emasterbuilder march2011
TRANSCRIPT
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Aquarius Engineers Pvt.Ltd
Aquarius Engineers Pvt.Ltd
Lucky International
Hess Concrete Machinery India Pvt.Ltd
Metecno India Pvt.Ltd
ACC Ltd
Fayat India
Richa Industries Ltd
Greaves Cotton Ltd
Gandhi Automations Pvt.Ltd
Techny Chemy
PNP Polytex Pvt.Ltd
Editor-in-Chief
Vice-Chairman
Director Editorial, Construction Chemicals
Editor-in-Charge
Sub-Editor
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Head-New Media Initiative
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K.P. Pradeep
K G K Moorthy
Dr. Y P Kapoor
Ravi Damodaran
Nigel Narayan
Bhavani Balakrishna, Saadat Ali, Sanjay
M.K. Prabhakar
H. Usha Devi
Pradeep Nair
G.B. Muralidharan
R. Prema
K. Sravanthi Kiran
Lakshmi
S. Nithiyanandam
Caroline D'sylva
R. Anand
R. Mariya Selvi, Sateesh Kuniyil, S. Sasi
MB Publishers Pvt. Limited
www.masterbuilder.co.in
K.P. Pradeep
Ashok Natarajan
Head - Content Development CE,Infrastructure & Environment
No.40, 2nd Floor, 7th "C" Cross,Ashwini Layout, Koramangala,Bangalore - 560047.
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P By
Sadagopan Seshadri
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 28555248Telefax: +91 44 28586703
o amount of words can console the grief of those, shattered by the Nquake and the consequential tsunami, which hit the east coast of
Honshu, Japan recently. Amidst live footage and by the minute reports on
Japan's battle to control its nuclear radiation, most tracking the story failed
to acknowledge the pivotal role played by building codes in neutralizing
what possibly could have ended up being right at the top of David B. Hall's
list of world's greatest disasters. It's worth mentioning that the quake,
which hit Japan on 11th March (4th most destructive ever to have been
recorded in human history) has been responsible for relatively a lower
death toll when compared to the quake that hit Haiti last year.
Reports made available by US geological survey led many to believe that
the event was cataclysmic enough to cause profound damage to
buildings vis-à-vis large scale human casualties. However, it was payback
time for Japan's high engineering standard and stringent building codes,
which came to the rescue of millions, hold up in structures close to the
epicenter. What made the difference was the commitment of the Japanese
policy makers to enforce earthquake-resistant building technology unlike
Haiti, which lacked a government capable of compliance to implement
strict construction standards.
Builders and government regulators world over should learn from Japan
and ensure global standards of construction is applied to protect their
citizens. After all it's no rocket science to realize that good engineering
practice pays. Look how well it did for Japan.
Back home Pranab Mukerjee's 2011-12 budget presented earlier this
month caused no such tremors. Development of Infrastructure remains
the key focal area of the UPA government, with budgeted spending in
infrastructure estimated at Rs 2, 14,000 Cr an increase of over 23% from Rs
1, 73,000 Cr during 2010-11, providing 48.5% of the plan allocation. The
budget has also proposed to provide the much needed foreign investment
in Indian infrastructure by mountaineering their venturing limit to USD 40bn
from USD 20bn earlier. The total disbursement target for India
Infrastructure Finance Company Limited (IIFCL) has been hiked to Rs
25000 Cr from Rs 20000 Cr.
The budget widens the classification of infrastructure by including cold
storage facilities and capital investment in fertilizers as sub sections of
infrastructure. With higher allocation into infrastructure coupled with the
move to provide long term resources through infrastructure debt fund, tax
free bonds worth Rs 30000 Cr and permitting a deduction of Rs 20000 in
Tax liability (by investing in long term infrastructure bond) there is no doubt
that this budget will act as an extremely positive move for the Industry.
Codes: 'The Unsung Hero'
EDITOR'S COMMENT
FORM IV: The Masterbuilder
Place of publication: Chennai, Periodicity of Publication: Monthly, Printers Name: Ashok Natarajan, Nationality: Indian, Address : Times Printers & Publishers, No.57 (29), Dr. Besant Road, Ice House, Chennai - 600 014 Publisher's Name: K P Pradeep, Nationality : Indian, Address : MB Publishers Pvt. Ltd, No.102/11, Tripti Apartments, Marshalls Road, Egmore, Chennai - 600 008. Editor's Name: K P Pradeep, Nationality: Indian, Address: MB Publishers Pvt. Ltd, No.102/11, Tripti Apartments, Marshalls Road, Egmore, Chennai - 600 008. Names and addresses of individuals who own the newspaper and partners or shareholders holding more than one percent of the total capital:K P Pradeep, No.102/11, Tripti Apartments, Marshalls Road, Egmore, Chennai - 600 008.Nigel Narayan, No.102/11, Tripti Apartments, Marshalls Road, Egmore, Chennai - 600 008.
Declaration
I, K P Pradeep, hereby declare that the particulars given above are true to the best of my knowledge and belief.
Date: 25/March/2011
Sd/-
K P Pradeep
K.P Pradeep, [email protected]
H & K Rolling Mill Engineers Pvt.Ltd
16 The Masterbuilder - March 2011
March has been yet another eventful month for team MB. We quite literally had
our hands full with key industry events that had been lined up in quick
succession. With the country in the midst of its largest ever infrastructure
development spree our editorial team as ever was at the forefront, reporting
the proceedings.
Henry Ford had once famously said, “Coming together is a beginning.
Keeping together is progress. Working together is success”. There could be
no better example of what teamwork can achieve than team MB. Reaching
milestones through teamwork has been the primary reason for our success,
over the years. The recognition of our ability to accomplish as a team came to
limelight with the announcement of the CIDC 'Vishwakarma' Awards that were
presented in a glittering function held at New Delhi on March 7th, 2011. While
Editor-in-Chief K.P. Pradeep bagged the “Best Journalist” award, Sub-Editor
Nigel Narayan accepted the “Best News Magazine” award on behalf of the
entire team.
As part of our ever growing presence as official media partner for major
industry related events, I had the opportunity this month to attend the 2nd
FICCI International Conference on Construction Chemicals “Construction
Chemicals Conclave 2011” held in Hotel Le Meridian, Bengaluru from
February 17-18, 2011. The virtual 'who's who' of the construction chemicals
industry was present during the occasion. A series of paper presentations by
industry experts covered an entire gamut of topics related to the construction
chemicals industry. This is one particular industry vertical, which is all set to
boom in the coming few years, with rising emphasis on sustainable building
strategies.
Talking about construction chemicals I'm delighted to announce that
Dr.Y.P. Kapoor, (a doyen in the domain he serves) will be joining me on the
board of MB as Editorial Director, Construction Chemicals with effect from 1st
April 2011.Dr. Kapoor, an experienced Admixture Specialist and Concrete
Technologist has been earlier associated with the Fosroc International, Kuwait
British Ready-mix Company, Ready-mix Beton, Qatar besides being part of
several landmark projects in the UAE. It is indeed an honour and privilege for
the entire team at MB, to have someone of Dr. Kapoor's stature joining us.
MB has been playing an increasingly prominent role in several industry-
academic platforms such as the BAI, ICI, ACCE, IEI, INSTRUCT etc. One such
very important forum, where MB is playing a crucial role is the Structural
Engineers World Congress (SEWC). It is a matter of pride for us to announce
that our Editor-in-Chief a key member in the Governing Council of SEWC has
been chosen as the Editor of the prestigious 'International Journal of SEWC'.
As the official media partner and an integral part of the forthcoming SEWC
2011 conference to be held in Como-Cernobbio, Italy our award winning
editorial team shall report on the deliberations.
Before concluding, I also would like to thank all those in the academy and the
industry for responding to our call to be part of the immensely successful XXIV
All India Builder's Convention that concluded recently at Chennai. The
technical session of the event headed by our Editor-in-Chief saw quiet a few
intresting presentations, which broadened the vision and enhanced the
capabilities of the delegates.
Eventful Month
K.G.K.Moorthy | Vice-Chairman
Wirtgen India Pvt.Ltd
108108
9292 140140
Editor's Comment.......................
News & Events............................
E-Scape.....................................
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226PEB: An Industry Analysis
M.K. Prabhakar
Pre-Engineered Building: Cost-Effective and Sustainable Construction Technique Set to Rule the Roost
18
Contents
The Masterbuilder - March 2011
5454
PEB: An Industry AnalysisPre-Engineered Building: Cost-Effective and Sustainable Construction Technique Set to Rule the RoostM.K. Prabhakar
46
Portable ArchitecturePortable Modular Buildings!Bhavani Balakrishna
54
64
78 Corrosion ControlGalvanic CorrosionR.K. Luther, Managing Director, M/s Atul Fastners Ltd.
Cool Roof CoatingsVersatile Coatings for Today's Roof SystemsAchal Narayanan
®Modular Building and LEEDModular Building and the USGBC's LEED™Special Correspondent
Industry AnalysisRoofing Industry: Diverse Product Range Drives DemandM.K. Prabhakar
Roofing: Material FocusZinc Roofing: Sustainable Roofing Option Comes Back into LimelightM.K. Prabhakar
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102
108
Standing Seam Roof
Metal Standing Seam Roof Systems: Going from Strength to StrengthSadagopan Seshadri, Chief - Content Development, CE - Infrastructure - Environment
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ProfileG.V.Engineering & Co: Offering Top of the line PEB SolutionsRaja Gana Nathar B.E.,M.K.S.E, Managing Director, G.V.Engineering & Co
Industry AnalysisConstruction Chemicals: Building Blocks of QualitySadagopan Seshadri, Chief - Content Development, CE - Infrastructure - Environment
Reflective SignageTechnology - A Key to Safer Roads
Seismic PerformanceComparison of Various Methods Including Time History Analysis in Seismic Performance Evaluation of RC FramesShah B. A. Associate Professor, Applied Mechanics Department, The M. S. University of BarodaPatodi S. C. Professor, Civil Engineering Department,Parul Institute of Engg. & Tech., Limda, Baroda
Asphalt RecyclingFractionation of Reclaimed Asphalt Pavement the way to Achieve Higher Percentages of UseJohn D'Angelo Ph.D. P.E.,
146 Construction Awards3rd CIDC Vishwakarma Award 2011: A Recognition of Notable achievements and Standards of Excellence
4646
JK Cements Ltd
20 The Masterbuilder - March 2011
Contents
182182
201201
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175
177
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194
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214
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Steel: Roving SeminarTRMA Launches Crusade for 'Proper Steel Reinforcement'
Student InteractionStimulus 2011 A Truly Invigorating Experience for Civil Engineering Students
RoundtableConcrete Roads & White Toppings:Hold Immense Possibilities for India
Communication FeatureTo Make Good Things Even Better
InteractionLucky International Tensile Fabric Roofing Specialist Raises the Bar Higher
Site ReportSite Report - MARINI MAC 200 - State of-the-art Efficiency Delivered
BC 2011: Post Event ReportbC India 2011 gets a Thumbs-up from CE Industry
Ajax Fiori: One on-one with Mr.K.Vijay, Managing Director, Ajax Fiori at the bC India 2011 Show
Ammann Group: The Road Construction Equipment Specialist has Big Plans for India
M&IG (A producer of Russian industrial machines CHETRA) Announces Plans for Production Unit at the bC India 2011 Show
DMI Engineering & Manufacturing Co Ltd: Superior Technology and Service Enable DMI to Stay Ahead
Greaves Cotton Launches Premium Range of Construction Equipment at bC India 2011 Show
Manitowoc Emphasizes Commitment to Indian Market at bC India 2011 Show
KAMAZ Vectra Showcases Russian Trucks of European Quality for India
Putzmeister - Showcasing a Wide Range of Products for the Indian Market
REL-CED forays into Foundation Equipment - Launches “CF” Series Piling Rigs at bC India Show
SCHWING Stetter India Unveils Two New Concrete Pumps at bC India Show
TIL - The Growth Story Continues
Volvo Drives Home the Fuel Efficiency Message at bC India 2011 Show
PALFINGER Launches Stiff Boom Crane at bC India 2011 Show
150 Rock Foundation: Case StudyInnovative Construction Techniques for Rock Foundation Treatment and Quality Assurance of Salma Dam Project, Afghanistan - A Case StudyR.B.Shivali1, Senior Research Officer K.S.Jamwal2, Ex. DDG, GSIA.N.N.Prasad3, Project Director Amar Kumar4, General Manager (P)R.K.Gupta5, C.M.D. 1 - CSMRS, New Delhi and deputation to WAPCOS Ltd. at Salma Dam Project in Afghanistan 2 - Geological Survey of India and, 3-5 - WAPCOS Ltd. at Salma Dam Project, Afghanistan
The Masterbuilder / equip Supplement, Volume 13, No.2, 2011
CORRIGENDUMPage 5Under the Section 'Overview'' the profile of M/s Aquarius Engineers Pvt.Ltd should read: Aquarius Engineers is a leading manufacturer and exporter of concrete equipments. The company represents Gomaco, USA in India for its complete range of slip form pavers curbing machines. Equipments manufactured by Aquarius are designed and built to maximize workers' safety at all times, whatever the situation. Aquarius also renders turnkey solutions from concept to commissioning of Concrete Batching Plants.
Thermal InsulationThermatek Thermal Barriers Offering the Complete Range of Cool- Roof Products
148
Sleek Boards India Ltd 69
Sohan Lal Gupta 139
Soilmec Foundation Equipment
P.Ltd 23
Speedcrafts Ltd 161
SSA Techno Construction Pvt. Ltd. 215
STA Concrete Flooring
Solutions 81, 127
STP Ltd 125
Structural Engineers World
Congress (SEWC) 208,209
Tac System Formwork Sdn Bhd 111
Technokolla 71
Techny Chemy 12
Texsa India Ltd 45
The Masterbuilder Corporate Ad 193
The Masterbuilder Subscription Form 213
Thermatek 53
Thermoshield India (P) Ltd 189
Toshniwal Systems & Instruments
Pvt.Ltd 175
Transweigh (India) Limited 27
Truevents, Singapore 217
Unisteel Engineering Works 135
Universal Construction Machinery 86,87,107
Venus Equipments And Tools Pvt. Ltd. 155
Viki Industries (P) Ltd 143
Wirtgen India Pvt.Ltd 17
Zamil Steel Buildings India.Pvt.Ltd Back Cover
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The Supreme Industries Ltd 39
A
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D
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ACC Ltd 7
Action Construction Equipment Ltd 95, 97, 99
Apollo Infratech Pvt.Ltd 25,31
Aquarius Engineers Pvt.Ltd Gatefold
Asons Enterprise 153
Atul Fasteners Ltd 57
Bomanite India 105
Bridge Seminar 199
Cemseal System & Sales (Webac) 179
Cerachem Pvt.Ltd 133
Chetra Machinery India Pvt.Ltd 35
Cipy Polyurethanes Pvt.Ltd 67
Columbia Pakona Engineering Pvt.Ltd 179
Cosmos Construction Machineries & Equip.Pvt.Ltd 167
Cosmos Sales Corporation 145
Dow Corning India Pvt.Ltd 43
Ermotec International Pvt.Ltd 195,225
Esquire -CMAC Pvt.Ltd 159, 165
Fayat India 8
Gandhi Automations Pvt.Ltd 11
Greaves Cotton Ltd 10
GV Engineering & Co., 117
H & K Rolling Mill Engineers Pvt.Ltd 15
Hess Concrete Machinery India Pvt.Ltd Front cover (2)
Jindal Aluminium 123
JK Cements Ltd 19
JK Works Bharuch (Guj) 149
JSW Serverfield Structures Ltd Back inner
Lipi Polymers Pvt.Ltd 33
Liugong India Pvt.Ltd 89
Lucky International Front inner (1)
Maco Coporation India Pvt.Ltd 185
Mangalore Chemical Fertilisers 61
Metecno India Pvt.Ltd Front inner (2)
MM Castings (P) Ltd 119
Nicomac Doors Pvt. Ltd 189
Nina Concrete Systems Pvt.Ltd 79, 115,131
Pennar Engineered Building
Systems Ltd 75
Pioneer India 195
PNP Polytex Pvt.Ltd 13
Putzmeister Concrete Machines Pvt.Ltd 37
Ramtec 195
Razon Engineering Company P.Ltd 101
Realm Intermediates (P) Ltd 51,185
Reliance Industries Ltd 171
Relyon Facility Services 215
Revathi Equipment Ltd 91
Richa Industries Ltd 9
Rockwool (India) Ltd 49
Roof India Exhibition 221
Schwing Stetter (India) Pvt.Ltd 29
Seven Hills Safety Equipments and Systems (P) Limited 215
Sika India Pvt.Ltd 59
Silicone Concepts Int'l.Pvt.Ltd 63
SKG Equipments Pvt. Ltd. 225
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21The Masterbuilder - March 2011
Advertisers Index______________________
Contents
Aluminium
Cement Manufacturers
Concrete Block Making Machinery
Concrete Pipes
Concrete Pump Manufacturers
Construction chemicals
Construction Equipment & Machinery
Doors-Automatic
Dozers
Events
Jindal Aluminium 123
ACC Ltd 7JK Cements Ltd 19
Columbia Pakona Engineering Pvt.Ltd 179Hess Concrete Machinery India Pvt.Ltd Front Cover (2)
Apollo Infratech Pvt.Ltd 25,31
Putzmeister Concrete Machines Pvt.Ltd 37Schwing Stetter (India) Pvt.Ltd 29
Cemseal System & Sales (Webac) 179Cerachem Pvt.Ltd 133Mangalore Chemical Fertilisers 61Nina Concrete Systems Pvt.Ltd 79, 115,131Technokolla 71
Action Construction Equipment Ltd 95, 97, 99Apollo Infratech Pvt.Ltd 25,31Aquarius Engineers Pvt.Ltd GatefoldChetra Machinery India Pvt.Ltd 35Cosmos Sales Corporation 145Fayat India 8Greaves Cotton Ltd 10Liugong India Pvt.Ltd 89Revathi Equipment Ltd 91Schwing Stetter (India) Pvt.Ltd 29SKG Equipments Pvt. Ltd. 225Speedcrafts Ltd 161Toshniwal Systems & Instruments Pvt.Ltd 175Transweigh (India) Limited 27Unisteel Engineering Works 135Universal Construction Machinery & Equipment Ltd 86,87,107Venus Equipments And Tools Pvt. Ltd. 155Wirtgen India Pvt.Ltd 17
Gandhi Automations Pvt.Ltd 11Nicomac Doors Pvt. Ltd 189
Chetra Machinery India Pvt.Ltd 35
Structural Engineers World Congress (SEWC) 208,209Truevents, Singapore 217
Excavator Attachments
Exhibition
Facility Services
Fire and safety Equipments
Flooring
Formwork
Foundation Equipment
Green Building Materials
Green Building System
Material Handling Equipments
OEM Suppliers
Particle Board
PEB
Repair & Rehabilation
Roofing
Ermotec International Pvt.Ltd 195,225
Roof India Exhibition 221
Relyon Facility Services 215
Seven Hills Safety Equipments and Systems (P) Limited 215
Bomanite India 105Cipy Polyurethanes Pvt.Ltd 67Reliance Industries Ltd 171STA Concrete Flooring Solutions 81, 127
Tac System Formwork Sdn Bhd 111
Soilmec Foundation Equipment P.Ltd 23
Ramtec 195Thermatek 53Thermoshield India (P) Ltd 189
Pennar Engineered Building Systems Ltd 75
Esquire -CMAC Pvt.Ltd 159, 165JK Works Bharuch (Guj) 149Maco Coporation India Pvt.Ltd 185
MM Castings (P) Ltd 119
Sleek Boards India Ltd 69
GV Engineering & Co., 117Pennar Engineered Building Systems Ltd 75Pioneer India 195Richa Industries Ltd 9Zamil Steel Buildings India.Pvt.Ltd Back Cover
Nina Concrete Systems Pvt.Ltd 79, 115,131Razon Engineering Company P.Ltd 101
GV Engineering & Co., 117Lipi Polymers Pvt.Ltd 33
Lucky International Front Inner (1)Metecno India Pvt.Ltd Front Inner (2)Pioneer India 195PNP Polytex Pvt.Ltd 13Realm Intermediates (P) Ltd 51,185Richa Industries Ltd 9Sika India Pvt.Ltd 59Texsa India Ltd 45Thermatek 53Thermoshield India (P) Ltd 189Zamil Steel Buildings India.Pvt.Ltd Back Cover
Asons Enterprise 153Atul Fasteners Ltd 57Realm Intermediates (P) Ltd 51,185Sohan Lal Gupta 139
Sleek Boards India Ltd 69
Cosmos Construction Machineries & Equipment Pvt.Ltd 167
Bridge Seminar 199
JSW Serverfield Structures Ltd Back Inner
Lucky International Front Inner (1)
Rockwool (India) Ltd 49
Viki Industries (P) Ltd 143
H & K Rolling Mill Engineers Pvt.Ltd 15
PNP Polytex Pvt.Ltd 13
Cemseal System & Sales (Webac) 179Cerachem Pvt.Ltd 133Dow Corning India Pvt.Ltd 43Nina Concrete Systems Pvt.Ltd 79, 115,131Sika India Pvt.Ltd 59Silicone Concepts Int'l.Pvt.Ltd 63SSA Techno Construction Pvt. Ltd. 215STP Ltd 125The Supreme Industries Ltd 39Technokolla 71Techny Chemy 12
Roofing fastners
Rubber MDF
Scaffolding
Seminar
Steel Structures
Tensile Membrane
Thermal insulation
TMT
TMT-Technology Suppliers
Turbine ventilators
Waterproofing
Advertisers Index / Classification_________
Contents
22 The Masterbuilder - March 2011
Soilmec Foundation Equipment P.Ltd
News & Events M B
24 The Masterbuilder - March 2011
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Link -Belt to debut New Crane Operating
System at ConExpo 2011
Tough Mustang 3300V Skid Steer Loader Creates
Ripples in the Market
New Pulverisers and Breakers from Stanley
Leica Geo Systems PowerDigger- A2
Dimensional Guidance System for Excavators
A Monstrous Demolition Machine
Stanley Hydraulic Tools, which is a leading name in the demolition industry, has announced the launch of two new attachments a 1,995 kg LaBountay MDP20R demolition processor that is designed for use on 18 to 25 tonne carriers and the MB05 three-in-one breaker that is designed for use on skid steer loaders and mini excavators.
The new pulveriser features the use of LaBounty's swift-lock process and the tool designed for tough working conditions. According to the company the pulveriser offers one of the highest power-to-weights - ratios in its class, which in turn results in safety and greater stability of the carrier.
The company has been in the fore-front when it comes to introduction of new technology products in the demolition equipment domain.
The Mustang 3300 V skid steer loader has been creating news right from the day it was launched in the market. Featuring a vertical boom, the skid steer loader model offers 131 inches of lift height.
The machine is powered by a 84 horsepower Yanmar Tier III turbo engine, which is claimed to be the strongest that is available in its class. The loader also features ergonomic cab design, which enables increased productivity of the machine.
system comes with self-diagnostic capabilities and helps in continuous monitoring of multiple crane func-tions.
The company will be providing comprehensive customer support for the newly designed system that has been completely designed in-house according to the company. According to the company, the system has been designed based on extensive customer input.
The system has been designed to make the operator's job easy. The user-friendly interface enables easy operations which in turn help in increasing productivity of the crane.
A host of new software packages, expected to ease the job of excavator
The machine has been developed specifically for high reach demoli-tion, a field which is dictating the trends, as far as demolition attach-ments and equipment are concerned. The unit is built on a Hitachi EX1200 excavator. The excavator model is considered one of the best for heavy duty nature of work in construction and demolition sites.
The new machine is said to have a maximum reach of 38 metres. One of the specialties of the machine is its ability to handle a variety of exca-vator attachments with relative ease for an equipment of its size.
A new monster demolition exca-vator has been jointly developed by Kocurek Excavators Limited and Heavy Decom International. Recent times have seen several innovations in the field of earthmoving equip-ment, and this is one more example in pushing the envelope, as far as modifications go in this heavy earth-moving equipment.
The cab consists of a standard joystick pilog control system. Tow hitch and rear bumper are standards in the machine.
The ConExpo event in Las Vegas to be held shortly will see Link-Belt introduce a new crane operating system called 'Link-Belt Pulse'. The
Apollo Infratech Pvt.Ltd
News & Events M B
26 The Masterbuilder - March 2011
operators are flowing into the marke. One of the latest to hit the market is the PowerDigger 2D guidance system which can eliminate over-excavation and features automatic elevation and dual slope control.
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Mobile Plant with Twin Shaft Mixer Unveiled
Equipment Sales in Italy down to 'Critical' Stage
If reports of UNACEA, which is the Italian construction equipment association, are to be believed then the sales figures have touched “criti-cal” levels. The figures fell 8.9 percent in 2010.
Incidentally, this was the third consecutive year that the figures have been touching rock bottom, for the beleaguered economy. According to industry sources, the sales of almost every type of construction equip-ment, including, truck mixers, road machinery, concrete batching plant and earthmoving equipment have fallen down in recent times, in the aftermath of the global economic slowdown.
Symbolic of the fall has been the drastic fall in the sales of mini excava-tors, which constituted the largest selling earthmoving equipment in the country. Several manufacturers in the country are now looking towards other markets including India and China for selling construction equip-ment.
T h e d e v i c e c o m e s w i t h PowerSnap, which allow the operator to swap control panels between grade-and-slope and 3D machine controls. The device is expected to reduce wastage during major excava-tion projects.
The system also helps in grade checking and reduces rework, which are sometimes the major reasons behind project costs overshooting estimated budgets.
US Construction Equipment Industry Exports Rise After a couple of years of
dull performance the US made construction equip-ment export figures have been pegged at US $ 16.4 billion , which is a rise of 28 percent over the previous 2009 figure. The figures have been recently released by the Association of Equip-m e n t M a n u f a c t u r e r s (AEM).
While the exports to Asia grew at + 10 percent, a growth of +23 percent was registered in Europe. The figures for neigh-bouring South American
continent were an encouraging +31 percent up from the previous year's figure.
With the Obama administration announcing a stimulus package for infra-structure development, domestic sales is also expected to receive a boost in 2011.
Transweigh (India) Limited
News & Events M B
28 The Masterbuilder - March 2011
After Posco and a few other projects, it is now the turn of a ` 17, 000 Cr ultra-mega power project to run into trouble with the Environ-ment Ministry. It has been reported that the project may not see the light of the day as the Power Ministry has not agreed to conditions that were imposed by the Environment Minis-try.
The former has reportedly not agreed to conditions that were imposed by the former for granting clearance for a coalmine that is attached along with the project. The Environment Ministry has granted approval to the project provided Orissa Power Generation Corpora-tion and NTPC give up their respec-tive Majorharpur and Dulaga coal blocks which are located in the vicinity of the project site.
The project is the latest to have got stalled due to issues related to environment clearance. The state has the dubious distinction of having a high number of projects which have been delayed due to issues related to
Another Project in Orissa Runs into Trouble with Environment Ministry New Power Projects
in Karnataka
land acquisition and environment clearance.
Yet another power project seems to have run into trouble for environ-mental reasons. The Ministry of Envi-ronment and Forests (MoEF) has directed the East Coast Energy to stop the construction of its proposed 2,640 thermal power project in Srikakulam, Andhra Pradesh, which is being opposed by local farmers.
The ministry has directed the company in its letter saying “the ongoing construction work related to
this project be suspended forwith.” The directive follows the incident of police firing at protestors at Kakrapalli village, which is located in the vicinity of the project site.
East Coast Energy though on its website maintained that the “ entire project land possession and all statu-t o r y a p p r o v a l s h a v e b e e n obtained.”The project had been approved by the ministry on April 9, 2009, subsequently though, the ministry had received a spate of complaints on the project, following which it was decided that the matter be looked into by the Expert Appraisal Committee (EAC).
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POWER SECTOR POWER SECTOR POWER SECTOR
Karnataka is one state that has been taking several steps to improve the power situation for rapid indus-trialization. The state has recently signed three power purchase agree-ments (PPAs) for not less than 1008 MW.
The deals including a waste to energy project, which the state is getting ready for these days. NTPC would be setting up a 4,000 MW mega coal-based thermal power plant in Pudimadakka in neigh-bouring Andhra Pradesh, where Karnataka's share would be 600 MW.
The state would get a share of 400 MW in the coal-based power project that would be set up by NLC at Sirkali in Tamil Nadu. The state would also have a waste to energy power project at Manduru village, on the outskirts of Bengaluru.
“If this plant is successful, the government wou ld ac t i ve ly encourage setting up more such plants which would effectively handle and dispose municipal solid waste in an environment-friendly and sustainable manner,” the state's Chief Minister Mr. Yeddyurappa said on the project.
MoEF clamps down on East Coast Energy
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News & Events M B
30 The Masterbuilder - March 2011
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Rail PPP Chugs Along Ever So Slowly
Will it be Smooth Sailing for the Pune
Metro Project?
While the government is always talking about utilizing private participation to improve the coun-try's crumbling transport infrastruc-ture, not much headway seems to have been actually made in reality.
The projected private investment of `211, 600 Cr in transport infra-structure has already been lowered by 60 percent to `86, 700 Cr in the current plan period, in which just over a year remains.
It does not come as a surprise that the Indian Railways, which has been opposing privatization for years now, has been the worst sufferer. The private investment for Railways has been slashed by as much as 83 percent to ̀ 8316 Cr from the earlier ` 50, 354 Cr by the Planning Commission for this Plan Period.
The news comes at a time when several projects in the country are languishing due to lack of funding and the Prime Minister himself has suggested that the country may soon see a fresh wave of investment through the PPP route.
state government fully supports the project. The government will make a provision for the project in the budget to be presented in March."
Congress leader Aba Bagul said the metro project will cost ` 2,281 crore. While the state would contribute 40 percent, the Pune Municipal Corporation would contribute 10 percent, while the remaining amount would come from private players.
Now that the Maharashtra State Government has approved the Pune metro rail project, it needs to be seen whether it would be smooth sailing for the project or would it be facing the hurdles that such projects have been facing elsewhere.
The proposal for the project is expected to be forwarded to the Central Government for final approval in another fortnight's time. According to NCP leader Nilesh Nika, “The chief minister said the
RAILWAYRAILWAYRAILWAY
Country's Longest Rail Bridge in Kerala
The longest rail bridge in the country has been constructed in Kerala, where it will connect Idapalli to Vallarpadam in Kochi. The bridge is 4.6 km long and offers key connectivity to the International Container Trans-shipment Terminal (ICTT) in Kochi.
The bridge has been built at a cost of ` 200 crore by the Rail Vikas Nigam Ltd, in a record time of 28 months. Sustainable
construction technology in the form of minimal use of cement has been incorporating as part of the building strategy of the bridge.
Another highlight of the project has been the smooth manner in which the land acquisition, often a contentious issue in India, and partic-ularly in Kerala, has been handled. Some innovative ideas were issued for the process and the bridge constructed in record time.
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News & Events M B
32 The Masterbuilder - March 2011
Aviation Sector set for Unprecedented Growth says PM
Last Hurdle for Navi Mumbai Airport
Project Cleared
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Perhaps the last remaining hurdle for the Navi Mumbai airport project has been cleared with the forest department giving it the go ahead. The Deputy Conservator of Forests of the Alibaug division Mr. Anwar Ahmed has been quoted in the media saying “I am satisfied with their last replies and have cleared the file at my end and will send the file to office of the Chief Conservator of Forests. Getting formal permissions won't be problematic now.”
The mangroves that surround the airport project site was the main issue that had to be addressed by the forest department after the project had got the other necessary clearances from the Centre . The issue of forest clear-ance had also cropped up due the distance between the Karnala Bird Sanctuary and the airport.
These issues along with the delays in getting clearance from the environment ministry had delayed the project earlier. With the latest maps showing the distance between the project site and the bird sanc-tuary at about 10 km, the last remaining hurdle for the project has been cleared.
The airport project is considered crucial for the metropolis with the existing airport not being able to handle the increasing traffic. The project earlier was cleared by the envi-ronment ministry after a long gap, which also saw a period of difference of opinion with the civil aviation ministry.
civil aviation sector. He highlighted the efforts of the government in improving the infrastructure to cope up with the projected growth in air transport.
"I am told that projected growth of India's aviation sector has a poten-tial to absorb investment of over $ 120 billion with the attendant job creation for lakhs of people, directly and indirectly," he said. He also said that that government was on a mission mode when it came to imple-
The boom in air transport has been described as being “unprece-dented” by the Prime Minister Dr.Manmohan Singh. The Prime Minister had recently after the inau-guration ofthe ̀ 289 Cr new Interna-t i o n a l Te r m i n a l a t t h e Thiruvananthapuram International Airport said that the sector was projected to absorb investment to the tune of over US $ 120 billion in the next few years.
The Prime Minister pointed out how the Centre had been taking a slew of measures to cope with the huge growth that is projected for the
AIRPORT AIRPORT AIRPORT
Several hurdles seem to have suddenly sprouted for the Dabolin Airport expansion project in Goa. Recently the Deputy Speaker of the state Mr. Mauvin Godinho alleged that there was a move from “within” to sabotage the project.
There has been lot of controversy generated by the move to expand the capacity of the Dabolin airport, with a
mentation of world-class facilities at airports.Dabolin Airport Expansion Project Runs
into Controversies
section of the government wanting to expand the Mopa airport instead. "The way things are proceeding, it is being sabo-taged from inside," Godinho alleged, adding that people should be taken into confidence in the matter.
The Deputy Speaker has further said that there is a possi-bility that two airports might be needed by the state in the near future. He was not happy with the progression of work though and also alleged that the “naval authorities are creating hurdles in transferring land.” With the state being one of the most important tourist destinations in the coun-try, there has been increasing demand for airport expansion in recent times.
Lipi Polymers Pvt.Ltd
handling capacity of the country's ports top the one billion tonne mark.
The Union Shipping Minister Mr. G.K Vasan observed during the inau-guration ceremony held recently that “Today is a golden day in the annals of Indian maritime history. We are
The Union Shipping Ministry is said to be seriously considering a plan to set up a financial institution specif-ically for funding port projects. Massive capacity addition is being planned for the port sector.
The long gestation period of mari-time port projects means that banks have always been averse to funding them for a long time now. The repay-ment schedule had been the bone of contention with banks who felt that it was too long for their comfort. The Shipping Ministry is therefore considering setting up a specific financial institution especially for the purpose, which would not result in the asset-liability mismatch.
The proposed financial institu-tion is likely to be set up on similar grounds as the India Infrastructure Finance Company, which has been
Financial Institution for Funding Port Projects
Planned
Addition of Three Ports lifts Cargo Handling
Capacity to 1 Billion Tn
SEA PORTS SEA PORTS SEA PORTS
News & Events M B
34 The Masterbuilder - March 2011
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targeting the Indian port capacity to 3.2 billion tonnes by the year 2020.”
While the capacity addition target is laudable, the country still needs to do some catching up to do with its neighbour China, which has a capacity of around 8 billion tonnes. The minister added that with the three projects car terminal, iron ore terminal and common user terminal, the country's port capacity has reached a capacity of 1.11 billion tonnes a year.
The ministry has also been aggress ively promoting PPP ventures for augmenting port capacity in the country. According to the minister in the last 18 months, 22 new PPP projects to the tune of ` 6, 172 crore have been awarded.
The recent inauguration of three ports at Ennore Port Ltd has helped in increasing the aggregate cargo
set up earlier in the past. The govern-ment is also looking at the option of setting up a debt fund for financing major infrastructure projects , with a size of around ̀ 50,000 Cr.
Kochi's Transshipment Hub Draws Praise from All Quarters
Kochi's transshipment hub, which is a first of its kind facility in India, has been drawing praise from all quarters. The facility will allow large ships and vessels to berth, refuel, offload, and upload cargo, before embarking on their respective journey paths from the port.
The opening of the hub is expected to further strengthen Kochi's position as one of the most important maritime desti-nations in Asia. The new facility is also expected to improve traffic significantly, especially for cargo containers that are moving from East Asia to Europe.
The new facility is expected to give stiff competition to the neighrbouring transshipment hub at Colombo. According to
the Secretary, Ministry of Shipping Mr. K Mohandas, “ This will save cost and time substantially in transportation of containers related to export and import, as the entire business India had to conduct at Colombo hub, would now take place here.”
The facility is being touted as yet another winner from the implementa-tion of PPP ventures. The hub, once it gets operation will be able to handle 1 million TEU container ships per year in its first phase.
Chetra Machinery India Pvt.Ltd
News & Events M B
36 The Masterbuilder - March 2011
Arunachal Pradesh Plans Development of Road
Infrastructure
2 New Flyovers for Navi Mumbai
Two New Road Projects in Himachal Pradesh
Chidambaram says Half of India's Road
Budget Wasted
be widened and improved as part of the project. This move is expected to strengthen the road network in the apple belt. Himachal Pradesh is the largest producer of apples in the country.
Apart from benefitting the apple growers in the region, the road projects are also expected to boost tourism in the area.
Two new road projects, specifi-cally for the smooth transportation of apples have been sanctioned in the state of Himachal Pradesh. The new road projects would entail an invest-ment outlay of ̀ 16 crore.
T h e G u m m a - B a g g i a n d Mashobra-Bhekalti stretches would
with consultants. The flyovers, once completed, will go a long way in reducing the traffic problems in the increasingly busy Mahape Road.
The northeastern state of Arunachal Pradesh is getting ready for the development of road infra-structure in four districts West Kameng, East Siang, West Siang, and Changland. The Ministry for Development of North Eastern Region (DoNER) has sanctioned funds to the tune of ` 69.92 Cr for the purpose.
The money for the project has been sanctioned from the Non Lapsable Central Pool of Resources (NLCPR). With the latest initiatives the total amount that has been sanc-tioned by the ministry for projects in the state now amount to ` 196.7 Cr in the current financial year, according to an official press release.
The release also quoted the DoNER Minister B.K. Handique as saying “We have also requested the Arunachal Pradesh government to expedite these projects in the greater interest of connecting the state with the rest of the country. During this financial year alone, about 80 per cent of NLCPR sanctions for Arunachal Pradesh have gone towards development of roads and bridges.”
There have been a series of trans-port infrastructure development initiatives that have been announced for the northeastern states in recent times.
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Navi Mumbai will soon have two new flyovers. The Mumbai Metro-politan Region Development Authority (MMRDA) is actually plan-ning four flyovers in Thane and Navi Mumbai.The tenders for the first two flyovers valued at ̀ 90 Cr were issued recently. The flyovers would be built on the Mahape Road. The construc-tion of the flyover is expected to be completed within a time period of two years.
The authority is reportedly on the verge of finalizing the technical details of the flyovers in consultation
The Union Home Minister Mr. P Chidambaram has said that half of the budget meant to build good roads never reaches its target. He said that the whole issue was the coun-try's “biggest swindle”.
Mr. Chidambaram gave his views during an interview to a leading tele-vision channel while on a visit to attend the World Economic Forum in Davos, Switzerland. He said that infrastructure development money was more vulnerable to corruption.
"Laying roads: this is the biggest swindle in the country. No more than 50 percent of the contracted amount is actually spent on the roads, “he is reported to have told the television channel. The country had embarked on an ambitious road development project, which had to be subse-quently scaled down due to various issues.
ROADS ROADS ROADS
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News & Events M B
38 The Masterbuilder - March 2011
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An increasing focus on infrastruc-ture development has been the high-light of the progress that the country has made in recent times. The government is increasingly realizing that infrastructural development is the key to sustaining the pace of economic growth.
Industry experts in the past have blamed the rickety infrastructure in the country for not being able to achieve double digit economic growth, an area where they cite the example of neighbouring China,
The Finance Minister also said that the government was planning to set up an infra debt fund to promote foreign investment in the infrastruc-ture sector. “We will introduce special infrastructure debt funds to
attract foreign financing in infra-structure.” This is a measure that was on expected lines.
Mr. Mukherjee said that tax-free bonds worth ̀ 5, 000 Cr each will be issued by the port sector and Hudco, respectively. He also said that the National Highways Authority of India Ltd (NHAI) and Indian Rail-ways Finance Corporation (IRFC) will also issue tax-free bonds of ` 10,000 Cr each.
Foreign portfolio investment would be now permitted in SEBI-registered mutual funds as per the new budget proposals. The Finance Minister has also hiked the FII investment limit by an additional US $20 billion for investment in infra-related sectors.
The Indian Infrastructure Finance Company Ltd (IIFCL) will disburse loans worth around ` 20,000 Cr by the end of this fiscal for various projects in the infrastruc-ture sector. The minister also added that cold storage chains would be given infrastructure status.
2011-12 said that the government was planning to spend ̀ 2.14 lakh Cr as budgetary support for the infra-structure sector in 2011-12.
Slew of Measures in Union Budget 2011-12 to
Spur Infrastructure Investment
Industry Analysts Happy with Infra Focus in Budget Realizing the importance of infra-
structure development in sustaining the economic growth rate, the Finance Minister Mr. Pranab Mukherjee has announced a slew of measures to boost investment in the all-important infrastructure sector. The measures include extending of income-tax exemption on tax saving infrastructure bonds up to a maximum of ` 20,000 Cr for one more year and issuance of tax-free bonds worth ̀ 30,000 Cr.
The Finance Minister while presenting the Union Budget for
URBANURBAN
Over 52% infra projects running behind schedule says Economic Survey
According to the pre-budget Economic Survey, over 52 percent of the ongoing infrastructure projects in the country are running behind schedule. "As on October, 2010, out of the 559 projects, 14 are ahead of schedule, 117 are on schedule, and 293 are delayed," the Survey said quoting the Department of Programme Implementa-tion (DPI) data.
The department moni-tors the progress of projects costing ` 150 Cr and above on a month l y ba s i s . According to the survey in the road transport and high-ways sector alone, 51
projects have been delayed for up to 36 months. In the case of power projects it is 20 projects up to 18 months over the targeted time schedule of completion.
In the oil sector the story has been no different with a total of 16 projects having been reported for overrun up to 16 months. The survey also added that “several non-financing" constraints needed to be addressed in order to avoid the issue.
The Supreme Industries
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which is said to be at least a decade ahead when it comes to infrastruc-ture in the country.
