even these durable designs,
however are subject to staining, cracking
and disfiguration over time. From
polished concrete to polyaspartic.
Choosing a coating or treatment, you
are making a conscious decision to
protect your flooring: a decision that will
improve the aesthetics and value for the
money. Concrete stains, concrete sealers,
polished concrete, liquid hardeners, dry
shake
This is a special polyurea /
polyaspartic system in which both layers
cure quickly (Same day dry time).
UltraFast-PS is a 2-layer system and mid-
priced in the $3.00 per square foot range.
The first layer, the 'epoxy' goes down and
cures in 1-2 hours, and the protective
topcoat cures in 2-3 hours. This system
mixes and applies like traditional epoxies,
but has very short working times and is
www.masterbuilder.co.in | The Masterbuilder - April 2011 189
Flooring
good where you need immediate
vehicular and equipment back in service
times in 24 hours. Typical applications for
UltraFast-PS are garages (where you can't
leave personal posessions outside
overnight), commercial kitchens, etc.
UltraFast is UV stable for outdoor use and
can be used outdoors and can be applied
down to 45-50 degrees. Deco
On the other hand, the elastomeric
properties of high tensile elongation and
high tensile strength of polyurea provide
a system capable of bridging contraction
joints, construction joints and shrinkage
cracks in concrete slabs up to 1/8”. These
features coupled with high abrasion and
impact resistance of polyurea, make for a
tough floor system. This provides the
added benefit of reduced maintenance
and a smoother transition for wheeled
traffic.
There is one key feature of polyurea
that defines the essence of the benefits
derived from this technology. For almost
every benefit we can think of, there is a
polymer flooring technology that can
provide similar benefits. However, none
can provide the rapid return to service
that is provided with polyurea.
The time has come now to shed off
redundant formulae and embrace newer
technologies that can rapidly decrease
the return to service time required for
polymer floor system installations.
In summary, the one day floors have
all the key features for a perfect floor
coating system. It doesn't blush in winter,
unlike epoxies. It doesn't react with
moisture, unlike polyurethanes. It
doesn't cure in seconds, unlike polyureas.
It doesn't yellow, unlike epoxies and
aromatic urethanes. It doesn't smell,
unlike MMAs and Vinyl esters. But it is
like epoxies in looks and aesthetics. It is
like polyurethanes in abrasion resistance
and crack bridging properties. It is rapid
setting and quick return to service like
polyureas and is affordable to the facility
owners. And it is green, with no VOCs
which comes handy while working
indoors.
Face to Face
Industry Interaction
“DURAmembrane is a versatile material”
T he Supreme Industries Ltd.,
founded in 1942, has been in the
forefront when it comes to the
introduction of many path-breaking
products in the country. The company
has become a trendsetter in plastic
products by introducing many
advanced solutions for various
different applications and industries.
Speaking exclusively to The
Masterbuilder, Mr.Ajay Mohta, General
Manager, Construction Accessories
Division, of the company, gave an
overview about the company's flagship
product, DURAmembrane and its
applications in the industry. Here are
the excerpts from the interview.
Could you please give us an overview
of your company?
Founded in 1942, Supreme
Industries is the leading and largest
plastics processor in the country
offering the widest and the most
comprehensive range of plastic
products. Supreme is an acknowledged
leader in India's plastic industry,
handling over 130,000 tonnes of
polymers annually and the group
turnover in excess of Rs 3500 crores.
Supreme has 17 state-of-the-art
manufacturing units strategically
located across India. Each of these
plants has world class amenities, ISO
9001: 2000 Certification and features a
large production capacity. The
Company is powered by technology
from world leaders that complement
the extensive facilities for R&D and new
product development. It is backed by
dynamic and resourceful marketing
190 The Masterbuilder - April 2011 | www.masterbuilder.co.in
team and committed top management
to ensure customer satisfaction and
continuous growth. With a business
p h i l o s o p hy o f a c h i ev i n g to ta l
commitment in quality and service, we
are serving the major growth impulses
of the Indian economy.
Our product portfolio includes:
§ Moulded furniture
§ Cross laminated films
§ Plastic piping systems
§ Protective packaging products
§ Material handling products
§ Industrial moulded products
§ Performance films
Tell us about the Protective Packaging
Division of Supreme.
The Protective Packaging Division
(PPD) offers a large basket of products
manufactured in-house. However, we
are willing to import material from
international sources, wherever
necessary. With 3 manufacturing
plants and 8 converting facilities spread
countrywide, the Division is ideally
placed to provide a complete range of
solutions. These units are equipped
with high-tech fabrication equipments.
We have offices in all the metros with
distribution network all over India
backed by a complete team of techno
commercial professionals. A powerful
synergy of men, material and
machines, backed by unrivalled
experience and expertise, and a huge
infrastructure that encompasses
production, warehousing and logistics
facilities, enables the Division to render
Mr. Ajay Mohta, General Manager
Construction Accessories Division,
The Supreme Industries Ltd.
professional services of the highest
order.
We have vast experience of six
decades, serving diverse industries and
a track record of successfully
partnering blue chip Indian and
international clients.
Do you also offer solutions for
insulation?
Yes. The Insulation Division (INSU)
of PPD offers superior insulation
products specifically for the insulation
requirements of various industries,
with the sole purpose of improving the
energy efficiency, and thereby helping
in conserving energy.
Give us an overview of The
Construction Accessories Division and
DURA range of civil products from
Supreme.
We, at supreme, work continuously
and diligently to understand your
needs of having cost effective and
efficient products for the construction
industry. Supreme Industries always
strives to give you products that are
best suited to your needs. With these
values and aspiration to give you
products that are durable, we present
our 'DURA range of civil products'.
What are the product offerings of the
Construction Accessories Division and
their applications?
The Construction Accessories
Division of Supreme has developed
customised solutions specifically for
the construction requirements of

various industries. We offer better
alternatives to conventional sold
materials including metals, wood etc.,
thus being cost effective. Many of
these products have been pioneered
by Supreme. A few of our DURA range
products are:
§ DURAboardHD100 (Formerly
SILFLEX):
A cross-linked, pre-moulded, high
performance joint filler board for
structural expansion joints in
concrete brick and block work.
§ DURArods (Formerly SIL SEAL):
Expanded polyethylene foam rods.
§ DURAvapourbarrier (Formerly SIL
VAPOUR BARRIER):
A high performance, multilayer
microcell PE film for water vapour
barrier application.
Are these products environment-
friendly?
We manufacture products in the
most environment-friendly manner
and constantly adapt our range of
products to the current challenges and
recommend you the best solution
always. We do not use any CFC / HCFC
gases. All our products help in reducing
consumption of available resources
thus helping the environmental cause.
Name some of the top projects you
have been associated with since last
year?
We have been associated with
several such projects. For e.g., NHAI,
Airports, Power and many more infra-
structural projects in India.
Are you planning to offer any new
products soon?
Supreme has always been offering
cost effective yet resilient solutions to
construction industry. All our products
have been developed after continuous
interaction with our customers, market
analysis and understanding thoroughly
the needs and changing demands of
the new generation structures. We are
now introducing DURAmembrane A
high performance waterproofing
membrane.
Tell us more about DURAmembrane.
Since past few years, there was a
continuous demand from all our
satisfied customers to develop
DURamembrane application
www.masterbuilder.co.in | The Masterbuilder - April 2011 191
Face to Face
waterproofing solutions to solve the
leakage problems in their factories and
offices. They were not very pleased
with the current waterproofing
systems available in the market. Hence
about one year back, our R&D team
started working full-fledged on this
project to develop a composite of
various polymers cross linked and
fused resulting in this exclusive high
performance membrane.
DURAmembrane is a new offering in
the portfolio of competent and durable
p ro d u c t s o f t h e C o n st r u c t i o n
Accessories Division. DURAmembrane
is a new generation, cost effective
solution for waterproofing of
basements and roofs. It is a versatile
material, capable of retaining the
dryness of concrete, masonry, metal
and wood structures and is resistant to
salts, alkalis, and most acids. It is
offered as a quick and easy-to-apply
system, ensuring hassle-free maximum
productivity. Supreme is the only
manufacturer of this type of water
proofing membrane in India. It can be
used for applications like - concrete
roof waterproofing , basement
waterproofing, and also water proofing
of bathrooms & terrace gardens.
on concrete terrace
Face to Face
DURAmembrane can not only be used
in new constructions but also at the
time of repair of a structure.
What makes this product different
from the bitumen based membranes
available in the market?
DURAmembrane is a high
performance, composite polymeric
membrane which is durable and
lightweight. It is non-deteriorating,
puncture resistant and is available in
length up-to 50 meters.Talking about
evaluation against bitumen based
products we all know that bitumen
disintegrates after contact with water.
Further, over a period it catches fungi
and also starts melting during summer,
thus lowering its puncture resistant
strength.
The striking feature of
DURAmembrane is that it has a very
good puncture resistance of 199 N (Test
method - ASTM E154: 1999) and being
polymer based, it won't deteriorate
also over a long period.
Is DURAmembrane cost effective in
comparison with other polymer based
membranes and waterproofing
chemicals?
Ve r y m u c h . N o n e o f t h e
waterproofing solution systems
provide any added advantage except
waterproofing whereas
DURAmembrane apart from being
100% waterproof is also an excellent
insulating material.
Any roof treatment has to contend
with the unrelenting assault of surface
expansion and contraction due to daily
/ seasonal temperature changes. Other
treatments have a tendency to absorb
moisture and conduct heat.
DURAmembrane does not absorb
water at all. Its 'K' value does not
deteriorate. Its inherent closed cell
192 The Masterbuilder - April 2011 | www.masterbuilder.co.in
structure ensures truly effective
thermal insulation and waterproofing
virtually for a life time.
Will DURAmembrane stand up to the
test against the extreme climatic
conditions in India? Is it stable and
resistant to wear and tear?
Climate of India is most unreliable.
India being a tropical country has
diversity in climates. Some regions in
India have hot tropical weather while
some parts have heavy monsoons.
When the ambient temperature varies
between 0 to 50°C, the overlying
treatment is called upon to withstand a
corresponding variation of 1 to 65°C.
DURAmembrane meets these
challenge with complete and effortless
ease and can withstand temperature
ranging from 40 to 115°C.
Roof treatments have to withstand
more than just surface expansion and
contraction. Like structural movements
or the setting of the building with time.
Sudden drops in temperature results
into thermal shocks. DURAmembrane
has excellent elongation and tensile
strength that enables it to take all
movements in its stride. It is fracture,
crumble, shatter, and abrasion proof
and resistant to most corrosive
chemicals.
How is the demand for water proofing
membranes in India?
Very high. With monsoons come
problems like leakage, seepage in
roofs, walls, basements, bathrooms
etc. in buildings - commercial /
residential and factories. After every
shower of rain, structures tend to
expose their limitations and flaws. The
monsoon rains actually test the
building with showers and reveals the
defects that are not normally observed
during sunny days. Leakage and
seepage in roofs, walls, bathrooms,
and basements are some of the typical
problems. Hence, to shield from the
huge losses incurred due to the rains,
people are determined to pay
attention to the problems prior to the
next rains.
With the current focus on constructing
green and sustainable buildings, what
is your company's contribution in this
area?
We have accomplished very high
standards in manufacturing, and we
firmly believe in the protection of our
environment. The Supreme Industries
Ltd. follows the philosophy of S.A.V.E.
Supreme Always Value Efficient.
Applied intelligence and innovation,
enabling cost-effectiveness and
precision in delivery are the drivers of
this belief. Every requirement is
understood meticulously, various
solutions are deliberated upon and the
most appropriate one is selected and
implemented flawlessly. Trust and
reliability are the cornerstones of our
delivery promise. Whatever be the
value, whether its superior protection,
energy saving insulation or durable and
long-lasting solutions in the civil /
thermal insulation industry our
customers are assured of a solution
from Supreme. Because at Supreme,
every single solution we create is
guaranteed to be Value Efficient.
What is your vision for this product?
This is a first of its kind of concrete
roof and basement water proofing
product, specially designed to
withstand the hot and humid Indian
conditions. Our membrane is going to
solve problems and reduce huge losses
arising out of water leakage. The entire
construction industry will benefit from
this product.
For further enquiries please mail us
at dura@supreme.co.in or log on to
our website: www.supreme.co.in
 Communication Feature

