The Masterbuilder - January 2012 - Construction Chemicals Special

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

here were times in the Indian retail story when departmental stores, that once flourished in our neighbourhood, ran low-in-stock on a particular brand of fast-moving consumer good; the stores would religiously place orders for several more boxes to avoid running out of stock. However, as luck would have it, consumer preferences changed dramatically and store owners more often than not ended up stocking supplies that would never complete its projected lifecycle. That's when the retail wizard's discovered Just-in-Time inventory control (JIT).Today, when you take your favourite brand to the checkout counter, the attendant scans the bar code and immediately a simple message is relayed up the distribution chain to the factory: 'Send me one more'. This tool not just simplified the process, but also economised trade. JIT is a manufacturing process that was perfected by Toyota. Originally, it described how materials should be processed and moved up the distribution chain in order to arrive just in time for the next operation. The lineage of JIT production goes back to Eli Whitney who is most famous as the inventor of the cotton gin. (However, the gin was a minor accomplishment compared to his perfection of interchangeable parts. Whitney developed this in 1799 when he took a contract from the U.S. Army for the manufacture of 10,000 muskets at an unbelievably low price.) Now, just imagine a scenario where Indian power utilities deploy JIT to supply electricity in a similar fashion. Wouldn't it be the beginning of a revolution? What if they could precisely map our consumption patterns, allowing them to reduce and manage the expense of producing power? Even better, if utilities and consumers could use real-time twoway communication to stay in immediate contact and reduce standby power? It should sound as good news to all of us that these initiatives are already in WIP as part of what's been dubbed as the smart grid, the full development of which according to experts may be possible in just a couple of years. By knowing the consumer better, power utilities will be better capable of meeting demand without the expense, not to forget the environmental impact, of relying on carbon-generating plants to support them in times of peak loads. Efficient use of the nation's electrical power grid is also seen as a way to avert major power outages. Getting the electrons to the right places at the right time in a country where nearly 350 million of the population still do not have access to electricity, is no mean task! But then it is unacceptable to have AT&C losses as high as 30 percent. If such losses can be scaled down to the world average with the aid of smart grid, it will not only provide the electricity to the most rural parts of country without any new capacity augmentation but also help reduce global warming and save considerable resources. Consumers and utilities have a responsibility of using electricity wisely as a means of protecting both our environment and our economy. The current edition of the Masterbuilder attempts to provide you with valuable information on smart grids and our country's progress with it.
K.P Pradeep, Editor-in-Chief

editor@masterbuilder.co.in
Chembond Chemicals Limited
It pays to catch them young

teven Paul Jobs, an extraordinary visionary who died in 2011, once wrote, Everyone here has the sense that right now is one of those moments when we are influencing the future. Nothing else can come so close to describing the mood that currently prevails in Indian Construction Chemicals (CC) industry. Certainly the growth story for the Indian chemical industry remains bright. However, I am not going to use this opportunity to convey how, when and to what extent the industry will be growing but rather stick to some fundamentals in the hope that it gets the attention of all stakeholders. As India looks ahead to the 12th Plan post a slowdown, domestic CC companies across different segments are likely to face stiff competition either from imports or global giants manufacturing locally to serve the Indian market. There is no common solution to counter such competitive pressures as each segment has different critical success factors. Indian CC companies would do well to tailor their strategy depending upon the segment in which they operate and most importantly explore newer markets. A rough industry analysis estimates that construction chemicals are used in nearly 95% of concrete that is produced in the developed world. In India, the numbers are as low as 5%, which reflects the ground reality to us. It's a fact that an approximate 85% of the contracting community in India is not fully aware of the benefits of construction chemicals. Pointing finger to a specific reason for this strange mismatch is quite difficult. But certainly there can be a solution if we can 'catching 'em young' as they did in so many other spheres, such as sports and information technology. There have to be steps taken by the government to promote the study of chemistry, for that matter all streams of science, in a big way. The lopsided growth of education is one of the major worrying aspects of our growth story. There is an urgent need to promote the study of pure science. A student's natural inclination should be gauged at a relatively young age, around high school, and that inherent talent needs to be promoted. In moulding young minds lies the key. It is here that initiatives such as BASF's 'Kids Love Chemistry' could come-in handy. Attempts need to be made to make people appreciate the benefits of chemicals and the crucial importance of studying chemistry. Similarly, there has to be increased emphasis on the study of construction chemicals in civil engineering. CCMA, the new kid in the block, has surly set the ball rolling by arranging a series of roving seminars in colleges across India. Remember, these are the people who will be going straight to the job site in a couple of year's time. Once an engineering student knows about the importance of construction chemicals, he or she will not think twice before using them at the job site. The message that construction chemicals will help in, quite literally, building a stronger India is something that needs to be reiterated time and again, right from a relatively young age, so as to shorten the gap between the pace of growth of the construction industry and the knowledge and intent of the use of construction chemicals. Standardization and ushering in newer codes are key aspects that need to be promoted. It will also be a decisive moment in the industry if key decision makers vis--vis planners, designers, architects and consultants specify the use of construction chemicals in projects they are associated with. All stakeholders should realize that construction chemicals, ultimately at the end of the day help in building stronger structures. While they may add a fraction to the upfront project cost, it is good to remember that their use will add years to a building. What we need are real 'green' buildings and not the unsightly, countless number of moss coated green coloured buildings that dot our cities. I wish CCMA and its members the very best and look forward to knowing your views on the current edition. Warm Regards
Dr. Y P Kapoor
Director Editorial, Construction Chemicals
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The Masterbuilder - January 2012 www.masterbuilder.co.in
H & K Rolling Mill Engineers Pvt.Ltd
Contents
Editor's Comment........................ 8 Special Editorial...........................10

Construction Chemicals: Industry Analysis
Focus: A Challenging Phase Awaits the Construction Chemicals Industry
M.K. Prabhakar, Associate Editor
130
116 118 128 150 184 198 180 202 120 122 124
News & Events............................20 E-Scape.....................................248
40 48 52 62 70 80 88 92 98
Infrastructure: 12th Plan 12th Five Year Plan: The Road Ahead for Indian Infrastructure
The Masterbuilder, Bureau Report
CE: Site Report Ramky Sets World Record on Marini Plants 4000 tons of Green and Profitable Asphalt Produced in Less than 21 Hours Communication: Feature Conmat - World-Class Product Range Ensures Rapid Growth Waltair Enterprises: A Quality Range of Construction Fibres and Chemicals Sika: Celebrating 100 Years of Innovation Chembond Chemicals Ltd: Growing Steadily on the Back of Strong Quality Focus CICO Technologies: A Tradition of Excellence in Construction Chemicals Zydex Technologies: A Technology Beyond An Array of Sustainable Products & Solutions from Chatelier Infrastructure Services Interaction Industry Interaction: Optimistic About Continued Growth of Indian CE Market Insulator: New Rollout Supreme Introduces INSUflex, A High Vapour Resistant Insulator for Air-conditioning Flooring: Epoxy / PU Comprehensive Guidelines for Execution of Epoxy / PU Floorings
Bhavani Balakrishna
Realty: 2012 Outlook Real Estate Industry: Outlook for 2012 Regulation: MMDR Bill 2011 The Landmark MMDR Bill 2011: The Sanctity of Equity - Profiting Justly
Sadagopan Seshadri, Chief - Content Development, CE - Infrastructure - Environment
Environment: Climate Change The Durban Durbar Unfolds
Infrastructure: Electricity Network Understanding the Smart Grid

Bhavani Balakrishna
Infrastructure: Power Grid India's National Grid: Being Grid Wise
Infrastructure: International Project 'Silicon Valley' Transportation Plan 2035

Ground Engineering Subsurface Utility Engineering: An Overview

Bhavani Balakrishna
Ground Engineering: Seismic Isolators Technical Characteristics of Friction PendulumTM Bearings

Victor Zayas, Ph.D., P.E., President, Earthquake Protection Systems, Inc
40 52
12 The Masterbuilder - January 2012 www.masterbuilder.co.in
62
80
Case New Holland Equipment Pvt.Ltd
Contents
Concrete: Water-Reducing Admixture 142 New Generation Water-Reducing Admixture for Concrete
1
J. M. Khatib1, S Negim2, M Tarek Uddin3 School of Engineering and the Built Environment, University of Wolverhampton, 3 School of Chemical Sciences, University of Sains Malaysia, 2 Department of Civil Engineering, The University of Asia Pacific, Dhanmondi R/A, Dhaka 1209, Bangladesh,
Chemicals 192 Construction Zentrament F BV - High Early Strength Plasticizer Waterproofing: Preformed Waterstops 194 Preventing Water Leakage through Construction Joints using Preformed Waterstops
Interaction 154 Industry Interview: Mapping the future with Subu Venkataraman, MD, Sika India
Fibre Cement 204 Cladding: Fibre Cement Cladding A Sustainable Alternative for
Special Correspondent
Natural Wood and Vinyl Cladding
158 Interview: Gangadharan Manari, Managing Director, Cera-Chem 178

One-on-One with Sunny Surlaker, Head, Admixtures Division, MC-Bauchemie India Interaction 138 Industry In Conversation with Samir Surlaker President,
Topping: Technical Meet 208 White UltraTech Cement Conducts Technical Meet on White Topping Roofing: Industry Analysis 210 Roofing Industry: Manufacturing Sector Holds Key to Market Growth Solutions 218 Roofing: Alia Formtech: Ushering in a New Era in Roofing Systems System: Product Focus 222 Roofing Multi-Seam SSR System A Truly Innovative, Screw Less, Maintenance Free Roofing System
Construction Chemicals Manufacturers Association & Chairman, MC-Bauchemie India Pvt. Ltd.
156 Interaction Interview: M.A.Waheed, Chairman, Perma Construction Aids

Viscosity-Modifying Admixtures 160 Concrete: Overview of Viscosity Modifying Agent for Concrete
Sonjoy Deb, B.Tech.Civil. N.I.T.Silchar, Research Scholar, Indian Institute of Technology
Buildings: Roof Linting 234 Metal Roof Lift: New Concept Holds Immense Possibilities in India Steel: Corrosion Protection 238 Structural Corrosion Protection Methods of Structural Steel against
E. Daflou1*, E. Rakanta1*, G. Batis2* 1 Chemical Engineer, 2Professor *Chemical Engineering School, Section of Materials Science and Technology, National Technical University of Athens, Greece
Rehab: Prepacked Shotcrete 166 Repair Prepacked Shotcrete Admixture
Sonjoy Deb, B.Tech.Civil. N.I.T.Silchar, Research Scholar, Indian Institute of technology
Atmospheric Corrosion
172 Waterproofing A Review of Waterproofing Systems

Defence 180 Infrastructure: Fifty years of Heavy Vehicles Factory, Avadi Waterproofing 186 Basement Solutions to Basement Moisture Problems
WFS in Concrete 244 Investigation: Utilisation of Foundry Sand in Concrete Production

1
Sonjoy Deb, B.Tech.Civil. N.I.T.Silchar, Research Scholar, Indian Institute of Technology
J. M. Khatib1, S. Baig2, A Bougara3, E S Negim4, S Kenai5 School of Technology, University of Wolverhampton,UK 2 Jacobs Engineering, Barnards Inn, UK 3 Civil Engineering Department, Faculty of Engineering Sciences, University of Chlef, Algeria 4School of Chemical Sciences, University of Sains Malaysia, Malaysia, 5Department of Civil Engineering, University of Blida, Algeria
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Civi Chem & Applications Pvt Ltd
Contents
Advertisers Index
A
20 Microns Ltd 221 Gayatri Polymers & Geosynthetics Greaves Cotton Limited H & K Rolling Mill Engineers Pvt.Ltd. Hess Concrete Machinery India Pvt.Ltd. Hyderabad Industries Limited Hyundai Construction Equipment India Pvt.Ltd. Igloo Tiles Instruct- Bangalore JBA Concrete Solution Pvt. Ltd. JSW Serverfield Structures Ltd. Larsen & Toubro Ltd. Lipi Polymers Pvt.Ltd. Liugong India Pvt.Ltd. Machines & Engineering Company (MEC) Mangalore Chemical Fertilisers Marini India Pvt Ltd. (Fayat India) MB Corporate MB Subscription form Mc Bauchemie (India) Pvt. Ltd. Metecno India Pvt. Ltd. MM Castings Pvt Ltd. Multicolor Steels (India) Pvt Ltd. National Conference on Container Infrastructure in India 2012 (IBK Media) Nawa Engineers & Consultants Pvt Ltd. Neocrete Technologies Pvt.Ltd. Nina Concrete Systems Pvt Ltd. Nuha Construction 3rd International Conference on Construction Chemicals (FICCI) 197 Action Construction Equipment Ltd Alia Formtech Allen Buildwell Pvt. Ltd American Society of Civil Engineers (ASCE India Southern Region) Aquarius Technologies Pvt.Ltd Asia's Leading Rail Industry Gathering Asons Enterprise Atul Fasteners Ltd Baicon 2012 BASF India Limited Case New Holland Equipment Pvt.Ltd Cerachem Pvt.Ltd Chatelier Infrastructure Services Chembond Chemicals Limited Chetra Machinery India Pvt.Ltd. Choksey Chemicals Pvt. Ltd. CICO technologies Limited Civi Chem & Applications Pvt Ltd. Conmat System Pvt Ltd. Construction & Mining Machinery Expo (Commex'2012) Construction Chemicals Manufactures Association (CCMA) Cosmos Construction Machineries & Equipment (P) Ltd. Cosmos Sales Corporation Dextra India Pvt.Ltd. Durotop Construction Chemicals Pvt. Ltd. 91 217 83 233 31 203 97 107
G
229 6
Perma Construction Aids Pvt. Ltd. Pidilite Industries Ltd. Pioneer Caps & Slopes Pvt. Ltd. Modern Formwork Systems For Building Construction Reliance Industries Ltd. Relyon Facility Services Revathi Equipment Ltd. Roof India 2012 Roshan Lal Jain & Sons (Roljack Industries) Rotho -Robert Thomas Metall and Elektrowerke GmbH & Co. KG Schwing Stetter (India) Pvt Ltd. Silicone Concepts Int'l.Pvt.Ltd. Sleek Boards India Ltd. Soilmec Foundation Equipments Pvt. Ltd. Speedcrafts Ltd. STA Concrete Flooring Solutions STP Ltd. Tac System Formwork Sdn Bhd Techny Chemy The Supreme Industries Ltd.
225 Back inner 109
H
11 145\Back cover Front inner/ 33 5
O
207
R
177 229 67 209 171 221
I
55 241
B
237 159
J
103 2nd Wrapper
S
25 61 47 17 157 51/115 153
C
13 133 19 9 29 137 165 15 119 185 188/189 169 175
L
79 65 35
M
27 57 7 199 231 129 Front inner-2 87 212/213
T
181 95 37
Toshaniwal Systems & Instruments Pvt Ltd. 193
U
Unisteel Engineering Works United Steel and Structurals Pvt Ltd. Universal Construction Machinery & Equipment Ltd. Waltar Enterprises (Xetex) Wendt (India) Ltd. Wirtgen India Pvt.Ltd. Zydex Industries 43 77 123
N
247 101 69 141/151 229
D
225 229
W
219 219 23
E
Emerging Trends in Contract Management and Dispute Resolution 243 Esquire -CMAC Pvt.Ltd. 127
P
Pennar Engineered Building Systems Ltd. 73
Z
163
16
Soilmec Foundation Equipments Pvt. Ltd
Contents
Advertisers Index / Classification

AAC Hyderabad Industries Limited Concrete Batching Plant Apollo Infratech Pvt.Ltd Conmat System Pvt Ltd Revathi Equipment Ltd Schwing Stetter (India) Pvt Ltd Universal Construction Machinery & Equipment Ltd Concrete Block Making Machinery Hess Concrete Machinery India Pvt.Ltd 145/Back cover Machines & Engineering Company (MEC) 27 Concrete Core Cutting Wendt (India) Ltd Concrete-Precast Rotho -Robert Thomas Metall and Elektrowerke GmbH & Co. KG Construction Chemicals BASF India Limited 159 Cerachem Pvt.Ltd 133 Chatelier Infrastructure Services 19 Chembond Chemicals Limited 9 Choksey Chemicals Pvt. Ltd. 137 CICO technologies Limited 165 Durotop Construction Chemicals Pvt. Ltd. 229 Mangalore Chemical Fertilisers 57 Mc Bauchemie (India) Pvt. Ltd. 129 Nina Concrete Systems Pvt Ltd. 141/151 Nuha Construction 229 Perma Construction Aids Pvt. Ltd. 225 Pidilite Industries Ltd. Back Inner Silicone Concepts Int'l.Pvt.Ltd 61 STP Ltd 153 Techny Chemy 95 Waltar Enterprises (Xetex) 219 Zydex Industries 163 Construction Equipment & Machinery Action Construction Equipment Ltd. 91 Allen Buildwell Pvt. Ltd. 83 Apollo Infratech Pvt.Ltd 21 Aquarius Technologies Pvt.Ltd 31 Case New Holland Equipment Pvt.Ltd 13 Chetra Machinery India Pvt.Ltd 29 Conmat System Pvt Ltd 119 Cosmos Construction Machineries & Equipment (P) Ltd. 169/175 Esquire -CMAC Pvt.Ltd 127 Greaves Cotton Limited 6 Hyundai Construction Equipment India Pvt.Ltd 5 Liugong India Pvt.Ltd 35 Marini India Pvt Ltd. (Fayat India) 7 221 219 21 119 67 25 123 Front Inner/ 33 Revathi Equipment Ltd Schwing Stetter (India) Pvt Ltd Soilmec Foundation Equipments Pvt. Ltd. Speedcrafts Ltd Toshaniwal Systems & Instruments Pvt Ltd Unisteel Engineering Works Universal Construction Machinery & Equipment Ltd Wirtgen India Pvt.Ltd Crushing Nawa Engineers & Consultants Pvt Ltd. Roshan Lal Jain & Sons (Roljack Industries) ECC Larsen & Toubro Ltd Facility Services Relyon Facility Services Flooring JBA Concrete Solution Pvt. Ltd. Neocrete Technologies Pvt.Ltd Reliance Industries Ltd Silicone Concepts Int'l.Pvt.Ltd STA Concrete Flooring Solutions Formwork Tac System Formwork Sdn Bhd Geosynthetics Gayatri Polymers & Geosynthetics Green Building Products Hyderabad Industries Limited Metal Building / PEB Metecno India Pvt. Ltd Front inner-2 Pennar Engineered Building Systems Ltd 73 Multicolor Steels (India) Pvt Ltd 212&213 OEM MM Castings Pvt Ltd Paving Machinery Allen Buildwell Pvt. Ltd Repair & Rehabilation BASF India Limited Cerachem Pvt.Ltd Chatelier Infrastructure Services Chembond Chemicals Limited Choksey Chemicals Pvt. Ltd. CICO technologies Limited Durotop Construction Chemicals Pvt. Ltd. Mangalore Chemical Fertilisers Mc Bauchemie (India) Pvt. Ltd. Nina Concrete Systems Pvt Ltd. Nuha Construction Perma Construction Aids Pvt. Ltd. 159 133 19 9 137 165 229 57 129 141/151 229 225 83 87 Front inner/33 73 Pennar Engineered Building Systems Ltd 229 181 103 69 177 61 51/115 229 79 101 171 67 25 17 157 193 43 123 23 Pidilite Industries Ltd Silicone Concepts Int'l.Pvt.Ltd STP Ltd Techny Chemy Waltar Enterprises (Xetex) Zydex Industries Roofing Alia Formtech Lipi Polymers Pvt.Ltd Multicolor Steels (India) Pvt Ltd United Steel and Structurals Pvt Ltd Universal Construction Machinery & Equipment Ltd Roofing Fastners Asons Enterprise Atul Fasteners Ltd Roofing Tiles Pioneer Caps & Slopes Pvt. Ltd. Rubber Doors Sleek Boards India Ltd Scaffolding Cosmos Sales Corporation Silica Fumes 20 Microns Ltd Splicing Systems Dextra India Pvt.Ltd Steel Building JSW Serverfield Structures Ltd Thermal Insulation The Supreme Industries Ltd Tiles Manufacturers Igloo Tiles TMT-Technology Suppliers H & K Rolling Mill Engineers Pvt.Ltd Waterproofing BASF India Limited 159 Cerachem Pvt.Ltd 133 Chatelier Infrastructure Services 19 Chembond Chemicals Limited 9 Choksey Chemicals Pvt. Ltd. 137 Civi Chem & Applications Pvt Ltd 15 Durotop Construction Chemicals Pvt. Ltd. 229 Mc Bauchemie (India) Pvt. Ltd. 129 Nina Concrete Systems Pvt Ltd. 141/151 Nuha Construction 229 Perma Construction Aids Pvt. Ltd. 225 Pidilite Industries Ltd. Back inner Silicone Concepts Int'l.Pvt.Ltd 61 STP Ltd 153 Techny Chemy 95 Waltar Enterprises (Xetex) 219 Zydex Industries 163 11 55 37 2nd Wrapper 225 221 175 47 109 97 107 217 65 212&213 77 123 Back inner 61 95 219 163
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Chatelier Infrastructure Services
News & Events
CONSTRUCTION EQUIPMENT
Big Diggers could make their Debut in India Soon
provides "Quick Link" access to other Caterpillar learning resources. The release said that in the School of Safety, comprehensive training modules teach students the fundamentals of safety and hazard-avoidance when operating equipment, using aerial work platforms and working in confined spaces, as well as cautions to observe when working around asbestos, dangerous chemicals, compressed gases, and dust-combustible environments. First-aid courses teach specific procedures and policies for first responders. It further stated that for operators, the School of Operator Training provides application-specific courses for hydraulic excavators, off-highway trucks, track-type tractors, wheel loaders, and pipe layers. Supplemental materials include manuals, instruction sheets, and walk-around-inspection videos. The School of Service provides more than 90 courses that present the fundamentals of design, operation, and diagnostics for air conditioning, brakes, electrical, engine performance, engine repair, hydraulics, and powertrain systems. The release further added that customers could self-register at the CaterpillerUniversity.com site to gain access to the broad and expanding range of instructional materials, available at no cost or at a nominal creditcard fee. Learn more about Caterpillar University.com by contacting Caterpillar Learning@cat.com.
The spurt in mining sector in India could see the entry of the really big mean machines in the near future. A good example for one of these big diggers is the Bucyrus RH400 hydraulic shove, which comes with a shovel that can hold up to a whopping 94 tons. Incidentally the company was in the news a few months ago, when Caterpillar Inc had announced its acquisition of it, with the deal valued at approximately US$ 8.8 billion. The proposed new mining bill is expected to further open up the mining sector, which is expected to see the entry of several global big wigs into the fray. With completion expected to get intense, these mean machines could be making the difference, when it comes to holding an edge over the competition.
A Truly Versatile All-Wheel - Steer Loader
CE Major's Online Learning Platform

Caterpillar, a global leader in construction equipment has announced the launch of a new online learning platform. CaterpillarUniversity.com, a new online learning platform for all Cat machine and engine customers, is aimed at adding value to the Caterpillar customer's business, the company said in a recent press release meant for the North American region. With the launch of CaterpillarUniversity.com, customers have another tool for enhancing growth and profitability in their businesses. The new learning site (http:// www.caterpillaruniversity.com) offers three basic schools of study Safety, Operator Training, and Serviceand also
Product innovations are the name of the game in the construction equipment marketplace. Just a few weeks ago we had featured a news item wherein we had reported on an excavator that could double up as pipe laying equipment. A latest versatile all-wheel -steer loader is the latest in line when it comes to product innovation. The product the Wacker Neuson 750T from a global leader in earth-
moving equipment features a unique telescopic boom that provides it with extra reach up to 15 ft, which can be then used for dumping or stacking. This unique feature of the product makes it some sort of a cross between a wheel and a steer loader, adding to its versatility quotient. The machine also features a spacious and ergonomically designed cab, and is powered by a 60.3 hp Deutz diesel engine.
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Apollo Concrete Solutions
News & Events
INFRASTRUCTURE POWER
Series of New Power Projects Announced
taking off, facing a fate similar to that of several delayed power projects in the country. However, a recent news report in The Telegraph stated that the power major is expected to begin work on the project even though half of the land that is needed for the project is yet to be acquired. Interestingly the Chief Minister of the State Mamata Banerjee had earlier asked the public sector giant to buy the additional land on its own or build the plant on the land that it had been provided with, further added the report. The project had come into limelight due to the Chief Minister's statement. The state government's stand on land acquisition is being keenly watched by potential investors, a vast number of whom had expressed reservations about investing in the state, given the backdrop of the suffering of projects such as the Katwa power plant, according to industry analysts.
A series of new power projects have been planned by state-owned ONGC. According to a recent news report the PSU is also planning to set up a nuclear power plant. The IANS news report stated that the company would be setting up solar projects in the states of Gujarat and Rajasthan. The state of Rajasthan is also the choice of the company for its wind power project, said the report. Not only this, the company is also planning a LED manufacturing unit , for which the location has not been finalized and a gas-fired fertilizer plant in north eastern Tripura, its Chairman cum Managing Director, Mr.Sudhir Vasudeva has been quoted stating in the news report. The PSU giant seems to be emulating another power major, NTPC's deeds in the sense that the latter too had recently been announcing plans for renewable energy projects.
opment of the region. The Chief Secretary of Tripura, Dr.S.K.Panda has been quoted stating in a recent news report in Shillong Times that the first unit of the project would be put on trial operation by March 2011 and is expected to be fully operational by May 15. The mega power project is being one of the key power projects in the country. The Chief Secretary was also quoted stating in the news report that the decision about selling power to neighbouring Bangladesh would be decided by the Centre. Bangladesh has incidentally recently sought the expertise of Indian companies in setting up power plants in the country.
Huge Hydro Power Potential in North East

The North Eastern region of the country is fast becoming a favourite with developers looking for power projects. A recent press release from the Ministry of Power said that the North Eastern Region is blessed with enormous hydro-electric potential. Based on the studies for re-assessment of hydroelectric potential of the country, CEA has identified 58356 MW hydro capacity (above 25 MW) in North Eastern (NE) Region of the Country which constitutes about 40% of the total identified hydro capacity in the country. Presently, only about 1.98% of the identified potential (above 25 MW) has been developed in N.E. region, while another 7.96% is under various stages of development. The Minister of State for Power, Mr.K.C.Venugopal had provided this information in a written reply to a question in the Rajya Sabha. The official statement further added that stateowned NTPC was entrusted for preparation of Pre-Feasibility Report (PFR) of Siang Upper Hydro Power Project (9750
Power Plant Work to Begin Despite Land Hiccups
Power Project Delayed

The Ministry of Power has been coming under severe criticism from several quarters for the delays being faced in the case of several power projects. The first unit of the Palatana power project in Tripura is expected to be commissioned by May next year, instead of the earlier projected time of February 2011, according to a recent news report. The 726MW power project is expected to play a key role in the economic devel-
Even though there has been delay in acquiring land for the 1600 MW Katwa power plant in West Bengal, work on the project is expected to begin soon, according to a recent news report. The project being executed by stateowned NTPC, has been in the news recently for the inordinate delays in it
22
Wirtgen India Pvt.Ltd
News & Events
INFRASTRUCTURE
Hindu also stated how experts in the field had pointed out that the eligibility criteria that were put up as qualifying criteria for the bidding process were too ambitious. The project has been among the most ambitious infrastructure projects in Chennai, which is grappling with the issue of ever increasing traffic in recent times. The project has had its share of critics almost right from the day it was announced. There have been critics who had pointed out that there was no planning that went into choosing the route and that it was not integrated with the other modes of transport in the city. ways about having selected six exclusive corridors for high speed rail projects in the country.
ROADS
Minister Reiterates Commitment to Road Projects
MW) in Arunachal Pradesh which has been completed and submitted to the State Government. It also added that till date till date, the Government of Arunachal Pradesh has not given further direction for implementation of Upper Siang Hydro-Power Project by NTPC
Bullet Trains in India move a Step Closer to Reality

One of the areas in which neighbouring China has forged way ahead of India, or for that matter even several other developed western countries, is in the field of high-speed rail transport. China now has the world's most extensive bullet train routes covering, quite literally the length and breadth of the country. Bullet trains in India have though, remained a promise for a long time now, from the time of the NDA regime, when talks about a network spanning important cities in the country began to do the rounds. However, the latest visit of the Japanese Prime Minister, Mr.Yoshihiko Noda, and his talks with the Railway Minister, Mr.Dinesh Trivedi holds out some promise. According to a recent news report in The Indian Express, the Japanese Premier has expressed his country's willingness to help India with bullet train projects. The news comes close on the heels of earlier reports from the Ministry of RailThe Union Minister of Road Transport & Highways, Dr.C.P .Joshi has once again reiterated UPA government's commitment to improving the road network in the country. In his speech during the 11th Auto Expo Inaugural Ceremony, which was released by the Ministry of Road Transport & Highways, Dr.Joshi said that government has already announced plans of investing Rs 550 billion in highway construction projects this year alone its biggest investment so far. The projects will see the construction of 7,300 km of roads including the building of new expressways in addition to expanding existing roads. We have initiated the etendering process on highway projects to achieve more transparency in the bidding process. 15 highway construction projects totaling over $3 billion have been recently approved and bids for several more have already been invited. He further said, In the road transport sector, several initiatives have been taken by the Ministry for addressing delay and harassment in administrative procedures. The work of computerization of Road Transport Offices is almost complete, facilitating availability of complete database of information. The scheme for centralized database of
RAILWAYS
Will this Monorail Project See the Light of the Day?
The Mumbai monorail project was launched amidst much fanfare a few years ago. The project was in news earlier this year for a ghastly accident that claimed the lives of two people at the construction site. Things, however seems to be progressing at a fair clip as far as this project goes. It is now the Chennai monorail project that has come under increased media scrutiny, amidst reports that all is not well with the progress of the project. A recent news report has stated that the there were not enough eligible bidders for the project, which has come as a stumbling block. The news report in The
24
Schwing Stetter (India) Pvt Ltd
News & Events
INFRASTRUCTURE
driving licenses called Sarathi was introduced in July last year. Vahan, for vehicle registration, was also implemented simultaneously. Very soon these portals will facilitate online payment of taxes, fees and transport charges. The ministry had come under criticism from several quarters for the sluggish pace of some of the road projects in the country. Bangalore recently, according to a recent IANS news report. The group which will chalk out a plan for tackling issues related to transport and transport infrastructure in the country is being headed by Mr.Ashish Verma , an Assistant Professor in Civil Engineering and associate faculty at the Centre for Infrastructure, Sustainable Transportation, and Urban Planning (CiSTUP) of IISc, further added the news report. According to the news report the group of experts will be meeting once in two years and would be sending the conclusions reached in the conferences to both the Centre and state governments. For a country that has been grappling with traffic related problems for a long time now, the news could not have come at a better time.
Plan to Decongest Metropolis through New Road Network
the major weaknesses of India and a thorn in its economic growth path is the poor transport infrastructure of the country. Things however seem to be looking up on the front, with the formation of the Transport Research Group of India (TRG), according to recent news report. The group consisting of experts from various prestigious institutions of the country had held its first conference in
Land Acquisition Issue Impacts Highway Projects

There is some good news awaiting all those harassed Mumbaikers. There are plans afoot to decongest the city and its sprawling suburbs through the creation of a new road network, according to a recent news report. The Mumbai Metropolitan Region Development Authority (MMRDA) is planning to build an extensive road network in the megapolis, according to a recent news report in the Economic Times. The authority plans investment to the tune of `1, 512 crore for developing the 26 km road network, the report added further. One of the highlights of the plan is the proposal for the Eastern Freeway. The megacity, which is quite literally, bursting at its seams has been grappling with the problem of traffic chaos for a long time now. Plans like the latest one, along with the completion of the metro project are being eagerly awaited by the citizens of the city. Land acquisition has become a burning issue affecting the progress of several key infrastructure and even realty projects in many parts of the country. A senior official has now openly acknowledged the issue being a major hindrance to the progress of road projects in the country. The Chief General Manager of the National Highways Authority of India (NHAI), Mr.G.Suresh has been quoted stating in a recent Press Trust of India news report that land acquisition is a problem affecting many states. He also added that the states will have to deal with the problem. The issue had been earlier pointed out as one of the prime reasons for delays in highway projects by industry analysts. Apart from causing delays for new road projects, land acquisition has also been affecting road widening projects. With the Centre and NHAI embarking on an ambitious road building spree, it is one major hurdle that could prove to be a stumbling block for their ambitious plans.
Expert Group to Chalk out Strategy for Transport Infrastructure

One of the key factors that several experts have pointed out of being one of
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Machines & Engineering Company (MEC)
News & Events
INFRASTRUCTURE
New Tunnel Projects Planned
Tunnel projects in the Himalayan region are becoming more common place nowadays. The government is said to be planning another 11 tunnel projects in the region, which borders China and Pakistan, according to a latest news report. The tunnels will improve the road connective in the north Indian state of Uttarakahand, according to a recent news report in the Times of India. The Border Road Organization (BRO) would be in charge of building these tunnels, said the report. The tunnels would cover a distance of about 89 km and would help in mobilization of troops, apart from improving the connectivity in the state. There has been a spurt in tunnel projects in the country in the recent past. Tunnel construction is in fact one of the fastest growing areas in the construction industry in India, particularly with several metro projects planned and the tunnels planned in the Himalayan region for improving road connectivity. tourist destinations, the state government is expected to give further impetus to the completion of airport projects in the near future.
Navi Mumbai Project Cost may Increase
around ` 450 crore towards the project, further added the report. An airport in Jamshedpur has been a long pending demand of the people of the region. The airport is expected to further boost economic development in the vicinity of the city. Land acquisition has been one of the single biggest obstacles in speedy implementation of infrastructure projects in general, particularly in the case of airport projects. Project developers have now come out openly expressing apprehensions over the new bill increasing project costs , in some instances by several times. One of the projects where the cost could up is the much talked about Navi Mumbai airport project. Mr.A.M.Naik, CMD of L & T , an engineering and construction major, has been quoted stating in an Economic Times report about How are you going to ever put up a project, because the airport project cost will go up by ` 5,000 crore. The report further added that the top L & T official saying that the costs could go up because farmers would now expect the compensation package to go up 5-6 times, once the new legislation comes into force. Industry analysts believe that developers may back out of similar projects if the government does take steps to address the issue. The Navi Mumbai airport project is one of the most prestigious projects in the country, with several large consortiums interested in being involved with the project. The airport whose cost has been pegged at around `10, 000 crore is expected to help decongest the everincreasing air traffic to the metropolis once completed by around 2015.
Airport projects in Tamil Nadu gets the much needed push
AIR PORTS
Airport Project Only After DGCA Clearance

An airport in Jamshedpur has been for long a demand of the citizens of the steel city. The project looks like commencing soon with the Managing Director of Tata Steel being quoted in a recent press report that the project would take off only after getting the clearance for land acquisition from the Director General of Civil Aviation (DGCA). The senior official of Tata Steel, Mr.H.M.Nerukar was quoted stating further in the recent PTI news report that around 500 acres of land would be needed for the proposed airport project near Jamshedpur, which is popularity referred to as the steel city. The steel major will be investing an amount of Tamil Nadu with its various industrial and tourist destinations is considered a very important state in the aviation map of the country. The state government is reportedly giving much needed push to various projects in the aviation sector. The state government is handing over land for the expansion of airports to the Airports Authority of India (AAI), according to a recent news report. Land is to be provided for expansion of airports in places including Tuticorin, Madurai and Coimbatore. The state is also bracing up for a revamped and swanky Chennai Airport, which will have more retail space than before. With the state having several important
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Chetra Machinery India Pvt.Ltd
News & Events
CORPORATE
Adani Group makes History with Solar Power Project
year 2013 the 50 MW solar power from Rajgarh Solar PV shall be bundled with unallocated power from upcoming coal based stations of NTPC by Government of India. The PPA was signed by Mr. M.K.V. Rama Rao, Executive Director (Commercial), NTPC Ltd and Mr.P .K.Vaish, Managing Director, MP Tradeco in the presence of Mr.I.J.Kapoor, Director (Commercial), Mr.S.N.Ganguli (REDWest-II) and Mr.Mohammad Suleman, Secretary (Energy), Government of Madhya Pradesh and other senior officials from NTPC, Government of Madhya Pradesh and State Government utilities of the state. moderate wind regimes. The S97 wind turbine is part of Suzlon's newer S9X suite that features turbines that address increased customer demand for low to medium wind-speed machines.
L & T Bags Orders worth over ` 2056 cr

L & T Construction has bagged new orders valued over ` 2056 crore across different business segments during December 2011. A recent press release from the company said that the Water and Effluent Treatment business has bagged two major orders aggregating `1262 crore. One order has been secured from the Tamil Nadu Water Supply and Drainage Board for combined water supply scheme at various locations in Madurai, Sivagangai and Vellore districts in Tamil Nadu. Another major order has been received from Raipur Vikas Pradhikaran for the construction of underground storm water pipelines, sewerage, water supply and other associated works at Raipur.
Solar energy is fast becoming the preferred choice when it comes to alternate sources of energy in the country. Gujarat has well and truly taken the lead when it comes to solar energy projects in the country. A latest news report has once again reiterated the leadership position taken by the state. Adani Group has commissioned, what is claimed to be the country's largest solar power project in Kutch district, according to a recent PTI news report. The report added that the company intends to expand the capacity of the plant from the present 40 MW to 100 MW in future. With several parts of the country facing severe power crisis, there has been a spurt in the announcement of renewable energy projects in recent times, especially on the solar energy front.
Suzlon Wins 120 MW Order in Western USA
Suzlon Wind Energy Corp., the North American subsidiary of Suzlon Group, the leading global wind turbine maker, has announced the sale of 57 Suzlon S97.2.1 MW wind turbines for a large wind energy project located in the western United States. A recent press release from the company said that the procurement and manufacturing commenced immediately on contract execution, while roadwork and foundation construction will begin in the second quarter of 2012. Delivery of the Suzlon wind turbines is expected to occur in the third quarter with construction of the wind turbine slated for soon after the first turbines arrive on site. Commissioning of the power plant is scheduled for the last quarter of the Calendar Year 2012. According to estimates by the American Wind Energy Association (AWEA), a 120 MW project could delivery enough green energy to power up to 36,000 homes. The 120 MW site will be powered by 57 Suzlon S97-2.1 MW turbines, specifically designed to improve energy yields in low to
NTPC signs PPA for 50 MW Solar PV with MP
NTPC, the power major, has announced signing of Power Purchase Agreement (PPA) with MP Tradeco on in Bhopal , for supply of power from 50 MW Solar PV Power Plant to be set up at Rajgarh in the State of Madhya Pradesh on 28th December, according to a recent press release from the company. Expected to be commissioned by the
The release further added that in the Rail Infrastructure segment, new orders including additional orders aggregating `406 crore has been bagged from various clients. This includes a major order for the construction of a viaduct including electrical, signaling and telecommunication works between Villupuram- Virudhachalam- Ariyalur sections from the Rail Vikas Nigam Limited (RVNL)
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Aquarius Technologies Pvt.Ltd
News & Events
POLICY
Changes to Urban land Ceiling Act Possible in WB
all commercial institutions which were set up and being run on residential plots to vacate, since they were violating clauses of land use, said the recent news report in the Financial Express. The report said that this is the first time that the Noida Authority had sent official intimation to the banks and other commercial institutions. Express. The report added that the developers too on their part can approach the body in case of any issues. According to industry analysts the move by the Maharashtra government could make other states follow suit and come out with their versions of similar legislation in order to bring out more transparency in the real estate sector in their respective states and union territories.
Construction of 1020 Projects Approved under IHSDP

Soon after it came to power, the Mamata Banerjee government had been seen as anti-industry by several quarters because of the comments of some of its leaders on the land acquisition issue. There were even widespread fears of flight of investment from the state to other parts of the country. However, the government is finally acting and is expected to come out with changes to the Urban Land Ceiling Act (ULCA), according to a recent news report. The Trinamool Congress (TMC) government's new policy initiative, according to the news report in Business Standard, seeks to place information technology outside the purview of the Act. While there have been critics of the government on its stand on the land acquisition issue, it had been considered favorable to the IT industry in the state. In political circles the move is being seen as one that would repair at least some of the damage that has been done to the image of the government as being one that is not investor friendly.
The banks have however, submitted petitions to the apex court in order to give them more time for vacating, further added the report. It remains to be seen whether the apex court actually gives the banks more time to vacate their premises.
Housing Sector Regulatory Authority Approved by Maharashtra Cabinet
The Minister for Housing and Urban Poverty Alleviation, Ms.Kumari Selja has said that under the Integrated Housing and Slum Development Programme (IHSDP) component of the Jawaharlal Nehru National Urban Renewal Mission (JNNURM), total 1439 Detailed Project Reports (DPRs) have so far been received out of which 1020 projects have been approved for construction of 549862 houses and related infrastructure facilities. A recent press release from the Ministry of Housing and Urban Poverty Alleviation quoting the minister's written reply in the Lok Sabha said that the remaining DPRs have not been either approved for lack of availability of Central allocation for the concerned States/Union Territories or returned to concerned agencies/States/Union Territories for rectification of deficiencies. The release further said that no DPR is pending in the Ministry. The minister in her reply stated that completion of projects in cities/towns depends on the implementation schedule /capacity/financial resources available for projects by States /Implementing Agencies. No target has been fixed for any city/town.
Banks Asked to Vacate Plots in Noida

Banks and commercial institutions have been asked to vacate their residential plots by the Noida Authority, according to a recent news report. The authority has asked them to adhere to the intimation by February 4th. The Supreme Court had earlier asked
Setting up of a regulatory authority for the housing sector has remained a demand in several states for a long time now. Maharashtra has taken the lead and is now on the verge of setting up a regulatory authority for the same, according to a recent news report. The state Cabinet has given its go ahead for the setting up of such an authority in order to bring in transparency into the housing sector. Builders will now have to register their projects with the authority. The new legislation will also allow consumers to approach the authority in case of any issues, said the recent news report in the Financial
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Hyderabad Industries Limited
News & Events
REALTY NEWS
UP's Loss is Haryana's Gain in NCR
Polls and politics for long have had a direct impact on the real estate sector in India. With the Election Commission announcing the dates for the poll in several states in India, industry analysts feel that the sluggish growth of the realty sector could continue till new governments are formed in some of the key states. One state which is being watched keenly by leading realty developers is Uttar Pradesh. With polls expected to be conducted in phases in the state, the important realty markets of Noida, Lucknow and Kanpur are expected to witness glut, as far as sales are concerned till such time the polls are over. Similarly, the realty market in Punjab is also expected to pick up only after the forthcoming Assembly elections. The case with Goa also is no different, with the state having recently become a much sought after destination for developers trying to promote premium luxury residential projects. housing activities in the capital. The report said that pretty soon another new regulator could be replacing DDA and that the finance ministry is working towards the proposal. It remains to be seen as to how the top echelons of DDA react to the news. Industry analysts expect stiff opposition to any such move for the creation of a new authority in the national capital.
Residential and Commercial Realty along MRTS Planned
With property prices shooting up sharply in Noida, there has been increased focus on other suburbs in the National Capital Region (NCR), particularly those which fall under Haryana. While the new expressway project in Noida was expected to give boost to its realty market, the rising property prices in the city which falls under Uttar Pradesh has meant that developers are looking towards suburbs which fall under Haryana, for their new projects. One of the suburbs which have emerged as a recent favourite with developers is Faridabad. While it was always a popular destination for industries, off late several residential projects have been announced here, making it an alternate destination to the already crowded Gurgaon.
DDA's Wings may be clipped
The Mass Rapid Transit Systems (MRTS) of the Delhi- NCR have come under praise from several quarters. In fact the system adopted by Delhi Metro has become a benchmark of sort for other similar projects in the country. The latest development on the front could bring further cheers to the citizens of the capital. Both commercial, as well as residential development is being planned alongside the MRTS, according to a recent news report. Mr.G.S.Patnaik, Vice Chairman, DDA has been quoted stating in a recent Indian Express news report that the Delhi Metro Rail Corporation (DMRC) was carrying out surveys for developing such projects. The survey is being carried out along the MG Road metro line, said the report. Similar plans elsewhere in the world have borne mixed results. Several Asian cities have had success with decongesting traffic with similar projects in the recent past.
Forthcoming Assembly Elections may Impact Key Realty Markets
The buzz about setting up of a regulator for the housing sector has been gaining ground all over the country. While several other states are thinking on the lines of setting up new authorities, the powers of one authority which is already in existence may be curtailed, if news reports are to be believed. The authority in question is none other than the seemingly all power Delhi D e v e l o p m e n t A u t h o r i t y ( D DA ) . According to recent news report in the Economic Times the authority could soon lose its monitoring role over
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Liugong India Pvt.Ltd
News & Events
WORLD NEWS
Now it seems that despite all the protests against the project, a judge has given his consent for the project to go on. According to latest news reports about the project, popularly referred to as the 'Pandora ' dam project, Norte Energia, the company in charge of the construction has assured the judge that the project would not cause any harm to the fishes living in the Xingu river. The project had hogged international headlines after environmentalists had pointed out that it could potentially lead to damage of the fishing ecosystem and also have impact on the families who make a living out of fishing in the region.
Construction Industry Maintains Steady Growth in Latin America
The construction industry in the South American countries is growing at a steady rate, despite the global economic slowdown. While the forthcoming sporting events including the Soccer World Cup and the Olympics have been driving the construction industry in Brazil, in neighboring Argentina it is the inherent demand for infrastructure development that is being the steady growth.
Incidentally, the construction industry in North America had also shown some signs of recovery in the recent few months. The US construction spending had in fact risen 1.2 percent, more than the earlier estimated figures of 0.5 % during the month of November 2011. However, industry analysts feel that it is not yet time to celebrate, since these could be only temporary phases. lished the presence of UAE as an economy that is to be watched out, the Chinese are not to be left far behind. The world's second tallest skyscraper is getting ready in Shanghai. The foundation laying work has been completed for the Shanghai Tower, according to news reports. Apart from Shanghai, super tall structures are also being planned in other cities of China. Beijing for instance is another city where several high-rise projects have been planned.
New Bullet Train Projects in Japan
Foundation Work of Shanghai Tower Completed
Three new stretches of bullet train routes are expected to be constructed in Japan in the near future. The planning for these new stretches dates back to 1973 according to a recent news report. The construction of these projects is expected to start next year. The total construction cost of the projects is estimated to be around 3 trillion Yen, according to a recent news report in The Mainichi Daily News. The new lines are expected to give further boost to the economy of the region, apart from helping in decongesting vehicular traffic. Japan along with France was earlier considered the trendsetter when it comes to bullet train projects, a title that has been usurped by China in recent times.
Skyscrapers have been for long remained symbols of economic might. While earlier it was the US which had pioneered the concept of skyscrapers, with cities such as New York and Chicago setting the trend, it now seems to be the turn of Asian countries. While Burj Khalifa in Dubai had estab-
Despite Protests Judge Allows Dam Construction to Continue in Brazil

If readers may remember it was only recently that we had carried a news item wherein the protests against the proposed Belo Monte dam in Brazil.
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The Supreme Industries Ltd
Infrastructure 12th Plan
TH
FIVE YEAR PLAN