News & Events M B
42 The Masterbuilder - March 2011
would have to come from the private sector.
"There is urgent need to stream-line land acquisition and environ-ment clearance for infrastructure projects. A national forest land bank, with clear paperwork and titles, could significantly reduce the approval time for forest clearances," the survey went on to add about the potential problems that afflict the infrastructure sector.
The country's infrastructure development would need ` 41 lakh Cr investments in the 12th Plan period said the Economic Survey, quoting preliminary assessment that was made towards the purpose by the Planning Commission.
"The Planning Commission has carried out a preliminary assessment of the investment in infrastructure during the 12th Plan. The projected investment requirement would be of the order of ` 40,999,240 Cr (about USD 1,025 billion)," the Survey said. The survey also went on to add that at least 50 percent of the investment
major water treatment project, which would be set up in Kharagpur, in Munger district in the state.
The project would be awarded on a turnkey basis by the Public Health Engineering Department of the Bihar state government. According to press reports the project has been bagged by Punj Lloyd, the infra-structure and construction major.
The project once completed will enable the supply of 6,224 million litres of drinking water per day (MLD) in the village of Khaira, which has been badly affected by fluoride contamination in water. The scope of work of the project includes engi-neering, procurement, construction, installation and commissioning of a centralized water treatment plant.
The Union Minister for Environ-ment and Forest Mr. Jairam Ramesh has said that he will be “positive” towards infrastructure development projects, softening his stance during a meeting of the Group of Ministers (GoM).He has also assured the team that he will soon lift the moratorium on 25 areas, a step that will help in revival of projects that have been stalled due to green concerns.
"I have assured them that from our Ministry's side, we will adopt a positive attitude," Ramesh told reporters after the meeting, which was headed by the Union Finance Minister, Mr. Pranab Mukherjee.
The Minister's changing stance had been evident in recent times when he head relaxed environment norms for mega projects like Lavasa and Posco. He also said that he did not intend to “stop the projects”, while maintain that decline in forest cover is something “which needs to be checked.”
Bihar is increasingly finding itself in the news for all the good reasons. The state is now getting ready for a
Several contentious issues seem to be slowing down the pace of infra-structure development in the coun-try. Land acquisition and environ-mental clearance issues are said to reason for the delay for several projects. Similarly frivolous litigation in terms of public interest litigations is another major headache for policy makers in India.
Industry experts though are hopeful that the budget would have the necessary stimulus package in it to give the much needed boost to the infrastructure sector this time around.
Major Water Treatment Project in Bihar
Infra Needs ` 41 lakh Cr Investment says Economic Survey
Jairam Ramesh Softens Stand at GOM Meeting
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An ` 125 crore housing project has been launched by M R and Asso-ciates and Promoters India Ltd, exclusively for senior citizens. The project will consist of 120 apart-ments.
The company according to its C h a i r m a nMr.D.MurugaRamanathan would be targeting NRIs, for whom their rela-tives or aged parents can be taken care off in a secure and comfortable atmosphere. The apartment units in the project would be priced between ` 50 lakh and ` 75 lakh. The villas however would cost upwards of ` 1 crore.
The housing units will come with all modern amenities including, lush greenery, garden, complete with medicinal plants. The project is expected to be completed in two years, Mr. Ramanathan added.
News & Events M B
44 The Masterbuilder - March 2011
Relaxed Norms for Teaser Home Loans Likely
Redevelopment FSI Hiked in Mumbai
An Exclusive Housing Project for Senior Citizens
Low-Cost Housing Loans of `15 lakh to get 1 % Interest Sop
recent past have resorted to offering teaser home loans to garner a larger share of the market.
According to reports, NHB is likely to listen to the arguments of housing financing companies and then take a decision on the same. With the realty market, especially the growth rate of residential projects not picking up pace, developers around the country had also been putting pressure on banks to come out with attractive housing finance schemes for buyers.
would get a floor space index of 3 for redevelopment. Interestingly the decision was actually taken by the preceding Chief Minister Mr. Ashok Chavan and the present incumbent had put it on hold till now.
The ratio of the built-up area to the total area of the plot is the FSI of a building. Till this decision was taken the FSI for old buildings in the city was 2.5. With the hike in the FSI to 3, developers are expecting a frenzied activity in the realty sector in the city.
The FSI for the redevelopment of old and dilapidated buildings in Mumbai has been hiked. The Chief Minister of Maharashtra Mr. Prithviraj Chavan cleared the deci-sion recently.
According to the decision, old buildings developed before 1969
The National Housing Bank (NHB) which is also a regulatory body is likely to revise its earlier direction on higher provisioning of teaser loans. Several banks in the
Buyers too on their part have been anticipating favorable market conditions for almost a year now. They are expected to have some relief after the budget session, which according to top industry experts is expected to bring some cheer to the realty sector.
In an effort to unlock the poten-tial of low-cost housing in the coun-try, the government in the Union Budget 2011-12 has announced that housing loans of ̀ 15 lakhs would be eligible for a 1 percent interest subsidy. The move is expected to give a boost to the sector.
The Union Finance Minister Pranab Mukherjee in his Budget speech said that he is liberalizing the existing scheme of one percent interest subvention on housing loans up to ̀ 15 lakhs, where the cost of the house does not exceed ̀ 25 lakh.
"To further stimulate the growth in housing sector, I am liberalizing the existing scheme of interest subvention on 1 per cent on housing loans by extending housing loan up to ` 15 lakh where the cost of the house does not exceed ` 25 lakh, from the present limit of ` 10 lakh and 20 lakh respectively," Mr. Mukherjee said during his speech.
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????????? PEB: An Industry Analysis
46 The Masterbuilder - March 2011 47The Masterbuilder - March 2011
The Pre-Engineered Building
(PEB) technology, although
widely used in other parts of the
world, is a relatively new concept in
India. PEB systems made an entry into
the Indian construction arena in the
1990s and since then there has been no
looking back for this particular indus-
try. The technology has been making
rapid inroads becoming part and parcel
of construction projects around the
country. The reputation of PEB-based
construction as a quicker, efficient, cost
effective and sustainable method of
construction has meant that it has
become a preferred technique in
today's world of demanding deadlines.
The PEB industry is estimated to be
growing at a compound rate of 25 to 35
percent, in the recent past. “The Pre-
engineered Buildings market in India
can be valued at approx: Rs. 2500
Crores”says Mr. Sureet Chatterjee,
Chief Marketing & Business Develop-
ment, Tata BlueScope Steel, a leading
player in the PEB domain. The rise in
demand for steel in the construction
industry is being directly attributed to
the increase in the popularity of PEB sys-
tems. It is still early days though, with
PEB accounting for an estimated 0.5
Mn ton of the total steel that is con-
sumed by the construction industry. To
put things into perspective one, just
needs to compare the per capita steel
consumption of India with that of
China. While the figure hovers around
the 40 kg mark for India, it is over 270
kg in the case of the latter. With
increasing awareness about PEB, the
scenario is set for a gradual but definite
change.
Exponential Growth
The acceptance of PEB systems by
the Indian construction industry has
meant that a host of manufacturers are
now vying for the market share. The
intense competition in the market has
also been responsible for product inno-
vations. Several big players such as Tata
BlueScope, Pennar Engineered Build-
ing Systems Ltd, Loya Constructions Pvt
Ltd , Interarch, Metaltech Construc-
tions Pvt Ltd , Era Buildsys, Zamil Steel
and United Steel & Structurals (P) Ltd ,
to mention only a few have been cater-
ing to the increasing demand for PEB
systems around the country. That cli-
ents are accepting the new technology
is aptly summed up by Mr.R.Elangovan,
CEO, Metaltech Constructions Pvt Ltd,
when he explained, “The market for
metal buildings in the country is grow-
ing at a healthy rate of more than 15
percent. With the numerous advan-
tages that PEB systems offer over con-
ventional construction, builders in
India too would gradually begin to
accept and promote them in the near
future. The growth is already there for
everyone to see.”
Several sectors are driving the
growth for PEB systems in the country.
Going into the details of applications
Mr. Anil Kumar Sharma, Senior Vice
President (Sales & Marketing), Era
Buildsys, remarked, “ PEB systems are
not confined to industrial and ware-
housing but have gained diverse appli-
cations such as in , industrial power gen-
eration buildings, aviation hangars,
industrial sheds, steel buildings and
cement boiler support plant structures,
cold storage facilities, stadiums, out-
door fuel stations with canopies, metro
rail, high-rise industrial building pro-
jects and railway projects.” The versatil-
ity of applications is in fact the reason
behind increased use of PEB technique
in infrastructure projects.
Giving additional insights into the
versat i l i ty of the appl icat ions
Mr.P.V.Rao, Executive Director of
Pennar Engineered Building Systems
Ltd, said “These Pre-Engineered build-
ings can help the end users whose
requirement is to have buildings with
large spans, higher bay spacing, factory
made quality, over head cranes, multi-
storied construction, architectural ver-
satility, speed of construction etc.”
With widespread research and devel-
opment going on, there are some
major breakthroughs expected, which
could further widen the application of
PEB systems.
The fact that PEB technology
enables lower life cycle cost vis-à-vis
conventional steel buildings is another
factor that is driving up the volume of
sales. The foundation for one is easy to
Lower Life Cycle Cost
construct, being light weight and con-
sisting of standard sections and con-
nections. This saves erection cost and
time. Erection is typically 20 percent
higher in the case of conventional steel
buildings. Moreover, basic designs can
be used over and over again in the case
of PEBs, leading to additional cost sav-
ings.
Contrary to popular perception, out-
standing architectural design can be
achieved using PEBs. Additionally, PEB
Pre-Engineered BuildingPre-Engineered BuildingM.K. Prabhakar, Staff Correspondent
Sureet ChatterjeeChief Marketing & Business Development,
Tata BlueScope Steel
“The Pre-engineered Buildings market in India can be valued at approx: Rs. 2500 crores”
Cost-Effective and Sustainable Construction Technique Set to Rule the Roost Cost-Effective and Sustainable Construction Technique Set to Rule the Roost
Erection of Industrial Pre-Engineered Building
????????? PEB: An Industry Analysis
46 The Masterbuilder - March 2011 47The Masterbuilder - March 2011
The Pre-Engineered Building
(PEB) technology, although
widely used in other parts of the
world, is a relatively new concept in
India. PEB systems made an entry into
the Indian construction arena in the
1990s and since then there has been no
looking back for this particular indus-
try. The technology has been making
rapid inroads becoming part and parcel
of construction projects around the
country. The reputation of PEB-based
construction as a quicker, efficient, cost
effective and sustainable method of
construction has meant that it has
become a preferred technique in
today's world of demanding deadlines.
The PEB industry is estimated to be
growing at a compound rate of 25 to 35
percent, in the recent past. “The Pre-
engineered Buildings market in India
can be valued at approx: Rs. 2500
Crores”says Mr. Sureet Chatterjee,
Chief Marketing & Business Develop-
ment, Tata BlueScope Steel, a leading
player in the PEB domain. The rise in
demand for steel in the construction
industry is being directly attributed to
the increase in the popularity of PEB sys-
tems. It is still early days though, with
PEB accounting for an estimated 0.5
Mn ton of the total steel that is con-
sumed by the construction industry. To
put things into perspective one, just
needs to compare the per capita steel
consumption of India with that of
China. While the figure hovers around
the 40 kg mark for India, it is over 270
kg in the case of the latter. With
increasing awareness about PEB, the
scenario is set for a gradual but definite
change.
Exponential Growth
The acceptance of PEB systems by
the Indian construction industry has
meant that a host of manufacturers are
now vying for the market share. The
intense competition in the market has
also been responsible for product inno-
vations. Several big players such as Tata
BlueScope, Pennar Engineered Build-
ing Systems Ltd, Loya Constructions Pvt
Ltd , Interarch, Metaltech Construc-
tions Pvt Ltd , Era Buildsys, Zamil Steel
and United Steel & Structurals (P) Ltd ,
to mention only a few have been cater-
ing to the increasing demand for PEB
systems around the country. That cli-
ents are accepting the new technology
is aptly summed up by Mr.R.Elangovan,
CEO, Metaltech Constructions Pvt Ltd,
when he explained, “The market for
metal buildings in the country is
ing at a healthy rate of more than 15
percent. With the numerous advan-
tages that PEB systems offer over con-
ventional construction, builders in
India too would gradually begin to
accept and promote them in the near
future. The growth is already there for
everyone to see.”
Several sectors are driving the
growth for PEB systems in the country.
Going into the details of applications
Mr. Anil Kumar Sharma, Senior Vice
President (Sales & Marketing), Era
Buildsys, remarked, “ PEB systems are
not confined to industrial and ware-
housing but have gained diverse appli-
cations such as in , industrial power gen-
eration buildings, aviation hangars,
industrial sheds, steel buildings and
cement boiler support plant structures,
cold storage facilities, stadiums, out
door fuel stations with canopies,
metro rail, high-rise industrial building
projects and railway projects.” The ver-
satility of applications is in fact the rea-
son behind increased use of PEB tech-
nique in infrastructure projects.
Giving additional insights into the
versat i l i ty of the appl icat ions
Mr.P.V.Rao, Executive Director of
Pennar Engineered Building Systems
Ltd, said “These Pre-Engineered build-
ings can help the end users whose
requirement is to have buildings with
large spans, higher bay spacing, factory
made quality, over head cranes, multi-
storied construction, architectural ver-
satility, speed of construction etc.”
With widespread research and devel-
opment going on, there are some
major breakthroughs expected, which
could further widen the application of
PEB systems.
The fact that PEB technology
enables lower life cycle cost vis-à-vis
conventional steel buildings is another
factor that is driving up the volume of
sales. The foundation for one is easy to
Lower Life Cycle Cost
construct, being light weight and
consisting of standard sections and con-
nections. This saves erection cost and
time. Erection is typically 20 percent
higher in the case of conventional steel
buildings. Moreover, basic designs can
be used over and over again in the case
of PEBs, leading to additional cost sav-
ings.
Contrary to popular perception, out-
standing architectural design can be
achieved using PEBs. Additionally, PEB
Pre-Engineered BuildingPre-Engineered BuildingM.K. Prabhakar, Staff Correspondent
Sureet ChatterjeeChief Marketing & Business Development,
Tata BlueScope Steel
“The Pre-engineered Buildings market in India can be valued at approx: Rs. 2500 crores”
Cost-Effective and Sustainable Construction Technique Set to Rule the Roost Cost-Effective and Sustainable Construction Technique Set to Rule the Roost
Erection of Industrial Pre-Engineered Building
erection and installation of PEB systems.
Use of industry-specific software is
another major reason for the growth in
PEB structures. The use of specialized
software enables correction and modi-
fications before the erection and instal-
lation process, which is not a possibility
with conventional construction meth-
ods. Interarch, another leading player
in the PEB domain, for example, uses
MBS for design of Primary and Second-
systems can be designed keeping in
mind future expansion plans. Since a
single supplier can coordinate all facets
including, design, erection, and instal-
lation, superior after sales service is
another aspect that is virtually assured
with PEB technology.
Manufacturers are now focusing on
offering the entire gamut of services
from sales right to erection and installa-
tion. Observed Mr.Sureet Chatterjee,
Complete Package
Chief Marketing & Business Develop-
ment, Tata BlueScope, “Tata BlueScope
Building Solutions division offers the
BUTLER™ Building System and
ECOBUILD™ Building System, which are
complete PEB solutions. The company
provides complete solutions for PEB
needs, right from design to erection.”
Companies are increasingly focusing their
marketing strategy on offering a com-
plete package, which takes care of the
client's requirement, right from selec-
tion of the right solution to the final
48 The Masterbuilder - March 2011
Pre-Engineered Building: Cost-Effective and Sustainable Construction Technique Set to Rule the Roost
R.ElangovanCEO, Metaltech Constructions Pvt Ltd
“The market for metal buildings in the country is growing at a healthy rate of more than 15 percent. With the numerous advantages that PEB systems offer over conventional construction, builders in India too would gradually begin to accept and promote them in the near future. The growth is already there for everyone to see.”
ary systems. The software has been tai-
lored to accommodate the company's
standard inventory.STAAD Pro is also
used by the company for special frame
designs. These tools helps us in very
fast preparation of elaborate and self-
explanatory design calculations and
are very convenient for checking and
approvals by the consultants and third
party institutions. Changes and revi-
sions can be accommodated and
attended quickly as per the end user
requirements. Detailing and shop draw-
Pre-Engineered Stadia
Screen Shot of Pre-Engineered Building Design in progres
PEB: An Industry Analysis
Rockwool (India) Ltd
50 The Masterbuilder - March 2011
ings are prepared using full scale
Autocad drawings , to ensure error free
releases and all the Part Marks, Bill of
Material and Shippers are monitored
using in-house techniques and the
interfacing with the latest ERP software
SAP. This helps in detailed explanation
to the end users, about all the items
related to their projects and also for
invoicing and bill certification pur-
poses.
Giving details about the usage of
specific innovations in their product
range Mr.Anil Kumar Sharma, Senior
Vice President (Sales & Marketing), Era
Buildsys said, “Usage of latest software
technology with forward integration
for direct loading to production lines
with state of art fully automatic and
semi automatic cutting, welding,
straightening, shot blasting and paint-
ing line is our strength. This reduces fab-
rication errors and ensures delivery of
quality product with high levels of pro-
ductivity.” Intense competition has
meant that companies are now focus-
ing their research and development
activities towards offering PEB solu-
tions that offer a quicker return on
investment.
Rising emphasis on sustainable
building strategies has been another
reason for the increasing presence of
The 'Green' Factor
Anil Kumar SharmaSenior Vice President (Sales & Marketing),
Era Buildsys,
“PEB systems are not confined to industrial and warehousing but have gained diverse applications such as in, industrial power generation buildings, aviation hangars, industrial sheds, steel buildings and cement boiler support plant structures, cold storage facilities, stadiums, outdoor fuel stations with canopies, metro rail, high-rise industrial building projects and railway projects.”
pre-engineered buildings across the
country. Spelling the reasons for their
range of PEB systems being sustainable
options, Mr.Sunil S.Loya, Managing
Director, Loya Constructions Pvt Ltd
said, “Basic ground line of PEB is 'Opti-
mization'. And optimization is the pos-
sible minimum utilization of the mate-
rials with support of highest degree of
engineering skills. Subsequently PEB
saves a lot of material. Compared to
conventional structures; bay spacings
are wider due to which less concrete
Versatile applications: A PEB structure for housing a speed boat garage
The durability factor makes PEB systems ideally suited for harsh factory environs
Pre-Engineered Building: Cost-Effective and Sustainable Construction Technique Set to Rule the Roost
PEB: An Industry Analysis
Realm Intermediates (P) Ltd
foundations are required. It reduces
unnecessary concreting and ultimately
even water. PEBs can be easily relo-
cated using same sections with any
addition or deletion. Also it can be recy-
cled.” He went on to add that construc-
tion activity takes around 50 percent
less time than with conventional sys-
tems. Additionally, it reduces pollution
while construction takes place. The ven-
tilating systems used in PEB are turbo
ventilating systems which are natural
wind driven. The company also makes
provisions for transparent skylight,
which promotes energy conservations.
Sharing a similar point of view,
Mr.Elangovan of Metaltech Construc-
tions quipped, “Pre-engineered build-
ings do contribute to the development
of sustainable habitat since there is
avoidance of materials such as sand,
mud, cement, granite, wood, etc.” All
these factors directly contribute to
development of sustainable habitat,
reduction of global warming and pro-
tection of the immediate environment,
making PEB construction technique
among the preferred choice in today's
scenario.
Not only is the end-product, even
the manufacturing process getting
greener. The best example is available
52 The Masterbuilder - March 2011
in the form of Pennar Engineered Build-
ing Systems Ltd's state of the art manu-
facturing facility at Sadashivpet, about
50 kms from Hyderabad on the
Mumbai National Highway, which
according to Mr.P.V.Rao, the company's
Executive Director is housed in 23,000
sq m and is “the first factory in India to
get Gold rating from the Indian Green
Buildings Council.”
While the industry has been show-
ing a buoyant growth pattern over the
past five years, there are several chal-
lenges that still remain. The ever-
Challenges
Mr.P.V.RaoExecutive Director of
Pennar Engineered Building Systems Ltd
“These Pre-Engineered buildings can help the end users whose requirement is to have buildings with large spans, higher bay spacing, factory made quality, over head cranes, multi-storied construction, architectural versatility, speed of construction etc.”
Sunil S.LoyaManaging Director,
Loya Constructions Pvt Ltd
“Basic ground line of PEB is 'Optimization'. And optimization is the possible minimum utilization of the materials with support of highest degree of engineering skil ls . Subsequently PEB saves a lot of m a t e r i a l . C o m p a r e d t o conventional structures ; bay spacings are wider due to which less concrete foundations are required. It reduces unnecessary concreting and ultimately even water. PEBs can be easily relocated using same sections with any addition or deletion. Also it can be recycled.”
increasing steel prices and its notorious
volatility are among them. With
increasing number of PEB projects,
economies of scale are expected to tilt
the balance in favour of manufacturers.
The continued impetus being provided
to infrastructure development projects
augers well for the PEB industry. The
unbeatable combination of improved
construction speed, cost-effectiveness,
and sustainability makes PEB based con-
struction technique the one to watch
out for in the next decade.
Factory-built components ensure minimal damage to immediateenvironment during PEB construction process
Pre-Engineered Building: Cost-Effective and Sustainable Construction Technique Set to Rule the Roost
PEB: An Industry Analysis
Thermatek
?????????
Portable Modular Buildings!
Portable Architecture
55The Masterbuilder - March 2011
With the limited availability
of spacious and centrally
located sites, rising mate-
rial, land and transportation costs,
architects and developers are exploring
alternative methods of construction
such as portable and modular build-
ings. While portable and modular
buildings enjoy extreme popularity in
places like Japan and other parts of
South East Asia and Scandinavia, the
general public still perceives modular
buildings as transient, cheap and plain-
looking and those that are built as
short-term solutions during exigencies
like earthquakes and other natural
disasters.
However, portable and modular
buildings are just an alternate method
of construction which can resemble
and match conventional, permanent
stick building in all aspects like architec-
ture, mechanical or electrical design
features. They have to comply with
building codes and are actually are sub-
ject to a rather strict design and engi-
neering review.
With significant advances in tech-
nology, construction materials and
practices, it is time that people and
other stakeholders review their per-
ceptions modular and portable archi-
tecture. Since these modular buildings
are 85%-90% built in factory quality con-
trolled environments, they provide
greater overall structural integrity as
against conventional stick buildings
that can be plagued by delays due to
weather. Also, waste is minimal.
Portable, modular buildings involve
manufacture of modules or three-
dimensional units that are typically con-
structed off-site in a factory controlled
environment and then transported and
assembled on site on a previously con-
Construction Method
PORTABLEMODULARBUILDINGS!
Bhavani Balakrishna
Creative and practical architecture play significant roles in bringing portable and modular architecture more into the mainstream. However, to ensure success, stakeholders like architects and developers need to educate consumers that portable, modular construction can score high on aesthetics and performance while being an eco-friendly and energy efficient alternative to in-situ construction.
structed foundation or set of piers. The
frames are normally made of steel, tim-
ber or concrete. Most modular con-
structions come with external and
internal finishes along with electrics
and plumbing while some provide just
the framework.
An integral part of modular build-
ings is light steel framing (LSF) that is
used as the modules' internal frame-
work to which a variety of cladding and
finishes akin to conventional buildings
may be attached. LSF ensures that
framework is strong and robust to pro-
tect the internal finishes from getting
damaged during transportation and
assembly on-site. With steel frames,
modular buildings typically have a life-
span of 60 years.
In most volumetric and panelized
steel modular constructions, units, the
stud and track method of connection is
used for constructing wall and roof
frames. This involves utilizing self-
drill/tap fasteners, bolts and rivets to
join cold rolled galvanized 'C' steel pro-
Steel Frame Modular Building
Internal finishing of portable modular building
54 The Masterbuilder - March 2011
?????????
Portable Modular Buildings!
Portable Architecture
55The Masterbuilder - March 2011
With the limited availability
of spacious and centrally
located sites, rising mate-
rial, land and transportation costs,
architects and developers are exploring
alternative methods of construction
such as portable and modular build-
ings. While portable and modular
buildings enjoy extreme popularity in
places like Japan and other parts of
South East Asia and Scandinavia, the
general public still perceives modular
buildings as transient, cheap and plain-
looking and those that are built as
short-term solutions during exigencies
like earthquakes and other natural
disasters.
However, portable and modular
buildings are just an alternate method
of construction which can resemble
and match conventional, permanent
stick building in all aspects like architec-
ture, mechanical or electrical design
features. They have to comply with
building codes and are actually are sub-
ject to a rather strict design and engi-
neering review.
With significant advances in tech-
nology, construction materials and
practices, it is time that people and
other stakeholders review their per-
ceptions modular and portable archi-
tecture. Since these modular buildings
are 85%-90% built in factory quality con-
trolled environments, they provide
greater overall structural integrity as
against conventional stick buildings
that can be plagued by delays due to
weather. Also, waste is minimal.
Portable, modular buildings involve
manufacture of modules or three-
dimensional units that are typically con-
structed off-site in a factory controlled
environment and then transported and
assembled on site on a previously con
Construction Method
PORTABLEMODULARBUILDINGS!
Bhavani Balakrishna
Creative and practical architecture play significant roles in bringing portable and modular architecture more into the mainstream. However, to ensure success, stakeholders like architects and developers need to educate consumers that portable, modular construction can score high on aesthetics and performance while being an eco-friendly and energy efficient alternative to in-situ construction.
structed foundation or set of piers.
The frames are normally made of steel,
timber or concrete. Most modular con-
structions come with external and
internal finishes along with electrics
and plumbing while some provide just
the framework.
An integral part of modular build-
ings is light steel framing (LSF) that is
used as the modules' internal frame-
work to which a variety of cladding and
finishes akin to conventional buildings
may be attached. LSF ensures that site.
framework is strong and robust to
protect the internal finishes from get-
ting damaged during transportation
and assembly on-site. With steel
frames, modular buildings typically
have a lifespan of 60 years.
In most volumetric and panelized
steel modular constructions, units, the
stud and track method of connection is
used for constructing wall and roof
frames. This involves utilizing self-
drill/tap fasteners, bolts and rivets to
join cold rolled galvanized 'C' steel
Steel Frame Modular Building
Internal finishing of portable modular building
54 The Masterbuilder - March 2011
to that of lumber. The most common
dimension used is an 8"x8"x16" hollow
core. Pre-cast blocks involve minimal
site preparation. The blocks are placed
upon a solid base pad resting on undis-
turbed soil (with organics removed).
Pre-cast piers are single stacked or double stacked (“Crib-Stack") wherein each course of block is crisscrossed in the stack for lateral stability. The pyra-mid-shaped steel piers are considered to be one of the strongest, efficient, and easy-to-install foundation systems for portable and modular structures. Typical spacing of piers is 8' on-center. The I-Beams in the building's frame rest on mounting brackets on top of the piers. Heights are adjustable due to screw-type mounting brackets. The piers are mounted on concrete or pres-sure-treated wood pads for even and smooth distribution of the building's load to the ground.
Some portable and modular con-structions use the block-and-level tem-porary foundation system which involves stacking concrete blocks from ground-level up to the I-beams in the chassis frame. Here, the building is jacked-up off of the ground (like a car jack) and 4 and 8 inch high concrete blocks are stacked to a point just short
filed sections. All floor and ceiling joists
are provisioned with holes or service
highways to allow running of cables
and pipework. Brackets, self-drill/tap
fasteners and rails are used to connect
the drylining, insulation boards and
façade panels.
Most often, modular buildings are
placed upon three different types of
foundations.
Temporary pre-cast Blocks or "pad-
on-grade"
Permanent poured-in-place grade
beams in conjunction with pre-cast
block
Permanent poured-in-place stem
wall in conjunction with isolated
piers or grade beams
Pre-cast blocks, made from a com-
bination of Portland cement, graded
aggregate (mainly fines) and water are
used as foundations for a majority of
modular building installations. Size
specifications of the blocks are similar
56 The Masterbuilder - March 2011
Wall and roof frame in modular building Roof of Modular Building
Pre-Cast Blocks for Modular Building Foundation
Portable Modular Buildings!
Portable Architecture
Atul Fasteners Ltd
58 The Masterbuilder - March 2011
of the finish elevation. The stack is then capped with a wood cap and wood shims for final leveling. The person set-ting-up the unit places a carpenter's level just inside one of the building's exterior doors. He checks the bubble to see if the building is level and adds or subtracts shims around the building, until the bubble indicates that the building is level. This process is called "blocking-and-leveling".
Poured-in-place grade beams and
stem-wall foundations are mostly used
for permanent installation.
One of the note-worthy examples
of portable and modular architecture is
the HSBC Building in Queen's Road in
Hong Kong, China. Built in 1985, this
44-storeys, high rise building, it took 6
years from concept to completion. Five
steel modules were prefabricated in
the UK were shipped to Hong Kong. In
total, 30,000 tonnes of steel and 4,500
tonnes of aluminum were used. On site
was former old Hong Kong & Shanghai
Bank-Hong Kong building. The building
was innovative because it lacked any
internal supporting structure, thanks
to eight groups of four aluminum-clad
steel columns which ascend from the
foundations up through the core struc-
ture, and the five levels of triangular
suspension trusses which are locked
into these masts which allows the
building to profit from natural
sunlighting all over its levels. The build-
Portable Modular Construction Classics
ing has a floor area of 99,000 m² and
has 10-story atrium, 52m tall, over the
public plaza. Construction costs are esti-
mated to be over USD 670 million.
Architects were Sir Norman Foster and
Partners and construction included
Alan G. Davenport Wind Engineering
Group BLWTL, Claude R. Engle, Lighting
Consultant, Cleveland Bridge Ltd.,
Cupples International Inc., J Roger Pres-
ton Ltd, Laservision Australia, Levett &
Bailey Chart. Quantity Surveyors Ltd,
Martin Professional A/S, Otis Elevator
Co., Ove Arup & Partners Hong Kong
Ltd., Pell Frischmann.
Another notable, portable modular
architecture is the Italian Pavilion in the
Expo Shanghai in 2010. Seen from
above, the pavilion resembles the start
of the Chinese game pick-up-sticks,
also known in Italy as the Shanghai
Game, where a number of sticks are
thrown in a random pile. The different
sections of the building making up a
geometrical variety is said to symbolize
a complexity of regional cultures that
define the Italian identity. The pavilion
has a floor area of 3.600 square metres
and its height is 18 metres. Internally,
the pavilion consists of asymmetrical
sections of varying dimensions, con-
nected by a steel bridge structure
Modular Building Foundation
HSBC's Portable Modular Buildingin Queens Road, Hongkong
Aluminium Clad Steel ColumnsAscending from the foundation
Portable Modular Buildings!
Portable Architecture
Sika India Pvt.Ltd
where the connecting galleries are visi-
ble. It is said that the pavilion can be dis-
mantled and reconstructed, on a
smaller scale, in any other part of the
city. The building is covered on three
sides by a film of water reflecting the
structure and highlighting the natural
shinny effects. The brilliance of the
structure is reproduced inside both via
slits which evoke the narrow alleys
between the city buildings, and the use
of transparent cement, a new, recently
created multifaceted material .
Because of its particular and diverse
component on the different sides of
the building, this material generates a
twofold architectural effect, from the
outside a nocturnal effect of the liveli-
ness inside, and from the inside, the
outside daylight atmosphere.
The surface of the pavilion will
appear transparent with the sides
made up of self-cleaning glass. Photo-
voltaic elements are integrated in the
glass covering to ensure protection
from radiation, while the light-
technologies of the building not only
highlight the spaces, but also makes
the structure energy efficient. Archi-
tects involved in the construction of the
Pavilion include the firm Iodice of
Aversa, the architects Teresa Crescenzi,
Antonello De Bonis, Cosimo Dominelli,
Francesco Iodice, Giuseppe Iodici and
Marcello Silvestre and Architect
Imbrighi.
Dutch practice HVDN architecten
have built this wood and aluminum-
clad building to temporarily house a
school in Amsterdam, the Netherlands
60 The Masterbuilder - March 2011
for about five to ten years until the per-
manent school is built. Called Het 4e
Gymnasium, the modular building has
a square plan constructed around an
internal courtyard and features a
wooden façade, interrupted by col-
oured aluminum panels. The 4000
square meter building includes a media
centre, an auditory and a large audito-
rium. The courtyard is the heart of the
school and the hallways around the
court are used to go from one class-
room to another. The facade has two
effects that intensify the character of
the building.
The plinth is made of flat, coloured
aluminum panels and continuously fol-
lows through into the facade of the
courtyard; the plinth as a foretoken of
the colour explosion in the court. The
wooden facade has been developed
more spatially and in depth and gives
the building plasticity. By choosing a rel-
ative deep outside facade, it was possi-
ble to bring on relief. Under the frame,
the facade withdraws 20 cm through
which the image of two piled up
arcades is created. Also the seams
between the modules are hidden; the
Italian Pavilion at Shanghai Expo, 2010
An Illuminated view of Italian Pavilion at Shanghai Expo, 2010
Portable Modular Buildings!
Portable Architecture
Mangalore Chemical Fertilisers
wooden front parts are built from nar-
row planks, which are placed vertically
and on small distance from each other.
Through the number of artificial seams
that arises, the real seams become
invisible. At the plinth and the facade of
the courtyard, the seams are hidden
behind the rhythmic placed coloured
aluminum boards of different widths.
The school has both on technically and
aesthetic area qualities and a level of
finishing which is similar to permanent
62 The Masterbuilder - March 2011
traditional construction. At the same
time the building is very flexible in sev-
eral aspects. It is movable and can be
used where is necessary the coming
years.
Creative and practical architecture
like the above examples play significant
roles in bringing portable and modular
architecture more into the main-
stream. However, to ensure success,
stakeholders like architects and devel-
opers need to educate consumers that
portable, modular construction can
score high on aesthetics and perfor-
mance while being an eco-friendly and
energy efficient alternative to in-situ
construction.
The flexibility of transportable,
modular construction have made them
popular within the education, retail
and healthcare industry but in general ,
both commercial and non-commercial
sectors can look at modular construc-
tions as versatile, high-quality and eco-
nomical long-term building alterna-
tives that can be relocated and recon-
structed anytime, anywhere.
Industry Outlook
Wooden Facade of Het 4e Gumnasium
Het 4e Gymnasium, Amsterdam, Netherlands
Portable Modular Buildings!
Portable Architecture
Silicone Concepts Int'l.Pvt.Ltd
®Modular Building and LEED?????????
64 The Masterbuilder - March 2011 65The Masterbuilder - March 2011
Modular BuildingModular Buildingand the USGBC's LEED™and the USGBC's LEED™Special Correspondent
®Modular Building and LEED
64 The Masterbuilder - March 2011
ous rating systems to a 100 point sys-
tem.
2. Give greater emphasis to those cred-
its that stress energy conservation,
renewable energy systems and the
US Green Building Council's drive
toward carbon neutral buildings.
3. Introduce a new Credit Category
that rewards LEED project teams
for successfully achieving credits
dealing with regional priorities. In
Version 3 (V3) these are referred to
as Regional Priority credits or “RPs”.
LEED for New Construction and
Major Renovations Version 3.0, 2009 is
based on Credit Categories with the
65The Masterbuilder - March 2011
as a global leader by influencing
and spearheading the green building
market transformation across the
world.
In response to market opportuni-
ties and the desire to respond to stake-
holder desires to make LEED more spe-
cific to building applications, LEED has
evolved from a single LEED for New Con-
struction and Major Renovations to the
following family of LEED products.
LEED for New Construction and
Major Renovations
LEED for Commercial Interiors
LEED for Existing Buildings
LEED for Core and Shell
�L�E�E�D� �f�o�r� �H�o�m�e�s
�L�E�E�D� �f�o�r� �N�e�i�g�h�b�o�r�h�o�o�d� �D�e�v�e�l�o�p�-
�m�e�n�t
�M�a�r�k�e�t� �S�e�c�t�o�r� �R�a�t�i�n�g� �S�y�s�t�e�m�s
�M�u�l�t�i� �B�u�i�l�d�i�n�g�s� �a�n�d� �C�a�m�p�u�s�e�s
�R�e�t�a�i�l
�H�e�a�l�t�h�c�a�r�e
�L�a�b�o�r�a�t�o�r�i�e�s
�T�h�e� �p�u�r�p�o�s�e� �o�f� �t�h�i�s� �p�a�p�e�r� �i�s� �t�o� �a�l�i�g�n�
�t�h�e� �i�n�t�e�r�e�s�t�s� �a�n�d� �g�o�a�l�s� �o�f� �t�h�e� �M�o�d�u�l�a�r�
�B�u�i�l�d�i�n�g� �I�n�d�u�s�t�r�y� �w�i�t�h� �L�E�E�D� �V�e�r�s�i�o�n� �3�,�
�2�0�0�9�,� �o�r� �L�E�E�D� �V�3�.� �T�h�e� �n�e�w�e�s�t� �v�e�r�s�i�o�n�
�o�f� �L�E�E�D� �r�e�f�l�e�c�t�s� �t�h�e� �U�S� �G�r�e�e�n� �B�u�i�l�d�i�n�g�
�C�o�u�n�c�i�l�'�s� �d�e�s�i�r�e� �t�o� �a�c�c�o�m�p�l�i�s�h� �t�h�e� �f�o�l�-
�l�o�w�i�n�g�:
�1�. �N�o�r�m�a�l�i�z�e� �t�h�e� �s�c�o�r�i�n�g� �o�f� �t�h�e� �v�a�r�i�-
While the spur in green
building movement a com-
bination of environmental
stewardship and economic opportu-
nity has created market opportunities
for several related construction indus-
tries, existing industries with products
and practices that resonate with the
tenets of sustainable design and devel-
opment and green building have natu-
rally benefited from the increased
awareness and market opportunities
inherent in this paradigm shift.
The US Green Building Council with
its Leadership in Energy and Environ-
mental Design (LEED™) building rating
system is increasingly establishing itself
Modular BuildingModular Buildingand the USGBC's LEED™and the USGBC's LEED™
same titles. As mentioned the
Regional Priority category has been
added. The Credits and attendant
points in LEED 2009 are now:
Sustainable Sites (SS)
(1) Prerequisite and (26) possible
points
Water Efficiency (WE)
(1) Prerequisite and (10) possible
points
Energy and Atmosphere (EA)
(3) Prerequisites and (35) possible
points
Materials and Resources (MR)
(1) Prerequisite and (14) possible
points
Indoor Environmental Quality (EQ)
(3) Prerequisites and (15) possible
points
Innovation & Design (ID)
(0) Prerequisites and (6) possible points
Regional Priority
(4) Possible points
This results in an arithmetic tally of
110 possible points. However the
nature of LEED in practice holds that
achieving all 110 points is not possible;
they are available but subject to the
influence of project context, design
and construction choices and design
and construction process variables. Pro-
ject context is simply a matter of where
the project is located. The many bene-
fits of modular building do not enable
the finish project to escape the influ-
ence of site selection. However, the
economies associated with manufac-
turing in a closed environment with
stringent material use and quality con-
trol capabilities makes modular build-
ing an ideal choice for manufacturing
energy, material and resource efficient
structures.
In LEED 2009 the threshold levels
for LEED certification are:
Certified 40 - 49 Points
Silver 50 - 59 Points
Gold 60 -79 Points
Platinum 80 or more Points
The goal of most stakeholders using
LEED as a building rating tool is to
achieve the highest LEED certification
rating possible. Certification is the pro-
cess by which a project team fulfills the
prerequisites and earns sufficient
credit points to reach one of four certif-
ication levels: Certified, Silver, Gold or
Platinum. This process is explained in
complete detail in the Reference
Guides issued for each of the LEED rat-
ing systems as well as on line at
www.usgbc.org.
In the LEED certification system pre-requisites are activities or processes that must be done but for which no points are awarded. Credits are pur-sued as a matter of choice for which points are awarded if the requirements of the credits are achieved. In LEED for New Construction and Major Renova-tions Version 2009 there are nine Pre-requisites, one hundred Base Points, six Innovation in Design Points and four Regional Priority Points.
In LEED 2009 there are nine prereq-uisites and seventy-nine possible points. The other LEED building rating systems vary but most carry a similar category / credit / point structure. The reader is referred to www.usgbc.org for a more complete description of each.
A LEED Accredited Professional is
anyone who passes any of the current
exams administered by the Green
Building Certification Institute (GBCI),
an organization allied with the USGBC
to provide professional development
and LEED accreditation testing. After
Special Correspondent
whole or in part to the construction
site to complete a finished unit.
Modular building applied to prefab-
ricated components can be used in any
building type LEED is used to certify. It is
important to note that if prefabricated
modular components are used in the
context of a larger building they must
meet the LEED criteria that apply to
them but also are subject to the LEED
rating system as it relates to the fin-
ished building type under consider-
ation.
The individual components or sub-
March 31, 2009, individuals wishing to
take the LEED AP exam will have to reg-
ister for the LEED Version 3 exam. A
LEED AP Plus exam will be available for
individuals who anticipate participat-
ing in the LEED certification process in a
more involved and technical capacity.
For the purpose of clarity, buildings
undergo a certification process. Indi-
viduals who pass a LEED accreditation
exam become LEED Accredited at the
level of the exam they take and are enti-
tled to use the credential LEED Accred-
ited Professional Associate or LEED
Accredited Professional, LEED AP.
For the purpose of this study modu-
lar building is considered to be one of
the following:
Prefabricated building compo-
nents, parts, pieces and sub assem-
blies assembled under controlled
conditions and shipped to become
part of a larger, primary building
project
Whole building units prefabricated
under controlled conditions and
delivered to the construction site in
66 The Masterbuilder - March 2011
assemblies do not, in themselves,
receive LEED certification.
In order to better understand what
affects a modular building's potential
for LEED certification and the way LEED
certification scores are compiled it is
necessary to consider the following
observations and conditions that
inform the LEED certification process
1. These issues are largely a func-
tion of where the project is located. They are not specific to modular building practice, processes or prod-ucts.
2.