MEET YOUR CONCRETE

DRY BLEND NEED
By Toshniwal Mixer

Mineral Admixture demands good mixing technology, it partly

substitutes the OPC Cement and supply the cementicious concrete mix
with cost effective building products.

C oncrete is known for its workability, mouldability, viability and feasibility

and it is used even for making thin elements like shells and folded plates
achieving strength and stability through the inherent properties of the
constituent materials and the form and shape of the structural member.
However conventional concrete of ordinary Portland cement in different
environmental conditions may not exhibit the required quality and durability and
thus admixtures such as fly ash, silica fume and blast furnace slag are used to
modify the concrete properties to make it more suitable for such aggressive
environment. The great advantages in use of these admixtures are to improve
the durability characteristics of concrete through the control of high thermal
gradients, pore refinement, depletion of cement alkalies and the capability of
continued long-term hydration by pozolanic reaction etc.
Mineral Admixture in Concrete Mix
The inclusion of mineral admixture in concrete blend process demand dry state
of mixing. The complexity of dry blend is to handle the very lighter ingredients
such as rice bran, silica fume and the other fly ash and Ground Granulated Blast-
furnace Slag (GGBS), hence the concrete process demands a good mixing
technology to pre blend the admixture homogeneously to include the same
efficiently and to get good quality concrete mix.
In many situation the demand of the building products are increasingly calling
for lower costs in terms of material, energy, capital and faster completion of
times of building projects. Hence the manufacturing OPC cements paved the
way to seek alternative solution of blending fly ash, ground blast furnace slag in
a customize proportion to meet ready mix concrete blend and supply the same
with economic cost.
Toshniwal Mixer
The unique "Fluidized Zone" mixing action of the mixer which make all
ingredients in a near weightless condition has enable the unit to handle lighter &
heavier particles by way of nullifying the gravitational force in the fluidized zone
allowing the irrespective of particle size / density / shape of the ingredients mix
homogeneously in a perfect manner.
Also these mixers had proven record for the building materials and construction
care products like
Building Material Construction Care
Dry Mortar Integral Water Proofing Compound
Renders Grouts Flour Hardener
Wall Plasters Repairing Mortar
Wall Putty (Dry) Tile Joining Compound
Floor Screeds Thermal insulation products
Skim Coats Fire Proof Cement
Blended Cement Wall Paper Compounds
Toshniwal provides the customized blending requirement such as
ª Pilot Scale Mixer Trials ª Production based product trials
ª Contract blending operation, etc
Further details from:
M/S. Toshniwal Systems & Instruments Pvt Ltd
267, Kilpauk Garden Road, Chennai - 600 010, India.
Phone: 91-44-26445626 / 26448983
Email: sales@toshniwal.net / Web: www.toshniwal.net

www.masterbuilder.co.in | The Masterbuilder - April 2011 193

Disaster Management
Putzmeister
@ Fukushima Nuclear Plant
T he recent tsunami and
earthquake in Japan had left a
trail of death and destruction in
the country. Apart from the loss of
lives, more disaster was awaiting,
when news began to trickle in about
the damage that has been done to
some of the nuclear power plants in the
country. This led to a dangerous
situation as nuclear radiations could
not only damage human life in Japan,
but could also leak into sea water,
reaching other parts of the world.
194 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Among the damaged nuclear
power plants, the worst affected was
the Fukushima Nuclear Power Plant,
which needed immediate attention.
The nuclear power plants had to be
cooled in order to contain the
radiation. In order to stop the worst
from happening, Japan requested
Germany's help to supply machines
that can help shut down the nuclear
power plants. Germany in turn sent
Putzmeister concrete machines to
Japan for the rescue operations.
Putzmeister Boom Pump to the Rescue
These Putzmeister concrete
machines can pump concrete, as well
as water, and therefore can be used to
control nuclear reactors. The machines
have excellent reach, apart from
flexibility. The machines also are
capable of very high pressures and
pumping capability. Since they are run
by the engine of the truck they are
mounted on, another advantage with
the machines is that they do not
require any external source of energy.

The concrete machines were
loaded and taken to Japan in special
wide-bodied 'Antonov' aircrafts.
Among the Putzmeister machines sent
to Japan, the most advanced is the
Putzmeister M70, claimed to be the
world's largest working concrete
machine by the company.
These Machines were modified for
carrying out the rescue operations at
Japan. Video Cameras & Radio Remote
Controls were added to these
machines, so that they could be
operated from a distance of approx. 2
to 4 kilometres, as human beings
cannot go near these nuclear reactors.
They machines were covered with thick
sheets of lead to protect them from
radiations which could damage the
electrical & electronic systems of these
machines.
At the reactor in Fukushima,
workers used the M58-5 truck-
mounted concrete pump (produced in
Aichtal near Stuttgart) that has a
vertical reach of 58 m and a 5-arm
boom in order to support the cooling of
the damaged cooling pools. The
advantage of this is that cooling water
can be fed a great distance over the
destroyed buildings and can be fed to
exactly where it is required.
The pump has an output of 160
m³/h at a pressure of 85 bar and is
driven by the truck's diesel engine. This
means that it does not have to rely on
any external power supply. The
machine is operated using remote
control which allows the distributor
arm to have flexible movement. The
Putzmeister M58-5 that is being used in
Fukushima was actually intended for a
customer in South-East Asia and was
redirected to Japan so that it could
quickly reach the nuclear power plant.
Incidentally, this is not the first time
that Putzmeister machines are being
used in a rescue operation involving
www.masterbuilder.co.in | The Masterbuilder - April 2011 195
Disaster Management
Radiation Cover
nuclear reactors. Around 25 years ago,
a similar disaster occurred in the then
Soviet Union (Russia) in 1986, at the
Chernobyl Nuclear Power Plant.
Putzmeister machines were the ones
that came to rescue even then to
control the nuclear reactors.
Putzmeister makes some of the
most technologically advanced
concrete machines. Its machines
were used for the construction of
the tallest building in the world- Burj
Dubai. Putzmeister is a German
company with 14 subsidiaries across
the globe. The company has its
subsidiary in India, with its
headquarters in Goa. The factory is
located at Verna Industrial Estate and
the MD of the Indian subsidiary is
Mr.Michael Schmid Lindenmayer.
According to the company, its Indian
subsidiary also makes India's largest
concrete machine the M46, as well as
the smallest concrete machine the
BSA702D.
Buzz
Construction Chemicals
Industry Captains See Happy Days Ahead
T he 2nd International
Construction Chemicals
Conclave was recently held in
Bangalore. The conclave was organized
by FICCI jointly with the Dept. of
Chemicals & Petrochemicals, Ministry
of Chemicals and Fertilizers, Govt of
India. The virtual “who's of who” of the
entire construction chemicals industry
in the country was present during the
event. Boasting delegates from around
the world, the conference was
nevertheless highly representative of
the Indian construction industry, with
approximately 95 per cent of attendees
hailing from the sub-continent. Kryton
Buildmat Co. Pvt. Ltd. was an Associate
Sponsor of the 2nd International
Construction Chemicals Conclave.
Kryton Buildmat Co. Pvt. Ltd. is a
subsidiary of The Kryton Group of
Companies, Canada.
Giving his views on the conclave
Mr.Akhil Kakkar, General Manager,
Kryton Buildmat, said “Over the two-
day event, one thing became clear: the
construction chemicals industry is
growing exponentially in India, and
tremendous opportunity awaits those
who can navigate the complicated
challenges we face.” Mr.Kakkar went on
to add that with 14.5 per cent year-on-
year growth, the construction
chemicals industry in India outpaces
the growth of the national cement
industry by five per cent, and yet the
construction chemicals industry is
worth much less than it should be. If, in
the building of structures in India,
construction chemicals were used
together with cement in the same
196 The Masterbuilder - April 2011 | www.masterbuilder.co.in
ratios as they are in developed
countries such as the United States, it is
estimated the construction chemicals
industry in India would be worth 9,000
crores annually rather than 1,800
crores.
According to Mr.Kakkar, one of the
biggest challenges facing India's
construction chemicals industry today
is lack of awareness across the sector.
The point was bought out by
Mr. R. Mukudan, Co-Chairman of the
National Chemicals Committee, FICCI,
during the conclave, when he pointed
out that a staggering 85 per cent of
industry players are not fully aware of
the benefits of construction chemicals.
Crystalline waterproofing admixtures,
for example, can reduce jobsite waste,
speed up construction processes and
eliminate the reliance on traditional
waterproofing products that are tough
on the environment.
Another huge challenge, according
to Mr.Kakkar “is how, as an industry, we
can align construction chemicals with
sustainable development. “ Although
there are green products on the
market, such as Kryton's Krystol
Internal Membrane, surprisingly few
companies have developed sustainable
options for infrastructure and
construction projects. Many speakers
tackled this idea by exploring the
co nfe re n c e ' s t h e m e , “ D u ra b l e
Construction Using Construction
Chemicals,” with the concepts of
recyclable concrete and 'cradle to
cradle construction' generating the
most buzz.
"The construction chemicals
industry is growing exponentially
in India, and tremendous
opportunity awaits those who
can navigate the complicated
challenges we face."
Akhil Kakkar
General Manager, Kryton Buildmat
While the construction chemical
industry in India also faces challenges
that require more long-term solutions,
including a shortage of natural
resources and pollution, there are
many that, as an industry, we can unite
to overcome. Giving his views on the
future pattern that the industry needs
to follow Mr.Kakkar was of the opinion
that durability through the use of
sustainable products, generating
awareness of the benefits of
construction chemicals, and educating
a new generation of skilled tradesmen
in the use of construction chemicals
will ensure the rapid growth, and help
the construction chemicals industry in
India remain durable and sustainable
well into the future.
Esquire -CMAC Pvt.Ltd