The Road Ahead for Indian Infrastructure
aster, sustainable and inclusive growth - this is the theme of the 12th Five Year Plan. With the previous five year plan coming to an end, the Planning Commission is revising its current approach paper. Similar to the 11th Five Year Plan, the thrust of the 12th Five Year Plan is on infrastructure and inclusive growth in the form of lower incidence of poverty, broadbased and significant improvement in healthcare facilities, universal access for children to school, increased access to higher education and improved standards of education including skill development. The Masterbuilder takes
a look at some of the key sectors that will be in the spotlight of the plan. As in the 11th plan, the 12th plan should continue to accelerate the pace of investment in infrastructure a critical element for faster, sustainable and inclusive growth. Construction, on average, accounts for more than half of the investment required for setting up critical infrastructure facilities like power projects, ports, railways, roads, bridges etc., given the high construction intensity in such projects. Infrastructure construction accounts for the maximum share (54.0 per cent) of construction activities. Industrial expansion contributes to 36.0
per cent of overall construction activity, and residential and commercial are at 5.0 per cent each. As India embarks upon an accelerated drive for infrastructure creation, it would be critical to enhance the capacity and capability of the construction sector. Ambitious plans for investment into various sectors of physical infrastructure are being prepared and the cumulative investment in infrastructure in the Twelfth Five Year Plan is targeted at around $1 trillion. Nearly half of this investment will be channelized into construction projects. To sustain the growth of the con-
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inadequate legislative support and enforcement that result in huge cost and time overruns for infrastructure projects. Implementing measures like the dispute resolution mechanism, standardization of contract documents for efficient and timely implementation of projects and streamlining levies like premiums and cess under the GST
IXth Plan
regime should provide some relief to the construction industry. In the 11th plan, the Government gave a huge emphasis on the National Highway Development Project (NHDP) with a target of 20 km per day. Of India's total road network of 34 lakh km, national highways account for 70,548 km and state highways 130,000 km.
Xth Plan XIth Plan XIIth Plan 9.0%Target 9.5%Target
1 2 3 4 5 6 7 6-7 8 9
Agriculture, Forestry & Fishing Mining & Quarrying Manufacturing Elect. Gas & Water Supply Construction Trade,Hotels & Restaurant Transport, Storage & Communication Trade, Hotels etc. + Transport, Communication, Storage Financing, Insurance, Real Estate & Business services Community, Social & Personal services Total GDP Industry Services
2.5 4.0 3.3 4.8 7.1 7.5 8.9 8.0 8.0 7.7 5.5 4.3 7.9
2.3 6.0 9.3 6.8 11.8 9.6 13.8 11.2 9.9 5.3 7.8 9.4 9.3
3.2* 4.7 7.7 6.4 7.8 7.0 12.5 9.9 10.7 9.4 8.2 7.4 10.0
4.0 8.0 9.8 8.5 10.0
4.2 8.5 11.5 9.0 11.0
11.0 10.0 8.0 9.0 9.6 10.0
11.2 10.5 8.0 9.5 10.9 10.0
Sectoral Growth Rates - Previous Plans and Target for Twelfth Plan
struction sector, a substantial addition (estimated to be about 4 million per annum) to the workforce is very necessary in the coming years. Hence, better managed processes are required for the development and deployment of human resources for this industry. The government should look at minimizing hindrances like delays in construction projects due to statutory clearances and permissions from multiple agencies, delays in land acquisition, lack of resource mobilization and inadequate integration between spatial planning proposals and economic development plans, and
Infrastructure projects accounts for the maximum share of construction activities in India
www.masterbuilder.co.in The Masterbuilder - January 2012
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Construction Intensity (%)
Construction Intensity (%)
Building Roads Bridges Dams, etc. Power Railways
76.0 63.0 65.0 75.0 38.0 78.0
Mineral Plant Medium Industry Transmission Urban Infrastructure Maintenance
18.0 20.0 22.0 66.0 81.0
Construction Components Involved in creation of Physical Infrastructure
File shot of protests against land acquisition in Maharashtra
2010 - 11*
2016-17@
Oil Of which imports Natural Gas & LNG Of which imports Coal Of which imports Lignite Hydro Of which imports Nuclear Renewables Total Energy Total Imports % of Total Energy
164.32 125.5 (76.4%) 57.99 10.99 (19%) 272.86 54 (19.8%) 9.52 10.31 0.48 (4.6%) 6.86 0.95 522.81 190.97 36.53
204.80 164.8 (80.5%) 87.22 24.8 (28.4%) 406.78 90 (22.1%) 14.00 14.85 0.52 (3.5%) 9.14 1.29 738.07 280.12 37.95
National Highways Authority of India (NHAI) planned to award 7,300 km this fiscal but in 2011, NHAI has completed only about 1400 km of the awarded 2,500 km of highways. These road development projects were largely delayed due to land acquisition issues and delay in award of tenders. Out of the 226 projects of NHAI, 56 projects are delayed due to non-acquisition of land. The availability of land has become a major bottleneck for expansion of infrastructure, development of mineral resources, industrialization and urbanization. The proposed Land Acquisition Bill is expected to provide some relief and help achieve these targets during the 12th year plan. Finalization of this legislation, with an appropriate balance between the need to protect the interests of current land owners and those dependent on it for livelihood and the broader objective of development, is critical. A GDP growth rate of 9% as estimated by the 12th Plan will require a growth rate of 6.5% in energy supply per year. Needless to say, meeting this demand will require expanding our domestic production in critical energy sub-sectors. Continued emphasis has to be placed on other renewable resources, especially on expanding wind power generation and in the emerging area of solar thermal and solar photovoltaic. The power sector many not reach the 11th plan target of 78.7 GW of additional capacity for grid power due to poor project implementation, inadequate domestic manufacturing capacity, shortage of power equipment, and slow-down due to lack of fuel, particularly coal. The 12th plan is targeting a capacity creation of about 100 GW. This is however only possible if the Government and industry can arrive at an effective resolution of issues holding up domestic production of coal and effective measures for improving financial health of power utilities. Getting Fundamentals Right While each sector has its own
Projected primary Commercial Energy Requirement (Million tonnes of oil equivqlent) Note: *Provisional data; @ On the assumption that annual demand/growth would be 6.5 percent up to 2016-17. the Figures include use of oil and gas feed stock for fertilizer and other non-energy usage.
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Unisteel Engineering Works
Coal Supply constraints has caused a slowdown in numerous power projects
demands, it is vital that the Government ensure through the 12th plan that the foundations of the country are strong for present and future sustainable and inclusive growth. These include: Quality Education Development of Skilled Workforce Research & Development and Innovation Good Governance Innovative Financing Options
Quality Education Despite the Shiksha Abhiyaan and the Right to Education (RTE) Act, 2009, the effort to expand educational access is severely constrained by the lack of suitably-qualified, appropriately-trained human resources in adequate numbers.
There are half a million vacancies of teachers in the country and another half a million teachers are required to meet the RTE norms on pupil-teacher ratio. Besides, 0.6 million teachers in the public school system are untrained. Focusing merely on Gross Enrolment Ratio (GER) is not enough. Statistics may indicate an increasing number of engineering colleges and students but sadly, the quality of education is declining across the country. In this line, the Central Government introduced a programme of creating new Central Universities and other institutions of higher learning in the Eleventh Plan. It must now further ensure that these Universities have updated curricula and qualified teachers with up-to-date
teaching methods if the efforts have to reach its full potential. State Universities suffer from under funding by State Governments with as many as 50.0 per cent of faculty positions unfilled, forcing frequent resort to contract teachers and an adverse impact on the quality of teaching. Faculty shortages need to be tackled through innovative ways such as technology-enabled learning, and collaborative information and communication technologies (ICT). Academic reforms should involve providing greater flexibility, choice and effective counseling for students and strengthening of research activity in universities by collaborating with the industry and other national and international academic and research institutions. This, to some extent, should limit the huge number of Indian students who continue to go abroad to pursue their research interests. Soft skills' training at university levels is another aspect which is completely ignored but is vital for the success of projects and teams. Development of Skilled Workforce Rapid growth in the construction and other sectors such as energy, healthcare and IT has been accompanied by shortages of specific skills and increasing rates of employee turnover. Much needs to be done in the area of skill development to adequately complement the potential expansion in the level of economic activity. The National Skill Development Corporation (NSDC) has been making some inroads but there is a need for concerted action
Statistics indicate an increasing number of engineering colleges and students. Collaboration between industry and Academia can provide greater flexibility to students
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Requirement of Human Resource for Construction (2022)
Engineers Technicians Support Staff Skilled Workers Unskilled / Semi skilled workers Total Manpower
3.72 million man years 4.32 million man years 3.65 million man years 23.35 million man years 56.96 million man years 92 million man years
in several key sectors in order to ensure that skill formation takes place in a demand driven manner. Curriculum for skill development has to be reoriented on a continuing basis to meet the demands of the employers / industry and align with the available selfemployment opportunities. Accreditation and certification system has to be improved. There is a need to establish an institutional mechanism for providing access to information on skill inventory and skill maps on a real-time basis. Skill Development Centres can be established in existing education and training institutions. This would ensure huge saving in cost and time. A system of funding poor people for skill development through direct financial aid or loan also needs to be put in place. Apprenticeship training as another mode for on-job training has to be remodelled to make it more effective and significantly up-scaled. Finally, vocational education at the school level and vocational training through Industrial Training Institutes (ITIs) and Industrial Training Centers (ITCs) need momentous expansion and overhaul. Research & Development and Innovation Despite Indian companies and individuals showing capacity for innovation, the level of R&D across sectors is abysmally low due to lack of a suitable platform for innovation such as improved infrastructure like reliable power and better logistics for transport and better financial access through development of institutions that can provide start-up finance for small and potentially innovative businesses. For instance, India's expenditure on
agricultural R&D and education is currently about 0.6 per cent of the GDP from agriculture and allied activities. The Government's proposal of Innovation Universities is commendable but it can bear good results only if it equipped with qualified faculty and research teams, up-to-date infrastructure, sufficient funding, greater autonomy and freedom and collaborations with research institutes, corporations, entrepreneurs and venture capitalists. Good Governance The Eleventh Plan had several programmes aimed at building rural and urban infrastructure and providing basic services with the objective of increasing inclusiveness and reducing poverty. Most of these programmes are Centrally Sponsored Schemes (CSS), which are implemented by State Government agencies, but are largely
funded by the Central Government with a defined State Government share. The total expenditure during the Eleventh Plan period is almost ` 700,000 crores. The effectiveness of their implementation varied from State to State. Factors like misuse of funds, duplication and poor implementation of schemes have not helped. It is essential that the 12th plan comes up with mechanisms and systems to ensure better implementation and improved accountability in order to have positive outcomes from the above-mentioned development schemes. Implementation of programmes can be improved by strengthening of local institutions, dovetailing efforts and coordinating across different agencies to facilitate progress in project implementation and using proper mechanisms to monitor the delivery and efficiency of these schemes. Misappropriation of funds has been a major cause of poor outcomes of these schemes. Establishment of an effective Lokpal, simplified judicial process, an effective RTI and the creation of a legislative framework governing the functioning of regulatory institutions that ensures both functional autonomy and accountability is crucial for translating the large outlays of the
NSDC Chairman M V Subbiah underlines how industry can partner the NSDC in transforming the country's skills landscape at a National Convention of CREDAI
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India's expenditure on agricultural R&D and education is currently about 0.6 per cent of the GDP
Poor implementation of CSS schemes by State Governments are a major cause of concern
Government's flagship programmes into enduring outcomes on the ground. Innovative Financing Options Efforts to attract private investment into infrastructure through the PPP route have met with considerable success, not only at the level of the Central Government, but also at the level of the individual States. Considerable progress has been made with PPPs in Power, Roads, Ports, Airports and Railways. Such projects may now also have to be taken up in other areas like education and health. Private and PPP investments are estimated to have accounted for a little over 30.0 per cent of total investment
in infrastructure in the Eleventh Plan. India has 1,017 PPP projects accounting for an investment of ` 486,603 crores. According to the Private Participation in Infrastructure database of the World Bank, India is second only to China in terms of number of PPP projects and in terms of investments, it is second to Brazil. Their share may have to rise to 50.0 per cent in the Twelfth Plan. There have been instances of PPP projects which were cancelled and renegotiated but the appointment of an independent regulator in several sectors and the setting up of dispute resolution mechanisms should give
added confidence to ease the adoption of PPPs as a model for infrastructure development. A Mckinsey report also suggest that the Government considers several policy reforms to stimulate capital flows into infrastructure such as allowing banks to raise resources through long term bonds exempt from statutory reserve requirements, easing norms for insurance companies and pension funds to invest in infrastructure assets. The government should also encourage direct financial participation in infrastructure through refinance support to infrastructure lending by commercial banks, credit enhancement of infrastructure instruments or direct investment in hybrid debt or equity issued by infrastructure companies through an Asset Management Company structure. Outlook Overall, the 12th Plan has a huge challenge in its hands. The country is on a growth wave, the citizens are getting more aware and empowered and calling for a total overhaul of the system. The Planning Commission itself admits that handing out subsidies and outlining schemes on paper is not sufficient. The current ad-hoc approach paper on the 12th plan touches on the above aspects but lacks concrete details. It is hoped that in the coming five years, the revised, new version will do much beyond what is mentioned in the approach paper.
Infrastructure through the PPP route have met with considerable success in India
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Sleek Boards India Ltd
Realty 2012 Outlook
Real Estate Industry: Outlook for 2012

Bhavani Balakrishna
n 2001, India's urban population, living in approximately 5,200 urban agglomerations, was about 285 million. It has increased to almost 380 million in 2011. Projections are that by 2030, out of a total population of 1.4 billion, over 600 million people may be living in urban areas. As a result, the new businesses and jobs created will require office spaces, retail outlets and residential development. Also, boom in organized retail is expected
to result in huge demand for real estate construction. However, the outlook for the real estate sector in the short term remains bleak. Year 2011 was witness to a global slowdown. While the rest of the world was following the crisis in Europe and the falling dollar, rising inflation rates in India caused the Reserve Bank of India to hike interest rates. Prices of steel, cement and labor, which together make for almost 75% of overall
construction cost, have risen by over 30% since 2009. Against a backdrop of tight and expensive credit scenario along with rising input costs, the Indian real estate sector had to bear the brunt. Increasing cost of debt and high construction costs and plunging sales have taken their toll on the profitability of real estate majors. The demand from the residential segment, the largest contributor to the demand for Indian real estate, remained lukewarm. Sales
48
Realty 2012 Outlook
and absorption across most cities in India were low due to prohibitive prices and high home loan rates. Developers were forced to offer discounts on their prices or other freebies to improve sales. The buyers kept expecting a price correction whereas the developers stuck to high property prices due to low margins. According to a recent Knight Frank research report, while residential property price appreciated between 10% - 30% in 2010 across major cities like Mumbai, NCR, Bangalore and Chennai, it declined by up to 10% in 2011. Also, there have been few new launches in year 2011. During 2010, 3,61,098 residential units were launched across the top 7 cities of Mumbai, NCR, Pune, Kolkata, Bangalore, Chennai and Hyderabad. However, in 2011 only 1,72,856 units were launched. This is a decline of 52% from the last year. Moreover, of the total housing inventory pertaining to the under construction projects, 39% or 3,06,859 units are lying unsold. A substantial portion of this unsold inventory belongs to the NCR market. Mumbai property market was even worse recording a sharp decline in the number of new project launches in 2011. Just about 19,470 units were launched in 2011 in comparison to the 54,968 housing units that were launched in the previous year. This decline of 65% fewer launches highlights the lack of buyer interest in the extremely expensive Mumbai property market. Moreover, 40,660 housing units or 32% of the inventory is lying unsold in the city. Demand for commercial office space, largely driven by the service industry like BFSI and IT/ITES, did not perform as well. Rentals in the top 7 cities remained under pressure as corporates trimmed hiring plans resulting in to reduced office space requirement. Of the total office stock of 367 mn.sq.ft. in these cities, 24% or almost 89 mn.sq.ft. remains vacant. NCR, Pune, Chennai and Kolkata have a high proportion of vacant stock followed by Mumbai and Bangalore. Hyderabad office market is
A view of a apartment project in NCR
relatively better placed in terms of the unoccupied stock. Majority of developers preferred to deliver committed projects, resulting in a dip in new launches. Small towns emerged as major hubs for residential realty. Liquidity crunch remained a sore eye for the Indian real estate industry in 2011. The rising cost of debt shot up added to the debt burden of real estate developers. Some of the market players even resorted to measures like scaling down their projects, selling off their nies
What is in store for the real estate sector in 2012 remains the biggest question. In terms of the residential segment, the deadlock between the buyers and developers should break in favour of buyers.
Pranab Dutta
Vice Chairman & Managing Director, Knight Frank India
non-core assets, selling stakes to private entities and offloading of unsold inventory at discounted prices. Banks adopted a cautious approach towards rescheduling debt or issuing fresh loans to real estate companies. With banks shutting their doors, the real estate firms turned to non-banking financial companies (NBFCs) for loans to pay for land, construction and predevelopment of projects. While banks usually lend to real estate firms at interest rates of 13-14%, NBFCs charge 16-20% and private equity (PE) firms seek returns of 24-30%. According to the Reserve Bank of India, the total lending to (commercial) real estate sector by mid-November stood at ` 117,000 crore. Between October 2010 and September 2011, according to a December report by IDFC Securities Ltd, lending by banks and non-banking financial companies (NBFCs) to real estate developers grew 14% to ` 1.6 trillion. Unlisted developers account for 62% of this sum. Any hope of PE funding as an alternate capital-raising option for real estate developers also appears to be fading. According to a report by Jones Lang LaSalle, there have been exits to the tune of $3 billion in the sector in the past four years. And as much as 83% of those have come in the past two years .
49
Realty 2012 Outlook
alone. Going forward, the industry is expected to face the $3 billion exit mark again for 2012, it adds. This implies that the real estate sector will continue to see net outflow of PE money. The near term outlook for residential real estate market in 2012 is likely to remain cautious, given the low market sentiments. Absorption and new launches are likely to remain low given the execution concerns. Developers may focus on execution and delivery of committed projects in 2012 instead of launching new projects to avoid insurmountable inventory overhang. Foreign direct investment (FDI) driven investment is expected to remain low while high debt levels remain a worry. If the proposal to allow 51% FDI in multibrand retail and 100% in single brand retail had been passed, the real estate developers in the retail space would have had something to look forward to.
State of residential property market City Unsold residential Units* Unsold inventory as a % of launched units
Bangalore Chennai Hyderabad Kolkata Mumbai NCR Pune Total
41,161 24,169 20,996 16,090 40,660 142,962 20,819 306,859
48% 40% 42% 46% 32% 40% 27% 39%
Source: Eyestate *Note: Residential projects with a size of INR 30 crores and above have been considered.
The implementation of the proposed Real Estate Regulation Bill that seeks to establish a regulatory oversight mechanism to enforce disclosure, fair practice and accountability in the real estate sector and provide adjudication machinery for speedy dispute redressal, should hopefully attract more foreign investment due to the transparency
A view of Oceanus Spandana Luxury Apartment at Kannur
and clarity that it will provide for investors and Private Equity players. Commenting on the prospects of the Indian real estate sector in 2012, Mr. Pranab Dutta, Vice Chairman & Managing Director, Knight Frank India says, What is in store for the real estate sector in 2012 remains the biggest question. In terms of the residential segment, the deadlock between the buyers and developers should break in favour of buyers. As this happens, the pent up demand from the section of buyers that are sitting on fence in anticipation of price correction would translate into improved fortunes for residential property market. Employment scenario, inflation and interest rate have a bearing on the overall sentiment of buyers. Since, houses are bought by people who are confident, these factors will have a role to play and hence cues from government action will be keenly observed. In terms of the commercial office market the performance of the service industry has a significant bearing. The slowdown in global economy which impacts the Indian BPO sector and muted expansion plan of domestic players will exert pressure on the commercial office property market. The commercial office market shall continue to remain subdued on account of weak global and domestic economic indicators. As policy deadlock breaks and reforms gather steam leasing activity shall improve however rentals will remain under check on account of a strong supply pipeline in major commercial centers.
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STA Concrete Flooring Solutions
Regulation MMDR Bill 2011
The Landmark MMDR Bill 2011: The Sanctity of Equity - Profiting Justly
Sadagopan Seshadri
Chief - Content Development, CE - Infrastructure - Environment
o regulate mining in India has been long overdue. The Mines Ministry felt the existing Mines and Minerals (Regulation and Development) Act, 1957, had already been amended several times and further amendments may not clearly reflect the objects
T
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emanating from the New National Mineral Policy. Rightly so, the central government has responded by replacing the over half-a-century old Mining Act by the Mines & Minerals (Development and Regulation) Bill, 2011. Introduced in Lok Sabha by Mines
Minister Dinsha Patel, the Mines & Minerals (Development and Regulation) Bill, 2011, there are several serious issues that the legislation promises to address, such as sharing of profits with project-affected people, environmental sustainability, competitive bidding to
an amount equal to the royalty that they pay to the state government annually. For those mining minor minerals like sandstone and marble, the states will decide the profit-sharing percentage in consultation with the proposed National Mining Regulatory Authority. As per the Bill, a Mineral Development Fund will be created in every district, in which profit and royalty shared by miners will be deposited and spent on the local population and area development, mines secretary S Vijay Kumar said. Apart from compensating project-affected people through profitsharing and royalty, the new Bill also obligates mining firms to pay a 10% cess to state governments and 2.5% to the Centre on the total royalty paid. Highlights of MMDR Bill Gives preference to tribal cooperatives for mining small deposits Suggests consultation with gram sabha or district council before granting mineral concessions and for mine closure plans. But does not give them power to veto a project Introduces a sustainable development framework under which a reserve can be exploited scientifically, keeping environmental concerns in mind Recommends setting up of special courts for hearing mining-related litigation at par with the civil courts Introduces auctioning of mineral concessions for proven reserves Expands the definition of project affected people. Apart from those who own the land, it includes those whose livelihoods and traditional land rights are affected. To ensure transparency in the system, the bill asks mining companies to put all data related to grant, extension, termination and plan of operations in the public domain
Twenty-year-old Anil Basnet pushes a coal cart, as he and a fellow worker pull coal out from the rat hole tunnel 300 ft below the surface on April 13, 2011 near the village of Latyrke near Lad Rymbai, in the district of Jaintia Hills, India. The Jaintia hills, located in India's far North East state of Meghalaya, miners descend to great depths on slippery, rickety wooden ladders. Children and adults squeeze into rat hole like tunnels in thousands of privately owned and unregulated mines, extracting coal with their hands or primitive tools and no safety equipment.
Image Courtesy: Daniel Berehulak/Getty Images
improve returns to States, and transparency in grant of permits. It also proposes setting up a National Mining Regulatory Authority at the Centre with power to detect, investigate and prosecute cases involving illegal mining.
The profit-sharing provision in the MMDR Bill of 2011 requires coal companies to share their net profit 26 percent every year with the affected communities. Companies that mine major minerals like limestone and iron ore will have to give the affected people
A gist of the provisions is cited at tables A & B The most logical idea was to create a system of granting equity (26 per cent) in companies. This would, as
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towards build local control over mining companies and shareholders with interests in sustainability. This is the first time the concept of natural resource rent is being established in the country. The MMDR Bill 2011 is a pointer towards inclusive growth by accounting the wealth of the nation in terms of its value to equity and sustainability. Need for Sharing Most of the country's mineral deposits are in regions that have most of its forests, tribal population and major river systems. The major mining districts of the country are not only ecologically devastated and polluted; they are also the poorest and most backward areas of the country. There is no dearth of examples. Keonjhar district of Odisha, for instance, produced over ` 7,000 crore worth of minerals, mainly iron ore, in 2009-10. Over 60 per cent of Keonjhar's population is BPL. It ranks 24th in the state's Human Development Index (HDI) of 2001. Koraput is another district in Odisha which produces 40
Table A: MMDR Bill 2011
"The Union Cabinet today approved the MMDR Bill, 2011, having provisions for 26% profit-sharing by coal miners and an amount equivalent to royalty by others with project- affected people"
Dinsha Patel
Mines Minister, Cabinet
per cent of the country's bauxite. Close to 78 per cent of population in the district is BPL. Similarly, Bellary in Karnataka, which has been in the limelight for illegal mining, produces about 20 per cent of India's iron ore. Most people here are impoverished; the district ranks third from bottom in the state HDI (See Figure 1).
Current Provisions
Proposed Provisions
Bhilwara of Rajasthan faces a similar fate. Producing over 80 per cent of India's zinc, Bhilwara ranks 25th in the HDI of Rajasthan. Cuddalore in Tamil Nadu produces three-fourth of India's lignite, while more than half of its population lives below the poverty line. By the reckoning of the Centre for Science and Environment (CSE), Delhi, the bill's profit-sharing provision will make around ` 10,500 crore a year available for the affected communities at the current level of mining. The calculation does not include minor minerals. However, the sum is seven times the budget of the Union Ministry of Tribal Affairs for 2011-12. About 86 per cent of the amount ` 9,000 crore will go to the top 50 mining districts, in terms of value of mineral production. Home to almost half the country's mining lease area, these districts are spread across Jharkhand, Odisha, Madhya Pradesh, Chhattisgarh, Andhra Pradesh and Maharashtra. With close to 2.5 million people directly affected by mining in these districts, the profit share translates to ` 38,000 per person a year, says Chandra Bhushan, deputy director general of CSE. This is about nine times the poverty line (` 4,380 a year for rural areas) in India. Unhappiness Unfounded
Royalty: Non-coal miners to share with local communities an amount equal to Government royalty. Coal miners to pay 26% of profit for benefit of local people. Bidding to be conducted for licences and leases National Mining Regulatory Authority to be set up at the Centre, with power to recommend prosecution Authorities can be set up in state level also Royalty based on market value of mineral and rate revised every 3 years
Allotment Mines allotted after MoUs between states and miners. India Bureau of Miners only acts as a technical regulator ensuring enforcement of Mines and Minerals (Regulation and Development) Act.
Regulator -
R K Sharma, Secretary General, Federation of Indian Mineral Industries (FIMI) says, We carry out corporate social responsibility voluntarily and this is how it should be. Making such mandatory conditions will only discourage investments in tribal areas and hamper their growth. This may lead to transfer of the additional burden to consumers, he adds. But an analysis of the annual reports of several mining companies shows the doubts of the industry are unfounded. Justified by all means Most mining companies, especially metallic and fuel minerals, make superprofits (see table 'Profit is still high'). Consider this. The profit to gross sales
Table1: Royalty Rates On Ores
Iron Copper Bauxite
10% of sale price on ad voleram basis 4.2% of the LME Copper price chargeable on the copper content of the ore 0.05% of the LME Aluminium price chargeable on the aluminium content of the ore
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Igloo Tiles
speedy trial of the offences relating to illegal mining. It empowers the central government to intervene in the cases of illegal mining wherever the respective state government fails to take action against illegal mining. The Domino Effect: Right down the line The GSI, IBM and all bodies under the MoM will be in for a grand overhaul with the new bill of 2011. This game plan is all about bringing the Indian mine and mineral industry fully toned up to international standards, latest technology use from prospecting, exploration to production in a sustainable and equitably shared manner among all stakeholders. The 12th Plan envisages implementing several of high feasibility high impact (HFHI) measures to spur up rapid growth. Some of the major thrust areas in the XII Five Year Plan are going to be: 1. GSI to complete geophysical and geochemical mapping expeditiously with the assistance of outsourcing and service contracts so as to develop potential areas for prospecting which can be competitively awarded for more detailed exploration and utilization of proved mineral resources. Geo-morphological and Lineament Mapping (GMM) on 1:50,000 scale by end of 2012-13. Complete National Geochemical mapping (NGCM) of the Obvious Geological Potential (OGP) areas by end of 12th Plan and rest of country of 13 Plan, with outsourcing and service contracts. Hyper Spectral Mapping (HSM) in OGP areas on 1:50,000 scale by end of 12Plan. (HFHI) 2. National Aeromagnetic Surveys by the GSI in collaboration with other stake holders in comprehensive and systematic manner for OGP by end of 12Plan and rest of the country (including off-shore) by end of 13th Plan. Conducting High risk exploration for deep-seated mineral deposits through modern technology infusion. Private sector will be facilitated to
Figure 1 Bellary produces 20 per cent of India's iron ore; most people here are poor (Photo: C.Bhushan)
ratio (the ratio of profit after tax, or PAT, to gross sales) of the National Mineral Development Corporation Ltd (NMDC) will go down from 55 per cent to 41 per cent post profit-sharing. That of Sesa Goa Limited (SGL), an iron ore miner, will go down from 40 per cent to 30 per cent. The ratio of Coal India Limited (CIL) will see a nominal dip, from 18 per cent to 14 per cent. The same stands true for companies with captive mines. Hindustan Zinc Limited (HZL), for instance, will see a drop in the profit to gross sales ratiofrom 44 per cent to 33 per cent post profitsharing. The ratio will dip from 14 per cent to 11 per cent for NALCO (National Aluminium Company Ltd), while that of Hindustan Copper Limited (HCL) will go down by three per cent once the profit-sharing provision comes into effect. (See Table B) People living in mining districts could certainly benefit from a share in these profits. It's unjustified to let them reel in poverty while displacing them from their own natural habitat to mine out treasures!! Making it Simple & transparent The Mines & Minerals (Development and Regulation) Bill, 2011 provides for a simple and transparent mechanism for grant of mining lease or prospecting licence through competitive bidding in
areas of known mineralisation, and on the basis of first-in-time in areas where mineralisation is not known. The draft Bill also seeks to establish a National Mining Regulatory Authority which would constitute a chairperson and not more than nine members to advise the government on rates of royalty, dead rent, benefit sharing with district mineral foundation. "It also provides for establishment of a National Mining Tribunal and State Mining Tribunals to exercise jurisdiction, powers and authority conferred on it," the Bill said. The Bill also seeks to empower the state governments to constitute special courts for the purpose of providing
We carry out corporate social responsibility and this is how it should be. Mandating profit-sharing will discourage investment"
R K Sharma, Secretary General,

Federation of Indian Mineral Industries
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Mangalore Chemical Fertilisers
Table B
Profit margin of mining companies (in ` crore)
PROFIT IS STILL HIGH
Company
Gross sales
PAT/gross sales Profit after PAT/gross MMDR provision PAT-MMDR (%) (after MMDR tax (PAT) sales (%) (26% of PAT) provision provision)
CIL GMDC MOIL NMDC SGL HCL HZL NALCO
52,188 1,066 966 6,230 6,654 1,430 6,142 5,311
9,623 280 466 3,447 2,639 155 2,728 814
18.44 26.27 48.24 55.33 39.66 10.84 44.42 15.33
2,502 73 121 896 686 40 709 212
7,121 207 345 2,551 1,953 115 2,019 602
13.64 19.44 35.7 40.94 29.35 8.02 32.87 11.34
Companies with captive mines
Source: CSE analysis as per the earlier version of MMDR Bill (based on annual reports of 2009-10) Abbreviations: GMDC-Gujarat Mineral Development Corporation, MOIL-Manganese Ore India Ltd
carry out exploration in LAPL for basemetal, gold and PGE, whereas GSI and MECL will also be strengthened to carry out exploration for PGE, technology metals, etc. (HFHI) 3. Prepare and implement project to enable 1:50,000 scale geological, geophysical, and geochemical maps to be served on internet in GIS platform in line with international practice. (HFHI) 4. Concession framework to be made more investor friendly through new legislations. Provide for independent Regulation of concessions and Legislations on Transferability of the mineral concessions. (HFHI)
5. Special attention needed for exploration and search for strategic, scarce and deficit minerals to reduce imports. 6. Create National Geophysical Data Repository and National Drill Core Repository to assist entrepreneurs to take-up exploration. 7. State Directorates of Mining and Geology to be developed to create facilities for concession system, mine plan and closure, sustainable mining practices (SDF) and stakeholder protection and royalty system. (HFHI) 8. Repositioning of MECL in promotional role for deep seated and concealed mineral deposit exploration using
HTREL (LAPL) under new MMDR Act. Facilitate capacity development of State Mineral Development Corporations and promote joint ventures in exploration with MECL and central PSUs and private sector. (HFHI) 9. Adoption of Globally acceptable reporting systems such as UNFC, JORC etc. for assessing mineral reserves/resources. (HFHI) 10. Develop beneficiation techniques for zero waste mining through R&D institutions. (HFHI) 11. GSI to complete purchase of Ocean Going Research Vessel (OGRV); Geotechnical Vessel(GTV) and Coastal Launch for offshore and coastal geosciences work.Create and enhance capacity of GSI and States for offshore / Coastal geosciences including Coastal geomorphology and beach sand / Tidal deposit resources.(HFHI) The Future Course: Sustainability, Technology and Conservation As prescribed by National Mineral Policy 2008, the development is made adhere to a path resulting in reserves / resources base augmentation by improving mining methods, beneficiation, utilization of low grade ores and rejects and
Figure 2 KALAHANDI - The tribals busy at a paddy field. In the background is Vedanta
Figure 3 Security beefed in Balitutha of Orissa to conduct anti Posco activists's agitation peacefully
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Continental Shelf). (HFHI) GSI will put to closely monitor the process of acquisition of a new multidisciplinary research vessel fitted with state-of-the-art scientific equipment (as replacement of R.V. Samudra Manthan) besides also procuring a new Geotechnical Vessel having drilling facility in shallow waters and down-thehole-tools for timely delivery. (HFHI) P unctual adherence to the Modernization Plan of GSI for procurement of various advanced equipment for the laboratories and research vessels is being planned. (HFHI) Attracting Investment A host of measures for making investment in mining sector profitable are on-going. A few major ones being undertaken are: GSI to prepare and implement the project under its Portal Phase IIII (OCBIS) to enable serving of 1:50,000 scale geological, geophysical and geochemical maps on Internet in GIS platform, in line with international practice. (HFHI) Implement project on Mining Tenement Registry and link up with State Land Records Database for digitized cadastral maps. IBM and 10 mineral rich States need to be enabled to upgrade their Hardware, Connectivity and Software for executing this project. (HFHI) Funding from World Bank during XII Plan is proposed to be around ` 265 crores for Technical Assistance particularly for knowledge upgradation in use of modern and sophisticated geophysical methods for regional mineral surveys; creation of a centre of Excellence for fundamental and multidisciplinary geosciences research; re-organizing The GSI Portal as a geodata service for a variety of societal and economic purposes; and developing the existing training infrastructure to evolve into a world class capacity Building centre [GSI-Training Institute, Regional Training Institutes and Field Training Centres]. [HFHI]
Figure 4 A file photo of mines where mining is in progress
recovery of associated minerals to achieve the national goal of zero waste mining.
This automatically means low volume high value minerals like gold, diamond, base metals, platinum group of minerals and rare earth elements are taken into plan's ambit. (HFHI) There has been hardly much discoveries of non-bulk surfacial deposits for quite sometime which is reason enough for exploring concealed mineral deposits. The pre requisite for this being a holistic multi-disciplinary approach, MECL is being suitably repositioned for exploration of concealed deposits. (HFHI) To achieve zero waste mining a coordinated effort in PPP mode between R & D institutions, the entrepreneurs, mining machinery manufactures and statutory bodies is considered the best resource pooling methodology. Finally, to meet the anticipated GDP growth without break, speedy exploitation
of the already proven and viable mineral deposits is essential. Best turn over can result through exhaustive mining for total exploitation of the resources as also simultaneous improvement in beneficiation techniques thus ensuring maximum utilization of low grade ores thereby reducing the wastage percentage and environmental degradation. (HFHI) Offshore Areas - The Need to know what lies yonder! Geo-Scientific Studies alone can reveal these secrets and future lies in off shore. The plan is to carryout close grid seabed mapping (geological, geophysical and geochemical) along with multi beam bathymetry, multi-channel seismic, magnetic, gravimetric, side scan, deep core sampling, dredge, heat probe etc. within EEZ (present as well as areas likely to be gained on delineation of outer limit of Legal
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Table C : Scheme-wise Estimated Plan Expenditure during the XII plan (2012 - 17)
(` in Lakh)
Schemes
2012-13
2013-14
2014-15
2015-16
2016-17
Total
Survey & Mapping (M-1) Mineral Exploration (M-II) Infrm.Dissm. (MIII+Pub& Adv) R&D (MIVA) Spl. Investigation (MIVB+Antarc) HRD (MV) Modernisation & Replacemt. (STSS) Total Grand Total
12412.52 5631.38 4058.03 2121.24 532.79 837.04 363000.00
13572.07 6183.04 4521.47 2746.95 573.98 908.19 43474.00
14618.40 6860.74 4988.72 3565.04 574.41 944.23 23848.64
15916.76 7635.20 5542.83 4195.13 620.86 1027.50 20826.01
16988.07 8476.11 6224.54 4702.43 629.03 1084.38 22006.42
73507.82 34786.47 25335.59 17330.79 2931.07 4801.34 146455.07
61893.00 71979.70 55400.18 55764.29 60110.98 305148.15 128200.00 433348.15
Outsourcing component for M-1
Indian Bureau of Mines (IBM) to be suitably modernized along scientific lines and strengthened to serve as single authority in all matters concerning mining (approvals, inspection and developmental) and environmental aspects, including forestry. Reservation of areas for government agencies to completely stop, except in exigencies of national security. (HFHI) Guarantee on Security of tenure should be given, and free transferability of concessions allowed without prior approval. (HFHI)
Internationally accepted 'first come- first served' principle, should be followed for grant of Concessions within a fixed time frames (3-4 months for RP and PL, and 56 months for ML) ensuring transparency in the transactions. (HFHI) To make the industry globally competitive all taxes, levies, royalties, duties to be rationalized. (HFHI)
For instance, POSCO and Vedanta Aluminium Ltd projects in Orissa have been delayed for quite some time due to opposition from local communities on fears of adverse social & Environmental impact. At present, royalty rates in India are calculated on ad volarem basis. The ad volarem system is based on value of a particular mineral with reference to international price. So, royalty is nothing but a percentage of the sale price of the mineral (grade-wise). Under this system, miners have to pay royalties, irrespective of profits or losses incurred. But the equitable positioning of all parties ensures transparency. Thus, the profit-based royalty assessment method tends to be detailed, reflecting all revenues and costs, including capital and recurring operating costs before arriving at profit for miners. Most mining companies in the developed world follow this method, which is transparent and based on the paying ability of the miner which ensures that all parties stand to gain. This equitable approach with owner communities too sharing the profits naturally becomes a Win- All situation!
Author's Bio
The author leads our Delhi bureau. An Engineer and qualified ADR professional (NALSAR alumnus), Sadagopan Seshadri has been a senior Contract Management Professional in large national & International Companies. His domain experience is in Building Products, Cement plants and Mega Power project execution. He is expert visiting faculty for Contract Management at the SSAA, IP University, New Delhi. Being passionate about Environment he has now turned to Landscape Projects design teamed with likeminded architects & engineers for sustainable landscapes development He is vocal with his views on these areas through his writings. He can be reached design2xcel@gmail.com at
Bringing Stakeholders' at par - A positive spin-off !: The Bill aims at resolving opposition from local communities, making it easier for mining projects to get approval from local communities.
Figure 5 Vedanta Aluminium - Jharsuguda, Orissa
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Silicone Concepts Int'l. Pvt.Ltd
Environment Climate Change
The Durban Durbar Unfolds

Sadagopan Seshadri
A deal to do a deal: 'Oxymoron Way' The Durban climate conference agreed a deal to agree a deal but quantum of work staring at the deal makers is tremendously huge. Ever since the disappointing Copenhagen climate summit, the 194 negotiating nations have stood indecisively for the past two years. The agreement to cut emissions of the greenhouse gases that cause global warming in an effective fashion has continued to be elusive with nations taking diametrically opposite stances on mode of ensuring realization of objectives. While some press for a global agreement legally binding on developed and developing countries alike, the others continued to shy away, by advocating nothing more than voluntary measures and good intentions, which as all know are backed by no guarantee thus being nothing more than a recipe for the whole world to be in Hot soup! In Durban, by a sheer quirk of fate, the world ended up opting for these opposites bundled in one agreement! That's why I call it The Oxymoron Way! After a night of high drama The Durban conference ended on Sunday Dec.11 with a last-minute deal whereby close to 200 developed and developing countries entered a deal for the first time to work on an agreement that should be legally binding on all parties, to be written by 2015 and to come into force after 2020. The EU and a few other developed countries signed up to a second commitment period of the Kyoto Protocol, that ends in 2013 to ensure presence of some form of legally binding treaty to cut carbon in place in the interim eight years before the new agreement comes into force at the end
COP17/CMP7 UNITED NATIONS

CLIMATE CHANGE CONFERENCE 2011
DURBAN, SOUTH AFRICA

As of now speculations on & doubts like Will Euro die faster than the Dollar? Will China now replace US as the new superpower? Are mundane matters & can take the back seat. The vital questions of the moment are: Now with COP 17 over, is Earth still headed for disaster? Does the 'Durban Platform' show that this is a cul-de-sac, a road to nowhere? Or there is still hope for the planet For 17 long years, representatives of nearly 200 countries gathered under the United Nations umbrella trying to deal with one of the most vexing questions of our era how to slow down the heating of the planet. But still conclusive measures on ground evade us. Although the NEED to restrict global warming is urgent and MEANS exist to avoid the catastrophe, it is Mankind's GREED that's blocking it!! Postponing resolutions and actions thereof, draws disaster only closer not push it away. 'The Durban durbar has come up to be termed by this COP as: The Durban platform. Can we hope to board the train to A safe Planet Earth from the Durban Platform? Here then, is what transpired in COP17.
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Figure 1: From left to right: UN Secretary-General Ban Ki-moon, President of South Africa Jacob Zuma, President of the Conference Maite Nkoana-Mashabane and UNFCC Deputy Executive Secretary Richard Kinley
of 2020. In any case, most of the developing world and the US remain in voluntary agreements to cut carbon until 2020. The UN and most of the countries present hailed the deal as a breakthrough as it opens up the serious prospect of a credible regime to bring global warming under control. The President of COP17 /CMP7 Maite Nkoana-Mashabane said: "What we have achieved in Durban will play a central role in saving tomorrow, today." The devil is in the detail The basic outcome itself was more than most expected, marking the second consecutive occasion after successful negotiations in Cancun, Mexico, just a year ago. The conference in this respect had its delegates and the world pleasantly surprised. But as rightly said, "The Durban platform provides an anodyne set of words, with much of the detail yet to be agreed and the teeth not really coming for eight years. The real challenge will be in agreeing the fine print." Getting an agreement that all countries sign up to will be intensely complicated. "No one should underestimate the difficulty of arriving at a legal agreement between the developed
and developing countries, let alone one that for the first time includes China, India, Europe and America. How real is the gigatonne gap? There continues to remain a considerable gap, which needs to be bridged, between how much carbon cut the world has pledged and extent of carbon emissions that have to come down if global warming has to be contained to sustainable levels. The UN puts this at six gigatonne gap over
the next decade, based on credible estimates by its commissioned group of more than 50 scientists to calculate the so-called 'gigatonne gap'. The report is candid enough to pronounce that for humanity to limit temperature rise to 2C (the threshold beyond which it could be catastrophic), the global emissions should peak at 44 gigatonnes of carbon dioxide equivalent (CO2e) by 2020. However, the best case scenario itself, where a global agreement is in place with massive renewable energy induction the world can do no better than 50Gt, leaving still a 6 gigatonnes to be bridged!! And with a business as usual approach, emissions will cross 56Gt; this would mean a spillover by 12 gigatonnes. The good news is that experts insist that this gigatonne gap can be bridged, if the world is prepared to even make a few changes in its conduct of food & energy production by resorting to clean sustainable method like Reducing energy waste, Using wind, solar and biofuels for energy production while cutting down emissions from intensive farming. This report was released a little before the COP17 in Durban. Ban Ki Moon, Secretary General of the UN, terms it as a message of hope. And as much, a clarion calls for action now!
Figure 2: The Baobab Tree at COP17 at Durban
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Business as usual 56 GtCO2e (55-59) 55

Power sector (2.2 - 3.9 GtCO2e)
REDD awaits green signal Reducing Emissions from Degradation and Deforestation (REDD) to continue lying on the table helplessly is another disturbing sight. The novel scheme to arrest low income economies from indiscrete deforestation by compensating them has hit the road block on account of lack of direction on how to raise cash as well of concerns that money from carbon markets could make it too corrupt and that indigenous people will be pushed out. REDD will have to be developed over the next few years as part of the new deal putting a full stop to deforestation, once and for all. Life isn't simple -- Neither are COPs
2020
Industry (1.5 - 4.6 GtCO2e) Transport (1.4 - 2.0 GtCO2e) Aviation & Shipping (0.3 -0.5 GtCO2e) Buildings (1.4-2.9 GtCO2e) Waste (about 0.8 GtCO2e)
50
20C range 45 Median estimate of level consistent with 20C: 44 GtCO2e (41 - 46) 40 2010 Time (years)
Forestry (1.3-4.2 GtCO2e)
Agriculture (1.1-4.3 GtCO2e)
Figure 3: How to Bridge the gap: Sectoral studies show the way
The magic number is two Stick to it! IPCC keeps returning to it. As said, temperature rise of 2C above preindustrial levels is now accepted to be the limit beyond which climate change becomes catastrophic and irreversible. For a 50:50 probability of conforming to it even, emissions must peak by 2020 at the latest and then also fall rapidly thereafter. Compared with 1990, Carbon output by mid-century should be halved IPCC 's fifth assessment report in 2014 based on an overwhelming research output is expected to clearly show, the alarming picture of the consequences of increasing human activity on global warming. This will come with a 'stern alarm raising' for an all out cut of GHGs compelling governments to raise the bar even higher. Pooling the money on the table Money's role will be significant for the cause. Developing countries have been promised $100bn a year by 2020, from rich countries and the private sector, in order to help them move to a green economy and cope with the effects of climate change. These are undoubtedly huge sums to be disbursed
and need crystal clear directions starting with the source of such sums. But as of now this too remains unclear. The details of the agreement are very vague. All that has been decided is that a body will be set up to distribute and manage the funds. It is not yet clear how the money will be raised. No plans to raise fund from a tax on shipping or aviation have been signed off.
Imagine the scenario where all the 200 odd nations sit down to work out a Per Capita formula by dividing up the cuts needed among the countries, according to emissions per head of population, or by also taking into account emissions per unit of economic output. Two decades down the road has shown that such elementary math will not work in these talks. The stands are complexly divided on matters that genuinely hurt individual or group interests. One key issue is historic emissions industrialized countries started burning fossil fuels earlier and
Figure 4: Ministers gather in a huddle during the Kyoto Protocol in Durban Photo: REUTERS
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Lipi Polymers Pvt. Ltd.
so bear responsibility for most of the CO2 already in the atmosphere. The developing ones now demand their opportunity for growth. Nevertheless, to balance some countries (like in EU) contributed more to reduce emissions than others. Japan has one of the most energy-efficient economies on the planet. These good Samaritans are sure to ask for credit for these actions. What credit would those with large forests serving to natural provide the invaluable service of absorbing carbon get? And there are those like Japan which on ethical grounds have pledged to phase out nuclear power, even when it does have coal power and may not even find enough renewable alternatives. Just how difficult it will be to resolve these issues was apparent in Durban. India's environment minister made an impassioned speech in the final hours in which she insisted that, "equity taking into account developing countries' economic capabilities, large populations still to be lifted out of poverty, and low responsibility for historic emissions must be the foundation of the negotiations". She said: "Equity is the centrepiece, it cannot be shifted. This
is not about India. Does fighting climate change mean we have to give up on equity?" And India made it clear that it is prepared to renegotiate the Durban COP if pushed on the issue any further. It was an impasse! China's minister Xie Zhenhua backed her up strongly. It looked certain to fail after India threatened to walk out. The emerging superpower was protesting against EU plans to force all countries to cut carbon emissions as part of a legally binding treaty. As the talks overran into the second night mirthlessly exhausted delegates were quite sure they may have to throw up their hands and go back home empty-handed. Just then in a highly unusual form of on-the-hoof diplomacy, the warring female ministers were forced to go into a public 'huddle' to find a resolution. The so called 10 minutes to save the world resulted in a form of words both parties could live with and relieved applause from the other 190 countries present. (See Figure 4) This way from the brink of collapse, talks got rescued by a last minute huddle between the EU and India to
create an historic deal to save the planet. (See Figure 5) The euphoria pervading the conclusion of talks was that the UN process had been vindicated, due to that fact that for years, the fundamental question of whether countries needed to sign a legally binding international treaty or could simply make national commitments that could later be changed so-called "pledge and review" has been solved, with all countries needing to sign a legally binding undertaking of compliance. At Durban, those arguing for a legally binding outcome won. "This is the end of pledge and review," said one senior diplomat from a developed nation. The next step will be on tangible numbers being frozen. These numbers have scientifically based consequences and negotiations on them will have to be consequence based. Now, what comes next? The next years will be witness to stormy sessions, and since each one of them can spring any surprise it will be foolhardy to predict the outcome in terms of carbon cuts. But since there is the Durban guarantee, that deals will have legal status, any agreement reached will have to be implemented. And the world can hope that one such agreement will be anyway reached. This hope emerges from the demonstration in Durban by all countries that they can, amid high emotions and livid exchanges, still keep bringing back to the negotiating table the issues for which they have assembled there in the first place. Durban was good enough for this reason too. A lot of work to freeze the agreement with the next UNFCCC meeting in Qatar 2012 starting negotiations towards the 2015 deal. These deliberations will include the kind of targets each country will sign up. There will also be discussion of carbon cuts for the EU and a few other countries under the second commitment period of the Kyoto Protocol. The rest of the world will be pushed to increase their targets to cut carbon through voluntary agreements
Figure 5: South African Foreign Affairs Minister and President of the 17th Conference of the Parties (COP17) Maite Nkoana-Mashabane (R) receives a standing ovation from Executive Director Christiana Figueres after the agreement was reached Photo: AFP/GETTY IMAGES
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Revathi Equipment Ltd
By mastering the challenging Durban agenda, governments can take a significant step towards a climate change regime that delivers on the ground".
Christiana Figueres
Executive Secretary UNFCCC
before 2020 through civil society and political pressure. Beware of these Stumbling blocks Equity -- Governments must agree country-by-country targets on emissions cuts, taking into consideration the historic emissions each is responsible for, the efforts on emissions each have made, their populations and how countries can continue to develop. Money -- Developing countries are demanding financial assistance to cut emissions and cope with the effects of climate change, but it is not clear where this will come from. The legal form-- The form of words settled on "an agreed outcome with legal force" means a legally binding commitment, say European Union EU's lawyers, but it is vague enough for countries to dispute. US elections--If a Republican becomes president next year, it may be impossible to negotiate a deal. Businesses -- What's in store? What has emerged is that Kyoto Protocol gets a second lease of life and will for the first time, include all the major emitters now to tackle climate change thus impacting many of the largest business operators around the world and many smaller, further down the supply chain. Businesses will see growth in business volume.
Further, with the second commitment period, starting from 2013, all of the treaty's rules, mechanisms and markets will remain in force. Hence, businesses can plan based on the premise that all market-based mechanisms such as the Clean Development Mechanism (CDM) will continue without break. With commitment to a new legal, global instrument in position by 2015 and operational by 2020, businesses can accordingly align themselves with prudent global strategies. Finally, COP17 at Durban made the commitment to develop a common system for measuring, reporting and verifying emissions reduction. Thus making accountability as prime criteria in business transaction has become the best assurance to investment entities as well as service providers. It makes key foundation for lending from the Green Climate Fund to be purely results-based. This provides for the private sector to invest at scale, based on an internationally accepted framework for evaluating achievement. The Green Climate Fund aims to mobilize US$100 billion annually to help developing nations reduce emissions and adapt to the effects of a warming climate. Absence of clarity on Business's role in the fund before COP17 has been put to rest. The Durban confirmation puts that the Fund will have a facility to fund private sector initiatives spurring up further public and private funds for public-private partnerships in developing nations acting as vehicles for sustainable growth. It means infrastructure development, growth of green industries, job creation, and poverty alleviation while tackling climate change. Business can see from Durban a clear signal that the international community is committed to taking the climate change agenda forward, that market-based mechanisms will continue and that there will be clear reporting guidelines. Politically right? Politically, Durban saw the emergence
"It may seem impossible, but working together we can all rise to our responsibilities"
Maite Nkoana-Mashabane
Minister of Foreign Affairs of S.Africa & President Designate of COP 17/CMP 7
of a strong coalition between the European Union and a large number of developing countries, coming together for a robust result that agreed to be bound by an all-encompassing legallybinding instrument. This perhaps is Durban's prime achievement, as with this basis, the numbers henceforth negotiated and committed for any parameter, be it pollution, time, and/or money will become legally enforceable. 2015: Will it be Icing on the cake If luck prevails, by 2015 the world will have left current economic crisis behind, thus creating more free space for all governments to make commitments that they will be able to keep with less strain on resources. Perhaps the negotiation climate would be more conducive to tackle climate change effectively as also address business needs. The 2015 deal will take place against the backdrop 2014 assessment by the scientific community engaged by UN. The report should give more clarity to business on status of actions taken and the makeup needed to keep temperature rises to below 2C. The Never say die spirit! The road ahead looks long and difficult, but as Nelson Mandela said, It always seems impossible until it's done.
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Neocrete Technologies Pvt.Ltd
Infrastructure Electricity Network
Understanding the Smart Grid

Bhavani Balakrishna
ndia now has the fifth largest electrical grid in the world and the world's third largest transmission & distribution network. Despite this, India has a power deficit of 12 percent with almost 300 million people living without electricity. Transmission losses amount to 1.5 percent of India's gross domestic product. According to the Ministry of Power, India's transmission and distribution losses are among the highest in the world, averaging 24 percent of total electricity production, and in some states it's as high as 62 percent. Aggregate Technical and Commercial (AT&C) losses largely reflect the poor state of the grid, low billing and collection efficiency, and power theft. Of the total power generated
in the country, only 50% is billed and only 41% of this is collected. Major challenges face India's grid including poorly planned distribution networks, overloaded systems, lack of regulation, inability to react to outages, pilferage of electricity and poor metering and billing systems. The power sector in India is expected to undergo a paradigm change, fueled by legislative and regulatory activities. The Ministry of Power has taken the gigantic task of mission Electricity for All by 2012. Therefore, it does not come as a surprise that India is already investing in the building of a modern, intelligent grid the Smart Grid.
The IEEE Standards Association, the standards development body of the Institute of Electrical and Electronics Engineers, predicts India would emerge as the world's third largest smart grid market after the United States and China. What is a Smart Grid? Smart Grid is the convergence of Information Technology (IT), communication technology and electrical infrastructure. A smart grid is an electricity network that uses digital and other advanced technologies to monitor and manage the transport of electricity from all generation sources to meet the varying electricity demands of end-users. Smart grids co-ordinate the needs and capabilities of all generators, grid operators, end-users and electricity market stakeholders to
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operate all parts of the system as efficiently as possible, minimizing costs and environmental impacts while maximizing system reliability, resilience and stability. The smart grid collects and analyzes data about power transmission, distribution, and consumption-in nearreal time, provides predictive information and recommendations to utilities, their suppliers, and customers on how best to manage power and promises a more efficient way of supplying and consuming energy. Increased connectivity in the smart grid gives consumers greater ability to control their power consumption and provides grid operators more visibility and control over power supply, its quality, and costs. Smart Grid Technologies & Applications The many smart grid technology areas each consisting of sets of individual technologies span the entire grid, from generation through transmission and distribution to various types of electricity consumers. However, not all technology areas need to be installed to increase the smartness of the grid. Utilities have already been implementing some of the key technologies such as supervisory control and data acquisition, automated meter reading and geographic information systems. The Smart Grid presents some primary benefits including lower operating and maintenance costs, lower peak demand, increased reliability and power quality, reduction in power theft and resultant revenue losses, reduction in carbon emissions and expansion of access to electricity. Smart Grids through demand response and load management reduce the per unit production cost. By reducing the peak demand, a Smart Grid can reduce the need for additional transmission lines. Research from Zpryme indicates that in 2015 India's smart grid market will be $1.9 billion. Further, Zpryme predicts the country's basic electrical infrastructure needs will grow beyond
1,400 1,200 1,000 800 600 400 200 0
Projected India Electricity Generation (in billion kilowatt hours) 2010 to 2015 l CAGR = 6.0% 999 1,056 1,117
1,187
885
941
2010
2011
2012
2013
2014
2015
that, totaling $5.9 billion in the same year. Smart grid does come with a cost. Utilities will experience both costs and savings in the deployment of smart grids, in the areas of operating and capital expenditure. But smart grids have the potential to reduce peak demand, better manage generation from both variable and dispatchable sources, and therefore reduce the potential increases in conventional infrastructure costs. Operating savings can come from decreased costs for maintenance, metering and billing, and fuel savings through increased efficiencies and other areas. Smart Grid in an Indian Environment Smart grids in India are likely to see many more challenges when compared to the ones being tried abroad. When the generation, transmission and
Smart appliances SMART GRID A vision for the future-anetwork Can shut off in response to of integrated microgrids that can frequency fluctuations. monitor and heal itself. Solar panels
distribution of power are carried out by a single utility, it is easier to integrate them and make the grid smarter. But in India, generation, distribution and transmission are mostly done by separate entities except in a few cases. The Government of India has identified distribution reforms as a key area to bring efficiency and commercial viability into the power sector. It has introduced multiple policies in the smart grid area including establishment of the Smart Grid Task Force, APDRP , R-APDRP initiative for distribution reform, DRUM India-Distribution Reform Upgrade, Management in four pilot sites (North Delhi, Bangalore, Gujarat, Maharashtra), BESCOM project in Bangalore towards Integration of renewable/distributed energy resources into grid, KEPCO a $10 Billion Smart Grid project in Kerala and others. The Restructured-Accelerated Power
Demand management
Use can be shifted to offpeak times to save money.
Houses Offices Processors Sensors