These are the
decisions that comprise how a pro-
ject is designed and constructed
such as material selection, con-
struction techniques, building sys-
tems selection, installation and con-
trols, building envelope, mechani-
cal, electrical and plumbing systems
and space conditioning are in this
category. Material handling, opti-
mal construction conditions and
Modular Building and the LEED Build-
ing Rating System
LEED prerequisites and credit oppor-
tunities fall into three broad areas of
concern:
Context and Community Connectiv-ity -
Architectural, Engineering and Con-
struction Choices -
Four Certification Levels
40-49 50-59 60-79 80+
Points
Modular Building and the USGBC's LEED™
®Modular Building and LEED
Modular Floor Plan
Cipy Polyurethanes Pvt.Ltd
Waldorf School, Charlottesville, VA
environmental control during con-
struction all can contribute to
attaining LEED credits and atten-
dant points. Much of this report is
focused on this area.
3.
These include activities
like commissioning, construction
waste management, and maintain-
ing superior interior air quality dur-
ing construction and before occu-
pancy and measurement and verifi-
cation. These again are not specific
to modular construction but pre-
Construction Administration and
Processes -
requisites for all construction pro-
jects. Instead they are prerequisites
and credit opportunities that are
common to all construction and the
project as a whole.
The Sustainable Sites Category in
LEED 009 has one Prerequisite and
twenty six possible points. The addi-
tional weight given to credits and
points in this category are in SS Credits
2 through 4.4, none of which have a
direct bearing on modular building.
Sustainable Sites and Modular Building
SS Credit 7.2: Heat Island Effect
Roof is the only Credit in this category
that is a matter of design and construc-
tion of a modular unit. The Prerequi-
sites and all other credits in this cate-
gory are a function of context and com-
munity connectivity. In order to
achieve SS credit 7.2 modular construc-
tions must meet the requirements for
solar reflective index or SRI in the roof-
ing material(s) used over 75% of the
roof area. These are SRI of 29 for roof
areas of more than 2 in 12 and SRI of 78
for roof areas in excess of 2 in 12 .
Modular construction may also
have unique attributes regarding SS
Credit 6.1 Site Development - Protect
and Restore Habitat. Option One in this
credit rewards construction techniques
that limit site disturbance and keep dis-
turbed areas to within the areas imme-
diately adjacent to the building foot-
print. Because modular components
and complete units are fabricated off
site and delivered by a variety of over
the road transport, it is possible to
achieve tighter site control and less dis-
turbed area in the project perimeter.
SS Credit 9 Site Master Plan and SS
Credit 10 Joint use of Facilities are spe-
cific to LEED for schools and are not reli-
68 The Masterbuilder - March 2011
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Jim Russell Racing Drivers School, Sonoma, CA
Modular Building and the USGBC's LEED™
®Modular Building and LEED
Award winning modular building
Sleek Boards India Ltd
ant on either conventional or modular
construction for credit compliance.
Modular construction techniques
have been shown to be inherently
advantageous in 7 major areas:
1. Less materials waste due to prefab-
rication and minimal on-site work
2. Less material exposure to inclem-
ent weather due to construction in
a controlled factory environment
3. Less site disturbance due to major-
ity of construction being executed
offsite
4. Safer construction
5. Flexibility for assembly, disassem-
bly, relocation and refurbishment
6. Adaptability since modular build-
ings are designed to quickly add or
remove one or more “modules”
minimizing disruptions to adjacent
buildings and surroundings
7. Built to code with shorter build
times
LEED rewards project stakeholders
How are modular structures more ben-
eficial?
Water Efficiency and Modular Building
for reducing dependence on munici-
pally supplied potable water for irriga-
tion, the transportation of waste using
potable water and overall water con-
servation through practices like rain-
water harvesting and intelligent land-
scaping and plan selection.
In the new version, project teams must achieve a minimum 20% reduc-tion in water use below that allowed in the Energy Policy Act of 199 in order to meet WE Prerequisite 1 Water Use Reduction 20%. In addition, LEED 2009 awards two points to each credit in the Water Efficiency category. WE Credits 1.1 and 1.2 associated with reducing potable water demand for irrigation are a matter of resource efficient land-scaping and site water management in any project.
WE Credit 2 Innovative Waste Water Technology rewards project stakeholders for utilizing fixtures that out perform the allowable water quan-tities listed in the Energy Conservation Act of 1992.
WE Credit 3.1 and WE 3.2 Water
Use Reduction recognize the potential
for conserving water in any way possi-
ble with the exclusion of potable water
used for irrigation which is accounted
for in WE Credits 1.1 and 1.2.
WE Credit 3.3 Process Use Water
Reduction is specific to LEED for
Schools. It is intended to reward any
effort to aggregate a number of water
conservation opportunities commonly
found in schools.
Modular construction that antici-
pates inclusion in projects with rain
water harvesting is best if it has antici-
pated the detailing, structural loads
and system interfaces that are part of
the building and site engineering nec-
essary to be part of the overall systems
integration.
Current literature supports the fact
that energy conservation and the
attendant reduction in building operat-
ing costs are two of the major drivers in
the high performance green building
movement. All of the LEED's Energy
and Atmosphere Prerequisite and
Credit opportunities can be applied
directly to modular construction pro-
jects. Modular construction that uses
structural insulated panels or SIPS can
produce relatively high R-values and
low infiltration rates if fabricated and
constructed with good quality control.
Steel and aluminum stud frame con-
struction can also produce energy effi-
cient units if care is taken to insure
proper installation techniques and air
sealing.
The following discourse summa-
rizes the relationship of modular build-
ing and the LEED Energy and Atmo-
sphere Prerequisites and Credits.
LEED requires fundamental com-
Energy and Atmosphere and Modular
Building
EA Prerequisite 1 - Fundamental Com-
missioning of the Building Energy Sys-
tems
70 The Masterbuilder - March 2011
Modular Building and the USGBC's LEED™
®Modular Building and LEED
Water efficient modular building
Technokolla
missioning of the HVAC and controls,
lighting and controls, domestic hot
water systems and renewable energy
systems if they are included. Commis-
sioning differs from traditional testing
and balancing or the startup primary
space conditioning equipment by man-
ufacturer suppliers or subcontractors
in that commissioning must insure that
all systems are working collectively as
intended. In the case of modular build-
ing commissioning is assumed to be
applied to a finished project.
If a modular building is fully assem-
bled prior to delivery and the systems
that must be commissioned are
installed and operational most funda-
mental commissioning activities can
take place in the factory. However, the
modular building is subject to addi-
tional commissioning activities if con-
necting to the civil infrastructure, site
mounted renewable energy systems,
site water supply pressure testing, etc.
These activities can only happen in the
field and are required for a complete
commissioning report.
LEED also requires designating an
individual with commissioning author-
ity experience as expected by the rating
system to lead, review and oversee the
completion of the commissioning pro-
cess activities.
In LEED 2009, all LEED projects are
subject to exceeding the minimum
energy performance criteria set forth in
Sections 5.4, 6.4, 7.4, 8.4, 9.4, and 10.4
of ASHRAE / IESNA 90.1 2007 without
amendments as well as the prescriptive
requirements of Sections 5.5, 6.5, 7.5
and 9.5 without amendments by 10%
for new construction and 5% for major
renovations. The reader is referred to
ASHRAE / IESNA 90.1 2007 for a com-
plete description of the requirements.
Generally the building categories are:
Building envelope
Section 6: Heating, Ventilating and
Air Conditioning (including parking
garage ventilation, freeze protection,
exhaust air recovery and condenser
heat recovery)
Service water heating
Power (including all
EA Prerequisite 2 Minimum Energy Per-
formance
Section 5:
Section 7:
Section 8:
building power distribution systems)
Lighting (including exit
signs, building exterior. Grounds and
parking garages)
Other Equipment (in-
cluding all permanently wired electric
motors)
In this case, the modular buildings
in question are assumed to be perma-
nently installed on foundations not
meant to facilitate removal or frequent
relocation.
This prerequisite prohibits the use
of CFC based refrigerants in new build-
ing HVAC&R systems. If central plants
that modular buildings are serviced by
use these products, the project must
obtain an inspection of the central
plant as well as a commitment to phase
out the equipment using CFCs in the
central plant over time. Each is
weighed on its merits.
This credit is based on meeting all
the requirements of EA Prerequisite
Minimum Energy Performance which
mandates exceeding ASHRAE 90.1 007
minimum energy performance
requirements by 10% for new construc-
tion. In Version 3, 2009, LEED provides
an opportunity to obtain up to twenty
one points for new construction by
computer modeling the proposed
design against a base case building
using Appendix G of ASHRAE / IESNA
90.1 2007. Once the base case is cre-
ated and an annual operating budget is
established the design team is tasked
with creating a design case building
that reduces the annual operating bud-
get by at least 12% below that required
Section 9:
Section 10:
EA Prerequisite 3 - Fundamental Refrig-
erant Management
EA Credit 1 - Optimum Energy Perfor-
mance
72 The Masterbuilder - March 2011
Modular Building and the USGBC's LEED™
®Modular Building and LEED
Solar photovoltaic panels on modular building
for the base case building before points
can be scored. Projects whose yearly
operating budget for energy is 12%
below the Base Building modeling as
established by Appendix G of ASHRAE
90.1 007 can score the minimum two
points. Projects with yearly energy
operating budgets forty eight percent
or more below the Base Building esti-
mate are eligible for nineteen points.
It is important to note that the mod-
ular building in question must be mod-
eled in the context of the site and the
final design. The LEED Reference Guide
contains an extensive discussion of
what evaluation procedures are most
appropriate and what is acceptable as
building envelope, building systems,
site and occupancy variables.
Once the yearly operating budget
of the design case building has been
determined using the procedures con-
tained in EA Credit 1 the project team
can address meeting the annual energy
demands of the project with renewable
energy sources and building systems.
LEED considers the following systems
eligible for consideration in this credit:
Photovoltaic systems
Solar thermal Systems
Bio-fuel based electrical systems
Geothermal heating systems (Geo-
thermal heat pumps are excluded
EA Credit 2 - On-Site Renewable Energy
Systems
but their benefits are considered
in EA Credit 1 Optimum Energy Per-
formance)
Geothermal electrical systems
Low impact hydroelectric power sys-
tems
Wave and tidal systems
The contribution of these systems
to the reduction of the annual energy
costs are reflected in the energy model-
ing or prescriptive approaches to
energy cost calculations found in EA
Credit 1. EA Credit 2 Renewable Energy
points are rewarded for displacing con-
ventional fuels and the attendant
reduction in yearly energy costs on a
graduated scale. The percentage listed
in the title of the credits refers to the
reduction in dollars below the yearly
energy cost in dollars for the base
building modeled in Appendix G or
through some other prescriptive
method. They are:
1% Renewable Energy 1 Point
5% Renewable Energy 3 Points
9% Renewable Energy 5 Points
13% Renewable Energy 7 Points
LEED 2009 awards two points for EA
Credit 3. Enhanced commissioning is
related to the basic commissioning
required for all LEED projects in EA Per-
quisite 1.
LEED 2009 awards two points for EA
Credit 4. LEED rewards project teams
that make responsible choices regard-
ing the selection, installation and main-
tenance of refrigerants. R410A or
Puron is preferable to R12 or R22. A
LEED point is rewarded for selecting a
refrigerant that is efficient while mini-
EA Credit 3 - Enhanced Commissioning
EA Credit 4 - Enhanced Refrigerant Man-
agement
73The Masterbuilder - March 2011
GeothermalEnergy System
Modular Building and the USGBC's LEED™
®Modular Building and LEED
mizes global warming and still meets
equipment performance and warranty
requirements.
LEED 2009 awards three points for
EA Credit 5. Measurement and Verifica-
tion is a process by which the operation
EA Credit 5 - Measurement and Verification
and associated energy performance of
a completed project is monitored for at
least one year using the processes and
practices set forth in the International
Performance and Measurement & Veri-
fication Protocol (IPMVP) Volume III.
Obtaining this point may require coor-
dination between the modular building
supplier and the HVAC and / or the
mechanical, electrical and plumbing
engineers. The intention is to acquire
sufficient building systems data to ver-
ify the building is performing as antici-
pated. The work associated with
obtaining this credit can be relatively
simple if the structures are modest in
scale and the systems are limited and
straight forward. Many modular build-
ing applications be they classrooms or
small office are in this category.
LEED 2009 awards two points for EA Credit 6. Green Power refers to electri-cal energy generated off site using cri-teria established by the Center for Resource Solutions (CRS) Green-e prod-ucts certification requirements. Pro-jects are rewarded one LEED point for contracting for at least 35% of the pro-ject's electrical requirements for two years. A second point is available if the contract doubles to 70% for the same two year period.
EA Credit 6 - Green Power
74 The Masterbuilder - March 2011
Modular Building and the USGBC's LEED™
®Modular Building and LEED
O-14 Nears Completion in DubaiThe striking beautiful latticed building O-14 tower in Dubai is finally nearing
completion. Designed by Jesse Resiser and Nanoko Umemoto of RUR Architecture, the building features an eye-catching façade that limits solar heat gain in addition to a sophisticated passive cooling system that reduces energy use.
Resembling a sculpture more than a building, the commercial tower has a central core for office space. The decorative façade has over 1,000 circular cut outs and functions as an exoskeleton. This outside structure supports the core, and thus allows for remarkably open interior spaces. Imagine a virtually column-free office space, able to be split and subdivided in any way tenants wish.The one meter of space between the exoskeleton and the core also acts a hot air chute. Although metropolitan, Dubai is essentially a desert city. The exoskeleton not only shields the core from the sun, but its shape forces hot air up and out, which saves money and energy on cooling the core. The circular holes are carefully positioned to provide views while limiting sun exposure.
The 21 open floors will house offices while the ground level will have an exclusive luxury shopping center, in true Dubai fashion, and an entrance to the waterfront esplanade.
Green award winning modular building - Xstrata
To be continued
Pennar Engineered Building Systems Ltd
Corrosion Control
78 The Masterbuilder - March 2011
bridged by an electrically conducting
fluid (which is electrolyte). Removal of
any if these three conditions will pre-
vent corrosion.
The Galvanic Table lists metals in
the order of their relative activity in sea
water environment. The list begins
with the more active (anodic) metal
and proceeds down to the least active
(cathodic) metal of the galvanic series.
The obvious means of prevention is therefore to avoid mixed metal fabrica-tions. Frequently this is not practical, but prevention can also be by removing the electrical contact - this can be achieved by the use of plastic or rubber washers or sleeves, or by ensuring the absence of the electrolyte such as by improvement to draining or by the use of protective hoods. This effect is also dependent upon the relative areas of the dissimilar metals. If the area of the less noble material is large compared to that of the more noble (cathodic) the corrosive effect is greatly reduced, and may in fact become negligible. Con-versely a large area of noble metal in contact with a small area of less noble will accelerate the galvanic corrosion
rate. For example it is common practice to fasten aluminium sheets with stain-less steel screws, but aluminium screws in a large area of stainless steel are likely to rapidly corrode.
Galvanic series relationships are
useful as a guide for selecting metals to
be joined, will help the selection of met-
als having minimal tendency to interact
galvanically, or will indicate the need or
degree of protection to be applied to
lessen the expected potential interac-
tions.
Generally, the closer one metal is to
another in the series, the more com-
patible they will be, i.e., the galvanic
effects will be minimal. Conversely, the
farther one metal is from another, the
greater the corrosion will be.
Notice that graphite is at the bot-
tom of the table. Think of the corrosion
potential if you put a big hunk of graph-
ite on a small piece of magnesium.
In a galvanic couple, the metal
higher in the series (or the smaller the
number given ) represents the anode,
and will corrode preferentially in the
Very frequently I am asked by my
leading PEB customers to
explain the Galvanic Corrosion
effect of using stainless steel grade 304
self drilling and tapping screws on
galvolume colour coated roofing
sheets. In this article I have tried to give
some facts about this aspect for guid-
ance in the use of stainless steel SDTS
on Galvalume colour coated roofing
sheets.
Corrosion is an electro chemical pro-
cess involving the flow of electric cur-
rent from cathode (-ve) to the anode
(+ve). At the point where electro
potential energy exist the cathode (-ve)
residue (red rust) is formed. Galvanic
Corrosion also arises from the contact
of dissimilar metals in presence of elec-
trolyte (an electrolyte is an electrically
conductive liquid or moisture on the
surface of steel).
In fact three conditions are
required for Galvanic Corrosion to pro-
ceed, the two metals must be widely
separated on the galvanic series (see fig-
ure in next page), they must be in elec-
trical contact and their surface must be
Galvanic Corrosion
R.K. LutherManaging Director
M/s Atul Fastners Ltd.
Nina Concrete Systems Pvt.Ltd
80 The Masterbuilder - March 2011
Galvanic Corrosion
Corrosion Control
environment.
For self-drilling screws, when it is
recessed head, like phillips head, the
material used is S/S-302HQ or S/S-305,
And, for Hex Washer Head, the mate-
rial used is S/S-304. When the total
thickness of fastening material only
runs from 0.5mm to 1.0mm, then Self-
Drilling Screws made of Stainless Steel
302HQ or 305, or 304 is good enough.
Metals widely separated in the gal-
vanic series must be protected if they
Types of Protection
Precautions for Joining
Other Approaches
Where it becomes necessary that
relatively incompatible metals must be
assembled, the following precautions
and joining methods are provided for
alleviation of galvanic corrosion.
For Electrical Connection - Select
materials which are indicated to be
more compatible in accordance with
the galvanic series.
Design metal couples so that the
area of the cathode is smaller (appre-
ciably) than the area of the anodic
metal. For example, bolts or screws of
stainless steel for fastening aluminum
sheet, but not reverse.
Interpose a compatible metallic gas-
ket or washer between the dissimilar
metals prior to fastening.
Seal all faying edges to preclude the
entrance of liquids.
Apply corrosion-inhibiting pastes or
compounds under heads of screws or
bolts inserted into dissimilar metal sur-
faces whether or not the fasteners had
been previously plated or otherwise
treated. In some instances, it may be
feasible to apply an organic coating to
the faying surfaces prior to assembly.
This would be applicable to joints
which are not required to be electri-
cally conductive.
Where practicable or where it will
not interfere with the proposed use of
the assembly, the external joint should
be coated externally with an effective
paint system.
Further quires on this subject the
author can be contacted on mobile no.
0 9 8 1 4 9 2 9 2 9 7 a n d e m a i l i d
are to be joined. Appropriate measures
should be taken to avoid contact. This
can be accomplished by several meth-
ods:
1. - By applying to the cath-
odic member a sacrificial coating
having a potential similar to or near
that of the anodic member.
2. - By sealing to insure that
faying surfaces are water-tight.
3. - By painting or coating
all surfaces to increase the resis-
tance of the electrical circuit.
Sacrificial
Sealing
Resistance
STA Concrete Flooring Solutions
Rajpal U.NavalkarCEO, and Executive Director
of Thermoshield India
“India can be said to be the frontrunner, with roofs being made up of locally available materials, such as wood, stone, bamboo, grass, and mud. The tradition of making thatched roofs using palm leaves dates back thousands of years”
Industry Analysis?????????
82 The Masterbuilder - March 2011
building is known to come through the
roof. With awareness levels increasing
about green buildings, there has been a
corresponding rise in the level of inter-
est on green roofs too in India.
The concept of green roofs surpris-
ingly has been in existence in India for
several centuries. Going into this inter-
esting fact Mr.Rajpal U.Navalkar, CEO
a n d E x e c u t i v e D i r e c t o r o f
Thermoshield India had during an
interaction with the Masterbuilder said
“India can be said to be the
83The Masterbuilder - March 2011
asbestos sheets, as was the norm till a
decade ago.
Along the way in the growth story of
the Indian roofing industry several
myths have been busted. For one, man-
ufacturers today vouch for the fact that
the typical Indian customer is not
driven only by the price factor but
wants value addition. No longer are
newer systems and innovative prod-
ucts shunned by certain segments of
the market. Fiberglass and metal roof-
ing are now being increasingly used in
residential projects as well.
Hurdles to Green Roofs
Roofing typically accounts for 25-30
percent of the total building construc-
tion cost. While roofs have always been
crucial for building aesthetics, what has
happened in recent times with the ris-
ing emphasis on sustainable building
strategies is the experimentation with
a variety of materials and technologies.
Eco-friendly roofing materials, which
are durable along with offering excel-
lent aesthetics is the norm today. An
estimated 15 percent of the heat in a
If there is one particular sector
which has undergone a dramatic
shift in trends in the Indian con-
struction scene, then it must be that of
the roofing and cladding industry. An
increasingly aware consumer and rising
emphasis on sustainable building strat-
egies have been dictating the trends in
this most dynamic of all industries. The
advent of fiberglass, asphalt and more
importantly, metal roofing options has
meant that the roofing industry is no
longer restricted to conventional RCC
roofs or the use of potentially harmful
frontrunner, with roofs being made up
of locally available materials, such as
wood, stone, bamboo, grass, and mud.
The tradition of making thatched roofs
using palm leaves dates back thou-
sands of years.” Even today there are vil-
lages around the country, with roofs
being made from materials including
cow dung and mud phuska. However,
green roofs not much more compli-
cated than just creating a potted plant
garden on a roof. The material and
labour cost involved for initial installa-
tion, plus the fact that the number of
green roof contractors in the country is
limited, are factors that need to be
taken into account. With the gradual
rise in demand though, upfront costs
are expected to decrease in the next
decade leading to the increase in green
roofs.
Tensile fabric roofing is another pop-
ular concept that is gradually finding an
increasing number of takers in the coun-
try. The semi-translucent nature of fab-
Roofing and Cladding in Single Ele-
ment
ric structures is what makes them a
favourite with engineers and architects
looking for roofing systems to cover
large areas, such as sports stadia or ter-
minals. Tension membrane structures
are usually reinforced using either
PVT/Polyester based coatings or PTFE -
based coatings.
ROOFING INDUSTRYDiverse Product Range Drives DemandROOFING INDUSTRYDiverse Product Range Drives Demand
M.K. Prabhakar
Limited number of specialized green roof contractors has beenhindering the growth of the concept in India
Rajpal U.NavalkarCEO, and Executive Director
of Thermoshield India
“India can be said to be the frontrunner, with roofs being made up of locally available materials, such as wood, stone, bamboo, grass, and mud. The tradition of making thatched roofs using palm leaves dates back thousands of years”
Industry Analysis?????????
82 The Masterbuilder - March 2011
building is known to come through
the roof. With awareness levels
increasing about green buildings, there
has been a corresponding rise in the
level of interest on green roofs too in
India.
The concept of green roofs surpris-
ingly has been in existence in India for
several centuries. Going into this inter-
esting fact Mr.Rajpal U.Navalkar, CEO
a n d E x e c u t i v e D i r e c t o r o f
Thermoshield India had during an
interaction with the Masterbuilder said
83The Masterbuilder - March 2011
asbestos sheets, as was the norm till a
decade ago.
Along the way in the growth story of
the Indian roofing industry several
myths have been busted. For one, man-
ufacturers today vouch for the fact that
the typical Indian customer is not
driven only by the price factor but
wants value addition. No longer are
newer systems and innovative prod-
ucts shunned by certain segments of
the market. Fiberglass and metal roof-
ing are now being increasingly used in
residential projects as well.
Hurdles to Green Roofs
Roofing typically accounts for 25-30
percent of the total building construc-
tion cost. While roofs have always been
crucial for building aesthetics, what has
happened in recent times with the ris-
ing emphasis on sustainable building
strategies is the experimentation with
a variety of materials and technologies.
Eco-friendly roofing materials, which
are durable along with offering excel-
lent aesthetics is the norm today. An
estimated 15 percent of the heat in a
If there is one particular sector
which has undergone a dramatic
shift in trends in the Indian con-
struction scene, then it must be that of
the roofing and cladding industry. An
increasingly aware consumer and rising
emphasis on sustainable building strat-
egies have been dictating the trends in
this most dynamic of all industries. The
advent of fiberglass, asphalt and more
importantly, metal roofing options has
meant that the roofing industry is no
longer restricted to conventional RCC
roofs or the use of potentially harmful
frontrunner, with roofs being made
up of locally available materials, such as
wood, stone, bamboo, grass, and mud.
The tradition of making thatched roofs
using palm leaves dates back thou-
sands of years.” Even today there are vil-
lages around the country, with roofs
being made from materials including
cow dung and mud phuska. However,
green roofs not much more compli-
cated than just creating a potted plant
garden on a roof. The material and
labour cost involved for initial installa-
tion, plus the fact that the number of
green roof contractors in the country is
limited, are factors that need to be
taken into account. With the gradual
rise in demand though, upfront costs
are expected to decrease in the next
decade leading to the increase in green
roofs.
Tensile fabric roofing is another pop-
ular concept that is gradually finding an
increasing number of takers in the coun-
try. The semi-translucent nature of fab-
Roofing and Cladding in Single Ele-
ment
ric structures is what makes them a
favourite with engineers and architects
looking for roofing systems to cover
large areas, such as sports stadia or ter-
minals. Tension membrane structures
are usually reinforced using either
PVT/Polyester based coatings or PTFE -
based coatings.
ROOFING INDUSTRYDiverse Product Range Drives DemandROOFING INDUSTRYDiverse Product Range Drives Demand
M.K. Prabhakar
Limited number of specialized green roof contractors has beenhindering the growth of the concept in India
Ravi MehtaDirector, Sujan Impex
“Initially we used to face a lot of skepticism from architects who were not aware of this new concept. However, slowly as the architects in India got more exposed to international trends, the concept has gained wide acceptance”
tain, when compared to say, glaze glass
roofing. The roof being factory welded
is also easy to install, apart from being
weather-proof, which means that they
don't contain expansion joints.
One of the best examples of the
remarkable span capabilities of tensile
roofing can be found in the Hajj Termi-
nal of King Abdul Aziz International Air-
port, Jeddah, Saudi Arabia, which is
Perhaps the biggest advantage with
tensile roofing is that it enables roofing
and cladding in one single structural ele-
ment. Typically the seam and curve of
the fabric structure that reflects the ten-
sion is aesthetically pleasing, while also
being important for the structural
integrity. Due to the integrity of the
roofing and cladding system, the struc-
tures are also easy to clean and main-
84 The Masterbuilder - March 2011
often cited as one of the marvels of
modern architecture. After the initial
teething troubles, the concept of ten-
sile roofing is gradually catching up in
the country. Dwelling on the point
Mr.Ravi Mehta, Director, Sujan Impex, a
leading name in the field, said, “Initially
we used to face a lot of skepticism from
architects who were not aware of this
new concept. However, slowly as the
architects in India got more exposed to
international trends, the concept has
gained wide acceptance.” The com-
pany offers the Fluotop T2 range of fab-
rics which are widely used for roofing
applications including, atriums, terrace
coverings, entrance roofs, cafeterias,
stadia roofs, etc.
Going into the details of varied
application of tensile roofing, Mr.Punit
Jhaveri, who heads Lucky International
observed during an interaction with
the Masterbuilder, “ PVC coated fabrics
for architecture is a very broad seg-
ment that includes applications in
small and medium membrane roofing
projects such as for shopping malls, toll
Roofing Industry: Diverse Product Range Drives Demand
Industry Analysis
Metal roofing is ideally suited for industrial applications
The Hajj Terminal, King Abdul Aziz International Airport, Jeddah,Saudi Arabia- Iconic structure is the best example for tensile fabric roofing
Sunil S.Loya,Managing Director,
Loya Constructions Pvt Ltd (LPCL)
“LCPL provides trapezoidal profile sheets using latest technology which has long term durability, spectrum of colours, special metallic coating, and aesthetic beauty, to enhance the appearance, life, and value of the building. The profile sheets are supplied in customized sizes with Pre and Post sales services by qualified Designers and Engineers”
Punit JhaveriLucky International
“PVC coated fabrics for architecture is a very broad segment that includes applications in small and medium membrane roofing projects such as for shopping malls, toll gates, entrances, compounds, parks, school yards, restaurants, swimming pools, etc and for large scale projects such as stadiums, exhibition halls and warehouse structures ”
gates, entrances, compounds, parks,
school yards, restaurants, swimming
pools, etc and for large scale projects
such as stadiums, exhibition halls and
warehouse structures.”
Presently manufacturers are
exploring the possibility of photovol-
taic (PV) integration with fabrics, which
will further increase the green quotient
of tensile roofing. 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 cells (OPVs), the technol-
ogy is expected to evolve rapidly in the
next few years.
While cost considerations and non-availability of specialized manpower may be the hindrances to the growth of the green roofs segment, there is an excellent alternative available in the form of metal roofs. In fact, the metal roofing industry has been growing at a healthy rate of 20-30 percent, annually and has become the preferred favour-ite of engineers and architects, both for a wide variety of applications, whether it is aviation hangars, stadiums, ware-houses, educational institutions or even hospitals , etc to mention only a
Surging Metal Roofing Industry
few. With their unbeatable combina-tion of being light-weight, fireproof, energy efficient and durable, they allow for implementation of sustain-able building strategies in a cost-effective manner.
The rising popularity of metal roof-
ing has meant that there are a number
of leading players who cater to this bur-
geoning market now in the country.
Many of the manufacturers who are
active with pre-engineered building
(PEB) products and solutions are also
concentrating on the roofing and clad-
ding industry. Some of the leading
names in the fray include Tata
BlueScope Steel, Everest Industries,
Pennar Engineered Building Systems
Limited, Interarch, Metaltech Con-
structions, Loya Constructions Pvt Ltd,
Lloyd Insulations, Multicolor Steel etc,
who are catering to the rising demand
for metal roofing and cladding systems.
Typically coated galvalume sheets,
because of their excellent corrosion
resistance are the most preferred when
it comes to metal roofing and walling.
The coated steel sheets offer a unique
combination of the strength of steel
with the corrosion protection of zinc or
zinc/aluminium alloy coatings. More-
over, these sheets are also more mal-
leable and can be roll-formed, pressed,
85The Masterbuilder - March 2011
No longer dull & drab: Metal roof sheets are today available in a wide range of colours
Roofing Industry: Diverse Product Range Drives Demand
Industry Analysis
Universal Construction Machinery
Universal Construction Machinery
Mr.P.V.RaoExecutive Director of
Pennar Engineered Building Systems Ltd
”Our engineering team is extremely talented and we are currently executing a project for Ultratech Cements in Rajasthan in which the clear span is 99 meters without any columns in between. No PEB company in India has ever executed any project with this big clear span “
Sureet ChatterjeeChief Marketing & Business Development,
Tata BlueScope Steel
“All profiles of LYSAGHT® range are specially designed and tested profiles and are manufactured from hi- strength ZINCALUME® steel and COLORBOND® steel ”
punched, or joined into innumerable
combinations of decorative building
products. Galvalume sheets today are
also available in a wide range of
colours, which additionally makes
them an attractive proposition from
the aesthetics point of view too.
Explaining the advantages of metal
roofing sheets, Mr.Sunil S.Loya, Man-
aging Director, Loya Constructions Pvt
Ltd (LPCL), a leading name in the roof-
ing and cladding industry, said, “LCPL
provides trapezoidal profile sheets
using latest technology which has long
term durability, spectrum of colours,
special metallic coating, and aesthetic
beauty, to enhance the appearance,
life, and value of the building. The pro-
file sheets are supplied in customized
sizes with Pre and Post sales services by
qualified Designers and Engineers.”
The company also offers a wide range
of accessories like gutter, flashings,
ridges, louvers, downpipe etc.
Product innovation is the name of
the game and intense competition has
meant that manufacturers are always
on the verge of the next breakthrough.
Tata BlueScope Steel for example,
offers the LYSAGHT range of roofing
and wall cladding systems, which come
with a host of features. Going into the
details Mr.Sureet Chatterjee, Chief Mar-
keting & Business Development, Tata
BlueScope Steel, observed “ All profiles
of LYSAGHT® range are specially
designed and tested profiles and are
manufactured from hi- strength
ZINCALUME® steel and COLORBOND®
steel.” According to Mr.Chatterjee the
range is different from others because
the steel is high strength ZINCALUME®
steel and COLORBOND® steel, far supe-
rior to mild steel. The metallic coating
of zinc/aluminium alloy lasts 4 times
more than galvanized steel of 275 GSM.
The paint system of COLORBOND®
steel is Super Durable Polyester paint
system which uses inorganic pigments
and an especially designed formulation
of paint system to suit environmental
condition. It has better resistance to col-
our fading and chalking.
The ability to enable even complex
structures with wider spans is another
reason why metal roofing is finding an
increasing number of takers nowadays.
88 The Masterbuilder - March 2011
The flexible nature of metal roofing enables their use in complex structureswithout slowing down the pace of construction
Roofing Industry: Diverse Product Range Drives Demand
Industry Analysis
Liugong India Pvt.Ltd
Citing one such example in a PEB pro-
ject, Mr. P.V.Rao, Executive Director,
Pennar Engineered Building Systems
Ltd, pointed out,” Our engineering team
is extremely talented and we are cur-
rently executing a project for Ultratech
Cements in Rajasthan in which the clear
span is 99 meters without any columns
in between. No PEB company in India
has ever executed any project with this
big clear span. The light transmitting sky
light panels we use are imported
(Ampelite) and they have UV protection
coating on both sides and the manufac-
turer gives a 10 year warranty for light
transmission. We have technical collab-
oration with a leading US company
called NCI and we offer 100% leak proof
Double Lock sheeting with 10 year leak
proof warranty. We do site roll forming
using mobile roll forming machine so
that end laps are avoided. “The slew of
advantages on offer has meant that
there has been no looking back for the
surging metal roofing and cladding
industry in the country.
According to industry estimates glob-
ally the market for roofing will be grow-
ing 3.1 percent, year on year through
2014, with the major demand coming
from the two fastest growing economies
in the world, India and neighbouring
China. These are the two countries
where all the action is taking place and it
is not surprising that almost every major
global player in the field of roofing has a
presence in the region. Factors such as
continued thrust on infrastructure
development, the burgeoning real
estate market, especially state-
promoted affordable housing projects
and growing acceptance of alternate
roofing and cladding systems, are
expected to drive the demand in the
next decade.
Exciting Future
90 The Masterbuilder - March 2011
Bamboo eco housing entryBamboo eco housing entryby Indian architects winsby Indian architects wins
Green AwardGreen Award
Tropical cyclones wreak havoc on poorly constructed homes. Winds tear roofs and walls apart and flood waters inundate homes, causing residents to flee to higher ground. An overall better solution is needed for low-income housing in disaster-prone zones. One possible idea is to build a solid, disaster-proof core to hold the home's key elements, and is designed to survive through the strongest of storms. Surrounding that core is a series of bamboo living units that will take the brunt of the storm, but afterwards will be inexpensive to rebuild.
These unique bamboo houses are part of a much larger disaster resistant community concept for the Philippines designed by a group of Indian architects Komal Gupta, Vasanth Packirisamy, Vikas Sharma, Sakshi Kumar and Siripurapu Monish Kumar. Their entry for the Design against the Elements Competition is a master planned eco community with cluster housing units, two community centers, prayer and meditation space, a library, and lots of open green space. Bioswales, rainwater collection, grey water recycling, plantations, commercial space are also incorporated to make this a mixed-use, sustainable community.
The housing concept is a three-story apartment building built on stilts with an earthquake, wind and water resistant core. This core holds all the necessary elements, like water lines, power, staircases and each apartment's kitchen and bathroom. Radiating out from the core are three living pods per floor, inexpensively constructed completely out of bamboo. Each family also has access to the roof and an escape hatch for the most dire of storms. Stilts help the house withstand flooding from storms or monsoons, and should the bamboo living pods get torn off they can easily be reconstructed when the family has time and can afford it. Spurred on by the devastation caused by the tropical storm Ondoy (Ketsana) in the Phillipines in 2009 MyShelter Foundation launched an entire design competition to create disaster proof housing. The winning entry from the competition will actually be built as a prototype disaster-resistant and liveable eco-village in Quezon City. The bamboo eco housing and community centre complex was awarded the Green Award and a cash prize of $3,500.
Roofing Industry: Diverse Product Range Drives Demand
Industry Analysis
Revathi Equipment Ltd
Metal Standing Seam Roof Systems: Going from Strength to Strength
Standing Seam Roof
92 The Masterbuilder - March 2011 93The Masterbuilder - March 2011
Standing Seam Benefits
Seamless system
No external through fixings
Low pitch Applications
Minimal maintenance
Range of finishes
Metal SSRs provide a secure weather tight solution that is designed to last. With minimal maintenance and maximum protection from the ele-ments, standing seam roof systems are widely used on public buildings from education to prisons, hospitals and data centres. Standing Seam systems are available in a range of external fin-ishes, meet and exceed Part L regula-tions and provide a very secure reliable roofing solution.
A standing seam metal roof boasts many qualities that account for its pop-ularity
Firstly, a standing seam roof
requires next to no maintenance, and
will not crack, shrink, erode, or perfo-
rate. Secondly, SSR provides extreme
weather protection, and is the most sta-
ble form of roofing during hurricanes. It
is about 50-100% recyclable, and is fire
resistant. SSRs reflect the sun rays, thus
reducing cooling costs. Being light-
weight it needs no additional framing,
translating into extra roof space. And
finally, a standing seam metal roof is
fairly quiet
SSRs installation is quick using snap-
lock standing seam roofing kits, making
it cost effective.
The dramatic rise in the popularity
of metal roofs arises from benefits it
provides to end users. Therefore there
has been a growing variety of metal
roof materials. Sheet materials like
stainless steel, copper, zinc, aluminum
and lead are inherently durable, the oxi-
dization of the base material forms a
protective patina. Modern steel roof
sheeting is coated with an alloy of zinc
and aluminum to give it some of the
durability of each of those materials at
a lower cost and higher strength than
either. Roofing is available as tradi-
SSRs: The Metal choice
Roofing forms a critical compo-
nent of the building envelope
protecting it from external ele-
ments, while playing an important role
in climate control, hazard mitigation,
and defining the aesthetic character of
a building. For all these reasons, it
becomes essential to keep pace with
the latest trends and technologies in
roofing.
Standing seam roof is a popular kind of metal roofing system used since the earlier periods when metal roofs were hand made from metals like cop-per or tin. A standing seam roof is con-structed from many interlocking panels that run vertically from the ridge to the eave of the roof. The interlocking seams where the two panels join together are raised above the roof's flat surface for easy water run-off. Standing seam roofing is suitable for either span-ning across purlins on typical spacing, or laid directly over rigid insulation and/or solid decking. Many combina-tions of panel widths, seam profiles, and rib heights provide extensive design flexibility, and standing seam roofing comes in a variety of styles and sizes to achieve an array of visual effects.
Standing seam roof or SSRs
an effective way to ensure perfect
weather tightness to roof. With this
machine the edges of connecting pan-
els can be bent together to form a
watertight seal. This roof system is
most reliable for large span buildings
Benefits of Metal Roofs in specific
can further be put as:
The Ultimate Benefits
Engineered for strength from 100%
metal
Air and water tight
Special coatings resist dirt and envi-
ronmental aging
less than 1/3 the weight of asphalt
sheeting
won't rot, crack, split, break or burn
Environmentally correct - made
Sadagopan Seshadri,Chief - Content Development, CE - Infrastructure - Environment
METAL STANDINGSEAM ROOF SYSTEMSGoing from Strength to Strength
Snap-lock standing seam roof kit
tional seam and batten, tiles, shingles,
and shakes. They come in a variety of
styles and colours. Metal roofs with
solid sheathing control noise from rain,
hail, and bad weather just as well as any
other roofing material.
They have made their place in the
mass consumption market like indus-
trial, commercial and residential.
The basic material is cold rolled
steel sheets in appropriate thickness to
specific duty. Steel is available with vari-
ous yield strength from 240 MPa to 550
Mpa for roofing and cladding applica-
tions.
Building applications steel sheets
are corrosion protected with metallur-
gical coating of 180 gsm to 275 gsm gal-
vanizing. 'Zincalume' / 'Galvalume'
sheets have metallurgical protection of
55 per cent hot dipped coated alumi-
num, 43.5 per cent zinc and 1.5 per
cent silicon. The coating density is
either 150 gsm or 200 gsm. The zinc-
aluminum alloy coating provides excel-
lent corrosion resistance coupled with
sacrificial protection provided by the
zinc in the alloy.
Organic coatings provide an aes-
thetic finish to galvanized/ zincalume;
coating choice depends on the point of
end use environmental conditions. Dif-
ferent types of profiles are available
from using continuous roll forming tech-
nique.
Expansion and contraction inherent
to metal roofs are coped up by attach-
ing the SSR to the building's structure
with a special clip-and-tab assembly. As
tab can move within the clip, entire
roof can expand and contract freely so
that cracks, blisters and splits will not
appear on the built-up roofs. Sealing
SSR panels by an electric remote con-
trolled electric roll-forming machine is
Composition & Characteristics
METAL STANDING SEAM ROOF SYSTEMS: CRIMPING AND SEAMING OPERATIONS
Electric Seam Machine Double-lock Seaming
Standing Seam Roof
Metal Standing Seam Roof Systems: Going from Strength to Strength
Standing Seam Roof
92 The Masterbuilder - March 2011 93The Masterbuilder - March 2011
Standing Seam Benefits
Seamless system
No external through fixings
Low pitch Applications
Minimal maintenance
Range of finishes
Metal SSRs provide a secure weather tight solution that is designed to last. With minimal maintenance and maximum protection from the ele-ments, standing seam roof systems are widely used on public buildings from education to prisons, hospitals and data centres. Standing Seam systems are available in a range of external fin-ishes, meet and exceed Part L regula-tions and provide a very secure reliable roofing solution.
A standing seam metal roof boasts many qualities that account for its pop-ularity
Firstly, a standing seam roof
requires next to no maintenance, and
will not crack, shrink, erode, or perfo-
rate. Secondly, SSR provides extreme
weather protection, and is the most sta-
ble form of roofing during hurricanes. It
is about 50-100% recyclable, and is fire
resistant. SSRs reflect the sun rays, thus
reducing cooling costs. Being light-
weight it needs no additional framing,
translating into extra roof space.
And finally, a standing seam metal roof
is fairly quiet
SSRs installation is quick using snap-
lock standing seam roofing kits, making
it cost effective.