Dextra India Pvt.Ltd

Technology: E-Surveying
E SURVEYING SOLUTIONS
Simplifying Survey Engineering Drawings
T he rapid advancements in the
field of software development
have not left any field untouched
and there is perhaps no better example
for it than in the field of civil and
structural engineering. Several types of
software packages are now aiding
engineers in enabling efficient
construction practices. E Surveying
Solutions is developing software
packages for Survey Engineering and
have developed easy to use solution for
Section Generation, Interpolation,
Contouring, Earthwork Calculation, and
Converter Survey data from Total Station
data in to CAD Drawing. The software
solutions offered by the company are
extremely beneficial to Surveyors /
Consulting Firms / Infrastructure
Companies / Engineering Colleges / CAD
Services / CAD Training Institutes and
Govt. Organizations.
Section & Interpolation
Using ESS Products Sections module,
Sections related to Road / Railway Lines /
Irrigation Canal can be created either
from Excel data or from CAD drawings.
Ava i l a b l e S e c t i o n d a ta c a n b e
interpolated along any alignment. Data
can even be imported from Field book.
Section Module allows the user to
modify the sections graphically, Section
presentation can be highly customized
with features like changing Scales along
Horizontal and Vertical directions.
Earthwork calculation can be done
between any 2 layer data and the
software generates complete Area and
volume reports. Interpolation can be
done either using triangulation or using
3D lines. Output can be generated
quickly as Designing both Horizontal
Alignment and Vertical Alignment is
simplified.
198 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Contour
Using E Contours, Contours can be
generated at specified intervals and at
specified levels. The software also
generates grid levels along with the
contour generation and can be done
from within CAD Software. This software
includes attractive modules like Area and
volume report depending on Contour
area.
Earthwork
Using E Earthwork, earthwork
calculation can be done very quickly. It
allows finding the volume of cutting /
filling for a given set of data at a given
elevation or it can find the earthwork
quantities for any two surfaces. It
generates all the required section
drawings instantly along with
calculation, and area and volume reports
can be generated in Excel.
TopoDraw
Using E Topodraw, Topomaps can be
created using Easting, Northing and
Elevation data available in Excel or CSV
File. Normally all the total station
instruments output the data in CSV
format i.e, Serial Number, Easting,
Northing, Elevation and Code. Using
Topodraw module converting this data
into to drawing with blocks is very easy as
it will automatically insert required block
diagrams in their respective places while
generating the draw.
E Survey Lisps
E Survey Lisps is a collection of
several extremely interesting small user-
friendly programs written for meeting
Survey drawing requirement. By using
E Survey Lisp editing time of Survey
Drawings can be brought down by up to
50%.
Unique Features
§ Works with 4 CAD Softwares
AutoCAD / ZWCAD / GStarCAD &
BricsCAD
§ Software Trail CD available with
Complete Video Tutorial
§ The entire software trial version can
be downloaded from
www.esurveying.net
E Surveying Solutions products are
also supplied to Engineering Colleges as
it bridges the gap between what is taught
in college and what the industry
practices. It is economically priced and
users can buy only the required modules.
Under 'Students Offer' students can avail
up to 90% discount.
Hormann India Pvt.Ltd E Surveying Solutions
CE: Company Focus

Mobile Crushing, Screening and

Washing Equipment from Powerscreen

P owerscreen is one of the world's

leading providers of mobile
crushing, screening and
washing equipment. It is part Terex
Materials Processing segment of Terex
“J a m es G h ilo tt i wa s my
grandfather,” said Ghilotti Brothers
President Michael M. 'Mike' Ghilotti.
“He originally called his company
James Ghilotti Contractor. In 1939 it
2000, my brother Dante and I
purchased the company from our
father, Mario Ghilotti, who remained
very much involved until his untimely
death, November 20, 2010.
Corporation. Terex is a diversified became James Ghilotti and Sons and “Throughout all that time and
global manufacturer operating in four then Ghilotti Brothers, Inc. in 1950. In transition, my grandfather's original
business segments: Terex Aerial Work
Platforms, Terex Construction, Terex
C r a n e s , a n d Te r e x M a t e r i a l s
Processing.
The company has scores of satisfied
customers around the world that can
vouch for the high standards of quality
and performance of their construction
equipment. One among them is
Ghilotti Brothers, Inc founded in San
Rafael, California, USA, in 1914 by
James Ghilotti, a 23-year-old Italian
immigrant, who began his business by
carting rocks from the hills of Marin
and Sonoma Counties with a horse-
drawn sled and practiced his craft as a
stone mason throughout the area.
Today, Ghilotti Brothers is one of the
largest employers of construction
personnel in Northern California. Mike Ghilotti, Mario Ghilotti, Paul Campbell