Detect fluctuations and disturbances, and can signal for areas to be isolated.
Disturbance in the grid
Execute special protection schemes in microseconds.
Storage
Energy generated at offpeak times could be stored in batteries for later use.
Isolated microgrid
Wind farm
Generators
Energy from small generators and solar panels can reduce overall demand on the grid.
Industrial plant
Central power plant
Smart Grid Prototype
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Development and Reform Program (R-APDRP) of 2008 intends to implement distribution reform and strengthen IT innovation in India. Split into two phases, the first concentrates on information and communications technology (ICT) and investments of power infrastructure to first measure and mitigate inefficiencies and theft. The second phase will focus on implementing changes based upon that data and power transfer systems with the broader goal of modernizing the electrical system as it is built. According to IEEE, the program is specifically designed to bring Aggregate Technical & Commercial (AT&C) losses below 15 percent in five years in urban and in high-density areas. In May 2010, the Ministry of Power (MoP) launched the India Smart Grid Forum with the aim of laying down a future roadmap for smart grid evolution in the country. The forum is a non-profit voluntary consortium, comprising both public and private stakeholders. The Indian Smart Grid Task Force headed by Mr.Sam Pitroda has five working groups to take up the different task related to SMART GRID activities i.e. trials/pilot on new technologies, loss reduction and theft, data gathering and analysis, power to rural areas and reliability & quality of power to urban areas, dist generation & renewable and
Technology Area Wide-area monitoring and control Information and communication technology integration Renewable and distributed generation integration Transmission enhancement Distribution grid management
Hardware Phasor measurement units (PMU) and other sensor equipment
Systems and Software Supervisory control and data acquisition (SCADA), wide-area monitoring systems (WAMS), wide-area adaptive protection, control and automation (WAAPCA), wide-area situational awareness (WASA) Enterprise resource planning software (ERP), customer information system (CIS
Communication equipment (Power line carrier, WIMAX, LTE, RF mesh network, cellular), routers, relays, switches, gateway, computers (servers) Power conditioning equipment for bulk power and grid support, communication and control hardware for generation and enabling storage technology Superconductors, Facts, HVDC Automated re-closers, switches and capacitors, remote controlled distributed generation and storage, transformer sensors, wire and cable sensors Smart meter, in-home displays, servers, relays Charging infrastructure, batteries, inverters Smart appliances, routers, in-home display, building automation systems, thermal accumulators, smart thermostat
Energy management system (EMS), distribution management system (DMS), SCADA, geographic information system (GIS) Network stability analysis, automatic recovery systems Geographic information system (GIS), distribution management system (DMS), outage management system (OMS), workforce management system (WMS) Meter data management system (MDMS) Energy billing, smart grid-to-vehicle charging (G2V) and discharging vehicleto-grid (V2G) methodologies Energy dashboards, energy management systems, energy applications for smart
Advanced metering infrastructure Electric vehicle charging infrastructure Customer-side systems
physical cyber security, standards and spectrum. The Minister of Power, Mr.Sushil Shinde said that Smart Grid envisages
The Union Power Minister, Shri Sushilkumar Shinde launching the India Smart Grid Forum, in New Delhi on May 26, 2010. The Advisor to Prime Minister on Public Information Infrastructure and Innovation, Shri Sam Pitroda is also seen.
providing choices to each and every customer for deciding the timing and amount of power consumption based upon the price of the power at a particular moment of time. He said that apart from providing choices to the consumer and motivating them to participate in the operations of the grid, causing energy efficiency and accommodating all generation and storage options, Smart Grid also envisages various properties for the Grid like self-healing and adaptive islanding. This all will enable electricity markets to flourish, ShriShinde added. IBM has partnered with India's Bureau of Energy Efficiency to create the country's first smart grid project. Together they will create a cost benefit analysis for smart grid activities as part of the National Mission for Enhanced Energy Efficiency (NMEEE).Through
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Pennar Engineered Building Systems Ltd
Revolutionising Pre-Engineered Buildings

Pennar Engineered Building Systems Ltd.
9th Floor (West Wing), DHFLVC Silicon Towers, Kondapur, Hyderabad - 500 084, Andhra Pradesh, India. T: +91 40 4021 0525 / 26 Email: contact@pebspennar.com
www.aakaram.com
Sales Offices: Hyderabad: T: +91 40 4021 0525 / 26, C: 0 9177333887 Guntur: C: 0 8008499258 Delhi: C: 0 9810053379 Bangalore: T: 080-40952351, C: 0 9008155224 Kolkata: C: 0 9433034747 Mumbai: T: 022-41237383, C: 0 9930989117 Chennai: T: 044-42318214, C: 0 9500007216 Nagpur: T: 0712-2552832, C: 0 9822225055 Ahmedabad: C: 0 9825927096 Jamshedpur: C: 0 9955998349 Pune: C: 0 8600529415 www.pebspennar.com
APPROVED
India Smart Grid Market Value by Technology Area 2011 and 2015 (In U.S. millions) (figure 1, source: zpryme) $500 $400 $300 $200 $137 $100 $0 $446 $392 $339 $287 $247 $236 $145 $289 $234
Software & Hardware
Smart Meters 2011
Sensors 2015
Comm.& Wireless Infrastructure
Smart T&D Equipment
this project, IBM plans to apply its deep services expertise to help determine smart grid readiness in India. The company will lay out a strategic assessment framework with an Indian perspective that looks at the adoption of new smart grid technologies, and identifies alignments in policy and regulatory frameworks to make each solution possible. It will help BEE determine global smart grid potential and also create toolkits for regulators and utilities for assessing benefits of smart grid investment decisions. As a part of this collaboration, IBM will generate the smart grid business case and tools that will help calculate the return on investment for all smart grid projects being rolled out country-wide and also within the ISGAN (International Smart Grid Action Network), of which BEE is a member. Indirect measures prescribed by the Electricity Act 2007 are expected to drive smart metering installations forward. Various pilots have been undertaken or are being implemented by state governments and private players. North Delhi Power Limited (NDPL), a joint venture between Tata Power and the Delhi government, is taking a leading role in smart initiatives in India. The NDPL project in Delhi involved installation of smart meters in about 500 households in select localities of Delhi. In Aug 2011, US Trade and Development Agency (USTDA) extended a grant of USD 0.6 Million to NDPL for
Implementation of Smart Grid Technology. NDPL is presently working on several new projects including the possible deployment of an Advanced Metering Infrastructure (AMI) which will allow remote management of metering
We welcome the association with USTDA. The smart grid solutions are designed to enhance the efficiency and reliability of power distribution and to increase the ability of consumers to manage and use energy in a more cost-effective and energy-efficient way. It will also enable us to optimize our power line grid planning, operations and maintenance, enabling us to deliver power more efficiently. We also expect the technology to contribute to fewer and shorter outages and increase reliability.
Sunil Wadhwa, Managing Director, NDPL
services and automated meter reading with two way communication with consumers. The new technology will enable consumers to better manage their energy use by providing more detailed and online information about their consumption with the opportunity to actively optimize consumption and reduce greenhouse gas emission as well as their overall cost of energy consumption. Said, Sunil Wadhwa, Managing Director, NDPL, We welcome the association with USTDA. The smart grid solutions are designed to enhance the efficiency and reliability of power distribution and to increase the ability of consumers to manage and use energy in a more cost-effective and energyefficient way. It will also enable us to optimize our power line grid planning, operations and maintenance, enabling us to deliver power more efficiently. We also expect the technology to contribute to fewer and shorter outages and increase reliability. In November 2010, a pilot project involving installation of about 700 meters in Hyderabad, Andhra Pradesh was announced. The pilot is being undertaken by the Central Power Distribution Company. The meters installed will be based on Radio Frequency (RF) technology. These meters will be first tested in a few selected areas and depending upon their successful functioning, the installation would be extended to highloss and VIP areas. The new meters will preclude the necessity of the department personnel entering the consumer's premises and taking down the figures of power consumption. Instead, the meters will automatically generate the figures upon receiving a radio signal from the transceiver encapsulated in the Spot Billing Machine (SBM) on the other end. The SBM, a hand-held device, will use radio frequencies to draw the readings once the person enters its pre-designated geographical range. Each hand-held device will be assigned around 1,000 meters grouped according to their geographical
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United Steel and Structurals Pvt Ltd
A BESCOM Employee generating a smart bill
location. The devices would already have a database of meter IDs and service numbers. Once the person enters the area and sends a request, the meters will start generating the readings automatically. The system will prevent power thefts apart from solving the problems pertaining to locked doors and forbidden entry for the department personnel, informed officials. Also in Delhi, Grinpal Energy Management is deploying smart meters and advanced metering infrastructure. Reliance has been using smart meters for its users since the last three years. They offer smart meters for home installation which allow users to track their electricity usage with the help of Google. Having around 20,000 subscribers, these smart meters make use of a communication port connected to a communication center, and can track events at remote locations from a central location. The central location can then in turn monitor efficient electricity consumption. Thus, smart meters have input and output functions. Consumers will be able to reduce their energy use by remotely switching off devices when not in use and by minimizing their overall energy use to crucial devices at times of peak load or low supply. With increased interactivity
between the consumer and utility, enabled by a smart meter, it is also possible for the utility to improve load management on the grid and for the consumer to save money. BESCOM plans to introduce Smart Meters that will give Bangaloreans the option to monitor and control their power consumption online. The consumer interface unit (CIU), displays power consumed in real time, thus helping consumers to monitor each one of the appliances for power consumption. Statistics abroad have shown that smart meters have helped consumers reduce their bills by 15 to 20 per cent. The Mangalore Electricity Supply
Reliance Energy deploys Google PowerMeter software to help consumers to save energy and cut electricity bills
Company (MESCOM) smart grid project, first of its kind in the state, enables Mescom to remotely control load of consumers using their existing static meters without restoring to load shedding. It is presently being tried out for 60 consumers and used to control 87 streetlights. The meters of 30 consumers in an apartment, 30 installations in industrial estate, and streetlights are connected to distribution transformer centres (DTC) from which real time data can be read at regular intervals. Each time Mescom receives a directive from load dispatch centre to reduce consumption during peak hours, the server of the smart grid located will send out alert to consumers connected to the grid to reduce their load in use. Supported by the Ministry of New and Renewable Energy of the Government of India, Ecolibrium is a smart-grid startup aimed at enabling consumers to manage power consumption in real-time. At present smart meters in India use GSM and GPRS based data acquisition systems, which increase the cost of each node, as each node requires a SIM card and GSM network access. Ecolibrium has reduced the cost of each node by developing Zigbee, a free radio frequency network-based proprietary device, which tracks real-time energy consumption and can also control the switch on/off function from an online portal or from a cell phone. The company offers solutions for automated metering which enables consumers to track generation of electricity from any distributed source in real-time. There is a huge demand for power grids that are energy efficient, intelligent and secure. Through this collaboration with BEE, our aim is to help overcome inefficiencies in the existing grid and move toward more sustainable energy networks, said Avinash V Joshi, Director, Communications Sector, IBM India/South Asia. The anticipated growth of the Indian power sector is substantial and this project will advance smart grid adoption across the country.
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Larsen & Toubro Ltd.
Infrastructure Power Grid
India's National Grid:

Being Grid Wise
Sadagopan Seshadri
Power for All With inclusive growth in perspective Indian Government has embarked on a strategic action plan to provide power to all. Bridging the existing gap between demand and supply while ensuring that the future requirements are also met, translates into a need to target for an installed capacity of about 275 GW by 2017. The capacity addition required during the 12th Plan will be about 75,715 MW (excluding capacity addition through renewable sources) in the thermal, hydro & nuclear sector during 12th. Five year plan, details of tentative yearwise phasing are as shown at Table 1. A capacity addition of about 94,400 MW has been tentatively projected for the 13th Plan period. Eternal Partners need to be at par Generation Capacities are as good enough as they are complemented with an evacuation facility in the form of Transmission & Distribution (T & D) Infrastructure. Both need to be in Sync to be able to reach the final consumer and be efficient enough in delivering his energy needs with minimum of
transmission & distribution losses enroute. Otherwise he ends up paying a bomb in terms of energy bills! India's demand for electricity sharply exceeded supply in recent years, with a peak power deficit being over 12 per cent in 2010. The increasing generating capacity has not been matched by transmission network. Some states have the capacity to generate more power than they need, while others are short of supply. Creating interregional transmission corridors is a step towards moving surplus electricity to areas with power deficit. National power grid to be ready by 2014 To improve transmission of power across the country, India plans to connect all regional grids into a national grid by 2014. Of the five regional grids in the country northern, southern, eastern, northeastern and western all except the southern one are interconnected. By 2013-14, all the grids will be interconnected for synchronous operations, says power secretary P . Uma Shankar. This will enable the transfer of huge amounts of electricity from one part of the country to another as required.
Easier said than done Truly said! But prompt action is underway. A national grid has been mooted to meet power demand across the country through a seamless transmission of power. This would mean an uninterrupted power supply by demand responsive dynamic mechanism. There are very many challenges to be overcome in the Indian case starting from a century old T&D infrastructure, fluctuating frequencies, pilferage, Energy mix, geographical & terrain constraints, to name just a few. More than half of India's rural population is not connected to the grid. Technical issues tormenting India's grid, surface as line losses averaging
TABLE 1: Generation Capacity Addition XII Plan Projection (Figures in MW)

Capacity Addition Projection for 12th plan* Type 2012/13 2013/14 2014/15 2015/16 2016/17 Total
Hydro Coal Gas Thermal Nuclear Total
1895 17385 1086 18471 0 20366
3875 18975 0 18975 0 22850
2405 14905 0 14905 0 17310
429 6080 0 6080 1400 7909
600 5280 0 5280 1400 7280
9204 62625 1086 63711 2800 75715
* Yearwise capacity addition plan from 'Renewable' not included
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26 percent, with some states tanking 62 percent!! On factoring in, the country's staggering electrical theft line losses reach a whopping 50 percent! The average frequency of the northern, eastern, northeastern and western interconnected grids is 49.86Hz; the southern grid's frequency is 49.8Hz. Global standards require that grid frequency be kept close to 50Hz. In India Grid frequency fluctuates anywhere from below 48Hz to above 52Hz. The mildest result is poor power quality. The energy mix presents a huge thermal power generation potential in the East and an equally large hydropower potential in the NorthEast warranting the need for a common
A National Grid will enable to reduce costs translating to possible lower tariffs. ` 1.4 trillion is earmarked towards setting up a national power transmission grid enhancing interregional transmission capacity to 32,000 MW by 2012. it is proposed to add 100,000MW during the 12th Plan period (2012-17) to the power generation capacity of 182,345 MW. Power Grid Corp. of India Ltd (PGCIL) the central transmission utility operates 86,000 circuit kilometres of transmission lines maintaining grid discipline supervising optimum scheduling and electricity delivery. There are 33 state load dispatch centres, five Rural load dispatch centres (RLDCs) and one national load dispatch centre (LDCs). PGCIL supervises 116 major substations
across states. A spend of 32 pc (` 17,700 crore) is planned as capital expenditure (capex) with New transmission capacity, worth 18,000 mva, addition envisaged in 2011-12. XII Plan (2012-17) The Transmission Program Interregional transmission capacity program: The interregional transmission capacity of all India grid at the end of XI Plan will be 25,650 MW. During XII Plan period a number of inter regional transmission links either associated with generation projects or as system strengthening schemes are planned and would be implemented as associated generating stations readiness. Inter-
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projects are put in place in XII plan or early XIII plan. HVDC transmission system growth (up to XII / early XIII Plan period): During XI Plan, BaliaBhiwadi 2500 MW HVDC Bipole and upgradation of Talcher Kolar Bipole by 500 MW has been completed. Another HVDC bipole as dedicated transmission line, i.e. Mundra Mohindergarh 2500 MW being constructed under private sector by Adani group is expected to be completed within XI Plan period. Three more HVDC systems have been planned for completion during XII Plan or early XIII Plan. 1200kV transmission system
Power-transmission cable system used in commercial power grid
The AurangabadWardha 400 kV Quad D/C line is part of the transmission system for evacuation of power from Mundra UMPP line would be converted into a 1200kV S/C line at a later date. Transmission schemes planned for XII Plan For XII Plan period, a total of about 1,09,000 circuit kilometers (ckm) of transmission lines, 2,70,000 MVA of AC transformation capacity and 13,000 MW of HVDC systems are estimated to be added. Development of the transmission system in XI Plan and that expected to be added during XII are shown in Table 2. These projections consider 76,000 MW generation capacity addition for XII Plan over and above the 62,374 MW capacity addition target of XI Plan:
Power theft account for a significant portion of T&D loss in the country
By 2013-14, all the grids will be interconnected for synchronous operations
regional transmission capacity at XII Plan end will be 63,000 MW. 765kV transmission system growth (up to XII / early XIII Plan period): The XI Plan added a number of 765kV lines and substations with a few more are under construction. New 765kV lines and substations have been
planned for evacuation of bulk power in the range of 3000 - 6000 MW over longer distances. These planned 765kV transmission systems are expected to be implemented during XII Plan or early XIII Plan period. Of these some 765 kV systems will be initially operated at 400 kV with the 765 kV operation commencing once their associated generation
P. Uma Shankar
Secretary, Power
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Allen Buildwell Pvt. Ltd
including smart meters, software and hardware for demand and supply management, sensors, wireless infrastructure, and transmission distribution equipment. India's Ministry of Power set up the India Smart Grid Forum, a publicprivate partnership uniting utilities, industry, and academia. The government has also created an interdepartmental task force called the Smart Grid Task Force (SGTF). What 'Smart' means For you & me The smart grid means we could enjoy better quality of power, be saved from Voltage and frequency fluctuations, especially the low voltage and frequency conditions of summer, wishing good bye to power outages and load-shedding. Increase in transmission Upgradation of transmission line Upgradation of HVDC terminal High capacity 400kV multi circuit / bundle conductor lines High Surge Impedance Loading (HSIL) line Compact towers Increase in current: High Temperature Low Sag (HTLS) conductor line Reduction in land for substation Regulation in power flow/ FACTS devices Improvement of operational efficiency with condition based monitoring and preventive maintenance 1200kV Test Station Smart - The How & Why? 'Smartness' of a smart grid lies in its versatile combination of computation and communication. The 'smart' digital components communicate and compute the most efficient routes to dispatch power to loads, resulting in a better quality of supply. The digital communication elements notify all parts of the grid rapidly in case of breakdowns so that alternative routes for power dispatch may be computed. Smart grids use a combination of digital communication and digital control technology to dispatch power with minimum loss. Power may be generated either centrally in large power stations operated by utilities or by local, small generators using green and renewable energy resources. Moving Data at the Speed of Light Utilities make the grid smarter and
PGCIL Power station
Transmission systems for a number of generation projects have been planned under the LTA process, majority of which are expected to materialize during XII Plan. The balance will be implemented during XIII Plan. Assessment for transmission capacity addition during XIII Plan period made is in table 3: Overcoming Transmission Challenges Growing power demand of different regions warrant a continuous upgrade of power transfer capacity and/or technology of the grid. Some challenges that need to be overcome are: Right of Way (ROW) Flexibility in line loading and regulation of power Improvement of operational efficiency
The Smart Transmission Grid The electricity sector worldwide is undergoing massive technological and policy changes, and electricity upgrades today inherently include smart grid,
The measures being taken to meet the challenges are:

Table 2: Transmission Lines XI & XII Plans
Transmission Lines (Both AC and HVDC systems) for XI Plan and expected in XII Plan (Values in CKM)
As at the end of X Plan
Addition during first four years of XI Plan (200711)
Expected at the end of XI Plan
Expected addition during XII Plan
Expected by end of XII Plan
HVDC Bipole lines 765 kV 400 kV 220 kV Total Transmission Line, CKM
5872 1704 75722 114629 197927
1580 1636 26856 19780 49852
9452 4164 114979 140976 269571
9440 27000 38000 35000 109440
18892 31164 152979 175976 379011
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reliable by deploying Phase Measurement Units (PMUs). PMUs are like traffic cameras at major intersections, monitoring for accidents and traffic jams. Normal PMUs take the "pulse" of the grid every few seconds which for smart dynamic response is too late for electricity moving at the speed of light (186,000 miles/second. New PMUs (Synchrophasors) monitor the grid's key functions 30 times per second. The information is time stamped with signals from GPS satellites. This allows utilities to react quickly to electrical power outages attempting to prevent blackout and brownouts. The Elements Smart Transmission Grid implementation in India is a major technological feat. In fact, India is third worldwide for smartgrid investment, behind the United States and China, with its smart grid spending projected to reach $1.9 billion in 2015 WAMS (Wide Area Measurement System) based technology is part of the Smart Grid implementation requiring Phasor Measurement Units (PMUs) at the substations and power plants. PMUs installation has already been started in the northern region with proposals for other regions in the pipeline. Full implementation of WAMS technology means hundreds of PMUs in each region and reliable communi-
Table 3: Transmission capacity addition for XIII Plan Transmission lines 130 Thousand ckm Substation 300 Thousand MVA (Transformation) Capacity Fund requirement INR 200,000 Crore
(220kV and above system)
cation network with very high band width and least latency. Phasor data concentrators (PDC) installation will be at national, regional and major State Load Despatch Centre (in states having 400 kV transmission system). Availability of PMU at strategically located 400 kV/ 765kV substations / power stations and a robust fiber optic communication network facilitates situational awareness (especially dynamic state of the grid in angular and voltage stability terms), control and regulation of power flow to maintain grid parameters, Remedial Action Scheme (RAS) and System Integrated Protection Scheme (SIPS) and aiding corrective actions to prevent grid disturbances. Fibre optic based communication system Reliable voice & data communication has become essential with the introduction of technologies that use special protection schemes, wide area measurement, SCADA system and remote operation. It is the communication system that facilitates access to real
orate Corp
time data of all power system elements i.e., substations, generating plants, HVDC links, interstate transmission lines etc enabling operator's immediate response to any situation. The fiber optics technology for communication systems thus is an important link in successful operation of modern power system as a 'Smart Transmission Grid'. Fiber optics technology mode of communication is a single stop solution that can replace the microwave links operating in 2.3 to 2.5 GHz band sas well as the PLCC usage for protection of the power system and providing speech communication in limited area. Checkmate: Robotics technology To monitor power transmission lines, PGCL plans using robotics technology and deploy helicopters for aerial patrolling. Power Grid operates and maintains over 87,000 circuit kilometres of EHV (Extra High Voltage) transmission lines. It said it has carried out a demonstration of the robotics technology application on 400 kV transmission lines (live state) "for the first time in India at Ballabhgarh, Haryana". Power Grid has signed an agreement with Canada based Hydro Quebec for technology to facilitate live line visual and infrared inspection of transmission line conductors/ground wires, to help transmission lines assessment in a better manner. Way Forward: Just be GRID WISE
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System Data Planning Warehouse CIS Work Mgmt
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Figure 1 : A view of the utility information systems impacted by smartgrid strategies.
The burdens of complexity of India's Grid Operation warrant induction of up to date technologies to meet most of the challenges with the promise of a seamless integration. One big solution is Smart Grid Technology. The traditional model large remote power stations with T&D primarily designed to deliver power to load centers with established load profiles are evolving. The SMART approach is to accommodate greater levels of demand side management; generation and storage resources on the distribution system; generation closer to the loads; even greater flexibility
l ria st du In
cia er
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Power Factor
1 0.9 0.7 1/1 4/10 7/19 10/27
Feeder Breaker
Substation EMS Regulator Controller Solar PV
0.8
Capacitor Controller
Meter
Demand Response
Data Communications PHEV, Storage
Integration Middleware
MDM Electrical Network
Asset Mgmt Billing and Acct'ing
GIS
SCADA
DMS
CIS
Scheduling Dispatch
Forecasting
Information Network
1000 kV UHVAC line is 25% that of the 500kV AC power line while for an 800 kV UHVDC it is a remarkable 39% of typical line loss. Reduced Costs: The cost per unit of transmission capacity of 1000 kV UHVAC and 800 kV UHVDC transmission is about 75% of 500 kV AC costs. Reduced Land Requirements: A 1000 kV UHVAC line power line saves 50% to 66% of the corridor area that required by a 500 kV AC line; A 800 kV UHVDC line saves 23%.
Figure 2 : Systems required to support the high penetration of distributed resources
for islanding and micro grids; and considerably higher levels of intermittent generation, especially on the transmission system. This model means changes to the power system capacity and capabilities, as also to the IT needed to monitor and control the reliable operation of the power system in a most economical manner. The IT on the distribution grid, will now be equipped with state of art sensors & other automation to enable real time information availability. These IT capabilities are the key to the smart grid. A broadbased implementation of the smart grid will impact many of the
existing utility operational and information systems, as shown in Figure 1. The other big solution is the advantage that UHV brings to the transmission grid. UHV Overall Advantages are: Increased Transmission Capacity: A single 1000 kV UHVAC circuit can transmit 5 GW!, (approx. 5 times of a 500 kV AC line). An 800 kV UHVDC transfer 6.4 GW!! Extended Transmission Distance: A 1000 kV UHVAC line transmits power up to 2,000 km; while 800 kV UHVDC line reaches consumers at 3,000 km ! Reduced Transmission Losses:
Put together, the benefits of large hybrid power system interconnections (Figure 2) in India are: Increased transmission distances & reduced losses using UHV and EHV HVDC serves as stability booster and firewall against blackouts Possibility to use most economical energy resource even if far from load centers Sharing of loads & reserve capacity
1000 kV UHVAC circuit
The ReStructured Accelerated Power Development and Reforms Program (RAPDRP) focused on ICT first measures, then mitigates line losses. In Smart grid space, lot of technological advancement through on-going R&D in India will help in its competing with the U.S. and China. The government spend is an additional $10.86 billion to reduce line losses to below 15 percent in five years in urban and high density areas. The Asian Development Bank will lend India $750 million for national grid improvement project, including smart grid innovations. In growing populations and high growth economy nations ( like India & China), UHV meets the challenge to deliver large quantities of electricity from power generating stations to urban centres with increasing electricity demand with room for few transmission lines. Imagine economical 800 kV UHVDC transmissions for bulk power, above 5000 - 7000 MW, over long distances of above 1000 2500 km!!
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MM Castings Pvt Ltd
Infrastructure International Project
'Silicon Valley'
Transportation Plan 2035
anta Clara County, located at the southern end of the San Francisco Bay Area in the US, in the state of California is one of the most affluent counties in the country. The county, better known as 'Silicon Valley' to Indians and people elsewhere in the world has its county seat in San Jose. The highly urbanized country is also the most populous county in the Bay Area region, with the number of people increasing quite literally by the day, given the area's reputation as a technology hub. As on 2010, the county had a population of 1,781,642 and is considered
one of the fastest growing counties in the US. The VTA online source in a detailed analysis of the population growth in the area states that the Association of Bay Area Governments (ABAG) projects an increase of 512,900 residents and 427,480 jobs in the county between 2010 and 2035, increases of 27 and 46 percent, respectively. These figures would outpace that of the entire nine-country Bay Area which is projected to gain 1, 619,00 new residents and 1,553,860 new jobs, increases of 22 and 42 percent, respectively. This being the case, the
transport infrastructure in the county had come under enormous strain and something needed to be done on an urgent basis. This is where President Barack Obama's signing of the American Recovery and Reinvestment Act or simply ARRA came to the county's rescue. ARRA signed on February 17, 2009 enacted a US $ 787 billion economic stimulus package which would help trigger economic growth. Importantly for Santa Clara County, ARRA included US$ 48 billion exclusively meant for the country's national transportation infrastructure.
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Santa Clara Valley Transport Authority, better known as VTA, has been selected as the Congestion Management Agency for the county. VTA helped secured over US$ 115 million from ARRA stimulus funding for improving the transport infrastructure in the county. Accordingly a Valley Transportation Plan 2035 (VTP 2035) was devised for planning the long range transportation plan for the county. The plan provides the planning and policy framework for developing and delivering future transportation projects. As per the Fact Sheets of VTP 2035, the funding amount of over US $ 115 million includes purchasing hybrid buses, road rehabilitation projects and congestion management solutions. As part of this package the authority received over US $ 73 million for various different transportation projects. The key program areas of VTP 2035 include: Highways: projects include freeway mainline improvements, safety improvements, interchange reconstruction, new interchanges, new high occupancy vehicle lanes (HOV) /Express Lanes and operational improvements. Local Streets and Roads: Addresses issue agencies have with raising revenue for transportation projects not associated with new developments. Projects include street connections and extensions, road crossings at expressways or freeways, operational improvements, traffic calming measures and grade separations. Expressways: Determines infrastructure needs of the country operated expressway network. Projects include signal, safety and operational improvement. Transit: Addresses transit capital needs for the existing and future bus/rail transit system. Program scope includes 2000 Measure A Transit Projects. Transportation Systems and Management: Includes projects
that use technology , electronics and computerized systems to collectively improve the operation and management of the overall transportation system. These technologies are often referred to as the Intelligent Transportation Systems (ITS). - Bicycles: Identifies investments to bicycle facilities and the CrossCountry Bicycle Network based Countrywide Bicycle Plan. Projects include on-street bikeways, trails, improving transit access and closing major gaps in the bike plan. Capitol Expressway Light Rail Project One of the key components of VTP 2035 is the Capitol Expressway Light Rail Project. The project is proposed to be completed in two phases and is expected to transform the key arterial link of Capitol Expressway running through the county into a multi-modal transit system integrating the running of buses and light transit rail systems. Under Phase I of the project improvements would be in the bus rapid transit system and for pedestrians. New sidewalks, ensuring pedestrian safety is another area which would be of focus in Phase I. Building of bus shelters and
amenities, apart from reconstruction of a particular stretch (the Eastridge Transit Center) have also been proposed under this phase. The light rail system will operate, for a vast majority of its distance, in the center of the Capital Expressway on elevated tracks. Phase II of the project envisages extension of the line and inclusion of three stations. The line would be running from Alum Rock Light Rail Station to the Eastridge Transit Center once completed. The three stations that would be added include, Story Road, Oscala Avenue and Eastridge. While Phase I is expected to cost US$ 60 million, Phase II will is expected to cost US$ 334 million. Federal environment clearance for the project has been obtained in 2011. The project schedule of the light rail system running on elevated structures is expected to be determined based on future funding. VTA Rapid 522 Bus Service Along with the Capitol Expressway Light Transit Rail system, the plan also focuses on the VTA Rapid 522 bus service. This new service would supplement the VTA Line 22 service, which runs along the El Camino Real
The light transit rail system is playing a key role in the county
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Santa Clara Street- Alum Rock Avenue corridor, considered a crucial nervecenter of the county. The corridor accounts for over 20,000 daily bus riders, which is a significant 20% of VTA's total bus ridership. The proposed new service would offer a more modern and frequent service along the 26 mile route. The travel time is expected to come down by as much as 25 percent. From the time of its inception of the service in July 2005, the total ridership in the corridor has increased by 15 percent, with the new service totalling ridership figures of over 5,200 passengers every day. The VTA Rapid 522 service operates on both standard 40 foot and 60 foot high capacity articulated buses. A specially designed system called 'Bus Signal Priority' (BSP) has been designed for the buses, since they need to travel through several intersections. The system automatically extends the green traffic light or reduces the red phase of traffic signals, whenever a bus is approaching. The system takes care of 55 such intersections in the corridor. Moreover, the scheduling has been designed in such a way that buses need not idle at bus stops even if they are ahead of the published time
Dedicated express lanes have been planned for getting rid of traffic congestion
schedule and can travel as fast as the traffic and signals allow them to between their destinations. Another highlight of the plan is the provision for allowing buses to bypass traffic at congested junctions by making use of an exclusive 'queue-jump lane' consisting of a combination of a right turn lane and a 'receiving lane'. The 26 mile corridor includes the cities of San Jose, Santa Clara, Sunnyvale, Mountain View, Los Altos and Palo Alto. The Rapid 522 bus service with a program funding of US
$3.5 million in Phase I, has been designed to be the precursor to the Bus Rapid Transit (BRT) service in the near future in the county. Some of the future improvements envisaged include, new higher-capacity vehicles, exclusive bus lanes, more BSP intersections and permanent rail-like stations, to mention only some. Development of Express Lanes The VTP 2035 plan has provisions for increasing efficiency of existing roadways (SR 237/I-880 Express Lanes) in the county. These plans, apart from ensuring smoother flow of traffic will also enable reduction in air pollution. For example, the plan proposes more efficient use of existing roadways by encouraging transit and carpools. Solo drivers will be given the option to pay a toll fee to get access to the lanes. Since idling cars are considered a major source of air pollution, this plan will ensure that fuel is conserved and air pollution reduced. Apart from the benefit to the environment, the plan also proposes revenue from the toll collected to be reinvested for the betterment of the corridor. A total of US $ 8.9 million in funding has been allocated for the project. References
A VTA Rapid 522 service cruises through Santa Clara County
a) www.vta.org b) Fact Sheet: VTP 2035
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Action Construction Equipment Ltd
Ground Engineering
Subsurface Utility Engineering: An Overview