The dramatic rise in the popularity
of metal roofs arises from benefits it
provides to end users. Therefore there
has been a growing variety of metal
roof materials. Sheet materials like
stainless steel, copper, zinc, aluminum
and lead are inherently durable, the oxi-
dization of the base material forms a
protective patina. Modern steel roof
sheeting is coated with an alloy of zinc
and aluminum to give it some of the
durability of each of those materials at
a lower cost and higher strength than
either. Roofing is available as tradi-
SSRs: The Metal choice
Roofing forms a critical compo-
nent of the building envelope
protecting it from external ele-
ments, while playing an important role
in climate control, hazard mitigation,
and defining the aesthetic character of
a building. For all these reasons, it
becomes essential to keep pace with
the latest trends and technologies in
roofing.
Standing seam roof is a popular kind of metal roofing system used since the earlier periods when metal roofs were hand made from metals like cop-per or tin. A standing seam roof is con-structed from many interlocking panels that run vertically from the ridge to the eave of the roof. The interlocking seams where the two panels join together are raised above the roof's flat surface for easy water run-off. Standing seam roofing is suitable for either span-ning across purlins on typical spacing, or laid directly over rigid insulation and/or solid decking. Many combina-tions of panel widths, seam profiles, and rib heights provide extensive design flexibility, and standing seam roofing comes in a variety of styles and sizes to achieve an array of visual effects.
Standing seam roof or SSRs
an effective way to ensure perfect
weather tightness to roof. With this
machine the edges of connecting pan-
els can be bent together to form a
watertight seal. This roof system is
most reliable for large span buildings
Benefits of Metal Roofs in specific
can further be put as:
The Ultimate Benefits
Engineered for strength from 100%
metal
Air and water tight
Special coatings resist dirt and envi-
ronmental aging
less than 1/3 the weight of asphalt
sheeting
won't rot, crack, split, break or burn
Environmentally correct - made
Sadagopan Seshadri,Chief - Content Development, CE - Infrastructure - Environment
METAL STANDINGSEAM ROOF SYSTEMSGoing from Strength to Strength
Snap-lock standing seam roof kit
tional seam and batten, tiles, shin-
gles, and shakes. They come in a variety
of styles and colours. Metal roofs with
solid sheathing control noise from rain,
hail, and bad weather just as well as any
other roofing material.
They have made their place in the
mass consumption market like indus-
trial, commercial and residential.
The basic material is cold rolled
steel sheets in appropriate thickness to
specific duty. Steel is available with vari-
ous yield strength from 240 MPa to 550
Mpa for roofing and cladding applica-
tions.
Building applications steel sheets
are corrosion protected with metallur-
gical coating of 180 gsm to 275 gsm gal-
vanizing. 'Zincalume' / 'Galvalume'
sheets have metallurgical protection of
55 per cent hot dipped coated alumi-
num, 43.5 per cent zinc and 1.5 per
cent silicon. The coating density is
either 150 gsm or 200 gsm. The zinc-
aluminum alloy coating provides excel-
lent corrosion resistance coupled with
sacrificial protection provided by the
zinc in the alloy.
Organic coatings provide an aes-
thetic finish to galvanized/ zincalume;
coating choice depends on the point of
end use environmental conditions. Dif-
ferent types of profiles are available
from using continuous roll forming tech-
nique.
Expansion and contraction inherent
to metal roofs are coped up by attach-
ing the SSR to the building's structure
with a special clip-and-tab assembly. As
tab can move within the clip, entire
roof can expand and contract freely so
that cracks, blisters and splits will not
appear on the built-up roofs. Sealing
SSR panels by an electric remote con-
trolled electric roll-forming machine is
Composition & Characteristics
METAL STANDING SEAM ROOF SYSTEMS: CRIMPING AND SEAMING OPERATIONS
Electric Seam Machine Double-lock Seaming
Standing Seam Roof
94 The Masterbuilder - March 2011
from recycled material and are 100% recyclable
Energy efficient
many styles, colors and finishes to choose from
increase building's value
reduces the rate of corrosion
The main deterrent to choosing
metal roofing is the price per square for
metal roof, which is at par with pre-
mium roofing materials, i.e. not cheap
in terms of first cost. Metal roofing
costs more than asphalt, but it typically
lasts 2 to 3 times longer than asphalt.
Metal roofs are not seasonal, and should be looked at on basis of “fit & for-get” solutions that save owners main-tenance costs.
With conventional roofing like
asphalt, the fact of falling shingle or
water dripping resulting in recurring
maintenance & replacement costs can-
not be wished away. These costs keep
increasing as asphalt being a petro-
leum product, continues to get costlier
like gasoline. Roofing experts tie the
nationwide and regional increases to
rising oil prices, as most roofing materi-
And the flip Side
Prudence Pays
als are made of petroleum products.
Always remember: Roofing materi-
als made from Stainless Steel, Zinc or
Copper rarely require maintenance
over their lifetime commonly lasting
over a century. Any required mainte-
nance is usually due to design or instal-
lation mistakes.
Metals are here to stay for all the
right reasons, now that cost too is
expected to be on their side!
One of the greatest benefits of
metal roofing is its astounding energy
efficiency. The source of metal roofing
energy efficiency lies in its finish an
unpainted metal roof will reflect major-
ity of the solar radiation that is
absorbed by a roof and attic in a regular
asphalt roof. Painted and granular
coated metal roofing system both
Importance of Energy Benefits
reflect solar energy and re-emit
absorbed radiation such that it can also
cool your home. In warm climates, a
highly reflective and emissive metal
roof is capable of re-emitting up to 90
percent of absorbed solar radiation,
and in doing so, greatly reducing
energy consumption. It has been calcu-
lated that the installation of a reflective
metal roof can save approximately 40
percent of cooling costs throughout
summer.
The most typical roof system in
India is the Hydrostatic i.e. Water Bar-
rier System designed to resist the pas-
sage of water at joints, laps and junc-
tures under hydrostatic pressure. In
addition, the roof system needs the
strength and capability of spanning
structural members such as circular/
square/rectangular hollow sections,
Metal SSR systems: Indian context
Recyclable seam roof system Special coatings on seam roofs
Metal Standing Seam Roof Systems: Going from Strength to Strength
Standing Seam Roof
Traditional RoofingMaterials absorb the
sun's rays.
Metal Roofing reflectsthe sun's rays away from
the roof.
Action Construction Equipment Ltd
96 The Masterbuilder - March 2011
is particularly suitable for situations
where long lengths need to be roofed
and clad. The system combines fluted
pans with a lock-action rib design and
has concealed fastening. This means
the roof sheeting does not need to be
pierced and the ribs make the profile
stronger.
Butler has billions of square feet of
constructed or retrofitted facilities. Its
MR-24® roof system is particularly
suited for wide buildings subjected to
roof movement induced by tempera-
ture change. A unique fastening
method, incorporated into the steel
panels seams allows MR-24 to accept
expansion and contraction freely with-
out compromising the structural integ-
rity. MR-24 system accounts for most
roofs in the US and is on 40 percent of
projects in India with Butler buildings.
MBCI an operating division of NCI
Group based in Houston (Texas) is
another major player manufacturing
quality metal products with a large
product selection , full engineering and
design capabilities. MBCI offers more
than 90 different metal roof and wall panel
profiles, along with secondary structu-
rals, trim and related accessory items.
MBCI's offers six most durable and
weather tight standing seam metal roof
systems roof systems with 4 types in
vertical leg structural standing seam
metal roof systems and 2 types trape-
zoidal structural standing seam metal
roof systems.
Vertical Leg Structural Standing
Seam Metal Roof Systems are
LokSeam®, BattenLok® HS, SuperLok®
and Curved BattenLok® with several UL
uplift ratings, assuring the reliability of
performance and also providing flexi-
bility to meet design challenges.
Each of these four SSRs is designed to be installed over open framing. LokSeam® must be installed on roof slopes of 3:12 or greater, BattenLok® HS and SuperLok® on roof slopes of ½:12 or greater while Curved BattenLok® can be installed on Radii down to 20'.
Trapezoidal Structural Standing Seam Metal Roof Systems are the snap-together system, Ultra-Dek®, and field-seamed system, Double-Lok®.
The standing seams are three inches above the lowest part of the panel, well above the water level as it flows off the roof. The rake/gable at both ends of each roof system finish with a 3-inch high standing seam, avoiding the necessity of finishing in the low, flat part of the panel where the greatest possibilities for leaks occur in many other systems.
channels, angles etc. acting as purlins
without support of any solid roof deck.
In achieving this, the roof covering also needs to act as a Hydrokinetic Sys-tem i.e. Water Shedding System in view of the heavy rainfall that is encoun-tered in large parts of the country, par-ticularly the N-E, E, S-E, S and S-W. The Central and Northern regions being lower rainfall zones, do adopt slope roofs of 1:6 or less, but, in general, slopes of 1:4 to 1:2.5 are recom-mended by the Bureau of Indian Stan-dards with slopes in snowfall areas as steep as 1:2, for smaller spans.
The opening up of the economy led to increased investment in sectors including infrastructure, manufactur-ing, warehousing facilities, residential and commercial buildings. Tata BlueScope, PEBS Pennar, Kirby, SML, Everest, Supertech and many others have hopped into the PEB bandwagon with off-shore affiliations or indige-nous improvised designs of which SSR systems form an essential part of build-ing envelope.
B ig p layers l i ke Aust ra l ian BlueScope Steel Limited forged equal partnership with Tata Steel, setting up Tata BlueScope Steel with two business divisions. Its products are metallic coat-ings that include Galvalume® coating technology and pre-painted steel; pre-engineered buildings (PEB) led by But-ler and steel components like roof sys-tems; wall panels and others for com-mercial construction. Their manufac-turing facilities are in Pune, Chennai and Bhiwadi.
Different companies have devised
their own systems and offer unique
advantages or qualities to this basic
combination of elements. Tata
Bluescope Steel's Lysaght®system
offers the KLIP-LOKTM mechanism that
The Players
The Pittsburgh double-lock standing seam produces exceptional weather tightness
Metal Standing Seam Roof Systems: Going from Strength to Strength
Standing Seam Roof
Action Construction Equipment Ltd
98 The Masterbuilder - March 2011
Ultra-Dek® and Double-Lok® panels
can be installed before or after the exte-
rior walls are in place. All trim is
attached after the roof is installed. With
a recommended minimum slope of
¼:12, these standing seam metal roof
systems can be used on all types of con-
struction, including metal, masonry or
wood, for either new construction or
retrofit.
All of MBCI's standing seam metal
roof systems are concealed fastened
systems. A choice of concealed fas-
tened clips hold the panels firmly in
place with the ability to accommodate
thermal movement.
The sliding clip in the Ultra-Dek® and Double-Lok® allows for thermal movement. A 4-inch sliding clip in the Double-Lok®, can eliminate roof steps on a double slope building up to 900 feet wide or a single slop building up to 450 feet wide!!
Each SSMR system carries the Underwriters Laboratories Fire Resis-tance and Wind Uplift (UL 90) ratings covering a wide range of roof designs. Double-Lok® and SuperLok® meet rat-ings per FM Global Corporation Stan-dard 4471. The BattenLok® HS, SuperLok®, Curved BattenLok® and Double-Lok® conform to requirements in CEGS 07416 / ASTM E 1592 Standing Seam Metal Roof System guide specifi-cation.
Special clips are available allowing
for thermal roof expansion and con-
traction during extreme temperature
changes. All trim is both weathertight
and aesthetically pleasing, giving the
roof a nice finished appearance.
Factory-applied sealant in the panel
sidelap ensures a tight, secure
weathertight lap whether it is a snap-
Uplift Ratings
Weathertight Roof Systems
together or field-seamed system.
PEBS Pennar brings international
standards to the Indian market with its
technical know-how agreement ® with
the NCI Group Inc., USA, to offer the
Double-Lok leakproof Standing Seam
Roofing System,
The Double-Lok® roof panel is a
mechanically field-seamed, trape-
zoidal leg standing seam roof system.
Double-Lok® panels are available in 12-
inch, 18-inch and 24-inch widths. Dou-
ble-Lok® requires a minimum slope of
¼:12. Double-Lok® panels are ideal for
industrial, commercial and architec-
tural applications. PEBS Pennar offers
this product in India.
50% complaints in steel buildings
relate to roofing components and
water infiltration problems PEBS
Pennar uses the Double-Lok® System
world-class standing seam technology
by MBCI ( NCI Group Inc., USA) & its
weather tightness advantages makes it
the favored choice for India.
Bead Mastic for roofing side and
end laps. Bead mastic, when
Double-Lok®
PEB PENNAR MBCI advantage
installed properly, provides the best
guarantee against roof leaks. Not all
PEB manufacturers in this region
use this technique
Roll-formed aesthetic Downspouts
with longitudinal full length corru-
gations in one piece upto 12 M
length reduce number of field joints
Supply of valley gutters of 1.5mm
thickness upto lengths of 6 M,
reduce number of joints. The epoxy
primer on the exposed valley gutter
face imparts long-term corrosion-
free surface.
Similarly, Kirby's Standing Seam Roofing System (KSS-600) is tested and approved by FM Global, USA and has double lock standing seam ends which provides 100% leak proof buildings with faster installation.
Not only can low slope metal roof-ing contribute to the bottom line, it can also contribute to LEED credits, which are awarded to buildings that use high recycled content and other “green” con-struction materials. A typical low slope metal roof has at least 25% recycled content, and at the end of its long use-ful life is 100% recyclable.
Conclusion
Panel Profiles
Double-Lok® Product Information
Coverage Width 12”, 18”, 24”
Minimum Slope ¼:12
Panel Attachment Concealed Fastening System; Low, High, Fix and Sliding and a 2” stand off clip
Finishes Smooth (standard); Embossed (optional)
Coatings Galvalume Plus®, Signature® 200,Signature® 300, Signature® 300 Metallic
Metal Standing Seam Roof Systems: Going from Strength to Strength
Standing Seam Roof
Action Construction Equipment Ltd
Factory Office Complex
Multistory Showroom
Aircraft hangarStadia
Cold storage Warehouse
100 The Masterbuilder - March 2011
Metal Standing Seam Roof Systems: Going from Strength to Strength
Standing Seam Roof
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 Profess ional in large nat ional & International Companies. His domain expe-rience 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 devel-opment He is vocal with his views on these areas through his writings.
He can be reached at [email protected]
In the area of roofing, to receive LEED Sustainable Sites Credit 7.2, at least 75% of the surface of a roof must use materials having a Solar Reflective Index (SRI) of at least 78,met by vege-tated roof on 50% of the roof area, or installing a high albedo and vegetated roof combination, meeting the for-mula: (Area of SRI Roof/0.75)+(Area of vegetated roof/0.5) = Total Roof Area.
Typically, low slope metal roof sys-tems being among the lightest roofing products place fewer demands on a building's structural support system, an important consideration in earth-quake-prone areas. Because of their interlocking or active fastening sys-tems, metal roof panels are designed to meet the requirements of ASTM E1592, UL 580, UL1897 and other severe wind and uplift tests.
While the idea of protecting a build-ing with metal originated centuries ago, the concept is still valid today. Whether the goal is many years of low-cost, low maintenance, problem-free performance, or an environmentally res-ponsible approach to roofing, low slope metal roofs make a lot of sense.
Razon Engineering Company P.Ltd
?????????
102 The Masterbuilder - March 2011
and waterproof a roof; they can also
improve reflectivity and emissivity
while reducing thermal shock. Coat-
ings can extend the life of low-slope
and flat commercial roof types for
many years while reducing energy con-
sumption, thus saving the owner more
money. With high-energy costs here to
stay and building energy efficiency stan-
dards tightening, qualified reflective
roof coatings will remain as one of the
most effective and most economical
ways to meet or exceed these emerging
standards.
Elastomeric roof coating can extend
a roof's life by creating a UV light bar-
rier, which prevents substrate degrada-
tion; providing low-temperature flexi-
bility; developing a high degree of adhe-
sion; and reducing daytime roof tem-
peratures. And the choice of high-
quality coatings, as designated by
ASTM (American Society for Testing
and Materials) performance standards,
can assure long-term performance and
protection of the roofing substrate.
Elastomeric roof coatings are help-
UV Light Barrier
elastomeric roof coatings. These dura-
ble liquid coatings prolong the life of
the existing roof. In fact, elastomeric
roof coatings have been used since the
early 1980s over multiple roof types,
including built-up roofing , modified
bitumen, metal, cement and wood.
Many white-coated roofs exist today
with excellent adhesion and high solar
reflectance more than 20 years after
their initial application.
An elastomeric roof coating creates
a uniform, seamless surface that
remains flexible even at low tempera-
tures. It expands and contracts with
changing weather conditions, protect-
ing a roof's surface from the sun's dam-
103The Masterbuilder - March 2011
Cool Roof Coatings
low-sloping roof, including metal ones.
(Elastomers are materials, usually syn-
thetic, having elastic properties i.e.,
capable of recovery from severe defor-
mation. Examples include natural rub-
ber and polyisoprene.)
Coatings these days play a useful role in the maintenance of all types of roofing substrates. They can be used to extend the service life of an existing sys-tem in nearly any environment, and in warmer climates they can offer signifi-cant energy savings.
The building industry around the
world is experiencing a greater sensi-
tivity to environmental concerns, like
energy shortages and energy savings.
These are influencing demands for
field-applied roof coatings that deliver
cool roofs for energy savings as well as
sustainability.
Most recently, the trend towards
cool roofing has favored the selection
of highly reflective and emissive coat-
ings for use over metal architects, engi-
neers and owners have become aware
of their value in reducing air-
conditioning requirements while pro-
viding a highly effective defense
against the elements.
Building owners and facility manag-
ers now realise the lasting benefits of
Lasting benefits
Reflective roof coatings remain
the fastest-growing product seg-
ment in the fluid-applied roof-
ing market. 'Cool roof' coatings can
lower energy consumption (a key goal
of building owners and facility manag-
ers) as well as meet stringent cool roof
performance requirements in the
building codes.
While it is true that the high solar
reflectivity and emissivity of white
elastomeric coatings can cut down on
air-conditioning costs, these products
do a lot more than just save energy.
The elastomeric coatings can restore
and protect most waterproofing sys-
tems and prolong the life of almost any
aging rays. This enables the coating to
handle the continual thermal stresses
over the lifetime of the roof. Its adhe-
sion characteristics enable the coating
to remain attached to the roof in wet or
extremely windy conditions. Such a
coating employs technology that helps
maintain energy-saving reflectance
qualities, as well as a bright, clean
appearance.
Finding ways to increase the service
life of roofs makes sense to owners and
reduces the waste generated by roof
tear-offs. Statistics compiled by the
U.S. Department of Energy and the Envi-
ronmental Protection Agency show
that waste generated from roof tear-
offs accounts for 15 to 20 per cent of
total landfill waste. By coating and
maintaining roofs, one can dramati-
cally increase the years of service they
can provide.
For most roof systems, coatings
renew the integrity of the surface of
the roof by filling in cracks and replac-
ing weathered and worn areas. Roof
coatings reinforced with membranes
such as polyester or fiberglass can seal
Versatile Coatings forVersatile Coatings forToday's Roof SystemsToday's Roof SystemsAchal Narayanan
Metal Roofs with Reflective Coating
?????????
102 The Masterbuilder - March 2011
and waterproof a roof; they can
also improve reflectivity and emissivity
while reducing thermal shock. Coat-
ings can extend the life of low-slope
and flat commercial roof types for
many years while reducing energy con-
sumption, thus saving the owner more
money. With high-energy costs here to
stay and building energy efficiency stan-
dards tightening, qualified reflective
roof coatings will remain as one of the
most effective and most economical
ways to meet or exceed these emerging
standards.
Elastomeric roof coating can extend
a roof's life by creating a UV light bar-
rier, which prevents substrate degrada-
tion; providing low-temperature flexi-
bility; developing a high degree of adhe-
sion; and reducing daytime roof tem-
peratures. And the choice of high-
quality coatings, as designated by
ASTM (American Society for Testing
and Materials) performance standards,
can assure long-term performance and
protection of the roofing substrate.
Elastomeric roof coatings are help it
UV Light Barrier
elastomeric roof coatings. These
durable liquid coatings prolong the life
of the existing roof. In fact, elastomeric
roof coatings have been used since the
early 1980s over multiple roof types,
including built-up roofing , modified
bitumen, metal, cement and wood.
Many white-coated roofs exist today
with excellent adhesion and high solar
reflectance more than 20 years after
their initial application.
An elastomeric roof coating creates
a uniform, seamless surface that
remains flexible even at low tempera-
tures. It expands and contracts with
changing weather conditions, protect-
ing a roof's surface from the sun's
103The Masterbuilder - March 2011
Cool Roof Coatings
low-sloping roof, including metal
ones. (Elastomers are materials, usu-
ally synthetic, having elastic properties
i.e., capable of recovery from severe
deformation. Examples include natu-
ral rubber and polyisoprene.)
Coatings these days play a useful role in the maintenance of all types of roofing substrates. They can be used to extend the service life of an existing sys-tem in nearly any environment, and in warmer climates they can offer signifi-cant energy savings.
The building industry around the
world is experiencing a greater sensi-
tivity to environmental concerns, like
energy shortages and energy savings.
These are influencing demands for
field-applied roof coatings that deliver
cool roofs for energy savings as well as
sustainability.
Most recently, the trend towards
cool roofing has favored the selection
of highly reflective and emissive coat-
ings for use over metal architects, engi-
neers and owners have become aware
of their value in reducing air-
conditioning requirements while pro-
viding a highly effective defense
against the elements.
Building owners and facility manag-
ers now realise the lasting benefits of
Lasting benefits
Reflective roof coatings remain
the fastest-growing product seg-
ment in the fluid-applied roof-
ing market. 'Cool roof' coatings can
lower energy consumption (a key goal
of building owners and facility manag-
ers) as well as meet stringent cool roof
performance requirements in the
building codes.
While it is true that the high solar
reflectivity and emissivity of white
elastomeric coatings can cut down on
air-conditioning costs, these products
do a lot more than just save energy.
The elastomeric coatings can restore
and protect most waterproofing sys-
tems and prolong the life of almost any
aging rays. This enables the coating
to handle the continual thermal
stresses over the lifetime of the roof. Its
adhesion characteristics enable the
coating to remain attached to the roof
in wet or extremely windy conditions.
Such a coating employs technology
that helps maintain energy-saving
reflectance qualities, as well as a bright,
clean appearance.
Finding ways to increase the service
life of roofs makes sense to owners and
reduces the waste generated by roof
tear-offs. Statistics compiled by the
U.S. Department of Energy and the Envi-
ronmental Protection Agency show
that waste generated from roof tear-
offs accounts for 15 to 20 per cent of
total landfill waste. By coating and
maintaining roofs, one can dramati-
cally increase the years of service they
can provide.
For most roof systems, coatings
renew the integrity of the surface of
the roof by filling in cracks and replac-
ing weathered and worn areas. Roof
coatings reinforced with membranes
such as polyester or fiberglass can seal
Versatile Coatings forVersatile Coatings forToday's Roof SystemsToday's Roof SystemsAchal Narayanan
Metal Roofs with Reflective Coating
104 The Masterbuilder - March 2011
ing to drive a better energy initiative
across the United States and around
the world. When the U.S. specialty
materials company Rohm and Haas
(founded a century ago in Philadelphia)
set out to apply elastomeric coatings
technology to roofing, it could have
restricted its focus to meet only the
immediate need for durability.
Instead, it raised its sights and raised
the roof to a new standard of perfor-
mance, durability, functionality and
eco-friendliness.
Elastomeric coatings, now recog-
nised as key components of the build-
ing industry, enhance structural integ-
rity, reduce maintenance, increase lon-
gevity, improve energy efficiency, and
provide significant, immediate and lon-
ger-term environmental benefits.
The use of solar-reflective (cool)
urban surfaces is a comparatively inex-
pensive measure that can reduce sum-
mertime temperatures. A reflective
roof is typically light in colour and
absorbs less sunlight than does a con-
ventional dark-coloured roof. Thus,
reflective roofs reduce air-conditioner
use and increase occupant comfort lev-
els. Cool roof technologies include coat-
ings, membranes, tiles and shingles.
Light-coloured building surfaces
are a time-honoured technique of stay-
ing cool in the Mediterranean, the
Caribbean and other sun-drenched
regions. Roofing materials with a high
solar reflectance (called albedo) can
reflect up to 85 per cent of incident
solar radiation, compared to normal
surfaces which may reflect only 20 per
cent. For commercial applications, flat
and poorly insulated roofs are the best
candidates for high-albedo materials.
Of special interest to India are the
findings of a case study undertaken a
few years ago at the Satyam Technol-
ogy Centre (STC) in Hyderabad. In a
demonstration sponsored by the U.S.
Agency for International Development
in 2006, the installation of a white roof
coating reduced the average summer-
time daily maximum roof-surface tem-
perature of a two-storey office build-
ing at the STC's training centre from 52
deg. C to 32 deg. C. The total air-
conditioning energy use was thereby
reduced by 30 kWh/day (5 per cent on
hot days and 8 per cent on average
days).
Significant cost-effective a/c elec-
tricity and peak load savings and
increased comfort levels can be real-
ised by installing such cool roofs on
industrial and commercial buildings
like malls, hospitals, offices, hotels, etc.
and residential premises in India.
A number of companies in India are
now engaged in the manufacture and
supply of roof coatings and other
related products. Some of them also
export these products.Roof Tear Off
Roof with protective coating
Versatile Coatings for Today's Roof Systems
Cool Roof Coatings
Bomanite India
In the United States, the Roof Coat-
ings Manufacturers Association
(RCMA) is the national trade associa-
tion representing the manufacturers of
cold-applied coatings and cements
used for roofing and waterproofing, as
well as the suppliers of products,
equipment, and services to and for the
industry. Founded in 1983, RCMA is
dedicated to advancing product tech-
nology and to ensure an ongoing sup-
ply of quality energy-efficient materials
to meet the needs of contractors and
consumers. Currently, the Association
has more than 70 companies as mem-
bers.
RCMA is working to set the record
straight about energy-efficient coat-
ings. Its membership represents manu-
facturers and raw material suppliers of
energy-efficient coatings that can be
considered part of a cool roofing solu-
tion. The Association believes that
'cool roofing' is not just white. There is
a full complement of colours, including
aluminum (silver/grey in colour) in a
bituminous asphalt base and various
white coatings that have been tinted
Not just white
with pigments that can be classified as
energy-efficient coatings.
According to RCMA, many of the
newer high-reflectivity aluminum and
coloured roof coatings can perform just
as well as, or better than, white coatings.
Tom Meyer of RCMA's Solar Reflective
Coatings Council, said: “In the past few
years, technological advances have rap-
idly moved the roof coating industry
beyond white to include a multitude of
high-performing coloured coatings and
silver aluminum bituminous coatings.”
While reflective roof coatings can
reduce energy consumption or
increase roof life for buildings with low-
sloped or flat roofs, Meyer said optimal
energy efficiency and sustainability
required looking at more than just a
whiteness factor. “Selecting the appro-
priate roofing system requires a thor-
ough consideration of climate, a build-
ing's location, installation specifics, aes-
thetics, insulation and other factors.
There is no single answer. White may
be the solution for one building, with
aluminum or coloured coating the best
for another,” he added.
White roofs were in the headlines
sometime ago when the U.S. Energy
Secretary, Dr. Steven Chu, suggested
painting the roofs of all buildings white
to reduce carbon dioxide emissions
and save energy used for cooling. Dr.
Chu's statement was criticised in many
quarters for ignoring energy and other
offsetting factors and costs in non-
temperate climes.
“The benefits of reflective roof coat-
ings are very real, but there needs to be
a reasoned approach and an under-
standing that there are many coating
types available to meet the nation's var-
ious building energy and sustainability
objectives,” said James Baker, RCMA's
director of industry affairs. “We're urg-
ing regulators and green building advo-
cates to be cautious and not increase
reflectivity requirements faster than
the technology will allow,” he added.
Cool roofs have nevertheless been
widely adopted in the United States.
All but a handful of the country's 50
states have established regulations and
/or incentives to encourage roofing of
this type.
Tom MeyerRCMA Council Member
“In the past few years, technological advances have rapidly moved the roof coating industry beyond white to include a multitude of high-performing coloured coatings and s i lver aluminum bituminous coatings.”
106 The Masterbuilder - March 2011
Aluminum Roof Sheets
Versatile Coatings for Today's Roof Systems
Cool Roof Coatings
Universal Construction Machinery
Roofing: Material Focus?????????
108 The Masterbuilder - March 2011
because of their versatility, aesthetics,
and application.
Zinc is the 27th most common natu-
rally occurring element in the world. It
is found in galvanized steel, batteries,
and brass. Even the human body is
depending on zinc for certain biological
functions such as fertility, vision, and
A Natural
109The Masterbuilder - March 2011
while being almost a standard in cer-
tain other parts of the globe. Zinc is one
such material. A cursory glance over
the Parisian skyline would convince any-
one of this paradox. Paris, under the
reign of Napolean III in the mid-1800s
was transformed into a city of almost
exclusively zinc roofs. Two hundred
years later, some of the original roofs
still crown historic buildings in the city.
Although Zinc made its appearance
in the United States around 1816, it
could not make as dramatic an impact,
as it had done elsewhere in Europe.
However, things are now gradually
changing. Zinc roofing is being seri-
ously looked into as an alternative in
most parts of the world, including
India. Zinc roofing strips are fast
becoming an architect's favorite,
The increasing emphasis on sus-
tainable building strategies has
meant that engineers today are
looking at both new materials and
quite a few other materials that have
been for long considered 'non-
traditional' in order to meet green
building standards. There are some
materials, that are considered 'non tra-
ditional' in some parts of the world,
ZINC ROOFINGZINC ROOFINGSustainable Roofing OptionSustainable Roofing OptionComes Back into LimelightComes Back into Limelight
cell production. Engineers in the 1800s
had discovered that zinc had certain
attractive benefits. For one, zinc sheet-
ing is highly malleable; it's durable and
almost completely recyclable.
The substance that gives zinc roof-
ing strips the distinct hue is known as
'patina'. It is actually a layer of zinc
hydroxycarbonate that forms on the
surface of the material when it is
exposed, in the presence of carbon
dioxide, oxygen, and water. The
patina's structure consists of a compact
protective layer, which strongly
adheres to the zinc beneath it. The
patina protects zinc from atmospheric
corrosion and also does not dissolve
easily in rainwater. Patinated metals
are generally considered naturally heal-
ing and long lasting. There are
instances in Europe when zinc roofing
strips are installed with the patina
already created, which is said to
enhance the longevity of the roof,
along with preventing accelerated cor-
rosion.
Patina
As 'Green' as they Come
In today's age of sustainable build-
ing strategies and green rating systems,
zinc roofing's potential can no longer
be underestimated. Today the use of
rolled zinc can contribute to obtaining
LEED certification under the Materials
and Resources category. The fact that
rolled zinc is 100 percent recyclable
also adds to the attraction of zinc roof-
ing as a preferred choice. Architectural
grade zinc sheeting is a mix of titanium,
copper, and zinc. This combination
helps in maximizing the tensile
strength of the roof, apart from helping
in improving malleability.
The combination also helps in
improving the innate resilience of this
wonder metal. There are scores of
buildings around Europe, where zinc
roofing has lasted for well beyond 100
years, compared to the 25 odd years for
those with asphalt shingles. The patina
forming characteristic of zinc, which
gives it the self-healing property con-
tributes to the durability and longevity
of the roofing strips.
M.K. Prabhakar
Zinc roofing dominates the Parisian skyline
Roofing: Material Focus?????????
108 The Masterbuilder - March 2011
because of their versatility, aesthet-
ics, and application.
Zinc is the 27th most common natu-
rally occurring element in the world. It
is found in galvanized steel, batteries,
and brass. Even the human body is
depending on zinc for certain biological
functions such as fertility, vision, and
A Natural
109The Masterbuilder - March 2011
while being almost a standard in cer-
tain other parts of the globe. Zinc is one
such material. A cursory glance over
the Parisian skyline would convince any-
one of this paradox. Paris, under the
reign of Napolean III in the mid-1800s
was transformed into a city of almost
exclusively zinc roofs. Two hundred
years later, some of the original roofs
still crown historic buildings in the city.
Although Zinc made its appearance
in the United States around 1816, it
could not make as dramatic an impact,
as it had done elsewhere in Europe.
However, things are now gradually
changing. Zinc roofing is being seri-
ously looked into as an alternative in
most parts of the world, including
India. Zinc roofing strips are fast
becoming an architect's favorite,
The increasing emphasis on sus-
tainable building strategies has
meant that engineers today are
looking at both new materials and
quite a few other materials that have
been for long considered 'non-
traditional' in order to meet green
building standards. There are some
materials, that are considered 'non tra-
ditional' in some parts of the world,
ZINC ROOFINGZINC ROOFINGSustainable Roofing OptionSustainable Roofing OptionComes Back into LimelightComes Back into Limelight
cell production. Engineers in the
1800s had discovered that zinc had cer-
tain attractive benefits. For one, zinc
sheeting is highly malleable; it's dura-
ble and almost completely recyclable.
The substance that gives zinc roof-
ing strips the distinct hue is known as
'patina'. It is actually a layer of zinc
hydroxycarbonate that forms on the
surface of the material when it is
exposed, in the presence of carbon
dioxide, oxygen, and water. The
patina's structure consists of a compact
protective layer, which strongly
adheres to the zinc beneath it. The
patina protects zinc from atmospheric
corrosion and also does not dissolve
easily in rainwater. Patinated metals
are generally considered naturally heal-
ing and long lasting. There are
instances in Europe when zinc roofing
strips are installed with the patina
already created, which is said to
enhance the longevity of the roof,
along with preventing accelerated cor-
rosion.
Patina
As 'Green' as they Come
In today's age of sustainable build-
ing strategies and green rating systems,
zinc roofing's potential can no longer
be underestimated. Today the use of
rolled zinc can contribute to obtaining
LEED certification under the Materials
and Resources category. The fact that
rolled zinc is 100 percent recyclable
also adds to the attraction of zinc roof-
ing as a preferred choice. Architectural
grade zinc sheeting is a mix of titanium,
copper, and zinc. This combination
helps in maximizing the tensile
strength of the roof, apart from helping
in improving malleability.
The combination also helps in
improving the innate resilience of this
wonder metal. There are scores of
buildings around Europe, where zinc
roofing has lasted for well beyond 100
years, compared to the 25 odd years for
those with asphalt shingles. The patina
forming characteristic of zinc, which
gives it the self-healing property con-
tributes to the durability and longevity
of the roofing strips.
M.K. Prabhakar
Zinc roofing dominates the Parisian skyline
Yet another factor that makes zinc
roofing an attractive proposition is the
fact that the metal is 100 percent recy-
clable. It is estimated that around 95
percent of the initial energy content is
conserved in the case of recycled zinc.
Moreover, it also makes economic
sense since the metal is almost always
in demand and an estimated 90 per-
cent of the zinc that is put up in the recy-
clable material market is sold out. Con-
versely, annually an estimated 9 million
metric tons of asphalt shingles are
reported to end up in landfills. The toxic
chemicals present in the shingles then
leach into the soil, creating havoc with
the environment, particularly ground-
water sources.
Another remarkable property of
zinc lies in the fact that it is highly corro-
sion resistant, whether it is in a marine
environment or inland. The metal com-
bines with salt in the marine environ-
ment to form zinc oxychloride (Zn2 O
C12). The substances then wash of the
surface easily forming the characteris-
tic blue-gray patina. The corrosion
rates of zinc vary between 0.5µm and
1.0µm per year. Generally, the corro-
sion rates are found to be higher in
highly industrialized areas where sulfur
dioxide concentration in the atmo-
sphere is high.
There could be corrosion issues
forming from the underside of roofing
sheets, if moisture is allowed to con-
dense beneath them. It is usually rec-
ommended for this reason to allow for
a drainage layer directly below the zinc
roofing for allowing moisture not to get
trapped and escape freely. Some manu-
Corrosion Factor
As a building material, zinc offers
several advantages, starting right from
the stage when it is mined from deep
beneath the earth's crust. For one the
amount of energy that is used to
produce zinc from its ore is the lowest
among all non-ferrous metals. The
e n e r g y c o n s u m p t i o n r e d u c e s
drastically in the case of zinc that is
produced from recycled material,
making it one of the most 'natural' of
building materials.
The primary energy that is required
to manufacture zinc roofing sheets is
again, substantially lower than most
other alternatives. This is because of
the fact that zinc has a relatively low
melting point of approximately 785 F,
which in turn means that a relatively
lower amount of fuel is required to
extract, smelt, alloy, roll, and fabricate
the metal. The primary energy content
of the metal is in fact lesser than that of
stainless steel, copper, and aluminum.
In fact, two times the energy is required
for the other comparative materials.
Moreover, the concentration of zinc
ore is higher as compared to other ores
in their respective ores.
110 The Masterbuilder - March 2011
Zinc Roofing: Sustainable Roofing Option Comes Back into Limelight
Roofing: Material Focus
Zinc roofing allows for easy installation of secondary components like light inlets on the roof structure
Architectural grade zinc has high tensile strength, remarkably malleable and corrosion resistant
Tac System Formwork Sdn Bhd
facturers also recommend venting the
zinc roof strips with panels, along with
a layer of protective coating on the
underside of the sheets.
Although a relatively simple pro-
cess, zinc roof installation is best done
by the manufacturer's authorized per-
Zinc Roof Installation
sonnel. Some of the key factors that
need to be taken into consideration for
proper installation of zinc roof strips
are physic-chemical compatibility, geo-
metrical continuity and project struc-
tural conformity. A thorough roof
inspection in order to adhere to these
conditions is a must before the installa-
tion process begins.
Future
Metal roofing as a concept is fast
becoming a preferred option globally.
In India too, no longer is metal roofing
limited to warehouses and factories.
With the boom in infrastructure and
real estate projects, metal roofing is
finding wide ranging applications. Zinc
roofing strips could play a crucial role in
the industry, what with the rising
emphasis on eco-friendly building
materials. While cost may be the inhib-
iting factor right now, with increase in
competition, it could soon be a thing of
the past. Moreover, the fact that low
maintenance and durability of zinc
mean that the longevity factor out-
weighs the initial price difference, mak-
ing it one of the preferred choice, when
it comes to roofing solutions. With
increasing endorsement from the
architectural and engineering frater-
nity, zinc could well become the roofing
metal to watch out for in the near
future.
A row of zinc roofs with the typical zinc ‘Patina’ on them
Zinc roofing is ideally suited for complex structural shapes
114 The Masterbuilder - March 2011
Zinc Roofing: Sustainable Roofing Option Comes Back into Limelight
Roofing: Material Focus
Nina Concrete Systems Pvt.Ltd
m a r ke t l e a d e r s h i p . S p e a k i n g exclusively to the Masterbuilder, Mr.Raja Gana Nathar gave insights into what makes the company's products and services special. Here are excerpts from the interview.
Pre-engineered buildings are preferable for their advantages such as cost-effectiveness, wider spans without intermediate columns, factory controlled quality, better stability due to framed action, easy and faster construction, and better earthquake resistance, etc, among others.
Moreover, the lightweight of the structures ensures better protection against earthquakes.
Latest software development has made it easy to analyze and ascertain any structure for their ability to perform under actual conditions, which leads to optimum design and
better stability.
Computer aided technology resulted in hi-tech machineries
What are the advantages of Pre-E n g i n e e r e d B u i l d i n g s o v e r conventional systems?
How has Computer Aided Design helped in increasing the popularity of PEB systems?
leading to quality and quantity manufacturing of built-up sections and other components, thereby reducing unwanted loss and saving time in the process.
In western countries, multi-storey buildings are very popular due to their fast and easy construction. Composite constructions actually reduce self weight which leads to reduction in frame and foundation loadings.
Longer spans with fewer columns allow for more space and deck profile provides safe working platform. Moreover, PEB systems have also got better earthquake resistance.
We provide complete design from the foundation to superstructure and undertake responsibility for safety of structures. We additionally provide stability certificate for structures to our clients. We thoroughly analyze every client's unique requirements and based on the product and process equipment involved we provide better specification for their building with su i tab le vent i lat ion , handl ing
Are PEB systems preferable for multi-storied construction?
How are the products and services offered by your company different from others?
Profile
145The Masterbuilder - March 2011
G.V.Engineering & Co: Offering Top of the line PEB Solutions
Profile
G.V.Engineering & Co is a versatile engineering firm that specializes in Pre-Engineered
Buildings, Multi-storey Steel Buildings, Industrial Structures, etc. The company's growth story has been driven by its firm commitment to the latest technology and advanced software, which has seen it successfully complete several major projects, globally.Ably led by Mr.Raja Gana Nathar-B.E,.M.K.S.E,. a technocrat with over two decades of experience, G.V.Engineering & Co, has been forging ahead in its journey towards attaining
G.V.Engineering & Co Offering Top of the line PEB Solutions
Raja Gana Nathar B.E.,M.K.S.E,Managing Director, G.V.Engineering & Co Raja Gana Nathar B.E.,M.K.S.E,Managing Director, G.V.Engineering & Co
144 The Masterbuilder - March 2011
equipment and other statutory requirements.
Some of our hi-tech projects include:
Utech Elsewedy Project in Riyadh, Saudi Arabia is one.
Chemical storage warehouse Sabic- 72 clear span with 29 m rid height.
Pipe rack and platform Fahud Station in Muscat for the Petroleum Development Corporation of Oman.
BCCI commercial complex in Bahrain. We have done the conceptual design for the 23 storey steel building.
We also provide consultancy services for PEB plant construction, textile mills, etc. We have a special project division for refinery projects and have handled many projects for P.D.O (Muscat), KNPC Kuwait, etc.
Visit us at:
Give us a few examples of your major
projects.
What are the other services that you provide?
www.gvcon.com
GV Engineering & Co.,
m a r ke t l e a d e r s h i p . S p e a k i n g exclusively to the Masterbuilder, Mr.Raja Gana Nathar gave insights into what makes the company's products and services special. Here are excerpts from the interview.
Pre-engineered buildings are preferable for their advantages such as cost-effectiveness, wider spans without intermediate columns, factory controlled quality, better stability due to framed action, easy and faster construction, and better earthquake resistance, etc, among others.
Moreover, the lightweight of the structures ensures better protection against earthquakes.
Latest software development has made it easy to analyze and ascertain any structure for their ability to perform under actual conditions, which leads to optimum design and
better stability.