200 The Masterbuilder - April 2011 | www.masterbuilder.co.in


Project Management - Highway 101-580, San Rafael - Early Aerial
philosophy has been paramount: 'Earn
respect by doing a job well, treat
employees with respect, and do good
work for the community.' Doing a job
well requires the very best people and
the very best equipment. We've also
found that the best quality equipment,
even though it costs somewhat more,
pays off that extra cost many times over
in better and more dependable service,
plus greater value when you sell it or
trade it in, ” added Mike Ghillotti
emplacing on the need for quality
construction equipment.
Some of the works of the company
include paving San Francisco airport
runways, heavy highway and road
construction, parking lots, sidewalks,
driveways, retaining walls; all kinds of
commercial and residential projects.
The company also does major grading,
excavation and demolition work, as
well as underground utilities, sewers
and storm systems. This also means
that the company uses a lot of concrete
and asphalt, and therefore, accumulates
a lot of concrete and asphalt rubble.
“In an emerging market in 1994, we
were looking at how we could use
materials most responsibly and not
have to dispose of very many
leftovers,” Ghilotti said before adding
“One major thing we decided was to go
in to recycling, for three basic reasons:
to keep quarries from being drawn
down; to save space in landfills; and to
have fewer trucks on the road, which
cuts fuel consumption and carbon
footprint, reduces road wear, and
lessens traffic and noise.”
This is when their search for the
right kind of equipment ideally suited
for their requirement started. “After a
thorough investigation, and in our
quest for state-of-the-art equipment,
www.masterbuilder.co.in | The Masterbuilder - April 2011 201
CE: Company Focus
we bought the first Powerscreen®
4242SR tracked impact crusher
delivered in North America.
Powerscreen of California brought the
machine in on demo. It performed so
well we bought it right away. In 2010,
we replaced the 4242SR with the first
Powerscreen® XH320SR tracked
impact crusher delivered in North
America, which we believe is the new
state-of-the-art in tracked impactors,”
Ghilotti remarked.
“We were very happy with the
4242SR and had no plans to get rid of it
until Paul Campbell, Owner of
Powerscreen of California, told us
about its successor, the new 320SR.”
As good as the 4242SR is, the 320SR
comes with even more features. It is
well designed for recycling and
demolition applications, as well as
aggregates. It is also compact and
manoeuvrable.
CE: Company Focus
Powerscreen - Quality Equipment story - Ghilotti Brothers
Going into the details of how they
used the machines, Ghillotti quipped
“ We a l s o b o u g ht a t ra c ke d
Powerscreen® Chieftain 1400 double-
deck dry screen, which is very easy to
transport and provides dependable,
versatile operation. Much of the
concrete rubble we recycle contains
steel mesh and rebar. The 320SR
impactor handles it well and has a
quick-and-easy hydraulic hood
opening if we need to clear any jams.
Further, the modular conveyor has a
raise-lower feature to aid in clearance
of rebar.”
Speaking about the performance of
the crusher Ghillotti said “Our new
impactor crushes up to 320 tons per
hour, depending on the feed rate and
materials. High production is critical,
since much of our business comes from
public works bids, where cost is king
and the lowest bidder usually wins.” He
also added that maintaining the machine
is simple, as it they just need to follow
the manufacturer's recommendations.
The XH320SR is a horizontal shaft
impact crusher plant with two full and
two half blow bars, hydraulic overload
protection, fully independent under-
crusher vibrating pan feeder, PLC
controls for crusher speed variation,
202 The Masterbuilder - April 2011 | www.masterbuilder.co.in
HFO clutch and fuel-efficient direct
drive system. Power is supplied by a
230-hp Caterpillar C9 Tier III ACERT
powerpack. An overband magnet is
optional.
Ghilotti Brothers uses the XH320SR
for two basic types of applications. The
first is at four crushing yards owned or
leased by the company at Lakewood,
Crockett, South San Francisco, and San
Rafael. Concrete/asphalt rubble is
trucked in by Ghilotti Brothers from
their excavating, demolition and other
sites to be crushed and used in the
company's various construction jobs or
sold on the market. Area contractors
also bring in and leave rubble to be
accumulated and crushed, and usually
leave with truckloads of crushed
materials. These normally include 3/4"
base and drain (clean) materials, plus
1" and 1/2" materials. Sometimes a
little asphalt is blended in to make a
sub-base product.
Secondly, the tracked crusher is
used at various Ghilotti Brothers job
sites such as road paving and
demolition. The company also does
contract crushing at customers'
locations. Going into the details about
the company's after sales support
services Ghillotti observed “We're very
happy with Powerscreen of California.
If we ever have an equipment problem,
they're here at the drop of a hat. And
we get good counsel from them, too.
They've helped us solve problems and
achieve greater production levels. We
can call the owner Paul Campbell any
time and get advice on all kinds of
crushing situations, equipment,
procedures or whatever.”
Emphasizing on value added
services Ghillotti said “When buying
equipment, any equipment, you need
to look at a lot more than just the initial
price. You have to look at how much
you are charging yourself for use of the
equipment. You determine an internal
rate based on initial price, maintenance,
anticipated downtime; it's the
unexpected downtime that wreaks
havoc on equipment production
capabilities, fuel consumption, parts,
and salvage value.“
Powerscreen is a company that has
been known for introducing various
innovative concepts and technology
from time to time. Recently , it has
brought customers a new way to access
its equipment through the launch of its
new Powerscreen Appfor the iPad® and
iPhone®, with a Blackberry® and Android®
version planned for later this year.
 Amogha Road Equipment

Ermotec International Pvt.Ltd

Columbia -Pakona Engineering Pvt.Ltd

Spotlight
GMMCO-CATERPILLAR
Celebrate 25 Years of Partnership
G mmco was formed in 1967
when the GP-CK Birla Group
took over Blackwood Hodge
Equipment, who were distributors for
the Terex range of products. On
February 26, 1986, a new chapter
opened for the company when it
signed up the dealership of Caterpillar
Inc., USA, the globally renowned heavy
machinery, and engine manufacturer
for South, Central, and Western India.
The company has made rapid
strides over the last 25 years to grow
into an INR 1600 Crore Company with
1500 employees operating out of over
a 100 establishments today, including
75 full fledged branches. The India Inc.
magazine, in their recent annual
survey, recognized Gmmco for
exemplary growth and sustainable
success, and ranked the company in
their Top 500 Best-Performing Mid-Sized
companies list at an impressive 199.
204 The Masterbuilder - April 2011 | www.masterbuilder.co.in
The company has been catering to
the needs of core sectors of the
economy whether it is roads, airports,
ports, urban development, granite,
cement, iron ore, coal and other
quarrying and mining activities, power
, oil & gas , marine and other sectors of
infrastructural activity.
Mining Expertise
The company's mining customers
include Coal India Limited (CCL, SECL,
WCL, NCL & MCL), Singareni Collieries
Company Limited, Hindustan Copper
Limited, Neyveli Lignite Limited,
NMDC, MOIL, and GMDC. Many
cement and iron ore mines have also
valued Gmmco's capability to provide
solutions to suit their needs.
Some of the highlights of Gmmco's
solutions to mining customers over 25
years include:
§ Supplying 14 Cat 773D, 60T trucks
valued at Rs. 25 Cr., to promote
mining contractor for deployment
in Malanjhkand Copper project in
2008-09
§ Supply of 22 large-capacity 240T
Dumpers to South Eastern
Coalfields Limited with a 12-year
Maintenance and Repair Contract
§ Largest bulldozers commissioned
at NMDC, Donimalai
§ Four 992K Front-end Loaders
commissioned at NMDC
§ Largest hydraulic excavator deal
for 12 sealed for a pipe-laying
application at Corrtech Intl
§ First 988H Front-end Loader
commissioned at Central
Coalfields Limited's Kathara
coalfields
§ India's First CAT-certified Rebuild
of Ambuja Cement's D9R Dozers
Spotlight

by GMMCO and TIL, and so are over a

100 engines owned by private drilling
contractors at any point in time in India,
according to the company. These
machines are used on the most critical
operations like power packs on Jack up
rigs and land rigs, emergency gensets,
fire water pumps, cranes, well
servicing, etc.
The company has been taking up
ambitious projects involving in-situ
replacement of Caterpillar D399
Engines with Caterpillar 3512B
Engines. The company offers its
partners to utilize the varied services
H.Jayaram addressing the audience
offered by its 5 Star Certified Workshop
§ 3 4 , 0 0 0 + o p e rat i o n a l h o u rs Gmmco is tied up with all the major facilities to encompass activities like
achieved at Singareni Collieries shipyards in the country, with ongoing top, in-frame and major overhauls in
Company Limited (SCCL) is an project execution with almost all of the shortest possible time frame.
outstanding example of our them. A dedicated Projects Cell renders Gmmco won a Service Rate
Product Support Capability specialized support to shipyards during Contract worth Rs.8 Crore for
the execution process. The company Caterpillar Engines on May 22, 2009,
§ Breakthrough order for over 30
has provided several marine engines for maintenance of Caterpillar Engines
machines (15x962H, 8x966,
for Mumbai Coast Guard boats. in ONGC's sites in Western and
2xD9R, 6x140K) from Sesa Goa,
Caterpillar engines will also soon be put Southern India. It also received a
one of the largest producers of iron
to use by the Indian Navy and the prestigious order from OPG Energy for
ore in India
Indian Coast Guard. the supply of 3 x 2 MW Natural Gas
Construction Solutions power plant.
Contribution to Oil & Gas Industry
To meet and support the booming
Gmmco has been a very successful G m m c o Po w e r, w h i c h i s a
construction industry in India, the
and important partner of ONGC in their subsidiary of Gmmco Limited, is
company offers a wide range of
E&P effort. Over 400 Caterpillar Perkins' Distributor in India, and brings
indigenously built and imported
Engines owned by ONGC are supported the complete range of Perkins Engines
Caterpillar Construction Equipment,
including: Backhoe Loaders, Hydraulic
Excavators, Motor Graders, Off
Highway Trucks, Track-Type Tractors
(Dozers), and Wheel Loaders.
Marine Solutions
The company also offers world-
class total propulsion systems to meet
unique requirements of its
customers.The generator offered can
be tailor-made for 'power management'.
It also offers Diesel Electric Propulsion
(DEP) units for Propulsion purposes. In
a nutshell, the company offers engines
for all applications and all types of
Rob Charter presenting a memento to C.K.Birla
vessels.

www.masterbuilder.co.in | The Masterbuilder - April 2011 205

Spotlight
to Indian users. This apart, the
company also offers Wheel Loaders
from SEM, Tires from Eurotire,
Technology Solutions from Trimble,
and other allied products, all
supported by our strong product
support and after-sale service
infrastructure.
State-of-the-art Facilities
Over the last 25 years, Gmmco has
absorbed, assimilated, and
implemented many of Caterpillar's
world-class facilities and processes to
train our people. The company's focus
in evident from its best in class Talent
Management Processes, Leadership
Development, Simulation based and
hands-on Technical Training to build
talent to provide top quality services its
customers. Gmmco's 4 Star certified
Learning Centre at Chennai helps train
field personnel in support and service.
Over 1500 dedicated and trained
Gmmco-ites propel the partnership
forward. Strong organizational values
such as Passion for Product Support,
Excellence in Action, Delivery on
Commitment, Enduring Partnership,
and Teamwork, have been the
cornerstone of the partnership's
success, according to the company.
C.K.Birla addressing the audience
206 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Audience
The company continuously strives
to improve its processes through 6
Sigma processes. Incidentally, the
company has won several awards for
excellence in implementing 6-Sigma
Processes.
A 5 Star certified contamination-
controlled workshop at Nagpur and 4
Star certified contamination-
controlled workshop at Chennai bear
testimony to Gmmco's flawless service
to its customers. Rental Stores and
Yards at 8 different locations across the
territory are fully equipped to serve
and reach out to customers.
To further increase customer focus
and market penetration across the
territory, Gmmco recently formed
Strategic Business Units in close
consultation with Caterpillar.
Celebrating Gmmco-Caterpillar
Partnership
An exclusive event was arranged
to celebrate Gmmco's Silver Jubilee of
the partnership with Caterpillar at
Chennai on February 28, 2011. Several
senior officials from Caterpillar
participated in the celebrations and
lauded the role played by Gmmco in
building the Nation, as its partner.
They were convinced that it is a very
exciting future ahead for the
partnership, the US $ 1 billion turnover
for Gmmco in the next few years
being another stepping stone ahead
in the partnership. Several of
Gmmco's customers too sent in their
appreciation of Gmmco's services on
the occasion.
To quote "We have a committed
dedicated team in Gmmco, we have the
Caterpillar focus and we are sure that
we will definitely make our journey
from what we are today, which is
$400mn to $1bn,” remarked Gmmco's
ED & CEO, Mr. H. Jayaram on the
partnership.
 classifieds

Relyon Facility Services SSA Techno Construction Pvt. Ltd.