Bhavani Bhavani Balakrishna Balakrishna ccording to recent reports, India's urban population is all set to soar from 340 million in 2008 to 600 million in 2030. As per projections, to meet urban demand, the country should be prepared to build between 700 million and 900 million square meters of residential and commercial space per year, 350 to 400 kilometers of metros and subways every year and somewhere between 19,000 and 25,000 kilometers of road lanes every year (including lanes for bus-based rapid transit systems). This increase in infrastructure buildout is guaranteed to increase the collaboration and coordination with civic infrastructure and a major portion of such infrastructure comprises of subsurface utilities networks. These could be utilities networks like water supply lines, sewage disposal networks, gas supply & cable systems for power & communications
social investment. The location and nature of many such utility lines have not always been properly documented, thus presenting unique challenges for future infrastructure projects since untimely discovery of an unknown underground utility needing relocation can be one of the major contributors to traffic disruptions and budget overruns. Knowing the location of under-ground utilities as early as possible during the project development process allows for the efficient use of that location data for planning purposes. These purposes include budgeting utility relocation costs and time; taking into account existing utility plans for new or upgraded service; public outreach for utility structure placements; and permitting for environmental issues, height restrictions, or other reasons. This does not happen on many projects for various reasons, including the following:
Utility issues are rated low in importance in the overall complexity of a huge infrastructure project Agencies are reluctant to expend resources for utility mapping for a project that may never be designed or for which the project footprint may change. Very often the civic bodies that manage a city's underground amenities are very detached and each has a different map or even mapping system for the location of their underground conduits. Another obstacle is that of the reliability of information sources. Utility information has been collected over the years in many different forms with widely varying standards of accuracy and quality control. Therefore, much of the existing locational information on buried utilities must be considered suspect until proven otherwise.
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Ground Engineering
Subsurface utility engineering (SUE) is becoming a significant method for reducing the potential for underground utility conflicts at the project planning phase. What is Subsurface Utility Engineering? Subsurface utility engineering or SUE, a highly-efficient and nondestructive engineering practice, assists designers in locating and mapping subsurface utilities thereby managing risks associated with underground utility construction. It combines geophysical investigation, surveying, civil engineering and asset management technologies. According to Dr.SanjayRana, Director of Parsan Overseas (P) Limited and a geophysicist who has been working in the field of engineering geophysics for last 15 years and has been emphasizing the role and significance of SUE in the engineering world, Indian experiment with trenchless technology has been very encouraging, except for the damages to existing utilities, causing inconveniences and heavy costs. Information obtained from other sources such as municipalities, is rarely accurate enough safe borepath determination. In addition, depth information is almost never available. Most of the information on past utilities has never been documented in systematic manner. SUE contractors on the other hand gather the primary data, and prepare an accurate and precise location map. This
Use of Ground Penetrating Radar (GPR or Georadar) is not new in India. GPR services are being used extensively by many trenchless contractors for obtaining prior information on existing utilities, which is an encouraging trend. A larger segment, however, is still operating without such information, resulting in costly damages to utilities. It is therefore required to arrive at a consensus among various service providers about making use of available technology to avoid damages and risks.
SUE accurately identifies, characterizes, and maps underground utilities through four quality levels. Using advanced 3D underground imaging, ground penetrating radar, and non-destructive vacuum technology, specially trained SUE professionals identify and classify to various quality levels existing subsurface utility data and map the utilities' horizontal and vertical locations. If a utility conflict does exist, viable alternatives can be found to resolve the conflicts before any damage occurs. SUE Process In 2003, the ASCE and its Construction Institute published the CI/ASCE 38-02 Standard Guideline for the Collection and Depiction of Existing Subsurface Utility Data. This standard formally defined SUE and set standard guidance for collecting and depicting underground utility information and gave official credence to a process that has proven useful for almost 30 years. The basic assumption of SUE is that the underground utility location data, as shown in the project plan, may be gathered from several sources such as records and data obtained from civic bodies, data obtained from application of technologies such as Geographical Information System (GIS), Global Positioning System (GPS), Remote Sensing and Geophysics (including Ground Penetrating Radar), determinations based on visible physical
Dr. SanjayRana
Director, Parsan Overseas (P) Limited
not only provides great insight to the subsurface conditions, but eliminates the unknown variables and contingencies designers face every day. PARSAN provides a whole range of services related to the field of engineering geophysics, geology, geotechnical in India, Singapore and many Middle Eastern countries.
One of the biggest problems in new construction today is unmapped existing underground utilities Underground Imaging
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Ground Engineering
3D mapping utility system
features, and conversations with reliable or unreliable parties. Based on the methodology used, data is qualified into four levels based on its reliability (prescribed by the American Society for Civil Engineers or ASCE). Such a classification allows project owners, engineers and constructors to develop strategies to reduce or allocate risks due to existing subsurface utilities. The three major activities of designating, locating, and data management can be conducted individually to meet the specific needs of a given project, but are most advantageously used in combination to create a complete 3D mapping of a utility system. While the practice of SUE is tailored to each project, the process typically follows these steps: - The first step involves gathering utility records from all available/ secondary sources - built drawings, field notes, distribution maps and even recollections from people who were involved in the planning, building or maintenance of the utilities in question. All the data is then compiled into a composite drawing and labelled ASCE Quality Level D. - The next step is a site visit, typically during the completion of the topographic survey of the project. The intention of the site visit is to find visible surface features of the existing underground utilities (e.g. manholes, pedestals, valves). This information is added to the composite drawing completed during the ASCE Quality Level D record research and upgraded to ASCE Quality Level C.
At this juncture, decisions are made as to which utilities may have an impact on the proposed design and deserve further investigation. Using a variety of geophysical technologies and methods, such as, electromagnetic, magnetic and elastic wave methods, the horizontal position of these critical utilities is determined. This information is compiled into the utility drawing as ASCE Quality Level B data. By taking utility information from the Quality Level B data at this point and referencing it with the proposed design, utility conflict areas are identified and organized in a database known as a conflict matrix. The conflict matrix identifies conflicts (existing utilities crossing the path of the proposed design) and allows the designers to make educated decisions regarding relocation or redesign. When using the plans, be sure to not only use the plan views but the crosssections, drainage profiles and staging plans as well. Many times, significant
conflicts will appear on these sheets and not on the plan sheet by itself. Once conflicts are identified using the conflict matrix, the final step in the data collection process is to excavate test holes at key locations where the exact size, configuration, material type and condition, depth and orientation of the utilities being investigated are identified. The test hole information is surveyed and included in the utility drawings, which are now ASCE Quality Level A. The additional data gathered from the completed test holes is added into the conflict matrix. At this point, designers are able to review all options the conflict matrix presents and decide the most economical course of action. The technology is now available to achieve a complete and precise three-dimensional mapping of subsurface utilities prior to, or at, the design phase of a project. If Quality Level A information is collected through the full use of the SUE process, the project owner, design engineer, and contractor can all proceed with confidence that utilities have been identified and categorised as to their horizontal location, depth, size, composition, and condition. The use of the process will continue to grow as project owners request higher quality levels of utility information to reduce and better manage their risks. In the end, the use of SUE will tend to shift the risk of bad information to the party most capable of handling that risk the subsurface utility engineer.
Technologies Involved in SUE Designation is the process whereby the approximate horizontal location of a utility is determined. Following a rough approximation of the general location of facilities provided by Historical records research and visual site assessment, a number of geophysical technologies can be used, selected by applicability, for identifying the horizontal locations of particular utilities. Some of them include the following. Induction Utility Locators that operate by locating either a background signal or by locating a signal
Utility locators
94
Techny Chemy
Ground Engineering
introduced into the utility line using a transmitter Ferrous Metal or Magnetic locators operate by indicating the relative amounts of buried ferrous metals. They have limited application to locating and identifying utility lines but can be very useful for locating underground storage tanks (UST's) and buried manhole covers or other subsurface objects with a large ferrous metal content. Electromagnetic survey equipment is used to locate metallic utilities. This method pulses the ground and records the signal retransmitted back to the unit from subsurface metal. Particularly useful for locating metal pipelines and conduit, this device also can help locate other subsurface objects such as UST's, buried foundations (that contain structural steel), and pilings and pile caps (that also contain steel) Ground Penetrating Radar (GPR) is an electromagnetic method that detects interfaces between subsurface materials with differing dielectric constants (a term that describes an electrical parameter of a material). Depth of investigation of the GPR signal is highly site specific, and is limited by signal attenuation (absorption) of the subsurface materials which, in turn, is dependent upon the electrical conductivity of the subsurface materials. Signal attenuation is greatest in materials with relatively high electrical conductivity such as clays and brackish groundwater, and lowest in relatively low conductivity materials such as unsaturated sand or rock. Maximum depth of investigation is also dependent on antennae frequency and generally increases with decreasing frequency; however, the ability to identify smaller features is diminished as frequency decreases. Acoustic location methods generally apply to waterlines. A highly sensitive Acoustic Receiver listens for background sounds of water flowing; (at joints, leaks, etc.) or to sounds introduced into the water main using a transducer. This method may have good identification results, but can be inaccurate. Acoustics can also being
Air vacuum excavation
utilized to determine the location of plastic gas lines. - Non-Destructive Air-Vacuum Excavation involves locating; the use of non-destructive digging equipment to expose buried utilities at critical points. The use of nondestructive digging equipment, particularly vacuum excavation, eliminates damage to underground utility facilities traditionally caused by backhoes. The combination of historical data and scientific data gathered from any of the above methods can produce a clear and exact visual representation of the position of underground utilities in an area of excavation is produced. Each of these tools, applied independently, offers a limited and only partial representation of the subsurface utilities. The benefits derived from the application of these procedures are maximized when each is fully utilized to complement one another. Subsurface utility engineering (SUE) is a fast growing industry segment in the civil engineering arena. The use of SUE services has become a routine requirement on highway and bridge design projects in the United States and Canada. It is strongly advocated by the Federal Highway Administration (FHWA), American Society of Civil Engineering, American
Association of State Highway and Transportation Officials and state departments of transportation. A study sponsored by the FHWA found that $US4.62 ($A5.68) for every dollar spent on SUE was saved on overall project costs. This figure was quantified from studying 71 projects that had a combined construction value in excess of $US1 billion. In 2003, the American Society of Civil Engineers (ASCE) published the Standard Guideline for the Collection and Depiction of Existing Subsurface Utility Data. This standard formally defined SUE and set standard guidance for collecting and depicting underground utility information, which elevated SUE to a new level. Commenting on the usage of SUE and its technologies in India, Dr. Rana said, Use of Ground Penetrating Radar (GPR or Georadar) is not new in India. GPR services are being used extensively by many trenchless contractors for obtaining prior information on existing utilities, which is an encouraging trend. A larger segment, however, is still operating without such information, resulting in costly damages to utilities. It is therefore required to arrive at a consensus among various service providers about making use of available technology to avoid damages and risks. The Indian civic bodies are already taking the first step in mapping out the underground utilities. In a first of its kind project in the country, the Department of Information Technology, Government of Delhi, has nearly completed digitization and mapping of all underground and over ground assets like telephone lines, water pipes and other public utilities in 3D digital format. Known as the Delhi State Spatial Data Infrastructure (DSSDI) or 3D GIS project, it has mapped out all the underground utilities in the city using state-of-art technology of ground probing radars. The govern-ment will soon unveil a unique portal comprising images and digital details of all the over ground and underground utilities and it will be made available to the departments. However, the Brihanmumbai Municipal Corporation (BMC) decided to leave out underground utilities as it prepares to undertake a project for a GIS-based digital map of the city's properties due to lack of budget.
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Asons Enterprise
Ground Engineering Seismic Isolators
Technical Characteristics of Friction PendulumTM Bearings
Victor Zayas
Ph.D., P .E., President, Earthquake Protection Systems, Inc
General Description Friction Pendulum bearings are seismic isolators that are installed between a structure and its foundation to protect it from damage due to earthquake shaking. The bearings reduce lateral loads and shaking movements transmitted to the structure. They can protect structures and their contents during strong, magnitude 8 earthquakes, and can accommodate near fault pulses and deep soil sites. Friction PendulumTM bearings use the characteristics of a pendulum to lengthen the natural period of the isolated structure so as to avoid the strongest earthquake forces. The period of the bearing is selected simply by choosing the radius of curvature of the concave surface. It is independent of the mass of the supported structure. Torsion motions of the structure are minimized because the center of stiffness of the bearings automatically coincides with the center of mass of the supported structure. The bearings offer versatile properties which can satisfy the diverse requirements of buildings, bridges and industrial facilities. The bearing's period, vertical load capacity, damping, displacement capacity, and tension capacity, can all be selected independently. Dynamic periods from 1 to 5 seconds, and displacement capacities of up to 60 inches can be provided. Dynamic frictions from 3% to 20% are available. Effective damping ranges
TM
from 10 to 40%. Individual bearings can support vertical loads up to 30 million pounds, and tension load capacities of up to 2 million pounds. The Friction PendulumTM bearing's versatile properties permit the seismic isolation design to be optimized for best seismic performance and lowest construction cost. The reliability of the dynamic and sliding properties of Friction PendulumTM bearings has been verified through hundreds of rigorous tests performed at internationally renowned earthquake engineering research centers [Refs. 1, 4, 6, 7, 9, 15, 16, 17, 18, 27, 28, 29, 30]. Test results demonstrate a consistent and reliable bi-linear response with no degradation under repeated cyclic loadings. The specified effective stiffness and damping values are accurately delivered for either unscragged or scragged bearings, new or aged bearings, and for temperatures ranging from 30 F to 100 F. Tests of full-size bearings show that they retain their full strength and stability throughout their displacement range, with high strength factors of safety. Dynamic Properties Friction PendulumTM seismic isolation bearings are based on an innovative way of achieving a pendulum motion. Geometry and gravity achieve the desired seismic isolation properties. The result is a simple and stable seismic response. The isolator period is controlled by the selection of the radius of curvature, R, of the concave surface. The natural period of vibration of a rigid structure supported on Friction PendulumTM bearings is determined from the pendulum equation,
where g is the acceleration of gravity. When the earthquake forces are below the friction force level, a Friction PendulumTM supported structure responds like a conventionally supported structure, at its non-isolated period of vibration. Once the friction force
Bearing Section
98
level is exceeded, the structure responds at its isolated period, with the dynamic response and damping controlled by the bearing properties. The operation of the bearing is the same whether the concave surface is facing up or down.
The Friction PendulumTM bearing has the flexibility to achieve a wide range of properties. Changing the sliding period from 2 to 3 sec. reduces the base shear and increases the displacement. Changing the friction coefficient from 0.10 to 0.05 further reduces the base shear and increases the displacement. The semi-spherical design of the articulated slider achieves relatively uniform pressures under the articulated slider. The relatively uniform pressure distribution reduces slip-stick motion and prevents high local bearing pressure from occurring. The lateral restoring stiffness of the Friction PendulumTM bearing is, k = W/R where W is the supported weight and R is the length of the radius of curvature of the concave surface. This is the stiffness of a simple pendulum. The fact that the period of the Friction PendulumTM bearing is independent of the mass of the supported structure is an important property which has advantages in controlling the response of a structure. The desired period can be selected simply by choosing the radius of curvature of the concave surface. The period does not change for light or heavy structures, or if the weight of the structure changes or is different than assumed. The damping is controlled by the hysteretic dynamic friction which also automatically adjusts for uncertainties or changes in structure mass. This ability of the bearing to automatically adjust for uncertain or added structure mass improves safety. Larger than expected bearing displacements, that would otherwise occur with larger than expected structure masses, are avoided. Tension Capacity EPS offers a cylindrical version of our Friction PendulumTM bearing, that can carry tension loads. This bearing typically has two orthogonal cylindrical rails interconnected by a housing-slider assembly. The housing slider assembly contains two cylindrical sliders, and the housing unit which structurally interconnects the two orthogonal rails. When loaded in compression this
Principles of Friction Pendulum Bearing Operation
Analysis and Modeling Method The Friction Pendulum Bearings can be modeled as bi-linear hysteretic elements in Programs such as 3D-Basis, ETABS and SAp 2000. Standard Radius (R) = 39, 61, 88, 120, 156, and 244 in. Standard Dyanmic Friction Range From 3% to 12%
Modeling the Friction Pendulum Bearings Tension Bearing
99
Test Results for 3 and 10 Cycles, respectively, at 1.2x Design Displacement
Tension Bearing in Test Machine
cylindrical bearing has the same pendulum based seismic isolation properties, including period stiffness, and friction damping, as the spherical bearing. However the cylindrical tension bearing also maintains the pendulum based seismic isolation properties while carrying tension loads. The cylindrical tension bearing allows free multi-directional shear movements as with the non-tension spherical bearing. Bearing tension capacity provides overall structural connectivity and integrity. The cylindrical bearing is also available with a single rail, permitting sliding movements in one direction, while restraining against movement in the perpendi direction. Performance and Quality Assurance Testing The performance and properties of Friction PendulumTM isolators have been supported by extensive testing at internationally renowned earthquake engineering research centers, including: the National Center for Earthquake Engineering Research (NCEER), State University of New York at Buffalo (now known as MCEER); and the Earthquake Engineering Research Center (EERC), University of California, Berkeley. The experimental hysteretic loops demonstrate an ideal bi-linear response of the Friction PendulumTM with no observable degradation under repeated cyclic loadings. The test results of full-size bearings for the U.S. Court of Appeals building show that Friction PendulumTM isolators retain their full strength and stability throughout their displacement range [9,17]. Friction damping reduces the
seismic displacements. The dynamic friction is measured from tests of full-size isolators. The dynamic friction coefficient is calculated by dividing the area of the hysteretic loop by the total displacement travel. The break-away friction is measured during the first movement of the tests. The dynamic friction values from tests of fullsize isolators were within 20% of the specified value. Breakaway friction is typically equal to, or less than, the dynamic friction value. Under no circumstances did the break-away friction exceed the specified dynamic friction value by more than 20%. The behavior and response of Friction PendulumTM isolators to a wide range of earthquake loadings and superstructure types have been investigated both experimentally and analytically. Physical properties of the bearings are well established and exhibited a high degree of consistency throughout the entire series of test programs. The performance and design of the Friction PendulumTM isolation system for the U.S. Court of Appeals was verified with shake table tests of unreinforced masonry structural models at the Earthquake Engineering Research Center, in August 1992. The isolated models were subjected to over 200 earthquake tests, including large, magnitude 8 earthquakes, without sustaining any damage to the
EPS Test Machine
100
Nawa Engineers & Consultants Pvt Ltd
Bearing in Test Machine
masonry panels. The isolation bearings were then locked in place, and the non-isolated structural model was tested. After 3 small magnitude earthquakes, all of the masonry panels in the non-isolated structure were severely damaged, and testing was stopped. Shake table tests carried out at the National Center for Earthquake Engineering Research in 1991 investigated the response of a 7 story steel framed structure having various lateral load resisting systems. Friction
1992 URM Tests: Non-Isolated structure fails after 3 earthquakes of magnitudes 5, 6 and 7, respectively.
PendulumTM seismic isolators reduced the structure base shears, story shears, and story drifts in this test structure by factors of 4 to 6. These tests showed that the Friction PendulumTM isolators were effective in reducing the earthquake loads on multi-story structures having a large overturning aspect ratio and with different structural configurations. The dynamic analysis models used to predict the behavior of the isolated structures have been verified with the results of shake table tests performed at EERC and NCEER. Comparisons of analysis models with test results show that the analysis results reliably and accurately predict the response of Friction PendulumTM isolated structures. Torsion Properties Their pendulum properties make Friction PendulumTM bearings particularly effective at minimizing adverse torsion motions which result from accidental mass eccentricities. The bearing's dynamic stiffness is directly proportional to the supported weight, so that the center of lateral stiffness of the bearings always coincides with the center of mass. Since the friction force is also proportional to the supported weight, the center of the friction forces of the bearing group also coincides with
1992 URM Tests: Isolated structure remains undamaged after 58 earthquakes including magnitude 8 earthquake loadings.
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JBA Concrete Solution Pvt. Ltd
Bearing Compression Strength Friction PendulumTM bearings offer strength and stability that exceed those of any other seismic isolation bearing. An isolator from the U.S. Court of Appeals project in San Francisco, was compression load tested to nine times its design vertical load at the design lateral displacement and at the centered position. The bearing was then cyclically tested under compression and shear, and the results show the bearing retained its operational ability for lateral stiffness, damping, and vertical load capacity. Individual bearings can support service level loads of 30 million pounds. Moreover, the bearings retain high strength factors of safety above the service load capacities. Vertical earthquake motions and seismic overturning moments make the bearing's vertical load factors of safety a critical life safety consideration. Bearings which resist seismic overturning moments experience the maximum vertical loads when they are at the maximum lateral displacement. While laterally displaced, the bearings must also sustain additional vertical loads due to vertical earthquake motions. Furthermore, the reduced vertical stiffness of the bearing, occurring at the design lateral displacement, increases the dynamic amplification of vertical motions, further increasing bearing loads. The vertical earthquake motions can increase bearing vertical loads by factors of 2 or more and should be accounted for in the design. During the Northridge Earthquake, dynamic amplifications exceeding 2 were observed for the vertical seismic motions within buildings supported with elastomeric bearings. Vertical bearing loads due to vertical earthquake motions are usually not explicitly accounted for in the UBC and ASHTO seismic isolation guidelines. To adequately resist vertical earthquake motions and other load uncertainties, EPS recommends the isolation bearings should provide strength factors of safety for compression loads of at least 2.0 at the maximum lateral displacement. UBC and ASHTO seismic isolation guidelines and typical seismic isolation designs with elastomeric bearings have required a vertical load factor of safety of only 1.0 at the maximum lateral displacement. Under combined vertical and lateral earthquake motions, a low strength factor of safety can result in overturning and collapse of the structure during the design seismic event. The most important life safety consideration in the design of seismic isolation bearings is vertical load stability in the laterally displaced position; at this position, isolation bearings perform their intended function and support their maximum loads. Compression Stiffness The compression stiffness of the Friction PendulumTM bearings is typically about 7 to 10 times greater than
1991 Shake Table Tests of 7 Story Frame
1992 Shake Table Tests of Bridge on Flexible Piers
the center of mass of the structure. Hence, the stiffness and friction forces automatically adjust for accidental mass eccentricities. Shake table tests have shown that these torsion properties significantly reduce torsion motions and stresses in the structure, improving structure safety, and reducing bearing displacements at the isolator level [ 7, 15, 16, 17]. Smaller isolator displacements reduce seismic gap requirements and expenses.
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Year Location
1986 1986 1989 1989 1989 1990 1990 1991 1992 1992 1993 EERC EERC EERC NCEER NCEER EERC NCEER NCEER EERC NCEER EERC
Description
Compression-shear tests of model bearings. Shake table tests of 2-story steel frame structure. Test Structures modeled full-size buildings with periods ranging from 0.3 to 3.0 sec. and torsional eccentricities of 0% to 45% Compression-Shear testing of model low friction bearings at velocities up to 20 inches per second. Shake table tests of a 6-story steel moment frame (quarter scale model) using bearings below a rigid base. Compression-shear tests of model bearings. Compression-Shear tests of full-size 2.0 sec. bearings used in the seismic retrofit of a 4-story apartment building.
Principal Investigator
Prof. Mahin Prof. Mahin Prof. Mahin Prof. Constantinou Prof. Constantinou Dr. Zayas
Ref. No.
16 16 15 7,8 7 13
Shake table tests of a rigid slab bridge on bearings. Prof. Constantinou Shake table tests on 7-story steel moment and braced frame buildings (quarter scale) with bearings below Prof. Constantinou individual columns. Shake table tests of unreinforced brick/granite masonry panels using full-size 2.5 sec. period bearings. Prof. Mahin Shake table tests of a highway bridge on flexible piers with the bearings isolating the bridge deck from the Prof. Constantinou piers. Compression-Shear testing of full-size 2.75 sec. period bearings. Vertical loading 44 to 1275 kips; sliding Dr. Zayas velocities from 0.1 to 20 inches per sec.; temperatures from 20F to 90F; simulated aging to 100 years. Shake table tests of computer equipment supported on bearings. Tests of temperature, longevity and reliability using model bearings. HITEC Compression-Shear tests and 10,000 cycle wear tests of full-size bearings for Caltrans and the Federal Highway Administration (FHWA). Caltrans shake table tests with bi-directional interaction for bridge applications. Shake table tests of model bearings for use in power transmission towers. Prof. Constantinou Prof. Constantinou Armand Onesto Prof. Mahin Prof. Shinozuka
1,17 9,17 6 3,17
1994 1995 1997 1999 1999
NCEER NCEER ETEC EERC NCREE Taiwan UCSD WA State Univ. UCSD UCSD UCSD MCEER
27 29 30 31
20002001 2001 2001 2001 2001 2002
Caltrans High Speed Compression-Shear tests of large (13 feet diameter) bearings for retrofit of the Benicia-Martinez Bridge. Shake table tests of a three story structural model with FP bearing and dampers (NSR Grant project). Caltrans, High Speed Compression-Shear tests of large Cylindrical Uni-directional FP bearing for retrofit of West Span of Oakland Bay Bridge. Government of Turkey, Bolu Viaduct Project, High Speed Compression-Shear Prototype tests on large FP bearings. Tennessee DOT, I-40 Project High Speed Compression-Shear tests of large FP bearings with vertical loads of up to 10,000 Kips Shake table tests of cylindrical tension bearings
Prof. Seible Prof. Symans Prof. Seible Prof. Seible Prof. Seible Prof. Constantinou 32 33 34 35
The following table lists chronologically the research test programs on the Friction PendulumTM seismic isolation bearings performed at University and Government sponsored laboratories.
elastomeric isolation bearings. Most importantly, Friction PendulumTM bearings retain these vertical stiffness values at their design lateral displacement. Typical elastomeric isolation bearings have approximately one half the vertical stiffness at the design displacement as compared to the undeformed position. Thus, the vertical stiffness that resists the overturning moment loads is about 14 to 20 times greater for Friction PendulumTM bearings than that of elastomeric bearings. This higher vertical stiffness minimizes loss of the structure's shear wall stiffness due to rocking about the base, reduces uplift displacement
demand on the bearings, and reduces the need for spreader trusses or walls across the base of the building to spread out the overturning moments. These factors can significantly reduce the isolator installation costs. The higher vertical stiffness of the Friction PendulumTM also results in a lower vertical period, which is less susceptible to dynamic amplification of the vertical motion. The vertical period of a typical Friction PendulumTM bearing is approximately 0.03 sec. From the UBC spectra, the dynamic amplification factor is 1.3. The vertical period of the typical elastomeric bearing, at the design lateral
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consistent stiffness and damping properties for either unscragged (virgin) or scragged (previously loaded) bearings. The first cycle of lateral loading on the virgin bearing resulted in friction coefficients approximately 1/ 2 % higher than those obtained from subsequent cycles. The first cycle virgin properties did not effect the tangent stiffness values. The bearings satisfied the design stiffness and damping requirements for the first and subsequent loading cycles. Since first cycle unscragged properties are stiffer than subsequent cycle properties, they result in higher seismic shear forces in the structure above. For the U.S. Court of Appeals and Revithoussa LNG Tanks, the first cycle properties were used for the structure shear force designs. Since the subsequent cycle properties are less stiff, the subsequent cycle properties were used to check maximum bearing displacement requirements. This approach results in a conservative design for both structure seismic shear forces and bearing displacements. Temperature Effects Low temperatures increase the stiffness of isolation bearings, and high temperatures reduce the stiffness. This applies to both elastomeric and sliding bearings. EPS recommends that the structure shear force design be based on the cold temperature bearing properties, as applicable to the structure site. Since tests of material
Comparison of Experimental Results and Analytical Prediction
displacement, is approximately 0.1 sec. with a dynamic amplification factor of 2.0. The lower dynamic amplification factor for the Friction PendulumTM bearing reduces vertical bearing loads due to vertical earthquake motions, improving vertical load stability and safety as compared to the specified elastomeric design. Unscragged and Scragged Properties Scragging is the repeated lateral loading of an isolation bearing, to achieve a softening of the bearing stiffness. Elastomeric isolation bearings typically recover 70 to 90% of the unscragged properties within 3 months to 2 years after scragging. EPS recommends that structure shear force designs be based on unscragged bearing properties, which are measured from three or fewer cycles of lateral loading to the design lateral displacement applied to a previously untested bearing. Multiple cycles of loading at lesser displacements have a progressive scragging effect and should be avoided when measuring design stiffness and shear values. Basing the structure shear force design on stiffness properties measured after significant prior loading results in unconservative designs. Averaging four or more cycles of loading has a similar unconservative effect. The first cycle of loading on each new virgin bearing tested for the U.S Court and the Revithoussa LNG Tanks, was recorded and reported, as were the subsequent loading cycles. The Friction PendulumTM bearings demonstrated relatively
Compression Load Test at Lateral Displacement of 11 inches
samples can produce significantly different results for temperature effects as compared to tests of full size bearings, EPS recommends that bearing temperature effects be based on tests of full size bearings. In order to quantify the effects of temperature on the properties of Friction PendulumTM isolators, full-size isolators were cooled or heated to the target temperatures at the bearing core, then subjected to combined compression and shear testing. A full-size bearing was cooled to -70 F, then tested as the temperature gradually rose. Another bearing was heated to 90 F, then tested as the temperature gradually
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Atul Fasteners Ltd
than the PTFE materials used in typical bridge or structural bearings. U.S. aerospace applications of this bearing material have very demanding performance and quality control requirements. They include: wing pivot bearings, landing gear bearings, helicopter blade bearings, aircraft engine bearings; and bearings in actuator systems for hydraulics systems; among others. The load requirements in the U.S. military aerospace applications are similar to, or exceed, those of the Friction PendulumTM bearings. Furthermore, the wear requirements exceed those of the Friction PendulumTM bearings.
Effect of Temperature on Dynamic Friction
lowered. The aerospace bearing liner is rated for operation from temperatures ranging from -320F to +400 F . The temperature tests showed that friction decreases as the temperature rises, and increases as the temperature decreases. There is no effect of temperature on the bearing dynamic stiffness or period. There is a small effect of temperature on the effective stiffness and period due to the friction coefficient change. Material Longevity and Aging The sliding interface components of the Friction PendulumTM bearing are constructed of materials with demonstrated longevity and resistance to environmental deterioration and aging [20, 21, 22, 23]. The bearing liner is a high strength, self-lubricating composite material that was developed for use in critical aerospace applications. It meets stringent specifications for use in military applications [21]. The concave sliding surface is a high grade stainless steel with exceptional corrosion and environmental resistance. The durability and long-term material reliability of Friction PendulumTM bearings result in an expected bearing life exceeding 100 years. The principal properties that affect the performance of seismic isolation bearings are the stiffness, period, and damping. For Friction PendulumTM bearings, the stiffness and period are controlled by the radius of curvature of the concave surface. The radius of curvature does not change with time. Aging effects on the dynamic stiffness and period of the Friction PendulumTM bearings are, therefore, not significant. The bearing liner is a high load/low friction composite, which provides non-degrading and low friction sliding, without the use of liquid lubricants. This composite material has been used in the U.S. aerospace industry for over 35 years for high load/high torque bearing applications. The rated static load capacity is 60,000 psi. The rated operating temperature range is -320F to +400 F. It provides much higher strength and wear durability
U.S. Military Specifications set no age limit or shelf life limit for the use of this bearing material. The bearing material components have been identified as chemically stable and inert, with no noticeable effect of aging. A ten year old sample of the bearing material has been tested and found to show no noticeable deterioration due to age. It's resistance to industrial chemicals is rated as excellent. The other component of the sliding interface is the main stainless steel concave surface. ASTM A240 stainless steel, austenetic grade 300 series with a polished finish, is used for the concave surface. The "Corrosion of Stainless Steels" section of the Metals Handbook Ninth Edition, Vol. 13 Corrosion, ASM International, reports results of observed corrosion of AISI 300 series stainless steels in a marine atmosphere [24]. Stainless steel samples were left exposed for 15 years, 250 meters from the sea. After 15 years, the Type 316 stainless steel exhibited extremely slight rust stains on 15% of the surface. The rust stains were easily cleaned to reveal a bright surface, and would have only a minor effect on the surface roughness and friction coefficient. For a sealed Friction PendulumTM bearing, installed in a building, similar rust stains would take more than 50 years to develop. Changes in the surface roughness of the concave surface have a modest effect on the dynamic friction value, primarily in the first cycle of loading. To simulate long term aging effects, Friction PendulumTM bearings were tested with different surface roughnesses, including high mirror polish, low polish, and no polish. The tests were correlated to aging based on the ASM exposure tests, and stainless steel exposure tests by Taylor Devices [20] of stainless steel samples with outdoor and indoor exposure times ranging from 10 to 39 years. The no polish specimen included surface contamination from the steel mill, and was considered a conservative simulation of the worst case 100 year aging effect. The effects of the simulated 100 year aging are shown in the figure on the following page. The figure shows the
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friction coefficients measured in the first cycle of loading. The 100 year simulated aged bearing demonstrated a 1% increase in the friction coefficient, as compared to the high mirror polish bearing. The friction increase was observed only for the first cycle of loading. Friction results for subsequent cycles were equivalent to the polished bearings. The dynamic friction values of full-size bearings have remained within specification when subjected to repeated loadings during a single test, or over a series of earthquake tests, reaching the design life of the bearings. The wear life of Friction PendulumTM bearings exceeds thirty design basis earthquake loadings. The friction coefficients of bearings subjected to more than fifty cycles of loading in a single test, and more than fifty sequential earthquake loadings have remained stable and within the design specification. The test results for the Friction PendulumTM composite bearing liner differ from those for soft PTFE materials used in typical structural and bridge bearings. The softer materials creep and impregnate themselves into the mate plates, causing break-away friction values that exceed the dynamic friction values [26]. In contrast, hundreds of tests on Friction PendulumTM bearings demonstrate the static break away friction coefficient is consistently less than, or equal to, the dynamic friction coefficient [1, 7, 15, 16, 18]. Moreover, Friction PendulumTM bearings were selected for the Revithoussa LNG Tanks over elastomeric bearing
performance requirements were required to be demonstrated by performing full-size bearing tests under the specified range of conditions. Elastomeric bearings were tested, but were not able to satisfy the performance requirements. Friction PendulumTM bearings satisfied all performance requirements. Fire Resistance The Friction PendulumTM bearing offers the innate fire resistance of heavy steel joints. Bearings for bridges typically weigh from 2000 to 10,000 lbs, making a concentrated mass which heats slowly, and maintains stability at temperatures exceeding 1500F. The aerospace bearing liner can withstand temperatures of 600 F without damage, and maintains operational ability up to 400F. All materials are non-combustible, except for the ethyleyne propylene seal which can withstand temperatures up to 350F. The seal is replaceable after a fire if needed. The bearings can be fire protected using standard fire protection methods for structural steel members. The exterior may be field sprayed with standard fire proof aggregate. Prior to spraying, the bearing's seismic movement joints should be fitted with expansion joint material to allow bearing movements. The bearing can also be supplied with pre-encased fire board, which can meet the fire rating requirements of an individual project. The fire board is fitted to allow bearing seismic movements, and is removable and replaceable. Installation Details and Requirements The Friction PendulumTM bearings offer many installation benefits compared to elastomeric bearings: The bearing does not require upper or lower base plates. This saves base plate material costs, handling costs, and installation time. The FP bearing is vertically stiff, minimizing the vertical deflections of columns that occur during bearing installation in retrofit applications. This avoids damage to architectural finishes in the upper floors, and reducing bearing installation time and cost. In retrofit applications, the FP bearing does not require flat jacks. This results in savings in flat jack costs and installation time. The low profile bearing can be installed in constrained locations, saving foundation and structure disruption costs and time. The FP bearing connection can be welded, offering flexibility and cost savings in connection details. The tension and side plates of the FP bearing provide
Effect of Aging
types, because they demonstrated the ability to satisfy the stringent performance requirements set for the effects of aging, temperature, and virgin (unscragged) properties. All bearings were required to satisfy the seismic performance requirements under the combined effects of 35 years aging, low temperatures of 10F , and virgin unscragged properties, as well as the combined effects of new bearing properties, high temperatures of 86F, and scragged run-in properties. Satisfaction of these
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The isolators can be installed either with the concave surface facing up or down. The articulated joint allows relative rotations between the structure above and below the isolators, and reduces the isolator moment loads on the structure. P-Delta moments are avoided for the structural members below the isolator, when the concave surface is facing down. P-Delta moments are avoided for the structural members above the isolator when the concave surface is facing up. The cylindrical retainer ring of the Friction PendulumTM provides a redundant support system capable of supporting the full design vertical and lateral loads. Friction PendulumTM isolators need less clear space around them to allow for isolator distortions. Only the sliding plane of movement needs to be accommodated. These installation details offer important advantages at locations such as exterior or interior walls, elevators, stairs, or entry ways. Seismic gap details are simplified because the slight rise of the isolators as they laterally deflect lifts overlapping plates in seismic gap joints away from expansion gap materials. References
1. Al-Hussaini, T.M., Zayas, V.A., Constantinou, M.C., "Seismic Isolation of Multi-Story Frame Structures with Friction Pendulum Isolators", Technical Report 94-007, National Center for Earthquake Engineering Research, State University of New York at Buffalo, 1994. 2. Al-Hussaini, T.M., Zayas, V.A., Constantinou, M.C., "Seismic Upgrade of Multi-Story Buildings Using the Friction Pendulum Isolation System", Proc., Tall Buildings in Developing Countries, International Conference on Tall Buildings, Dhaka, Bangladesh, June, 1993. 3. Amin, N., Mokha, A. and Fatehi, H., "Rehabilitation of the U.S. Court of Appeals Building Using Sliding Isolation System", Proc., ATC-17-1 Seminar on Seismic Isolation, Passive Energy Dissipation and Active Control, Applied Technology Council, San Francisco, March 1993. 4. Zayas, V.A., Constantinou, M.C., Tsopelas, P . and Kartoum A. "Testing of Friction Pendulum Seismic Isolation Bearings for Bridges." Proceedings of the Fourth World Congress on Joint Sealing and Bearing Systems for Concrete Structures, Sacramento, California, September 1996. 5. Constantinou, M.C., Mokha, A.S., and Reinhorn, A.M., "Teflon Bearings in Base Isolation II: Modeling" Journal of Structural Engineering, American Society of Civil Engineers, Structural Division, Vol. 116, No. 2, 1990. 6. Constantinou, M.C., Tsopelas, P., Kim, Y-S. and Okamoto, S., "NCEER-Taisei Corporation Research Program on Sliding Isolation Systems for Bridges: Experimental and Analytical Study of Friction Pendulum System", Report No. 93-0020, National Center for Earthquake Engineering, State University of New York at Buffalo, Nov. 1993.
Typical Installation Details
the necessary temporary lateral force resistance needed during construction, avoiding the cost, time and space constraints of installing temporary bracing. The bearings can be installed with the concave surface facing either up or down. P-Delta moments are avoided for the structural members below the isolator, when the concave surface is facing down. This reduces the seismic forces transmitted to the foundation. P-Delta moments are avoided for the structural members above the isolator when the concave surface is facing up. This reduces the seismic forces transmitted to the upper structure.
The installation benefits of the Friction PendulumTM bearings have saved millions of dollars in project construction costs and time. The compact Friction PendulumTM bearing can accommodate constrained and difficult installation conditions. This often results in substantial savings in the costs of construction installation details. The relatively small height of the Friction PendulumTM isolator makes it preferable for installation in constrained crawl spaces, or at elevator and stair locations. The isolators are vertically rigid, retaining their full height after installation and loading. This avoids long-term creep concerns.
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7. Mokha, A.S., Constantinou, M.C., and Reinhorn, A.M. "Experimental Study and Analytical Prediction of Earthquake Response of a Sliding Isolation System with a Spherical Surface" Report No. NCEER 90-0020, National Center for Earthquake Engineering Research, State University of New York at Buffalo, October 1990. 8. Mokha, A.S., Constantinou, M.C., Reinhorn, A.M. and Zayas, V.A., "Experimental Study of Friction Pendulum Isolation System." Journal of Structural Engineering, American Society of Civil Engineers, Structural Division, Vol. 117, No. 4, April, 1991. 9. Zayas, V.A., and Low, S. "Seismic Isolation Retrofit of a Historic Building", Proceedings of National Earthquake Conference, Central United States Earthquake Consortium, Memphis, Tennessee, May 1993. 10. Zayas, V.A., and Low, S.S., "Earthquake Resistant Design Using Friction Pendulum Connections." Seismic Engineering: Research and Practice, The American Society of Civil Engineers, Structures Congress, San Francisco, May 1989. 11. Zayas, V.A., and Low, S.S., "A Simple Pendulum Technique For Achieving Seismic Isolation." Earthquake Spectra, Professional Journal of the Earthquake Engineering Research Institute, May 1990. 12. Zayas, V.A., and Low, S.S., "Seismic Isolation Retrofit of an Apartment Building." The American Society of Civil Engineers, Structures Congress, Indianapolis, April 1991. 13. Zayas, V. and Low, S., "Application of Seismic Isolation to a Four Story Wood Building", 1991 SEAOC Proceedings, SEAOC Convention, 1991 14. Zayas, V.A., and Low, S.S., "Seismic Isolation Retrofit of an Historic Building", 1993 National Earthquake Conference, Memphis, Tennessee, May 1993. 15. Zayas, V., Low, S., Bozzo, L. and Mahin S., "Feasibility and Performance Studies on Improving the Earthquake Resistance of New and Existing Buildings Using the Friction Pendulum System", UCB/EERC-89/09, Earthquake Engineering Research Center, University of California, Berkeley, 1989. 16. Zayas, V.A., Low, S.S., and Mahin S.A. "The FPS Earthquake Resisting System, Experimental Report." Report No. UCB/EERC 87/01, Earthquake Engineering Research Center, University of California, Berkeley, June 1987. 17. Zayas, V., Piepenbrock, T. and Al-Hussaini, T., "Summary of Testing of the Friction Pendulum Seismic Isolation System: 19861993", Proc., ATC-17-1 Seminar on Seismic Isolation, Passive Energy Dissipation and Active Control, Applied Technology Council, San Francisco, March 1993. 18. Zayas, V.A., Low, S.S., and Mahin S.A., "Shake Table Testing of a Friction Pendulum Seismic Isolation System." Seismic Engineering: Research and Practice, The American Society of Civil Engineering, Structural Congress, San Francisco, May 1989. 19. Zayas, V.A., Low, S.S., Mahin, S.A., "Seismic Isolation Using the Friction Pendulum System." The 10th International Conference On Structural Mechanics in Reactor Technology, Anaheim,
California, August 1989. 20. Soong, T.T. and Constantinou, M.C. (1994). Passive and Active Structural Vibration Control in Civil Engineering, Springer-Verlag, Wien-New York. 21. Gardos, M.N. (1982). Self -lubricating Composites for Extreme Environmental Applications, "Tribology International, October, 273-283. 22. Bowden, F.P . and Tabor, D. (1964). The Friction and Lubrication of Solids. Part II, Oxford University Press. 23. Derjaguin, B.V. and Toporov, Y.P . (1982). "Influence of Adhesion on the Sliding and Rolling Friction," in Microscopic Aspects of Adhesion and Lubrication, edited by J.M. Georges, Tribology Series 7, Elsevier Scientific Publishing Co. 24. ASM International (1987). Metals Handbook, Vol. 13 on Corrosion, Metals Park, Ohio. 25. International Nickel Company (1963). "Corrosion Resistance of Austenitic Chromium-Nickel Stainless Steels in Atmospheric Environments. 26. Mokha, A., Constantinou, M.C. and Reinhorn, A.M. (1991). "Further Results on the Frictional Properties Bearings," J. Struct. Engng., ASCE, 117(2), 622-626. 27. Lambrou V. and Constantinou, M.C. "Study of Seismic Isolation Systems for Computer Floors." Technical Report NCEER-940020, National Center for Earthquake Engineering Research, State University of New York at Buffalo, July 1994. 28. Zayas, V.A., Constantinou, M.C., Tsopelas, P . and Kartoum A. "Testing of Friction Pendulum Seismic Isolation Bearings for Bridges." Proceedings of the Fourth World Congress on Joint Sealing and Bearing Systems for Concrete Structures, Sacramento, California, September 1996. 29. Constantinou, M.C. "Research on Longevity and Reliability of Sliding Seismic Isolation Systems.", NCEER Highway Project Technical Report, National Center for Earthquake Engineering Research, State University of New York at Buffalo, 1996. 30. CERF Report: HITEC 98-07 #40370 "Evaluation Findings for Earthquake Protection Systems, Inc. Friction Pendulum Bearings" September 1998. 31. Madden, G.J., Symans, M.D., and Wongpraset, N. (2002). "Experimental Verification of Seismic Response of Building Frame with Adaptive Sliding Base Isolation System," J. of Structural Engineering, ASCE, Vol. 128, No. 8. 32. Seible, F., UCSD Test Report on Uni-directional Cylindrical FP bearings for retrofit of West Span of San Francisco-Oakland Bay Bridge, 2001. 33. Seible, F., UCSD Prototype Test Report on FP bearing for Bolu Viaduct Project for government of Turkey, 2001. 34. Seible, F., UCSD Test Report of FP bearings for retrofit of I-40 project, Tennessee DOT, 2002. 35. Constantinou, M.C., MCEER Shake table tests of cylindrical tension bearings.
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STA Concrete Flooring Solutions
CE Site Report
Ramky Sets World Record on Marini Plants
4000 tons of Green and Profitable Asphalt Produced in Less Than 21 Hours
n 16 December 2011, the Marini MAC 200, plant installed at Ramky's NAM project site produced over 4000 tons of high quality asphalt mix in little less than 21 hours, creating a historical landmark and re writing its own historical benchmarks. The MAC 200 plants have clocked around 3000 tons several times at numerous job sites pan India, however 4000 plus tons of asphalt on a single day, is the new benchmark. When Ramky began work on the 212 Km long Narkatpali AddanikiMedarametla road project, they simply didn't want to construct a highway. Mr. Y Nagaraja MD, Ramky, wanted the project to be a model for sustainable development. The sheer size of the project called for a continuous production of asphalt in large quantities and high quality. Commitment to sustainable development and focus on leadership
"Marini plants are acclimatized to Indian operating conditions. This explains the reason for its amazing performance and productivity."
in the infrastructure development industry, were the key drivers behind Ramky installing Marini plants on this project. World Record, Very Routine On 16 Dec 2011, by the time the villages on the stretch woke up, Ramky's team had already laid 600 tons of asphalt mix. It was just a normal production day for us at the site, states Srikanth, at the helm of plant production. Marini plants are designed to perform. The plant works very smoothly and loves to be revved up to its capacity.
Everyday we run at its full capacity, with great ease, he further adds. By the time the plant was shut down, the team had already laid over 4000 tons of hot mix asphalt. Little did they realize that, they had set a world record with the Marini plant. It is no surprise for us at Marini, MAC plants are designed to set records. We celebrate with our customers as they begin to see that we deliver what we promise and benefit greatly from the reliability, exceptional efficiency, productivity and performance of our asphalt plants- States Blesson Varghese Marini's National Director. Track Records, Very Evident We at Marini are committed to deliver productivity and profitability to our customers. Ramky decided to invest in a Marini plant, as they wanted to graduate to the next level. Now with the
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CE Site Report
"The decision to buy Marini was very strategic, we wanted to graduate to the next level. With Marini we found the right technical partner and products which could help us achieve our focus on sustainable development."
Y R Nagaraja
Managing Director, Ramky Infra. Ltd.
efficiency, productivity and uptime achieved on the Marini plants, they surely have carved a niche and have launched themselves ahead of the pack in terms of Fuel Savings, Environmental friendliness, Green Technology and Sustainable development. Designed, very tough & very intuitively Marini plants are acclimatized to Indian operating conditions. This explains the reason for its amazing performance and productivity. Years of Indian site experience and knowledge are built in to Marini products. The plant has intuitive design features like the perfectly sized bag house filter and dryer, tuned to perform even under high dust content in the cold aggregates. Our dryer and filtering system is uniquely designed to ensure that dust take off is reduced drastically, thereby a Marini user never faces troubles with blocking of bag house filters and low fuel efficiency. Indian site have issues with gradation and at times quality of aggregates, these are handled well by the patented Marini dryer drum and a very reliable screening unit. Marini plants screen 45% more sizes compared to others in the market, capable to deliver a very
high quality mix even under severe operating conditions.
"It is no surprise for us at Marini, MAC plants are designed to set records. We celebrate with our customers as they begin to experience that we deliver what we promise and benefit greatly from the reliability, exceptional efficiency, productivity and performance of our asphalt plants-States."
reliability, performance and ease in operations states Sathish Kumar, Senior Support Manager on Ramky's NAM project. Round the clock operations are very easy, the highly reliable control system, automatic process controls, and ease in operations keep the plant operators devoid of any stress and extended working hours are always a pleasure, he further adds. Very Productivity, Very Profitable In an age of tough competition where every dime matters, Productivity is no secret for profitability. It is needless to mention that productivity can never be achieved without reliability. By producing 4000 tons of asphalt flat out on the MARINI plant, Ramky could cut nearly 20 % or even more of carbon emission compared to piece meal production on lesser efficient and lower reliable plants. These reductions in carbon footprints, can be directly linked to the profits. Marini plants have been clocking exceptional fuel efficiency and once again on the Ramky project they proved unbeatable.
For further details on Marini products visit www.marini.co.in
Blesson Varghese
Director, Marini India
Round the Clock Very Easy The reason we are able to operate the plant so stress free is due to its
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Communication Feature
Conmat - World-Class Product Range Ensures Rapid Growth

onmat, a group of companies, engaged in designing and manufacturing of construction equipment, material handling systems and providing oil & gas pipeline services, has carved a niche for itself, as an industry trendsetter in its chosen domain. The group has been growing by leaps and bounds, recording an average annual growth of more than 100 percent over the last few years and is expected to reach further dizzy heights of achievement in the near future. Starting off its Indian operations from a humble 200 sq.ft rented space in 2003, by two persons, today its state-of-the-art manufacturing facilities are spread over 2, 50,000 sq.ft employing more than 400 people in Vadodara, Gujarat. The company's extensive sales and service network includes branches in Mumbai, Delhi, Kolkata, Pune, Bangalore, Hyderabad, Indore, Nagpur, Guwahati, Lucknow and London. The company offers a range of world-class construction equipment, including automatic concrete batching & mixing plants, concrete paving machines for canals & roads and transit mixers for the infrastructure sector. The company as on date offers automatic concrete batching & mixing plants with twin shaft mixers, of 20, 30, 45, 60, 90 & 120 cum./hr capacities. Responding to the demands of the infrastructure sector,
Conmat has successfully introduced fully automatic mobile batching plants of 20, 25 & 35 cum/hr capacities. These plants work on the same principle as of a stationary plant and offer the same mix quality with the added advantage of mobility. The company is considered a market leader in concrete canal paving machines, which are capable of slope and bed paving up to 110 ft. in a single pass. The same machines can also be used for city and village concrete roads, ensuring multi-utility and therefore, better returns on investment. Participation in Excon 2011 The company had recently displayed its state-of-the-art machines during the recently held Excon 2011 trade show in Bengaluru. The company had showcased its recently launched CSP 3000 Slipform Canal Paving model during the event. A totally indigenous product from the company, the CSP 3000 allows for entire cross section paving for minor and distributary canals for a canal top width up to 3 meters. In addition to the slipform paver, the company also displayed certain other products from its portfolio including, 120 cum concrete batching plant with double transit mixer discharge, fully mobile 20 cum batching plant with twin shaft mixer, canal and road cylinder finisher and a low height 30 cum concrete batching plant with SCADA controls.
Corporate Social Responsibility The company has also been a front runner among its peers when it comes to corporate social responsibility (CSR) initiatives. Through these initiatives Conmat ensures that its efforts and actions impact the people at grass root level and the company is able to cater to every stakeholder of the society. Some of the CSR activities initiated by the company include the following: Tree plantation, sapling distribution. Supporting and upbringing cultural art and artists though exhibitions, camps and scholarships. Environmental awareness in schools and colleges by associating for various events and competitions. Supporting events and activities for deaf and dumb students. Adopt villages around factory premises and educate them on environment and health front. Facilitating eco-friendly religious rituals.
For further details:

A/2-845, G.I.D.C., Makarpura, Vadodara - 390 010. Gujarat, India. Ph: 0265-2647276 Fax: 0265-2630763 Mob: 09898870278 / 09898870548 Email: sales@conmatindia.com Web: www.conmatindia.com
Conmat Systems Pvt. Ltd.
Slip Form Paver
Conmat Factory Building
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Conmat System Pvt Ltd
Interaction
Industry Interaction: Optimistic About Continued Growth of Indian CE Market

the top players in the construction equipment industry in the country. In an exclusive interview to The Masterbuilder, at the company's stall during Excon 2011, Mr. A. M. Muralidharan, Managing Director, gave insights into the company's growth strategies for the Indian market. Here are excerpts from the interview.
A.M. Muralidharan
Managing Director, Volvo India Pvt Ltd
an improvement on its preceding one. This time around too it is no different. This edition of Excon is better than the last one. What about your expectations from the event? Excon is a platform where we display machines and new technologies. Normally during the time of this quarters around November December, the market peaks out . We see better market for our products this month than say during October. Has the Eurozone crisis had an impact on the Indian construction equipment industry?
Tell us about your impressions of Excon 2011. The show has been really good. There have been people coming from all parts of the country visiting our booth. This is one of the best editions of Excon. Each edition of Excon has been
olvo India Private Limited (VIPL), the Indian subsidiary of Volvo Construction Equipment (Volvo CE), has made rapid inroads into the market and is now considered among
Models displayed at EXCON 2011
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Interaction
Our market operates more on home consumption not as in the case with other countries where they are more focussed on exports. Slowdown is again an internal issue. For instance, because of inflation the government increased the interest rates. You can see in the market that 'wait and watch' policy is being adopted by people, for making purchases such as a car or a new home. So, it is purely an internal issue. How do you foresee the immediate future of the Indian construction equipment industry? I do not see anything to worry. I see very little negative impact. I think that we should be back to normal by April or May i.e. during the second quarter. It may not be as nice as it was in the beginning of this year. The costs would continue to be high. The operations would come to be normal. People would start accepting that cost, i.e., the higher cost. We need not worry about the temporary situation today. What are the products that you are manufacturing in Peenya? In Bangalore we had announced a 90 crore investment plan. We have doubled the road construction machinery production capacity. We
have also introduced excavators in the production line. We have just launched two products here. We have sufficient capacity for next five six years. Is 'Reman' a part of this factory? Yes, 'Reman' is part of this factory. Remanufacturing is only for components. The response for Reman has been really
good. We are planning to launch more 'Reman' components in the future. Are you looking to increase your product portfolio? We normally look at what the market growth pattern is, where opportunities are existing, etc before taking any such decision. Like here we have launched our rock breaker since we feel that there is a huge potential for rock breakers in India. It is a continuous process. Any plans of a new plant? Not as of now. Anything else that you may like to tell our readers. We need to be positive about the market. With a GDP growth rate of about 7.2 percent, we are still one of the highest growing economies. So we should remain positive and continue to do our part of the work in the industry and make sure that we are visible we are available when the market comes up again. We should always try and take advantage of the market growth that is the message that I would like to share.
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Insulator New Rollout
Supreme Introduces INSUflex, A High Vapour Resistant Insulator for Air-conditioning

of proof and ownership of the material ultimately lies with the end user but all channel participants involved in the decision making process will shoulder some degree of responsibility if a failure were to occur. A failure of any magnitude and regardless of the cause is detrimental to the industry. Assumption of equivalence and warranty support could be costly. Unless financial instruments / funds are involved guarantees / warranties do not leave the user much choice. Supreme introduces INSUflex, which has a high diffusion resistance factor to water vapour transmission 7000, a low thermal conductivity and excellent fire safe performance. It is suitable for a temperature range from 55C to +105C. The product does not depend on any additional outer thick skin or coverage. But, is built in with the insulation and extends through the full thickness. It provides a very high efficient method of insulating to control condensation against both heat loss and heat gain. The material is particularly suitable for insulating pipe works for condensation control. It can be used on chilled water pipe lines, refrigerated pipe-works, hot & cold water services and Sheets / Rolls in airconditioning ductwork. INSUflex products are resistant to corrosion fungal & mildew growth. Thus they are suitable for clean room applications. Insulation material with low 'K' value exhibits high energy saving potential & thermal performance. Thermal conductivity is the main data used to technical calculated insulation thickness required to prevent condensation. The main goal of a good insulation material should be that of preventing water vapour from spreading through insulation as water is an optimal heat conductor. INSUflex, having a high water vapour resistance factor, can prevent a flow of water vapor that tends to pass through the insulating material created in air-conditioning system as result of difference in pressure between the pipe (low pressure) and the surrounding air temperature (high pressure). A high water vapor value corresponds to greater material resistance to water vapour penetration. Advantage INSUflex Good flexibility at low temperature Clean, dust-free, fast and easy installation Low thermal conductivity High water vapor resistance factor 7000 Protects pipes against corrosion by environment elements Low toxicity index means minimal toxic fire hazard for safety assurance and rescue operations Good fire performance, for buildings with high occupancy, Class 1 product Unique closed cell structures, provides an ideal vapor barrier resistance.
Mr. Atul Khanna

GM Insulation Division The Supreme Industries Ltd.
ver since a catastrophic fire in an insulation manufacturing facility, foreign manufactured materials have been more amiable to all. The end-user, in many cases, does not place primary importance on where the product is made if the product meets the specification. Therein lies a very important question, does the foreign manufactured material meet the applicable material specification and standards? It may look and feel the same and is in a similar wrapper but is the composition, health and safety aspects, quality and its performance standards measured on the same basis as domestic manufactured materials? This is not suggesting that imported materials are inferior to those manufactured locally. It is simply raising a caution flag to those individuals and companies that are considering the use of imported materials. Are they tested and is the performance being measured on the same basis considering local ambient conditions? The burden
INSUflex is available in combination of various wall thicknesses and diameters to suit G.I., copper and PVC pipes. The product is applied to the surface using an adhesive compound. A protective layer of glass cloth, in two layers with an adhesive compound is then applied before providing a weather barrier, such as aluminium / G.I. cladding for outdoor application.

E-mail: insulation@supreme.co.in Web: www.supreme.co.in
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Universal Construction Machinery & Equipment Ltd
Flooring Epoxy / PU
Comprehensive Guidelines for Execution of Epoxy / PU Floorings
Prachi Mahajan
Director, Neocrete Technologies Pvt. Ltd.
lmost all industries in India today have epoxy/PU floorings in their plant area in order to provide seamless, joint-less, aesthetic, chemical-resistant, hygienic, dust-free atmosphere. An overall survey will indicate that not all users are happy with the result. Many of the users express that they experience variety of problems such as de-bonding, bubbling, scratches, uneven surfaces and so on and expressed concern regarding its durability. This article aims to address many of these issues related to selection, execution and aftercare of epoxy/PU floorings so as to minimize these instances, though not eliminate them completely. A survey in USA on epoxy/PU floorings have indicated that about 20% of the problems were due to wrong selection of material/thickness, 60% due to wrong application and 20% due to poor quality of the products. Hence it is important to divide the discussion into three parts: pre-installation guide-lines installation procedures post-installation practices
Curt Augustsson, in his Epoxy handbook gives the following guideline: First calculate the maximum load distribution of the moving load, say Fork lift. Customer will give you the info as to the max load of Fork lift including the dead weight say 3000 Kg. Find out the contact area of wheel on to the floor. (keep a white paper on the floor under each wheel and draw the contact area of all the wheels.) Let us assume that it works out to 5 cm2. Then load distribution works out to 3000/5 = 600 Kg/cm2. If the grade of concrete is M25 (comp. strength of 250 Kg/cm2), then load factor is 600 divided by 250 equals to 2.4. Check the graph below, go to 2.4 on the vertical axis and you will arrive at 3mm for the floor thickness.
Part I: Pre-installation guidelines Selection of right product: Whether Epoxy or PU, solvent-borne or water-borne systems are suitable for a specific application has been dealt by various authors before me and hence am not addressing in this article. The major difference between epoxy & PU systems is that PU is more flexible and hence is more suitable in high-impact areas. Selection of right thickness: It is very important to arrive at correct thickness of flooring to provide optimum service to the required traffic conditions. Higher the thickness, higher the durability, but higher the cost. Hence it is pertinent to calculate the right thickness. How do you calculate the right thickness? Engineer
Analysis of requirements: This is the most important part of the process for the selection of right product as well as the right application methods. Obviously, a single product cannot meet all the requirements and hence the customer has to allot a priority for each requirement. The following table gives an empirical selection criteria ( based on our experience in assessing various industrial requirements). Light duty
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Flooring Epoxy / PU
flooring can be laid from 500 microns to 1mm, Medium duty at 1mm to 2mm and heavy duty varies from 3mm to 6mm.
Priority Rating for typical traffic type
Resistance to wear Resistance to Impact & static loading Ease of Maintenance Resistance to penetration of oil, grease etc Cleanability Chemical resistance Anti-slip/Anti-stain resistance Flammability & Fire safety Scratch/scuff resistance Hygienic/anti-bacterial (seamless) Aesthetics Dust-protection
Check for moisture content preferably under plant operating conditions (Refer the detailed instruction given below) Check for ingress of water thro' Roof/Wall cracks and floor joints Any chemical / solvent spillage & its concentration, temperature etc Any possibility of steam impingement Type of traffic envisaged and the condition of material handling equipment (type of wheel etc) Any cracks / pot holes Understand customer's expectations Estimate the job correctly by preferably measuring the area.
Heavy Duty Medium Duty Light Duty

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 9 5 7 11 8 12 10 6 9 10
8 11 5 6 7 12 4 3 2 1
b.Moisture testing: Moisture in the concrete or rising moisture from subsoil has been the single most contributing factor for failure due to bubbles. Moisture doesn't just mean water droplets, it could include high humidity. Some coatings shouldn't be applied when humidity levels are high. More obvious sources of serious moisture are things like rising moisture through the concrete pores, higher moisture content in a new concrete, standing water puddles on a concrete slab, or, even more likely, a damp or even saturated surface. Surface dry doesn't mean really dry. Surface moisture
All the above parameters can be said to resist the following four broad categories: Mechanical effects: Static and dynamic loads, abrasion, impact, vibration, skidding, conductive or ant-static etc Chemical effects : Oil, grease, chemicals, soluble salts, cleaning agents, solvents Environmental effects: Thermal exposure such as heat or cold, UV and other weather conditions, noise Biological effects: Bacterial impact
d) Pre-installation checks: a. Check List : This is the most important step in ensuring that the final floor meets or exceeds the expectations of the customer. Check the type of floor - Mosaic / Concrete/ Tile / Stones / Marble . (If so, level of polish) If concrete, any floor-hardener, curing agent etc have been used? Check the soundness of the floor by hammer/ scratching the surface with coin etc. Check the porosity of the concrete by putting a few drops of water and check for beading etc Check the level-differences/undulations on the floor Check for oil spillage, grease or any other contaminants content can be measured by means of a hand-held moisture meter and the thumb-rule is that the moisture content shall be less than 5% to allow impermeable coatings to be laid . However, surface moisture is only an indicative test and not sufficient to test rising moisture. There can be (and often is) a high moisture content
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Flooring Epoxy / PU
hidden just below the surface. The standard test is to tape a four foot by four foot plastic sheet to the concrete and see if visible moisture collects under the plastic. Some of the modern epoxies can be applied to wet or damp surfaces but generally a moisture rich surface means no possibility of coating. c. Check for oil/grease: Generally coatings do not stick to greasy, oily, waxy surfaces. This includes many kinds of plastic surfaces. Oily surfaces can be tricky, Just grinding the surface is often not good enough, as oil within the concrete is bound to rise to the surface before the primer has the chance to stick. Even on what seems like a non-greasy surface, many coatings will 'bead-up' leaving behind hollow, coating-less circles or voids. d. Check for dust, salts etc: This is one of the neglected steps and can lead to disastrous consequences. Coating may stick to the dust but not to the base floor
and can lead to de-bonding. Salts and/or minerals either deposited out on the surface from the curing of fresh concrete, or from the evaporation of seawater on concrete or steel can quickly ruin a coating. All the above pre-installation steps are very important activities that should not be ignored to ensure a longlasting epoxy/flooring solution. Second-part will deal with installation procedures and post-installation practices.
Authors Bio
Prachi Mahajan is one of the directors of Neocrete Technologies Pvt Ltd and has an extensive experience in executing waterproofing coatings and epoxy/PU floorings of over 10,00,000 sq.ft. In this 2-part article, she shares her experience in order to provide the best flooring solution to the customer and avoid problems faced by the applicators
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Esquire -CMAC Pvt.Ltd.
Waltair Enterprises: A Quality Range of Construction Fibres and Chemicals

ETEX construction fibres and chemicals from Xetex Corporation are considered the preferred choice of the construction industry. Starting six years back in the domestic market, the company has made deep inroads into the highly competitive Indian market. The company is also exporting its products to Sri Lanka, Malaysia and African countries. Additionally it is planning expansion into the Middle East and European markets in the near future. The company's products apart from being cost-effective, they also help in improving the quality of construction. The company uses superior quality raw material and ensures that all its products are in accordance with industry parameters and standards. Its strong R & D focus has seen it come out with an innovative range of products in recent times. ISO-9001:2008 certified. Salient features of some of the company's products are as follows: 1. CETEX Construction Fibres: This product improves the impact and abrasion resistance of concrete, prevents cracks formation and water seepage. It also prevents opening of micro cracks which develop at the time of casting and create seepage problems after 1.3 years. Impact resistance and flexural & residual strength increases with higher dosage of fibre. The additional cost incurred is ` 0.40-4.50 per sq.ft per inch of thickness, depending on the dosage. Mostly when the fibres are used as secondary reinforcement (min dosage @ 600 gram/cubic meter), the cost works out to ` 0.40 per sq.ft of area per inch thickness of concrete/mortar. For certain flooring projects one can do away with steel in the floor and therefore recover the above mentioned cost. In certain other cases, overall saving can be ensured by reducing the thickness of concrete. Fibres are also used in tunnel lining and other concrete structures to prevent spalling (explosion) of concrete during fire. Available lengths are 3 mm to 5 mm.
2. LSH / LSD/LH: This particular product improves the abrasion resistance and surface gloss, apart from reducing porosity, thereby water seepage and the makes the surface dustproof. LSD is a premium nano lithium based product which apart from all the features of LSH also makes the surface water repellent. It can be also used over old concrete surfaces. The extra material cost incurred for the surface works out to ` 0.50-2.50 per sq.ft depending on the surface condition. It does not form a film, but becomes an integral part of the concrete. The volatile organic content (VOC) in the product is nil and it conforms to the green building code. It can also be used as a curing agent, thereby enabling saving of the cost of curing. 3. CETEX SPWP or SPWR: This is a Lignosulphonate or naphthalene based admixtures. It helps in increasing the compressive strength of concrete and makes it compact. Extra cost for the screed is ` 0.10 to 0.15 (app.) per sq. ft per inch of thickness. This product can be used when the mixing is on site. 4. CETEX LS: This product seals the surface, thereby not allowing liquid penetration and preventing corrosion. The material cost works out to ` 1.00 per sq.ft. It is inert and non reactive, apart from conforming to green building code since the Volatile Organic Content (VOC) is nil. 5. Other Products: New products like bonding agents, curing compound
(water emulsion) and Micro-silica have been developed by the company. It is now in the process of developing Deshuttering oil (with nil-VOC) for better quality and durability of concrete. The company's products, at a nominal extra expenditure of ` 050 -10.00 per sq. ft enable to increase the life of concrete slabs, road, screed, floor, mortar, etc. They also help in saving recurring cost of repairs of the top surface which works out to more than ` 55 (app.) per sq.ft per inch of thickness, which includes the breaking of the damaged surface and rebuilding. Some of the projects where CETEX construction fibres and chemicals have been used include, (a) Outlet of German retailer, Metro, in Mumbai-commercial floor, (b) site of Terex India at Hosur, (c) Konkan Railways for fast setting of tunnel lining, (d) Warehouse of Future Group at Ghaziabad, (e) MRF, Hyderabadmaking the floor dustproof, (f) Keshar Solitair, Keshair Symphony and Keshar Harmony- floor of parking area and car movement area, (g) GLS Industries P Ltd, Gurgaon, (h) VS Patel, warehouses in Nairobi, Kenya (i) Concrete road projects at Mumbai and Thane.