Computer aided technology resulted in hi-tech machineries
What are the advantages of Pre-E n g i n e e r e d B u i l d i n g s o v e r conventional systems?
How has Computer Aided Design helped in increasing the popularity of PEB systems?
leading to quality and quantity manufacturing of built-up sections and other components, thereby reducing unwanted loss and saving time in the process.
In western countries, multi-storey buildings are very popular due to their fast and easy construction. Composite constructions actually reduce self weight which leads to reduction in frame and foundation loadings.
Longer spans with fewer columns allow for more space and deck profile provides safe working platform. Moreover, PEB systems have also got better earthquake resistance.
We provide complete design from the foundation to superstructure and undertake responsibility for safety of structures. We additionally provide stability certificate for structures to our clients. We thoroughly analyze every client's unique requirements and based on the product and process equipment involved we provide better specification for their building with su i tab le vent i lat ion , handl ing
Are PEB systems preferable for multi-storied construction?
How are the products and services offered by your company different from others?
Profile
145The Masterbuilder - March 2011
G.V.Engineering & Co: Offering Top of the line PEB Solutions
Profile
G.V.Engineering & Co is a versatile engineering firm that specializes in Pre-Engineered
Buildings, Multi-storey Steel Buildings, Industrial Structures, etc. The company's growth story has been driven by its firm commitment to the latest technology and advanced software, which has seen it successfully complete several major projects, globally.Ably led by Mr.Raja Gana Nathar-B.E,.M.K.S.E,. a technocrat with over two decades of experience, G.V.Engineering & Co, has been forging ahead in its journey towards attaining
G.V.Engineering & Co Offering Top of the line PEB Solutions
Raja Gana Nathar B.E.,M.K.S.E,Managing Director, G.V.Engineering & Co Raja Gana Nathar B.E.,M.K.S.E,Managing Director, G.V.Engineering & Co
144 The Masterbuilder - March 2011
equipment and other statutory requirements.
Some of our hi-tech projects include:
Utech Elsewedy Project in Riyadh, Saudi Arabia is one.
Chemical storage warehouse Sabic- 72 clear span with 29 m rid height.
Pipe rack and platform Fahud Station in Muscat for the Petroleum Development Corporation of Oman.
BCCI commercial complex in Bahrain. We have done the conceptual design for the 23 storey steel building.
We also provide consultancy services for PEB plant construction, textile mills, etc. We have a special project division for refinery projects and have handled many projects for P.D.O (Muscat), KNPC Kuwait, etc.
Visit us at:
Give us a few examples of your major
projects.
What are the other services that you provide?
www.gvcon.com
MM Castings (P) Ltd
Industry Analysis
120 The Masterbuilder - March 2011 121The Masterbuilder - March 2011
more than 30% p.a. for the next few years. There is no published data avail-able indicating the exact growth rate of the construction market. The Indian construction chemical market is highly competitive and fragmented, with large numbers of small and specialized suppliers. Besides small distributors who import these chemicals, there are a large number of global construction chemical companies who have manu-facturing operations in India.
This market is likely to grow at the
rate of around 10 15% p.a. in the next
few years.
Most of these companies remain
highly specialized thus serving their spe-
cific market segment supplying a few
product types of different technology /
application methods, quality and price
to meet specific construction needs
such as waterproofing, leakages or fire-
proofing. In general, the distribution of
each particular product involves instal-
lation/application and most impor-
tantly a warranty on product perfor-
mance. As a result, it is necessary that
distributors of construction chemicals
specialize in solutions to specific con-
struction needs.
Construction chemicals are one of the niche segments from the specialty chemical segment of
the chemical industry. These are spe-cialty products that are used in struc-tures to increase their life, and also to impart additional protection from envi-ronmental hazards. Construction chem-icals additionally help in minimizing the quantities of cement and water gener-ally required during the construction.
The new construction projects mar-ket is expected to increase the demand for construction chemicals. The con-struction market is expected to grow at
tial component of the renovation and
repair aspect of large-scale projects
contributing to their sales in India.
The construction industry has had
its fair share in the overall growth of the
Indian Economy. With exciting pros-
pects ahead, there is an increased
emphasis on high quality construction
requiring detailed designing, good
workmanship, and the selection of
appropriate building materials. Build-
ing structures would require protection
from natural hazards and industrial cor-
rosives and regular maintenance to sus-
tain for a longer duration of time. Chem-
icals used in construction impart these
qualities to structures.
Construction Chemicals can
broadly be categorized into five groups:
Concrete and Mortar Admixtures
Water Proofing Compounds
Floor Hardeners
Protective Coatings and Resins
Adhesives and Sealants
Global construction chemicals mar-
ket is projected to cross US$34 billion
by the year 2015, according to a Global
research report. “Though the market
continues to reel under the impact of
recession, the ongoing and proposed
high construction projects in develop-
Types of Construction Chemicals
Consistent Growth Trend
A variety of construction chemicals are used in most large-scale construc-tion projects as also in projects involv-ing special design and engineering so as to cater to their specific needs. These materials include concrete admixture, surface treatment, waterproofing, grout, floor topping, coating, sealer, and floor hardening.
Thus, the potential demand for con-
struction chemicals takes in its ambit
the creation of infrastructure in core
sectors of economy, high-rise buildings
and industrial complexes. Besides, con-
struction chemicals become an essen-
?????????
CONSTRUCTIONCHEMICALSBuilding Blocks of Quality
CONSTRUCTIONCHEMICALSBuilding Blocks of Quality
Sadagopan Seshadri,Chief - Content Development, CE - Infrastructure - Environment
2002-03
CC Industry Turnover*
2003-04 2004-05 2005-06 2006-07 CAGR %
Rate of Growth of CC Industry
Construction Industry Turnover*
Rate of Growth of Construction Industry
750
13%
31078
16.55%
855
14%
36015
15.88%
992
16%
42885
19%
1130
18%
48679
22%
1500
20%
51200
23.70%
18.06%
14.20%
ing countries of Asia-Pacific, Latin Amer-
ica and Eastern Europe are expected to
buoy future market growth. Further,
trends such as increasing urbanization
and green building constructions are
expected to spur the market growth
momentum,” said Global Industry Ana-
lysts (GIA) in its report.
The growth rate of the Indian Con-
struction Chemical Industry is consis-
tent. This shows that the application of
construction chemical in construction
works is increasing gradually. The end
users are coming to know about its
usage.
Rossari Biotec
M.J. Construction chemicals
Chembond
JBA Concrete Solutions
Chowgule Koster
BASF
Dow Chemicals
Rheoplast technology
Technokolla
Tech-Dry
Don Construction chemicals
Razon Engineering
Techny Chemie
Nina Concrete Systems
Sunanda Speciality Chemicals
Dow Chemicals
Rheoplast Technology
Some key players in the CC space
*The figures are in Rs. Crore ; CC=Construction Chemical (Source: Chemical Weekly)
Growth Rates: Construction Chemical V/S Construction Industry
Industry Analysis
120 The Masterbuilder - March 2011 121The Masterbuilder - March 2011
more than 30% p.a. for the next few years. There is no published data avail-able indicating the exact growth rate of the construction market. The Indian construction chemical market is highly competitive and fragmented, with large numbers of small and specialized suppliers. Besides small distributors who import these chemicals, there are a large number of global construction chemical companies who have manu-facturing operations in India.
This market is likely to grow at the
rate of around 10 15% p.a. in the next
few years.
Most of these companies remain
highly specialized thus serving their spe-
cific market segment supplying a few
product types of different technology /
application methods, quality and price
to meet specific construction needs
such as waterproofing, leakages or fire-
proofing. In general, the distribution of
each particular product involves instal-
lation/application and most impor-
tantly a warranty on product perfor-
mance. As a result, it is necessary that
distributors of construction chemicals
specialize in solutions to specific con-
struction needs.
Construction chemicals are one of the niche segments from the specialty chemical segment of
the chemical industry. These are spe-cialty products that are used in struc-tures to increase their life, and also to impart additional protection from envi-ronmental hazards. Construction chem-icals additionally help in minimizing the quantities of cement and water gener-ally required during the construction.
The new construction projects mar-ket is expected to increase the demand for construction chemicals. The con-struction market is expected to grow at
tial component of the renovation
and repair aspect of large-scale pro-
jects contributing to their sales in India.
The construction industry has had
its fair share in the overall growth of the
Indian Economy. With exciting pros-
pects ahead, there is an increased
emphasis on high quality construction
requiring detailed designing, good
workmanship, and the selection of
appropriate building materials. Build-
ing structures would require protection
from natural hazards and industrial cor-
rosives and regular maintenance to sus-
tain for a longer duration of time. Chem-
icals used in construction impart these
qualities to structures.
Construction Chemicals can
broadly be categorized into five groups:
Concrete and Mortar Admixtures
Water Proofing Compounds
Floor Hardeners
Protective Coatings and Resins
Adhesives and Sealants
Global construction chemicals mar-
ket is projected to cross US$34 billion
by the year 2015, according to a Global
research report. “Though the market
continues to reel under the impact of
recession, the ongoing and proposed
high construction projects in develop-
Types of Construction Chemicals
Consistent Growth Trend
A variety of construction chemicals are used in most large-scale construc-tion projects as also in projects involv-ing special design and engineering so as to cater to their specific needs. These materials include concrete admixture, surface treatment, waterproofing, grout, floor topping, coating, sealer, and floor hardening.
Thus, the potential demand for con-
struction chemicals takes in its ambit
the creation of infrastructure in core
sectors of economy, high-rise buildings
and industrial complexes. Besides, con-
struction chemicals become an essen
?????????
CONSTRUCTIONCHEMICALSBuilding Blocks of Quality
CONSTRUCTIONCHEMICALSBuilding Blocks of Quality
Sadagopan Seshadri,Chief - Content Development, CE - Infrastructure - Environment
2002-03
CC Industry Turnover*
2003-04 2004-05 2005-06 2006-07 CAGR %
Rate of Growth of CC Industry
Construction Industry Turnover*
Rate of Growth of Construction Industry
750
13%
31078
16.55%
855
14%
36015
15.88%
992
16%
42885
19%
1130
18%
48679
22%
1500
20%
51200
23.70%
18.06%
14.20%
ing countries of Asia-Pacific, Latin
America and Eastern Europe are
expected to buoy future market
growth. Further, trends such as increas-
ing urbanization and green building con-
structions are expected to spur the mar-
ket growth momentum,” said Global
Industry Analysts (GIA) in its report.
The growth rate of the Indian Con-
struction Chemical Industry is consis-
tent. This shows that the application of
construction chemical in construction
works is increasing gradually. The end
users are coming to know about its
usage.
Rossari Biotec
M.J. Construction chemicals
Chembond
JBA Concrete Solutions
Chowgule Koster
BASF
Dow Chemicals
Rheoplast technology
Technokolla
Tech-Dry
Don Construction chemicals
Razon Engineering
Techny Chemie
Nina Concrete Systems
Sunanda Speciality Chemicals
Dow Chemicals
Rheoplast Technology
Some key players in the CC space
*The figures are in Rs. Crore ; CC=Construction Chemical (Source: Chemical Weekly)
Growth Rates: Construction Chemical V/S Construction Industry
122 The Masterbuilder - March 2011
The Growth Drivers
Expanding construction businesses
in the largely untapped rural areas are
also expected to provide a huge thrust
to the construction chemicals market.
Moreover, the Government's decision
to allow 100 percent foreign direct
investments (FDIs) in the real estate
business has boosted construction
activities throughout India. Although
the economic downturn had bogged
down the real estate business, it is
already showing signs of recovery. This
revival, along with foreign investors'
popular perception of India as a high-
growth market, has given a shot in the
arm for construction chemicals compa-
nies.
Upen Patel, head-marketing, BASF
Construction Chemicals (India) Pvt Ltd,
based on the development in the infra
segment feels. “As a developing coun-
try, India has shortage of shelter, power
and transport infrastructure. As the
country creates the wealth it would
invest in these key sectors which would
keep driving the demand for construc-
tion chemicals,” he says.
Patel believes the power and trans-
port sector would create additional
demand for construction chemicals
making up for continuing lack-luster
performance of the downturn hit real
estate sector. “Globally a construction
project would consume 2-3% value
worth of construction chemicals, while
in India this ratio is only 0.3-0.7% at the
moment. As the ratio improves we will
see further growth for construction
chemicals.
Not less than CAGR at 15-20% for
next ten years is anticipated. As per
Anasuya Gupta, managing director,
Cico Technologies Ltd, one of the mar-
ket leaders, “One of the major growth
drivers would be the ability of the play-
ers in the sector to deliver logistics and
services at the doorsteps of the users”.
A key growth driver of this sector in
the last decade has been the accept-
ability of ready mix concrete (RMC). In
India around 7% of the domestic
cement consumption is consumed in
RMC. This is expected to grow 25-30%
in the near future driving up the
demand for construction chemicals
Large RMC players promote the value
added concrete concepts thus spurring
up the knowledge driven demand of
specialty admixtures by end users.
Incidentally, BASF has been working
with many construction companies in
making it possible to reduce the usage
of cement and still maintain the perfor-
mance of concrete and also to reduce
the energy used in concrete production
and placement. It is working with other
organizations actively involved in the
concrete industry like the Indian Con-
crete Institute for creating awareness
on the usage and benefits of construc-
tion chemicals.
CFI- Streamlining the CC Industry
The Future Holds Promise
Bodies like Construction Federation
of India (CFI) strive to strengthen the
sector by establishing linkages in the
industry & working with the Planning
Commission to secure the future of the
construction chemicals sector. “In fact,
viewing the growing importance of this
segment, a construction chemicals
division has been set up under the
aegis of CFI “, said SC Mehta, secretary
general, CFI.
Several major construction chemi-
cals manufacturing companies have
joined hands with CFI to be an active
constituent of the Construction Chemi-
cals Division. Key objectives of this divi-
sion include creating awareness about
the use of right type and quality of con-
struction chemicals to have durable
structure and standardization of mate-
rials and prices.
The construction chemical industry
in India is at a nascent stage as com-
pared to the rest of the world. But with
the growth in economy, growth in con-
struction is inevitable and this should
translate in higher growth in construc-
tion chemicals to meet quality & speed
aspects in project deliveries. A respon-
sible SWOT analysis is a must to keep
this sunrise industry on the right track.
The Indian consumer is realizing
that while the cost of construction
chemicals is only 2 percent of the over-
all construction cost, the benefits are
manifold. “Effective marketing and
product innovation are keys to success
in the Indian market,” says the analyst
of Frost & Sullivan research and adds,
“It is imperative to maintain long-term
relations with customers and exert
influence over channel partners to stay
afloat in this market.”
Construction Chemicals: Building Blocks of Quality
Industry Analysis
Jindal Aluminium
Reflective Signage
124 The Masterbuilder - March 2011
estimates based on the Approach
Paper to the 11th Five-Year Plan have
put a figure of $48 billion towards roads
and highways infrastructure alone.
However, ironically India has the
highest number of road accidents in
the world as revealed by the World
Health Organization (WHO). In India,
the death toll rose to 14 per hour in
2009 as opposed to 13 the previous
year. The total number of deaths every
year due to road accidents has now
passed the 135,000 mark, according to
the latest report of National Crime
Records Bureau or NCRB. And this is
where the country is losing 3% of its
GDP to road crashes every year. While
drunken driving is one of the major
causes of accidents, it is also seen that
lack of proper road infrastructure espe-
cially on highways and treacherous
mountain roads contributes largely to
this number. The IRF (International
Road Federation) has recently recog-
nized the criticality of the situation and
has proposed to seek active participa-
tion of corporate houses in building
infrastructures having direct bearing
on road safety. It also proposes that the
government should exempt tax on
these expenditures incurred by the cor-
porate houses in a given year.
The public private model has lead to
the use of progressive technology and
upgraded quality and designs, suited to
match the needs of commuters and
drivers.India implemented the PPP
model in road development in a big
way and achieved financial closure of
more than 270 projects until Novem-
Transportation infrastructure is
an essential ingredient for rapid
growth of an economy and a
vital input to economic development,
trade and social integration. The physi-
cal world is still grappling with the inad-
equacy of quality roads and highways,
creeping into the greenscape. Financ-
ing the maintenance of transport infra-
structure, managing urban congestion,
supply chain disruption on account of
poor rural connectivity and loading of
environmental cost as an integral pro-
ject cost, are some of the challenges
that the transport infrastructure indus-
try is grappling with. Economists hold
India's inadequacy in infrastructure as
the main impediment to its growth and
roads in particular have a critical role to
play in the growth story. Sector-wise
TechnologyTechnologyTechnologyA Key to Safer RoadsA Key to Safer RoadsA Key to Safer Roads
Harish Banwari
STP Ltd
Author's Bio
The Author is Mechanical Engineer & MBA currently working with 3M India Limited as
General Manager for Traffic Safety Systems Division. Harish has been associ-ated with road and vehicle safety for the last 8 years and has played a crucial role in upgrading the safety standards in this field.
ing both motorists & pedestrians in
way finding and caution them of
upcoming changes in road conditions.
These examples only prove that pro-
gressive technology is the buzz word
for India. The country has already seen
its benefit in reducingwastage and
costs, while simultaneously improving
the quality of products. The Govern-
ment is also committed to building a
world-class infrastructurefor improv-
ing the quality of life and enhancing
competitiveness of theeconomy. With
all these developments paving the way
for growth in the country, good times
have just begun!
ber 2009. Infrastructure shortages are
proving a key constraint in sustaining
and expanding India's economic
growth. The government is actively pro-
moting PPPs in key infrastructure sec-
tors like transportation. A KPMG report
titled 'Opportunities in Infrastructure
and Resources in India' reveals that
investments of the order of US$ 500 bil-
lion are expected to take place in the
coming years. Through these partner-
ships, corporates are not just investing
in technology that will not just improve
infrastructure but also create a safe
environment for commuters and
motorists.
One such technology is the micro-
replication technology that has been
used extensively to create reflective
signage. Microreplication is a manufac-
turing technology that combines the
art and science of applying precise,
microscopic three-dimensional pat-
terns on various surfaces. Based on this
technology, companies like 3M India
have created retroreflective signage
that reflects the light back to its source
with minimum scattering. This allows
greater visibility for motorists espe-
cially at night. The technology in its vari-
ous forms has been reinvented to suit
the growing needs of overcrowded cit-
ies. The Diamond Grade Prismatic
Sheeting has been used extensively as
conspicuity sign to highlight obstruc-
tions or hazards on the road such as
roundabouts, median openings, pillars,
sometimes even trees. These prismatic
reflective sheeting can be directly
applied on very rough, textured or cor-
rugated surfaces too. This material
finds applications in various areas like
median openings, trees, concrete
structures, roundabouts, flyovers etc.
Raised Pavement Markers (RPMs) are
also helpful on dark roads and bad road
Technology - A Key to Safer Roads
designs. The median markers using fluo-
rescent yellow reflective sheeting, con-
structed on the roads, help to delineate
two-way traffic. They are also useful in
dawn, dusk and foggy conditions.
Improving the visibility of road signs
has been shown to reduce road traffic
accidents by up to 80% - a significant sta-
tistic based on the fact that signs not
only show the correct route and format
of the road layout ahead but also act as
vital hazard warning. In fact, surveys
carried out by independent consul-
tants TMS Consultancy, on behalf of 3M
UK, found that using reflective sheeting
made a significant contribution to acci-
dent reduction. These findings were
based on 'before and after' statistics at
a number of individual test sites in the
UK. The results of the survey showed a
79% reduction in the total number of
accidents that occurred over the
twelve test locations.
Traffic safety solutions like reflec-
tive signage, raised pavement markers,
median markers and conspicuity tapes
have made roads safer and visible, help-
126 The Masterbuilder - March 2011
Reflective Signage
STA Concrete Flooring Solutions
The Masterbuilder - March 2011128
Seismic Performance
In the current study, G+3 to G+7 storey RC
building frames are modeled and analyzed by five
different lateral load analysis methods by using
commercially available ETABS software. The analysis
methods like linear static, nonlinear static (push
over), response spectrum as per IS 1893, response
spectrum as per Bhuj India (2001) earthquake and
time history as per Bhuj earthquake are used to
compare the response of the buildings in terms of base
shear, roof displacement and storey drift. Two
variations in column cross section are considered i.e.
rectangular and equivalent square. It is found that the
square shaped columns perform better as compared to
rectangular columns under earthquake forces
regardless of the method adopted for the analysis. It is
also observed that the forces and displacements
induced in the RC structures due to time history
analysis are much higher than the code specified linear
static method of analysis of structures.
Kalkan and Kunnath (2004) have used analytical
methods to compare with actual response of a
structure under time history analysis by using data of
instrumented steel buildings during the Northridge
earthquake. Rofooei et al (2006) have used the time
history analysis to estimate the target displacement
for pushover analysis. As observed by Penelis and
Kappos (2002), inelastic time history analysis albeit
useful and most reliable analysis technique, it proves
to be cumbersome for practicing engineers due to its
lengthy and complicated data input requirements.
Despite lot of work done on time history analysis as a
Comparison of Various MethodsIncluding Time History Analysis inSeismic Performance Evaluationof RC Frames
Comparison of Various MethodsIncluding Time History Analysis inSeismic Performance Evaluationof RC Frames Shah B. A.1
Patodi S. C.2
1Associate Professor, Applied MechanicsDepartment, The M. S. University of Baroda
2Professor, Civil Engineering Department, ParulInstitute of Engg. & Tech., Limda, Baroda
powerful tool for estimating the seismic response of a
structure, there are hardly any papers on comparing
the various methods of analysis with reference to a
specific RC frame problem. This type of comparison
will be very useful to a practicing structural engineer
who needs an idea of the difference in forces induced
in a structure under time history analysis vis-à-vis
linear static analysis specified by codal provisions.
In the present study, therefore, the linear dynamic
response spectrum and time history analysis are
adopted to evaluate the response of RC space frames.
For undertaking a time history analysis the recorded
data of the time history which is available online
from the cosmos website is utilized here. The other
type of dynamic analysis performed is the response
spectrum analysis as per the 5% damped IS 1893
(2002) spectrum considered for the medium soil and
building lying in zone 3. The response spectrum due
to Bhuj time history is also generated for 5%
damping and a scale factor of 0.102 to convert the
time period versus spectral acceleration in units of g.
This spectrum is utilized here to define another
response spectrum case and the building is analyzed.
The non linear static analysis is also carried out by
using the ATC 40 (1996) and FEMA (1997) guidelines
for comparison purpose.
The Mathematical Models Considered
Five space frames of G+3 to G+ 7 storeys are
considered with an overall plan dimension of 6m x
6m having four panels of 3m x 3m. Nine columns are
Shah B. A. Patodi S. C.
The Masterbuilder - March 2011 129
considered at the panel points having a cross sectional
dimension of 230mm x 450mm throughout. The
column height in each storey is considered as 3m and
it extends below the plinth level up to 3m. The size
of the column below plinth level is considered as
280mm x 500mm. Another set of five similar models
having equivalent square column cross section of
322mm x 322mm is considered for comparison. The
beam size is taken as 230mm x 450mm. A rigid
diaphragm is defined for each storey to account for
the slab stiffness when subjected to lateral loads. The
M25 grade of concrete and Fe 415 grade steel
reinforcement is considered. Typical isometric and
plan views of a G+7 storey frame are shown in Fig.
1. All the joints are considered to be fixed at the
foundation level.
Fig. 1 Typical Isometric and Plan Views of the G+7 Frame
Static Load Cases
Following are the four static load cases considered
for the models:
Ø Dead load: This load consists of a uniformly
distributed area load of 2 kN/sqm on terrace and
1.5 kN/sqm on all floors along with a uniformly
distributed line load of 6 kN/m at terrace level
and 13 kN/m on all peripheral beams at typical
floor level to account for 230mm thick brick
walls. Self weight is automatically calculated by
the program for all beams and columns.
Ø Live load: An area load of 3 kN/sqm on all floors
is considered except for the terrace floor where the
load considered is 1.5 kN/sqm.
Ø Earthquake load EQX: This load case is a static
load calculated as per the Indian code IS 1893
(2002) for 5% damping with seismic zone factor z
= 0.16 and medium soil with importance factor of
1 and a response reduction factor of 5. It is
calculated as per the seismic parameters for the
frame. The load direction being considered is
global X. The loads are applied at the diaphragm
centre. The mass considered for generating the
lateral load is total dead load + 25% of the live
load lumped at diaphragm centre.
Ø Earthquake load EQY: This load case is exactly
similar to the load EQX except for the fact that it
is applied in the lateral Y direction.
Dynamic Load Cases
Ø Time History Analysis: In the time history
analysis, a typical time history for the Bhuj
Earthquake of January 26, 2001 at 08:46:42.9
I.S.T. Mag: 7.0 mb, 7.6 Ms recorded at
Ahmedabad station having latitude and longitude
as 23 02 N, 72 38 E component: N 78 E is used.
Accelerogram band pass filtered between 0.07 Hz
and 27.0 Hz having an initial velocity of -
0.1411E-02 m/s, initial displacement = 3.970 mm
and peak acceleration = -1.0382 m/s/s at
46.940 sec is utilized. A total record of 133.53 sec
is used having 26706 acceleration data points (in
m/s/s) at 0.005 sec. The plot of acceleration versus
time used for the time history is shown in Fig. 2.
Fig. 2 Time versus Acceleration Record for Bhuj Earthquake
This file is used as the input for time history
function. As the file is having values of acceleration in
m/sec2, the time history load case is defined as
acceleration in the X direction with a scale factor of
Seismic Performance
Comparison of Various Methods Including Time History Analysis in Seismic Performance Evaluation of RC Frames
The Masterbuilder - March 2011130
1. After the analysis, the response spectrum curve of
the ground level node is extracted for time period
versus pseudo spectral acceleration as ordinate in the
arithmatic scale for 5% damping and X direction is
extracted from the time history traces display in the
form of a text file.
The response spectrum extracted for the central
node at the base for each of the models is presented
in Fig. 3. The values of this response spectrum are
input as a response spectrum function for the response
spectrum dynamic analysis in ETABS software. The
output of the results is obtained at a time step of 0.04
sec giving 25 output steps per sec.
Fig. 3 Response Spectra for Models for Bhuj Earthquake
Ø Response Spectrum Analysis: First a response
spectrum function is defined to carry out the linear
dynamic analysis. For the current mathematical
models, following two response spectrum
functions are defined: i) IS 1893 specified response
spectrum for zone factor z = 0.16 having medium
soil and 5% damping defined by using the built in
function of the ETABS software and ii) Response
spectrum generated from the time history analysis
under Bhuj earthquake for each model which is
read from a text file containing the values as
shown in Fig. 3.
Next, the response spectrum load cases are defined
wherein again two separate cases are specified for IS
1893 specified spectrum and the response spectrum
function defined for Bhuj earthquake. For both the
response spectrum cases, the structural and functional
damping considered is 5% which gets modified in the
analysis as per the structural properties. The
Complete Quadratic Combination (CQC) method is
used for modal combinations and the Square Root of
Sum of Squares (SRSS) method is used for directional
combination. Input response spectrum is defined in
the U1 (corresponding to X) direction with a scale
factor of 9.81 to convert the acceleration in m/sec2
units from units of g. The results of the analysis are
obtained by running the analyze command of the
ETABS software.
The Results of Analysis
For the lateral load analysis, the important values
like base shear, roof displacement and storey drift are
noted from the analysis results. Five different
methods are applied for evaluating these parameters
for the ten RC space frame models under lateral loads.
The methods employed are: i) The linear static
method (EQX), ii) The non linear static method (Push
Over), iii) The linear dynamic response spectrum
method (as per IS 1893 response spectrum), iv) The
response spectrum method for Bhuj earthquake
response spectrum and v) The linear dynamic time
history analysis as per Bhuj earthquake strong motion
Parameter
Base Shear kN
Roof Displ. in m
Max. Drift in m
1893
822
695
0.101
0.123
0.0052
0.0068
Min
-987
-1493
-0.102
-0.155
-
-
Max
1010
1461
0.102
0.157
0.0060
0.0125
Analysis Type
Column
Square
Rect
Square
Rect
Square
Rect
Linear Static
147
147
0.023
0.034
0.0011
0.0016
Non Linear Static (Push Over)
827
708
0.169
0.192
0.0102
0.0198
Bhuj
531
455
0.068
0.079
0.0034
0.0044
Response Spectrum Time History Bhuj
Table 1 Comparison of Seismic Performance of a G+7 Frame
Seismic Performance
Comparison of Various Methods Including Time History Analysis in Seismic Performance Evaluation of RC Frames
Nina Concrete Systems Pvt.Ltd
The Masterbuilder - March 2011132
data. The results of analysis are reported for G+7
storey frame in Table 1. The results noted down for
the time history analysis are time dependent and the
maximum results may occur at different times.
However, they are presented here for comparison.
The graphical comparison of base shear variation
in the G+7 storey RC space frame is presented in Fig.
4. A similar comparison for roof displacement is
Fig. 4 Base Shear Comparison for a G+7 Storey RC Frame Fig. 5 Roof Displacement Comparison for a G+7 Storey Frame
shown in Fig. 5 whereas Fig. 6 shows the variation in
maximum storey drift.
The base shear and the roof displacement
evaluated under lateral loads by five different methods
for all the ten models are presented in Table 2. Also,
the variation in base shear for all the models is
graphically represented in Fig. 7 and that for roof
displacement is depicted in Fig. 8.
Model
G+7
G+6
G+5
G+4
G+3
1893
822
695
0.101
0.123
826
691
0.087
0.107
834
687
0.077
0.091
842
687
0.061
0.077
868
688
0.052
0.063
Min -ve
987
1493
0.102
0.155
1755
894
0.187
0.089
1595
1277
0.127
0.140
2192
1350
0.164
0.149
1525
1957
0.076
0.149
Max
1010
1461
0.102
0.157
1791
905
0.185
0.087
1596
1265
0.145
0.137
2182
1362
0.160
0.166
1493
1938
0.077
0.149
Parameter
Base Shear in kN
Roof Displ. in m
Base Shear in kN
Roof Displ. in m
Base Shear in kN
Roof Displ. in m
Base Shear in kN
Roof Displ. in m
Base Shear in kN
Roof Displ. in m
Column Shape
Square
Rect
Square
Rect
Square
Rect
Square
Rect
Square
Rect
Square
Rect
Square
Rect
Square
Rect
Square
Rect
Square
Rect
Linear Static
147
147
0.023
0.034
85
69
0.011
0.014
84
68
0.010
0.012
82
67
0.008
0.009
79
64
0.006
0.007
Bhuj
531
455
0.068
0.079
825
381
0.091
0.058
712
606
0.068
0.084
816
590
0.062
0.068
521
655
0.031
0.061
Response Spectrum Time History BhujNon Linear Static
(Push Over)
827
708
0.169
0.192
818
685
0.145
0.161
812
664
0.123
0.145
799
643
0.102
0.124
780
616
0.082
0.103
Table 2 Comparison of Base Shear and Roof Displacement for Various Frame Models
Seismic Performance
Comparison of Various Methods Including Time History Analysis in Seismic Performance Evaluation of RC Frames
Cerachem Pvt.Ltd
The Masterbuilder - March 2011134
Fig. 6 Storey Drift Comparison for a G+7 Storey Frame
Fig. 7 Base Shear Variation Graphs for the Frame Models under
consideration
Fig. 8 Roof Displacement Variation Graphs for the Frame Models under
consideration
The variation in storey drift over the height of the
structure is also important as it gives an insight into
the seismic performance of a structure. The storey
drifts for all the five cases of lateral load in the global
X direction for G+7 storey space frames with square
and rectangular columns are presented in Table 3
Storey
9
8
7
6
5
4
3
2
1
Square
0.0005
0.0007
0.0009
0.0010
0.0011
0.0011
0.0011
0.0010
0.0005
Push Over RS Bhuj Spectrum Time History BhujEQX
Rect
0.0006
0.0010
0.0013
0.0015
0.0016
0.0016
0.0016
0.0015
0.0008
Square
0.0027
0.0043
0.0056
0.0066
0.0071
0.0075
0.0078
0.0102
0.0020
Rect
0.0040
0.0066
0.0089
0.0104
0.0115
0.0122
0.0130
0.0198
0.0040
RS 1893 Spectrum
Square
0.0020
0.0030
0.0037
0.0043
0.0046
0.0049
0.0052
0.0052
0.0028
Rect
0.0022
0.0036
0.0046
0.0052
0.0057
0.0061
0.0065
0.0068
0.0035
Square
0.0012
0.0019
0.0023
0.0027
0.0031
0.0033
0.0034
0.0034
0.0018
Rect
0.0015
0.0024
0.0030
0.0034
0.0037
0.0039
0.0042
0.0044
0.0023
Rect
0.0052
0.0080
0.0088
0.0086
0.0089
0.0088
0.0099
0.0125
0.0072
Square
0.0028
0.0039
0.0042
0.0046
0.0055
0.0058
0.0055
0.0060
0.0035
Table 3 Storey Drift Values for G+7 Storey RC Frame by Various Methods
which are also plotted in Fig. 9 for all the methods on
a single plot for comparison. It may be noted here
that the values of storey drift for non linear static
(push over) case are the drift values at performance
point when the space frame is pushed in the X -
direction. For rectangular columns, the X direction is
the weak direction for lateral load resistance.
Fig. 9 Storey Drift Plots for G+7 Storey Frame in X Direction
Seismic Performance
Comparison of Various Methods Including Time History Analysis in Seismic Performance Evaluation of RC Frames
Unisteel Engineering Works
The Masterbuilder - March 2011136
The plot of storey drift for the G+6 to G+3 space
frame models by all the methods are presented in
Figs. 10 to 13.
Fig. 10 Storey Drift Plots for G+6 Storey Frame in X Direction
Fig. 11 Storey Drift Plots for G+5 Storey Frame in X Direction
Fig. 12 Storey Drift Plots for G+4 Storey Frame in X Direction
Observations and Discussions
Ø Table 1 indicates that the linear static method
which is followed to estimate the lateral loads as
per the codal provisions is very much on the lower
side. The base shear as per time history is 10.15
times that as per linear static method and it is
almost 5.6 times in case of response spectrum
method. The response spectrum developed for a
specific time history gives a value of base shear
less than that obtained by the code specified
generalized response spectrum. The base shear
noted by push over analysis at performance point
is almost same as that observed for response
spectrum as per the codal provisions. However,
comparing the forces in frames with square and
rectangular columns reveals that the force is
higher in square column but at a lower roof
displacement.
Ø Table 1 also shows that the roof displacement
under time history load for square columns is 4.43
times that obtained by linear static method and
the same ratio for rectangular columns is 4.61.
This indicates that square columns show a less roof
displacement as compared to rectangular columns.
Even if one compares the roof displacement of
each method, the displacements for frame with
square columns are less in comparison to that with
rectangular columns.
Ø The roof displacement is observed to be maximum
in case of push over analysis which is expected
because of the formation of plastic hinges. The
storey drift is also higher in case of push over
analysis because of the plastic hinges. This fact is
clearly indicated in Fig. 6.
Ø From Fig. 4 it can be seen that the base shear is
highest in case of Time History case followed by
that due to push over analysis which is almost
same as response spectrum as per IS 1893. The
response spectrum developed for specific time
history gives a force which is less than that due to
Fig. 13 Storey Drift Plots for G+3 Storey Frame in X Direction
Seismic Performance
Comparison of Various Methods Including Time History Analysis in Seismic Performance Evaluation of RC Frames
The Masterbuilder - March 2011 137
code specified spectrum. In general, the base shear
due to linear static analysis is 3.6 times smaller
than that due to dynamic load due to Bhuj
response spectrum for square columns and it is 3.1
times smaller for rectangular columns.
Ø Table 2 and Fig. 7 indicates that the base shear
obtained by push over analysis and code specified
response spectrum are almost same for a specific
column shape. For a particular model say G+6
storey frame, square columns are subjected to
higher shear force as compared to rectangular
columns. The base shear value decreases as the
number of storey decrease from G+7 to G+3. For
Bhuj time history load case, the base shear
variation between square and rectangular columns
for different storey structures are quite random. A
similar trend is observed for Bhuj earthquake
response spectrum analysis, however, the base
shear because of Bhuj response spectrum analysis is
less as compared to base shear for code specified
response spectrum analysis. In general, the base
shear response of the structures for G+3 to G+7
frames is quite consistent for code specified
response spectrum analysis and push over analysis.
The base shear response of the same set of
structures is quite random for a specific time
history data.
Ø It can also be observed from Table 2 and Fig. 8
that the roof displacement which is another
important response parameter for seismic
evaluation is also quite random for time history
load due to Bhuj earthquake. The roof
displacement for a particular model with square
shaped columns is found less than that with
rectangular shaped columns. It is also seen that the
roof displacement in models analyzed with code
specified response spectrum and that due to push
over analysis show almost a linear trend for G+3
storey to G+7 storey structure for both square
and rectangular shaped columns.
Ø The storey drift variation which is presented in
Table 3 and plotted in Fig. 9 shows the values for
all the analysis methods for both the models in a
single graph for G+7 frame. It shows that the
highest drift occurs at the first storey slab level for
all the methods of lateral load analysis. As per
drift criteria, the methods can be classified in the
increasing degree of severity as linear static, linear
dynamic Bhuj response spectrum, linear dynamic
IS 1893 response spectrum, linear dynamic time
history for Bhuj and non linear static push over
analysis.
Ø Frames with square columns particularly
performed well as compared to those with
rectangular columns when the maximum storey
drift criterion is considered. It is clear from Fig. 9
that the maximum drift under all cases for square
columns is 1.94 times less compared to the
maximum drift in frames with rectangular
columns for G+7 frame. Also, the maximum drift
for frame with square columns under time history
dynamic analysis is less than that due to IS 1893
response spectrum analysis for rectangular
columns.
Ø Figures 10 to 13 show that the storeys drift due to
push over analysis for frames with rectangular
columns is particularly very large at the first
storey level for G+3 to G+7 frames. For all the
models, the storey drift due to time history
analysis under Bhuj earthquake for rectangular
columns is quite random as compared to models
with square columns. The storey drift for
rectangular columns for G+6 frame under time
history analysis is less which is an exception to the
trend. The storey drift of a square column is less
than rectangular column regardless of the method
of analysis or the size of the frame.
Conclusions
It can be seen from the data presented that the
recorded time history being random in nature does
not give any trend based on the size of the frame
(G+3 to G+7) or the cross sectional shape of the
columns (square or rectangular). However, when the
five different methods of analysis are compared for
evaluating the seismic performance of a low rise RC
Seismic Performance
Comparison of Various Methods Including Time History Analysis in Seismic Performance Evaluation of RC Frames
The Masterbuilder - March 2011138
space frame up to G+ 7 storeys, the square shaped
columns perform better as compared to the
rectangular shaped columns. As the base shear values
for non linear static (push over) analysis is near the
value of base shear due to code specified response
spectrum analysis, it can be concluded that the push
over analysis represents the state of the structure in
terms of plastic hinges in a more realistic manner for
G+3 to G+7 storey space frames.
References
Ø ATC-40 (1996), "Seismic Evaluation and Retrofit of Concrete
Buildings", Volume 1 and 2, Report No. SSC 96-01, Seismic Safety
Commission, Redwood City, CA.
Ø FEMA-273/274 (1997), NEHRP Guidelines and Commentary on the
Guidelines for the Seismic Rehabilitation of Buildings, Washington DC,
USA.
Ø http://db.cosmos-eq.org Cosmos Virtual Data Centre, Consortium of
Organizations for Strong Motion Observation Systems.
Ø IS 1893 (2002), Indian Standard Criteria for Earthquake Resistant
Design of Structures, Part 1: General Provisions and Buildings,
Bureau of Indian Standards, New Delhi.
Ø Kalkan E. and Kunnath S. K. (2004), "Method of Modal Combinations
for Pushover Analysis of Buildings", Paper No. 2713, Proceedings of
the 13th World Conference on Earthquake Engineering, Vancouver,
Canada.
Ø Penelis G. G. and Kappos A. J. (2002), "3D Pushover Analysis: The
Issue of Torsion", Paper No. 15, Proceedings of the 12th European
Conference on Earthquake Engineering, London.
Authors Bio
Bimal A. Shah is currently an Associate
Professor with Applied Mechanics Department,
Faculty of Technology & Engineering of the M. S.
University of Baroda. He received his B.E. (Civil)
and M.E. (Structures) Degrees from the M. S.
University of Baroda in 1985 and 1987 respectively.
He is pursuing Ph.D. in the field of Earthquake
Engineering and has published 13 research papers in
national and international conferences and journals.
He has visited Manila, Philippines, Geneva and
Switzerland to present technical papers in 2004 and
2006.
Subhash C. Patodi received his Ph.D. from IIT
Bombay in 1976. After serving for 30 years as
Professor of Structural Engineering at the M. S.
University of Baroda, he is currently working as
Professor in Civil Engineering Department at the
Parul Institute of Engineering and Technology,
Baroda. He has published 276 research papers in
National and International Journals and
Conferences. His current research interest includes
Cementitious Composites, Numerical Methods and
Soft Computing Tools.
Ø Rofooei F. R., Attari N. K., Rasekh A. and Shodja A. H. (2006),
"Comparison of Static and Dynamic Pushover Analysis in
Assessment of the Target Displacement", International Journal of Civil
Engineering, Vol. 4, No. 3.
Seismic Performance
Comparison of Various Methods Including Time History Analysis in Seismic Performance Evaluation of RC Frames
Sohan Lal Gupta
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FRACTIONATION OF RECLAIMEDFRACTIONATION OF RECLAIMEDASPHALT PAVEMENTASPHALT PAVEMENT
140 The Masterbuilder - March 2011
scalping screen over the cold feed bin is used to remove large particles over 25mm. A picture of typical millings is shown below. The milling process will generate various size particles in addi-tion to a large amount of fines. When the RAP is used in small percentages this can easily be handled in the mix by adjustments to the virgin aggregate to produce mixes that will meet all design requirements such as gradation, binder content and mix volumetric properties. As higher percentages of RAP are used in the mix a higher degree of control is need over the RAP material to maintain the quality of the final mix. This is done by the process of fractionation.