Seven Hills Safety Equipments

and Systems (P) Limited

Ramtec

The Masterbuilder - April 2011 | www.masterbuilder.co.in 207

CE: Finance
Analysing Asphalt Plants
A Key Ingredient to Success
Blesson Varghese, Director, Marini in India
A n asphalt plant purchase is
unlike any other purchase of
road building equipment. Road
building contractors are used to
changing brands and models faster
than their clothes for equipment like
rollers, loaders or dump trucks.
However an Asphalt plant purchase is
quite vital and critical, while also being
different.
Asphalt plants cannot be dumped
off, like rollers, loaders or excavators.
Capital investments cannot be
reversed quickly and are almost
irreversible, especially when an asphalt
plant will stay put with your company
for the next fifteen to twenty years or
more. Hence a hasty decision without
critical thinking could prove costly in a
fiercely competitive market and an
ever-evolving environment.
208 The Masterbuilder - April 2011 | www.masterbuilder.co.in
As asphalt plant purchase involves
substantial capital investment, most
contractors & company managers do
not get a lot of experience in buying
them. Hence while undergoing the
most difficult decision you will make in
your career.
A clear perspective is what is
required to get through the marketing
stunts and to understand what rightly
process of selection of plants, you are
deserves your investment. Although
sure to be bombarded with several
your purchase decision is focused to
views from salesmen, each of them
meet your company's immediate need,
telling entirely different stories. The
the future of the market and
success of a road project, which again
competition must not be forgotten.
involves sizeable amount of
investment, hangs on the performance Making a decision based on your
of this particular equipment. No company's future needs is one that
amount of trained or experienced calls for visionary eyes, and a truly
manpower can correct, if the decision discerning mind.
is wrong. Even long after the roads are
Long term planning needs Visionary eyes
built, improper mix, if produced and
laid will continue to haunt and even We are all in our respective
damage a company's bottom lines. businesses to make decent profits,
Therefore it is quite likely that purchase without cutting corners. Visionary eyes
of a new plant would be one of the are those which are able to see beyond

the present situation and able to look in
to what the future will become.
The simple formula to make profits
without cutting corners is to reduce
production costs. Ingredients that
comprise the asphalt production cost
a re R a w m ate r i a l co st , P l a nt
maintenance costs and Energy costs
(including Fuel & Power). This will be
the turf on which the market will
compete and where your profitability
hangs.
Productivity Matters: Productivity
and efficiency are two key words that
asphalt producers should never miss. It
is easy to understand the savings that
can result from asphalt plants which
deliver capacities as promised by
manufacturers.
For e.g. when you buy a plant rated
at 200 Tph, which delivers only 160 Tph
in reality, the purchase may seem to be
an absolute deal, however the final
numbers will deny anything close.
Lesser output means longer project
duration, higher equipment running &
operating costs and losses that could
be turned in to profits, if you had just
made one right choice.
Demands of the Future: The costs
of aggregate production is bound to
increase, the dearth of natural
resources, guarantees its further
escalation. Our country is on the
CE: Finance
building stage at the moment; however
we are already facing the heat of raising
costs. This will necessitate use of
Recycled asphalt (RAP) in the mixes.
Moreover we cannot be laying layers
over layers, raising kerb heights;
reduced clearances on underpasses,
weight limitations on bridges would
further force use of Recycled asphalt
mixes.
Presently technologies world-wide
limit the use of Recycled asphalt to a
maximum of 50-70%. If thoughtfully
worked upon, RAP can help sustain our
natural resources, and reduce our mix
production costs greatly. Do note
Recycled asphalt contains precious
bitumen, the most expensive of all
components in a mix, which can be re-
vitalized ensuring high levels of
profitability. The existing roads will asphalt. Simply put, you must be able
become the future quarry in a future to produce Recycled asphalt cheaper
not very distant from now. than all your competitors.
A very important point that you In addition to conservation of
must not miss here is: Only energy- natural resources and energy savings,
efficient plants with the technology to the plants of the future must be able to
process RAP will benefit the producer meet increasingly strict environmental
in the future. If you are smart, your re g u l at i o n s . We a l re a d y h ave
decision today hence must be geared witnessed the trouble that various
to take up this challenge that you will asphalt producers had to face, when
surely face tomorrow. New plants they were forced to move out of New
hence must be able to produce up to 50 Delhi.
% RAP without additional energy costs,
Some additional points to be kept in
for you to stay competitive, when the
mind include:
market would be ready for recycled
Eco-Friendliness: The world is
facing the heat of carbon emission.
Carbon taxes are already in place, road
construction activity is being closely
monitored now for carbon emissions,
this will necessitate that to stay in the
race, carbon emissions from your
asphalt plant must be controlled today.
Alternative fuels: Reduction of carbon
emission will force us to look at
alternative resources for energy. While
on the other side, raising fuel costs, will
force us to look at using cheaper
solutions. Asphalt producers hence
must be able to find the right balance,
which calls for a partner who can
www.masterbuilder.co.in | The Masterbuilder - April 2011 209
CE: Finance
sustain you to face these challenges
confidently.
Night time readiness: Asphalt Plants
must necessarily be able to operate
silently at night, since much of the
paving in urban areas will happen post
sundown. To facilitate night time
paving, plants must be equipped with
large storage silos that can hold mix for
longer durations. You will need to
produce during the day hours, stock
them in large storage silos, in order for
you to be bang on for your night time
laying operations.
Low Downtime: As markets become
more competitive, asphalt producers
will be forced to look at each paisa that
is spent. Manpower cost is increasing,
investment costs will become more
demanding, which in turn will make
downtime costs unbearable and a
serious threat to the profitability of the
company. This is the reason we need
plants, which must be built to perform,
face tough site conditions, have high
level of reliability, can be hooked up
and serviced remotely and assistance
must reach immediately.
Future Ready: The world of asphalt is
witnessing some massive changes.
Each asphalt producer will be forced to
meet the regulatory requirements. If
your plant does not meet the norms,
then it does not matter what it costs.
210 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Some of these product features
mentioned may not seem to be of
tremendous importance to most
asphalt producers today, they are sure
to become inevitable in the near future.
The facts mentioned here can be
consolidated to reduce a plant's total
operating costs. These facts must be
considered by the asphalt producers to
ensure sustainable profits and success
for them and the generations.
Profitable decisions require Forward
Thinking
We all know, the bitter taste of poor
quality lingers long after the sweetness
of low price is gone. Asphalt plants
geared for the future do not come
cheap, as these features require more
than just steel. Years of experience,
research and intuition along with
technology can only deliver features
that will help you face the future.
To put things into perspective, a
20% price differential between two
competing hot-mix plants is only about
2% over 20 years. But again, you can
easily overcome this cost gap if you
choose a plant that can give you
increased energy efficiency, allow use
high content RAP in your mixes, and
operating savings of 10 to 20%.
It doesn't need rocket science to
understand this and that is exactly why
I encourage you to look beyond the
price when buying a new plant.
We a t M A R I N I h a v e b e e n
developing technologies since over
100+ years to ensure that our asphalt
plant not only delivers high quality
asphalt but also help customers churn
their expenses in to profits. Marini
MAC is one such example, where we
have tried to equip our clients to
confidently face the future. We are
convinced like our customers, that
because of the increased costs of fuel,
asphalt and electricity the MARINI
plants have become the plant of
choice. We have hence ensured that all
plants delivered in India have the
highest fuel efficiency compared to any
other manufacturer, is Recycling ready
up to 40 %, reflect green plant
technology and are future ready.
Selecting the right asphalt plant is a
critical decision that calls for
discernment, as this decision of yours
will affect the success of your company
and its future. It is a decision that should
be based not on what your company's
needs today, but what your company's
needs in the future. Remember, profitable
decisions aren't merely based on today.
Blesson Varghese, is the Director of
Marini in India, and also serves SAARC,
SEA and Australasia. Send your
comments to - info@fayat.co.in
MB subscription form
Liugong India
Eyes US$ 175 Million Annual Revenue by 2012
L iuGong India is a subsidiary of
Guangxi LiuGong Machinery Co.,
Ltd., one of the top 25 largest
construction machinery companies in
the world. With over 50 years of
manufacturing experience, LiuGong
not only offers the booming Indian
construction machinery market
machines that are east to own and easy
to maintain but machines that are built
locally in its factory in Madhya Pradesh.
“LiuGong's mission is to support
customer with a total solution with our
products and services. We believe there
is great opportunity in India, especially
in infrastructure as India is booming at
least for next 15-20 years. LiuGong,
with its full line of construction
equipment & local dealer network,
provides the right combination of
products and service for the Indian
market” says Sunil Sapru, President of
LiuGong India. The company offers
212 The Masterbuilder - April 2011 | www.masterbuilder.co.in
wheel loaders (1.5 to 10 ton),
excavators (6 to 35 ton), compactors,
motor graders, cold planners and
dozers, cranes, forklifts and
multipurpose products like skid steer
loaders, backhoe loaders.
Presently LiuGong India with its
head office in Delhi has a parts depot in
Chennai and the manufacturing facility
in Pithampur in Madhya Pradesh. “LiuGong's wheel loader segment is
LiuGong India's manufacturing facility is expected to push LiuGong India's
a milestone for a China company in projected annual revenue to over
India. The facility, covers 44 acres, will US$175 million by 2012,” says Mr.
produce 2,000 wheel loaders and Sapru.
excavators annually in its first phase
A Global Market Leader
and other products will be launched in
the future. LiuGong's association with In the modern age, LiuGong
India dates back to 2002, during these Machinery Corp. is one of the
eight years, the company has vanguards of a new trade explosion
demonstrated market competitiveness between China and the remainder of
and the market performance has far the world. As the world's largest wheel
exceeded the industry's average loader manufacturer, LiuGong is the
growth rate. Chinese leader in quality construction