6th floor, 120, Vaswani Chamber, 120, D.V. Road, Opp KC College, Churchgate, Mumbai-400 020 Ph: +91 93222 13698 / 99877 99688 Web: www.waltar.in / www.xetexcorp.com
Waltar Enterprises
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Mc Bauchemie (India) Pvt. Ltd
Construction Chemicals Industry Analysis
Focus: A Challenging Phase Awaits the

Construction Chemicals Industry

t is often said that the state of the construction industry is one of the best indicators for judging the economy of a country. Nowhere does this apply more than in the case of India, where the construction industry had set a scorching pace, growing consistently over the last decade. Although the impact of the vagaries of global economic uncertainties are being felt by the construction industry, the fact remains
that the industry continues to grow and maintain its position as the second largest employer after agriculture. One of the direct beneficiaries of this growth story has been the construction chemicals industry, popularly referred to as the 'sunrise industry' among the construction fraternity. The Indian construction chemicals market is considered among the fastest growing in the world. The market for
construction chemicals has grown at a CAGR of 14% in the recent few years. Despite the economic slowdown the market is expected to maintain a healthy growth rate in the near future. Dominating the market has been admixtures, which constitute about 35% of the market while flooring chemicals follow suit with about 20% market share. The share of admixtures does not come as a surprise since an estimated 75%
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contributing to the growth of the construction chemicals industry. While a significant onus of the growth of the industry lies with the government initiatives, there have been some positive developments happening for the construction chemicals industry. The formation of the Construction Chemicals Manufacturers Association (CCMA) is a development that augers well for the industry. CCMA is taking efforts towards raising the awareness level about proper usage of construction chemicals. As put rightly by Mr.Samir Surlaker, President of CCMA, The toughest challenge facing the industry today is the proliferation of incorrect usage of construction chemicals. In many instances such usage leads to failures and construction problems. This can be rectified by standardizing construction chemicals and switching the entire industry to performance based specifications. Sharing similar views is Mr.Sanjay Bahadur, CEO, Pidilite Industries, a market leader in the domain, who feels that raising awareness is the only way people will get to know about the benefits of using construction chemicals. Highlighting the fact, Mr.Sanjay Bahadur opined recently, Propagation of the multiple benefits of
The toughest challenge facing the industry today is the proliferation of incorrect usage of construction chemicals. In many instances such usage leads to failures and construction problems. This can be rectified by standardizing construction chemicals and switching the entire industry to performance based specifications
Samir Surlaker
President, Construction Chemicals Manufacturers Association & Chairman, MC-Bauchemie India Pvt. Ltd.
construction chemicals is the need of the hour. According to him, diminishing natural resources, demands of mass housing, high-rise construction, high speed construction,
of concrete that is used globally contains admixtures in the mix. The rest of the market is shared by other key segments including, waterproofing, repair & rehab, adhesives, sealants, among others. The total construction chemicals market including the significant unorganized sector, could be anywhere to the tune of over US$700 million, according to industry estimates.
Lack of entry barriers means that the industry has to grapple with a large unorganized sector
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Applicator Training One of the toughest challenges in the Indian context for major players in the construction chemicals field has been training. The onus has been on individual companies to devise specific strategies to train the lakhs of applicators in the country on the proper use of construction chemicals. A good thing about the focus on training programs has been that companies have been able to reach to the unorganized sector through this route. Explained Mr. Swapnil Deshmukh, Marketing Manager, Chembond Chemicals Ltd, a market leader in the field, We have recently come out with a quarterly technical bulletin, 'Techconnect' for contractors, structural engineers, and developers which will enhance their knowledge on the latest construction practices. Also, we are in process of
Infrastructure and high-rise projects are examples of demand drivers for construction chemicals
all challenges for the construction chemicals industry. Complexities of Indian Market Building up awareness about construction chemicals is easier said than done, given the size of the Indian market, a majority of which is being catered to by the unorganized sector and the difficulties in getting the 'owners' involved. Going into details about the difficulties involved in the process, Mr.Subbu Venkataraman, Managing Director of Sika India, an acknowledged technology leader in the field, observed, The vast size of the country means
The vast size of the country means that the process of raising awareness could take years, even decades
Subbu Venkataraman
Managing Director, Sika India Pvt. Ltd.
that the process could take years, even decades. People can always ask why companies like us can't go in for television advertisements. But I am not too sure whether that is the right way to go. It can definitely help you to promote the brand, but we are not like an FMCG product. For example, everyone knows how to use soap and an advertisement may be able to sway people from using one brand of soap instead of another. But tell me how many people know how to use an admixture? Or how to use a repair mortar or a waterproofing compound? Even if they were to buy based on such publicity, unfortunately in many cases, the owner or in some cases the contractor himself doesn't know how to use the product, hitting the nail on the head, about the complexities involved in the process. Big names such as Sika, Fosroc, Pidilite, MC -Bauchemie, BASF, Chembond, Perma, Zydex, Choksey, etc , have been focusing their efforts towards increasing awareness about construction chemicals in the country. In an increasingly globalized world every manufacturer in the market is emphasizing on industry best practices in order to gain the competitive edge, thereby attracting more end users.
Propagation of the multiple benefits of construction chemicals is the need of the hour
Sanjay Bahadur
Global CEO, Pidilite Industries Ltd.
conducting meets with our customers which will include a speaker session from an expert in the construction industry and make them aware on the new technology and solutions available in the market. The company has also come out with a new brochure which includes in-depth information about its products, its usage, and its application. MC-Bauchemie India Private Limited, another market leader also provides specialized training. Going into the details, Mr.Sunny Surlaker, Head Admixtures Division of the company said, We train our engineers in India and abroad. Our applicators are trained
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Cerachem Pvt.Ltd
structure development and real estate, both commercial and residential, is one of the biggest pluses for the construction chemicals industry in India. The country is in the midst of its biggest ever infrastructure building spree. The economic uncertainties notwithstanding, there are indications that the government may pump in investments to the tune of US$ 1 trillion for infrastructure development during the 12th Five Year Plan period (201217). A vast majority of the projects that will be awarded in the future are expected to be in the public-private partnership
Unique construction requirements, like in the case of tunnel projects pushing demand for specialty construction chemicals
and certified by independent institutes in Germany. Zydex Industries is yet another company which offers specialized training for applicators. Explaining the methodology, Dr.Ajay Ranka, the Managing Director of the company said, Our technical staff periodically arrange training program for our dealers, applicators or direct users and assist to solve their queries. Conduct of specific training programs
is also high on the agenda of CCMA and is one of its important objectives. According to Mr.Subu Venkataraman, the solution, lies in all the CCMA members contributing resources in the form of technical abilities, with the industry association acting as a focal point for conducting training programs. Growth trend The inherent demand for infra-
We train our engineers in India and abroad. Our applicators are trained and certified by independent institutes in Germany
Sunny Surlaker
Head Admixtures Division, MC-Bauchemie India Pvt. Ltd.
Increased usage of RMC bodes well for the construction chemicals industry
(PPP) mode, which augers well for the construction chemicals industry. With contractors expected to adhere to strict project deadlines and at the same time not compromise on the quality front, construction chemicals are gradually becoming their best allies. It is not surprising then that construction chemicals have become the common factor among all types of infrastructure projects gradually, whether it is roads, tunnels, metro, flyover, irrigation or canals, to mention only some, construction chemicals are playing an important role. The thrust given to the manufacturing sector is good news for the construction chemicals industry. The draft National Manufacturing Policy aims to create world-class National Investment and Manufacturing Zones (NMIZs), which would be mega investment zones. This along with the
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Our technical staff periodically arrange training program for our dealers, applicators or direct users and assist to solve their queries
Dr.Ajay Ranka
Managing Director, Zydex Industries
proposed Delhi-Mumbai Industrial Corridor projects is expected to give push to demand for construction chemicals. Flooring chemicals for example, could be one of the segments to gain from the rapid industrialization. Grouts are another segment that may witness a huge growth in demand. Another key area, particularly in a market like India is the repair & rehab segment. While a major chunk of the business is expected to come from new construction, maintenance of old ones is another area that is already
driving the demand for construction chemicals. Clients around the country are realizing that repair & rehab works out much cheaper than demolition and re-construction and this is driving the market for construction chemicals, particularly in urban areas. The market for very high strength concrete has also been on the rise. The unique requirement of mega infrastructure projects and high rise projects, for example has been driving this demand. The gradual evolution of the market, from being price-driven to becoming value driven has meant that newer products are making an entry into the market. The market for admixtures is a good example. From superplasticizers to hyperplasticizers, every kind of admixtures is today making an impact on the market. Contractors on their front are becoming aware that construction chemicals on an average would constitute only about 2 % of the total construction cost, but offer immense benefits in the long run. One of the best examples for the acceptance of newer concepts and technologies by contractors can be found in the form of ready-mix concrete (RMC). In fact, the increased usage of RMC has been
another factor fuelling the growth of the construction chemicals market. Of Primitive Codes and Lack of Standardization Worldwide research has pointed out that almost 80%-85% concrete that is produced in the developed world contains construction chemicals in some form or the other. The corresponding figures for India although low, points out to the immense potential of the market. There are some tough challenges that the construction
Our Building Codes by the BIS are primitive, and there are neither Codes nor Codes of Practice for waterproofing, repairs, flooring, structural rehabilitation etc. Our civil engineering curriculum in the engineering colleges is also very old and obsolete
M.A.Waheed
Chairman, Perma Construction Aids Pvt. Ltd.
Companies are focusing on training for proper onsite application of construction chemicals
chemicals industry first needs to surmount. Lack of adequate codes and standardization for example are issues that need urgent attention. Pointing out the lacuna that exists in the industry, Mr. M.A.Waheed, Chairman, Perma Construction Aids Pvt Ltd, another leading name in the field, said, Our Building Codes by the BIS are primitive, and there are neither Codes nor Codes of Practice for waterproofing, repairs, flooring, structural rehabilitation etc. Our civil engineering curriculum in the engineering colleges is also very old and obsolete. This automatically means that knowledge among the civil engineers about construction chemicals
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mention the consequential damages that they suffer. Introducing a minimum standard for any product and making it mandatory for all manufacturers a challenge faced by the industry. The Formula for Success Without any entry barriers, the construction chemicals market is still dominated by the unorganized sector in India. This has resulted in low value products rubbing shoulder with worldclass products, leading to skewed competition prevailing. However, things are gradually but surely changing. Manufacturers have realized that product diversification, apart from making efforts to provide high value
Basement Waterproofing
is very low. Selection of construction chemicals if any, when it becomes a necessity, is often done by the non technical staff on site on the cost basis and not on the utility basis. Bemoaning the lack of standardization and its impact on the construction chemicals industry, Mr. Samir Surlaker, President, CCMA added, The most important improvement I would like to see for this
There are a number of unorganized small operators in this sector. Many of them are fly-by-night operators who offer cheap products luring potential customers. They shake the confidence of customers due to non-performing products, not to mention the consequential damages that they suffer
Gangadharan Manari
Managing Director, Cera-Chem Pvt. Ltd.
industry is standardization of construction chemicals. The standardization is a must for end users to compare between different products. Secondly, most of our specifications are prescriptive. i.e. we mention the formulation ingredients. We have to change specifications to performance based so as to effect durability enhancement, and sustainability of structures. The formulation and generic basis can be mentioned for uniformity and equivalence testing which is more to control the quality and uniformity. Consistent shortage of key high performance raw materials, along with increasing costs are another big worry in the short term, according to Mr. Swapnil Deshmukh of Chembond Chemicals. The unchecked entry of inferior quality product manufacturers is tarnishing the image of the industry, lamented Mr. Deshmukh, pointing out to another issue that needs to be addressed on an urgent basis. Sharing similar views, Mr. Gangadharan Manari, Managing Director of Cera-Chem Private Limited quipped, There are a number of unorganized small operators in this sector. Many of them are fly-bynight operators who offer cheap products luring potential customers. They shake the confidence of customers due to non-performing products, not to
We have recently come out with a quarterly technical bulletin, 'Techconnect' for contractors, structural engineers, and developers which will enhance their knowledge on the latest construction practices
Swapnil Deshmukh
Marketing Manager, Chembond Chemicals Ltd.
products at competitive prices holds the key to being successful in the Indian market. The key also lies in increasing awareness about high value products to the end users and increasing their consumption. The coming together of leading players under the banner of CCMA also bodes well for the growth of the industry. Apart from the sustained pace of infrastructure growth, the push being given to affordable housing and rapid urbanization, are all driving factors, set to play a crucial role in the rapid growth of the construction chemicals industry in India in the near future.
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Choksey Chemicals Pvt. Ltd.
Industry Interaction
In Conversation with Samir Surlaker

Samir Surlaker
he construction chemicals industry is among the most important components of the construction industry in the country. Although the construction chemicals industry is still at a nascent stage in the country, there is no doubting its vast potential. Its rapid growth in recent years has been fuelled by the need for faster and safer construction. One of the turning points for the growth of the industry has been the formation of the Construction Chemicals Manufacturers' Association (CCMA). The key objective of CCMA is to promote the growth of the construction chemicals industry by raising the awareness and quality standards as well act as a representative body for communicating with government, chambers of commerce, regulatory authorities and other forums, be it domestic or international. Editor-in-Chief, K. P. Pradeep, recently interviewed Samir Surlaker, President of CCMA, who gave detailed insights into the formation of the
association, its aims and objectives, the state of the construction chemicals industry in the country and the future plans of CCMA. Mr.Samir Surlaker is a Civil and Structural Engineer from VJTI having over 30 years of national and international experience in construction chemicals, rehabilitation strategies, injection systems, having worked in various locations including, Germany, Europe, Middle East and India. He is currently the Managing Director of MCBauchemie (India) Pvt Ltd, a joint venture with MC-Bauchemie, Germany manufacturing over 100 construction chemicals. Mr.Surlaker is a member of several technical and organizing committees conducting seminars and symposiums in topics related to advance developments in Civil, Structural Engineering and Concrete Technology. He is Fellow of The Concrete Society (UK), IEI, Indian Institute of Valuers, ICI and IIBE, IWWA, IGS etc. He is associated with several professional bodies is a member of ACI, ASCE, IRC, ICA, AEI, International Society for Soil Mechanics and Geotechnical Engineering, Deep Foundation Institute (USA), SPC (USA). Mr. Surlaker is also member of the BIS in CED 41 committee for Waterproofing and heads few sub committees for formulations of IS Codes for advanced techniques and materials in waterproofing and concrete protection. Here are excerpts from the exclusive interview. Given the huge potential for construction chemicals in the country, why is that the formation of an industry. Why was there a delay in the formation of an industry body in the CCMA. The Indian construction industry
has come of age. Contractors are now more focused towards sticking to strict project deadlines, without compromising on the quality front. The construction industry in the country has been growing at a rapid pace over the last decade. The use of construction chemicals was however not keeping pace with the rapid growth of the construction industry. The formation of CCMA is a positive step towards this process. The growth in the construction industry, combined with the demand for safer, as well as faster construction will fuel the growth of the construction chemicals industry. The key objective of CCMA will be to be the voice of the industry which would represent the industry in communicating with the government, regulatory bodies, chambers of commerce and other domestic and international forums. I am glad to state that the response has been extremely positive towards forming a strong apex body. Even raw material suppliers to the industry have shown keen interest in joining the association as associate members. Apart from being a voice of the industry, CCMA is also focused towards raising awareness levels among the various stakeholders of the construction industry on construction chemicals, through the conduct of various training programs, seminars, events, etc. What are the aims and objectives of CCMA? The main aims and objectives of CCMA include: One of the primary objectives of CCMA is to provide a forum for construction chemical manufac-
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turers wherein they could discuss common problems and arrive at solutions through exchange of information amongst the members. Raising awareness about construction chemicals is one of the key objectives of CCMA. It would educate members through means of seminars, meetings, events, etc. on construction chemicals and on the provision of various central and state enactments and their amendments. Collection and dissemination of statistical and technical information to create awareness and to maintain high standards among users, leading to accelerated growth of the construction chemicals industry is another important aim of CCMA. CCMA will act as the voice of the industry. It would be a constructive forum to communicate with the various governmental bodies/ associations/institutions, chambers of commerce and other commercial, industrial and public bodies within India or abroad, in order to promote the objectives of the association. Conduct of continuous education programmes for raising awareness levels is another important objective. CCMA intends to do so in order to ensure manufacturers maintain high standards and business ethics, by organizing workshops, conferences, lectures, seminars, dissemination information through periodicals, journals, books, institution of scholarships, fellowships, awards, and encouraging research studies in the field of construction chemicals. CCMA wishes to work in close tandem with other industrial bodies with common interests. One of the objective is to subscribe to become a member of or otherwise affiliate or cooperate with any other body in India or elsewhere with which the association has common interest to establish, cooperate with, or receive into the
Association or otherwise assist any Association or accept affiliation of any other Association having objects similar to those of the Association. It would regulate the conduct and practice of construction chemicals trade and manufacture by establishing just and equitable standards and principles. CCMA would do all such acts, deeds and things as may be necessary and conducive to the manufacture, and development of trade and commerce in relation to or incidental to the construction chemicals industry, in the promotion or attainment, or in the overall interest of the objectives of the Association.
What according to you are major challenges facing the Indian Construction Chemicals industry? The toughest challenge facing the industry today is the proliferation of incorrect usage of construction chemicals. In many instances such usage leads to failures and construction problems. This can be rectified by standardizing construction chemicals and switching the entire industry to performance based specifications. The most important improvement I would like to see for this industry is standardization of construction
Collection and dissemination of statistical and technical information to create awareness and to maintain high standards among users, leading to accelerated growth of the construction chemicals industry
chemicals. The standardization is a must for end users to compare between different products. Secondly most of our specifications are prescriptive. I.e. we mention the formulation ingredients. We have to change specifications to performance based so as to affect durability, enhancement, and sustainability of structures. The formulation and generic basis can be mentioned for uniformity and equivalence testing which is more to control the quality and uniformity. Many a times, lack of codes is cited for making performance-based specification. Since our codes are being updated or more BIS codes are being formed, in the meantime we can reference international codes like EN, ASTM and guidelines by several Associations and institutions to arrive at performance based specifications. There is standardization all over world and with open information gateways we can be at par to state-of-art in this field. Standardization will be the need of the hour. Another issue is that, faced with innumerable products the end user is confused and cautious to new technologies as there are different claims and wide spectrum of price structure. The awareness is low and market is growing haphazardly. It will take some time for industry to stabilize to the European/ international level with respect to quality, value addition, and awareness. Looking at the immediate future, what are the key issues that CCMA proposes to take up with the government? We have formed an exclusive commercial committee which would deal with issues that are related to the industry. One of the important aspects that we are looking into is the different VAT/ST rates that are being collected in different states. We are in the process of collecting the data. The prevalence of different rates has meant there is no level playing ground for construction chemical manufacturers. The committee
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will be approaching the government in order to rationalize the differentiated rates. We will also be putting forward a request for concessions, with respect to import/excise duty, etc. Additionally we plan to involve other industry bodies such as CII and FICCI in the process. Given the shadows of economic slowdown looming large, were you satisfied with the performance of the Indian construction chemicals industry in 2011? I would say so. Despite the slowdown, the market sentiments have been positive. The industry has been growing at a rate of 20 %-25% over the last five years. I attribute the growth rate to increased awareness. The formation of CCMA is focused towards increasing awareness and brings in standardization in the industry. Tell us about the opportunities ahead for the CC industry? The continued thrust on infrastructure development from the government is good news for the construction chemicals industry. With investments to the tune of US$ 1 trillion envisaged in infrastructure development and the continued growth of the realty industry, auger well for the construction chemicals industry. CCMA is taking steps to promote the industry as a singular powerful
entity, something that was not possible for individual companies. Our initiatives like the forthcoming C3 event are focused towards this end. The key lies in focusing on correct usage of construction chemicals. We will have to work towards enhancing end-user confidence in using construction chemicals during everyday construction activities. I feel that the two factors, rising awareness and steps towards standardization will help the industry maintain its healthy growth rate in the near future. Which are the sectors that are likely to fuel the growth of the construction chemicals industry? Construction chemicals encompass a vast range of products meant for the construction industry. Since these products are used along with concrete, it automatically means there large scale usage in infrastructure projects such as canals, highways, railways, power sector, etc. Then you have product categories for example, which are meant for flooring. Now, the rapid pace of industrialization means that the demand for floorings and grouts is expected to go up. Repairs and rehab is another key segment that is expected to grow in India. Restoration of old structures is becoming a big industry by itself and construction chemicals ensure that increased life expectancy of the civil engineered assets. Another key are which would fuel growth is protection of concrete from environmental pollution. Injection technologies would also be in demand given the spurt in irrigation projects and water retaining structures. To put it in a nutshell, there is virtually no sphere of the construction industry which won't be impacted by the use of construction chemicals. It is difficult to imagine modern day construction without construction chemicals. What are CCMA's plans vis--vis increasing its network covering all parts of the country?
For a relatively new association, CCMA boasts of a membership of over 35 companies and growing. In order to further strengthen the organization, we tend to open regional centres initially in Gujarat, Chennai, and Delhi. These regional centres will be headed by local members. We have already made a beginning towards the end with a regional meeting of manufacturers in Gujarat, wherein we spoke about the benefits of joining CCMA. We have similar plans for Chennai and Delhi, where we want to address manufacturers from south and north India respectively. We are confident that our membership would increase substantially in the next few months. Tell us about the C3 being organized by CCMA. How would this event help CCMA with respect to achieving its objectives? As mentioned earlier, one of the main objectives of CCMA is to increase awareness about construction chemicals in end users. The International Construction Chemicals Conference (C3) will focus on this cause. The participants in the conference would be end users, specifiers, government decision makers, etc. Reputed speakers, from both India and abroad will be able to instill confidence among the different stakeholders in the construction industry about the benefits, as well as correct usage of construction chemicals. Under the theme' Emerging Materials, Methods and Practices', captains of the industry , besides scholars from top research organizations and academicians will be sharing their words of wisdom during the event to be held on 17-18 February 2012, at Hotel Ramada , Powai, Mumbai. 'C3' is expected to be an excellent opportunity for all stakeholders to learn from the people who research and manufacture construction chemicals, on the latest and relevant innovations, materials and practices currently doing the rounds globally.
Despite the slowdown, the market sentiments have been positive. The industry has been growing at a rate of 20 %-25% over the last five years. I attribute the growth rate to increased awareness.
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Nina Concrete Systems Pvt Ltd
Concrete Water-Reducing Admixture
New Generation Water-Reducing Admixture for Concrete

J. M. Khatib1, S Negim2, M Tarek Uddin 3
1 4
School of Engineering and the Built Environment, University of Wolverhampton, School of Chemical Sciences, University of Sains Malaysia, 2 Department of Civil Engineering, The University of Asia Pacific, Dhanmondi R/A, Dhaka 1209, Bangladesh,
The use of a new generation of water-reducing chemical admixture on the properties of concrete has been investigated. Ten concrete mixes were produced for various amounts of water-reducing admixture (AD) dosages ranging from 0 - 0.7% (by mass of cement) with W/C of 0.28, 0.34, and 0.38. Workability of fresh concrete was investigated. Concrete cubes were made for evaluation of compressive strength and dynamic modulus of elasticity (Ed). Concrete prisms were made for evaluation of length change. Tests were conducted at 56 days. Generally all mixes containing AD achieved higher strength than the control mix without AD. The presence of AD caused a reduction in shrinkage. Recommendations for using a higher dosage of AD and different mix proportions were proposed.
Concrete technology is improving significantly since around 1980 due to the advent of water reducing chemical admixture and air-entraining chemical admixtures,. Highrange water reducing and air-entraining chemical admixtures are used to produce concrete of higher strength, obtained a specified strength at lower W/C, or increase the slump of a given mixture without an increase in water content. Also, development of new generation water reducing admixtures is continuing to meet with the necessary requirement of the ready-mixed as well as the precast concrete industries (Mitsui et al 1994, Izumi et al 2003). For example, by using a specially designed polycarboxylate ether polymer based superplasticizer, it became possible to accelerate the strength development at the very early stage of cement hydration. With the advent of such an admixture, it is now possible to develop a zero energy system that allows eliminating the energy requirements for placing, consolidation and heat curing of concrete in pre-cast applications (Demirboga et al (2004). A new hybrid type superplasticizer with two different lengths of polyethylene oxide (PEO) side chains is also a new polycarboxylate derivative. The moderation of PEO amount can maximize fluidity and minimize setting retardation. This new generation superplasticizer leads to develop a stable workability of pre-cast concrete, ready mixed concrete, and high performance concrete. It has been found that the new hybrid type superplasticizer, which is a polycarboxylate type polymer with polyethylene oxide side chains, provides both of viscosity lowering ability and flowing ability. This new superplasticizer possesses several components which adsorb to cement particle very fast, but also adsorb very slowly. This technology can stabilize the adsorption properties of superplasticizer which makes lower of viscosity and a better flowing ability of mortar possible (Izumi et al 2003). In recent years, polycarboxylate based superplasticizer has been used for the purpose of producing high strength concrete and high fluidity concrete. This kind of superplasticizer is a safe chemical admixture for health, because it contains no formaldehyde, so its application is expected to expand in the future. However, a retarding property of this type of superplasticizer has caused rare application in cement based pre-cast products. Therefore, with optimization of the chemical structure of polycarboxylated copolymer, a novel polycaboxylate based SP powder is also developed (Tsukada et al 2003). Investigations are still necessary to develop better chemical admixtures to mitigate the negative influences of superplasticizer. Durability based studies are also necessary to check the long-term durability of the chemical admixtures in various exposure conditions. In this study, some selected properties of concrete having various dosages of a new generation modified polycarboxylic based superplasticizer are investigated. The properties of concrete investigated include workability, density, compressive strength, absorption, ultrasonic pulse velocity and drying shrinkage. The
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dosage of chemical admixtures varied from 0 - 0.7 % by mass of cement. Experimental Materials The constituents of mixes were Portland cement (PC), water, fine aggregate and coarse aggregate. The PC complied with EN 197-1. The chemical composition and other properties of cement used in this study are summarized in Table 1. The fine aggregate used conformed to BS EN 12620: 2002, and 10 mm nominal size crushed and washed stone was used as coarse aggregate. The water-reducing admixture (AD) used was a liquid based on a modified polycarboxilic ether. The AD conformed to Types A and F Admixtures of BS EN 9342:2001. Mixtures Proportions A total of 10 mixtures were investigated to understand the performance of concrete containing a relatively new high-range water-reducing admixture. Details of all mixtures are given in Table 2. Mixtures 1 to 3 had water to cement ratio of 0.38 and three different dosages of admixture (AD), 0.30%, 0.35% and 0.40% (by mass of cement) respectively. In mixtures 4 to 6, the water to cement ratio was 0.34 and the dosages of admixtures were 0.45%, 0.50% and 0.55% respectively. A low water to cement ratio of 0.28 was used in mixes 7 to 10 and the AD dosages were 0%, 0.60%, 0.65% and 0.70% respectively. Properties of concrete investigated were, workability, density, compressive strength, ultrasonic pulse velocity, dynamic modulus of elasticity and drying shrinkage. Casting, Curing and Testing Cubes of 100 mm in size and prisms of dimensions 75
Items
SiO2 Al2O3 Fe2O3 CaO MgO SO3 Na2O K2O Insoluble Residue Loss on Ignition Free Lime Specific Surface Area Residue Retained on 45 m Sieve Initial Set
PC: Portland cement Table 1: Composition and Properties of Portland Cement
Mixtures AD (%)
M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 0.30 0.35 0.40 0.45 0.50 0.55 0.00 0.60 0.65 0.70
W/C PC
0.38 0.38 0.38 0.34 0.34 0.34 0.28 0.28 0.28 0.28 464 464 464 473 473 473 487 487 487 487
Quantity (kg/m3) Water FA

176 176 176 161 161 161 136 136 136 136 585 585 585 596 596 596 613 613 613 613
CA
1207 1207 1207 1230 1230 1230 1266 1266 1266 1266
Table 2: Details of Concrete Mixtures PC: Portland cement; AD: Admixture in % by mass of cement; FA: fine aggregate, CA: coarse aggregate
mm 75 mm 300 mm were made. For each mix, 12 cubes and 4 prisms were prepared. Before casting of the specimens, workability of concrete was measured by slump value, the compaction factor and Vebe test. Specimens (cubes and prisms) were cast in steel moulds and placed in a mist room at 20oC and 95% RH for 24 hours. Thereafter, specimens were demoulded and all cubes and two of the prisms were placed in water at 20oC. The remaining two prisms were left to cure in water at 20oC. The cubes were used to determine the compressive strength and the determination of dynamic modulus of elasticity (Ed) and length change were conducted on the prisms. Testing was done at 1 day, 7, 14, 28 and 56 days but in this paper the results at 56 days were reported, except the In addition, length change was also measured at 2 and 3 days. The determination of compressive strength, Ed and length change was done according to BS EN 12390-3:2009, BS 1881-209:1990 and BS ISO 1920-8:2009 respectively. Results and Discussion Workability The workability results are presented in Table 3 (Khatib et al 2010). All mixtures exhibited very low workability.
Mixtures AD (%)
M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 0.30 0.35 0.40 0.45 0.50 0.55 0.00 0.60 0.65 0.70
Unit
% % % % % % % % % % % m2/kg % Min
PC
20.2 4.2 2 63.9 2.1 3 0.14 0.68 0.37 2.81 2.37 368 15.16 115.0
W/C
0.38 0.38 0.38 0.34 0.34 0.34 0.28 0.28 0.28 0.28
Slump Vebe (s) (mm)

20 15 20 10 10 10 0 0 5 0 4.9 5.3 5.2 7.9 8.9 8.3 33.5 26.8 24.8 26.6
Compaction Factor
0.86 0.86 0.81 0.79 0.80 0.82 0.78 0.76 0.75 0.78
Table 3: Workability of Concrete
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Slump values were below 20 mm and the Vebe times increased with the decrease in water content. The increase of Vebe time is particularly noticeable at water to cement ratio of 0.28. The compaction factor increases with increasing the water content. The results indicate that the dosages of AD used in this study give no remarkable improvement in workability. The low values of the slump obtained suggest that higher dosage of admixtures is recommended well above those recommended by the manufacturer, so that meaningful comparison can be made. This is particularly relevant in the case of low water to cement ratio. Compressive Strength The compressive strength of concrete for all mixed at 56
days of water curing is shown in Figure 1. Using an optimum dosage of AD seems to cause an enhancement in strength compared with low or high dosage of AD (Figure 1). The values of the slump obtained suggest that higher dosage of admixtures is recommended well above those used in the present investigation and well above the manufacturer recommendations, so that meaningful comparison between the strength values can be made. Dynamic Modulus of Elasticity The data of dynamic modulus (Ed) of concrete are summarized in Figure 2. As for the compressive strength
Fig. 1. Compressive Strength of Concrete at 56 days
Figure 2: Dynamic Modulus of Mixtures at 56 days of curing
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We put concrete into shape

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Hess Concrete Machinery India Pvt.Ltd.
Hess Concrete Machinery India Pvt Ltd. No 85, Richmond Road, Sheriff House, Richmond Road, Bangalore - 560 025 Tel no: 080 40050600: Email info@hessindia.com Web:www.hessindia.com
of concrete, the dynamic modulus increases with time. Comparing the control case (M7) with the other cases (M8, M9, and M10), it is seen that dynamic modulus is increased significantly with the addition of AD. The effect of dosage of AD is not clear as observed for the compressive strength of concrete. The dynamic modulus versus compressive strength data are correlated and the following logarithmic relation is found between the dynamic modulus (y in MPa) and the compressive strength of concrete (x in MPa), with a coefficient of correlation (R2) of 0.85. y=9621.8 In(x)+3343 Expansion The expansion of all mixes is shown in Figure 2. Generally, the results suggest that the use of AD cause an increase in expansion and there is no clear trend on the effect of higher AD dosage on the expansion. As can be noticed that the expansion continues to increase up to at least 56 days.. The change in expansion with time can be described by the following equation (ACI 1992, Huo et al 2001): (2)
where is the expansion in micro-strain, t is time in days, a is a constant related to strength and b is another constant related to ultimate expansion values and other factors including environmental conditions, specimens size and strength. Fitting the above equation to the experimental data, values of a and b were obtained for each of the mixes. Similar relationship is reported elsewhere (Khatib 2005) Conclusions and Recommendations Generally all mixes containing admixtures achieved higher
Fig. 3. Effect of admixtures dosage on expansion
strength than the control mix without any admixtures. The presence of admixture caused a reduction in shrinkage. A logarithmic relationship between strength and dynamic modulus of elasticity yielded a coefficient of correlation of 0.85 suggesting this relationship is appropriate. Based on the preliminary results of this investigation, it is strongly recommended to use higher dosage of admixture, than those used in the present work so that so adequate slump can be obtained. In the present work the dosages used were those recommended by the manufacturer but the low water to cement ratio in the mixes exacerbated the effect and dosages of admixtures above those recommended should be used Acknowledgements The authors would like to thank Mr. Field for conducting the experimental programme (a part of his dissertation) and the concrete laboratory technical staff Mr. Skelton and Mr. Harwood for their assistance.
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References
Amercian Concrete Institute - ACI (1992), Prediction of Creep, Shrinkage and Temperature Effects in Concrete Structures, ACI 209R-92, American Concrete Institute, Farminghton Hills, MI, p. 47. Demirboga, R., Turkmen, I., Karakoc, M.B. (2004), Relationship between ultrasonic pulse velocity and compressive strength for high-volume mineral-admixtured concrete, Cement and Concrete Research, Vol. 34, No. 12, pp 2329-2336. Huo, X.S., Al-Omaishi, M.K., Tadros, M.K. (2001), Creep, Shrinkage and modulus of elasticity of High-Performance Concrete, ACI Material Journal, Vol. 98, pp 440-449 Izumi, T., Satoh, H., Yamamuro, H., Hamada, D., and Mizunuma, T. (2003), A New Hybrid Type Superplasticizer, Supplementary Papers, Proceedings of the 7th CANMET/ACI International Conference on Superplasticizers and Other Chemical Admixtures in Concrete, Berlin, Germany, pp. 67-82. Khatib, J.M. (2005) "Properties of Concrete Containing Fine -
Recycled Aggregates", Cement and Concrete Research Journal, Vol. 35, No. 4, April 2005, pp 763-769. Khatib, J.M. and Clay, R.J. (2004), Absorption characteristics of metakaolin concrete, Cement and Concrete Research, Vol. 34, pp 19-29. Khatib, J.M., Tarek Uddin, M., Zhang, J.S. and Hamada, H. (2010), "New Generation Water-Reducing Admixtures for Concrete", 2nd International Conference on Sustainable Construction Materials and Technologies, Ancona, Italy, 28-30 June, (Editors:J Zachar, P Claisse, T R Naik, E Ganjian), Vol 2, pp 939-947 Mitsui, K., Yonezawa, T., Kinoshita, M., Shimono, T. (1994), Application of a New Superplasticizer for Ultra High Strength Concrete, ACI SP 148, Ed. Malhotra, V.M., American Concrete Institute, pp. 27-45. Tsukada, K., Ishimori, M., and Kinoshita, M. (2003), Performance of an Advanced Polycarboxylate-Based Powder Superplasticizer, ACI SP 217, Editor - Malhotra, V. M., pp. 393-408.
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Sika: Celebrating Years of Innovation

ika Group is an acknowledged trendsetter in the field of construction chemicals. The Group has during its journey of over 100 years crossed several milestones and is now a globally renowned brand synonymous with an innovative range of construction chemicals. It all began with the invention of mortar water-proofing agent, named Sika 1 in 1910. Kaspar Winkler the founder of Sika, invented 'Convervado', and 'Purigo', which were essentially developed to protect and clean granite in 1910 and a legend was born. There are some interesting theories regarding the origin of the name 'Sika'. While one theory states that the name is derived from the Italian word 'secco', which means dry, another theory says that silicate when translated into German is 'Silikat' which contains two syllables
'si' and 'ka'. A third theory says that the name was because Kaspar Winkler demonstrated the accelerating effect of Potassium compounds which has a chemical name of 'Kalium' and symbol 'ka', which when combines with silicates, makes it 'sika'. The fourth and most widely accepted theory is that word combined with the German spelling of the word calcium, which is 'Kalzium', led to the name- Sika. While there could be arguments about the origin of the name, there could be none about the fact that the company has grown remarkably over the years, on the strength of quality products. The breakthrough for the company came when Sika-1 was used to waterproof the Gotthard tunnel project in 1918. The Swiss National Railways waterproofed 67 tunnels with
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Nina Concrete Systems Pvt Ltd.
100 honored staff of Sika Vietnam lighting 100 candles
Sika during the following years. The company grew gradually, and between 1921 and 1928 subsidiaries were set up in Germany, England, Italy, and France. The operational leadership was transferred from family owners to nonfamily managers between 1970 and 1980, and it continues till date. Another important milestone was when Sika launched the one-component elastic polyurethane adhesive Sikaflex in 1980 and made a successful foray into the automotive industry. The period from 1990-2000 saw Sika found 16 new subsidiaries and made its presence in Asia, Eastern Europe, Latin America etc. In 2005, Sika acquired Sarna, making it a market leader in the roofing business. In fact, between 2000-2008 36 firms were acquired by Sika taking its turnover to 4.6 billion Swiss Francs and its workforce touched 13,000 plus. In 2010, Sika commemorated its eventful journey of over 100 years, when it had the privilege of again providing technological solutions with its construction chemicals for the extension of the Gotthard Railway Tunnel project. Indian Arm Sika India originally began operations in 1985 as an Indian company and was known as Qualcrete India Limited. Subsequently in 1987, Qualcrete India Limited entered into an alliance with Sika AG, Switzerland and was renamed Sika Qualcrete Limited. In 2002, Sika AG, Switzerland acquired 100 % stake in the company and since then it has been known as Sika India Pvt Ltd, which is a wholly owned subsidiary of Sika AG. The company has a widespread network consisting of 11 branch offices and 5 state of the art manufacturing units. Sika India also serves five export markets namely, Sri Lanka, Nepal, Bhutan, Maldives, and Bangladesh through a network of associates. An ISO 9001-2008 certified company's products are being used in several major infra-structure projects in the country, where it has grown rapidly and is considered a trendsetter, when it comes to the introduction of innovative products, ideally suited for the Indian market.
Sika Headquarters - Sweden
Range of Products from Sika for the construction industry
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STP Ltd.
Interview: Mapping the future with Subu Venkataraman, MD, Sika India
its construction chemicals for the extension of Gotthard Railway Tunnel to commemorate its glory of 100 years. You find very few takers for Chemistry in college and professional courses these days. As a founding member of CCMA what can be done to reverse this trend? Yes, it is a reality which we need to accept. I feel that it is more a social problem rather than educational. Ultimately it is the parents who decide on what their wards need to study. Peer pressure plays a key role. If children were to hear from their parents that they would become a computer engineer from the day they were born, that is where their mindset gets conditioned. The decision on what a student should study is being taken by their parents. Finally we end up with a situation where a student is forced to study a subject, rather than what he/she would have liked to study in the first place. Ultimately, it is the government which has to take initiatives. If someone like a Sika or CCMA tells people to study chemistry, people feel that they are doing it because they want people to work in their organization. Suddenly it is felt that the statement is being for a personal gain and your credibility gets lost in the process. Being one of the leading players in the vertical you serve, please take us through some of your activities that involve promoting the use of construction chemicals in the unorganized sector. Our construction chemicals business is organized into three business units. We have a concrete business unit, a contractors' business unit and a distribution business unit. The concrete and contractors business units are technology driven. The business of the concrete unit goes into admixtures,
Subu Venkataraman, Managing Director, Sika India
ika India is counted among the top names in the construction chemicals domain. A part of the famed Sika Group, which is considered the oldest construction chemicals company in the world, it is highly respected among the entire construction fraternity. In an exclusive interaction with Mr. K.P . Pradeep, Editor-in-Chief, Sika India's Managing Director, Mr. Subu Venkataraman, spoke about the company's product line, the innovative training programs that it conducts for applicators, the role of CCMA in furthering the progress of the construction chemicals industry and his own personal involvement in CCMA. Here are excerpts from the conversation. We are aware that Sika celebrated 100 years recently. Please take us through some of the important events & innovations over these 100 years. During its journey of 100 plus years, Sika has crossed several milestones. It all started with the invention of mortar waterproofing agent and naming it Sika 1 in 1910. Kaspar Winkler, the founder of Sika invented Convervado & Purigo, which were essentially developed to
protect and clean granite in the same year. The breakthrough for the company came when Sika-1 was used to waterproof the Gotthard tunnel project in 1918. The Swiss National Railways waterproofed 67 tunnels with Sika during the following years. The company grew gradually, and between 1921 and 1928 subsidiaries were set up in Germany, England, Italy, and France. The operational leadership was transferred from family owners to nonfamily managers between 1970 and 1980, and it continues till date. Another important milestone was when Sika launched the one-component elastic polyurethane adhesive Sikaflex in 1980 and made a successful foray into the automotive industry. The period from 1990-2000 saw Sika found 16 new subsidiaries and made its presence in Asia, Eastern Europe, Latin America etc. In 2005, Sika acquired Sarna, making it a market leader in the roofing business. In fact, between 2000-2008 36 firms were acquired by Sika taking its turnover to 4.6 billion Swiss Francs and its workforce touched 13,000 plus. In 2010 Sika again had the privilege of providing technological solutions with
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precast mortars, ready mix concrete, performance enhancers, supporting agents like mould release agents , etc. In a nutshell everything that has something to do with concrete. The contractors' business unit takes care of a lot of other applications like flooring, waterproofing, strengthening, repairs, roofing, etc. Our role is basically on a project basis. For example, if there is an industry which wants epoxy flooring, it will be handled by the contractors' business unit. Other examples for projects being handled by the contractors' business unit include repair of a dam or a railway bridge. In cases such as waterproofing of tunnels in metros or hydro power projects, it goes either to the concrete or contractors unit, depending on the exact nature of the activity. These two units are working to a large extent with the organized sector in India and are involved in very large projects. Coming to our distribution business unit, it is actually a route to the market. It involves selling products for smaller projects, as well as the typical G+3 kind of projects, which are relatively small projects. Waterproofing compounds, which are used for small repairs, typically in the kind of a house owner, also fall under this division. Tile adhesives which are used in small apartment units are another example of products which come under this business unit. The reason why we go through the distributor route in India is because of the vast size of the country. This route offers us a way to reach across the country. We have got something like 600-700 distributors and retail outlets where our products are available throughout the country. The retail outlets where our products are available number close to 10,000. If you have to really reach to every nook and corner of the country, my gut feeling is that if you do not have 100,000 outlets, you have not even started in India. To the extent possible, every Saturday, wherever we have a presence, we conduct either training for masons or all those workers at the ground level. This is done with the help of our distributor in the particular location. During these
training sessions we explain the technology behind our products and the purpose behind using them. Of course, the end users are free to use similar products from the competition. Our basic aim is to make people at that level to understand that there is a need to use such products in order to build a better building. Now, I would say that this is about addressing the unorganized sector in some form or the other. These training sessions make those people who are not using construction chemicals to at least make a beginning. Give us a few examples of major infrastructure projects where your products have played a key role. Some of the major recent / ongoing projects in India where our products have been used during various stages of construction include: Delhi Metro-waterproofing, etc. Kolkata Metro- waterproofing, etc. Formula One racing Track, Noida N u c l e a r Po w e r C o m p l e x e s waterproofing, etc. Renault-Nissan, Chennai-roofing, etc. Cognizant Technology Centre, Chennai- waterproofing, etc. Cyber Tower, Hyderabad-roofing, etc. L&T Mitsubishi Heavy Engg. Project, Hazira- waterproofing, etc. Reliance Petrochemical ProjectPhase 2 expansion-waterproofing, etc. Cast iron Wheel Manufacturing Unit, Bihar- waterproofing, etc. To mention only a few. Any new product launches in the pipeline? As far as the concrete admixtures front goes, providing custom made products that meets the needs of each customer/project is an ongoing process. Some of the new products in the pipeline include, (a) Sika Maxtack-A, which is an instant adhesive suitable for fixing any surface and (b) Sika Viscobond, which is powered by Viscocrete technology and is a one of its kind polymer emulsion.
Please tell us about your association with CCMA The very first meeting, this was even before CCMA was formally formed, was actually held at the Sika office in Mumbai. This happened somewhere in 2008. It really gained momentum afterwards and the association got formed in 2009. I got into the picture during the time when the association was formally launched. There is an interesting factor which makes CCMA different from other similar industry bodies. This is one association where ea ch member is a competitor but you don't feel it in any of the meetings. It speaks volumes about the aims and objectives for the formation of the association. The membership base is already reasonably large and is expected to grow further in the near future. How can the construction chemicals industry collectively scale the huge market potential that India has to offer? I would say the answer lies in building awareness and converting it into executable action. When I say awareness, it is among owners, consultants, engineers, big project owners, etc. It's going to be a massive task. It is not going to be easy. But I would say that every company is doing something towards it. For instance, when we do our specificationer activity, which large companies do, every single meeting that we do towards the specificationers' activity is increasing the awareness. You can already see the receptiveness fairly good now. People have been travelling a lot, looking at the quality of buildings elsewhere and they are beginning to demand why I can't get similar quality here? There are international consultants coming in with their requirements saying, look I have used Sika in other countries, I want to use Sika here. We have a range of internationally available products and there are people who come and ask for the product by its name. I mean, after that you don't even need to explain them about the features or the specialty of the product. They actually come with technical data sheets themselves. We don't even have to give them one.
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Interactions
Interview: M.A.Waheed,
Chairman, Perma Construction Aids

majority of them being multinational companies. Their products are formulated and made based on the requirements of overseas market. Whereas, Perma is a fully Indian company and hence all its products are designed and formulated, keeping the specific needs of Indian construction industry in mind. It is very important that products are designed in such a way that their application methods match the general skills of construction workers. Give us a few examples of major infrastructure projects where your products have played a key role? Generally speaking, admixtures are used mostly in the case of infrastructure projects. Perma has supplied admixtures to the prestigious Bandra Marine Outfall project in Mumbai, throughout its construction period. Ennore Port Project near Chennai has been other major prestigious project where Perma's admixtures have established performance in most demanding situations. Apart from this Perma has been regularly supplying its admixtures to various MSRDC bridge projects and to various commercial batching plants which supply concrete to various infrastructure projects. What according to you are the major challenges facing the Indian construction chemicals industry? It is a well known fact that the construction chemicals industry's growth is directly related to the growth of the construction industry. But in India the percentage of construction chemicals used in any building project is very negligible. It could be in fact a figure in decimals, where as in the developed countries and the Gulf countries the percentage of funds utilized on construction chemicals is up to 5% of the overall cost of the project. In India construction chemicals and the waterproofing treatments are not specified by the structural engineers and architects. Hence they are not reflected in the Bill of Quantities and often the contractor does not take this into account while bidding. During the construction or towards the completion of the project this necessity of water proofing or use of construction chemicals, crops up as an unavoidable necessity for which no provision has been made earlier. This somehow happens, even with the most economic products or services available, often defeating the purpose. Our own Building Codes by the BIS are primitive and there are neither Codes nor Codes of Practice for waterproofing, repairs, flooring, structural rehabilitation etc. Our civil engineering curriculum in the engineering colleges also is very old and obsolete. This automatically means that knowledge among the civil engineers about construction chemicals is very low. Selection of construction chemicals if any, when it becomes a necessity, is often done by the non technical staff on site on the cost basis and not on the utility basis. Looking at the size of the construction industry in India and recession in Europe, many MNCs have set up their businesses in India. The enthusiasm of the MNCs to establish market at any cost and the entry of several local players from the unorganized sector to take advantage of the low cost purchasing mentality of the buyers make the field complicated for an average manufacturer and fair player. How big according to you, in terms of value, would be the market for Construction chemicals in India? Present constructions chemicals market is roughly estimated to be around ` 2500/- crore. If construction chemicals were recommended by architects and structural engineers and if they were utilized as per specifications, this market could be ten times this figure. The current need is to bring in proper Codes for the quality and soundness of structures, and stricter norms for issuing occupation certificates for the residential buildings, ensuring better life of the structures.
M.A.Waheed
Chairman, Perma Construction Aids Pvt. Ltd.
erma Construction Aids Pvt Ltd is considered a leading name in construction chemicals. The company offers a wide range of products to cater to all the critical applications in civil engineering. Speaking exclusively to The Masterbuilder, Mr.M.A.Waheed, Chairman of the company, went into details about the various products it offers, their specialty, and the market for construction chemicals industry in the country. Here are excerpts from the interview. Tell us briefly about your product range? At Perma we manufacture the full range of construction chemicals. Our products are divided into six groups. Each group has ten to twelve products. They are as follows: Group I Group II Group III Group IV Group V Group VI Waterproofing Systems Tiling Aids Repair & Bonding Agents Admixtures for Concrete Coatings & Protection Systems Construction Aids
We keep on adding new products to cater to the growing needs of the construction industry. What makes your construction chemicals different from others? As far as the Indian market is concerned, there are several construction chemical manufacturers in fray, with a
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Speedcrafts Ltd.
Managing Director, Cera-Chem
Interview: Gangadharan Manari,