There are several different
approaches to the fractionation of the
RAP material. The approach taken will
be governed by the percentage of RAP
to be used in the new asphalt mixture.
For mixes using up to 30% RAP it is com-
mon to crush the roadway milling to a
single 0- 12mm stockpile. The crushing
of the milled RAP from the roadway
down to a 12mm maximum size will
help improve gradation control by elim-
inating any large aggregate that may
have been in the existing pavement. It
driver in the interest of using higher per-
centages of RAP in the asphalt mixture.
The average usage of RAP in the US
is about 15%. However, asphalt mixes
with 50% have been produced and
placed with success. The RAP can't just
be dumped in the mix at high percent-
ages though. The use of higher per-
centages of RAP requires some
improvements in material handling.
Without care and attention to detail
high percentage RAP mixes can be a
disaster. If done right they can be a
high quality cost saving way to produce
asphalt mixtures.
The production process starts with taking up of the existing roadway. This is typically done with large milling machines that grind up the pavement and deliver it into haul trucks to be taken back to the asphalt mix plant. A standard milling operation is shown in the picture below.
The milling machine uses carbide
teeth mounted on a drum to chip out
the existing asphalt pavement. Depths
from as small as 10 mm up to 150 mm
can be removed at one pass. The mill-
ing process typically produces material
40mm and smaller. The milling
141The Masterbuilder - March 2011
Fractionation of Reclaimed Asphalt Pavement the way to Achieve Higher Percentages of Use
Asphalt Recycling
Reclaimed asphalt pavement
(RAP) has been used in the US
since the mid 1970's. It has
been put to many different uses. RAP
has been used as aggregate base mate-
rial. It has been used as shoulder mate-
rial on lower volume roads. However,
the most cost effect use of RAP is as a
component in a new asphalt mixture.
The asphalt binder and quality aggre-
gate in the RAP will reduce the cost of
producing new asphalt mixture.
The costs of asphalt binders have
steadily increased over the past several
years with the typical price now over
$450 a ton. This increase in cost of the
binder makes it the most costly portion
of the asphalt mix. The use of RAP in
the new mix will reduce the asphalt
binder needed and reduce the cost of
the mix. The asphalt binder typically
accounts for 50% of the cost of materi-
als for the asphalt mix and by replacing
a portion of the asphalt binder with
RAP binder significant savings can be
realized. High quality aggregates are
also becoming in short supply and
increasing in cost. The aggregate in the
RAP also contributes to the reduction
in cost that can be achieved with its
use.
RAP usage has fluctuated over the
years. When first introduced typical
RAP percentages used in new mixes
were in the 20 to 25% range. However,
drop off in the cost of asphalt binder in
the 80's and 90's saw a reduction in the
use of RAP. Introduction of the
Superpave system also caused a reduc-
tion in the use of RAP as agencies
wanted to implement the new system
with minimal additional issues such as
using RAP. As Superpave has become
the standard in the US and contractors
and agencies are now familiar with the
system the use of RAP has increased.
As noted earlier the increased cost of
asphalt binder has been the major
machine will mill and pick up the mate-
rial in one operation and then conveys
it to haul trucks. The existing pave-
ment has been picked up by using rip-
pers to pull up the pavement and load-
ers to pick it up. However, this process
typically creates large pieces of which
are more difficult to handle in the recy-
cling process.
In mixes with lower percentages of RAP, 10 to 15%, the milled material is often fed into the asphalt mix plant with little additional processing. A
John D'Angelo Ph.D. P.E.,
The Way to Achieve Higher Percentages of UseThe Way to Achieve Higher Percentages of Use
Picture of typical RAP milled from the roadway
Picture of a typical milling machine removing asphalt pavementand transferring the millings to a haul truck.
?????????
FRACTIONATION OF RECLAIMEDFRACTIONATION OF RECLAIMEDASPHALT PAVEMENTASPHALT PAVEMENT
140 The Masterbuilder - March 2011
scalping screen over the cold feed bin is used to remove large particles over 25mm. A picture of typical mill-ings is shown below. The milling pro-cess will generate various size particles in addition to a large amount of fines. When the RAP is used in small percent-ages this can easily be handled in the mix by adjustments to the virgin aggre-gate to produce mixes that will meet all design requirements such as gradation, binder content and mix volumetric properties. As higher percentages of RAP are used in the mix a higher degree of control is need over the RAP material to maintain the quality of the final mix. This is done by the process of fraction-ation.
There are several different
approaches to the fractionation of the
RAP material. The approach taken will
be governed by the percentage of RAP
to be used in the new asphalt mixture.
For mixes using up to 30% RAP it is com-
mon to crush the roadway milling to a
single 0- 12mm stockpile. The crushing
of the milled RAP from the roadway
down to a 12mm maximum size will
help improve gradation control by elim-
inating any large aggregate that may
driver in the interest of using higher
percentages of RAP in the asphalt mix-
ture.
The average usage of RAP in the US
is about 15%. However, asphalt mixes
with 50% have been produced and
placed with success. The RAP can't just
be dumped in the mix at high percent-
ages though. The use of higher per-
centages of RAP requires some
improvements in material handling.
Without care and attention to detail
high percentage RAP mixes can be a
disaster. If done right they can be a
high quality cost saving way to produce
asphalt mixtures.
The production process starts with taking up of the existing roadway. This is typically done with large milling machines that grind up the pavement and deliver it into haul trucks to be taken back to the asphalt mix plant. A standard milling operation is shown in the picture below.
The milling machine uses carbide
teeth mounted on a drum to chip out
the existing asphalt pavement. Depths
from as small as 10 mm up to 150 mm
can be removed at one pass. The mill-
ing process typically produces material
141The Masterbuilder - March 2011
Fractionation of Reclaimed Asphalt Pavement the way to Achieve Higher Percentages of Use
Asphalt Recycling
Reclaimed asphalt pavement
(RAP) has been used in the US
since the mid 1970's. It has
been put to many different uses. RAP
has been used as aggregate base mate-
rial. It has been used as shoulder mate-
rial on lower volume roads. However,
the most cost effect use of RAP is as a
component in a new asphalt mixture.
The asphalt binder and quality aggre-
gate in the RAP will reduce the cost of
producing new asphalt mixture.
The costs of asphalt binders have
steadily increased over the past several
years with the typical price now over
$450 a ton. This increase in cost of the
binder makes it the most costly portion
of the asphalt mix. The use of RAP in
the new mix will reduce the asphalt
binder needed and reduce the cost of
the mix. The asphalt binder typically
accounts for 50% of the cost of materi-
als for the asphalt mix and by replacing
a portion of the asphalt binder with
RAP binder significant savings can
be realized. High quality aggregates
are also becoming in short supply and
increasing in cost. The aggregate in the
RAP also contributes to the reduction
in cost that can be achieved with its
use.
RAP usage has fluctuated over the
years. When first introduced typical
RAP percentages used in new mixes
were in the 20 to 25% range. However,
drop off in the cost of asphalt binder in
the 80's and 90's saw a reduction in the
use of RAP. Introduction of the
Superpave system also caused a reduc-
tion in the use of RAP as agencies
wanted to implement the new system
with minimal additional issues such as
using RAP. As Superpave has become
the standard in the US and contractors
and agencies are now familiar with the
system the use of RAP has increased.
As noted earlier the increased cost of
asphalt binder has been the major
machine will mill and pick up the
material in one operation and then con-
veys it to haul trucks. The existing pave-
ment has been picked up by using rip-
pers to pull up the pavement and load-
ers to pick it up. However, this process
typically creates large pieces of which
are more difficult to handle in the recy-
cling process.
In mixes with lower percentages of RAP, 10 to 15%, the milled material is often fed into the asphalt mix plant with little additional processing. A is
John D'Angelo Ph.D. P.E.,
The Way to Achieve Higher Percentages of UseThe Way to Achieve Higher Percentages of Use
Picture of typical RAP milled from the roadway
Picture of a typical milling machine removing asphalt pavementand transferring the millings to a haul truck.
142 The Masterbuilder - March 2011
will also produce a more consistent
material with less variation from loca-
tion to location in the crushed stock
pile. The crushing process will also
reduce the variability in the binder con-
tent of the RAP material. A picture of
the crushed RAP is shown below. The
smaller size RAP material also is heated
more rapidly and therefor mixes more
easily with the new aggregate and
binder. The one disadvantage to this
crushing of the RAP is the generation of
additional fines that have to be
accounted for in the production of the
new asphalt mix.
When higher percentages of RAP
are to be used in the asphalt mixture
even greater fractionation of the RAP
material will make it easier to produce
a mix that will meet design require-
ments and can consistently be pro-
duced at the mix plant. Asphalt mix-
tures with RAP percentages greater
than 30% made from one RAP stockpile
will be difficult to produce at the mix
plant, on a consistent bases. As with
any mixture controlling the gradation
from one or two stockpiles is very diffi-
cult and the overall quality improves
wit increased stockpiles. This is true for
RAP also.
The process of fractionating the
RAP into multiple sizes is very similar to
the crushing and screening of aggre-
gate to meet specific size require-
ments. The one major difference is
that the RAP binder will bond some of
the finer material to the larger aggre-
gate so that there will be a larger varia-
tion in sizes for any individually sized
RAP stockpile. The picture of a typical
RAP fractionation process is shown
below. Here the RAP is crushed and
screened into 3 sizes; 9 to 12mm, 5 to
9mm and 0 to 5 mm.
The fractionation process starts
with crushing of the roadway millings
or other RAP material. A
horizontal shaft impact
crusher is typically used for
the crushing operation.
This type of crusher can eas-
ily be set for a small max
size and the impact on the
crusher walls breaks-up the
RAP with less dust genera-
tion. The goal is to break-
up the RAP material with as
little crushing of the exist-
ing stone as possible.
From the crusher the
material is sent to the high efficiency
screen deck. These screen decks are
set at steep angles with slotted screens
to provide more surface area and help
prevent clogging of the screens. The
material is then separated into sepa-
rate stockpiles for feeding back into the
asphalt mix plant using separate cold
feed bins for the different sizes.
One important think to note when
fractionating RAP is that the different
size material has to be treated as com-
pletely different material sources.
When the RAP has been fractionated
the binder content on the existing
aggregate will be different for the dif-
ferent size material. The fine portion
will have the highest binder content
and the coarsest portion with have the
lowest binder content. It will be com-
mon for the RAP that may have an over-
all binder content of 5% to have 7%
binder in the fine portion and 3% in the
coarse portion. During the asphalt mix
design process this has to be taken into
account when putting the overall job
mix formula together and in the deter-
mination of the final binder content. In
some cases with higher percentage
RAP mixes a softer binder will be used
to offset the increased stiffness from
the RAP binder. This is governed by the
stiffness of the RAP binder and per-
Picture of RAP crushed to minus 12 mm size
Picture of a RAP crushing and screening operationshowing the crusher, screen deck and stockpiling operation
Fractionation of Reclaimed Asphalt Pavement the way to Achieve Higher Percentages of Use
Asphalt Recycling
Viki Industries (P) Ltd
centage used. There are several
approaches that are use to evaluate
when and how much adjustment is
needed to the binder grades. This
information can be found from many
agencies such as the National Asphalt
Pavement Association and in the Amer-
ican Association of State highway and
Transportation Officials documents.
RAP stockpiles have a tendency to
hold moisture. Therefore it is impor-
tant to use good stockpile manage-
ment when using RAP. To help remove
water, the stockpiles should be placed
on sloped ground that is preferably
paved to drain the water away. Some
contractors use large sheds to cover
the RAP stockpiles so they will not be
exposed to rain and can be kept dry.
Separate cold feed bins should be
used when introducing RAP to the
asphalt mix plant. When the RAP is frac-
tionated a separate cold feed bin
should be used for each size RAP. A pic-
ture of a multiple RAP cold feeds is
shown below. Using separate cold
feeds improves the quality manage-
ment at the plant and helps control the
mix properties.
Once the RAP has gone through the
mix plant and been added to the new
aggregate and binder the mix is treated
the same as standard asphalt mixes.
The material is loaded into haul trucks
and taken out to the roadway. Paving
operations will be very much the same
as for standard asphalt mixture. The
RAP mixture is typically produced at
higher temperatures than a mix pro-
duced from completely new virgin
materials. The RAP mixes can be some-
what stiffer than virgin mixes so higher
temperatures will help adjust for this.
The amount of temperature increase
will depend on the percentage of RAP
used in the mix and the stiffness of the
aged binder. The paving crew should
see very little difference from virgin
mixes.
Reclaimed asphalt mix has been
144 The Masterbuilder - March 2011
Author's Bio
Dr. D'Angelo is the chief operating offi-cer of a consulting firm specializing in asphalt materials testing, pavement design and construction quality assurance. Previously he worked for Federal Highway Administration for over 32 years. He has worked in the areas of construction manage-ment, pavement design, materials testing, and quality control. He has been involved with the implementation of the Strategic Highway Research Program, Superpave Asphalt Design System, to the highway industry and further development of the sys-tem. He has also worked extensively in the asphalt binder area, mixture design, warm mix asphalt and recycling. He has published numerous papers on asphalt material test-ing and quality control.
used for many years in the production
of new asphalt mixes. These mixes
have overall performed well and pro-
vide a high quality riding surface. The
use of fractionation of the RAP makes it
possible to produce mixes with higher
percentages of RAP and still meet all
quality control requirements and meet
the standard acceptance criteria. The
use of RAP helps reduce cost and saves
valuable resources. The use of frac-
tionation helps to increase that use.
RAP Cold Feeds
Paving operation in progress using RAP mixture
Fractionation of Reclaimed Asphalt Pavement the way to Achieve Higher Percentages of Use
Asphalt Recycling
Cosmos Sales Corporation
Construction Awards
146 The Masterbuilder - March 2011
Associates Ltd, Dr.J.L.Narayan, Mem-
ber of the Jury, Retd. Joint Advisor, Min-
istry of Statistics and Programme
Implementation, Govt of India, and
Mr.K.K.Sharma, Principal Secretary
PWD, Delhi, among others.
In yet another highlight of the
award ceremony, the late Shri
B.G.Shirke, Founder Chairman,
B.G.Shirke Construction Technology
Pvt Ltd was posthumously awarded the
Special Jury Award for Life Time
Achievement.
147The Masterbuilder - March 2011
3rd CIDC Vishwakarma Award 2011: A Recognition of Notable achievements and Standards of Excellence
Construction Awards
residential and commercial) and social
infrastructure was introduced from this
year onwards.
Several prestigious projects were
awarded for their design and applica-
tion. One such project which received
the award including the “ Construction
of Elevated Road along Barapulla
Nallah, Saraj Kale Khan to Jawaharlal
Nehru Stadium “ by the Public Works
Department, Govt. of NCT , Delhi. The
project's design received praise from
all quarters and the dedicated signal-
free access from Games Village to the
main venue of the recently concluded
Commonwealth Games 2010, the
Jawaharlal Nehru Stadium, was recog-
nized for its outstanding design.
Yet another project connected to
the Commonwealth Games Delhi 2010,
which was awarded was the “Thyagaraj
Sports Complex.” PWD, Govt of Delhi
received the award for this truly world-
class stadium.
The awards ceremony this year saw
a total of 168 awardees being chosen
from eight prime categories. The
awardees included 4 women. The
award winners were honoured with tro-
phies, medals, and certificates.
The Hon'ble Minister of State for
Urban Development Prof.Saugata Ray
was the Chief Guest during the cere-
mony. Other distinguished dignitaries
who graced the occasion included
Dr.Kavuri Samba Siva Rao, Member of
P a r l i a m e n t , P a d m a b h u s h a n
Dr.G.V.Ramakrishna , former Chairman
Disinvestment Commission & Member
Planning Commission, Dr.Uddesh Kohli,
Chairman Emiretus , CIDC, Dr. Pronab
Sen, Principal Advisor, Planning Com-
mission, Dr.D.G.Kadkade, Member of
the Jury, Principal Advisor, Jaiprakash
The CIDC Vishwakarma Awards
are considered among the most
prestigious recognition for
those in the construction industry. The
awards have been inspired by Lord
Vishwakarma, the presiding deity of
construction practices in India are pre-
sented to those who have contributed
their might towards the betterment of
the construction industry in various
capacities.
What makes the CIDC Vishwakarma
Awards different from similar events is
the fact that it is one award where arti-
sans, the unsung heroes of the con-
struction industry are recognized for
their thankless work. The 2011 award
glittering award ceremony saw 45 such
artisans being awarded and honoured
with a commemorative trophy, medal,
and certificate.
The event is celebrated on the 7th
of March each year, a date which is also
the foundation day of Construction
Industry Development Council (CIDC) ,
which is the apex body established by
the Planning Commission of India and
the Construction industry. CIDC has
been working towards promoting best
practices in the construction industry
and help it achieve global stature.
A new category of awards for “ Best
Projects” covering construction sub-
sectors such as roads & highways,
dams, power, railways, bridges, oil &
gas, transmission, urban infrastructure
, health infrastructure buildings ( both
3rd CIDCVishwakarma Award 2011
A Recognition of Notable achievements and Standards of Excellence
tion and how large-scale urbanization
was creating the problem of housing in
urban cities in countries like India.
The CIDC Vishwakarma Awards are
being given to a wide number of repre-
sentative categories that covers the
entire spectrum of the construction
industry, right from the artisans to the
industry experts and construction firms.
I t was a pr iv i lege for the
Masterbuilder to be awarded under
the 'Best Magazine' category. Editor-
in-Chief, Mr.K.P.Pradeep was awarded
under the 'Best Journalist' category.
The awards were yet another testimo-
nial to the team of the Masterbuilder,
which has been setting the benchmark
in all round reportage of the construc-
tion industry in India.
The Minister also released the offi-
cial brochure for the forthcoming CIDC
event 17th Asia Construct Event, Inter-
national Exhibition & Conference in
New Delhi. As part of the event an
International Conference & Exhibition
will be held from 13th-15th December
2011 under the theme,” Asian Eco-
nomic Overview 2011 & Outlook 2012.
The event would be showcasing some
of the latest technologies, best prac-
tices, equipment, materials, products,
and services.
Chief Guest Prof.Saugata Ray
lauded the efforts that CIDC was taking
in order to promote the betterment of
the construction industry. The Minister
had a word of praise especially for the
Green Rating system and the efforts
that CIDC was putting for the adaption
of several good practices. He went on
to add that excellence in every field
should be recognized and rewarded.
The Minister during his address
pointed out to the two problems of ris-
ing population and rapid industrializa-
Nigel Narayan, Deputy Editor, The Masterbuilderreceiving the Visvakarma award 2011 for Best News Magazine
Inaugural Ceremory
Construction Awards
146 The Masterbuilder - March 2011
Associates Ltd, Dr.J.L.Narayan,
Member of the Jury, Retd. Joint Advi-
sor, Ministry of Statistics and
Programme Implementation, Govt of
India, and Mr.K.K.Sharma, Principal Sec-
retary PWD, Delhi, among others.
In yet another highlight of the
award ceremony, the late Shri
B.G.Shirke, Founder Chairman,
B.G.Shirke Construction Technology
Pvt Ltd was posthumously awarded the
Special Jury Award for Life Time
Achievement.
147The Masterbuilder - March 2011
3rd CIDC Vishwakarma Award 2011: A Recognition of Notable achievements and Standards of Excellence
Construction Awards
residential and commercial) and
social infrastructure was introduced
from this year onwards.
Several prestigious projects were
awarded for their design and applica-
tion. One such project which received
the award including the “ Construction
of Elevated Road along Barapulla
Nallah, Saraj Kale Khan to Jawaharlal
Nehru Stadium “ by the Public Works
Department, Govt. of NCT , Delhi. The
project's design received praise from
all quarters and the dedicated signal-
free access from Games Village to the
main venue of the recently concluded
Commonwealth Games 2010, the
Jawaharlal Nehru Stadium, was recog-
nized for its outstanding design.
Yet another project connected to
the Commonwealth Games Delhi 2010,
which was awarded was the “Thyagaraj
Sports Complex.” PWD, Govt of Delhi
received the award for this truly
world-class stadium.
The awards ceremony this year saw
a total of 168 awardees being chosen
from eight prime categories. The
awardees included 4 women. The
award winners were honoured with tro-
phies, medals, and certificates.
The Hon'ble Minister of State for
Urban Development Prof.Saugata Ray
was the Chief Guest during the cere-
mony. Other distinguished dignitaries
who graced the occasion included
Dr.Kavuri Samba Siva Rao, Member of
P a r l i a m e n t , P a d m a b h u s h a n
Dr.G.V.Ramakrishna , former Chairman
Disinvestment Commission & Member
Planning Commission, Dr.Uddesh Kohli,
Chairman Emiretus , CIDC, Dr. Pronab
Sen, Principal Advisor, Planning Com-
mission, Dr.D.G.Kadkade, Member of
the Jury, Principal Advisor, Jaiprakash
The CIDC Vishwakarma Awards
are considered among the most
prestigious recognition for
those in the construction industry. The
awards have been inspired by Lord
Vishwakarma, the presiding deity of
construction practices in India are pre-
sented to those who have contributed
their might towards the betterment of
the construction industry in various
capacities.
What makes the CIDC Vishwakarma
Awards different from similar events is
the fact that it is one award where arti-
sans, the unsung heroes of the con-
struction industry are recognized for
their thankless work. The 2011 award
glittering award ceremony saw 45 such
artisans being awarded and honoured
with a commemorative trophy, medal,
and certificate.
The event is celebrated on the 7th
of March each year, a date which is also
the foundation day of Construction
Industry Development Council (CIDC) ,
which is the apex body established by
the Planning Commission of India and
the Construction industry. CIDC has
been working towards promoting best
practices in the construction industry
and help it achieve global stature.
A new category of awards for “ Best
Projects” covering construction sub-
sectors such as roads & highways,
dams, power, railways, bridges, oil &
gas, transmission, urban infrastructure
, health infrastructure buildings ( both
3rd CIDCVishwakarma Award 2011
A Recognition of Notable achievements and Standards of Excellence
tion and how large-scale urbaniza-
tion was creating the problem of hous-
ing in urban cities in countries like India.
The CIDC Vishwakarma Awards are
being given to a wide number of repre-
sentative categories that covers the
entire spectrum of the construction
industry, right from the artisans to the
industry experts and construction firms.
I t was a pr iv i lege for the
Masterbuilder to be awarded under
the 'Best Magazine' category. Editor-
in-Chief, Mr.K.P.Pradeep was awarded
under the 'Best Journalist' category.
The awards were yet another testimo-
nial to the team of the Masterbuilder,
which has been setting the benchmark
in all round reportage of the construc-
tion industry in India.
The Minister also released the offi-
cial brochure for the forthcoming CIDC
event 17th Asia Construct Event, Inter-
national Exhibition & Conference in
New Delhi. As part of the event an
International Conference & Exhibition
will be held from 13th-15th December
2011 under the theme,” Asian Eco-
nomic Overview 2011 & Outlook 2012.
The event would be showcasing some
of the latest technologies, best prac-
tices, equipment, materials, products,
and services.
Chief Guest Prof.Saugata Ray
lauded the efforts that CIDC was taking
in order to promote the betterment of
the construction industry. The Minister
had a word of praise especially for the
Green Rating system and the efforts
that CIDC was putting for the adaption
of several good practices. He went on
to add that excellence in every field
should be recognized and rewarded.
The Minister during his address
pointed out to the two problems of ris-
ing population and rapid industrializa
Nigel Narayan, Deputy Editor, The Masterbuilderreceiving the Visvakarma award 2011 for Best News Magazine
Inaugural Ceremory
Thermal Insulation
148 The Masterbuilder - March 2011
mal insulation product designed to inte-
grate seamlessly with the concrete roof
system. The product is environmentally
sound, commercially successful, and
suitable for a wide range of projects in
hot climatic conditions on multiple sub-
strates. The tile conforms to ECBC/
LEED/IGBC cool roof standard require-
ments.
A listed product available in dry mix
form, the Thermatek Cool Mortar is a
carefully proportioned blend of white
cement, select assortment of fine metal
and mineral stabilizers that provides a
heat barrier to a building. When used as
a complement to Thermatek Heat
Resistant Terrace Tiles, the product
provides enough insulation and heat
reflectance that eliminates the need for
additional insulation like PUF, XPS,
Thermacole, etc.
Thermatek Heat Reflective Paint is a
Thermatek Cool Mortar
Thermatek Heat Reflective Paint
white roof reflective paint (SRI 90.6)
that insulates buildings from heat, lasts
much longer than 3 years, costs no more
than standard roof paint and is also envi-
ronment friendly. The company would
be shortly introduced coloured reflec-
tive paints in collaboration with the
Institute of Chemical Technology (for-
merly University Department of Chemi-
cal Technology), Bombay University.
Apart from the benefits derived
from each of the individual products of
the company, customers stand to gain
immense benefits from the combined
application of Thermatek Heat Resistant
Terrace Tile and Thermatek Cool Mortar.
This synergetic approach combines a
number of high-performance elements
as well as individual performance
characteristics ensuring, economy,
energy efficiency and environment
friendliness.
Web: www.thermatek.co.in
Mixed Product Application
For further details visit
Research has clearly proven that
over 15 percent of heat inside a
building comes through the
roof. This being the case, it is important
for incorporating energy efficient ther-
mal barriers that act as a barrier for heat
and improve the energy efficiency of a
building. Ishaan Industries is a leading
name in the industry when it comes to
offering a wide range of cool-roof spe-
c i f ic products . The company's
Thermatek Thermal Barriers help in
improving the sustainability of quotient
of a building manifold. The company's
products including, Thermatek Cool
Mortar and Thermatek Heat Reflective
Paint help in addressing all the green
concerns energy, environment, and
human health.
This is the signature product of the
company whose popularity has been
growing by the day. A unique, patented,
stand-alone over deck, multilayered,
non-porous, dense, dry-look, and ther-
Thermatek Heat Resistant Terrace Tile
Thermatek Thermal BarriersOffering the Complete Range of Cool- Roof Products
Premium Products
JK Works Bharuch (Guj)
The Masterbuilder - March 2011150
Rock Foundation: Case Study
This paper deals with rock foundation treatment
and quality control assurance of the grouting
operations (slush/consolidation/curtain) and
permeability tests carried out in CoT area of earth
and rockfill dam. Efficacy of grouting was determined
by conducting permeability tests before and after
grouting. Curtain grouting is done to prevent/reduce
leakage, seepage and downstream flow into the
foundation to increase the percolation path to prevent
possible piping and washing the fines from the core
into cracks, fractures, fissures and joints in the rock
foundation. Slush grouting is also done to fill the
joints/fissures between rock mass on account of
shrinkage of core clay and uneven over breaks in the
CoT and shrinkage of concrete. Proper grouting of
surrounding rock mass around the opening helps in
monolithic behaviour of the rock mass. Curtain
grouting was done in three rows by ascending and
descending both the stages as per condition of rock
strata.
The foundation strata in depth of 70 m in the rock
mass revealed from the cores taken from five initial
primary holes in the first row comprises of numerous
joints, opening, cavities and water intrusion confined
zone. Rock mass in certain reach was jointed and
Innovative Construction Techniquesfor Rock Foundation Treatmentand Quality Assurance of SalmaDam Project, Afghanistan- A Case Study
Innovative Construction Techniquesfor Rock Foundation Treatmentand Quality Assurance of SalmaDam Project, Afghanistan- A Case Study
some reach it was continuous solid rock mass as
indicated by high core recovery and low RQD. Both
permeability values and grout intake were low in
these reaches. At depth 37-40 m the water confined
zone was encountered and heavy water ejection was
observed from these drill holes. The core recovery
was poor and shear zone were noticed in this reach.
This is due to geological underground structure i.e.
steeply plunging downstream anticline and it was
intercepted confined ground water condition and such
situation/condition continued till water pressure
reduced itself through joints and fractures formed at
the crest of anticline. Water was passing through this
zone of intercepted confined ground water condition,
grout intake with simple grout mix was not success.
The Chemical grout mix with sodium silicate, sand,
Rice Husk Powder/straw fibers and spongy (foam)
materials with different combination were used to
seal/plug as well make the grouting success with
quality control check with fine cement in the
laboratory for first row of Primary holes. The
permeability of rock mass after the first row of grout
was more than 5 lugeons. Hence second and third
row of grout holes were taken up at 1.5 m either side
of the first grout row. About eight holes have been
drilled and grouted in the second and third row to
R.B.Shivali1, Senior Research OfficerK.S.Jamwal2, Ex. DDG, GSIA.N.N.Prasad3, Project DirectorAmar Kumar4, General Manager (P)R.K.Gupta5, C.M.D.
1 - CSMRS, New Delhi and deputation to WAPCOS Ltd.at Salma Dam Project in Afghanistan
2 - Geological Survey of India and,3-5 - WAPCOS Ltd. at Salma Dam Project, Afghanistan
The Masterbuilder - March 2011 151
reduce the permeability of rock mass. The secondary
and tertiary holes were also done with use cement of
43 grade OPC as per grout intake requirements.
Project
Salma Dam project located near Chist-e- Sharif in
Herat Province had planed as multipurpose project
and was under active constructions till late 1970`s.
The construction activities of Project came to halt
after out break of hostility in the area in early 1980's.
After restoration of normalcy in Afghanistan
Government of India with under the Reconstruction
& Development programme to Afghanistan decided
to undertake the development of this Project as a
monument of friendship between two countries and
appointed WAPCOS, who had earlier been involved
with the Design and Construction supervision as
Consultants & Executors to carry out the works of
this landmark infrastructural project undertaken by
the Government of India,
The Salma dam Project is envisaged on river
Harirud. The Harirud is one of the major rivers of
western Hindu kush in Central Afghanistan. This
river is formed near at an altitude of 4000 m and
flows mostly west ward for a distance of about 560
Km, then turn north words forming boundary
between Afghanistan and Iran and there after the
boundary between Turkmenistan and Iran. The
objectives of Salma Dam Project is of three fold
� Generation of Hydro Power with an installed
capacity of 3x14 MW
� Stabilizing the existing irrigation facility to the
extent of 35,000 hectares and
� Development of additional irrigation facility to
the extent of 45,000 hectares
Present scope of work covers the Generation of
Hydro Power to the extent of 42 MW only. The
WAPCOS Limited (A Government of India
Undertaking) is executing the project on behalf of
GOI (Ministry of External Affairs, New Delhi).
The Project envisages construction of 107.5
meters high, 550 meter long rock fill dam across the
river. Other components of the project consist of a
Surface Powerhouse, Chute Spillway, Irrigation Sluice
and Diversion tunnel.
The diversion tunnel is located in the right flank
of the river and the rock fill dam built across the river
to create a reservoir. The spillway is located in the
right flank of the river. The over flow spillway is 36
m wide and has a clear over flow width of 24 m. It
consists of 3 bays of 8 m (width) X 10 m (height) and
is controlled by the radial gates. The spill way
comprises of an approach channel, a control structure
with standard ogee profile, a chute for leading water
to a flip bucket and a plunge pool at the end.
Two sluice out lets are provided in the two piers of
chute spillway, one for feeding the water to
powerhouse and other for meeting the irrigation
demands. The sluices are controlled by the gates
A surface powerhouse having an installed capacity
of 42 MW with three units of 14 MW each will be
constructed at the toe of the dam A single circuit
110 Kv transmission line of about 157 Km is being
constructed for evacuation of power to Heart city.The
project is under execution since March, 2006.
Geology
Gneissic group of rocks with thin shears, marble
bands, granite veins and small volcanic intrusions
have been exposed along the COT of Salma dam. The
gneissic stratigraphy has revealed Augen gneiss,
Biotite gneiss, micaceous quartz gneiss, Biotite
amphibole quartzitic gneiss, Quartzo-feldspathic
biotite gneiss, amphibolite bands, mylonitized gneiss
with impure marble bands and scanty sulphide
mineralization.
Problematic Situations
Foundation Materials
Unacceptable or inadequate materials rich in
organic substances such as top soil, swamp muck or
peat, loose deposits of sand or silt, talus
accumulations and plastic, active, sensitive, or
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swelling clays or gaugy materials in foundations bed
of natural deposits all may reveal inadequate localised
or widespread. The loose poor foundation conditions
in rocks which are associated with close fracturing,
weathering or hydrothermal alteration or poorly
indurated sedimentary rocks which require treatment
or total removal.
Confined Ground Water
Ground water was intercepted at a depth between
21m and 28 during the first hole in the sequence of
the No.5 vertical primary holes, drilled upto 70m
depth. These holes released the confined ground water
with great pressure in the beginning but gradually as
further drilling progressed, the water pressure and
discharge was reduced considerably.
Fig. 1 Confined ground water coming with great pressure during drilling
The water table was again noticed between depth
of 37m and 40m depth i.e. about 12-15 m below the
earlier level of water table in primary holes. Confined
ground water coming with great pressure during
drilling was shown in Fig-1
At this depth the encountered water confined zone
was heavy pressure ejection water from two drill holes.
The core recovery was poor and shear zone were
noticed in this reach. Water was passing through this
zone of intercepted confined ground water condition,
grouting with simple grout mix was not success.
Drilling And Grouting Equipments:
The type and size of equipment required to drill
grout holes, proportion/mixing of the materials,
deliver and inject grout into the hole in an
underground depends on site conditions and size of
the excavation. The most common power sources for
underground grouting equipment are air compressor,
electric and electric-hydraulic. Diesel powered
equipments are also common but can be used with
additional ventilation requirements in underground
opening.
Drilling Equipment
Two common drilling methods used in surface
structures are percussion and rotary. Percussion
drilling for surface grouting application can be used
effectively to drill hole depths up to approximately
15m and rotary drills are better suited for holes in
excess of 15m. This criterion is based on the fact that
proper holes alignment becomes difficult beyond 15m
while using percussion drilling. The rock chips
produced by the impact or chipping action of
percussion drilling could preseal fractures in the rock,
thus preventing the injection of grout slurry. This
problem can be alleviated by thorough flushing of the
hole with water to remove all the cutting caused by
the percussion drilling. On the other hand due to
grinding action, presealing of the grout hole is not
seen as a problem when rotary drilling is used. The
rotary drilling equipments (Indian and Iranian) are
shown in Fig.2
Fig.-2 Drilling equipments (Indian and Iranian)
Mixer
Two types of mixers are predominantly used in
surface/underground grouting applications, viz. paddle
mixers and colloidal mixers. A paddle mixer consists
of either vertically or horizontally mounted paddles
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that rotate slowly within a cylindrical tank. During
the mixing process, the grout materials are stirred
and thrown against baffles attached to the side of
tank. The baffles prevent the formation of a vortex
within the swirling mixture, which can cause
centrifugal separation. The heavy materials are thus
better broken apart and more evenly distributed
throughout the mixture. Once completely mixed, the
grout is discharged from the mixer into an agitator
tank when a single mixer arrangement is used or
directly into the grout pump while using a twin
mixer arrangement. In either arrangement grout
should be discharged by direct suction into the grout
pump, not by gravity. Colloidal mixer works by
recirculating the grout through a centrifugal pump.
The pump which operates at high speeds of 1500-
2000 rpm, impacts a shearing force to the grout as it
paddles through the narrow steel pump casing. The
pump discharges the grout tangentially into a vertical
cylindrical tank causing a vortex to form. The speed
of mixing and the high output capacity are important
attributes to the colloidal mixers. Details of the
grouting mixer and pump equipment is shown in Fig.3
Fig. 3 Details of the grouting mixer and pump equipment
Agitator
An agitator is a storage tank where the thoroughly
mixed grout from the mixer is stirred by a slowly
revolving paddle to keep the particles of unstable
grout in suspension while awaiting injection.
Water Meters
Water meters for measuring the amount of water
added to the grout mix should always be required by
the specifications. Other methods, such as calibrated
buckets and predetermined water level marking on
the sides of the mixing tank should not be allowed.
But due to site conditions and not availability of
arrangement could be done. A water meter with a
"reset-to-zero" feature is strongly recommended. This
eliminates the risk of miscalculating the correct
cumulative meter reading by the mixer operator.
Pump
Two common pumps used for grouting in surface/
underground structures are progressing helical cavity
pump and piston pump. Progressing helical cavity
pumps produce a continuous, uniform flow of grout
into a hole at relatively constant pressure. These
pumps are used primarily to pump grout mixtures of
water, cement and bentonite if availabe. However,
these are also capable of pumping sand grout mixes.
The abrasiveness of the sand, however, increases the
wear of the pump. A piston pump is better suited to
pump sand mixes. Piston pumps are used
predominantly to fill large voids, caverns, for backfill
grouting for confined water zone, intrusive water
zone, water spring and behind precast concrete/steel
liners and for contact/slash grouting. One
disadvantage of piston pump is that these deliver a
pulsating pressure that makes pressure control
difficult when constant or low pressures are required.
Pressure gauge
Pressure gauges are used to monitor the injection
pressure of the grout being delivered to the grout
hole. The pressure gauge helps to ensure that the
maximum allowable pressure is being applied to
achieve the desired results of the grout programme as
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designed. It also helps to prevent the application of an
injection pressure that is too high and could
overstress the structures being grouted. The range of
pressure reading of the gauge should be appropriate
for the grout pressure being used. As gauges get easily
damaged during constructional operation and
frequently usage, they should be checked for
calibrations very regularly.
Gauge Savers
The grout mix should never be allowed to come
into direct contact with the pressure gauge.
Therefore, a protective medium must be used to
separate the grout from the gauge. A gauge saver,
also called a "diaphragm seal" can be used for this
purpose. Within the body of a gauge saver, the upper
portion is isolated from the grout by a diaphragm.
The area between the top of the diaphragm and the
pressure gauge is completely filled with a suitable
fluid, usually oil.
Packers
Packers are used to seal off or isolate a portion of
grout hole that allows grout to be injected under
pressure into a specified section of the hole. Packers
are installed either at the top of the hole, also called
the hole collar or at other locations along the length
of the hole. The packers are set at the top of the hole
for slush grouting. It is also most often installed at
the collar of the hole for consolidation grouting
operations, when the hole is grouted in single stage.
Holes are grouted using a single-packer or double-
packer arrangements. In a single-packer arrangement
the grout is discharged into the hole just below the
location of the packers. In the double-packer
arrangement, the grout is discharged into an isolated
section of the grout hole located between an upper
and lower packer. The single-packer arrangement is
used in contact/slush grouting and most of the
consolidation and curtain grouting operations. Two
common types of packers are the mechanically
activated packer and the pneumatic/hydraulic
inflatable packer.
Grout Materials
The following are the Grout materials used for
curtain grouting:
� Cement
� Sand
� Rice Husk Powder /Straw Fibre
� Spongy (foam)
� Water and
� Accelerators- Sodium Silicate
Test Reults
Laboratory Testing Of Grout Mix
Laboratory testing is used to evaluate the proposed
grouting materials for chemical and physical
properties of the grout mix. Density tests were used
to check proper mix proportioning. Viscosity was
measured in time (seconds).
The properties of grout mix such as compressive
strength, viscosity and density were evaluated in the
site laboratory before use at site, so as to have a check
on grouting operations. Behaviour and performance of
grouting materials with proposed accelerator of
Table 1: Laboratory tests results of on grout mixes at different water cement ratio.
S.No.
1
4
5
6
7
8
Grout Mix (Water :
Cement)
1.0:2.0 (0.5)
1.5:2.0 (0.75)
1.0:1.0 (1.0)
2.0:1.0 (2.0)
3.0:1.0 (3.0)
4.0:1.0 (4.0)
Density g/cc
1.761
1.630
1.505
1.204
1.073
1.024
Equivalent Cube Compressive
Strength at 28 days age Mpa
32.42
29.06
9.53
5.13
3.41
2.04
Average Viscosity in
Seconds
65
48
33
30
26
22
Equivalent Cube Compressive
Strength at 7 days age Mpa
23.99
21.32
7.06
3.75
2.39
1.48
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Sodium Silicate was also evaluated in laboratory and
field tests were performed during the grouting
operation.
Compressive strength testing was performed in
the laboratory on specimen of grout. A set of three
grout cubes of 50mm x 50mm x 50mm is the most
common type of specimen used. The cubes are cast,
cured and tested as per IS: 4031- (Part-6) - 1988. The
requirement of compressive strength tests of grout is
not common for geotechnical grouting application.
However, it is more common for structural grouting
such as contact/slush grouting. The laboratory test
results of grout mix at different water cement ratio
are given in Table 1.
It is seen from Table-1 that 28 days cube
compressive strength and density decrease with
increase in water cement ratio. The compressive
strength of 32.42 MPa was obtained with water
cement ratio of 1:2 and it reduced to 2.04 MPa at a
water cement ratio of 4:1.
Field Testing Of Grout Mix
The laboratory test results are directly applied to
the field grouting operation during the problematic
situations to seal/plug the joints, cavities, fractured
and fissure inside the rock mass to make monolithic
rock mass. The field results are also tabulated in
Table-2
It is seen from Table-2 that 28 days cube
compressive strength decrease with increase in water
W/C ratio
by weight
0.45:1.0
0.5:1.0
0.5:1.0
0.5:1.0
0.5:1.0
0.5:1.0
0.5:1.0
0.5:1.0
Sodium Silicate %
by wt. of cement
nil
nil
nil
1.5
nil
1.5
1.5
1.5
Sand % by wt. of
cement
nil
nil
3.5
3.5
7.0
3.5
nil
4.0
Compressive Strength (MPa)Rice Husk Powder/
Straw Fibre, % by wt.
of cement
nil
nil
nil
nil
3.0
1.0
3.5
3.0
Spongy (foam)
nil
nil
nil
nil
nil
nil
nil
0.1
7 days
23.41
16.38
16.83
14.04
15.38
5.35
11.03
4.62
7 days
35.44
24.91
23.96
19.39
23.74
16.72
15.05
11.77
Table 2: Field tests on grout mix for Rock foundation treatment
cement ratio with neat cement. The compressive
strength with combination of sand and Rice Husk
powder increasing with their percentage of doses
increases. The compressive strength of 24.91 MPa was
obtained having neat cement with water cement ratio
of 1:2 and the same ratio with sand and Rice Husk
powder it is 23.74 was successful with 1.5% of
sodium silicate to plug the water intrusion zone areas
with rich grout mix1:2.
Rock Foundation Tratment
To improve the strength properties such as bearing
capacity, shear resistance and bond between the dam
and abutment to make the rock mass monolithic,
rock foundation treatment by grouting technique is
essential to sustain the structure.