machinery exports, and the company is
successfully expanding around the
world by marrying Chinese ingenuity to
best practices of Western management.
LiuGong Machinery Corp.,
headquartered in Liuzhou, China has
produced high quality construction
equipment for more than 50 years and
is expanding throughout the world. The
company has been named one of the
top 100 brands in China, ranking 60th.
With $1.49 billion USD in sales revenue
in 2009, China's premier heavy
equipment manufacturing firm is
within the top 25 largest construction
machinery companies globally. The firm
employs over 11,800 including more
than 650 R&D engineers, and produced
more than 56,000 machinery units in
2010. LiuGong offers a full line of
machines, including wheel loaders,
bulldozers, backhoes, skid steers,
forklifts, graders, excavators, rollers,
truck mounted cranes, pavers and cold
planners. LiuGong has a significant
share nearly 15% of the total
worldwide market share for wheel
loaders, and growing share of the global
market share for rollers.
Several “Firsts” to its Credit
The company claims many
important “firsts.” LiuGong was
founded in 1958 in Liuzhou, China and
built the country's first modern wheel
loader in 1966. Currently LiuGong
manufactures the largest wheel loader
built in China, the CLG899. In addition,
LiuGong became China's first publicly
traded machinery company when it
began trading shares on the Shenzhen
Stock Exchange in 1993.
LiuGong has 16 machine factories
and in 2009, successfully opened its
first overseas plant in central India, one
of the few Chinese machinery
companies to do so. The company's
success rests in part, on elegant design
and intense durability. LiuGong
equipment is easy to own and easy to
operate, as the company excels in
providing features that customers
demand, but also focuses on using only
well-proven technologies that are easy
to service. The result, customers report,
is highly durable machines that stand
up to the rigors of the tough operating
environments customers face.
Sound Growth Strategy
LiuGong's approach to growth is
tied to a strategy of carefully expanding
its global footprint. In each country it
enters, LiuGong first carefully courts
www.masterbuilder.co.in | The Masterbuilder - April 2011 213
Profile
well-capitalized, experienced, and
dedicated dealers. This means
customers have access to a worldwide
network of LiuGong dealers with
locations in nearly every country. Eight
LiuGong subsidiary companies are
strategically located to provide expert
support close to important markets.
These regional offices are staffed with
engineers, technical experts and sales
and marketing support. The regional
offices are located in USA, Brazil,
Australia, The Netherlands, India,
Dubai, South Africa and Singapore.
LiuGong stands behind its dealers
with eight highly sophisticated parts
depots currently in operation around
the world whose goal is to ship parts
within 48 hours of the order. In India,
the parts depot is located in Chennai,
Tamil Nadu.
LiuGong's expansion strategy also
includes the regular introduction of
carefully designed, rigorously tested
new machines. For example, in 2009,
LiuGong introduced a bulldozer line and
a truck mounted crane line, a forklift
line, and new roller models.
Several new models of wheel
loaders were added to the machine
line-up as well. LiuGong, as a company
that has adopted and pursues Six Sigma
quality standards, is continuously
refining design, product support,
customer service and other aspects of
its business, based on customer
feedback.
The company is also expanding its
manufacturing and support capabilities
in an aggressive way. In early 2009,
LiuGong opened a bulldozer factory in
northern China, and opened the India
wheel loader plant in July 2009 in
Bangalore. The company also just
completed a major investment in a
state-of-the-art automated warehouse
located in Liuzhou. The facility helps
improve logistics, stocking quality,
accuracy, and inventory information.
Industry Interaction
TIL Introduces
Double Barrel Technology to India
T he road construction industry is
witnessing rapid changes with
the introduction of newer
technologies by the day. Double barrel
technology is one such technology
that has been in the news recently.
T h e M a ste r b u ild er s p o ke to
Mr.R.Nandagopal, Vice President,
Equipment & Project Solutions, TIL Ltd,
about Astec asphalt batch mix plants,
which the company offers, featuring
this technology. Here are excerpts from
the interview.
What are the advantages of Double
Barrel technology over batch mix
technology?
All over the world road
construction authorities and the
contractors tend to look at cost
214 The Masterbuilder - April 2011 | www.masterbuilder.co.in
effective methods to design, build, and
maintain road infrastructure.
The Double Barrel innovation is a
result of the requirement of the
customers and the authorities alike and
the consistent superior performance of
the same has made it 'the preferred
choice' for the customers in many a
countries and has replaced the
conventional plants.
The Double Barrel with its RAP
friendly technology offers the following
significant benefits to the customer
and also leaves a lower carbon
footprint -
§ Protects environment from pollutants
and other toxic ingredients which
are present in dumped milled
bituminous pavement
TIL-ASTEC Double Barrel Hot Mix Asphalt Plant
R Nandagopal, Vice President
Equipment & Project Solutions, TIL Limited
[A part of material handling solutions division]
§ Prevents afforestation and
depleting mountains due to
continuous mining of the same for
production of aggregates required
for hot mix asphalt
§ Offsets increasing cost of fuel,
bitumen and aggregate and overall
lowering the project cost
§ Reduces carbon foot print of the
road construction
§ Makes sustainable asphalt pavement
With increase in road project size,
what are the technical attributes that
you feel that make your asphalt mix
plants ideally suited for Indian
conditions?
The size of the road projects have
been growing under PPP / BOT etc and
Tunnel Design & construction (IQPC -Singapore)
Industry Interaction
TIL -ASTECC Double Barrel HMA Plant
this has translated into higher capacity
and the better mobility of the plant and
machineries to fully optimize the
investment cost.
The double barrel plant with
portable options up to 400TPH and
stationary options up to 600TPH will
meet up with the growing demands of
infrastructure.
Double Barrel is a combination
aggregate dryer and mixing unit
separated from each other uses
sequential mixing to produce larger
volumes of consistent and
homogeneous hot mix in shorter time
than any other plant. It is equipped to
provide multiple job mixes at a very
short notice.
The features like, automatic
aggregate gradation unit, dual fuel
modulating burners, infrared sensors
to maintain heating of aggregate at
specified temperature, ability to
handle larger dust/ exhaust volumes,
ease of operation and maintenance,
availability of spares parts, ability to
run upto 50% RAP and option to
produce warm mix asphalt with
foamed bitumen provide the leading
edge to this technology.
216 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Technology-wise what are the 'green'
features that have been incorporated
in your asphalt plants?
We have incorporated various
features to maintain their green
quotient:-
(i) Generous application of insulation
throughout the bitumen storage
tanks, bitumen pipe lines, hot oil
pumps and piping, Double Barrel
itself- all these results in heat
retention significantly and reduces
the carbon foot print.
(ii) Ability to run upto 50% RAP
(iii) Ability to produce warm mix
asphalt (WMA) using bitumen
foaming technology popularly
known as “Double Barrel Green
System”. The WMA foaming system
is presently the industry standard
for producing warm mix asphalt
and is a giant step forward for the
industry because it uses water as an
additive to produce warm mix
asphalt. It allows contractors to
produce warm mix material that is
equal to hot mix material in
performance while requiring less
fuel for drying and generating fewer
emissions. Double Barrel Green
makes the production of
sustainable WMA a reality.
How suitable are your asphalt mix
plants for asphalt recycling?
W h e n a re c l a i m e d a s p h a l t
pavement is used in any plant following
precautions need to be taken
1. Exposure of the RAP to the flame.
2. The RAP has to be introduced
gradually to prevent a steam
explosion when RAP comes in contact
with super heated aggregates.
3. A bag house design to take care of
the high exhaust fumes.
The Double Barrel technology takes
into account all the concerns
mentioned above and its design
incorporates a combination aggregate
dryer and heater, wherein heating /
drying takes place in inner drum and
mixing is carried out in outer drum
away from direct flame of burner. RAP
is added with heated virgin aggregates
in outer barrel and thus Double Barrel
technology offers users a unique ability
to run high percentage of RAP upto
50% in their mixes without increasing
fuel usage. In fact, when it comes to
recycling Double Barrel's ability is
unmatched.
How does your asphalt mix plant
compare with others with respect to
ease of setting up the plant and
operation?
We have truly portable plants
which has set industry standards for
Portability and Productivity. Our
Portable Six Pack Plant can be erected
and commissioned within 36 hours of
its arrival at site. No civil foundation, no
carnage, etc. is required for erection of
the plant. Our plants are also equipped
with PLC based automatic controls
operating on WINDOWS operating
system making it easier to operate.
Partnership contracting (Hongkong)
Profile: Shoring System