through retail outlets, across the counter, to our customers. Give us an insight into the quality assurance system that you have in place and your key R &D focus areas? We have an established quality assurance system developed and implemented in our factories. All the input raw materials are tested before they are approved for production. Similarly the finished products are tested to meet the minimum required specifications before dispatch. We are an ISO 9001 certified company and we strictly follow the documented processes and systems. Our R&D focus is on developing environment-friendly products at a competitive price, without compromising on the quality and performance front. Give us a few examples of major infrastructure projects where your products have played a key role. We take pride in stating that our products were used in Hyderabad International airport, Delhi Metro, north Chennai port etc. We are associated with GMR Infrastructures Pvt Ltd. in the construction of the Vijayawada-Hyderabad Express Highway and with IVRCL infrastructure Pvt Ltd for the construction of NH-TN08 between Coimbatore and Avanashi at present. Our repair products have been used in number of National Highway bridge repair projects in Andhra Pradesh and Kerala, in the recent past. Are you comfortable with your order book? As on today, we are comfortable with our order booking. However, we find delay in realization of revenues. Is there an impact as a consequence of the slowdown in organized construction sector? The slowdown in construction sector is definitely a matter of concern in our business. We are trying to sustain our growth by concentrating on products for repair & rehabilitation and retailing to some extent. Are you planning new product launches for 2012? We have developed a high performance integral waterproofing product which works on the theory of capillary crystallization. This product helps in completing the waterproofing of underground and water retaining structures at the time of concreting itself. Hence, many of the hassles associated with waterproofing can be overcome. We have successfully marketed and used this product in critical applications in South India. We plan to launch this product on an all India basis, this year. How big according to you, in terms of value, would be the market for construction chemicals in India? The value of construction chemicals business in India is estimated to be 1600 1700 crore per annum. What according to you are the major challenges facing the Indian construction chemicals industry? The use of construction chemicals is still at nascent Stage in India. Creating awareness in the use of construction chemical is a real challenge. We have to do lot of work to ensure construction chemicals become an integral part of any construction. This is challenging but will ensure the growth of the industry. CCMA is working on these lines. There are a number of unorganized small operators in this sector. Many of them are fly-by-night operators who offer cheap products luring potential customers. They shake the confidence of customers due to non-performing products, not to mention the consequential damages that they suffer. Introducing a minimum standard for any product and making it mandatory for all manufacturers is another challenge faced by the industry. The growth of the Indian construction chemical industry has been relatively slow when compared to the other emerging markets despite the huge untapped market. Your thoughts! Yes, as I mentioned earlier, the industry is still at a nascent stage here. The onus is one the manufacturers to create awareness about the benefits of the use of construction chemicals, in terms of speedy construction and durability of structures. The government on its part needs to come out with policies that will make construction chemicals being identified as any other construction material in all projects.
Gangadharan Manari
Managing Director, Cera-Chem Pvt Ltd
era-Chem Pvt Ltd is one of the leading construction chemicals manufacturers in the country. The product range of the company comprises of almost every conceivable high performance chemical requirement of the building construction and repair industry. Mr.Gangadharan Manari, Managing Director of the company, in an exclusive interview with The Masterbuilder, gave insights into the company's product range, quality assurance mechanism, R & D focus areas, and the challenges confronting the construction chemicals industry in India. Here are excerpts from the interview. Tell us briefly about your product range. Cera-Chem is manufacturing a wide range of construction chemicals to meet the specific requirements of the civil engineering sector, vis--vis, infrastructure projects, real estate, commercial and industrial buildings, repair and rehabilitation industry etc. The product group that we offer includes tile adhesives & joint grouts cementitious and resin based, water proofing products & systems, industrial flooring products including floor hardeners, coatings, overlays etc, sealants, industrial grouts, concrete admixtures and surface treatments etc. We also offer a range of products for repair & rehabilitation of concrete structures, concrete and steel protection systems etc. We offer our products in small user-friendly packages
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BASF India Limited
Concrete Viscosity-Modifying Admixtures
low water-to-binder ratio (w/b) of mortar and concrete is required for numerous applications to achieve improved strength and durability. The use of superplasticizers (HRWR) allows reducing w/b of mortar and concrete without significantly changing their flow properties. However, several problems can show up when using HRWR. When the concrete or mortar flow is kept constant by the addition of HRWR, the flow time (V-Funnel) as measure of viscosity is increased, because the volume fraction of particles in the suspension increases. By changing concrete flow properties using HRWR, problems in concrete production may result. For example, mixtures with HRWR are very sensitive to small changes in the w/b increasing the probability of segregation and bleeding. This is often observed in the production of self-compacting concrete (SCC) . On the one hand, viscosity modifying agents (VMA) can be used to enhance the resistance to segregation and bleeding. On the other hand, their use enables a modification of the flow properties and rheology of mortar and concrete. This property can be used to optimize various types of concrete. Shotcrete for example demands a relatively high yield stress and a relatively low viscosity to control adhesion and rebound behaviour respectively. As another example, when concrete is pumped, a
high viscosity of the mixture decreases the output at a constant pumping pressure. Viscosity-modifying admixtures (VMAs), also known as antiwashout admixtures, are relatively new admixtures used to enhance the cohesion and stability of cement-based systems. Such VMAs are water-soluble polysaccharides that enhance the water retention capacity of the paste. They are used in concrete intended for underwater repair of marine and hydraulic structures, and tremie concrete for the construction of curtain walls and deep foundation walls, etc. Such admixtures can also reduce the risk of separation of the heterogeneous constituents of concrete during transport, placement, and consolidation and provide added stability to the cast concrete while in a plastic state. Flowable concrete is commonly used for casting congested structural members that are often encountered in heavily reinforced mat foundations and in reinforced concrete structures in seismic regions. It is also used in restricted areas where the access for placement and consolidation is limited, as in the case of tunnel lining. The incorporation of a VMA in flowable concrete can enable the production of a stable and yet highly flowable concrete to facilitate
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filling congested reinforced members with minimal vibration and segregation. The improved homogeneity of the concrete can enhance bond strength to reinforcement and aggregate, thereby decreasing permeability. VMAs are also used in shotcrete for the repair of deteriorated structures, since it can enhance the sagging resistance of the concrete and enable the application of thicker lifts. Classification, Type, and Mode of Action of VMA's Mailvaganam categorized anti-washout admixtures and pumping aids into five classes according to their physical actions in concrete. These classifications are as follows. Class A: Water-soluble synthetic and natural organic polymers that increase the viscosity of the mixing water. Class A type materials include cellulose ethers, polyethylene oxides, olyacrylamide, polyvinyl alcohol, etc. Class B: Organic water-soluble flocculants that become adsorbed onto cement grains and increase viscosity due to enhanced inter-particle attraction between cement grains. Class B materials include styrene copolymers with carboxy1 groups, synthetic polyelectrolytes, and natural gums. Class C: Emulsions of various organic materials which enhance interparticle attraction and supply additional superfine particles in the cement paste. Among the materials belonging to Class C are acrylic emulsions and aqueous clay dispersions. Class D: Water-swellable inorganic materials of high surface area which increase the water retaining capacity of the paste, such as bentonites, silica fume, and milled asbestos. Class E: Inorganic materials of high surface area that increase the content of fine particles in paste and, thereby, the thixotropy. These materials include fly ash, hydrated lime, kaolin, various rock dusts, and diatomaceous earth, etc. VMAs were first used in Germany in the mid-1970s and later in Japan in the early 1980s. In North America, such admixtures have been used since the late 1980s in specialty grout and concrete applications. The VMAs that are commonly used in cement-based systems are water-soluble polysaccharides, such as cellulose ether derivatives and microbial-source polysaccharides, such as welan gum, that bind some of the mixing water, thus enhancing viscosity. Acrylic-based polymers, such as partial hydrolysis products of a polyacrylamide copolymer and sodium acrylate, are also employed. Cellulose derivatives often contain non-ionic cellulose ether as the principal component in which different materials are used. The main components of a cellulose-type VMAs are non-ionic cellulose ether, in which different substitutes are introduced into the cellulose. Viscosity-modifying admixtures can be powder based or liquidbased products. For example, Kelco-Crete is a powder-based product that contains welan gum and is used typically at a
concentration ranging between 0.05 and 0.20% by mass of cementitious materials, or 0.10 to 0.40% by mass of water for typical underwater concrete mixtures made with 0.45 W/C. The 81-11 Celbex 208 product is a cellulose-based admixture supplied by Fosroc and used at a recommended dosage of 0.7 to 1.2%, by mass of cementitious materials, for mixtures made with 0.45 W/C. Master Builders' Rheomac UW 450 is a cellulose-based VMA supplied in a liquid form and used at a recommended dosage of 260 to 1300 ml/100 kg of cementitious materials. Another liquid-based VMA is the Sikament 100 SC and 300 SC admixtures that are intended for use in underwater concrete and grouts for post-tensioning applications, respectively.
VMAs were first used in Germany in the mid-1970s and later in Japan in the early 1980s
The mode of action of a VMA depends on the type and concentration of the polymer in use. In the case of welan gum and cellulose derivatives, the mode of action can be classified in three categories, as follows:Adsorption. The long-chain polymer molecules adhere to the periphery of water molecules, thus adsorbing and fixing part of the mix water and thereby expanding. This increases the viscosity of the mix water and that of the cement-based product. Association. Molecules in adjacent polymer chains can develop attractive forces, thus further blocking the motion of water, causing a gel formation and an increase in viscosity. Intertwining. At low rates of shear, and especially at high concentrations, the polymer chains can intertwine and entangle, resulting in an increase in the apparent viscosity. Such entanglement can disaggregate, and the polymer chains can align in the direction of the flow at high shear rates, hence resulting in shear thinning.
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Rheological properties and HRWR demand The various water-soluble VMAs form viscous solutions that bind some of the mixing water in the fresh cement paste, thus increasing viscosity and yield value of the cement-based system. The yield value refers to the minimum shear stress needed to overcome the internal resistance of a fluid to initiate plastic flow. The extent of the increase in water viscosity depends on the type and concentration of the VMA, as well as on the applied shear rate. The increase in VMA dosage results in a sharp increase in viscosity, especially in the case of welan gum addition. Systems modified with a VMA exhibit a shear thinning (or pseudoplastic) behavior where the apparent viscosity decreases rapidly with the increase in shear rate. Aqueous solutions containing VMAs exhibit a shear thinning behaviour where relatively high viscosity at low shear rate drops significantly with the increase in shear rate. Resistance to water dilution The improvement of washout resistance of a cement-based material is advantageous in underwater placements where high strength, good durability, and sound bonding to reinforcing steel and adjacent surfaces are often required. The casting of fluid, yet washout resistant concrete is especially advantageous in the repair and rehabilitation of existing structures, and can be necessary to improve the constructibility, performance, and cost effectiveness of the repair. The resistance of a cement-based material to water dilution can be enhanced by reducing the fluidity of the mixture. Resistance to bleeding, segregation, and surface settlement Bleeding, segregation, and surface settlement can weaken the interface between the aggregate and cement paste, which has a direct implication on permeability and strength. The incorporation of a VMA can imbibe some of the free water in the system and increase the viscosity of the cement paste. As a result, less free water can be available for bleeding. The enhanced viscosity of the cement paste can also improve the capacity of the paste to suspend solid particles which decreases the rate of sedimentation (Stokes' law). Thus, the incorporation of a VMA can enhance the cohesiveness and stability of the cement-based system, hence reducing the risk of bleeding, segregation, and surface settlement. Stability and uniformity of self-consolidating concrete In general, an SCC is characterized by a low yield value and a relatively high viscosity. The low yield value is essential to enhance spreading of the concrete away from the discharge location, while the viscosity is needed to maintain a homogeneous dispersion of solid particles during the handling and placement as well as once the concrete is cast into place and until the onset of hardening. A highly flowable concrete that does not possess sufficient viscosity can undergo segregation, especially as it flows
between closely spaced obstacles such as reinforcing bars. This can lead to blockages that can interfere with the filling of the congested section. The cohesiveness of the concrete is related to the free water content in the mixture, which can be reduced by decreasing the W/C or by incorporating a VMA. Mixtures made with a VMA and a relatively high cement paste content can exhibit less segregation and flow more readily around closely spaced obstacles than mixtures of similar consistencies containing low water and paste volumes and no VMA. Top-bar effect Internal bleeding can increase the porosity of the hydrated cement paste near the lower parts of horizontally embedded reinforcement or under the ribs of vertically positioned bars, hence reducing bond strength. The settlement of fresh concrete around the reinforcement reduces the effective projection of the concrete lugs and contributes further to the reduction in bond strength. The inability of rigidly positioned, horizontally embedded bars to settle with fresh concrete can also cause a gap between the lower portions of fixed horizontal reinforcement and the concrete and result in a further reduction in bond strength. The reduction of bond strength to horizontally anchored or overlapped bars located in the upper sections of structural elements as opposed to those located near the bottom is known as the top-bar effect. A high top-bar factor necessitates an increase in the anchorage length and further contributes to the congestion of some structural sections.
Improved Resistance to bleeding, segregation, and surface settlement of VMA added concrete
Resistance to forced bleeding and settlement of cement grout Specialty cement grouts are used in a variety of applications, including sealing rock tendons in tunnel excavation, pressure crack injection of submerged structures and filling bonded posttensioned ducts for corrosion protection. In such
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Zydex Industries
applications, it is essential to control the bleeding of the mix water and settlement of suspended cementitious materials. The incorporation of a VMA can enhance the cohesiveness and reduce the risk of separation of solid constituents. This is advantageous for a cement grout used to fill vertical posttensioned ducts where differential hydraulic pressure at the lower part of the ducts between the fresh grout and air voids among closely spaced tendons and strands can lead to the seepage of some of the mix water through tight gaps between the tendons and strands. Such water can then move upward by capillary action and become deposited further up in the post-tensioning ducts, hence forming voids that can reduce the corrosion protection of bonded tendons Setting time The effect of a VMA on the setting time depends on the type and concentration of VMA, the type and dosage of HRWR, as well as on the cement composition and W/C. In general, the incorporation of a VMA can cause some delay in setting time because the VMA polymer chains can become adsorbed onto cement grains and interfere with the precipitation of various minerals into solutions that influence the rate of hydration and setting." In general, mixtures incorporating a cellulose-ether-type VMA can exhibit some delay in setting time, and those made with acrylic-type VMA s do not delay the setting time. Mechanical properties When a VMA is used in a low W/C system (for example 0.30) it may interfere with the degree of cement hydration and reduce the rate of strength development.30 However, when used in typical mixtures that necessitate the incorporation of a VMA to enhance stability (W/C > 0.40), the VMA does not seem to have a significant effect on strength development. Owing to the increase
in stability, the resulting cohesive concrete can develop a denser transition zone between the cement paste and aggregate that can enhance bond strength to embedded reinforcement and impermeability. This can also result in a greater flexural-tocompressive strength ratio compared with non- VMA concrete of similar consistency. Summary The use of a VMA in a cement-based system reduces the amount of free water available for lubrication of the paste and increases its yield value and viscosity. An HRWR is often incorporated to secure a given level of consistency. With the increase in VMA content, the effectiveness of adding HRWR to enhance fluidity is reduced, hence necessitating greater HRWR addition. Combined with an adequate dosage of HRWR, losses in fluidity due to the incorporation of a VMA can be regained without significant effect on cohesion and stability. Cement paste containing a VMA can be highly pseudoplastic and thixotropic, where the viscosity increases with the reduction in shear rate and the elapsed time, respectively. The pseudoplastic behavior can enhance the suspension of solid particles at low shear rates without much interference with the ease of mixing, pumping, and casting that take place at relatively high shear rates where the modified system exhibits a reduction in viscosity. Regardless of slump, W/CM, casting height, or degree of consolidation, the incorporation of a proper combination of VMA and HRWR can significantly reduce bleeding, segregation, and surface settlement. The combined additions of a VMA and an HRWR can result in some delay in setting time, especially at high HRWR concentrations. However, such delays are limited in concrete mixtures containing normal admixture dosages. The slightly adverse effect of VMA on mechanical properties can be partially due to the additional entrapment of air in the fluid, yet viscous, cement-based material. Reference Andreas Leemann , Frank Winnefeld, The effect of viscosity modifying agents on mortar and concrete, Cement & Concrete Composites 29 (2007) 341-349. M. sahmaran , N. zkan, S.B. Keskin, B. Uzal, I.. Yaman, T.K. Erdem, Evaluation of natural zeolite as a viscositymodifying agent for cement-based grouts, Cement and Concrete Research 38 (2008) 930-937. M. Lachemia, K.M.A. Hossaina, V. Lambrosa, P.C. Nkinamubanzi, N. Bouzoubaab, Performance of new viscosity modifying admixtures in enhancing the rheological properties of cement paste, Cement and Concrete Research 34 (2004) 185-193. Andreas Leemann, Frank Winnefeld, The effect of viscosity modifying agents on mortar and concrete, Cement & Concrete Composites 29 (2007) 341-349. Kamal H. Khayat, Viscosity-Enhancing Admixtures for Cement-Based Materials, Cement and Concrete Composites 20 (1998) 171-188
Specialty cement grouts are used in a variety of applications, including sealing rock tendons in tunnel excavation, pressure crack injection of submerged structures and filling bonded posttensioned ducts for corrosion protection
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CICO technologies Limited
Repair Rehab Prepacked Shotcrete
Prepacked Shotcrete Admixture

Sonjoy Deb
B.Tech.Civil. N.I.T.Silchar, Research Scholar, Indian Institute of technology
"Shotcrete is concrete (or sometimes mortar) conveyed through a hose and pneumatically projected at high velocity onto a surface, as a construction technique". During the depression years of the 1930's, a Cincinnatibased ready-mix producer recognized that a growing number of people were requesting a bucket or shovelful of "drippings" from returning ready mix trucks. The reason; they had a small job to complete around the house and simply didn't need the minimum 1 or 2 cubic yards of concrete. Over the past 10 years, the wet shotcrete method has become increasingly used in the repair of vertical and overhead concrete surfaces. This is due, in part, to advances in materials such as the introduction of silica fume (microsilica), fibers and super-plasticizers, which not only make shotcrete easier to place, but also improve its durability. Batching all these materials in the right proportions with sand and cement can be difficult, so
many manufacturers have developed pre-packed shotcrete repair mortars to which contractors add only water. The pre-packed materials simplify batching and provide more consistent quality. Recognizing a good business opportunity, the entrepreneur developed a process that combined dried aggregates and Portland cement in a package, with a moisture barrier to form a single easy to use unit. T oday, millions of bags of pre-packaged concrete, shotcrete, grout, and mortar are produced at production facilities around the world and shipped to jobsites on remote islands, in deep underground mines and on more typical jobsites everywhere. The most compelling reasons for choosing to have shotcrete provided in a pre-packaged form are quality, convenience and flexibility. With the availability of quality packaging plants across North America, contractors no longer have to be concerned with the task of proportioning and mixing shotcrete components on jobsites. The blending can and should
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be done accurately and under controlled conditions where components are accurately weight batched; aggregates are dried, eliminating varying moisture contents, and thorough blending ensures mix consistency from batch to batch. In addition to the expected ratio of cement and blended aggregates, many of today's shotcrete mixes may also contain very small amounts of multiple admixtures such as accelerators, air entraining agents, corrosion inhibitors, or superplasticizers (for wet-mix shotcrete). Steel and synthetic fibres are also used to enhance certain hardened properties and silica fume is used to reduce permeability and provide the shotcrete with improved shooting characteristics. Dosage of these components must meet extremely precise tolerances and blending must be done in a manner that ensures thorough distribution of all mix components. Most quality mixing plants are equipped with counter current, high shear mixers that have the ability to efficiently handle both fine and coarse shotcrete blends. The high shear action of these types of mixers will allow even and thorough distribution of components of varying dosages and varying bulk densities (for example Portland cement (94 lbs/ft3) and silica fume (25 lbs/ft3). With this type of control of the shotcrete mix, especially when compared with site mixing, one of the biggest "quality variables" is eliminated. Arguably, one of the most difficult variables to control is the consistency of the aggregate supply. The desired particle size distribution must be maintained through a blend of fine and coarse aggregates. In the case of site mixed shotcrete, bulk, stockpiled sand and gravel will often be subject to segregation and variations in moisture content when left exposed to the elements. An improper aggregate blend with too little coarse aggregate will affect compaction and result in poorly consolidated shotcrete. An aggregate blend with increased fines will result increased water demand, compromising the benefits of good quality shotcrete (low shrinkage, low permeability, high strengths etc.). The quality offered by pre-packaged shotcrete materials ensures that the proficiency of the nozzelmen, and the efficient operation of the equipment are the only variables preventing a quality shotcrete application. Steps to improve the proficiency of nozzelmen have been introduced through the development of an ACI nozzelmen training and certification program. This program has been accepted by shotcrete contractors and specifying authorities across North America and gives them the confidence that specific nozzelmen have the capabilities and talent to properly apply shotcrete. Shotcrete test panels or mock up panels should also be used however, to replicate the shotcrete application and orientation. Pre-packaged
Fig. 1 Mesh installation- le-aux-Tourtres Bridge
Fig. 2 Hydronozzle
materials can further facilitate this operation by ensuring the same shotcrete mix is used to shoot mock ups or test panels as is used on the job. The convenience of pre-packaged materials cannot be argued as is evident from the growing number of shotcrete contractors who, when given the choice, have chosen to use pre-packaged shotcrete mixes on their projects. Excess (unused) material can be returned to the contractor's warehouse reducing job clean up. Movement of materials on the jobsite is much easier when pallets of product can be dropped in multiple locations. In cold climates, pre-packaged products when properly stored will not freeze, eliminating the need to heat sand and stone piles. Bulk tote bags can be suspended over the hopper of the shotcrete machine, eliminating the need to
Fig.3 Portable penetrometer measuring plastic dry-mix shotcrete consistency
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mix shotcrete indicate that concrete shot at it's "wettest stable consistency" will provide good reinforcing bar encapsulation when proper craftsmanship is followed. A typical hydronozzle for shotcrete application is shown in Fig.2. In most cases, "wet" consistencies correspond to
Fig 4: Mechanical spinning trowel with a high-density rubber disk
have an individual continuously feeding the machine. And most importantly, the contractor, consulting engineer and owner all have the "peace of mind" knowing that the components in each bag conform to the specified mix design. The step to shotcrete placement involves concrete demolition, surface preparation, mesh installation, shotcrete placement, surface finishing followed by curing. Concrete demolition can be achieved by jack hammers. Surface preparation determines the bonding between steel reinforcement and shotcrete material. All corrosion materials and delaminated epoxy coatings to be removed from the surface which can be achieved by high pressure water blasting. A typical mesh installation as shown in Fig. 1 helps in arresting drying shrinkage cracks. During its installation, both the mesh and reinforcing bar must be anchored and attached correctly to avoid movement or vibration during shotcrete application. Otherwise, the energy produced may adversely affect the bond of freshly applied shotcrete to the reinforcing steel and adjacent substrate, particularly for overhead surfaces. Recent research programs related to the rheology of dryFig 6: Synthetic fiber burlap, saturated with water
the water-cementious material ratios (w/cm) varying from 0.40 to 0.45, which is controlled by the nozzleman. Physical properties of the in-place material, such as compressive strength, shrinkage, permeability, and others, are all related to the w/cm for a given mixture design. The specification documents require that dry-mix shotcrete be applied at a sufficiently "wet" consistency, enough to achieve complete reinforcing bar encapsulation, to provide reduced dust and rebound levels, and increased finishability. The w/cm, however, Should be minimized to avoid sloughing, as a high w/cm will adversely affect both plastic and hardened shotcrete properties. The correct consistency at which the shotcrete should be placed is subjective. Portable penetrometers were developed as a result of research projects undertaken by the Industrial Chair. This apparatus objectively measures the penetration resistance, and thus the consistency, of the dry-mix shotcrete immediately after placement. Such penetrometers (shown in Fig. 3) are calibrated and used
Fig. 5: Curing system already in place while
Fig. 7: Shipment of prepackaged Shotcrete in 2205 lb (1 metric tonne) bags To an underground mine
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Cosmos Construction Machineries & Equipment (P) Ltd.
Fig. 8: Shotcrete storage area at Falconbridge Raglan property
by MTQ inspectors/lab technicians on shotcrete rehabilitation projects to monitor shotcrete consistencies for quality control purposes. Preliminary surface finish can be achieved by a mechanical spinning trowel (finishing machine), with a high-density rubber disk (Fig. 4). The second finishing procedure is to finish the surface with a wood float, which leaves a final uniform finish with a granular texture. Guide wires are removed during this segment. These procedures must be completed without adding more water to the surface, as it will be detrimental to the quality and durability of the shotcrete repair. The finishing tolerance of the shotcrete patch repair profile specified must not exceed 5/8 in. (15 mm) over 10 ft (3 m) linear. After finishing operations, the fresh material is weak and cracks may develop. The tensile strength of the shotcrete, however, increases with time, which reduces the possibility new cracks forming. It is more likely that existing cracks will widen than new ones will develop. To prevent crack initiation from occurring, it is important to reduce the time delay between finishing and curing operations. Therefore, the curing program should be available and ready prior to shotcreting (as shown in Fig. 5 and Fig. 6). Over the years, changes in packaging methods have provided the shotcrete contractor with added flexibility on the jobsite. Although the majority of pre-packaged shotcrete mixes are still supplied in 50 lb (23 kg) paper bags, manufacturers have expanded packaging options to include bags that can hold a cubic yard of shotcrete and greater. These bags can facilitate the transportation of large quantities of shotcrete to areas that are difficult to access such as underground mines, tunnels, islands and remote or isolated locations (as shown in Fig. 7 and 8). Hardrock mines in northern Ontario often rely on shotcrete for small construction projects, for support in large, permanent, underground installations or as a primary ground support in development areas. This shotcrete, supplied in 1 metric tonne (2,205 lb) reusable bulk tote bags, provides shotcrete crews with large volumes of high
quality mixes while working more than 7,000 ft (2200 m) below ground. The development of moisture resistant packaging has further improved the ability of manufacturers to deliver shotcrete to further, more remote destinations. Working with their shotcrete supplier, Falconbridge Limited of Toronto, has developed a system of shotcrete delivery for their Raglan Property, located in northern Quebec, approximately 50 miles (80 km) south of the Arctic Circle. Shotcrete is packaged in 1360 kg (3,000 lb) specially designed bulk bags that have been fitted with plastic liners to prevent moisture from prematurely hydrating the shotcrete mix. The shotcrete material can be stored outside, where it is often buried in snow before it is "dug out" and transported by ramp underground. This unique mix, which has been designed to perform in below freezing temperatures, is then applied to the frozen rock surface by Raglan shotcrete crews. By contrast, the same shotcrete supplier has used similar packaging methods to ship shotcrete mixes to warmer climates in the Caribbean. Sea freight containers are filled with bulk tote bags and similar packaging is used to prevent water from coming in contact with the shotcrete mix during the voyage from North America to the islands of the Caribbean. The pre-blended mix is stored on site, sometimes for several months; before being used by shotcrete crews and despite rain and high humidity, instances of hydrated chunks in the bags are almost unheard of. Despite the perception that site mixed materials are cheaper, contractors around the world are turning to prepackaged shotcrete to ensure that their materials are properly proportioned. These contractors have weighed the risk of using inexperienced labour to properly proportion the shotcrete mix for their experienced shotcrete crews. Prepackaged shotcrete mixes will provide the contractor, specifier and owner with the same consistent quality mix design from the start of a shotcrete project until its completion. Whether your project is across the ocean or around the block, the convenience and flexibility of pre-packaged shotcrete materials make it a logical choice! Reference
Pre-packaged Materials - Providing Quality, Convenience and Flexibility, Joe Hutter. State-of-the-Art Specifications for Shotcrete Rehabilitation Projects, Jean-Franois Dufour; Simon Reny, and Daniel Vezina. Tests to characterise properties of fresh dry-mix shotcrete,, Marc Jolin, Denis Beaupre, Sidney Mindess. Shotcrete for Rock Support: a Summary Report on the State of the Art in 15 Countries, International Tunnelling Association Working Group on Shotcrete Use Prepared by Swedish Rock Engineering Research (Bo Malmberg, author).
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Roshan Lal Jain & Sons (Roljack Industries)
Waterproofing
A Review of Waterproofing Systems
M.A.Waheed
Chairman, Perma Construction Aids Pvt. Ltd
Waterproofing of building to prevent the ingress of water is an activity, which, perhaps is practiced in one form or the other, ever since the first building was built on earth. The methodology has been changing with the changes in the architectural designs and with the availability different building materials in construction. In the initial stages when stone was the main building construction material placed in position with mud or lime mortar the emphasis used to be to make the construction in such a way that the rainwater does not collect on the roofs. Hence old architecture relied mainly on dome structures or slanting roofs. The slow speed of such construction and unaffordability of common man to build such structures for their own dwelling, made constant evolution and development in the construction material technology. With these developments the concepts of waterproofing also changed. Now in present day construction wherein the ordinary portland cement and its blends with puzzolonic and slag materials has come to stay a lot of compatible alternatives are available for a builder to choose from various waterproofing systems. Some systems are old and conventional but still practiced successfully and some are modern systems designed taking the material and structural behaviour into consideration. There are some compounds, which are used in plastic concrete to make it less permeable to water. These compounds are known as integral waterproofing compounds. They are based on plasticising and air-entrainment or water repellence principles. These are used as a good waterproofing precautions when other factors such as good mix-design, proper mixing/placing, compacting/curing etc are taken care of. This subject of integral waterproofing compounds requires in depth discussion hence will not be taken up here. Similarly there are some water proofing techniques for vertical surfaces. These techniques are also used for preserving heritage buildings by stopping/minimising the aging process of these buildings. This subject also will not be discussed here. First let us review some of the old and conventional waterproofing systems and then discuss the modern
waterproofing techniques. 2. Review of the old Waterproofing Systems Some of the old waterproofing systems are as follows: Brick Bat Coba system or Lime Terracing Bituminous Treatment Metallic Sheet Wrapping Poly-urethane based Waterproofing treatment Epoxy Based Water proofing Treatment Box Type Water proofing System
2.1 Brick Bat Coba System This system was developed during the initial stages of flat roof construction with lime mortar burnt clay brick pieces. This system involved laying lightweight mortar on the roof and spreading it to give gentle slopes for draining away the rainwater immediately. The mortar consisted of lightweight brick pieces as aggregates and ground brick with lime as binding matrix. During British rule this system became more popular not because of its waterproofing efficiency but because of its efficiency in keeping the interiors cool. Some applicators developed better skills in laying these systems, with neatly finished top with lines engraved on top of plastic mortar now known as IPS. Some practiced embedding broken tile or ceramic pieces in the plastic mortar and called it china mosaic. This type of system remained most popular with multi-storeyed construction in all major cities. The system lasts up to 15 years if done by skilful applicators. This system may be considered more from its weather proofing abilities rather than its waterproofing qualities. Once water starts entering into the brickbat coba the brick pieces absorb too much of water and the roof becomes an invisible pond of water continuously causing leakage and increasing burden on the roof slab. It will be highly beneficial if brick-bat coba is laid on a flexible
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Waterproofing
waterproofing membrane as water proofing as well as economical weather proofing can be achieved with this system. 2.2 Bituminous Treatment Discovery of petroleum and its products and by-products has given the construction industry an indispensable product in the form of bitumen. Bitumen is more commonly used in the form of felt or flexible membrane formed by sandwiching jute fabric or fibreglass/polypropylene mats with chemically modified bitumen. These membranes are laid on the roofing over a bitumen primer. There are two types of membranes one is cold applied and the other hot applied which means one needs to heat the edges of the felt with a torch so that they melt and stick to the second layer in the overlap area. On the RCC flat roofs the bitumen felts have not been successful because of the unacceptable black appearance and inaccessibility of the terrace for other social uses. Technically it is not preferred because bitumen layer or felt on the terrace not only makes it watertight but also airtight. Concrete has the breathing property. It takes water/moisture and breathes out water vapour. Hindrance of this breathing property of concrete develops pore pressure, which causes blisters in the felt. After a few seasons the blisters multiply and eventually delaminate the felt from the concrete surface. Hindrance of breathing property of concrete makes the concrete weak. But on the asbestos cement sheets and zinc sheets in factory roofs this bitumen felt is the only dependable waterproofing system. Hence all factory roofs in India adopt this water proofing system. Bitumen is very effective in waterproofing of basements from outside. Bitumen primers have very successfully been used as damp-proof course in earlier days. This practice is slowly discontinued for whatever reasons now very few engineers now believe that this was in practice once. As consequence of this absent DPC we have a lot of cases of rising dampness, which we tend to attribute to wrong reasons such as the quality or salinity of sand etc. Bitumen still is the product of first choice where it is commonly recommended, in areas such as industrial roof waterproofing, basement waterproofing, and damp-proof course. More over bitumen is the most economical product available for waterproofing. 2.3 Metallic Sheet Wrapping Because of the non-existence of suitable expansion joint filling compounds before the discovery of poly-sulphides, a complex procedure used to be adopted to treat expansion joints, in concrete dams and such huge structures utilising thick copper sheets. An extension of this practice was to try thin foils of copper and aluminium for wrapping the concrete surfaces with nagging leakage problems. Unavailability of common joining material for these metal foils and the concrete and mortar created weakness in the system at the joints. This discouraged the system in its infancy only. But there after the metal manufacturers have been trying to market this type of waterproofing system with improved
adhesives as and when the metal market slumped. 2.4 Polyurethane based water proofing Treatment Polyurethane consists of two liquid components one is called the Base component and the other is called reactor or curing agent. Base is a polyol and the reactor is an isocyanide such as TDI or MDI. There are various grades of polyols and so also there are numerous isocyanides. The combination of these two ingredients results in a formation liquid applied rigid membrane or a foam depending upon the selection. In water proofing this rigid liquid membrane was tried with fibreglass reinforcing mats. The systems failed because coefficients of thermal expansion of concrete and rigid PU membrane being different lateral movement or creep occurred with the passage on one working climatic cycle. When exposed to ultra violet rays or direct sunlight most polyurethane rigid membranes became brittle and crumbled. Apart from this the application of polyurethane coating needed very rigorous surface preparation. The surface needed to be neutralized by removing alkalinity from the concrete surface through acid itching then washing and blowtorching to make the surface bone dry. This kind of surface preparation with acids angered the civil engineering community and the product ceased to be used as waterproofing material apart from its several failures. Never the less continuous research in the polyurethane technology gave the construction industry excellent sealant for glazing industry and foams for thermal insulations. The new generation polyurethanes, which are alkali stable and water-based, may find better applications in waterproofing industry. 2.5 Epoxy Based Water proofing System Like polyurethane is also a two-component system having a base resin and a reactor or curing agent. Base resin is obtained by dissolving Bis-phenol 'A' flakes in epichlorohydrin. This base is available in various viscosity ranges to suit different application conditions. The curing agent is an amine/polyamine aliphatic or aromatic, or an amine-adduct for general applications and polyamide or an amino-amide for coating purposes. After mixing base and reactor components the resultant viscous liquid or paste if some fillers are added to it can be brush applied like a paint or trowel applied like a mortar. Here also epoxies not withstanding the alkalinity of concrete and the concrete needs to be acid washed and neutralised, which the civil engineers hated. Here again the coefficient of thermal expansion of concrete and epoxy being different the compatibility of epoxy in waterproofing exposed concrete surfaces such as roofs became limited. Later the use of epoxy in waterproofing was discarded. But epoxies have come to stay in civil engineering industry as bonding agents, floor & wall coatings, coatings for food processing units, operation theatres and computer and pharmaceutical industries.
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Waterproofing
2.6 Box Type Waterproofing This type of water proofing system is used only for basement waterproofing or waterproofing structures below the ground level from outside to prevent leakages of subsoil water into the basement. In this method limestone slabs (Shahabad Stones) are first laid in the excavated pit over blinding concrete in a staggered joint fashion to avoid the continuity of the mortar joints. The joints are effectively filled with rich mortar admixed with integral waterproofing compound and cured. Over this the raft is laid and shear/brick walls constructed. The limestone slabs are erected around the walls in a similar fashion leaving a gap of one to two inches between the external surface of the wall and the inner face of the stone surface. The joints again effectively sealed with rich admixed mortar and the same mortar is filled in the gap between the wall and the stones. This stonework is continued up to ground level. In this system the raft and the sidewalls are protected from direct exposure to sub soil water. This system works on two principles of common sense. First the area exposed to subsoil water is only the area of the joint where as the whole stone is impervious to water, hence only a fraction of area, that is, that of the joint is exposed to subsoil water, when the joint itself is filled with rich and quality mortar. Secondly, the path of water to reach the raft or the sidewall is elongated. This elongated path is through quality mortar. This system seeks to delay the occurrence of leakages in the basements. A lot of building structures are waterproofed by this system. A few notable successes are to its credit especially in five star hotels and of-course there are a few failures as well. 3. Modern Techniques in Water Proofing Modern technique aims to understand the functional behaviour of the structure, understand the properties of the available materials arrive at a system, which is best suited for the structure and incorporate the system at the design stage only. A single product or technique is not usually enough, involvement of various bodies and techniques in coordination is essential for making structures waterproof. For success of any system the building structure should have sufficient and efficient control joints if the slabs dimensions are more than twenty meter in any direction. Control joints are structural engineering design features. These joints are supposed to be designed and their configuration marked on the drawings and their detailing needs to be given with respect to waterproofing system proposed in large buildings. Different types of control joints are Construction joints or day joint, crack inducer joint, contraction joint and expansion joint. Coefficient of thermal expansion of concrete is between 6 to 10 X 10-6 mm/mm/oC. If proper control joints are not provided in large slabs, no waterproofing system works. Modern technique relies basically on two main waterproofing systems,
which are fool proof and simple. They are as follows: Crystalline waterproofing system Flexible membrane water proofing system
3.1 Crystalline Waterproofing System This system involves blocking the water bearing capillaries with insoluble crystals. This method is used for waterproofing waterretaining structures like overhead/underground water tanks, sunk slabs of bathrooms and toilets, swimming pools, basements, terrace gardens etc. The main product in this system is a grey or brown looking powder. The method of treatment involves saturating with water the surface to be treated. Then mixing two and half volume of the powder with one volume of water to form neat consistency hot slurry. This slurry is brush applied on the saturated surface. The active ingredients in the slurry pass through the water bearing capillaries and react with calcium oxide in the concrete to form insoluble crystals, which effectively block the capillaries. Further the chemical ingredients of the product remain in concrete to reactivate the process of crystallisation as and when a new capillary is developed. This system of water proofing the water retaining structures is practiced in all the developed countries. Typical specification for this type of system is as follows: Clean the surface to remove all loose particles, grease shuttering oil and such deleterious materials to get a sound concrete surface. Cracks if any should be cut into 'V' shaped grooves one inch wide and one inch in depth. Cut honey combed areas back to sound concrete. Repair these areas first by priming with crystalline waterproofing slurry and then by filling them with crystalline modified mortar produced by mixing crystalline waterproofing powder OPC and zone II sand in the proportion of 1:1:4 and water enough to produce a stiff consistence paste. Allow the repair mortar to dry. Thoroughly sprinkle water on the area to be treated till the surface becomes saturated. Some recommend overnight ponding for effective results Prepare crystalline waterproofing slurry by mixing the powder and water in the proportion of two and half volume of powder to one volume of water to form a hot slurry. Brush apply this slurry on the water saturated surface in two coats. When the second coat is still wet plaster the surface with 1 : 4 cement sand mortar admixed with an integral waterproofing compound and cure normally.
3.2 Flexible Membrane Waterproofing System The main product used in this system comprises of two
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Cosmos Sales Corporation
Waterproofing
components one liquid and the other is a powder packed roughly in the proportion of 1:4 by weight. The liquid component is an acrylic emulsion and the powder component is a polymermodified cement with film forming chemicals and fillers, and some manufacturers add reinforcing fibres to make the product extra effective. When these two ingredients namely the pre-weighed powder and the liquid are mixed together an uniform slurry results. This slurry is brush applied on the roof surface, which upon drying forms a flexible film. Since there is cement in this product its compatibility with concrete is excellent. The film further allows the breathing of the concrete without any hindrance hence there is no problems of its de-lamination from the concrete surface. This film being flexible takes care of the deflections in the slab and the movements caused because of primary or secondary settlements, movements due to wind loads and temperature stresses developed in the concrete. This system can be used on surfaces, which had bituminous treatment earlier. In European countries this type of product is used as coating on pre-stressed concrete bridge girders to protect them from aggressive chemical atmosphere. A typical waterproofing specification using flexible membrane system will be as follows: Clean the surface to remove all loose particles, grease shuttering oil and such deleterious materials to get a sound concrete surface. Cracks if any should be cut into 'V' shaped grooves one inch wide and one inch in depth. Cut honey combed areas back to sound concrete. Repair these areas with a stiff paste of fibre reinforced polymer repair mortar generally sold in the name of crack fill. Mix the powder and the liquid components of the product to form an uniform slurry and brush apply this slurry on the surface to be waterproofed. When the waterproofing coating is still tacky apply 1 : 4 cement sand screed and cure normally.
Stretching the coverage of the products beyond the specified limits by the manufacturer results in inefficiency of the product and hence a failure.
5. Precautions to be Taken by the Client Selection of an effective waterproofing system for a structure taking all the performance criteria of the structure into account and also taking into the consideration the performance of the materials in the system is of prime importance for any success of the waterproofing job. Waterproofing jobs awarded to waterproofing contractors purely on economical price considerations often fail. It is always advisable to involve the architect or the structural engineer in selection of a system, and requisite performance guarantees should be taken from the contractors. It is better to avoid bargaining for the job value out of contractor's margins. This could result in stretching the product beyond the coverage specified by the manufacturer or substitution of cheaper material in the system to cover the cost. Always supervise the job and the incoming materials for the intact tamperproof seals and quantities. Use the services of an engineer or architect in selection of materials.
6. Conclusions Generally, architects in India, do not specify in depth waterproofing details and leave this aspect generally to ignorant client to chose whatever system he likes, and many structural designers give least importance to the control joints. As a result of this many systems have failed in several prestigious buildings and the blame went to waterproofing contractors or the product manufacturer. There is a need for the architects and the structural designers to understand the various systems available and specify them clearly and in sufficient detail, taking into consideration the in-service conditions of the structure. The client should also insist on the architect to provide waterproofing design details in advance so that no ambiguity remains till the end. This would give enough time in selecting the specified material.
4. Failure of Water Proofing Systems Especially in large buildings waterproofing systems fail if the control joints are not in position or not properly executed. This failure occurs after one complete year when the structure has passed through one complete summer and the winter cycle. One can't repair this type of failures. It needs a different type of approach involving provision of crack inducer joints and then tackling the waterproofing in movement restricted bays. Application of a waterproofing product in non-specified areas, such as, using a crystalline waterproofing system in waterproofing the terrace or using a flexible membrane system in the water tank results in failures even though the products themselves may be genuine.
Perma Construction AIDS Pvt Ltd.

611 / 612, Nirmal Corporate Centre, L.B.S. Marg, Mulund (W), Mumbai - 400 080, India. Tel.: 91-22-2591 8911 / 2567 4690 Fax: 2590 3008 E-mail: info@permaindia.com Web: www.permaindia.com
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Reliance Industries Ltd
Head, Admixtures Division, MC-Bauchemie India

American Society of Civil Engineers (ASCE), Institution of Engineers India (IEI), Indian Concrete Institute (ICI) and Indian Society of Structural Engineers (ISSE), Sunny is passionate about conducting laboratory trials, field trials, field training for engineers and on-site admixture / additive improvements and fine-tuning. His interest also includes non-destructive testing of concrete, repair and retrofit materials and project management. Here are excerpts from the interaction. Give us an overview of your range of construction chemicals. MC-Bauchemie has a full range of construction chemicals manufactured in technical and financial collaboration with MC-Bauchemei, Germany. We specialize in systems and technologies rather than products. We are an ISO 9001:2000 certified company. Our range includes technology for a full spectrum of admixtures including PCE's for HPC & SCC, admixtures for block manufacturing, precast concrete and new generation waterproof concretes, curing compounds, and other products for concrete technology. Our strength is in providing clients with full solvent-free systems like waterproofing, injections, repairs & rehabilitation systems. Our clients and consultants can chose from full range of systems which have compatible products which avoid issues of combining several products from different manufactures wherein it is impossible for end user to decide cause of failures. We have wide range of products for water and wastewater industry and products to take care of pH values from 1 to 14. Our coatings for enhancing the life expectancy of civil engineering assets
One-on-One with Sunny Surlaker,

are one of the most popular systems as they are crack bridging, carbonation resistant while maintaining breathability. These coatings vibrate with dynamics of structures to give long-term protection to concrete. Our other popular systems are Injection Technologies to cater for each and every type of water entry and soil stabilization. Our flooring systems whether resin based or dry shake are favorite with industries on account of durability over a period of time in service conditions. They are designed on principles of maximum unit surface density and with very high abrasion resistance. In addition, we have Polymer bonding agents for repairs and maintenance, water-proof tile adhesives, waterproofing slurries for waterproofing by crystallization, non-shrink and injection grouts, concrete curing compounds, and surface retarders. Apart from this, we always have access to MC-Bauchemie Germany's immense technical expertise and portfolio for products. This ensures that we are geared to solve any constructional problems on-site. What makes your construction chemicals different from others? We believe in technology. We cater to the technical and quality conscious segment of the market and not the price sensitive segment. We never let ourselves forget that MC-Bauchemie has a worldwide reputation to keep. Due to our technical focus, our customers keep coming back to us. In addition, we provide technical service to solve difficult on-site problems. Further we train our engineers in India and abroad. Our applicators are trained and certified by independent institutes in Germany. The main factor that differentiates
Sunny Surlaker
Head, Admixtures Division, MC-Bauchemie India
C-Bauchemie is a name that has become synonymous with product innovations in the field of building chemicals. Considered a trendsetter in the field, MC-Bauchemie India Private Limited, a joint venture with MC-Bauchemie, Germany, has been setting new standards in the Indian market with its innovative product range. M.K.Prabhakar, Associate Editor, The Masterbuilder recently caught up with Sunny Surlaker, who heads the Admixture Division of the Indian arm, to know more on the company's core business, product offering and future plans. After completing his graduation in civil engineering from V.J.T.I Mumbai in 2005, Sunny went on to get his Masters in civil engineering from the University of Michigan, Ann Arbor, USA. He has worked extensively in Germany and Brazil with MC-Bauchemie. Prior to that, he pursued a carrier as a material specialist with global multinational, AMEC Earth and Environmental based in Phoenix, Arizona, USA. An active member in a number of AcademyIndustry initiatives such as the American Concrete Institute (ACI),
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us from others is our extraordinary technical service through our technical advisors and German trained IRP applicators, who work with consultants and contractors to evolve solutions for problems encountered in practice. As far as products go, we develop technologies to suit and solve actual site problems in Civil Engineering based on state-of-the-art technologies. To this effect we work together with leading universities and technologists to transform laboratory researches to field conditions. Being a company with technical and financial collaboration with MC-Germany we have access to their international experience and expertise. High technical standards, extensive research and development, technical service and training are key factors that make us clear favorites. Give us a few examples of major infrastructure projects where your
products have played a key role. We are in the Indian market for over a decade and we have foreign collaboration with MC-Bauchemie, Germany, which is a 50-year-old company. We use their experience and expertise and international exposure. Our list of clients reads like a virtual who`s who of the Civil Engineering industry. To mention a few, large construction companies like Afcons, Gammon India, HCC, L&T and reputed builders like Hiranandani, Rahejas, Kukrejas, Lokhandwala are our esteemed customers for over a decade. Our products are used in major infrastructure projects like Delhi Metro, NPC, Dams, Concrete Roads, Indian Railways, DGNP , MDL, PWD's etc. We are present at all places where high quality products are appreciated. As far as structures go, we have been involved in residential and commercial construction as well
as infrastructure projects like roads, railways, dams, bridges, etc. We also cater to the quality conscious industrial segment. Our unique marketing strategy has helped us through the ups and downs of the construction industry. We do not try to find markets after developing our products. We identify the needs of our clients and then develop suitable products and solution. How big according to you, in terms of value, would be the market for construction chemicals in India? In recent times, FICCI has pegged the industry size to Rs.1600-1800 and industry pundits predict the industry to grow to ` 5,000 crore in the next five years. This growth can only come if the industry joins hands to promote awareness in constructors and end users. Ultimately the users should believe that use of such chemicals would provide them with clear advantages.
Protests Continue Against Construction of Pandora Dam