Need for Rock Grouting
In surface/underground caverns and tunnels, therock grouting is required for various purposes such as:
� Strengthening the rock mass by filling up thejoints, fissures, cavities and cracks
� Filling of voids, joints and cavities between therock mass to the rock mass,
� Strengthening the shattered and fractured rockmass around the excavation,
� Closing up the water bearing passages to preventthe flow of water into deep rock mass & tunneland or to concentrate the area of seepage intochannel from where it can be easily drained out.
Slush, consolidation and curtain grouting were
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performed in CoT area at Salma Dam Project as
suggested by the designers. The rock treatment by
grouting can be mainly categorized as Surface and
Sub-surface treatments
Surface Tratment:
For suitable rock available at Shallow Depths
� Surfaces against which material is to be placed are
excavated to a slope not greater than 0.5
horizontal to 1 vertical which is generally follows.
� The weathered and exposed rock is treated by
shotcrete to protect the rock.
� All seams, relief joints and faults are excavated
and filled with concrete.
� Where rock is friable, and subject to cracking by
exposure and drying, slush grout was desirable.
� The treatment involves improvement of contact
between foundation rock and embankment by
stripping the foundation area and development of
uniform and smooth surface without abrupt
changes in slopes and ledges / overhangs.
The surface on which the core material is placedshould be wet but free from standing water, and thecore material should be wet of optimum desired OMC.
Sub-Surface Treatment
It involves slush, consolidation and curtaingrouting
Contact/slush Grouting
Slush grouting involves the filling of voids
between the parent rock mass. Slush grouting was
carried out in CoT area and abutments at a low
pressure of 1.0 to 3.0 kg/cm2 for filling up of the
joints, fractures, voids and cavities in between rock
mass. Ordinary Portland cement (OPC) was generally
used for slush grouting. Minimum diameter of drill
hole was kept as 38mm and depth of holes were kept
4-6 m into the rock mass depending upon the
situation. Grouting was continued without
interruption until refusal. Grout mix of 3:1, 2:1 and
1:1 (water: cement) were used for slush grouting. In
case of high grout intake, grout mix was thickened up
to 1:2. After refusal of grout materials, the grouting
was stopped. The grouting was considered complete
when intake of grout was less than 1 litre/minute
averaged over a period of 10 minutes. The maximum
pressure of 3-5 kg/cm2 was maintained by way of
closing the valve for sufficient time (20-30 minutes.)
to prevent backflow.
Consolidation grouting
� If the core foundation consists of closely fractured
rock and jointed rock a blanket grout pattern is
used with holes spaced at 3m to 5m with depths
up to 6m to 10m.
� If the foundation rock is massive no blanket
grouting is done.
� It is done to prevent possible piping of the fine
core material through the foundation. It also
increases the strength and deformation properties
of the mass rock foundation and abutment.
Consolidation grouting in CoT area were essential
to reduce the coefficient of permeability and
improving the deformability characteristics of
surrounding rock mass. Consolidation grouting in the
surrounding rock mass area was carried out up to a
desired depth of 8 m as per designer and rock mass
strata. Consolidation grouting minimises the flow of
water outward through into the rock mass. Primary
holes were drilled at 6m spacing and grouted and then
secondary holes were drilled in between primary holes.
Maximum pre-grouting permeability valueobserved was 27.58 lugeons. After grouting inprimary and secondary holes, permeability observedat certain location was more than 3 Lugeons.Additional tertiary holes were drilled and grouted inbetween adjacent grouted primary and secondaryholes. The permeability, in general, has thus been
brought down to less than 3 Lugeons.
Average consolidation grouting cement intake in
primary, secondary and tertiary holes in bed rock of
CoT was 24.45 kg/m, 15.04 kg/m and 19.77 kg/m,
respectively.
Consolidation grouting in CoT area were carried
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Fig. 4 Pattern and depth of drill holes for consolidation grouting in CoT
out in 38mm diameter and 8 m deep drill holes in the
rock up to a maximum pressure of 5 kg/cm2. Pattern
and depth of drill holes for consolidation grouting as
shown in Fig. 4 were governed by the geological
and the design requirements.
Consolidation grouting was considered completewhen the grout intake reduces to less than 1 litre/minute averaged over a period of 10 minutes. Groutpressure was maintained for a sufficient time toprevent backflow. The ratio of water: cement wasvaried from 6:1 to 1:2 depending upon the amount ofgrout intake. Grouting was continued till refusal.After the final setting time of grout, the holes wereredrilled up to 2/3rd filled with dry pack mortar of
same consistency as that for filling of grouting holes.
Sometimes inter-connection of holes during
grouting was observed. In this case, the grout was
allowed to escape from the connected holes till the
escaping grout was of the same consistency as that of
being injected. These coupled holes were then capped
and combined holes were grouted up to the specified
pressure of 5 kg/cm2 and grouting continued till
refusal. Such inter connected holes were not regrouted
again.
Curtain Grouting
� Generally, curtain grouting is carried out when
permeability exceeds 1-3 lugeons depending on
the height of the dam.
� It is done to reduce the seepage flow through the
dam foundation and also to reduce the hydrostatic
pressure (uplift) in the downstream foundation of
the dam.
� Curtain grouting should be carried out in split
spacing method starting from wide spacing in the
Primary stage then gradually reducing the spacing
in Secondary and Tertiary stages.
� It is done to safeguard the foundation against
erodibility hazard.
In bed rock foundation of CoT holes were drilled
at 70 m in depth. Initially primary holes at 6 m
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spacing were drilled and grouted, and then secondary
holes were drilled in between primary holes bringing
the spacing of holes to 6 m c/c. Permeability tests
conducted in test holes drilled between adjacent
primary and secondary holes revealed zones where
lugeon value was still higher than 6 lugeons. The
tertiary holes were drilled in between primary and
secondary holes bringing the spacing of holes to 3 m
c/c. Pattern and depth of drill holes for consolidation
grouting as shown in Fig. 5 were governed by the
geological and the design requirements.
Fig. 5: Location of drill holes in CoT area for curtain grouting
The problematic situation of CoT bed rock
foundation strata in depth of 70 m in the rock mass
where water was passing through this zone of
intercepted confined ground water condition, grout
intake with simple grout mix was not success. The
Chemical grout mix with sodium silicate, sand, Rice
(foam) with different combination were used to seal/
plug as well make the grouting. The permeability of
rock mass after the first row of grout was more than
5 lugeons. Hence about eight holes were drilled and
grouted in the second and third row at 1.5 m either
side of centre line of COT from first grout row. For
primary and secondary holes maximum pressure
adopted was 22 kg/cm² and grout mix used varied
from 4:1 to 1:2. For tertiary holes maximum
pressure adopted was also 22 kg/cm² and grout mix
used was either 4:1to 1:1. Average curtain grouting
intake in primary, secondary and tertiary holes in bed
rock of CoT was 746.88 kg/m, 520.67 kg/m and
227.10 kg/m, respectively.
Quantity Of Grout Intake:
The amount of grout intake in COT depends upon
many factors, viz. nature and extent of overbreaks,
nature and pattern of discontinuities, method of
excavation, seepage in the rock mass, grout pressure
and finally the consistency of the grout. The
Chemical grout mix with sodium silicate, sand, Rice
Husk powder/straw fibers and spongy materials
(foam) with different combination were used to seal/
plug as well make the grouting success with quality
control check with fine cement in the laboratory for
first row of Primary holes.
The quality of these materials needs to be checked
from time to time. The tests on the cement such as
consistency, setting time and the compressive
strength were performed regularly. Sand passing
Table 3: Grout intake during curtain grouting in COT area for rock foundation treatment
S.No.
1
2
3
4
5
Grout materials
Cement
Sand
Rice Husk Powder/
Straw fibre
Spongy (foam)
Sodium Silicate
Primary Grouting
8822 bags
6347 kg
557 kg
7.7 kg
1239 lit
449250.7 kg
Secondary Grouting
4454 bags
5246 kg
250 kg
2.2 kg
378 Lit.
228576.2 kg
Tertiary Grouting
3015 bags
600 kg
-
-
120 lit
151470.0 kg
Primary Grouting
733
10.55
0.93
0.013
2.06 lit/m
746.88
Secondary
Grouting
507.28
11.95
0.57
0.005
0.86 lit/m
520.67
Tertiary
Grouting
226
0.90
-
-
0.18 lit/m
227.10
Grout Intake, kg/m LengthTotal Grout Intake
Total intake material (Av.)
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through 2.36 mm sieve and 10-25%was used in the
curtain grouting along with sodium silicate by 1.5%
of the weight of cement and Rice Husk powder/Straw
fibres with 8% and foam of 0.1% by wt. of cement to
seal and plug the problematic confined zone of
pressure water.
The amount of grout intakes in COT during
curtain and consolidation grouting have been
tabulated in Table-3 and Table-4. It is clear from
Tables that there is no fix rule for quantity of grout
intake. In general, grout intake in consolidation
grouting is lesser than in curtain grouting.
Total Nos. of holes for grouting: P=5, S=4, T=9
in First row, 4 Nos. in Second row and 4 Nos. in
Third row Total hole depth of grouting: P-601.5 m,
S-439.0 m, T-667.0 m Total Nos. of holes for
grouting: P=58, S=39, T=20 Total hole depth of
grouting: P-463.8 m, S-312 m, T-159 m
Permeability Tests
Field permeability test is the most important tool
for checking the effectiveness of grouting operation at
all stages of execution. For in-situ water pressure
testing, a section of hole is isolated with a double
packer or single packer. Water is injected at specified
pressure into the test hole section. The amount of
water loss to the geological formation at a particular
pressure over a time interval is recorded. This is used
to evaluate permeability coefficient (k) as expressed in
terms of cm/sec. The unit of measuring the co-
efficient of permeability is called lugeon, which is
defined as percolation of 1 litre of water per minute
per meter length of drill hole at a pressure of 10 kg/
cm2 (1 bar).
Criteria for Locations of Permeability Tests
Locations for conducting the permeability tests
S.No.
1.
Grout materials
Cement
Primary Grouting
11339.42 kg
Secondary Grouting
4692.73 kg
Tertiary Grouting
3143.60 kg
Primary Grouting
24.45
Secondary
Grouting
15.04
Tertiary
Grouting
19.77
Grout Intake, kg/m LengthTotal Grout Intake
Table 4: Grout intake during consolidation grouting in COT rock foundation treatment
before consolidation grouting were decided on the
basis of grout intake in the contact grouting and the
available geological data of the reach. On the basis of
results of the permeability tests conducted in the pre
consolidation stage as well as amount of grout intake
during the consolidation grouting, the locations for
conducting the permeability test in the post
consolidation grouting stage, were finalised. In the
regions of low permeability values during the pre
consolidation grouting stage, certain holes can be
skipped during the consolidation grouting.
Permeability Tests in COT
Permeability tests were conducted beforeconsolidation grouting to decide the pattern of drillholes, grouting planes, consistency of grout mix andfinally to check the efficiency of grouting operation.Permeability tests were conducted up to a maximumpressure of 5 kg/cm2 in the drill holes drilled in
different depth into the rock.
Permeability test results and the degree of
efficiency of grouting at some of the typical locations
in COT are given in Table 5 and Table 6 for
consolidation and curtain grouting respectively. The
lugeon values obtained after consolidation grouting
were compared with those determined in the pre-
consolidation grouting stage and the same
accordingly for the curtain grouting. This was used as
a measure for checking the effectiveness of grouting
operation. The locations where high coefficient of
permeability values were obtained after consolidation
and curtain grouting, the drill holes were regrouted
and the permeability tests were conducted again to
confirm the efficiency of grouting.
It can be seen from Table-5 and Table-6 that
proper grouting of surrounding rock mass helps in
sealing of cracks/joints/fissure/cavities and other
Rock Foundation: Case Study
Innovative Construction Techniques for Rock Foundation Treatment and Quality Assurance of Salma Dam Project, Afghanistan - A Case Study
The Masterbuilder - March 2011164
discontinuities present in the geological strata. Thewater table after completing the grouting has been
shifted below the original water table which has been
shown in Fig.6
Quality Assurance
Sl. No.
1
2
3
4
5
6
7
8
Location/ RD in m
121, 3m towards d/s from c/l
121, 21m towards d/s from c/l
118, 6m towards d/s from c/l
127, 3m towards u/s from c/l
133, 3m towards d/s from c/l
142, 9m towards u/s from c/l
148, 9m towards u/s from c/l
151, 6m towards u/s from c/l
Before
24.74
27.58
11.84
18.80
17.44
19.28
21.60
10.08
After
1.28
5.28
1.56
0.20
3.36
2.60
1.29
1.92
Efficacy of Consolidation Grouting in %
95.0
81.0
87.0
99.0
81.0
86.5
94.0
81.0
Coefficient of Permeability Lugeon
Table-5: Permeability test results and degree of efficacy of consolidation grouting
Table-6: Permeability test results and degree of efficacy of curtain grouting
Fig.6: Details of water table after completing the grouting
The desirable quality for a structure includes its
serviceability, safety, durability, economy, timely
completion, environment friendliness, least or
minimum maintenance, easy maintenance, allowance
for modification and aesthetic acceptability. As per
ISO: 8402, the term Quality is defined as the totality
of features and characteristics of a product or service
that bear on its ability to satisfy stated or implied needs.
The development of a Quality Assurance involves
the identification of quality objectives, and their
implementation. A Quality Assurance System is
defined as 'an administrative control system which
sets for the commitments, policies, designated
responsibilities and requirements of the owner/ client.
The overall quality as defined above can only be
achieved through an effective Quality Assurance
System as per ACI Committee 121. The two basic
elements of a Quality Assurance system are:
� Quality Assurance Plan
Sl. No.
1
2
3
4
5
Location/ RD m
106 at different location in 20m depth hole after
that water intrusion felt
109m at different location in 30m depth hole
127m at different location in 70m depth hole
151m at different location in 70m depth hole
164m at different location in 25m depth hole
Before
5.5
2.72-7.43
At some location 40-45 and some
depth heavy water intrusion
At some location 36-42 and some
depth heavy water intrusion
2.10-6.22
After
1.01
0.89
4.10
4.86
0.76
Efficacy of Curtain
Grouting in %
82
88
90
88
88
Coefficient of Permeability Lugeon
Rock Foundation: Case Study
Innovative Construction Techniques for Rock Foundation Treatment and Quality Assurance of Salma Dam Project, Afghanistan - A Case Study
Esquire -CMAC Pvt.Ltd
The Masterbuilder - March 2011166
� Quality Assurance Programme
Quality Assurance (QA) Plan
QA plan is a written guideline for a project,
developed by the owner/ client which contains the
client/owner's policy statement and describes the
scope of work, organizational relationships and the
quality objectives for the project. A Quality
Assurance plan should include the following elements:
� Client/Owner's policy statement including
authorization of engineers or consultants for
developing a QA system and verifying its
implementation.
� Quality objectives.
� Scope of work.
� Organizational relationships.
� Authority and responsibilities of various
organizations.
Quality Assurance (QA) Programme
A QA programme is a document that describes
the policies, practices and procedures to comply with
quality requirements and contract documents. Each
organization assigned responsibilities in QA plan has
its own QA programme detailing the methods to be
used to meet the client/owner's quality objectives
applicable to that organization's scope of work. The
elements of QA programme are:
� Organizational responsibilities-Defining
organizational structure and delineating the
responsibilities of various personnel.
� Control of design-Detailed design, verification of
design basis such as codes, standards, assumptions,
documentation, checking and applied of
calculations.
� Material control- Supplier evaluation and
selection, storage and handling of material, testing
of material prior to use for compliance with
contract documents.
� Inspection - Inspection personnel with approved
qualification, inspection programme (check lists &
criteria for acceptance), inspection records.
� Testing & evaluation - Sampling and testing of
materials, documentation of testing details.
� Identification of non- complying conditions
including corrective actions to be taken such as
repair, rework etc.
� Records- Documents that furnished evidence of
quality of materials, equipment or activity to be
kept accurately.
Quality Control in Grouting Operations
� Checking for location of grout holes
� Checking of pipe connections for leakage etc.
� Checking of pressure
� Checking of water cement ratio, proportions and
consistency
� Checking for permeability rate
� Checking for the efficacy of grouting
Conclusions
� Impact and successful proper grouting of the
surrounding rock mass is essential in sealing of
cracks/joints/fissures/cavities and other
discontinuities present in the geological strata.
This will not only help in controlling and
minimising the seepage of water from structures
to the geological mass but will also help in
behaving the rock mass monolithically around the
core of embankment dam body.
� Rock Permeability and groutability tests
conducted before and after consolidation and
curtain grouting proved to be an important tool
for checking the efficiency of problematic
grouting. It also helped in taking decisions for
regrouting in the reach of certain sections of COT
where coefficients of permeability after grouting
were found to be high.
� The field grout mix properties with different
proportion of the materials with sand, Rice Husk
powder/Straw fibres and spongy (foam) during the
problematic situation in the curtain grouting
having setting time and viscosity determined in
the laboratory before the grouting operation
Rock Foundation: Case Study
Innovative Construction Techniques for Rock Foundation Treatment and Quality Assurance of Salma Dam Project, Afghanistan - A Case Study
Cosmos Construction Machineries & Equip.Pvt.Ltd
The Masterbuilder - March 2011168
proved to its usefulness. These properties of the
grout mix improved considerably the success in
problematic zone for the grouting.
� In general, the design criteria given in different
manuals were followed for grouting. However,
based on the water permeability tests conducted
during pre consolidation and curtain stage, some
holes may be skipped during consolidation as well
as curtain grouting after few trials at site. This
may not only help in savings in terms of time but
will also lead to financial savings as well as per the
technical requirements of grouting.
References
The suggestions and advices given by Sh. Murari Ratnam, Director,
CSMRS, Dr. Anbalagam, Prof. IIT Roorkee, Dr. T.N.Singh, Prof.
Geology Deptt. IIT Mumbai, Sh. Y.R. Putty, GM & Expert Grouting, ITD
Cementation and Sh. Jaggi sahib, Vice President, Afcon Co. Pvt. are
highly appreciable during the problematic situation of high pressure water
intrusion for making successful grouting with different mix
proportion of grout materials.
� IS 12169:1987 Criteria for design of small embankment dams
� IS 9429:1999 Code of practice for drainage system for earth and
rockfill dams
� IS 8414:1977 Guidelines for design of under seepage control
measures for earth and rock fill dams
� IS 6066:1994 Pressure grouting of rock foundations in river valley
projects - Recommendations (Second revision)
� IS 4031 (Part-6):1988 "Methods of Physical tests for Hydraulic
Cement" (Part-6, "Determination of Compressive strength of
Hydraulic cement other than masonry cement"), Bureau of Indian
Standard, New Delhi.
� IS 5529 (Part-2):1985 "Code of practice for In-situ Permeability
tests" (Part 2 Tests in bedrock), Bureau of Indian Standard, New
Delhi.
� IS 5878 (Part VII):1972 "Code of practice for construction of tunnels"
(Part VII - Grouting), Bureau of Indian Standard, New Delhi.
� IS 1498:1970 Classification and identification of soils for general
engineering purpose
� IS 7894:1975 Code of practice for stability analysis of earth dams
� IS 516: 1999 "Methods of tests for strength of concrete", Bureau of
Indian Standard, New Delhi.
� Barton N., Lien R and Lunde J. (1974), "Engineering Classification
of Rock Masses for Design of Tunnel Support", Rock Mechanics
Vol. 6, No. 4, pp 189-236.
� Grimstad E and Barton N. (1993), "Updating of the Q-System for
NMT", Proc. Of Int. Symp. on Sprayed Concrete for Underground
Support, Fagernes, Norwegian Concrete Association, Oslo.
� Lecture notes on Rock Permeability and Groutability Related to
Dams and Reservoirs, by Ewart, Friedrich-Karl, University of
Paderborn, Germany, September, 1994.
� Manual No. 1110-1-2908 for Engineering and Design, Rock
Foundation by U.S. Army Corps of Engineers, Washington, DC
20314-1000, November 1994.
� Water Resources Commission N.S.W., Grouting Manual, 3rd
edition, Australia, 1980.
� Field Manual, Foundation Treatment for Rockfill Dams, Journal of the
Soil Mechanics and Foundations Division, Proceedings of the
American Society of Civil Engineers, Vol. 98, No. SM10, pp. 995-
1016, October 1972.
� Preparation of Rock Foundations for Embankment Dams,
Embankment Dams Engineering, New York, John Wiley and Sons,
Inc., pp. 355-363, 1973.
� Treatment of High Embankment Dam Foundations, Journal of the
Soil Mechanics and Foundations Division, Proceedings of the
American Society of Civil Engineers, Vol. 98, No. SM10, pp. 1099-
1113, October 1972.
� Engineer Manual No. EM 1110-2-2300, General Design and
Construction Considerations for Earth and ̀ Rock-Fill Dams by U.S.
Army Corps of Engineers, Washington, DC 20314-1000, July, 2004
Authors Bio
Ram Bachan Shivali is graduate B.Tech. (CivilEngg.) from NIT Warangal, A.P (Formerly REC)
and M.Tech. (WRD) from IITRoorkee (Formerly
University of Roorkee). He is the member andReview Committee member of American Concrete
Institute (ACI), Indian Society for Construction
Materials and Structures, Indian Society for RockMechanics and Tunneling Technology and Indian
Geotechnical Society. His interest of works are in
the fields of Concrete Technology, Rock Engineering& Rock Mechanics and Geotechnical Engineering
for field constructions of dam (Concrete dam,
Earthen dam and Earth & Rockfill dam), QualityControl and Quality Assurance programme and
design & planning for different components of their
related structures and construction. Investigationworks related to construction materials, fields and
laboratory testing of all above fields and results
analysis & data as per design parameters requiredfor designing the structures.
Rock Foundation: Case Study
Innovative Construction Techniques for Rock Foundation Treatment and Quality Assurance of Salma Dam Project, Afghanistan - A Case Study
high-ductility rebars because 60%
of India (Mumbai, Thane, Kutch,
Delhi and many other parts of
North and North-East India) lies in
the high-hazard seismic zones 3, 4
and 5.
3. Myths surrounding rebars such as
Earthquake Resistant Steel bars, X-
pattern ribs etc.
4. Potential savings of Rs. 8,000 crore
per year if India switches from the
rebars it has been using since 1972
to today's high-strength and high-
ductility rebars such as Thermex
Grade500 that are easily available
across the country.
Lending credibility to TRMA's crusade
were independent professors, engi-
neers and auditors who drew atten-
tion to:
1. Production of spurious 'TMT' steel
reinforcement bars. These impar-
tial speakers regretted that the new
Indian Standard (IS):1786-2008
gave a license for use of improper
TMT quenching technology by stat-
ing that non-uniform peripheral
quenching was not a ground for
rejection.
2. 70-year old buildings on Mumbai's
Marine Drive continue to stand tall,
while newer stories built atop the
same buildings using CTD steel
rebars need repair within 5-6 years,
testifying to CTD's poor perfor-
mance. Even so, many Indian build-
Thermex Rebar Manufacturers'
Association (TRMA) officially
flagged off its all-India drive for
'Proper Steel Reinforcement' in
Mumbai city in the presence of a ster-
ling group of government and non-
government bodies. TRMA, a no-profit
company comprising Thermex steel
rebar manufacturers, has set out to
uplift the quality of steel rebars used in
India's civil construction by spreading
awareness of desirable properties in
rebars.
At its inaugural Mumbai seminar,
TRMA laid bare the myths and realities
of rebars to eminent representatives
from MMRDA, CIDCO, MCGM, Indian
Society of Structural Engineers, India
Chapter of American Concrete Insti-
tute, Association of Consulting Civil
E n g i n e e rs , L a rs e n & To u b ro ,
Hiranandani Group, Nuclear Power Cor-
poration of India, and several structural
engineers.
1. India's continued used of improper
Cold Twisted Deformed (CTD)
rebars in construction activity since
1972. While such rebars were dis-
continued in Europe almost 40
years ago, many Indian builders con-
tinue to use these improper rebars
in their current projects.
2. India's need for high-strength and
Attention was drawn to 4 key points:
TRMA Launches Crusade for'Proper Steel Reinforcement'
169The Masterbuilder - March 2011
Steel: Roving Seminar
ers continue to use CTD rebars.
3. The need for IS to specify the same
level of high ductility for rebars irre-
spective of the Yield Strength, as is
specified in the codes of European
countries.
4. The need for IS to specify higher val-
ues of elongation and stress ratio
for rebars to be used in earthquake
prone areas.
5. IS code gives importance to elonga-
tion at fracture instead of uniform
elongation of rebar. This poses a
grave risk to residents of buildings
in high seismic hazard places. Other
countries have already shifted to
uniform elongation since the past 5
years - the correct option.
6. Many expressed surprise that dif-
ferent chemical compositions were
specified for 7 differing rebar
grades in the code.
All speakers felt the IS code must be urgently revised to keep pace with global standards. This conference will travel to many other Indian cities and towns to address the civil engineering fraternity. The conference's next instal-ment will be in Chennai.
The inventor, Mr. Franz Tamm, of
the world-famous and much-in-
demand 'Thermex Quenching & Self
Tempering' technology of HSE technol-
ogy graced the occasion. He was felici-
tated at the event for his contribution
to steel reinforcement, as was Mr.
Surendra Hiranandani, Managing
D i rector and Founder o f the
Hiranandani Group. In keeping with its
outstanding reputation for quality and
innovation, the construction conglom-
erate was the first to adopt Thermex
Grade500 rebars in its projects. Mr.
Hiranandani received the 'Pioneer in
Building Construction' award.
TRMA Launches Crusade for 'Proper Steel Reinforcement'
In the Indian sub-continent, Thermex
systems have already been commis-
sioned in 128 steel mills, while 22 are
currently under execution. Today, more
than 60% of the steel reinforcement
bars produced in India is Thermex rebars.
Although Thermex rebars are pro-duced by 128 different steel plants or companies, great effort is made to ensure consistency in quality. Thermex rebars from each Thermex Licensee are subject to quarterly, third-party, qual-ity audit to ensure that besides meet-ing the IS Code they also a) exhibit uni-form peripheral tempered martensite and b) meet the strict Thermex stan-dards of tensile properties and ductility as per global norms. Steel mills found to be producing rebars of lower quality risk the danger of losing their Thermex licence. Thus Indian builders can source Thermex rebars from any of the several Thermex licensees in their region, while at all times being assured the quality of the rebar will be consis-tent no matter from which steel plant it is sourced. In the Indian sub-continent, Thermex systems are supplied, installed and commissioned by H&K India, the exclusive and perpetual col-laborator of HSE Germany.
At the event, the new Thermex sym-
bol was officially unveiled. From now
onwards structural engineers can use
the new symbol in all their project draw-
ings/designs to specify use of Thermex
rebars.
The patented Thermex technology
enjoys front-runner status in the world
for 'quenching and self-tempering'
technology. The technology enables
production of desired high-strength
steel reinforcement bars that meet all
requirements of civil construction -
yield strength ranging from 500MPa or
more, toughness, ductility, weldability
and excellent bend properties. Ductil-
ity is key as it prevents the rebar from
snapping outright and causing the
immediate collapse of a building during
an earthquake. High-strength, high-
ductility rebars drastically reduce the
risks of total building collapse - as wit-
nessed in the Bhuj quake of 26 January
2001 - thereby increasing the opportu-
nity for residents to escape instead of
being crushed to death.
Thermex systems are installed
worldwide, ranging from Asia,
Australasia, Europe, Russia, Africa,
Americas, and the Indian sub-continent.
Steel: Roving Seminar
170 The Masterbuilder - March 2011
Reliance Industries Ltd
Student Interaction
172 The Masterbuilder - March 2011 The Masterbuilder - March 2011
Stimulus 2011 A Truly Invigorating Experience for Civil Engineering Students
Student Interaction
The regional rounds of the event
were held in Chennai, Vellore, Kochi,
Koz h i ko d e , S a l e m , Tr i c hy a n d
Coimbatore repectively. This one-of-its-
kind event received enthusiastic
response from engineering colleges
with students showing keen interest in
participation. What set the event apart
was the fact that it was being conducted
by a major industrial house and was
exclusively focused on civil engineering.
Students thronged all the venues
where the regional rounds of Stimulus
2010-11 were held in large numbers. A
good example was the Coimbatore
round, where six institutions partici-
pated with PSNA College of Technology
walking away with the first prize, fol-
lowed by the PSG College of Technology.
The Salem round of the quiz pro-
gram saw six institutions participate
with the Institute of Road and Transport
Technology, Erode, walking away the
deserved winners. The event was held
at Sona College of Technology, Salem.
The Kozhikode round of the quiz saw
the participation of six engineering col-
leges in the region. The round saw
enthusiastic participation with the
respective college students cheering
and encouraging their teams.
Nowhere perhaps the lively atmo-
sphere more evident than in the Trichy
round of Stimulus 2010-11, with the
quiz master Mr.Giri Balasubramaniam
With the objective of incul-
cating competitive spirit
and motivating students to
become better professionals, UltraTech
Cement Ltd, part of the Aditya Birla
group, conducted a Civil Engineering Quiz
for final year civil engineering students.
STIMULUS 2011A Truly Invigorating Experience for Civil Engineering Students
'Pick Brain' Giri Balasubramanian firing his salvo
Enthralled audience keenly watching the fierce competition
Stimulus 2011 winners and runners with other participating teams in theirteam attires aptly provided by the organisers
Dr. M R Kalgal, Dr. V Ramachandra, Mr. N Balachandran Nair officials from UltraTech Cement Limited giving away the trophy and the cash prize to the Stimulus 2011 Champions
Ravali Tata and K. Srinath, IIT Madras - Champions of Stimulus 2011
T. Anu Vetriselvi and Yogesh Dahal of PSNA College of Technology
Dindigul - Runnder of Stimulus 2011
likening it to a 20-20 cricket match. The
competition was intense between the
NIT-T and Periyar Maniyam University
teams and had a nail biting finish to
boot.
The grand finale of Stimulus 2010-11
was held at Hotel GRT Convention Cen-
tre, Chennai on 01st of March 2011 with
IIT Madras represented by Ravali Tata
and K. Srinath walking away as winners.
The quiz programme was designed
to bridge the gap between textbook
knowledge and industry expectations. It
gave prospective engineers an insight
into what exactly industry experience is
all about.
173
Student Interaction
172 The Masterbuilder - March 2011 The Masterbuilder - March 2011
Stimulus 2011 A Truly Invigorating Experience for Civil Engineering Students
Student Interaction
The regional rounds of the event
were held in Chennai, Vellore, Kochi,
Koz h i ko d e , S a l e m , Tr i c hy a n d
Coimbatore repectively. This one-of-its-
kind event received enthusiastic
response from engineering colleges
with students showing keen interest in
participation. What set the event apart
was the fact that it was being conducted
by a major industrial house and was
exclusively focused on civil engineering.
Students thronged all the venues
where the regional rounds of Stimulus
2010-11 were held in large numbers. A
good example was the Coimbatore
round, where six institutions partici-
pated with PSNA College of Technology
walking away with the first prize, fol
lowed by the PSG College of Tech-
nology.
The Salem round of the quiz pro-
gram saw six institutions participate
with the Institute of Road and Transport
Technology, Erode, walking away the
deserved winners. The event was held
at Sona College of Technology, Salem.
The Kozhikode round of the quiz saw
the participation of six engineering col-
leges in the region. The round saw
enthusiastic participation with the
respective college students cheering
and encouraging their teams.
Nowhere perhaps the lively atmo-
sphere more evident than in the Trichy
round of Stimulus 2010-11, with the
With the objective of incul-
cating competitive spirit
and motivating students to
become better professionals, UltraTech
Cement Ltd, part of the Aditya Birla
group, conducted a Civil Engineering Quiz
for final year civil engineering students.
STIMULUS 2011A Truly Invigorating Experience for Civil Engineering Students
'Pick Brain' Giri Balasubramanian firing his salvo
Enthralled audience keenly watching the fierce competition
Stimulus 2011 winners and runners with other participating teams in theirteam attires aptly provided by the organisers
Dr. M R Kalgal, Dr. V Ramachandra, Mr. N Balachandran Nair officials from UltraTech Cement Limited giving away the trophy and the cash prize to the Stimulus 2011 Champions
Ravali Tata and K. Srinath, IIT Madras - Champions of Stimulus 2011
T. Anu Vetriselvi and Yogesh Dahal of PSNA College of Technology
Dindigul - Runnder of Stimulus 2011
likening it to a 20-20 cricket match.
The competition was intense between
the NIT-T and Periyar Maniyam Univer-
sity teams and had a nail biting finish to
boot.
The grand finale of Stimulus 2010-11
was held at Hotel GRT Convention Cen-
tre, Chennai on 01st of March 2011 with
IIT Madras represented by Ravali Tata
and K. Srinath walking away as winners.
The quiz programme was designed
to bridge the gap between textbook
knowledge and industry expectations. It
gave prospective engineers an insight
into what exactly industry experience is
all about.
173
476 AD. Innovative materials including 'Pozzolana'cement from a village Pozzouli near Italy with the use of horse hairs as fibres in concrete and primitive forms of admixtures including, animal blood, milk and fat were used by the Romans, which in fact led to the famous adage “ all roads lead to Rome”.
The success of white-topped roads in the USA is a fascinating case study in itself, something that is worthy of emulation, by a country like India, which is in the midst of its largest ever road-building spree. The intricacies involved in the process, along with the various related aspects that are involved were bought out in detail in a recent roundtable on “Concrete Roads & Toppings- Experience and Success in USA', c o n d u c t e d b y l e a d i n g c e m e n t manufacturer, Ultra Tech Cement. The round table saw experts from the USA share their experience on white topped roads with a select audience.
Welcoming the audience and the speakers, Mr.Vijay Shankar, General Manager (Technical Services) Ultra Tech and Chairman, Indian Concrete Institute, Tamil Nadu Centre, gave an insight into the various divisions of the Aditya Birla Group. He highlighted how Ultra Tech has today grown into becoming among the top 2 cement manufacturers in the country. Speaking about the company's state-of-the-art R & D Centre at Taloj near Mumbai he explained how the company was “focused on sustainability”.
Stressing on the growing importance of white topped roads, Mr.A.K.Jain, Senior Consultant of Ultratech Cement spoke about the increasing number of concrete roads in India. “It was a bold
The US Success Story
Expert Speak
proven technology. “1000s of kilometers of overlay stand testimony to the technology,” quipped Mr.Vanikar on the subject. Mr.Vanikar pointed out to the steps that are needed for the success of such projects including, evaluating the pavement in place, choosing the right type of overlay, repair any damage-if needed, preparing the interface, cutting joints, and curing, as part of the successful procedure for concrete white topped roads.
The technology has wide ranging implications for a country like India, where conditions of roads are appalling in some areas. Apart from its use in laying new roads, white topping can also help in restoring or increasing the load carrying capacity or both of existing roads. The
Huge Potential
decision to create the NHDP program in 1999 by the then government,” he said before going into the details of the various other similar initiatives including the NHAI, Expressways, and PMGSY. Speaking about the challenges faced today he said “ The trucks in our country cover on an average 300-400 kms per day against 700-800 kms in countries where good roads are available,” before he went on to explain how concrete roads with white topping can help in ending this anomaly.
The rising price of bitumen was another facet that was highlighted by Mr.Jain. He pointed out how estimates projected the rate of bitumen would be around 1, 80,000 per ton by 2021, prices which would not be economically viable for the country. “Cement is available locally throughout the country. Good quality aggregates is another thing that is available in India. We can create world-class concrete or rigid pavements in India,” remarked Mr.Jain highlighting the cost benefits of the technology during his address.
Dr.Gajanan Sabnis, Professor Civil Engineering , Howard Univers ity, Washington DC, considered an authority on concrete, began by saying “Concrete roads are here to stay. The long pavement life makes it a sustainable option.” He was of the opinion that sustainability of concrete pavements is something that is to be looked at from a long term perspective. He added further that concrete pavement systems will require very low maintenance and as such their impact on environment is very small. Dr.Thomas Van Dam, of Michigan Technological University, one of the American experts who had come for addressing the seminar pointed out that “You have to design a structure so that it
The Masterbuilder - March 2011
Concrete Roads & White Toppings: Hold Immense Possibilities for India
Back-breaking drives on pot-holed filled blacktopped roads may soon be a thing of past on Indian cities.
The encouraging results of pilot projects on white-topping that has been undertaken in a few cities including Bengaluru and Mumbai has meant that white-topping of roads would become fairly commonplace in India.
To put it in simple terms, white-topping road involves laying a concrete surface and then giving it a white coating. White-topping is a common procedure in Europe and America where there are thousands of kilometers of roads that have benefited from the concept. Not only are white-topped roads pot-hole free, they are also skid resistant and help in reducing fuel and maintenance expenses.
Contrary to popular perception, concrete roads are not a recent phenomenon. Historical references point out to concrete roads being built by Romans way back in time during 300 Bc-
The Masterbuilder - March 2011
lasts under the traffic that you anticipate.” He went on to add that “You can have the best design, the best materials, but if you built it (roads) poorly, it will fail,” stressing on the importance of the right engineering methodology.
Going into detail as to how concrete roads have already made an appearance in India, Mr.Suneel Vanikar, FHWA, Office of Pavement Technology, Washington DC, said “I have come across several news reports on concrete roads in India. The case for them has been made in several quarters.” He went on to tell the select gathering about how the US had been inspired by Europe when it came to adopting concrete pavements in a major way, particularly German and Austria. Mr.Vanikar dwelling on the two-lift projects spoke about the fact that concrete roads and white topping was a
176174
Concrete Roads & White Toppings
A.K.Jain, Senior Consultant, Ultratech Cement
Jayasankar, GM (Technical Services)UltraTech & Chairman ICI TNCC Dr.Thomas Van Dam, Michigan Technological University Suneel Vanikar, FHWA, Office of pavement technology, Washington, DC
Hold Immense Possibilities for India
Dr.Gajanan Sabnis, Professor, Civil Engineering,Howard University, Washington DC
experts during the round table pointed out how concrete overlays restore the rideabaility of existing pavements, which have suffered long due to rutting and deformation in addition to addressing other issues such as improving thetexture of roads. With the concept fast catching up with policy makers, the con-cept of concrete roads with white top-pings is all set to increase in the country. The recent times have seen rapid devel-opments in the field of production and lay-ing of concrete, which in turn favour con-crete overlays as a cost-effective and sus-tainable road construction option for a country like India. Plus the fact that the country produces about 250 million tonnes of cement, which is among the highest in the world, has set the ball roll-ing for concrete roads with white topping in the country.
Roundtable Roundtable
175The Masterbuilder - March 2011
�In today's Modern World the “Construction Industries”
are in need for good supply for quality products to the
market in order to stand strong. Basic blend products
like OPC / blended special cement etc in the case of
specialty construction aim for quality assurance.
The advanced technology is compelled to include the micro
ingredients in building products formulation to enhance
Fast processing at site Building performance
The surface finish & Durability of the structure
Toshniwal offers the new generation powder mixing
equipment which works on “fluidized zone” principle
mixing technique. Their main characteristics are :
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The Mixer has proven record for the building materials and
construction care products like
Dry Mortar Integral Water Proofing CompoundRenders Grouts Flour HardenerWall Plasters Repairing MortarWall Putty (Dry) Tile Joining CompoundFloor Screeds Thermal insulation productsSkim Coats Fire Proof CementBlended Cement Wall Paper Compounds
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sized batch mixing plant on job work basis to blend as per
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M/S. Toshniwal Systems & Instruments Pvt Ltd267, Kilpauk Garden Road, Chennai - 600 010, India.Phone: 91-44-26445626 / 26448983Email: [email protected] / Web: www.toshniwal.net
Right Mixing Technique
Further details from:
Building Material Construction Care
Communication Feature
To Make Good Things
Even Better
Toshniwal
476 AD. Innovative materials including 'Pozzolana'cement from a village Pozzouli near Italy with the use of horse hairs as fibres in concrete and primitive forms of admixtures including, animal blood, milk and fat were used by the Romans, which in fact led to the famous adage “ all roads lead to Rome”.
The success of white-topped roads in the USA is a fascinating case study in itself, something that is worthy of emulation, by a country like India, which is in the midst of its largest ever road-building spree. The intricacies involved in the process, along with the various related aspects that are involved were bought out in detail in a recent roundtable on “Concrete Roads & Toppings- Experience and Success in USA', c o n d u c t e d b y l e a d i n g c e m e n t manufacturer, Ultra Tech Cement. The round table saw experts from the USA share their experience on white topped roads with a select audience.
Welcoming the audience and the speakers, Mr.Vijay Shankar, General Manager (Technical Services) Ultra Tech and Chairman, Indian Concrete Institute, Tamil Nadu Centre, gave an insight into the various divisions of the Aditya Birla Group. He highlighted how Ultra Tech has today grown into becoming among the top 2 cement manufacturers in the country. Speaking about the company's state-of-the-art R & D Centre at Taloj near Mumbai he explained how the company was “focused on sustainability”.
Stressing on the growing importance of white topped roads, Mr.A.K.Jain, Senior Consultant of Ultratech Cement spoke about the increasing number of concrete roads in India. “It was a bold
The US Success Story
Expert Speak
proven technology. “1000s of kilometers of overlay stand testimony to the technology,” quipped Mr.Vanikar on the subject. Mr.Vanikar pointed out to the steps that are needed for the success of such projects including, evaluating the pavement in place, choosing the right type of overlay, repair any damage-if needed, preparing the interface, cutting joints, and curing, as part of the successful procedure for concrete white topped roads.
The technology has wide ranging implications for a country like India, where conditions of roads are appalling in some areas. Apart from its use in laying new roads, white topping can also help in restoring or increasing the load carrying capacity or both of existing roads. The
Huge Potential
decision to create the NHDP program in 1999 by the then government,” he said before going into the details of the various other similar initiatives including the NHAI, Expressways, and PMGSY. Speaking about the challenges faced today he said “ The trucks in our country cover on an average 300-400 kms per day against 700-800 kms in countries where good roads are available,” before he went on to explain how concrete roads with white topping can help in ending this anomaly.