STAXO 40
The Lightweight, Economical, Safe and Efficient Shoring System

D oka is a name that has become

synonymous with formwork
globally. The company, with its
headquarters in Austria, has rapidly
spread its wings across 150 sales
locations around the world. It has also
got its logistics centres in more than 65
countries. Doka has always been
known for its strong focus on research
and development, resulting in
innovative solutions. The Staxo 40,
which is a lightweight, economical, safe
and efficint shoring system for the
building construction industry is an
example of the company's prowess for
innovative products and solutions. The
newly developed Doka load-bearing
tower Staxo 40 is deliberately geared to
meeting the requirements of the
building-construction segment, and
sets brand-new standards of speed,
safety and efficiency. The system's
significantly weight-reduced and
ergonomically optimised H-frames
make for very easy handling meaning
fast erection and dismantling times
combined with high stability and
workplace safety.
frame geometry and well-balanced
centre of gravity are further factors
which facilitate the workflows. Add the
system's logical assembly sequence
and small number of separate parts,
and it is clear why it achieves
substantially faster erection and
dismantling times. Thanks to its
optimised frame construction, Staxo 40
can be set up much more quickly than
single-leg shoring towers, as these
often have up to 32% more weight and
up to 78% more separate parts which
slow down assembly. For Staxo 40, this
is a crucial advantage when it comes to
shoring large areas efficiently.
Emphasis on Safety
As well as being extremely light
and efficient, the newly developed
load-bearing tower system also comes
with a very high standard of safety.
Features such as the tested anchorage
points for personal fall arrest systems,
integrated safety catches for fixing the
diagonal crosses, gapless assembly
decks in and between the towers, and
a sturdy built-in ladder system, all
ensure a safe working environment at
any height. The facility for assembling
the towers in the horizontal, with
tension-proof connections between
the frames so that the towers can be
lifted into position by crane, gives a
further boost to safety and to the
speed of work.
Enables High-Speed Working
The H-shaped frame geometry of
Staxo 40 makes it possible to have
gapless, full-area assembly decks not
only inside the towers, but also for

Innovative H-shaped Geometry

By using the finite-element method

in the constructional design process,
Doka's engineers were able to greatly
reduce the weight of the Staxo 40
frame while permanently improving its
strength. The results speak for
themselves: a standard-version Staxo
40 frame only weighs between 15 and
24 kg and so can easily be shifted by just Light, sturdy and safe: The Staxo 40 H-frame was developed on the basis of the finite-elementZ
one person. The innovative H-shaped method. It stands out for its low dead weight yet high strength, and for its many safety features.

218 The Masterbuilder - April 2011 | www.masterbuilder.co.in

 Profile: Shoring System

the first time ever between them as

well. This ingenious concept “puts all
the pieces in place” for high-speed
working combined with high safety.
Beneath the towerframe superstructure,
the 1.70 m of headroom provides the
space needed for erecting and
dismantling the formwork both
quickly and ergonomically. The work-
deck levels can also be extended
beyond the scaffold itself, so as to
ex t e n d b e n e a t h c a n t i l e v e r i n g
superstructures. Safe, systematic
working is ensured here by easy-to-
attach brackets. To adapt to different
heights, Staxo 40 gets by with it three
different sizes of frame, screw-jack U-
heads and feet that can be adjusted
with millimetre precision, each having
a max. 75 cm extension length. Their
novel thread geometry and three-
wing spindle nut permit effortless
height adjustment, even under full
load. Maximum flexibility and cost-
optimised equipment utilisation are
the welcome results of the large inter-
Tower assembly made easy: The low weight and ergonomically optimised geometry of the
frame spacing of up to 3.00 m, using
Staxo 40 frame allow the towers to be assembled very quickly and make work much easier. diagonal crosses of different lengths.
When it comes to repositioning, too,
Staxo 40 is designed to be highly cost-
efficient and very fast. Staxo 40 towers
can be travelled on shifting-wheels, or
crane-lifted, in their entirety, i.e.
without having to be dismantled.

For further information contact

Doka India Pvt Ltd.

Mumbai:
Hiranandani Business Park,
"Sentinel" Building,2nd Floor,
Commercial premises No. 201 & 202,
Powai, Mumbai - 400 076.
Ph:022-4026 4435
Delhi:
1203-1204, 12th Floor, Chiranjiv
Tower, 43,Nehru Place,
New Delhi - 19. Ph:011-4652 5695
Fast and safe: the gapless, full-area workdecks inside and between the towers provide Email: india@doka.com
safe workplace access and speed up the assembly operations. Web: www.dokaindia.com

www.masterbuilder.co.in | The Masterbuilder - April 2011 219

Construcion Chemicals: Company Focus

Don Construction Chemicals India Ltd now

Part of DCP International

D CP international is a group of
multinational companies which
operates in the North American
Continent, Europe, Middle East, and Asia.
The Chairman of DCP international
Mr. James F. Igoe launched the logo of
DCP in India on 23rd March 2011 at a
f u n c t i o n h e l d i n H o te l A c co rd
Metropolitan at Chennai. Mr.Igoe
appreciated the Indian market for
opening up and allowing new range of
products. He also spoke about the
group's plans for infrastructure
development, marketing and after sales
technical support activities. Mr. Tawfic
Ghandour, Global CEO of DCP International
speaking on the occasion shared his
excitement in exploring the Indian
Market.
DCP is operating in India with its head
office and manufacturing Unit I at
Chennai. Manufacturing Unit 2 is
situated in Jaipur, Rajasthan. Mr. Feroze
Chatelier, Managing Director, Indian
Operations, in his speech said that the
new product range of DCP will provide a
suitable and complete solution for more than 80 years with experience in All manufacturing sites comply with the
construction needs in India. Additionally the manufacture of quality construction highest quality standards and are
he felt that the company's extensive chemical products with operations in committed to operate with no harm to
network of operations will enhance its Europe, Africa, and Asia. The company's the environment.
reach to all places in the country. business lines are served by professional The group has a dedicated in-house
Mr. Prashant Patry, the Director South engineers that provide services for technical department which ensures
East Asian operations, was also present designers, consultants, and contractors that technical advice is readily available
on the occasion. alike. The group has its advanced R & D by phone, email, or site visit to all clients.
centre located at Jordan, which is DCP's specifications department
DCP is a world leader in developing, equipped with facilities to test products provides specifications for projects to
manufacturing, and marketing advanced in a wide range of climatic conditions to cover all site conditions and
technology products to service professional produce products that are ideally suited performance requirements.
customers in the construction industry for different environments and climatic
For more details, please visit the
and building maintenance. conditions.
group's international website at
Don Construction Products has been DCP serves customers in over 35 w w w. d c p - i n t . c o m o r e m a i l :
serving the construction industry for countries with a wide range of products. marketing@dcp-int.com

220 The Masterbuilder - April 2011 | www.masterbuilder.co.in

Unitech Exhibitions - Roof India (Barter Ad)
Automated Doors
Smart Reset
Self-Repairing Automatic Flexible Door
G andhi Automations Pvt Ltd is a
leading name in importing,
distributing and installing,
easy to operate, Entrance Automation
Systems and Loading Bay Equipment.
Smart Reset, a high performance and
self-repairing heavy duty automatic
flexible door is one of its product
offerings. With the self-repairing
system; should the curtain accidentally
get dislodged, it will automatically be
recovered with a simple opening and
closing operation.
Reliable and Compact
Smart has been designed by the
company in order to produce a
practical and highly modular high-
speed door to simplify installation and
allow all the components to be
operated easily. Sturdy and compact
structure, scientific design and tested
Ditec motors and components, are the
key features that make Smart Reset a
safe, aesthetic, easy and quick to fit
door. Furthermore, the door is also
practical and easy to inspect, check and
requires minimal maintenance.
The reduced size of the door allows
it to be installed even where space is
available at a premium. The motor
outside the door can be supplied
complete with the manual emergency
re-opening device.
Distinct Features
The company can supply Smart
Reset in different levels of design (basic
and comfort) to satisfy the different
operating requirements and to comply
with different local standards. Some of
the technological features of product
include:
222 The Masterbuilder - April 2011 | www.masterbuilder.co.in
§ The inverter system makes it easy to
adjust speeds. The SOFT START and
the SOFT STOP facilities avoid
mechanical parts stress and wear,
thus ensuring the reliability and
long life of the door.
§ Ho t galvan ized steel metal
structure available in the RAL
versions with oven baked epoxy
coating with smooth finish or fine
satin-finish AISI 304 stainless steel,
complete with galvanized curtain
winding pipe and vertical uprights
fitted with special self-lubricating
sliding guides installed on a shock-
absorbing spring system.
§ Provision for roll-up roller casing.
§ DSC electronic safety device to
reverse motion when door is
closing if an obstacle is hit.
§ Heavy duty motor: 3 phase 400V
motor, complete with limit switch
and electrically operated hand brake.
§ IP55 rated electronic panel
complete with push button panel
with open-close-stop membrane
control featuring an autotest
function, compliant with 98/37/EC
and 89/106/EC European
Directives.
§ Provision for manual opening
device with operation rod.
§ Full size flexible curtain made of
class 2 self- extinguishing polyester,
with no horizontal strengthening
parts, which slides inside the side
hinges and features self-repairing
properties and high resistance to air
and wind pressure: resistant to
120km/h wind.
Control and Safety Systems
§ RMM Microwave radar with
function discrimination vehicle-
pedestrian direction of movement.
§ TEL 2 RMM radar distance
adjustment remote control
§ GOL4 transmitters fixed code four
channel-four function, with cloning
option, or with rolling code system.
§ LAB 9CS board detector with cable
for magnetic loop
§ XEL 22 C4- pair of columns H 2.5m
with four synchronized precabled
photocells, for general use.
§ LAMP H 24V flashing light.
For further details contact
Gandhi Automations Pvt Ltd
2nd Floor, Chawda Commercial Centre
Link Road, Malad (W) Mumbai- 400064
Off: 022- 66720200/66720300 (200 lines)
Fax : 022-66720201
Email : sales@geapl.co.in
Web: www.geapl.co.in
 Equipment: New Roll Out