Environmental activists have been against the construction of the dam, which when complete is expected to be the third largest in the world. The dam would have an installed capacity to produce around 11,200 MW of electricity, according to a news report in Forbes. There have been widespread protests over the construction of the dam, which according to environmentalists would wreak havoc with the fragile ecosystem of Amazon. The report also stated that construction of the dam could be disruption of livelihood of at least 20,000 people. There are fears that the flooding caused by the construction of the dam would mean that several thousands of people will need to be placed elsewhere. Apart from this factor, environmentalists also feel that the dam could also prove detrimental to various species of fish found in the region.
he construction of 'Pandora Dam' seems to have opened a Pandora's Box quite literally for the Brazilian government. Protests have gathered momentum against the construction of the massive Belo Monte dam in the famed Amazon valley, according to news reports.
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Infrastructure Defence
Fifty years of Heavy Vehicles Factory, Avadi

n 28th December 2011, the Heavy Vehicles Factory, Avadi, Chennai, turned 50. The journey has been memorable, reinforcing the success story of India's self-reliance efforts. The army tanks that have rolled through the floor shops of the Avadi facility have quelled the threats from unfriendly neighbours. Of course, there has been use of the tanks during non-war situations, like during the flushing out of terrorists from the Golden Temple in Amritsar. The world also remembers the lone, brave Beijing student who stopped the march of tanks at Tiananmen Square, during the tragic democracy protests. In another, outrageous instance, BBC television reported that Indian tanks were being currently used to blast the Hazratbal mosque in Kashmir. The visuals shown to support the story were actually of Russian tanks pummeling the Chechnyan Republic shrines. It required an alert Indian defence ministry official to point out the grave error in reporting. It is another story that the red-faced broadcaster took the flawed report off the news program, and without a pubic apology. On 29 Dec., 1965, HVF, Avadi rolled out the first Vijayanta, with British collaboration, and went on to produce 2266 more. A tie-up with the USSR enabled the facility to bring out the T-72 in 1988, and with its variants later. Then came the T-90 in 2004. The Arjun tanks that came up in the same year made the factory proud; a breakthrough had been made, and self-reliance would soon be the norm; 124 Main Battle Tank Arjuns have been produced till date, while the T-90's indigenous version, the Bhishma started rolling out in August 2009. This product has many USPs in terms of mobility and safety, protection and fighting capacity, hitech communications, an integrated firecontrol system with computerized ballistic facilities. Other vehicles vary from bridge laying tanks, missile-launching vehicles, self-propelled launchers, Backing the efforts are an army of the latest CNC machines delivering what the nation just wanted. In addition, a successful program of overhaul and supply of vital spares has been made possible with input from scientists from the DRDO. From September 2011, the Avadi facility's T-90 capacity has been increased from 100 to 140 per year.
Special Arrangement
S.D. Dimri is Director General of the 39 Ordnance Factories in India, and the Chairman of the Ordnance Factory Board. His mild, smiling nature camouflages a sharp intellect. At the Q&A meet with this correspondent, this was amply evident. Some of his statements are matter-of-fact and some, thoughtprovoking. He begins with, HVF is also known as Highly Visited Factory, and follows it up with HVF is the back-bone of the Ordnance factories and contributes 20-25 % of the production of the Ordnance Factory Board. In the latest projections, Ordnance factories would produce ` 10,400 crore of goods this financial year, and HVF's contribution would cross ` 2,800 crore.
Two new projects, two new tank capabilities: New projects have been finalized at Korba and Nalanda. In Nalanda, a facility would come up to produce the propellant, the bi-modular charged systems; these are necessary for tank ammunition production. At Korba, another facility is being set up to make state-of-the-art carbines. A futuristic plan is to manufacture a tank that would weigh less than 30 tonnes. Currently, the Bhishma weighs 45 tonnes, while the Arjun's is close to 60. So, it is necessary to build tanks light enough to fly aboard C-130 transport planes, land on dirt strips and roll off ready to fight. These light tanks would be fuel efficient and less reliant on supporting infrastructure, and provide all-round protection against mines, rocket-propelled grenades and capable of quickly firing 30 mm cannon shells. As anti-tank weapons are gaining an edge over tanks, it is imperative that one makes tanks smart enough to counter missiles mid-air. The tank would sense an incoming missile with an automatic radar tracking system, and a kinetic energy system fires a beam of energy at the missile, destroying it in mid air. The Indian Main Battle Tank needs to best France's Leclerc, Britain's Challenger, Germany's Leopard, America's Abrams and Israel's Merkava, just like the Indian forces busted Pakistan's M 48 Patton tanks, even before India's Vijayantas were readied for action. Futuristic, yes, but not optimistic. Text & Pic: MJK
"HVF is also known as Highly Visited Factory. HVF is the backbone of the 39 Ordnance Factories in India and contributes 20-25 % of the total production of the Ordnance Factory Board".
S D Dimri
Chairman, Ordnance Factory Board
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Chembond Chemicals Ltd: Growing Steadily on the Back of Strong Quality Focus
hembond is a leading manufacturer and supplier of specialty performance chemicals to a variety of industries across India. The company has a widespread network consisting of laboratories, offices, manufacturing plants, dealers and strategically located personnel across the country. The company has been a leader in the field of corrosion protection of metals and of water treatment chemicals from the time of its inception in 1973. Drawing on these experiences, from 1992, Chembond began introducing a range of products directed towards the building and construction industry. The construction chemicals division of the company offers a wide range of products for applications in concrete modification, waterproofing, and repair & rehabilitation of structures. It also offers a host of other products like sealants, concrete admixtures, tile fixing adhesives, tile joint fillers and engineering grouts aimed at the construction and civil engineering industries. The 'K-Fix' brand of construction chemicals from the company cater to the distribution channel and applicator segment with small pack sizes, while the infrastructure projects are catered to in bulk pack size. Giving an insight into what makes the company's products different from others, Mr.Swapnil Deshmukh,
Waterproofing
Joint Sealant
Marketing Manager of the company said, At Chembond, we are working on various development projects. We expect to introduce new and innovative solutions to construction industry in the coming years. Our goal will be to strengthen our technical function and share the wealth of our experience and knowledge with our customers. We believe in partnering our customers in growth and carrying our personnel along on the journey. Our products targeted at the retail channel are sold under the K-FIX brand. Our products for larger construction are organized in the infrastructure vertical. These are now increasingly being made by incorporating industry best raw materials from leading global suppliers. Our quality assurance and R&D lab is housed in a spacious 2000 sq.ft well-equipped facility attached to our plant in Gujarat, making the focus on product development and quality enhancement more pronounced. We have invested significant resources to this end.
The company has been making rapid inroads into the Indian market with its focus on problem solving, learning from its customers, specifiers and influencers. One of the highlights of the company's growth story has been its ability to develop an innovative range of products based on the feedback it gets from the various stakeholders, an aspect that is sure to hold the company in good stead in the future. This customer-focused approach, robust infrastructure covering all aspects of its operations and a range of quality products has seen Chembond emerge as one of the leading players in fray in the construction chemicals market. For further details:
Chembond Centre, EL-71, Mahape MIDC, Navi Mumbai - 400710, India Ph: +91-22-39213000, Fax: +91-22-39213100 E-mail:enquiries.conschem@chembondindia.com Web: www.chembondindia.com
Chembond Chemicals Limited
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Construction & Mining Machinery Expo (Commex'2012)
oisture is the most common problem in basements - either entering from outside sources or being produced inside by the occupants' activities.
Condensation on windows, pipes and other fixtures. Wet insulation. Moisture damaged finishes. Musty or damp carpets. High humidity. Stuffy, damp smells.
The soil around the walls can contain a large amount of moisture from surface water that is seeping down or from a high water table. Water can find its way inside by gravity or through a crack or flaw in the water protection layer of the foundation. Water can also be pulled up by a "wicking action" or "pushed up" by hydrostatic pressure from the soil under the walls or floor. In the summer, warm moist air from outside can enter the house and lead to condensation on the cool basement walls or floor. Daily activities also produce moisture that can be trapped inside the home. Basement moisture problems often include: Foundation cracks that leak. Standing water. Efflorescence (white, chalky stains). Wet decaying wood in contact with concrete. Damp or moldy walls or floor.
A house is much more than just four walls and a roof-it's an interactive system made up of many components including the basic structure, heating, ventilation and air conditioning (HVAC) equipment, the external environment and the occupants. Each component influences the performance of the entire system. A renovation provides an opportunity to improve how the house performs. Moisture problems are caused by a buildup of a variety of water sources. Whether it comes from surface or ground water that leaks in, water that wicks up or water vapour that condenses, it must be controlled. The easiest way to control moisture is to stop it from coming in and to exhaust the water vapour produced in the house to the outside. Here are some of the likely situations that people encounter. However, every situation
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is unique. One may need to hire a qualified professional to do a thorough investigation, find the moisture problems and suggest the best solutions. A probable set of problems for basement moisture problems along with solutions and effects of not attending the problem is given step by step:Water drainage If the roof, eavestroughs, downspouts and grading direct surface water away from the house and or window wells drain freely will lead to a large volume of water that can leak in or overwhelm basement drainage system. Also water may accumulate in the wells, leading to possible leakage into the basement through or around the window. The solution is to repair or replace a leaky roof. Ensure that eavestroughs and downspouts with extensions direct water away from the building. Slope the grade away from the house. There is a need to install drainage below window wells also.
damp spots on the walls or if there is a working floor drain at the lowest point of the floor or there is a working sump pump in a covered sump pit or past flooding of the basement. Without a floor drain, any water spilled inside can't get out. Working sump pumps may help, but open pits can be another source of humidity and soil gases. If future flooding is possible, interior insulation and finishes give mold a place to grow and will cause more difficulty and expense in flood clean up. The solution to this problem is to dampproof or waterproof the outside of the foundation walls. Install a perimeter drainage system. Install a floor drain with a trap and a sump pump in a covered pit. Make sure that the sump cover is tightly sealed. If future flooding seems unavoidable, do not install interior insulation or finishes that will be damaged by water. Existing problems This may include white, chalky stains (efflorescence) on the walls or floor, black or white or green mold stains or fuzzy growth on the walls or floor, wet or decaying wood windows or sill plates or columns or beam ends in contact with concrete, lifted floor tiles, damp or musty carpets, wet insulation or framing or moisture damage on finished walls. The continued efflorescence is a sign of ongoing moisture problems. Wood in contact with concrete will continue to decay and will eventually result in structural problems. Tiles won't stick to damp floors. Damp carpets will continue to be a haven for dust mites and mold. Materials that are wet from any source (leaks, capillary action or condensation) will get moldy and decay, leading to unsightly finishes, durability problems and hazards to health. The solutions may be to :provide better drainage and dampproofing to the outside. Efflorescence indicates water evaporation of moisture that has wicked through the foundation wall.
Design for drainage around window well
Foundations If water found to leak in through cracks in the foundation wall or floor, Water may penetrate cracks, continue to deteriorate the existing house, affect IAQ and any proposed renovations. Severe or active cracks may be an indication of future structural problems or even present unsafe conditions. Without exterior protection and drainage, water will eventually find its way inside. Dirt floors are a huge source of moisture and soil gases. The solution is to patch small cracks from inside with cement-based material or use an injection-type foundation repair system. Fill large cracks from inside (and outside if possible) with "hydroscopic material that expands as it dries. Consult a structural engineer or basement specialist concerning multiple, severe or expanding cracks. Install a concrete floor over a sealed polyethylene moisture barrier. Basement flooding There may be case of any pools of water on the floor or
Water seepage through foundation wall
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Construction Chemicals Manufactures Association (CCMA)
Construction Chemicals Manufactures Association (CCMA)
Some tasks such as a thorough basement cleanup don't require special skills. A homeowner with good fix-it skills may be able to do a lot of the other work too, including: Roof, eavestrough and downspout repairs. Grading and landscaping. Patching small basement cracks. Clean-up of small mold patches. Removing damp insulation, finishes or carpets. Insulating cold water pipes. Installing dryer venting. Installing storage shelves.
Typical moisture problems and there after effects in the basement are depicted in the Figure.1
Figure 1: Moisture problems to solve
Remove the sources of moisture. Replace decaying wood. Provide a capillary break between wood and concrete. Seek professional advice as damage may compromise structural strength. Damp concrete causes lifting floor tiles and damp carpets. Improve foundation drainage. Install a polyethylene moisture barrier over the concrete floor as part of a retrofit floor system. Replace carpets with hard surface flooring. Remove wet insulation or finishes. Fix the moisture source before refinishing.
A typical and most common problem in the basement is because of basement floor crack. Repairing basement floor cracks is a job that can be done by the owner himself without having to hire an expensive professional. Cracks in concrete flooring are a natural occurrence. They can appear as the concrete starts to dry and are considered a normal part of the drying process. The concrete starts to shrink as it dries. This shrinking produces stress that is released by cracking. Contractors know this and place steel reinforced bars throughout to insure the strength of the concrete. If extra water was added to the concrete mix to make spreading easier, more cracks are likely to appear. The proper preparation of the ground underneath the concrete is an important step to minimize cracking when pouring the foundation. If the crack is 1/8" wide or less, it is safe to seal it with a commercial waterproofing material. Generally these are made of a latex cement and epoxy compound. If the crack is any larger than that, the best way to proceed is to
High humidity There may be some condensation on windows, pipes or other surfaces. The air may be humid, stuffy, damp or smelly. There may not be any basement ventilation system installed (like dehumidifier or air conditioning) in the house. The solution involves:Install energy-efficient windows, insulate cold water pipes and insulate walls (and floors, when possible) to achieve warm surfaces. High humidity plus cold surfaces results in condensation. Keep basements ventilated and heated. In summer, use a portable dehumidifier or air conditioning to reduce humidity. In warm, humid weather, keep basement windows closed. Run the furnace fan continuously to circulate house air. Provide ventilation to get rid of humidity. Run dryer exhausts directly outside. Do not hang wet laundry or store firewood inside.
Dimpled Plastic Drain Sheet act as a capillary break
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it up, and apply it to the crack. Hydraulic cement expands when it dries. This is the opposite of foundation cement. As we know concrete shrinks as it dries. The expansion of the hydraulic cement does not produce further stress on the cement crack. Instead it expands to fill the crack helps to waterproof it. It is quick setting. Mixing as much as can use in about 10 minutes at a time. Remember that hydraulic cement is not a permanent fix and will need to be replaced as it wears. Painting of basement walls with specialized vapor barrier paint is another preventive measure for basement moisture problems. This is however a specialised job which involves adequate surface preparation prior to application. Preventive measures for basement flooding involves following:Check around the house to make sure that the slope of the yard or lot around the house is outward Check all the eavestroughs. They should always be directed so that the water will flow as far away from the side of the house as possible. Check and know the capacity of the sump pump The pipe that then carries the water to the drainage ditch must be in a well-maintained condition If the residential area receives a large amount of rainfall or snow in certain months, it may be wise to invest in a sump pump alarm system Basement may flood in the case of a blackout, if it occurs during a heavy rainfall. This is why a portable generator or secondary battery-operated sump pump may be necessary in the area If there are cracks in the foundation walls, these must be repaired immediately as they are noticed.
Figure 2 : Flooding effects
prepare the mortar mix to seal the crack. Water can enter the basement once cracks appear. Even if water is not leaking through the crack, it will, given time, so one should repair all of them. This will also help maintain the integrity of the basement floor. The area around the crack and the crack itself should first be cleared of all dirt, debris and oil. For hairline cracks, cleaning in this manner should be sufficient. For larger cracks one should chisel out all loose concrete and then use a circular saw with a diamond blade and cut a dove tail groove on either side of the crack. Then follow with cleaning. One may need to insert a foam backer rod, available in home improvement stores, to fill a large crack which contains a void. A layer of concrete sealer can be applied before the application of crack filler. In cases of tiny, hairline cracks several applications of concrete sealer may be sufficient to permanently fix the crack. Two common methods to be followed for fixing the crack in the basement slab are as mentioned below:(A) Polyurethane Foam Polyurethane foam injection is done from the inside of the basement. The polyurethane foam enters the cracks in a liquid form. When it meets water that is in the basement cracks, the liquid polyurethane reacts and starts to foam inside the cracks. The foaming action greatly increases the volume of the polyurethane. When applied to the length of the crack, the polyurethane foam will fill the foundation cracks from top to bottom and end to end. Polyurethane foam can be used for any size crack that is big enough to hold water. Once hardened, it can be painted to match the rest of the floor. It can also be purchased in many colors and shades. (B) Hydraulic Cement Hydraulic cement comes in a dry powder form. Simply add water according to the manufacturer's directions, mix
No one wants a flood in their basement, and no one wants to have to deal with the associated clean-up costs and replacement money that can occur as a result of basement flooding (Figure 2). The required degree of water tightness of basement walls depends on the use of the basement space. Utility uses such as for car parks, pump rooms, and road tunnels can tolerate a higher level of dampness or wetness of walls and the base slab than habitable uses such as offices, apartments and shops, and special uses such as archives. The higher or more stringent the requirements of watertightness, the higher would be the cost of the final construction at the same time lower will the maintenance cost as moisture problem will be reduced considerably. Hence one should judiciously decide the construction methodology and repair
methodology based on the usage of the basement area.
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Construction Chemicals
Zentrament F BV - High Early Strength Plasticizer

The development of strength is rapic enough to enable early stripping of moulds ensuring speedy constructions as well as overall economy on account of lesser formwork requirements. Approximate one day strength of concrete with Zentrament F BV is 1.6 times that of reference concrete. About 20% cement can be saved by maintaining the same slump and strength. MC-Bauchemie (India) Pvt Ltd manufacturers full range of concrete admixtures and other Building Chemical Products under Technical & Fiancial collaboration with MC-Bauchemie, Germany.
entrament F BV is an high early strength superplasticizer especially formulated for concretes designed for high strengths. The superplasticizer based on selected polymers is free from chlorides and aids concretes in attaining high early and final strengths. The concretes with Zentrament F BV are homogeneous and
free from bleeding and segregation. The superplasticized concretes are pumpable and require minium compaction. It is suitable for use in prestressed as well as precast industry while manufacturing elements like beam, columns, slabs and also for railway sleepers, concrete piles, rails, posts, electricity poles, concrete pipes etc.

411, Arenja Comer, Sector 17, Vashi, Navi Mumbai 400 703 Tel.: (022) 2789 2856 / 2788 0803 Fax: (022) 2789 3870 E-mail: info.india@mc-bauchemie.com mcbindia@yahoo.co.in mcbindia_goa@rediffmail.com Web: www.mc-bauchemieindia.com
MC- Bauchemie (India) Pvt. Ltd.
An Energy Generating Waterfall

he hosting of Olympics are a time when many of the host countries plan for remarkable buildings or structures, whether for sporting events or otherwise. With Rio in Brazil expected to host the 2016 Olympics, a Zurich based architect firm, RAFAA Architecture & Design has come out with a design of a giant waterfall kind of a structure that would be apart from being an aesthetic delight will also generate electricity. The waterfall like structure will in fact, generate solar power during the days. Featured on popular online blog Inhabitat, the design of the project called, 'Solar City Tower' will be such that it will store water and use it for generating electricity during the nights when solar power generation is not possible. Once completed the landmark structure would not only be able to provide electricity to the games village but also to the grid in Rio.
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Get away the Menace of Powder Transfer by Toshniwal Powder Transfer System
oshniwal offers reliable Powder Transfer System for Batch / continuous Mixing plant operation such as transporting, storing, unloading, sifting, dosing and packing etc. The heart of the system is Vacuum Pump which is provided by Toshniwal with experience in Vacuum technology more than 3 decades. The best solution offered to the customer from the drawing board and pilot scale study of the customer requirement. How Vacuum Conveying System works: With Vacuum Conveying materials are drawn to the delivery port through a enclosed pipeline in a clean, contained stream of air generated by Toshniwal make Vacuum Pump. In Vacuum Conveying System no moving parts contact the materials, no dust escapes into the atmosphere and no contamination can enter through system.
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Batch Mixing Plant with Toshniwal Powder Transfer System
The advantages of Vacuum Conveying

Efficiency Safety Hygiene Cost Effective Flexibility Automation Dust Free Operation No Contamination
Application in Use
Gypsum Lime powder White cement Fly Ash Zinc Dust Dolomite Silica powder Quartz Powder
Toshniwal Supports the customer for the successful Powder Transfer System need and tuning their innovative project into reality with the Technology of the future. Further details from: M/s. Toshniwal Systems & Instruments Pvt. Ltd., 267, Kilpauk Garden Road, Chennai - 600 010, India Phone No: 91-44-26445626 / 26448983 Email: mixer@toshniwal.net / Web : www.toshniwal.net
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Waterproofing Preformed Waterstops
Preventing Water Leakage through Construction Joints using Preformed Waterstops

S. Md. Fazrulla Basha Nuha Construction Solutions typical problem in most Water Retaining Structures is the leakage of water through Construction and Cold Joints. A construction joint is formed when concrete is cast in different stages successively. These joints may be horizontal, vertical, inclined or curved depending on how the concrete is cast. Structures which are prone to leak through their construction joints: Water Tanks and Swimming Pools Sump Tanks, Overhead Water Tanks Basement Wall and Floor perimeter joint Basement column and floor slab joint Vertical joints in basement retaining walls Sewage Treatment Plants Potable water Reservoirs, Fish hatcheries Septic tanks, Utility vaults Raft Slabs cast in more than one pour Final roof slabs cast in more than one pour
Pipe intrusions in concrete walls Pedestrian and below grade tunnels Precast structures such as box culverts Butt joint between old roof and new roof Raw Water tanks in Water Treatment Plants Raw and Treated Water Tanks in Factories Concrete lined storm water channels Concrete lined Irrigation water channels
Why does water leak through construction joints? Leakage occurs because of two reasons: (a) Generally, after the base slab is cast, when the first lift of concrete is being placed for the wall of the water retaining structure, it is very difficult to vibrate at the bottom of the lift (floor and wall joint). Because of this, an unfilled joint approximately 1 mm 5 mm in height is created at the floor wall joint. (b) cement shrinkage further widens this joint marginally. Water then leaks through this open joint. Traditionally, engineers have tried to solve the problem by various means. These include using PVC Waterstops, (sketch) applying epoxy adhesive to the joint, (sketch) grouting into the joint using cement grout (sketch) etc. However, each of these methods has its own problems and may not be hundred percent effective. Hence engineers are highly divided on the effectiveness of each method. In fact, most engineers prefer not to use any of
Harmful effects of Leakage: In the case of water retaining structures like overhead water tanks and swimming pools, water leakage is unsightly and leads slowly to corrosion of the steel in the concrete. In addition there is loss of water. In basements, rise in water level outside the structure allows water inside the basement and the basement may become unfit for use. Final roof slabs which have joints allow water to leak into the building which may destroy expensive interiors.
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the above methods. They prefer to leave the joint as it is (knowing that there is a problem) and look for a solution only after the entire water retaining structure has been completed. Existing Methods and Problems associated with them a. PVC Waterstops PVC Waterstops have been used for many years to try to prevent leakage in Construction joints. They have succeeded in some places and have failed in many places. Basically, PVC is incompatible with concrete and hence will never bond hundred percent effectively with concrete. A thin line of delamination is always present through which water will try to leak. The idea of introducing a PVC waterstop is to increase the path of the water flow and make the water lose its head before it exits from the construction joint. This is not always effective because of other problems during placement. For eg., in heavily reinforced areas, conventional PVC waterstops are difficult to insert and maintain while concrete is being poured. PVC waterstops are meant to be welded at joints using a PVC welding machine. This is not done in most of the sites. Most PVC Waterstops available in the market are actually made from Recycled Rubber to lower costs. Skilled labour is required to place PVC waterstops on the site and a lot of care needs to be taken during concreting.
Carelessness will lead to a tunnel being formed when the PVC waterstop folds thus allowing water to leak even more. Because of the above problems engineers today are reluctant to use PVC Waterstops. b. Epoxy Coatings in Construction Joints Epoxy Coatings have been suggested many times as a solution to prevent leakage in construction joints. These will not work all the time. The problem that we are attempting to solve is not of bonding but of filling the opened joint. If the joint has opened by 4 mm, an epoxy coating of 200 microns will not be able to fill up the gap. Hence the joint will continue to leak. c. Cement Grouting Engineers have also tried grouting cement into construction joints after the water retaining structure has been constructed to stop possible leakage. This method is totally dependent on the skill of the grouting expert. More often than not, the grouting expert is interested in drilling as many holes as possible and putting in the maximum number of grouting nipples possible since he charges per drilled hole and per nipple that he has inserted. Consideration is not at all given to the diameter of the hole to be drilled, depth of the hole to be drilled, angle of drilling or anything else that is remotely technical. In this method, most of the holes end up as blind holes, i.e., the holes end up not inside the crack (where they are actually meant to be)
but as a dead end in actual good concrete. Thus, when grouting is attempted, no grout goes in. The grout that actually goes in fills up the hole that has been drilled. Hence this method is also not successful. Repeated drilling of holes in a weak joint will actually destroy the integrity of the concrete and weaken the joint even further. d. Epoxy or other chemical grouting Epoxy can be grouted into leaking joints. Other than epoxy, hydrophobic and hydrophilic polyurethane and various other acrylic solutions can also be grouted into leaking construction joints. Most are time consuming and expensive. e. Swelling Type Waterstops Bentonite/butyl based rope type waterstops which swell in contact with water have been used successfully on many projects. These have been successful whenever a skilled workforce is able to place it in dry condition and is able to ensure that no water falls on it before concreting is carried out. Unfortunately, in our country, ideal conditions are not maintained. After laying the waterstop, wall shuttering is to be erected and then wall concreting is to be carried out. Water used for curing may fall on waterstops which are already in place. During this time, unexpected rain water may enter and make the waterstop wet before concreting. Such incidents will render the swelling type of waterstop ineffective since it will expand even before the concreting is carried out. If none of the above methods are successful, is there actually a method to solve the above problem ? Preformed Flexible Waterstop It is now recognized that Preformed Flexible Compressible Waterstops are the best answer to prevent leakage in Construction joints.Preformed Waterstops are a specially formulated flexible material in the form of a strip (or rope) which needs to be placed in the construction joints before concreting. The waterstop gets compressed in the joint and does not allow water to pass through.
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Laying Waterstop in a horizontal construction joint: - Cast the base slab. Cure for three days. - Clean the joint where the wall is to be cast using a cloth. Apply primer 25 mm wide along the length of the joint. Lay the preformed waterstop end to end with an overlap of about 25 mm. Press firmly at the overlap so that there is no airgap below the waterstop. - Install wall shuttering. - Cast concrete wall. - Make sure that dust does not fall inside the shuttering before concreting takes place How do Preformed Waterstops work? Preformed Waterstops work like a pressure cooker gasket. Typically, the waterstop has a thick cross section of approximately 20 mm x 25 mm. When concrete is poured onto the joint, it is designed to deform slightly and seal the joint. Since most construction joint gaps are 1 5 mm, the joint gets effectively filled up by the waterstop and the structure remains watertight for the rest of its life. The waterstop fuses
with fresh concrete thus forming a lasting watertight bond. Placement is very easy with no skill being required to place the waterstop in the joint. These waterstops are not to be inserted during concreting. They can be placed after the first placement of concrete but before the second lift. Where can Preformed Waterstops be used? Preformed Waterstops can be effectively used for horizontal, vertical, inclined and curved joints (pipe intrusions through concrete). They can be used in water reservoirs, sewage treatment plants, basements, swimming pools, fish hatcheries and other structures where entry or exit of water is a problem to contend with. It can easily resist a water head of 20 metres. Preformed Compressible Waterstops can be laid even when the joint is wet. In fact, in extreme conditions, it can even be laid underwater and will still function effectively provided it is prevented from sliding out of alignment by nailing it in position.
Preformed Compressible Waterstops are flexible and can be bent like a rope. Its consistency is like clay and it is compressible. In vertical joints, it can be nailed in position if it does not stick to the surface. As long as it is kept in position and is not displaced during concreting, such waterstops will work perfectly. Minimum recommended clear cover to Preformed Waterstops is 50 mm from the outer face of the concrete. Invest in Preformed Compressible Waterstops Professional engineers know that it is always cheaper to prevent water leakage than try to solve it after it starts leaking. Preformed Waterstops are a 100 percent solution which do not rely on the skill of any individual for successful application and performance. It can be easily laid by an unskilled worker. Experienced engineers have relied on Preformed waterstops for more than thirty years for preventing water leakage through various structures. Tabulate the cost of leaking water, subsequent grouting or other methods and the risk of not being able to stop leakage fully. Compare it with your investment in Preformed Waterstop which guarantees a 100 percent watertight joint. You will find that your investment is fully rewarded with the satisfaction of having professionally executed a successful job. Synkoflex is the Leading Preformed Compressible Waterstop in India Today. Synkoflex is Manufactured by the Henry Company, Usa and is Imported and Distributed in India by Nuha Construction Solutins, Bangalore

74, 2nd Floor, Nehru Road, Yadav Layout, ST Thomas Town Post, Bangalore 560084 Ph: +91-080- 42041113, 25478966
Fax: +91-9845941499
Nuha Construction Solutions
E-mail: nuhacs@gmail.com Web: www.waterstopindia.com
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3rd International Conference on Construction Chemicals (FICCI)
CICO Technologies
ICO Technologies Limited, an ISO 9001:2008 certified company is one of the largest construction chemical companies and is also the oldest and most trusted brands with high quality construction chemicals and solutions in India. CICO has wellequipped, state of the art manufacturing facilities supported by a strong R&D department to meet the current demand of construction chemicals. CICO a motivated, committed and responsive organization which is focused on maintaining and enhancing the brand reputation by strictly adhering to quality control standards of production. CICO maintains the market reputation of 80 plus years by respecting the value of customers' relationships. CICO also fulfills its corporate social responsibilities by its support to the 'Amit Gupta Foundation'. CICO's brand Tapecrete is the most preferred brand in the field of waterproofing. Reliable products range of CICO includes:
A Tradition of Excellence in Construction Chemicals
Koyna Dam, Chiplun
Jal Mahal, Jaipur
Water Proofers/Sealers; Concrete Admixtures; Grouts and Grouting Compound; Industrial Flooring; Epoxies and Repair Compound; Adhesives, Sealants, Protective Coatings etc. CICO has provided more than 80 years of excellence in services in the field of construction chemicals. CICO products and systems have been extensively used in prestigious construction projects, from heritage buildings to national lifelines, from
power plants to soil stabilization, from restoration and refurbishing of many old heritage structures that are built to last like the Charbagh Railway StationLucknow,Taj-ul Masjid-Bhopal,Jal Mahal-Jaipur, Matri Mandir-Auroville, Koyna Dam-Chiplun and many more.
CICO Product Collage
Owing to the recognition of its superior quality products & services, CICO has won many prestigious awards like: - 'Corporate Leaders' Awards by IEDRA in 2008 and 2011; - Global Golden Award for the quality & Business Prestige-2008, BerlinGermany; - QC 100-Total Quality Management Award-2006; - Bhartiya Udyog Ratna Award by IEDRA-2005.

Visit: www.cicogroup.com
Tapecrete Products
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MB Corporate
Zydex Technologies:
'A Technology Beyond'

ydex nanotechnologies modify the surface of aggregates and soils from hydrophilic polar to non-polar by nano modification to eliminate de-bonding of asphalt binder to aggregates and eliminate damages to pavements due to moisture. Zycosoil additive in asphalt binder changes the bonding mechanism from polar-polar to non-polar to non-polar interaction thereby increasing bonding by 10 20 times in the asphalt layers. Zycosoil modified asphalt mixes are easier to compact both in the laboratory and in the field. Field compaction is improved by 1 to 1.5% with the same compactive effort, resulting in construction cost savings and increased durability of asphalt pavement with reduced air voids. The benefits of Zycosoil in asphalt mixes like improved tensile strength of asphalt mix by 15 to 20%, resulting potential to increase its fatigue life, increases the Marshall stability to provide increased resistance to rutting
while keeping it flexible (that is, maintaining the same flow properties). Zycosoil is almost odor free, neutral and does not generate corrosion and skin irritation. Zycosoil is being used in highway projects in India and abroad. Nanotac is a new generation reactive
100% organo silane nanotechnology for water resistant tack coat with no tire pick up. It is soluble in water and cationic bitumen emulsion and ensures chemical bonding of the tack coat with better wetting, spreading, sets quickly and reduces the cationic bitumen emulsion.
ZYCOSOIL - THE CHEMICAL ACTION

-OH groups make surface very hydrophilic (water loving)
OH Si OH Si O O O O Si O O O Si O O O O Si O O OH Si O O Si O O OH Si O O Si O OH Si O O Si Si O OH Si O O OH Si O
AGGREGATE-ASPHALT BINDER INTERACTION

Silanol Groups
TYPICAL INTERACTION
ZYCOSOIL INTERACTION
Particle surface
Asphalt Binder
Soil / Clay / Sand / Aggregate surface silicate structure
Newly formed Alkyl Siloxane Nano layer 4-6 nm
Zycosoil creates molecular level hydrophobic zone (water repellent)

O O O Si O O O O Si O Si C O O Si O Si O O Si O O O O O Si O O O O O Si O O Si O O Si O Si O Si O O Si O O O Si O Si O O Si Si O O O Si O Si O O O O Si O Si O O
Aggregate
Polar - Polar Interaction
Non Polar Non Polar Interaction
Particle surface
10-20 fold
Internal Siloxane bonds
5-15 % Asphalt participates in Bonding
Increase
85-95 % Asphalt participates in Bonding
Soil / Clay / Sand / Aggregate surface silicate structure after Zycosoil reaction
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Project Vartak, BRO
Nanotac mixed with MS emulsion (3:1)
Tack Coat Spray
Setting in 10 minuts
It converts dust, stone powder, broken aggregates on base asphalt layer to asphalt loving and gives better bonding to new asphalt concrete layer. It improves stability of cationic bitumen emulsion and lowers surface tension of cationic bitumen emulsion and keeps the nozzles clean. Terrasil is 100 % Organo Silane, water-soluble, UV and heat stable, reactive soil modifier to waterproof soil sub-grade and stone bases and control the soil erosion in side slopes & shoulders. It reacts with water loving silanol groups of sand, silt, clay, aggregates to convert to highly stable
water repellent alkyl siloxane bonds for the following benefits: - Reduced water permeability (10-7 cm/sec) of soil bases while maintaining 100% vapor permeability - Formation of breathable waterproofed soil-subgrade and stone base layers - Maintain frictional values between silt, sand, clay particles leading to retention of strength and resistance to deformation - Stopping of the capillary rise Prime Coat with Terrasil Terrasil as Prime coat additive waterproofs the non-bituminous WMM / WBM to stop the migration of moisture
into the bituminous course in 1 2 hours. It reduces the consumption of emulsion while increasing the performance. The below pictures are application of Terrasil mixed with cationic bitumen emulsion in Panchayat road project Bhartana Bhartani village, Vadodara. For further details:
Zydex Industries
25-A, Gandhi Oil Mill Compound, Gorwa, Vadodara 390016, Gujarat, India Ph: +91-265-2280865 / 2283386 , Fax: +91-265-2280872 E-mail: info@zydexindustries.com Web: www.zydexindustries.com
Compact WBM
Terrasil Prima coat with bitumen emulsion
Waterproofing Confirmation
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An Array of Sustainable Products & Solutions from Chatelier Infrastructure Services

experience, the company has quite literally grown by leaps and bounds in the recent past and is today considered a trendsetter with its array of products and consultancy services. The team of professionals at Chatelier has been in the forefront when it comes to offering an innovative range of products, utilizing cutting edge technologies. The company's product range includes:
Feroze Chatelier
Managing Director, Chatelier Infrastructure Services
he rising emphasis on adoption of sustainable construction practices has meant that today there are several companies offering green products and services. Chatelier Infrastructure Services is one such company that has carved a niche, all its own, through a range of clean, green, & efficient products and services for the growing needs of the construction industry, and the infrastructure sector. The company's commitment to quality products and superior services has seen it become a preferred choice among the construction fraternity, in a relatively short span of time. Ably led by Mr. Feroze Chatelier, ex-MD of Don Construction Chemicals India Ltd. brings with him rich and varied
Geo-polymer based products for Rapid Repair & Rehabilitation Liquid Granite which is an EcoFriendly Surface Coating System. Green Roofs Eco- Friendly Geo Polymer based low cost thermal insulated tiling designs. Drainage Systems & Roof Garden Designs
Rapid repair and rehabilation system
One of the key reasons behind the company's range of world-class green products and solutions has been its strong R & D focus. The top management of the company firmly believes in investing in the latest technologies for coming out with trendsetting products for the construction industry and the infrastructure sector. The company's other division, Chatelier Consulting [P] Ltd., offers
specialized services for developing state-of-the-art facilities. Aquaculture and fishfarming for example, is an area where the company's expertise is much sought after around the country. Another niche area where the company specializes in is Waste Management Services. The company offers environment-friendly waste management services that are compliant with domestic regulations and international waste management standards. This combination mitigates risks to the clients and the local community. Another key area where Chatelier Consulting has unmatched expertise is in Repairs and Maintenance of Heritage Structures. The company has a dedicated team of experts who offer technical solutions and implement them for the protection and preservation of heritage structures.

F-C2, Sri Sai Raj Apartments Indian Airlines Colony, Trimulgherry, Secunderabad - 500015. Andhra Pradesh, India. Ph: +91 040 64646228 / 64606228 / 64546228 E-mail: info@chateliergroup.com Web: www.chateliergroup.com
Chatelier Infrastructure Services
New generation waterproofing system
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Asia's Leading Rail Industry Gathering
Cladding Fibre Cement
Fibre Cement Cladding

A Sustainable Alternative for Natural Wood and Vinyl Cladding
ne of the direct impacts of the Green Building movement has been the number of newer building materials hitting the market, almost every passing day. The rising emphasis on sustainable building practices has meant that certain types of building materials, which have been
O
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in existence for a long time now and were maintain a low profile, are now suddenly in the limelight. Fibre cement cladding is one such type of material. Also known as fibre cement siding in many parts of the world, while the concept was originally developed in the 1980s it has now gradual risen in
popularity as a durable exterior product. The use of fibre cement cladding has been gradually increasing since it is known to cost less on an installed basis than wood or natural stone cladding. Additionally, it is also scores over other options such as aluminium, vinyl, or wood, when it
comes to the durability factor. For those looking for a durable alternative for wood or vinyl, which needs lesser maintenance and does not give repair hassles, then fibre cement cladding, is an excellent choice. The composite material can not only be used as an exterior siding, it can also be used as a substitute for timber fascias. Used both in commercial and domestic applications, fibre cement cladding is made up of sand, cement and cellulose fibres. They are also used as a tile underlay in bathrooms and decks. Usually available in the form of horizontal boards, imitating wooden siding or shingles, they are also manufactured in sheet form. The fibre cement thickness in the boards could vary anywhere from 4 to 18mm. Generally speaking, the thicker and denser a fibre cement board is, the better will be its resistance to temperature and sound transmission. With both thermal and acoustic insulation being considered key factors in today's world of sustainable building practices, it is not surprising
that fibre cement cladding is rising in popularity. Durability is one factor that has been behind the gradual increased usage of the product, which was originally developed as an alternative to asbestos cement sheeting. The thicker and denser products also exhibit excellent impact resistance, making them ideally suited for exterior application. There are in fact, a whole lot of advantages associated with the material. Let us take a look at them one by one. - Aesthetics: One of the biggest advantages with fibre cement cladding is the number of options available, when it comes to choosing a colour for the cladding. Additionally the variety of textures available and not to forget the various shapes and sizes the claddings come in, have been behind the rising popularity of this building material. With fibre cement cladding you can now get the traditional wood grain appearance without the drawbacks that are associated with using wood.
Dimensional Tolerances: The durability factor of the product also makes it score high when it comes to dimensional tolerances and stability. The color and texture on the cladding do not easily fade, making it ideally suited for outdoor use. The fact that they do not warp easily, is another aspect that makes this building material special. Just after it is formed, the material is still pliable, which means that it can be easily moulded into a variety of 3 dimensional shapes. The entire installation process of fibre cement cladding is apart from being relatively easier than that of its wooden counterparts, is also less expensive. In fact, the installation process is much less expensive when compared to other types of building material such as wood, natural stone or cedar, and has been one of the important reasons why it has become a preferred building material over the years. The cost for installation of fibre cement claddings is less expensive
Fibre cement cladding is ideally suited for both commercial and residential sectors
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Fibre cement cladding has emerged as an excellent alternative for vinyl and wood Fibre cement cladding is both aesthetically pleasing and high on functional advantage
than that for natural stone, cedar, wood siding, and hardboard siding. Another important advantage of fibre cement cladding is its ability to hold paint well. In fact, it is known to hold paint well for 7-15 years. They are therefore considered an excellent rot free alternative for traditional timber weatherboard. Fibre cement cladding cannot be penetrated by birds or insects. It also won't rot and holds up well against ultra violet rays of the sun. It is additionally not susceptible to rot or termites. The benefits keep increasing since it is hardy against the corrosive effects of salt spray too, making it ideally suited for the exteriors. As a building material, fibre cement cladding is ideally suited to places having cooler climes too, apart from its ability to perform sturdily even under hot conditions. The material also does not melt in the presence of heat sources. It does
not become brittle in freezing conditions either, unlike certain other types of materials, adding to its effectiveness. Fire resistance is another characteristic property of fibre cement cladding. The non combustible nature of the material has been the reason why it is used extensively near bush fire prone areas in Australia. While the combination of all the above factors is in itself enough to term fibre cement cladding as one of the most sustainable materials available, there are certain other factors that accentuate the case for declaring it so. A close look at the impact the material has on the total energy costs of a building further strengthens its case. Fibre cement has one of the lowest embodied energy per square metre of cover, as compared to other similar building products. This in turns means that environmental costs
incurred by using the material are typically around 20 percent lesser than using other material such as brick. Adding to the sustainability factor is the fact that fibre cement requires less energy to produce and to construct, as compared to other building materials. The production method is also more environment friendly since there is no or negligible levels of solid waste or carcinogenic emissions involved in the process. Most of the leading manufacturers add to the sustainability quotient by using natural raw materials and ensuring no pesticides are used during the production process. And now for the downside. Perhaps the only downside of the building material that is the fact that it is heavy and therefore needs special care when it comes to transportation and carrying around at the construction site, since it could easily break or get damaged.
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Modern Formwork Systems For Building Construction
White Topping Technical Meet
UltraTech Cement Conducts Technical Meet on White Topping

ltraTech Cement, which is one of the leading cement makers in the country, conducted a technical meet on Concrete Roads & White Topping at Jenney's Residency, Coimbatore on 13.12.2011. The technical meet attracted a wide range of audience, including practicing engineers and teaching faculty from leading engineering institutions, in and around Coimbatore. The welcome address was given by Mr.Stanley Jacob, Assistant Vice President-Marketing, of the company, which was followed by a detailed product presentation by Mr.K.Jayasankar, Assistant Vice President- Technical Services, and Chennai. Mr.Jayasankar highlighted the various companies that come under the Aditya Birla Group and the product offerings. The technical presentation on Concrete Roads & White Topping was given by Dr.V.Ramachandra, Assistant Vice President, Technical Services, Bengaluru of the company. Dr. Ramachandra during his presentation pointed out how white topping is both a cost-effective and reliable option for road building for a country like India. He gave detailed insights into the procedure and also went into the details of some of the future technologies that could
soon impact the road construction sector in the country. Dr.Ramachandra in his presentation pointed out that the concept of white topping, apart from its functional superiority also scores on the sustainability front. This apart, he also highlighted the fact that asphalt roads are increasingly becoming an expensive proposition and with costs expected to go up further in the near future, policy makers should seriously look into concrete roads and white toppings for road construction projects in the future.
Dr.Ramachandra gave examples of concrete roads in cities like Mumbai and other places in India, which have stood the test of time and stand testimony to the efficacy of the technology. The presentation was followed by a round of questions and answers, wherein Dr.Ramachandra responded to pointed queries about the technology from the select gathering. The vote of thanks was given by Mr.T.Sivashanmukam, Senior ManagerMarketing of the company's Coimbatore division.
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Roof India 2012
Roofing Industry Analysis
Roofing Industry:
Manufacturing Sector Holds Key to Market Growth
n an age and day where convergence is the buzzword, if there is one area in construction where the term would fit aptly, it is perhaps in the case of roofs. Today a roof is not merely meant for providing shelter from the elements. It now supports insulation for one. It also collects rainwater or solar energy or even both, as the case maybe. Additionally, the modern day
roof is designed for allowing superior ventilation and daylighting. Along with being functional, aiding all these factors, it is also expected to be aesthetically pleasing. Keeping in mind all these factors, it is not surprising that roofing has become a multi-billion dollar industry worldwide. Globally the roofing industry is estimated be growing at a rate of just
over 3% annually and is expected to continue in the same vein in the next few years. It won't be a misnomer to say that the over 10 billion square meter world roofing industry has changed beyond recognition. Today a host of materials are being used for roofing and it is one of the fastest growing segments in the Indian construction industry. Despite the recent economic
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multiplexes, etc , to mention only a few has been driving forward the roofing market, particularly metal roofing in the country. While roofs have always played a key role in aiding building aesthetics, the increased emphasis on sustainability has added another angle to the choice of roofs, especially in the case of the commercial sector. Metal roofs with their several advantages, particularly with respect to sustainability have made a strong case for themselves in the Indian market. The rapidly growing pre-engineered building industry has given a direct fillip to the growth of metal roofing. Talking about the market size , Mr.Amit Bharana, President, Era Buildsys, an acknowledged industry leader in the domain, said, The PEB Industry overall is valued to be approx. ` 4000 crore and the sheeting / cladding market is said to be approx. ` 400-500 crore. These numbers are growing quite rapidly given the numerous advantages that metal buildings offer, especially in the case of construction of industrial units and commercial establishments. Faster construction times, without any compromise on the quality front has meant that PEB
rate of 15%-20% in recent times. Expressing his optimism at the continued growth of the industry, Mr. Ajay Rattan, General Manager- Sales & Market Development, Tata Bluescope, another leading name in the field, pointed out, Growth in the infrastructure and industrial segment has been a major demand driver for roof and wall cladding industry and has registered a double digit growth over past three years. The future of roof and wall cladding industry in India is bright considering the low steel penetration and high demand in construction industry. Versatility is another key factor driving forward the PEB industry thereby directly impacting the metal roofing industry. Highlighting this point, Mr.Gautam Suri, CTO & Founder, Interarch, an industry leader in the field had during an earlier interaction with The Masterbuilder, observed, The beauty of pre-engineered building solution is its versatility across sectors. This is further corroborated by some of our projects wherein we have had the privilege to work with some of the most diverse set of construction projects from agriculture, rural retail, and healthcare to amusement parks. In fact, many modern corporate parks and
slowdown the Indian construction industry is expected to continue in its growth path, maintaining a rate of around 10% in the commercial and about 5% - 6% in the case of the residential sector, which bodes well for the roofing industry. The huge growth in urban infrastructure in the form of retail malls, airport terminals, IT Parks, SEZs,
The Indian metal roofing market has grown rapidly in recent times
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Multicolor Steels (India) Pvt Ltd
Multicolor Steels (India) Pvt Ltd
The PEB Industry overall is valued to be approx. ` 4000 crore and the sheeting / cladding market is said to be approx. ` 400-500 crore
Amit Bharana
President, Era Buildsys
commercial buildings are also now turning to pre-engineered metal structures. These entire pointers auger well for the future of metal roofing industry in the country. It is not surprising given the sustained demand that there are several leading players such as Zamil Steel, Pebs Pennar, Loya PEB, United Steel & Structurals, MPIL , etc, to mention only a few, offering metal roofing products in the market. An entire host of metals are now being used for roofing. Metal roofing can be made of galvanized steel, galvalume steel, stainless steel, aluminum, zinc, copper, and lead tin
alloy. Galvanized steel is widely used, along with galvalume, which is steel in combination coating of both aluminium and zinc, which provides additional protection and ultimate weather resistance. Aluminium roofs are another popular choice as they are lighter in weight and rust free. Copper is also being preferred for it is rust proof and doesn't require painting. On the flip side though, copper is consider an expensive roofing proposition. Zinc roofing is another popular option, particularly popular in European countries. In fact, some of the zinc roofs in cities like Paris have been functioning without any problem for well over two hundred years. The intense competition prevailing in the market has meant that companies are leaving no stone unturned when it comes to product differentiation. Going into the details of how their products differ from others, Mr.Amit Bharana of Era Buildsys explained, Our unique roofing and cladding services are manufactured in a completely automated plant comprising of machines imported from Europe and Middle East. Also, our plant has the highest production capacity in North India and we supply sheeting materials to almost every
Growth in the infrastructure and industrial segment has been a major demand driver for roof and wall cladding industry and has registered a double digit growth over past three years. The future of roof and wall cladding industry in India is bright considering the low steel penetration and high demand in construction industry
Ajay Rattan
General Manager, Sales & Market Development, Tata Bluescope
Era Buildsys expertise at work
Govt. body. It is the only plant having a continuous production line (UPS backup) which ensures accurate and timely delivery. These features give our firm an edge over the others. Companies are investing heavily in modern manufacturing units for catering to the growing customer base in India. Tata Bluescope the name behind the popular LYSAGHT brand has been focusing on this key aspect. Giving an insight into the company's plants, Mr.Ajay Rattan said, Our strategically located world-class manufacturing facilities with advanced, high-end rollforming equipments are backed-up by strong engineering support with advanced design software and R&D support from BlueScope Steel, Australia. Moreover it ensures reduced delivery cost of goods in shorter lead time. Our profiles cater to varied segments that provide cost efficiency (due to optimized steel solutions), shorter lead time, high strength (with design flexibility) and superior quality paint & coating system (with long lasting aesthetics). We also follow world-class safety standards in construction. Thermal mass, which is the ability of
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Tensile fabric roofs seen here in Jawaharlal Nehru Stadium hold immense potential in India
a material to absorb and retain heat, is another factor that is going for metal roofs. Since metal roofs relatively lower thermal mass, they respond much more quickly to temperature variations, since they do not absorb nearly as much heat as compared to say, clay, concrete or stone tiles. Metals reflect much of the sun's heat, rather than absorb it. Metals also cool more quickly, which makes them score higher on the thermal efficiency factor, so crucial in today's world of sustainable construction practices. Tensile and ETFE Fabric Roofs Another popular option that is fast becoming a preferred choice is that of tensile roofing. Tensile membrane roofs are typically being used in stadium, concert halls, exhibition centres, hotels, airports, petrol bunks, recreation halls, etc, to mention only some. The semitranslucent nature of fabric structures is what makes them a favourite with engineers and architects looking for roofing systems to cover large areas, such as sports stadia or terminals. Tension membrane structures are
usually reinforced using either PVT/ Polyester based coatings or PTFE based coatings. They also come with the advantage in the sense that in their case, roofing, and cladding is possible in one single structural element. Integration of photovoltaic (PV) cells with fabrics is another area that is gaining ground these days. The availability of lighter and more efficient solar cells is enabling further breakthroughs in this exciting field. With the incorporation of nanotechnology and the use of organic photovoltaic
The beauty of pre-engineered building solution is its versatility across sectors
Gautam Suri
CTO & Founder, Interarch
cells (OPVs), it is one area that needs to be closely watched in the near future. The 60,000 seat Jawaharlal Nehru Stadium in the capital is a good example of the rapid strides made by India in the field of tensile roofing. Similarly ETFE or Ethylene Tetraflouroethylene fabric roofs are another segment that is expected to grow in the near future. One of the key reasons why ETFE is gradually becoming a favorite with engineers and architects is because of its high translucency. It can in fact transmit light across the entire visible light region (380-780mm). With up to 95 percent transmission of light, it can even support plant life underneath, a good reason why ETFE was chosen for the landmark Eden Biomes Project in the United Kingdom, which involved growing several species of plants inside the domes. ETFE also scores high on the sustainability factor since it has the property to absorb infra red light, has excellent thermal insulation qualities, can last for decades together, and is 100% recyclable. Adding to the sustainability quotient of ETFE is the fact that is easy to transport and install.
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the demand for the construction industry and therefore the roofing industry. The several airport modernization projects for example are fuelling demand for both metal, as well as tensile fabric roofs. Metro station projects, IT parks, hotels, and resorts are other type of projects which are driving the demand for roofing products. Sporting facilities have emerged as another key market for roofing products. Although the residential realty sector has been going through one of its slowest growth phases in recent times, it still constitutes an important demand driver for the roofing industry.
Fillip to manufacturing sector could further boost demand for metal roofs
Green Roofs Another niche segment that is making its mark gradually is that of green roofs. The concept of vegetation being used for roofs is something that is not new to India. Roofs made up of palm leaves, bamboo, grass, and mud have been in existence in the country for several centuries now. The modern avatar of the same- green roofs is a concept that is yet to catch up in a big way in the country. The small number of contractors specializing in the field, plus the higher initial investment are said to be the reason for the slow growth. However, with the increase in demand, economies of scale are expected to bring down the price and demand for green roofs is expected to increase in the near future. The Future According to industry estimates India is expected to be one of the key growth markets for roofing products in the next decade, along with the other BRIC nations. Factors such as the continued thrust on infrastructure and manufacturing, along with the acceptance of alternate roofing systems are expected to drive demand in the near future. With contractors being under pressure to adhere to stricter project deadlines, there has been a change in trends, with acceptance levels of clients when it comes to various types of roofing systems going up in recent times. The future bodes well for the Indian roofing industry.
Key Driving Factors One of the key driving factors for the commercial roofing industry is the spurt in industrialization. Although there could be doubts regarding the time frame of implementation of many initiatives, there is no doubt in the fact that the government is banking on the manufacturing sector to revive the economy in a big way. Several initiatives towards this purpose, such as the Delhi-Mumbai Industrial Corridor, Textile Parks, Spice Parks, Food Processing
Parks, IT Parks, etc, are being seen as the spurt that is being given to the manufacturing sector. The cabinet had also approved the draft National Manufacturing Policy, a few months ago, which seeks to increase the share of manufacturing in the GDP to 25 % by 2025, which automatically translates into tremendous opportunities for metal roofing suppliers. Despite the economic slowdown, the country's inherent demand for better infrastructure is expected to drive
Green roofs could be the lung spaces that metro cities are looking for in the future
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Alia Formtech
Roofing Solutions
Alia Formtech: Ushering in a New Era in Roofing Systems

affect the building, whether it is air pressure, explosions, seismic or whir winds, something that is again not available in the case of conventional steel buildings with straight corners. Modular Canopy Car Parking System The Alia Modular Canopy System is a flagship product of the company. Alia Formtech is the first company to introduce modular car parking system in India. The Alia Modular Canopy System is a result of lot of research and is a result of the sustained efforts of the company to provide a different approach towards providing pre-engineered building solutions. The canopy systems offer 100 % heat protection as per stringent quality specifications. The systems are distinguished by their beautiful architectural and geometrical design that helps in enhancing the exterior view of buildings. Alia Modular Canopy Car Parking Systems are available in a variety of designs, such as 'M' canopy, 'L'canopy, 'T' canopy, Alia Modular Butterfly Canopy Car Parking System and Alia Modular Butterfly Canopy Cantilever System. The profile of the system is light weight and they are also available as tile form, corrugated, and trapezoidal system. Self Supporting Arches One of the highlights of the Alia
Corrugated System
K.R.Shajahan, Managing Director,

Alia Formtech Steel Roll Forming Industries
lia Formtech Steel Roll Forming Industries (AFSRI) is a leading manufacturer of corrugated sheet, tile forming sheet and steel construction works in the country. The company has been one of the preferred and trusted building systems contractor and manufacturer in Kuwait since 2000. The company's Indian operations are based out of Kerala and it has in a relatively short span of time, become a name to reckon with in the industry on the basis of uncompromised quality, reliability and service. Unique Roofing System The 'Alia Rainbow Roofing System' from the company comes with a host of advantages over normal construction methods. No trusses, nuts, bolts, rivets, or screws are required to erect the system. The system allows for the design of aesthetically pleasing architecture, which is also functionally strong, whether outside or inside a building. The arch shape of the building, apart from being aesthetically pleasing also disperses the forces that
Trapezoidal System
Rainbow arch building system is that they are designed to be totally self supporting and do not require any supporting structure, as it is needed in the case of a standards steel frame building. The arches found by the rainbow system are used either as complete building, or as a roof cover side walls .the self supporting arches can span up to 25 meters clear width without any intermediate support of columns, beams or tresses. The alia rainbow building can be utilized specially in the factories up to the top of roof without any prevention and the roofs looks as beautifully decorated as gypsum board ceiling or cement roof, if not better. The company offers a variety of solutions including: -
Tile Form
Building system manufacturing and construction
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Waltar Enterprises (Xetex)
Wendt (India) Ltd.
Roofing Solutions
conditions the Alia Rainbow Building systems can be completely insulated to provide desired temperature and comfort level inside buildings. Once insulated the system can be airconditioned or heated by using conventional air-conditioning or heating systems. Along with offering thermal, acoustic and fire protection insulation, the system is also less expensive than any other type of insulation in the case of conventional steel buildings, according to the company. The weather protection capabilities of the system have made the system preferred for covering basins and stadiums. Several Advantages
Canopy Car Parking System
Latest model tile roofing sheets manufacturing, specially designed for Kerala style. Corrugated roof sheet manufacturing. Manufacturing of roofing accessories and various rain water accessories. All kinds of metal sheet shearing and press bends.
Rainbow Building systems is that they do not require any water proofing. The arches are seamed together in a totally water proof manner, joined by electric seaming machine. No nuts, bolts, or screws are used in the erection of the system. Superior Insulation Not only this, for temperature control in either heat or cold climatic
No Waterproofing Required Another major advantage of Alia
Moreover, skylights can also be made in the roof of the Alia Rainbow Building System allowing natural sunlight to enter the building. The roofing sheets are available in a wide range of colors and require very minimal maintenance, making them a favourite of several sectors. The color metal roofing raw material used by the company is imported and specially developed to provide durability for exterior applications with good formability. Typically used as roofing, wall cladding, panels, etc, they come with universal corrosion inhibitive primer coat with custom made premium polyster system finish coat, along with custom formulated backer with 35% (600) gloss and other gloss levels, which are not easily available in the market. Steel is formed and produced at the mill by cold roll forming process according to the specifications of the American Institute for Steel Industry (A.I.S.I.).

Kunnikodu, Shasthri Jn. Kollam Dist. Kerala, Pin - 691508 Ph: +91-475-2322600, Fax: +91-475-2032172, Mob: 09645090413 E-mail: alia_formatech@yahoo.com Web: www.aliaformtech.com
Canopy Car Parking System
Alia Formtech Steel Roll Forming Industries
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20 Microns Ltd
Rotho -Robert Thomas Metall and Elektrowerke GmbH & Co. KG
Roofing System Product Focus
Vizag Steel Plant
Multi-Seam SSR System A Truly Innovative, Screw Less, Maintenance Free Roofing System
etal roofing systems are one of the fastest growing segments in the Indian construction industry. With the continued thrust given to the manufacturing sector through various policy initiatives by the government, the rapid industrialization process has meant that the market for metal roofing systems has grown exponentially, particularly over the last two decades, after the advent of prepainted galvanized steel in the mid- 90s. Metal roofing systems have transformed into big business over the last decade and today one can safely say that there are hardly any industrial buildings that
are not covered by profiled steel sheets. It is one industry which The Masterbuilder wanted to analyze in-depth and find out in detail through a market survey about the various new technologies and concepts that have made an entry into the Indian market. The team at The Masterbuilder set about the purpose in the right earnest and in the process found out a truly innovative and trendsetting metal roofing system 'Multi-seam' SSR system offered by Multicolor Steels India (MPSL), considered a trendsetter in the industry. This innovative, screw less, maintenance free roofing system is all set to
revolutionize the metal roofing industry in the country. In order to find out what makes the Multi-seam SSR system so special, we will first of all need to look at the various types of metal roofing systems that are available in the Indian market first. The sheeting systems available in the market can be broadly classified into three categories. 1. Trapezoidal profiled sheets: screw down fixing 2. Hidden fix-clip profiles: metal clip is fixed to purlins 3. Standing Seam Roofing System (SSR)
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Out of the three the latest entrant into the market are SSR, an area in which Multicolor is considered the pioneer. The system essentially involves two seams, left side for underlaps and right side for overlap. The seams are formed as a vertical fold formed on both edges of profiled sheet, designed to overlap each other when laid on roof. The seams are then joined together mechanically in a 360 deg. Standing Seam roofing systems (SSR) were developed to overcome the limitations and constrains of earlier roofing systems, and to make the roofs more aesthetic, more weather tight, and enable lay a new roof over old roof without disturbing the underside. While various types of Standing Seam roofing systems are available in India, what is that makes 'Multi- seam' SSR so unique? Well, our team during the detailed analysis and market survey our team conducted, we found out that the best solution is the one which ensured the following: It is a non-penetrative roof without any fasteners penetrating the membrane. Instead a clip is anchored to the secondary members with screws and the stub attached to the clip is jointed to the roofing panel firmly into the seam.
SS stub is twice as strong as and more durable than a GI stub. This is the most critical component of the whole system. The Clip assembly consists of a yoke frame made of thick gauge galvanized steel strip, a triangular shaped slider bar, self centering sleeves on either side of stub, a Y shaped stainless steel stub wrapping around the slider bar that folds tightly into the seam providing indirect anchor to the sheet with secondary structural member. The sheet rests on top flange upturned lips of yoke frame
Latest Motorized Electrically Operated Seamer Machine
The membrane system is able to accommodate thermal movements caused by temperature variance in tropical countries like India where extreme weather conditions prevail in many parts of the country. The Stainless Steel stub is not only providing strong grip to the sheet but also allows as much as 30mm movement in both directions to accommodate thermal stresses. On a clear hot summer day, with no wind, the steel skin temperature in roof cladding can reach even up to 80 deg.C. A full length 120 meter long sheet expands as much as 12mm with 10 deg.C change in temperature. This clip also obviates the necessity of expansion joints even in roof lengths exceeding 100 meters. Another salient feature of the system is the unique configuration of the membrane panel which has twin step troughs 51mm plus 31mm deep each with over all depth of 80mm which is the deepest trough available in SSR. 485 mm wide Pan stiffened with 30mm wide 255mm long cross rib stiffeners spaced at regular intervals across the pan width all through the length of the panel impart added strength to the panels. Even if heavy built persons walk on the roof, the sheet will not deform. The panel is strong enough to permit 2 meter purlin spacing, thus enabling cost savings.
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among more discerning customers and engineering consultants. The key features and dimensional characteristics of the Multi-seam SSR system include: Totally Screw less Roof. Maintenance Free Roof. Trough depth & Pitch 51 mm & 255 mm respectively. Covered width 485 mm. Material options Bare Galvalume / Color Coated Galvalume. Thickness 0.47 mm to 0.60 mm tct. Fixed with the help of special type concealed clips with stubs made of stainless steel. The minimum possible roof pitch for this profile is as low as 1:50 (1deg) slope. Roof panels are permanently seamed together with a full 360 deg Pittsburgh double lock seam. Single length panels from eaves to ridge to eliminate end laps. Ideal for high wind, high rainfall & coastal areas, and also suited for re-roofing over existing old roof.
Another unique feature is the panel seam that provides strong side lap connection to the adjacent panels, integrating all the panels into a monolithic strong membrane. Unlike other systems which just crimp the seams, or slide / insert a cap. This system ensures a 360 deg Pittsburg seam lock using a motorized roof seamer machine used on the roof after installation of the sheets. The 360 deg. Lock seam not only ensures a strong and leak proof, weather tight joint, but also is resistant to unlock / un-seam under live load / strong wind uplift /adverse weather conditions. Given the various advantages of the Multi-seam SSR system, it is not surprising to find that Multicolor has already installed over 500,000 sq.mtrs of such sheeting system in India and major clients include; Samsung, Maruti Suzuki, Northern Railways, Toyota-JV, Honda, Yamaha, Vizag Steel Plant, and Panasonic. Single length sheets of up to 80 meters have been installed at above projects, and at Vizag Steel, a new record of 18000 sqm in a month has been created by the company. The system is gaining wide acceptance

Multicolor Steels India Pvt. Ltd.
Corporate Office: White House, 1/18-20, Rani Jhansi Road, New Delhi - 110055. Ph: +91-11-30511200, 23513661-64,
Fax: +91-11-23513660
E-mail: enquiry@multicolorsteel.com Web: www.multicolorsteel.com
All these salient features make 'Multi-seam' SSR system, a truly oneof-its kind product. The remarkable system provides an ideal solution wherein all the components are designed to work together to provide a weather tight metal membrane shield for a building. This is an integrated system designed to accommodate the site conditions and field assembly constraints and yet give a weather tight performance. Another highlight of the system is that it combines the best aspects of secret fix clip system and Standing Seam system, making it truly unique.
Maruti Suzuki Project
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Perma Construction Aids Pvt. Ltd.
Dextra India Pvt.Ltd.
Insulation
Eco-trends for 'Greener' Homes: Insulation

Chaitanya Goyal, Special Correspondent
o Green has been the popular chant among the masses over the past couple of years. Among the many changing trends, as a result of this green revolution, is the growing popularity and demand of energy efficient and sustainable residences which have now become the hottest trend of the year. Energy efficient homes cost much less to heat, cool and light as compared to a typical home, thus contributing to the cutting in greenhouse emissions and power dependency while at the same time creating a healthier and comfortable indoor environment to live in.
Insulation is the biggest stakeholder in the development of today's 'modern energy saving' homes. From creating and modifying buildings for comfort and energy efficiency to reducing the intensity of sound or the rate of heat transfer, insulating your home will do the trick! Insulation: A necessity or an 'attractive add-on'? Not surprisingly, energy savings & comfortable indoors come hand in hand with an insulated home. Insulation helps providing an even indoor temperature year round. In summers, insulation
prevents the heat exchange between indoors and outdoors, thus keeping the heat out and keeping the house cool. Homes built in cold regions as usually designed to trap maximum sunlight or heat captured from the sun to keep indoors warm or else heaters are used, as an alternative to tackle winters. It is of utmost importance that this heat is incapable of escaping through the walls, ceilings or floors of a house. Also, the warm insulated surfaces prevent the formation of condensation on them, thus reducing the likelihood of mold & mildew and the consequent respiratory illness and
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Insulation
allergies. Research has also found that installing insulation will lead to health benefits such as reduced incidence of asthma. A new residence being built can inculcate the insulation techniques during its construction as prescribed by the building codes, while the old houses and buildings can be retrofitted for the same, thus resulting in considerable financial savings over a certain period and added comfort in extreme weather conditions. The large number of advantages thus resulting from it undoubtedly proves insulation to be a critical necessity in residential constructions, as we transit into an era of sustainable homes from the current times! How does it work? The Insulation materials work on a single basic principle, i.e., the heat moves from warmer to colder areas. It is known that on cold days, heat from inside a building seeks to get outside, while on warmer days, the heat from outside the building seeks to get inside. The insulating material slows down this process. The conduction ability of construction materials drifts downwards from concrete and mortar, to wood, and then to the worst conductors such as thermal insulating materials. Gases like air are even worse conductors but they are prone to convection.
Insulation materials work on basic principle of heat moving from warmer to colder areas
Pint-sized pockets of trapped air exist in an insulating material which resists the transfer of heat between the two environments. The smaller the pocket, the better is the insulation. Though this material will not stop the loss or gain of heat completely, it minimizes it considerably. We can insulate our homes by providing cavities of still air, such as in wall insulation or double-glazing. Another method is to use surfaces that reflect heat, such as silver foil behind radiators. Where to apply? The quantity and quality of insulation a house needs depends on its location and the part of the house to be insulated. Space heating & water heating make the largest contribution to your power bill in cold weather, amounting to 34% and 29% of the power bill respectively.
Insulating your hot water system is an obvious priority because it takes little effort. Insulating your hot water pipes reduces heat loss and can raise water temperature 2F - 4F hotter than un-insulated pipes can deliver, allowing for a lower water temperature setting. You also won't have to wait as long for hot water when you turn on a faucet or showerhead, which helps conserve water. Also, if your hot water cylinder has an 'A' rating it is already well insulated; if not it will benefit from a hot water cylinder wrap. Major amount of heat loss in a home occurs through the ceiling, so that should be the top priority for insulation. Roofs and ceilings work most effectively if they are insulated together. About 42% of heat loss from an average un-insulated home occurs through this area (up to 60% in older houses). Walls also lose a significant amount of heat,
Pictures taken using thermal imaging shows a well insulated building on the left while the house on the right shows an un-insulated building
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Insulation
Ceiling Insulation
but they are difficult to retrofit with insulation without removing the internal lining. About 24% of heat from an average un-insulated home is lost through the walls. Also, wall insulation can double as a moisture barrier. Floors lose only about 10-12% of heat, but they are easy and cheap to insulate and the comfort benefits of a warmer floor are great. Windows are responsible for highest heat drain per unit area which amounts to 20-30% of the total loss. Use of reflective insulation under the roof and bulk insulation in the ceiling or rolling bulk blanket insulation across ceiling joists is one of the most effective way to insulate the ceiling, while windows can be fitted with drapes or blinds, but these need to be well fitted or usage of double-glazing can be made. For wall insulation, while using a framed construction system, insulation should be placed within the wall framing. Insulation can also be installed outside the framing but the insulation must be weatherproof to be effective. Where heat is stored in the thermal mass of a building it is important to install the insulation on the cold side of the mass. A concrete floor used for heat storage needs to have the insulation underneath,
not on top. Since, the concrete floors lose heat mainly at the edges; the detailing should be paid proper attention. The design and construction of your home will affect the specific types of insulation that can be used and where they can be placed. Some construction systems like aerated concrete blocks, glass blocks and straw bales when used,
require little or absolutely no additional insulation. Also, it's always better to analyze personal habits and preferences. For example, if one is habitual of open curtains at night to enjoy the view, double-glazing is a sensible choice. Or if a family is used to walking barefoot in the middle of winter, under-floor insulation becomes important. How much is enough? A materials ability to resist the flow of heat is measured according to the R- values. The higher the R-value, the greater is the insulating effectiveness. The R-value depends on the type of insulation and includes its material, thickness, and density. When calculating the R-value of a multilayered installation, add the R-values of the individual layers. The Building Codes prescribe a minimum insulation level for new buildings and major renovations. Installing insulation to the best levels in your home increases the R-value and the resistance to heat flow. The recommended R-values depend on the climate, location and type of construction materials used. These values may range between 0.3-0.35 for windows, 1.2-3.2 for floor, 1.2-2.6 for
The R-value depends on the type of insulation and includes its material, thickness, and density
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Gayatri Polymers & Geosynthetics
Durotop Construction Chemicals Pvt. Ltd.
Relyon Facility Services

Nuha Construction
Insulation
Insulation material can be ineffective if it is not installed properly
Spray foam insulation work in progress
walls and 1.9-4.6 for roof. These R-values for windows can be achieved only with double glazing. Consider the R-value before buying insulation, and check the product label to determine the insulation's proper thickness, especially if you plan to install it in a confined space, such as in wall cavities and cathedral ceilings. It's much easier to fit insulation while building than to retrofit it later. In countries like the USA, the U.S. Department of Energy's Zip Code Insulation Calculator is used to determine where you need to insulate and the recommended R-values based on your location climate and type of heating and cooling system, etc. The program also provides the cost estimates and a rate of return. Before a new home is insulated, it also needs to be properly air sealed and arrangements for moisture control should be properly done. Usually, the design engineer or the architect of the house advises well on the matter. Installation The best insulation material can be ineffective if it is installed poorly. Most importantly, gaps and spaces must be
avoided, as they will allow warm air to bypass the insulation and escape. Insulation should never be compressed, as this could make it less effective. Thermal bridging might also result in heat loss as a result of which, sneaky heat takes the path of least resistance, flowing mainly through the low thermal resisting material rather than through the insulation in the spaces between. Proper installation is crucial because a gap of only 4mm in a panel of insulation can reduce the R-value of that panel by 40%! Compressing or folding insulation material also reduces its R-value. Insulation Rolls are available in sealed packages and these expand when the bag is opened. The cavity in which the roll is being used must be measured accurately. The insulation should be cut an inch more than the cavity dimensions on the sides having no facing. Push the insulation into the cavity and make sure that the edges and corners are properly filled up and not folded over. If the vapor retarder facing is being used, it should be towards the interior of the room. Insulation can be stapled to the joists rather than
completely depending on friction to hold it. Floor insulation should be secured by using wire fasteners. Adjacent rolls of insulation should only fit snugly against each other and should not overlap. Insulation should never be compressed as it will lose its effectiveness. If you find you have to do that you have the wrong thickness selected. Some Non-structural forms of insulation include batts, blankets, loose-fill, spray foam, and panels. Such insulations can be rolled over the ceiling framing, which will save time cutting segments to size. It also has the benefit of covering the framing, reducing thermal bridging. When used in walls or under the floor it needs to be stapled to the framing to prevent sagging. Such type of insulations must be carefully cut to fit around obstructions, such as window frames, pipes, wires, and electrical boxes with no gaps & under skilled supervision. Blown-in cellulose or spray foam can be used to fill wall cavities. Both of these products can do a good job of filling in the space around wires and other obstructions and in filling any
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MB Subscription form
Insulation
Rigid polyurethane foam insulation materials are popular in the country today
oddly-shaped areas. For cellulose, some form of netting is used to hold the cellulose in place until the drywall is installed. Concrete block walls can also be insulated. There are systems available that have in-built sheets of polystyrene, and others that are hollow polystyrene blocks or formwork that are then filled with concrete. The hollow polystyrene blocks provide very good insulation values. Always get the contractor to give you a guarantee of the R-value and the thickness. Variety of materials available & Cost considerations A huge variety of insulation materials is available in the market, each having its pros and cons! The type of material to be used depends on the required R-value and both the bulk type & the reflective type insulation materials are employed in varying combinations to achieve the desired outcome. Factors affecting the type and amount of insulation to be used in a building include
Climate, ease of installation, durability, i.e., resistance to degradation from compression, moisture & decomposition, ease of replacement at end of life, cost effectiveness, toxicity, flammability and environmental impact & sustainability. Some common type of insulation materials include Fiberglass, Mineral (Rock Or Slag), Wool & Its Blends, Plastic Fibers, Natural Fibers, Recycled Paper, Pumice, Foil-Faced Kraft Paper, Plastic Film, Polystyrene, Polyethylene Bubbles, Cardboard, Polyurethane Foams etc. Other materials less commonly used include cork, wood wool, and straw. In straw-bale construction, very high R-values are achieved from thick walls of straw plastered on both sides. Materials are mainly chosen based on their applicability to the location, R-value and economy. Obviously the cost-effectiveness of insulation depends on the material chosen and the R-value. In new construction, the cost of the extra insulation and wall framing may be
offset by not requiring a dedicated central heating or cooling system, required to ensure sufficiently uniform thermal conditions. Pelmet fitting, which is cheap & can be done on own is effective in keeping the room air from getting behind the curtain and pumping heat outside. Hot water cylinder wraps & Pipe lagging are also cheap and one can install them himself. Insulation has today become a necessary and popular trend in the Real Estate industry and is acting as a driver for active sales over the common antes. Properly insulating your house can save hundreds on your energy bills and cut your greenhouse emissions. A well-insulated house requires less heating and cooling to maintain a comfortable indoor climate, and that translates directly into smaller energy bills. Besides, a well maintained house has a great resale value and every one, invariably have a small businessman in their minds who seeks profits. Construction experts thus rightly say Insulate today: save tomorrow!
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American Society of Civil Engineers (ASCE India Southern Region)
Metal Buildings Roof Linting
Roof Lift: New Concept Holds Immense Possibilities in India

t a time when property prices seem to be quite literally going through the roof, there is one solution that could possibly bring the smiles back to the faces of those grappling with the problem of not having enough space in their commercial or industrial establishments roof lifting. While the concept may seem quite simple, just raise the levels of the roof, and build the walls up to the newer levels, it is not as easy as it appears, since it would directly impact the structural stability of a building. Roof lifting is a concept that has caught the fancy of owners of industrial and commercial establishments in a big way in the North American continent.
Whether it is an old warehouse which needs to be made more spacious, a retail outlet that needs more racks on the top, or an industrial shed that needs more space, roof lifting or roof raising, has come to the developers rescue in recent times. While there are no exact figures available about the market for roof lifting, industry analysts claim that it is an area that has tremendous potential and could be growing at a rate of 25%-35% in US and Canada. Given the rapid strides that the Indian market has taken with respect to metal buildings, it is a field that is taking its baby steps and holds immense possibilities in the future. The rising emphasis on
developing the manufacturing sector and the various initiatives could have a direct and positive impact on the market for roof lifting concept in India. Scores of existing industrial and commercial establishments could quite drastically increase their areas thanks to the concept. The whole concept of roof lifting or roof raising started off when warehouses in the US were running out of space. It is quite ironically that despite forming one of the key components of supply chain, warehouses are not often given the kind of credit they should be. Research in the US market has pointed out that the average height of warehouses in the country has been
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space is one of the obvious advantages of roof lifting, it also comes with a series of other benefits. Since the modern day roof lifting method uses hydraulics the entire process can be done without disturbing work at an industrial or commercial unit. The downtime is very less and adds to the cost-effectiveness factor of the entire process. The roof lifting method also scores over demolition when it comes to the cost factor. Successful projects in the US and Canada have proved that roof lifting can be done with minimal demolition, which in turn adds further to the cost-effectiveness of the method. It also adds to the sustainability quotient of the method since almost every component of the roof can be utilized. The reuse of buildings after roof lifting is in fact, gradually turning into an industry by itself. The makeover means better marketing opportunities for the owners. There have been instances when buildings have been able to draw significantly more number of tenants after the roof lifting process. Roof lifts additionally offer an alternative to relocating. In fact, creative use of roof raising is an area that has been keeping the architect community interested in recent times. This is because with roof
Specially designed hydraulic jacks for roof lifts
lift it is possible to dramatically transform a building. For instance, a depilated or abandoned industrial shed could easily be transformed into a retail facility or a warehouse or in some instances, even a modern workplace. The roof lift process quite literally allows designers to let their imagination run riot. The Lift Process Apart from the obvious cost benefit , another key reason why roof lifting is becoming a popular option , particularly with respect to industrial sheds is the fact that the process can be completed
steadily increasing. While in the 1950s it was around 20 feet, it has now almost doubled and hovers around the high 30s or even the 40 feet mark in certain instances. One of the primary reasons given for the increased height has been attributed to the availability of specialized lifting equipment that has made stacking goods a lot easier. Forklifts and specialized reach stackers that are often seen in warehouses near ports are a good example of the rapid strides made in the equipment sector, which has had an impact on the height of warehouses. Advantages Galore While addition of precious cubic
Roof raising is fast finding an increasing number of takers
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Before and after a roof lift (photo courtesy: www.isenj.com)
Contractors specializing in the field use hydraulic lift jacks in order to accomplish the job. The number of hydraulic jacks depends on the span of the roof that needs to be lifted. One of the biggest advantages of the hydraulic system is that all the work is done at the ground level, ensuring both speed and speed of work. A series of hydraulic jack posts are first planned in proportion to the roof being lifted. These interior vertical columns are jacketed within steel 'sleeves'. The new sections are added at the bottom level with the hydraulic system raising the columns to the desired height. Telescoping columns that have the ability to rise are fitted
onto the existing peripheral columns. The entire roof raising operation is centrally coordinated ensuring even lifting to the desired height. Before the lifting process begins, all the connections such as those meant for firefighting water systems and lightning are severed. Once the hydraulic system lifts the entire roof, the next process consists of raising the existing walls of the structure. The columns of the structure are extended and the roof then re-attached to the walls. With the hydraulic system in place, it is possible to lift roofs at a rate of 5-15 inches per hour. Once the roof is re-attached the electrical and mechanical services are then re-
connected completing the roof raising process. Since it is a specialized process, it is best left to specialists in the field. Roof lift contractors take into consideration the building codes in the particular location while planning the roof lifting process for the building. India- A Potential Market Roof lift is a concept that has got enormous potential in a country like India. With the country in the midst of its biggest ever expansion of the manufacturing sector, it is a market segment offers excellent growth prospects. With realty prices shooting up in most parts of the country, roof lifting offers an economic option for those owning industrial or commercial units to increase cubic space. Warehousing is another key area that offers roof raising great prospects in the country. Apart from saving on realty space, the process also ensures that there is no disturbance to the existing work pattern in the building. The increased emphasis on sustainable construction practices is another crucial aspect that could give the push to roof raising in the country. Since the process involves recycling the existing roof, it scores high on sustainable quotient. The advent of latest stacking equipment has meant that warehouses can now afford to go higher than before. All these facts point to a market that has offers immense scope for companies specializing in hydraulic roof lifts.
Existing industrial and commercial units in India could spell a huge market for roof lifts
236
Baicon 2012
Structural Steel Corrosion Protection
Corrosion Protection Methods of Structural Steel against Atmospheric Corrosion

E. Daflou1*, E. Rakanta 1*, G. Batis2*
Chemical Engineer, 2Professor Chemical Engineering School, Section of Materials Science and Technology, National Technical University of Athens, Greece
* 1
The aim of this study is to examine the anticorrosive performance of two different primers, one based on VpCI technology and the other based on rust converter technology, against atmospheric corrosion of steel reinforcement exposed to the atmosphere, prior to its installation into concrete. The performance against atmospheric corrosion of the aforementioned corrosion inhibitor was evaluated by means of microscopy techniques and corrosion rate measurements (electrochemical and weight loss measurements). Electrochemical parameters such as corrosion current density, Icorr, and linear polarization resistance, Rp were evaluated. In addition, Measurements of the bond strength between concrete and steel treated with the corrosion inhibitor primers were performed in order to investigate their effect on bond strength between the steel surface and concrete. Furthermore, visual observations were used to identify the rust strains and the corrosion product morphology of steel reinforcement before its installation into the concrete. The results indicate that both primers exhibit satisfactory protective behavior under the specified conditions.
The process of atmospheric corrosion is a natural action of a material, in most cases a metal, returning to its original state through an electrochemical process caused by a reaction with the surrounding environment. Even though it is a natural process, there are certain environmental conditions to which metals are exposed during manufacture, processing, storage, or shipment that can aggressively accelerate the degradation. In normal atmospheres containing pollutants, metals begin to corrode at this accelerated rate when the relative humidity of the air layer next to the surface exceeds about 75%, mostly in coastal areas where the main factor of corrosion is the presence of chloride ions [1,2]. Greece is a country surrounded by sea, with high average temperatures and high relative humidity during the summer. The sea spray and wind driven salt leads to the formation of corrosion products on the surface of steel reinforcement, which many times is left exposed during transportation and storage at buildings sites for a long period prior to its installation in concrete structures. When these weathered steel bars are to be used, the presence of corrosion products affects the concrete/steel bond strength and the chemical composition of the cement. If they are going to be considered viable as a construction material, these weathered reinforcement bars should be used only if their corrosion products do not have any detrimental effect on
the mechanical and chemical properties of concrete. As a result of the concerns mentioned above, the question, that emerges is when such corroded steel rebar can be used without causing harmful effects on the mechanical
and corrosion behavior of reinforced concrete structures [3].

The protection of steel rebar prior to its installation into the concrete is of great importance for the durability of concrete structures and prevents great economic loss. Among the available protection systems for steel, the use of coatings is the most popular and economical method. Over the last decade, the need for environmentally safe coatings gave rise to many research studies with significant results that promoted the use of anticorrosive coatings containing vapor phase corrosion inhibitors commercially. VpCIs are organic compounds (such as amine based compounds) that have sufficient vapor pressure under ambient atmospheric conditions to essentially travel to the surface of the metal by diffusion and physically adsorb onto it, including recessed areas and cavities not reached with conventional methods. In the presence of moisture, the VpCI molecule becomes polarized and is attracted to both anodes and cathodes on the metal. Once the VpCI protective ions have adsorbed onto the surface, the
238
electrochemical process of corrosion is interrupted as the ions create a protective barrier to contaminants such as oxygen, water, chlorides, and other corrosion accelerators. With the protective barrier in place, the corrosion cell cannot form and corrosion is halted. That barrier selfreplenishes through further condensation of the vapor [4, 5, 6]. VpCI technology focuses on the metal itself, actually passivating the metal's surface. In fact, VpCI molecules use the same mechanism that accelerates corrosion to accelerate the release of protection molecules as a builtin defense mechanism. Whereas many methods of corrosion protection alter the metal (i.e., stainless versus carbon steel, cathodic protection, and treatment of metal), VpCIs do not alter the surface as the protective ions are adsorbed to the surface rather than becoming permanently attached [7]. Electrochemical behavior investigations show that these VpCI compounds belong to mixed or "ambiodic" inhibitors capable of slowing both cathodic and anodic corrosion processes. The reduction of the cathodic reaction results from a decrease in oxygen concentration caused by the formation of an adsorbed film that acts as a diffusion barrier for oxygen. Strong inhibition of the anodic reaction results from the inhibitor's two acceptor-donor adsorption centers that form a chemical bond between the metal and the inhibitor. Adsorption of mixed VpCI compounds changes the energy state of metallic ions on the surface, diminishing the tendency of metal to ionize and dissolve [8]. The two important properties of VpCIs are the functional groups linked to the nucleus of the inhibitor molecule, which are responsible for the adsorption, thickness and inhibition efficiency of the absorbed film, and the hydrophobic properties of VpCIs, which allow them to act as buffers to hold the pH at the metal inhibitor interface on the alkaline side for optimum corrosion protection.
The functional group (R1), linked to the nucleus (R0) of the inhibitor molecule, is responsible for establishing a stable bond with the metal surface and controls how firmly the inhibitor is adsorbed on the metal. The functional group (R2), also linked to the nucleus, controls the thickness and penetrability of the film, which is important in resisting the penetration of aggressive ions. As the inhibitor molecules are adsorbed on the metal surface, the R2 groups form a continuous line of defense to protect the metal from corrosive species [9]. In this work the performance against atmospheric corrosion of reinforcing steel rebar of two primers was evaluated, a neutral rust converter and an organic primer coating containing VpCI corrosion inhibitor. These primers are available in the market for coating metallic surfaces which are already corroding. The rust converter has a pH of 7, can be directly applied to rust and also combines with existing rust to form a permanent protective layer of a ferro-organic-acid-free coating. Rust is reduced to pure iron and the liberated oxygen molecules are bound together to form a black protective layer which prevents any new corrosion [10].
The experimental procedure was built to simulate three typical exposure conditions for storage areas and building sites of reinforcing steel located in coastal and urban regions, where the weather is characterized by pollutants such as: sulphur dioxide (SO2), salt particles (Cl-) and carbon dioxide (CO2 ), high temperatures and relative humidity. In the present study the interest in atmospheric corrosion of reinforcing steel lies in the fact that Athens has a marine environment (Cl-) with a combination of urban contaminants, for example SO2 and CO2. The experimental method used to assess the condition of the steel rebar included weight loss measurements throughout the experimental period. Measurements of the bond strength between concrete and steel rebar were performed in order to investigate the effects of the corrosion products on steel surface. Materials and evaluation methods For all test specimens S500s Temcore reinforcing steel was used. The steel rebar specimens had a cylindrical shape (100 mm long and 12 mm ). Prior to exposure, the surface of the steel rebar was washed with water, then immersed for 15 min in strong solution of HCl (500 ml HCl in 1000 ml distilled water, density 1:19 g/ml3) with organic corrosion inhibitor (3.5 g hexamethylene tetramine in 1000 ml distilled water)
Figure 1: Proposed inhibition mechanism
239
Mn
Si
Ni
Cr
Cu
0.21
V
0.002
Mo
0.021
0.18 0.99
0.047 0.023 0.15 0.09 0.09
Corrosion Rate (m/year) =8.76 x 107
(1)
Table 1 : Chemical compositions (% atom) of steel rebar S500s, type of Tempcore
washed with distilled water to eliminate traces of the corrosion inhibitor and chloride ions (according to ISO/ DIS 8407). Following that, they were cleaned with alcohol and acetone and then weighed to 0.1 mg accuracy. The two above mentioned primers were then applied to the steel rebar specimens and left in a drying chamber (T = 40C, RH = 50% ) for 7 days. The test specimens were exposed to atmospheric conditions over a period of 18 months on the roof of the Chemical Engineering building at Zografou campus in Athens. The performance against atmospheric corrosion of the aforementioned corrosion inhibitor and rust converter was evaluated by means of corrosion rate measurements (electrochemical and weight loss measurements). Electrochemical parameters such as corrosion current density, Icorr and linear polarization resistance, Rp, were evaluated. In addition, measurements of the bond strength between concrete and steel treated with corrosion inhibitor were performed in order to investigate the effect of corrosion inhibitor on bond strength between the steel surface and concrete. For all the electrochemical measurements, a standard corrosion cell was used. The corrosion cell consisted of a reference electrode which was a Saturated Calomel Electrode (SCE) in a luggin capillary filled with electrolyte (NaCl), a working electrode which was the reinforcing steel and a counter (auxiliary) electrode. A carbon electrode was used as the counter electrode. In the LPR technique, the reinforcing steel bar is polarized to 20mV of the open circuit potential (Ecorr), the potential at which the current varies linearly with applied potential. In the Tafel technique, the reinforcing steel bar is polarized to 250mV of the open circuit potential (Ecorr). The potential scan rate used for both techniques was 0.1mV/sec. Steel pull out testing was carried out according to ASTM C-234, to investigate the difference in bond stress and rebar slip behavior. Results and discussion 1. Weight loss measurements After 6, 12 and 18 months of exposure the test specimens were removed and cleaned according to the standard (ISO/DIS 8407.3). The weight loss of the steel rebar was determined and the corrosion rate evaluated using the following equation:
Where W: weight loss (g), A: area of steel specimen (cm2), T: exposure time (h), D: density of steel (7.8g/cm3). The results of the mass loss (%) and corrosion rate measurements for the 6, 12 and 18 months of exposure are given in Fig. 2 and 3. The results of the rust converter primer are not shown in these figures because of the excellent adhesion of the rust converter to the steel surface and the extremely low values of weight loss.
Figure 2: Gravimetric weight loss measurements after 6, 12, and 18 months of exposure for the control (RF) and VpCI primer coated specimens.
Figure 3: Corrosion rate measurements of control (RF) and VpCI primer coated reinforcement after 6, 12 and 18 months of exposure
2. Electrochemical measurements Linear polarization and Tafel techniques were used in this study for the determination of the anticorrosive performance and the rate of protection against atmospheric corrosion examining electrochemical parameters. The results from electrochemical measurements are summarized in Table 2, and it can be seen that both techniques show similar responses and both coatings provide significant corrosion protection. The Icorr vs. exposure time values of the polarization technique are displayed in Figure 4.
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Linear polarization technique Specimens type

RF RU VpCI RF RU VpCI RF RU VpCI 18 12 6 4451 41,72 29,33 5615 216,1 104,8 4373 189,8 174,2 6,265 536,9 784,1 3,896 133,7 342,3 5,0335 117,8 228,9 132,16 1,239 0,871 166,75 6,416 3,113 144,4 5,763 5,130 3705 20,25 49,03 5430 103,8 50,53 6033 57,66 62,06
Tefel technique
111,0 0,6013 1,4560 161,4 3,082 1,5010 184,9 1,712 1,8960
Exposure time (months) Icorr (A/cm2) Rp (kOhms) Corrosion Rate (mpy) Icorr (A/cm2) Corrosion Rate (mpy)
Table 2: Linear polarization and Tafel technique electrochemical parameters evaluated during the exposure time
Conclusions The results show that both primers offered significant protection against atmospheric corrosion, especially the VpCI primer. Visual observation of the rebar after 18 months of exposure in atmospheric conditions show that corrosion products appear mainly at the neurons of the rebar on the specimens coated with the RU primer, whereas those coated with the VpCI primer show pitting corrosion over a small area of the specimens.
Figure 4: Corrosion current density for the 6, 12 and 18 months of exposure
The electrochemical measurements listed in Table 2 shows that the VpCI primer provided better corrosion protection and 23 times better corrosion resistance than the control specimens. There is not a considerable difference between the two coatings on the effect they cause on the bond strength between the concrete and the rebar in pull-out measurements. There was also no significant difference between measurements on the coated specimens versus the control. References
1 2 B.Boyle, Metal Finishing, 2004,02, 37-41. P .R. Roberge, R.D. Klassen, P .W.Haberecht,Materials and Design,2002, 23,321-330. 3 Batis G., Rakanta E.,Cement and Concrete composites, 2005, 27,269-275 4 B.A.Miksic, R.H.Miller,5th European Symposium on Corrosion Inhibitors, Italy, 1980. 5 M.Prenosil, , Suppl.Materials Performance, 2001, 14. 6 C.J.Chandler, Corrosion 2002 NACE, paper no 01194. 7 A.Y.Furman, M.Kharshan, C.J.Chandler, Corrosion 2004 NACE, paper no 04418 8 M.Zubielewicz, W.Gnot, Progr. in Organic Coatings, 2004, 49, 358-371 9 D.M.Bastidas,E.Cano,E.M.Mora,Anti-Corrosion Meth.&Mats., 2005, 52/2, 71-77 10 G.Batis, N.Kouloumbi, E.Soulis,Anti-Corrosion Meth&Mats, 1998, 45/4,222-226.
242
Emerging Trends in Contract Management and Dispute Resolution
Investigation WFS in Concrete
Utilisation of Foundry Sand in Concrete Production

J. M. Khatib1, S. Baig2, A Bougara3, E S Negim4, S Kenai5
School of Technology, University of Wolverhampton,UK Jacobs Engineering, Barnards Inn, UK 3 Civil Engineering Department, Faculty of Engineering Sciences, University of Chlef, Algeria 4 School of Chemical Sciences, University of Sains Malaysia, Malaysia, 5 Department of Civil Engineering, University of Blida, Algeria
2 1
Selected properties of concrete containing waste foundry sand (WFS) are investigated. Fine aggregate was replaced with 0-100% WFS. The water to cement for all mixes was kept constant. Fresh and hardened properties of concrete were investigated. Hardened properties included water absorption, strength, ultrasonic pulse velocity (UPV) and length change. Testing on hardened properties was mainly conducted at different curing times. The results show that the workability of concrete reduces with the increase as the WFS increases which was attributed to the larger surface area of WFS compared with the fine aggregate used. Although the compressive strength and UPV decreased with the increase in WFS, an adequate strength was achievable even when all the fine aggregate was fully replaced with WFS. As may be expected, an increase in compressive strength is associated with a decrease in water absorption. Furthermore, there is an increase in shrinkage as the content of WFS is increased.
Traditionally, the UK has the highest amount of waste in all of Europe and recycles the least. Until recently, over 75% of the U.K waste goes directly to landfill [Collins, 1997] and over 60% of this waste could actually be recycled. The UK government has set targets to reduce the CO2 emission and using recycled materials would serve achieving this target. [DEFRA, 2008] indicated that the use of recycled/secondary aggregates for construction has increased by 94% from 1989 to 2002 showing that the construction industry is changing and has made substantial progress in the right direction. The construction industry consumes 400 million tonnes of materials per year [Bond, 1998]. Concrete is one of the most frequently used materials in the construction industry which is made up predominantly of aggregate. The fine aggregate used in concrete is normally mined virgin sand and sources where it can be extracted in the U.K are diminishing. The cost of virgin sand is around 5.70 per tonne [Rugby cement, 2007] and reflects on the price of ready mixed concrete. If the materials used in the process could be sourced from waste, this would reduce the cost of ready mixed concrete and greatly aid construction companies in implementing sustainable construction by reducing waste and increasing recycling. The UK Department for Communities and Local Government has noted that over one million tonnes of foundry sand waste is created each year and only 0.3 Million tonnes is reused therefore there is a large amount of material that potentially be exploited. A potential alternative for fine aggregate in concrete is to utilise waste foundry sand (WFS). If WFS is a viable replacement for fine aggregate in concrete and its reuse would reduce the amount of waste sent to landfill. The reuse of foundry sand in concrete is already commonplace in many parts of Europe and North America and is becoming more appealing to foundries in the UK as landfill levees rise. Naik et al. [1994] showed that concretes containing foundry sand gave a much lower slump, which was partly attributed to the presence of binders that increased the water demand and partly because of the fineness of foundry sand. Naik et al. [2004] reported that substitution of part of the sand with used foundry sand in concrete mixtures caused a small reduction in strength. This agrees with the results obtained by Bakis [2006]. Naik et al. [2003] found that partial replacement of cement with foundry sand resulted in considerable reduction in strength and increase in abrasion. Khatib and Ellis [2001] investigated a wider spread of mixes with different types of foundry sand; fine sand, blended sand and spent sand. As the amount of foundry sand increased, the compressive strength of the concrete reduced, this was found to be nearly linear decrease in strength as the foundry sand increases regardless of the type of the sand used. All types of sand displayed themselves to have increased shrinkage with the greater the replacement of sand. The clean sand gave shrinkage levels most comparable to the control. The blended sand mix showed shrinkage levels higher than both the control
244
and clean sand although the rate of shrinkage occurred was similar to the control. The waste foundry sand gave the highest shrinkage values and also the fastest shrinkage rate. All other sands showed a gradual shrinkage whereas the waste sand shrunk at an accelerated rate for the first 20 days then the shrinkage rate levelled out to a similar rate as the other mixes. As the use of foundry sand in the UK concrete industry is not wide spread. Therefore this paper reports some results on the properties of concrete containing foundry sand from a UK foundry. Properties included; compressive strength, ultrasonic pulse velocity and absorption. Experimental The cement used was Portland cement (PC) and the sand (fine aggregate) used complied with class M of BS 882: 1992. The coarse aggregate was 10 mm nominal size. The waste foundry sand (WFS) was obtained from a foundry in the WestMidlands, UK. The particle size distribution of sand and WFS is given in Tables 1. A total of 6 concrete mixes were used to conduct this study. The control mix (M1) had a proportion of 1 (cement): 2 (sand): 4 (coarse aggregate) and did not include WFS. In mixtures M2-M6, the sand was replaced with 20%, 40%, 60%, 80% and 100% WFS (by mass) respectively. The water to binder ratio for all mixes was maintained constant at 0.50. Details of mixes are given in Table 2. Specimens were cast in steel moulds. Cubes of 100mm in size were used for the determination of compressive strength and for water absorption specimens of 100mmx100mmx50mm in size were used. Prisms of dimensions 100mmx100mmx250mm were used for the determination of ultrasonic pulse velocity (V) and
Cumulative Passing (%) Sieve Aperture
10mm 5mm 2.36mm 1.18mm 600 m 300 m 150 m 75 m
Mix Number
1 2 3 4 5 6
WFS* (%)
0 (Control) 20 40 60 80 100
Mixture constituents (kg/m) Cement

320 320 320 320 320 320
Free Coarse Sand WFS* Water Aggregate

160 160 160 160 160 160 1278 1278 1278 1278 1278 1278 639 511 383 256 128 0 0 128 256 383 511 639
* Waste foundry sand (% by mass of sand) Table 2: Details of mixtures
Results and Discussion Figure 1 shows the slump values for the various concrete mixtures. There is systematic loss in workability as the foundry sand content increases. The slump dropped approximately in a linear manner from 200mm for the control mix (0% WFS) to zero for mix containing 80% and 100% WFS as replacement of sand. This decrease is largely due to the increased fineness of fine aggregate as the percentage of WFS increases. Figure 2 shows the ultrasonic pulse velocity (UPV) for concrete containing various amounts of foundry sand as partial replacement of the sand at the age 28 days of curing. There is a systematic decrease in UPV with the increase in foundry sand content.
Sand
100 98 86 81 70 11 2 0
WFS
100 100 100 100 99 92 5 0
Figure 1: Slump of concrete mixes
The compressive strength at 28 days of curing for concrete with varying percentages of foundry sand is shown in Figure 3. The compressive strength of concrete also decreases with increasing amounts of WFS. This decrease is systematic in that the strength of the control mix (0% WFS) is 43.6 N/mm2. At 60% WFS, the strength dropped to 32.9 N/mm2 and at 100% WFS the strength is nearly half of that of the control. Figure 3 shows the water absorption at 28 days of curing for concrete incorporating different WFS contents. The mass of water absorbed was conducted after 0.5 hour, 1 hour, 2, 4 and 72 hours of full immersion in water. The control mix shows the least water absorbed and generally the water absorption increases as the WFS in the concrete increases. An increase in water absorption is associated
Table 1: Particle size distribution of sand and waste foundry sand (WFS)
shrinkage. After casting specimens were covered and left in the laboratory at for 24 hours. After that demoulding took place and specimens for strength and absorption were placed in water for a total period of 28 days. The specimens for shrinkage and V were left in a chamber at 201C and 60% RH.
245
Figure 2. Influence of WFS on ultrasonic pulse velocity (UPV) of concrete
Figure 3. Influence of WFS on the 28 days compressive strength of concrete
Figure 4. Influence of WFS on water absorption of concrete at 28 days of curing
with a decrease in compressive strength and UPV. Figure 5 presents the shrinkage values at 28 days of air curing. The data indicate that shrinkage increases as the WFS in the concrete increases and this increase is systematic. For example at 100% sand replacement with WFS, the shrinkage at 28 days is twice as much as the control mix (i.e. 0% WFS).
-
Method for determination of particle size distribution. BS 812Part 103, London. British Standards Institution (BSI) (2000), Testing fresh concrete. Slump test. BS EN 12350-Part 2, London British Standards Institution (BSI) (1992), Aggregates for concrete, BS 882 British Standards Institution (BSI) (2002), Testing concrete. Methods for analysis of hardened concrete Testing hardened concrete. Compressive strength of test specimens, BS EN 12390-Part 3, London British Standards Institution (BSI) (2004), Determination of ultrasonic pulse velocity, BS EN 12504-Part 4, London. Collins, R. (1997) Recycled Concrete Quarry Management, 1st ed., QMJ Publishing, Nottingham, December, pp31 - 36. Ciesielski, S. K. and R. J. Collins. (1994) Recycling and Use of Waste Materials and By-Products in Highway Construction. National Cooperative Guthrie, P. and Mallett, H. (1995) Special Publication 122 Waste minimisation and recycling in construction - a review, CIRIA, London, p33 Department for Environment, Food and Rural Affairs (DEFRA), UK.<http://www.defra.gov.uk/news/latest/2008/waste-0602.htm Khatib, J,M. and Ellis.D,J., (2001) Mechanical Properties of Concrete Containing Foundry Sand. International Conference on Recent Advances in Concrete Technology, CANMET/ACI, pp 733-748 Naik, T. R. (1989) Foundry Industry By products Utilization., Center for by products Utilization, College of Engineering and applied Science, University of Wisconsin-Milwaukee Naik, T. R., Patel, V. M.., Parikh, D.M. and Tharaniyll, M. P . (1994) Utilization of used foundry sand in concrete. Journal of Materials in Civil Engineering, 6(2), pp.254-263
Figure 5: Shrinkage at 28 days of curing
Conclusions The incorporation of waste foundry sand in concrete causes a systematic decrease in workability, ultrasonic pulse velocity and strength and an increase in water absorption and shrinkage of concrete. However, an acceptable concrete strength can be achieved using foundry sand. Acknowledgments The assistance of the technical staff; Mr G Cooper and Mr M Lloyd at the School of Technology, University of Wolverhampton is greatly acknowledged References
Bakis, R. (2006) An investigation of waste foundry sand in asphalt concrete mixtures. Waste Management and Research, 24(3), pp. 269-274. Bhat, S.T and Lovell, C.W., (1996) Design of flowable fill: waste foundry sand as a fine aggregate,Transportation Research Record, n 1546, Nov, p 70-78 Bond, A.J, (1998). <http://users.aber.ac.uk/zwk/distlearn/virtlib/ projects/deeble/deeble.htl> British Standards Institution (BSI) (1985), Testing aggregates.
Naik, T. R.,Singh, S. Shiw, and Ramme, W. Bruce.,(2001).

Performance and Leaching Assessment of Flowable Slurry. Journals of Environmental Engineering, 127,No. 4,pp 359-368.
Naik, T.R.; Kraus, N. Rudolph; Chun, Yoon-moon; Ramme, W. Bruce; and Singh S.Shiw,. (2003) Properties of Field Manufactured Cast-Concrete Products Utilising Recycled Materials. Journals of Materials in Civil Engineering 15 (4) Naik, T.R., Rudolph, K. N., Yoon-moon. C., Ramme, W. Bruce; and Siddique, R. (2004) Precast Concrete Products Using
Industrial By-Products.ACI Materials Journal.101 (3) pp 199206.

Waste and Resources Action Programme (WRAP) (2008) Quick Wins Guide. Banbury, UK. www.wrap.org.uk downloads Civil_Quick_Wins_Guide_lo_res.6aec4bad.pd
246
National Conference on Container Infrastructure in India 2012 (IBK Media)
E.Scape
Amazing
Twisting Structure
Planned in Israel
A TRULY UNIQUE DATA CENTRE

hile we have heard of data centres being located even inside caves, this particular one takes the cake, when it comes to the uniqueness of its location. The Green Mountain Data Centre is buried underground in Norway's Fjords. The swanky underground data centre is spread over 21,000 sq.m and houses several departments. The designers have cleverly utilized several natural advantages in order to make the centre one of the most energy efficient in the world. Featured on popular online source Inhabitat, this carbon neutral facility is now being considered a trendsetter, whose example could be soon emulated in other parts of the world, with similar geographical terrain. Data centre, location, Green Mountain, Norway, departments, natural, energy efficient.
he plan for the Netanya City Hall building is already making headlines around the world, because of its unique shape. The building that is proposed to be constructed in the Israeli city will have a rather exclusive twisting shape that will make it stand out from the crowd. The building once complete, is expected to become a major landmark in the city. Featured and reported on Arch Daily, the building will have several sustainable features incorporated in its design. A good example is the extensive glass faade that will cover the building. Another highlight of the design from leading architect firm Yaniv Pardo is the proposal for geothermal energy powering the building, which would add to its sustainability quotient.
A Building Inspired by Wind Energy

lements of nature have always been a source of inspiration to architects around the world. It was no different in the case of AECOM, a leading architect firm which was given the task of designing Envision Energy, a leading wind turbine manufacturer's head quarters in China. The architects came up with this design which just about perfectly sums about the business the company is into. The massive, undulating exterior skin is the highlight of the building, featured on popular online source Inhabitat. The designers have also been clever to incorporate several sustainable features in the building. The building's design that has been inspired by wind energy, has already made it some sort of an online celebrity.
An Incredible House Perched on Tilts

rchitects are forever coming out with outrageous designs for making houses distinct and truly unique. A good example is a house in Hiroshima which apparently rests on tilts. The idea behind the design of the architect Kimihiko Okada was to construct a house with minimal footprint. Featured on popular online source Inhabitat, the house which rests on sturdy pieces of tilts gives excellent views of the surroundings in Hiroshima. The design of the house also incorporates several innovative sustainable features. The vast courtyard, which allows for plenty of sunlight to percolate in, is a good example. The news report on the online source also said that apart from allowing ample sunlight, the courtyard also allows for good natural ventilation.
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The Masterbuilder - January 2012 www.masterbuilder.co.in

Schwing Stetter (India) Pvt Ltd

News & Events

Plan to Decongest Metropolis through New Road Network

Land Acquisition Issue Impacts Highway Projects

Expert Group to Chalk out Strategy for Transport Infrastructure

The Masterbuilder - January 2012 www.masterbuilder.co.in

Machines & Engineering Company (MEC)

News & Events