New High Pressure

Concrete Pump from REL
R EL, a well known entity in the
field of construction equipment
, has in technical collaboration
with Waitzinger Baumaschinen Gmbh,
Germany, introduced the THP 45 D high
pressure concrete pump suitable for
high- rise pumping as well as horizontal
pumping up-to 500 meters .
The concrete pump features the
latest 'S' valve technology and comes
with a host of features including the
Split type wear plat for lesser service
time, apart from the PLC and sensor
controlled operation with alternate
pressure feedback as back-up option.
The standard scope includes Air
Compressor and the pump has optional
automatic greasing system.
The THP 45 D comes fitted with a 4
cylinder air cooled engine and boasts of
high-rise pumping upto 100 metres
vertical ( appx 30 floors) in the piston
side pressurization, due to its
robust design. A large hopper
of 600 liter capacity and dual
hydraulically driven
agitator motor
keep even the
concrete in the bottom most portion of
the hopper also properly agitated, to
prevent chocking of pipelines due to
segregation.
The THP 45 D concrete pump has
been positioned as the ideal solution
for the typical Indian contractor, who is
on the lookout for economical and
'India-specific' products. The concrete
pump has features that try and answer
the issues of both high-rise and high
output pumping with a lower operating
cost.
The stationary concrete Pump
range of REL also has the THP 60 D
model, with a 6 Cylinder Air cooled
engine and concrete pressure of 120
bar. This model is suitable for vertical
pumping up-to 175 meters. REL offers
the full line of concrete equipment
including concrete batching plants
ranging from 30 to 120 cbm/hr, transit
mixer, boom placer, and stationary
concrete pump.
T h e co m p a ny h a d re c e nt l y
augmented its range by adding two
new products in the foundation
equipment segment, namely, Hydraulic
Piling Rig with TESCAR Srl, Italy, and
Vibro-Hammers with Chowa Kogyo Co
Ltd, Japan.
The company had inaugurated its
new manufacturing plant in
Gummidipoondi, near Chennai, last
year, enhancing its production capacity
and also expanding its network across
the country. Today REL CED has 7
strategically located offices with sales,
service, and spare parts operations.
Apart from their own network, REL CED
also has their Tier II after sales support
mechanism through their network of
16 dealerships spread across the
country.
For further details about the product,
contact:
SUNIL M, Associate Vice President
REL -Construction Equipment Division
Email: ced-sales@revathi.co.in

THP 45 D Stationary Concrete Pump

www.masterbuilder.co.in | The Masterbuilder - April 2011 223

Viewpoint
ERP for SMEs
I n the beginning ERP was considered
out of reach by almost all the
companies of SME sector and as a
tool of fortune meant for 500
companies, who could spend huge
sums of money on purchasing the
s o f t wa re , i n sta l l i n g ro b u st I T
infrastructure and could dedicate
manpower, time, and money for its
implementation. But with the change
in time and with rise of more and more
ERP solution providing companies the
upper market got very competitive,
now to grow and bear the growing
expenditures the software companies
have developed marketing strategies
to target mid and small size market.
This has initiated change in the design
and structure of present day ERP to suit
to the needs of SME market.
As it is easily understood that the
benefits of ERP are more realistic and
practical to SME than large companies,
as large companies can invest money
and manpower to find out an
alternative way of doing tasks, such
cushion is not available with SMEs, the
biggest disadvantage being the amount
of money a mid- size company will have
to invest to get the benefits of ERP. So
the ERP solutions for SMEs need to be
cost effective and easy to implement.
The professional services which a large
organization can avail a small or mid-
size company may not be able to. Cost -
effective ERP software with less
complex implementation process is the
most suitable option for SMEs.
224 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Low cost of implementation alone
cannot push ERP solutions down the
throat of SME market. Some of the mid-
size companies might be small in size
and business, but they might have been
in the market for quite some time. And
it has been noted, in most of the cases,
that such companies have number of
different types of systems working
simultaneously in one organization.
When ERP is implemented all of those
systems either need to be integrated
with the ERP or the old data has to be
converted according to the format and
design required by the ERP to
understand, for smooth and trouble
free transition and working. This calls
for a flexible architecture of ERP
software which should be able to
integrate with different software,
platforms, and operating systems.
Most of the SMEs would like to
deploy ERP in a step by step process
where they will switch over one
module after another, this makes the
To Subscribe Your Copy Today!
Call: 044-28555248 / 044-28586703
www.masterbuilder.co.in
Kunal Mehta, Managing Director,
SKG Equipments Pvt. Ltd.
process easier and less cumbersome.
To target SME market companies have
started offering ERP software in suite,
which allows the buyer to purchase one
application with complete functionality
of a particular department of organization
like SCM, CRM, Financial management
etc and with smooth and easy
integration facilities with other
applications. Instead of buying whole
ERP for the organization switching over
in steps is more attractive for SME units.
Hosted ERP, cloud computing, SaaS
models have been promoted by almost
every ERP company and with a primary
aim of attracting more clients
from the SME sector. These models
take away most of the worries and
deterrents of companies from the SME
market regarding ERP implementation
and cost. The availability of top ERP
solutions in such models has been
the major factor that has played its role
in making ERP popular in the SME
market.
 SKG Equipments Pvt. Ltd.
Ermotec International Pvt.Ltd
Site Report

Putzmeister M32
at work in Alakhnanda Hydro Project

P utzmeister, a global leader in

stationary concrete pumps,
truck mounted concrete pumps
and boom pumps has been part of
several prestigious projects. The
company's truck mounted concrete
pump M32 with 150 mm pipeline once
again proved their robust performance
under strenuous working conditions at
the Alakhnanda Hydro Project in
Uttarakhand.
The hydro electric facility being
built by M/s GVK Projects presented a
unique set of challenges due to the
rugged terrain and extreme climatic
conditions, where concrete had to be
pumped in the right quantity at the
right time. The project developers once
again relied on the proven
performance of Putzmeister's range of
concrete pumps to adhere to project
guidelines and schedules. The concreting process of the concrete pump along with 150 mm
The work site perched on the project required planned execution. pipeline was equal to the tough task at
The engineering team had to first of all hand. The M32 model with its reach
Himalayas, presented the engineers
plan the logistics part, involving the M height and features including modul
with a daunting set challenges because
32 concrete pump and the location of boom control and cable remote control
of the terrain. Adding to the complexity
the concrete batching plant. proved its efficacy once again under
of the project was the flow of the
Alakhnanda River. The company's truck mounted M32 conditions of extreme duress.

Intake Tunnel and Dam site Dam Side

226 The Masterbuilder - April 2011 | www.masterbuilder.co.in

 Site Report

Power House and Penstock Area

Putzmeister Truck mounted concrete Pump M 32 with 150 mm pipe line

at job site - Pumping and conveying Aggregate up to 40mm De silting Chambers site

360 CUM/Hr capacity Batching plant. Construction Site of Power House

The team at the project had to plan
everything in detail, right from the
procurement of the raw material for
the concrete to the placing of concrete.
The concrete came from the stationary
concrete batch plant that was
specifically set up for the project.
The work site consisted of different
types of work, which included
construction of the intake and outlet
tunnels, apart from the power house
and penstock area.
The desilting chamber site was
where the M32 truck mounted
concrete pumps were placed for
pumping the concrete.
The team relied on meticulous
planning for adhering to the project
guidelines and schedules. The
Alakhnanda hydro project is yet
another milestone for Putzmeister's
range of concrete pumps. The M32
truck mounted concrete pump has
once again proved its mettle.

www.masterbuilder.co.in | The Masterbuilder - April 2011 227

E.Scape
World's Largest
Illuminated Façade
Galleria Centercity, Cheonan, South Korea
A new futuristic departmental store in South Korea
now holds the distinction of having the largest
illuminated façade in the world.
Located in the Cheonan region, the Galleria Centercity
boasts of an energy-efficient double skin that is as
much part of its attraction as the goods that are stocked
inside for avid shoppers. The designers have tried to
maintain to match the social components of the design
with the retail elements that are found in the building.
Designed by architecture firm UN Studio, the building is
public and private, open and intimate at the same time,
according to its designers.
The design is such that there are several places where
translucent exterior lets daylight penetrate without
overheating the complex. The entire building virtually
glows like a lantern on nightlife, making it the cynosure
of all eyes in town.
Renzo Piano's, 'Vulcano Buono'
Colosal Volcano
Building Rises in Italy
228 The Masterbuilder - April 2011 | www.masterbuilder.co.in
Abandoned Oil Rigs Could
Become Bustling Mini Cities
A bandoned industrial infrastructure is
increasing by the day and designers are now
thinking of using them in an innovative way. A
design by Ku Yee Kee and Hor Sue-Wern hopes to
reclaim oil rigs and use them as habitation units,
with common recreation areas.
The concept however is not new, since the
controversial 'Principle of Sealand' near UK, which
has claims to be the world's smallest country, is in
fact an old oil platform. The design consists of
stacked units that offer great views of the vast
ocean.
The structure would also have labs for marine
research beneath the water. Other features that
will be incorporated include solar electric panels
on the roof, wind turbines and tidal energy
generators to power the structure.
A jaw dropping piece of architecture has risen in Italy.
This iconic structure has been constructed in the Italian
city of Nola.
Inspired by volcanoes, the structure in fact lies just a
stone's throw away from the famous Mt.Vesuvius. Designed
by architect Renzo Piano, the cone-shaped commercial
centre has been christened 'Vulcano Buono', which
translated from Italian means "good volcano".
The sloping green roof is just one among the several
sustainable features that have been incorporated as part of
the building's design. The epic building is now the most
important landmark in Nola, which is an important freight
terminal hub in central Italy.
Kamaz Vectra Motors Ltd
Hess Concrete Machinery India Pvt.Ltd