The rising price of bitumen was another facet that was highlighted by Mr.Jain. He pointed out how estimates projected the rate of bitumen would be around 1, 80,000 per ton by 2021, prices which would not be economically viable for the country. “Cement is available locally throughout the country. Good quality aggregates is another thing that is available in India. We can create world-class concrete or rigid pavements in India,” remarked Mr.Jain highlighting the cost benefits of the technology during his address.
Dr.Gajanan Sabnis, Professor Civil Engineering , Howard Univers ity, Washington DC, considered an authority on concrete, began by saying “Concrete roads are here to stay. The long pavement life makes it a sustainable option.” He was of the opinion that sustainability of concrete pavements is something that is to be looked at from a long term perspective. He added further that concrete pavement systems will require very low maintenance and as such their impact on environment is very small. Dr.Thomas Van Dam, of Michigan Technological University, one of the American experts who had come for addressing the seminar pointed out that “You have to design a structure so that it
The Masterbuilder - March 2011
Concrete Roads & White Toppings: Hold Immense Possibilities for India
Back-breaking drives on pot-holed filled blacktopped roads may soon be a thing of past on Indian cities.
The encouraging results of pilot projects on white-topping that has been undertaken in a few cities including Bengaluru and Mumbai has meant that white-topping of roads would become fairly commonplace in India.
To put it in simple terms, white-topping road involves laying a concrete surface and then giving it a white coating. White-topping is a common procedure in Europe and America where there are thousands of kilometers of roads that have benefited from the concept. Not only are white-topped roads pot-hole free, they are also skid resistant and help in reducing fuel and maintenance expenses.
Contrary to popular perception, concrete roads are not a recent phenomenon. Historical references point out to concrete roads being built by Romans way back in time during 300 Bc-
The Masterbuilder - March 2011
lasts under the traffic that you anticipate.” He went on to add that “You can have the best design, the best materials, but if you built it (roads) poorly, it will fail,” stressing on the importance of the right engineering methodology.
Going into detail as to how concrete roads have already made an appearance in India, Mr.Suneel Vanikar, FHWA, Office of Pavement Technology, Washington DC, said “I have come across several news reports on concrete roads in India. The case for them has been made in several quarters.” He went on to tell the select gathering about how the US had been inspired by Europe when it came to adopting concrete pavements in a major way, particularly German and Austria. Mr.Vanikar dwelling on the two-lift projects spoke about the fact that concrete roads and white topping was a
176174
Concrete Roads & White Toppings
A.K.Jain, Senior Consultant, Ultratech Cement
Jayasankar, GM (Technical Services)UltraTech & Chairman ICI TNCC Dr.Thomas Van Dam, Michigan Technological University Suneel Vanikar, FHWA, Office of pavement technology, Washington, DC
Hold Immense Possibilities for India
Dr.Gajanan Sabnis, Professor, Civil Engineering,Howard University, Washington DC
experts during the round table pointed out how concrete overlays restore the rideabaility of existing pave-ments, which have suffered long due to rutting and deformation in addition to addressing other issues such as improving the texture of roads. With the concept fast catching up with policy makers, the concept of concrete roads with white top-pings is all set to increase in the country. The recent times have seen rapid devel-opments in the field of production and lay-ing of concrete, which in turn favour con-crete overlays as a cost-effective and sus-tainable road construction option for a country like India. Plus the fact that the country produces about 250 million tonnes of cement, which is among the highest in the world, has set the ball roll-ing for concrete roads with white topping in the country.
Roundtable Roundtable
High-tenacity Polyester Yarn
Double Layer PVC
Backside With Double
Protective Lacquering
Double Layer PVC
Frontside Double InkAbsorption Lacquering
LUCKY INTERNATIONALLUCKY INTERNATIONALTensile Fabric Roofing Specialist
Raises the Bar Higher
Tensile fabric architecture and textile construction is an area that is rapidly finding an increasing
number of takers globally. Lucky International has been a trendsetter and industry leader in this highly specialized field. The company offers a range of laminated textiles including, PVDC, PVC, PU, and acrylic coated fabrics, which find wide application in architectural structures, gazebos, market tents, structure for tents, etc. The company is also leading name in the production and supply of PVC Coated Paper and Paper Board, which find wide application in book binding and dairies. Speaking exclusively to the Masterbuilder, Mr.Puneet Jhaveri, who heads Lucky International, gave an insight into the company's products and future plans. Here are excerpts from the interview.
India is predominantly a sunny country during most part of the year. Then there are rains for some 3-5 months. Hence, you can understand- that some kind of shade is required to protect against this heat and rains. This is where
What are your views on the growth of fabric roofing industry in India?
pools, warehouses, etc.
Lucky International, part of Jhaveri Group, is a diversified business entity dealing in Technical Textiles, PVC Coated Paper & related product. We are merchant exporter and importer for these products. For more than five decades, our group has been at the forefronts of the Coating & Laminating Industry. Our grandfather, Mr. Rajmal Jhaveri la id the foundation for Dharampur Leather Cloth Co Ltd, which was Original Equipment (O.E.) supplier of PVC Coated Fabrics to Indian Railways, Defense, automobile industry, etc.
Give us a brief insight about Lucky International.
these Tensile Shade Structures come into play. Apart from offering protection against heat, dust, and rain, they are also aesthetically pleasing.
With the growth of the IT industry in the recent years, there has been an increased demand for these products. The Indian market is demanding a wide range of high quality products that are able to withstand extreme weather conditions while being durable and maintenance friendly.
You see these architectural fabrics used in various tensile structures, tent, and temporary roofing projects like sun awnings, gazebos, structures for restaurants, market tents, swimming
177The Masterbuilder - March 2011
Interaction
Lucky International Tensile Fabric Roofing Specialist Raises the Bar Higher
Mr.K.V.SrikanthSr.Sales Manager, Doka
life of the product. It has a self cleaning property, hence no need to use the services of an expert or expensive cleaning detergents.
SIOEN has the entire production process under one roof, from the raw fabric and pigment pastes to coating and processing the technical textile. Firstly, with respect to the coating layer or protective layer, consisting of polymers in liquid or solid form - with SIOEN Chemicals- they produce all pastes, varnishes and granules themselves. Second, with respect to the carrier or substrate, in the form of a woven or knitted fabric or non-woven item - SIOEN has one spinning mill and 3 weaving mills. Finally, with respect to the coating technology: this includes the entire process of applying the coating layer to the substrate- SIOEN specializes in 5 coating techniques
In the recently concluded Olympics in Beijing, China, SIOEN's fabrics were extensively used for the tent structures.
SIOEN has been following a pro-active environmental policy. The company's slogan for many years now h a s b e e n ' P r o t e c t i o n t h r o u g h Innovation'. They produce products that p r o t e c t h u m a n b e i n g s , t h e i r environment, and their possessions and do so in an environmentally friendly way.
The group is making increasing use of re c yc l i n g a n d e n e rg y re co ve r y technologies. Coating sites are fitted with distillation and combustion towers, which minimize exhausts and recover hot air which can be used to pre-heat ovens. At Ardooie, contaminated solvents from cleaning paste tubs are distilled for re-use and we use heat exchangers. The new extension at Ardooie (Veranneman production hall plus storage warehouse) is fitted with electricity generating solar panels.
Please give us examples of major International projects done with SIOEN Fabrics.
Tell us about the green initiatives of the company.
of technical textiles. It is the largest manufacturer of Coated Fabrics (> than 80 mn SQM p.a.). With a Euro 349 million turnover, the company has 38 subsidiaries in 14 countries, with more than 4,600 employees and sales in over 90 countries. SIOEN Industries also owns a color pigments manufacturing plant.
Our PVC Coated Fabric is a Nine Layer fabric. The high tenacity Polyester Fabric is coated with 2 layers of PVC on both sides and then lacquered with 2 layers of Protective film on each side.
Its applications include, architectural structures, sun awnings, gazebos, structures for restaurants, market tents, tarpaulins for truck containers, partition walls, inflatables games and promotions, car boxes, balloons, swimming pools, etc.
SIOEN's product line is backed by solid research by an experienced R & D team. The Tensile Fabric is coated with 2 layers of PVDF on both sides of High Tenacity Polyester Fabric which is also treated to low wick.
It has excellent UV- which adds to the
What is the specialty of your product?
What makes your products and services superior to the others?
Another group company by the name Coated Sales Co Pvt Ltd, specializes in the manufacturing of PVC Coated Fabrics and P VC C o ate d Pa p e r fo r va r i o u s applications like tents, awnings, canopies, inflatables, balloon, umbrella, auto& jeep hoods, book binding, etc.
We have tied up with the world's largest manufacturer of Coated Fabrics- SIOEN Industries, Belgium. It's a win- win situation for both of us- with SIOEN's technically advanced products and our market presence of so many years and e x p e r t i s e . W e a r e e x c l u s i v e representative of SIOEN for Tent, tensile membrane and truck tarpaulins fabrics.
Headquartered in Ardooie, Belgium- SIOEN Industries is a diversified stock quoted group with an extensive portfolio of products and activities: spinning, weaving and coating, manufacturing of clothing, production of fine chemicals and processing of technical textiles.
SIOEN Industries is a world leader in coated technical textiles. The company has strong specialization in high end technical apparel. It is a specialist in fine chemicals and global player in processing
Tell us about your principal SIOEN Industries.
SIOEN headquarter located in Ardooie, Belgium
World leader in PVC knife coating we are committed tosupply best materials to our international customership.
178 The Masterbuilder - March 2011
Interaction
Columbia Pakona Engineering Pvt.Ltd
Cemseal System & Sales (Webac)
Site Report
180 The Masterbuilder - March 2011
SCM, during a meeting with the Fayat team stated “We wanted to graduate and keep our leadership position in the market. India's road construction industry is quite dynamic and the standards are ever-raising. Strategic investment into the right crucial tool like the asphalt plant is therefore a must. We have realized that it is impossible to be profitable without being efficient and green. MARINI MAC featured several energy efficient features and carbon saving technology that we were convinced about the plant being the right tool to keep up with the vision of our company.”
Stating his views Mr. Haribabu - VP Transportation, a key member of the decision making team observed, “ The decision for MARINI asphalt plants were taken because they have excellent track record in India, as well as world-wide. To ensure our bottom lines, we needed our project durations to be shortened, as much as possible. This calls for a highly efficient, productive, and reliable asphalt plant. Once the plant is on project site, project handling, commissioning, and testing procedures need to be done very efficiently to save time. The plant must be bang on the job and produce quality mix, as each day costs the contractor a lot… and that is exactly what MARINI MAC did.”
Ramky's MARINI MAC has been supplied with state-of-the-art features. The plant is capable of producing futuristic and low carbon emitting mixes; recycled asphalt mixes with up to 35 percent RAP content with traditional specification mixes. The plant features dual storage facilities to stock reclaimed filler. This feature was particularly important for Ramky, as they didn't want to have a plant with a top-notch bag filter but then have dust fly all over and around the asphalt plant. A 36 Cbm foreign filler silo with
181The Masterbuilder - March 2011
Site Report - MARINI MAC 200 - State of-the-art Efficiency Delivered
Site Report
landmark record that was achievedby Ramky in the project is that the MARINI MAC 200 plant was installed in a record number of hours. The plant, installed by India's leading sustainable development focused company, has been delivered with a host of special features that are aimed at improving productivity and at the same time reduce fuel consumption.
The record time in which the plant was erected and commissioned has come as a pleasant surprise for everyone involved with the project. Said Mr.L.Narayanel, Senior Manager Resources from Ramky, who till now was used to seeing asphalt plants take
around 45-60 days to be erected and commissioned in the country, “ We erected and commissioned the plant in a record 20 days time. MAC's modular design facilitates quick set-up and thanks to the pre-wired and pre-tested units, it was all plug and play, “before adding, “All the components fit so well w i t h o u t t h e n e e d f o r f i e l d modifications. In addition, the plant's control system help diagnose plant problems with ease.”
S p e a k i n g a b o u t t h e p l a n tMr.Y.Nagaraja - Managing Director, Ramky Infrastructure had recently said, “O u r co m p a ny i s fo c u s ed o n sustainable development and we found in Fayat Group the right partner”. The recent addition of Green asphalt plants from MARINI have further fortified Ramky's image in terms of a green company. The management team at Ramky did a thorough analysis of the various aspects before opting for the MAC asphalt plant.
Describing the process of selection of the plant Mr.Mahendra Kumar - VP-
The MARINI MAC Series of hot mix asphalt plants, known for their superior energy efficiency
and design have been making waves in recent times. Ramky Infrastructure Ltd, one of the leading infrastructure development companies in the country, has been the latest to experience the immense benefits of the series. Ramky has recently installed, the largest plant of theirfleet- there are no prizes for guessing, - the MARINI MAC 200 for their Moradabad project.
Incidentally, the plant is now known as the greenest asphalt plant installed in North India. Another impressive
Site Report - MARINI MAC 200 -State of-the-art Efficiency Delivered
"If something goes wrong, the
control system will indicate exactly
when a motor came on, the amps it was
drawing, and when it was turned off.
When you have a problem, this control
system saves you a lot of time and
trouble. Instead of running around all
over the plant trying to see what
has gone wrong, you just go to the
screen, and the control system will
tell you. That way, you know exactly
where to start to make the repair."
Mr. Soundarraj reiterated the fact that
the plant is state-of-the-art, before
rounding off saying “It is a great piece
of work and is exactly what Ramky
wanted”.
feeding arrangement for both filler bags and bulk conveying along with modified bitumen handling tanks come as standard on MARINI plants supplied in India.
This New Generation MARINI plant has being designed to perform at very high efficiency. The plant is configured to work on the highly acclaimed heavy/waste oil firing system of MARINI, which helps customers realize huge savings on production costs. The waste heat recovery system, advanced blue flame assisted burner system, highly efficient bitumen heating system, ensure that Ramky's production costs are always unbeatable.
Site Report
180 The Masterbuilder - March 2011
SCM, during a meeting with the Fayat team stated “We wanted to graduate and keep our leadership position in the market. India's road construction industry is quite dynamic and the standards are ever-raising. Strategic investment into the right crucial tool like the asphalt plant is therefore a must. We have realized that it is impossible to be profitable without being efficient and green. MARINI MAC featured several energy efficient features and carbon saving technology that we were convinced about the plant being the right tool to keep up with the vision of our company.”
Stating his views Mr. Haribabu - VP Transportation, a key member of the decision making team observed, “ The decision for MARINI asphalt plants were taken because they have excellent track record in India, as well as world-wide. To ensure our bottom lines, we needed our project durations to be shortened, as much as possible. This calls for a highly efficient, productive, and reliable asphalt plant. Once the plant is on project site, project handling, commissioning, and testing procedures need to be done very efficiently to save time. The plant must be bang on the job and produce quality mix, as each day costs the contractor a lot… and that is exactly what MARINI MAC did.”
Ramky's MARINI MAC has been supplied with state-of-the-art features. The plant is capable of producing futuristic and low carbon emitting mixes; recycled asphalt mixes with up to 35 percent RAP content with traditional specification mixes. The plant features dual storage facilities to stock reclaimed filler. This feature was particularly important for Ramky, as they didn't want to have a plant with a top-notch bag filter but then have dust fly all over and around the asphalt plant. A 36 Cbm foreign filler silo with
181The Masterbuilder - March 2011
Site Report - MARINI MAC 200 - State of-the-art Efficiency Delivered
Site Report
landmark record that was achievedby Ramky in the project is that the MARINI MAC 200 plant was installed in a record number of hours. The plant, installed by India's leading sustainable development focused company, has been delivered with a host of special features that are aimed at improving productivity and at the same time reduce fuel consumption.
The record time in which the plant was erected and commissioned has come as a pleasant surprise for everyone involved with the project. Said Mr.L.Narayanel, Senior Manager Resources from Ramky, who till now was used to seeing asphalt plants take
around 45-60 days to be erected and commissioned in the country, “ We erected and commissioned the plant in a record 20 days time. MAC's modular design facilitates quick set-up and thanks to the pre-wired and pre-tested units, it was all plug and play, “before adding, “All the components fit so well w i t h o u t t h e n e e d f o r f i e l d modifications. In addition, the plant's control system help diagnose plant problems with ease.”
S p e a k i n g a b o u t t h e p l a n tMr.Y.Nagaraja - Managing Director, Ramky Infrastructure had recently said, “O u r co m p a ny i s fo c u s ed o n sustainable development and we found in Fayat Group the right partner”. The recent addition of Green asphalt plants from MARINI have further fortified Ramky's image in terms of a green company. The management team at Ramky did a thorough analysis of the various aspects before opting for the MAC asphalt plant.
Describing the process of selection of the plant Mr.Mahendra Kumar - VP-
The MARINI MAC Series of hot mix asphalt plants, known for their superior energy efficiency
and design have been making waves in recent times. Ramky Infrastructure Ltd, one of the leading infrastructure development companies in the country, has been the latest to experience the immense benefits of the series. Ramky has recently installed, the largest plant of theirfleet- there are no prizes for guessing, - the MARINI MAC 200 for their Moradabad project.
Incidentally, the plant is now known as the greenest asphalt plant installed in North India. Another impressive
Site Report - MARINI MAC 200 -State of-the-art Efficiency Delivered
"If something goes wrong, the
control system will indicate exactly
when a motor came on, the amps it was
drawing, and when it was turned off.
When you have a problem, this control
system saves you a lot of time and
trouble. Instead of running around all
over the plant trying to see what
has gone wrong, you just go to the
screen, and the control system will
tell you. That way, you know exactly
where to start to make the repair."
Mr. Soundarraj reiterated the fact that
the plant is state-of-the-art, before
rounding off saying “It is a great piece
of work and is exactly what Ramky
wanted”.
feeding arrangement for both filler bags and bulk conveying along with modified bitumen handling tanks come as standard on MARINI plants supplied in India.
This New Generation MARINI plant has being designed to perform at very high efficiency. The plant is configured to work on the highly acclaimed heavy/waste oil firing system of MARINI, which helps customers realize huge savings on production costs. The waste heat recovery system, advanced blue flame assisted burner system, highly efficient bitumen heating system, ensure that Ramky's production costs are always unbeatable.
Thomas LöfflerCEO bC Expo India
“This result shows clearly that our decision to launch bC India just came at the right time at the right place. Furthermore, the number of exhibitors as well as the feedback from all participants evidence impressively that bC India truly is a new dimension for the construction industry.”
?????????
bC India 2011 gets a thumbs -up from CE Industry
BC 2011: Post Event Report
182 The Masterbuilder - March 2011 183The Masterbuilder - March 2011
petence in the organization of interna-
tional trade fairs for construction
machinery. In Munich, it hosts bauma,
the world's leading trade fair for the sec-
tor. In Shanghai, it organizes bauma
China, the leading event of its kind for
the Asian market. For the Indian mar-
ket bC India represents the compe-
tence of MMI. AEM has an ownership
stake in and/or manages several world-
class exhibitions, including CONEXPO-
CON/AGG, one of the world's largest
gathering places for the construction
and construction materials industries. bC
India 2011 marked the coming together
of these two globally reputable orga-
If there was any proof required of
India's growing prowess as the coun-
try to watch out for in the near
future when it comes to construction
equipment, it was clearly evident by
the resounding success of the bC India
show held 8 to 11 February 2011 at the
Bandra Kurla Complex in Mumbai. The
show exceeded all expectations and
went onto reiterate, once again, the
coming of age of the Indian construc-
tion equipment industry.
More than 22,000 visitors from 69
countries attended the first edition of
the International Trade Fair for con-
struction machinery, building materials
machines, mining machines, and con-
struction vehicles. The event was a
jo int venture between Messe
Munchen International (MMI) and the
Association of Equipment Manufactur-
ers (AEM). MMI has built up global com-
nizers for a truly epoch making event in
the annals of Indian CE industry.
The importance of India as a market
for world-class construction equip-
ment was aptly bought out by Mr.
Eugen Egetenmeir, Member, Manage-
ment Board, Messe Munchen GmbH,
when he had during an interaction with
the Masterbuilder said, “Messe
Munchen has made strategic decisions
to organize successful trade fairs in
countries where there is an appropri-
ate demand. This has inevitably led the
most successful construction machin-
ery fair in the world to the booming eco-
nomic market of India, “a sentiment,
which was shared by almost every over-
seas exhibitor at the event.
The event only went on to reiterate
the burgeoning growth of the construc-
tion equipment market in India, which
had hit new highs in 2010. The industry
had reportedly hit an all time high
when 58, 715 machines were sold in
Growing Might of Indian CE Market
2010, which was a remarkable 42 per-
cent jump over the preceding year. Mar-
ket buoyancy and increased expecta-
tions made the event one of the most
eagerly awaited in recent times. The
tone for the show was set during the
inaugural address by Eugen Egetenmeir,
who during his inaugural address
remarked, “With this level of participa-
tion, we can say it is a real success.”
Thomas Löffler, Chief Executive
Officer of the show organizer bC Expo
India and Deputy CEO of MMI India
highlighted the success of the event
when he observed during his address
“This result shows clearly that our
decision to launch bC India just came
at the right time at the right place. Fur-
thermore, the number of exhibitors as
well as the feedback from all partici-
pants evidence impressively that bC
India truly is a new dimension for the
construction industry.”
The Union Minister for Urban
Development, Mr.Kamal Nath unfortu-
nately could not make it to the inaugu-
ral function due to foggy conditions
affecting the take off of his aircraft in
New Delhi. His absence was made up
by the presence of Dr.Leopold-Theodor
Heldman, Consulate General of Ger-
many in Mumbai, who during his inau-
gural address drew the attention to the
pace of progress of India, which accord-
ing to him “ we have only in China,”
before adding “ India will become one
of the largest economies in the world.”
Expressing his views on the occa-
sion Mr.Bhagwan Deokar, President ,
the Builder's Association of India said , “
We need technology in construction
and technology in machinery to come
bC India 2011 gets abC India 2011 gets aThumbs-up from IndustryThumbs-up from IndustryThumbs-up from Industry
Bhagwan DeokarPresident,
The Builder's Association of India
We need technology in construction and technology in machinery to come here”
The inaugural bC India show exceeded all expectations, mirroring the growth of the CE sector in the country. The Masterbuilder team was present in full strength during the show, covering the premiere event in detail from its booths at the venue. As part of our post event reportage we bring to you a host of valuable information on the products, technologies, services, and people that made the bC India show a grand success.
bC India 2011 gets a thumbs -up from CE Industry
Thomas LöfflerCEO bC Expo India
“This result shows clearly that our decision to launch bC India just came at the right time at the right place. Furthermore, the number of exhibitors as well as the feedback from all participants evidence impressively that bC India truly is a new dimension for the construction industry.”
?????????
bC India 2011 gets a thumbs -up from CE Industry
BC 2011: Post Event Report
182 The Masterbuilder - March 2011 183The Masterbuilder - March 2011
petence in the organization of inter-
national trade fairs for construction
machinery. In Munich, it hosts bauma,
the world's leading trade fair for the sec-
tor. In Shanghai, it organizes bauma
China, the leading event of its kind for
the Asian market. For the Indian mar-
ket bC India represents the compeof
tence of MMI. AEM has an owner-
ship stake in and/or manages several
world-class exhibitions, including
CONEXPO-CON/AGG, one of the
world's largest gathering places for the
construction and construction materials
industries. bC India 2011 marked the
coming together of these two globally
If there was any proof required of
India's growing prowess as the coun-
try to watch out for in the near
future when it comes to construction
equipment, it was clearly evident by
the resounding success of the bC India
show held 8 to 11 February 2011 at the
Bandra Kurla Complex in Mumbai. The
show exceeded all expectations and
went onto reiterate, once again, the
coming of age of the Indian construc-
tion equipment industry.
More than 22,000 visitors from 69
countries attended the first edition of
the International Trade Fair for con-
struction machinery, building materials
machines, mining machines, and con-
struction vehicles. The event was a
jo int venture between Messe
Munchen International (MMI) and the
Association of Equipment Manufactur-
ers (AEM). MMI has built up global com
nizers for a truly epoch making
event in the annals of Indian CE indus-
try.
The importance of India as a market
for world-class construction equip-
ment was aptly bought out by Mr.
Eugen Egetenmeir, Member, Manage-
ment Board, Messe Munchen GmbH,
when he had during an interaction with
the Masterbuilder said, “Messe
Munchen has made strategic decisions
to organize successful trade fairs in
countries where there is an appropri-
ate demand. This has inevitably led the
most successful construction machin-
ery fair in the world to the booming eco-
nomic market of India, “a sentiment,
which was shared by almost every over-
seas exhibitor at the event.
The event only went on to reiterate
the burgeoning growth of the construc-
tion equipment market in India, which
had hit new highs in 2010. The industry
had reportedly hit an all time high
Growing Might of Indian CE Market
2010, which was a remarkable 42
percent jump over the preceding year.
Market buoyancy and increased expec-
tations made the event one of the most
eagerly awaited in recent times. The
tone for the show was set during the
inaugural address by Eugen Egetenmeir,
who during his inaugural address
remarked, “With this level of participa-
tion, we can say it is a real success.”
Thomas Löffler, Chief Executive
Officer of the show organizer bC Expo
India and Deputy CEO of MMI India
highlighted the success of the event
when he observed during his address
“This result shows clearly that our
decision to launch bC India just came
at the right time at the right place. Fur-
thermore, the number of exhibitors as
well as the feedback from all partici-
pants evidence impressively that bC
India truly is a new dimension for the
construction industry.”
The Union Minister for Urban
Development, Mr.Kamal Nath unfortu-
nately could not make it to the inaugu-
ral function due to foggy conditions
affecting the take off of his aircraft in
New Delhi. His absence was made up
by the presence of Dr.Leopold-
Theodor Heldman, Consulate General
of Germany in Mumbai, who during his
inaugural address drew the attention
to the pace of progress of India, which
according to him “ we have only in
China,” before adding “ India will
become one of the largest economies
in the world.”
Expressing his views on the occa-
sion Mr.Bhagwan Deokar, President ,
the Builder's Association of India said , “
We need technology in construction
bC India 2011 gets abC India 2011 gets aThumbs-up from IndustryThumbs-up from IndustryThumbs-up from Industry
Bhagwan DeokarPresident,
The Builder's Association of India
We need technology in construction and technology in machinery to come here”
The inaugural bC India show exceeded all expectations, mirroring the growth of the CE sector in the country. The Masterbuilder team was present in full strength during the show, covering the premiere event in detail from its booths at the venue. As part of our post event reportage we bring to you a host of valuable information on the products, technologies, services, and people that made the bC India show a grand success.
bC India 2011 gets a thumbs -up from CE Industry
nologies. The show was marked by the
demonstration of a wide variety of con-
struction equipment including, lifting,
concrete making, pneumatics, hydrau-
lic power tools, material handling and
earthmoving equipment. These cate-
gories apart, the bC India 2011 show
also saw the enthusiastic participation
of several firms dealing with construc-
tion vehicles. The positive sentiments
shared by a majority of the exhibitors
were aptly put forward by Mr. Michael
Schmid-Lindenmayer, Managing Direc-
tor, Putzmeister India when he quipped
“We had crowds of visitors at our stand,
and lots of contacts, including many
new customers. The quality of the visi-
tors was very good. India definitely
needed bC India. We shall certainly be
taking part again next time, with a
stand of at least the same size."
The event saw several companies
hold press meetings, either at the con-
ference halls that were available in the
venue or in their respective stalls. With
interest levels on the higher side,
thanks to the presence of the strong
'bauma' brand name, the event
received widespread media coverage,
here” and went on to explain how latest
technology will help the Indian economy
to grow at a rate of 8.5 to 9.5 percent.
Responding to very strong demand from exhibitors in the run-up to the show, the exhibition space for bC India had been extended to a total of around 88,000 square meters. In all, 508 exhib-itors from over 30 countries showcased their latest products and innovations in machinery and equipment for con-struction, mining and building materi-
International Participation
als. In addition to that the show is the most international event within the construction exhibition sector in India, as 70 percent of the registered exhibi-tors were headquartered outside of India.
The international character of this
trade fair was further underlined by the
fact that it saw the participation of
nine national pavilions from Australia,
China, Finland, France, Germany, Italy,
Korea, Spain and the United Kingdom,
all showcasing state-of-the-art tech-
nology produced in these countries.
The joint venture partners were
also highly satisfied with the outcome
of the show. “bC India proves to be a
premium platform for the construction
machinery industry in India by setting
new organizational standards,” said
Eugen Egetenmeir, Managing Director
of MMI. Dennis Slater, President of
AEM, added: “The overall numbers are
outstanding. I am convinced that bC
India will indeed play a very important
role in the Indian market in the near
future.”
The show offered just about the per-
fect platform for global giants, as well
as several first time exhibitors to show-
case their products, services, and tech-
184 The Masterbuilder - March 2011
Dennis SlaterPresident of AEM
“ T h e o v e r a l l n u m b e r s a r e outstanding. I am convinced that bC India will indeed play a very important role in the Indian market in the near future.”
Michael Schmid-LindenmayerManaging Director, Putzmeister Inida
“We had crowds of visitors at our stand, and lots of contacts, including many new customers. The quality of the visitors was very good. India definitely needed bC India
bC India 2011 gets a thumbs -up from CE Industry
BC 2011: Post Event Report
bC India 2011 gets a thumbs -up from CE Industry
Maco Coporation India Pvt.Ltd
Realm Intermediates (P) Ltd
186 The Masterbuilder - March 2011
both from the print and electronic
media.
The event also gave an insight into
the organizational skills of the key orga-
nizers. Almost every exhibitor was sat-
isfied with the indoor and outdoor exhi-
bition area. "The organization has been
perfect and we are enjoying a first-class
exhibition. I recommend this event to
all equipment manufacturers. We will
come back", said José Luis del Prim,
CEO of Enarco, and President of the
Committee for European Construction
Equipment CECE.Mr. Liang Weisen,
Managing Director, Liugong, China
lauded the organizers when he said
"Congratulations on a successful
launch of bC India. We are impressed
by the quality of Indian and interna-
tional visitors as well as the strong par-
ticipation of local and international
companies." High praise for the event
also came from Dr Christof Kemmann,
Chairman of the VDMA Construction
Equipment and Building Material
Machinery Industry Association and
CEO BHS Sonthofen, Germany, who
observed "I am deeply impressed and
very excited about what the organizers
have achieved here. We had lots of cus-
Organization Draws Praise
tomer contacts and many new leads.
Our expectation is that bC India, just
like bauma China, will grow and estab-
lish itself in the Indian market."
The choice of Mumbai as the venue also came in for praise from several quarters. “So far, Mumbai hasn't had a good fair and bC India has filled that gap,” observed Mr.V.G.Sakthi Kumar, Chief Operating Officer, Schwing Stetter, Germany's Indian subsidiary. The central location could mean that exhibitors and visitors from virtually every nook and corner of the country had a presence in the event. The event has also reportedly drawn visitors from as far away as the Gulf countries.
That a lot of thought had gone into
ensuring quality business visitors was
evident from how the visitors had been
divided into different categories. By
offering free of cost pre-registration
and charging an entrance fee to non
pre-registered visitors, a high profes-
sional level of business visitors was
achieved. "The quality of visitors has
been extremely good thanks to the
restricted entry policy", said Mr. V.
Venkataramana, Vice-President of
Puzzolana, a thought that was shared
by Mr. Ramesh Palagiri, Managing
Director and CEO of Wirtgen India,
added: “All visitors at our booth were
100 per cent quality visitors." E. Moses,
Business Development Head, Kobelco,
Japan, seconded these views when he
chipped in saying "Most of the footfall
has been meaningful and related.
Being a part of this exhibition is very
important for our company in particu-
lar."
Another interesting coincidence
about the entire event was the time
that it was held. It could not have been
Perfect Timing
V.G.Sakthi KumarChief Operating Officer, Schwing Stetter India
“So far, Mumbai hasn't had a good fair and bC India has filled that gap,”
V. VenkataramanaVP, Puzzolana
"The quality of visitors has been extremely good thanks to the restricted entry policy"
bC India 2011 gets a thumbs -up from CE IndustrybC India 2011 gets a thumbs -up from CE Industry
BC 2011: Post Event Report
more perfectly timed, since the econ-
omy has now almost completely recov-
ered from the lull that was experienced
during the global economic downturn
and the government being bullish
about infrastructure projects. Thomas
Furtado, Group General Manager,
Greaves Cotton Limited, India put
things into perspective when he
observed "bC India is very unique as
bauma and CONEXPO came together it
surely is a good thing. As the Indian mar-
ket is very strong right now, bC India
came just at the right time. All the big
names are here." With plans to pump in
funds to the tune of US 1 trillion in the
12th Plan Period (2012-17), things
could not have been better planned,
when it came to the staging of an event
of this magnitude.
With the global economy well and
truly on the recovery path and with
infrastructure development activities
in India on an overdrive, the event has
come as a shot in the arm for the rap-
idly growing construction equipment
industry in the country. For exhibitors
the event offered the perfect launch
pad for the hectic future that is on offer
in the form of the Indian construction
and mining equipment market. Going
into the trend that was observed Mr.
Raj Lakhani, Managing Director, Peri
Germany, Indian subsidiary explained
"We had customers from different
parts of the country at our booth. More
than 90 per cent of who were quality
visitors. bC India has the potential to
become the major platform here in
India." Similar sentiments were shared
by Mr. Prashant Nair, Marketing Man-
ager, Mahindra & Mahindra, India,
when he said "The quality of the visi-
tors was good. Such exhibitions are
important as they add value to our busi-
ness."
The Indian construction and mining
equipment industry has been growing
by leaps and bounds in recent years
and it has received the necessary stim-
ulus through the successful conduct of
bC India 2011. The epoch making event
promises to return in a bigger and
improved form a couple of years down
the line. The event has already set the
benchmark higher for similar other
events that take place in the country.
The Masterbuilder, as ever has cov-
ered the event extensively for its read-
ers. The Masterbuilder had an exclu-
sive stand in the event, manned by a
large contingent that had been assem-
bled from our various branches for
extensive coverage of the show. Read-
ers can find reports on the various par-
ticipants, new product launches and
one-on-one interaction with industry
big-wigs in this issue.
The Masterbuilder- Coverage
Raj LakhaniManaging Director, Peri India
"We had customers from different parts of the country at our booth. More than 90 per cent of who were quality visitors. bC India has the potential to become the major platform here in India."
Ramesh PalagiriManaging Director
and CEO of Wirtgen India
“All visitors at our booth were 100 per cent quality visitors."
187The Masterbuilder - March 2011
bC India 2011 gets a thumbs -up from CE IndustrybC India 2011 gets a thumbs -up from CE Industry
BC 2011: Post Event Report
Dragline Batching Plant. With a typical concrete output of 30 cubic metres per hour, the plant features a Planetary Mixer, comprising of hydraulic operated discharge doors, interchangeable wear resisting linings, reversible mixing blades, round mixing arms in NiCr spe-cial steel and inspection covers for easy maintenance, among others.
Speaking exclusively to the Masterbuilder on the sidelines of the bC India 2011 show, Mr.K.Vijay, Managing Director of the company gave insights into the new launch and its future plans. Here are excerpts from the interview.
I am very happy with the show. This time around, quite a spectrum of com-panies is participating in the show. I see
On the bC India 2011 Show
without a doubt a very large European presence. It is perhaps because of the 'bauma' and the fact that the European market has shrunk recently, that they are focusing towards overseas markets.
It is a good sign to note that only seri-ous visitors are coming to our stall. In fact, every footfall has been very pro-ductive.
The new Dragline Plant is what we have added to our product range during this show. A dragline plant as a concept is not something new. What we have done in it is to add a Planetary Mixer. A Planetary Mixer vis-à-vis a Turbo Mixer is a much better product both in terms of energy efficiency and the quality of mixing. We have a tie up with a reputed European company called Euro Star for the product. Planetary mixers from the company are well-known globally and we are making them in India.
The dragline plant comes with a spe-cial customized control system, which is more operator-friendly. Moreover, cus-tomers are assured that it is backed by a well known company with high brand equity.
With the addition of the dragline plant, we have the complete range of batching plants. We already had several
On the visitor profile at bC India 2011 Show
On the New Product Launch
On the Company's Product Range
188 The Masterbuilder - March 2011
Ajax Fiori Engineering (I) Pvt Ltd is one of the leading construction equipment manufacturers in
India. The company manufactures a wide range of equipment for the con-struction industry including, self-loading mobile concrete mixers, batching plants and site dumpers. Ajax Fiori machinery has been used for RMC operations, at building construction , canal lining, dam, road and other infra-structure construction projects, to name only a few. The company has a long standing Joint Venture with Fiori S.p.A of Italy, who have been prominent in the global market for well over six decades now.
The company displayed its entire range of products during the recently held bC India 2011 show. The centre piece of its booth was its new launch
Ajax Fiori:One on-one with Mr.K.VijayManaging Director, Ajax Fiori at the bC India 2011 Show
Nicomac Doors Pvt. Ltd
Thermoshield India (P) Ltd
other concepts. This product comple-ments our existing range. We have a solution for every kind of batching plant activity now with the introduction of this new product.
We would not like to be tempted by the rise in demand for asphalt plants. We would like to have a clear identity as a concrete specialist. We want to stay focused on concrete.
Having said that, you must remem-ber that we already have a big presence in the road construction industry, par-ticularly in the Pradhan Mantri Gram Sadak Yojana - Rural Road Development Program. A lot of our machines can also be found in various urban projects too.
Being a new product concept, it has been a case of the application and the product developing together. Each has driven the growth of the other. Every time a company wanted a new applica-tion, it has driven us to do some kind of development on the product.
It is a of course a competitive market out there. But we are confident about our product range. We are looking to sustain a growth rate of30 percent annually. Our machines are working all over the country and we hope that with increased capacity, we will be able to match the market expectations and our production volumes in the near future.
We have a range of products that
are ideally suited for the African mar-
ket. These products are also suited for
the immediate markets around India.
Exports to these countries could be one
of the probable areas of focus for us in
the near future.
On Ajax Fiori's Focus Areas
On the Self-Loading Concrete Mixer
On Competition
On Future Plans
190 The Masterbuilder - March 2011
Ajax Fiori: One on-one with Mr.K.Vijay, Managing Director, Ajax Fiori at the bC India 2011 Show
BC 2011: Post Event Report
ing rapid inroads in the Indian market
with its array of road construction
equipment, ranging from high quality
asphalt plants to compactors. Apart
from the Indian market, the brand is
now a familiar name elsewhere in the
Asia-Pacific region too. Explained
Mr.Rolf J.Jenny, “For the past two years,
we have grown rapidly in countries
such as China, Malaysia, Vietnam and
Thailand. We also have a major pres-
ence in Australia and even as far away
as New Zealand now.”
According to Mr.Rolf J.Jenny, the
spurt in road projects has meant that
an increasing number of people
involved in the road construction
sphere are now aware of the Ammann
brand. He also felt that the market has
now evolved, with a distinct change visi-
Ammann is a globally renowned
construction equipment brand
that has made a mark with its
range of high quality machines, sys-
tems, and services catering to the var-
ied needs of the construction industry.
The group, which has a rich legacy of
being in the forefront of introducing
technologically superior products since
1869, offers high quality asphalt mix
plants, concrete mixing plants, mineral
processing equipment, compact exca-
vators, and compaction equipment.
The group is now making aggressive
forays into the rapidly growing Indian
infrastructure scene. Ammann Group's
booth at the recently held bC India
2011 show was one of the busiest in the
event, with visitors envisaging keen
interest in their products. In an exclu-
s i v e i n t e r a c t i o n w i t h t h e
Masterbuilder, Mr.Rolf J.Jenny, Senior
Vice-President, Corporate Develop-
ment, Ammann, observed,” We have
had very good response. More and
more people are interested in our prod-
uct now, which gives us increased con-
fidence in offering a wide range of prod-
ucts for the Indian market.”
The Ammann Group has been mak-
AMM NN GROUPAThe Road Construction EquipmentSpecialist has Big Plans for India
191The Masterbuilder - March 2011
BC 2011: Post Event Report
BC 2011: Post Event Report
192 The Masterbuilder - March 2011
ble in buyer behavior. He pointed out
that “the typical Indian customer is no
longer making buying decisions only
based on the price. Customers are now
looking for reliability, quality, prompt
after-sales technical support and lesser
downtime. All these factors have
meant that we have a competitive
advantage in this burgeoning market.”
The company has already installed
over 3,000 asphalt mixing plants glob-
ally, being a pioneer in the field, with its
strong R & D focus. Speaking about the
group's R & D initiatives Mr.Rolf Jenny
said “We have invested heavily on our
R & D Center in Switzerland. We have
been successful in introducing technol-
ogy with which asphalt can be pro-
duced at 115 degrees Celsius, instead
of the usually 170 degrees Celsius. This
means lesser energy consumption. We
already have completed 20 plants in
Europe and 6 plants in Australia, where
the technology has been put to use.”
He went on to add that the company
had plans to bring the technology to
India too in the near future.
Ammann offers a range of asphalt
mixing plants, ranging from mobile to
semi-mobile and stationary high per-
formance units, with capacities ranging
from 80 TPH to 400 TPH worldwide.
The company has also added paving
machinery to its product portfolio in
recent times. Mr.Rolf Jenny said that
the paving equipment could soon be
introduced for the Indian market too.
Ammann also offers state-of-the-art
compactors including single drum roll-
ers and pneumatic tyre rollers. High
compaction quality with a low number
of compaction runs is the distinguish-
ing features of these rollers which are
known to work efficiently even under
conditions of extreme duress. The high
efficiency pneumatic tyre rollers of
Ammann Group: The Road Construction Equipment Specialist has Big Plans for India
launched in Bauma Munich, has a role
to play, “observed Mr.Rolf Jenny. With 6
plants already working in various parts
of Europe and with asphalt recycling
picking up in a big way in other parts of
the world, the company intends to
launch the product in the Indian mar-
ket in the near future.
Ammann are capable of achieving com-
paction on both natural, as well as bitu-
minous asphalt layers.
Ammann has also recently come
out with its latest plant- the 100 %
recycler. “Once the roads are built, they
need to be maintained and this is
where the 100 % recycler, which we
The Masterbuilder Corporate Ad
194 The Masterbuilder - March 2011
impact with its wide range of products,
featuring latest technological innova-
tions from Russia. To fulfill the growing
demand of Indian customers for techni-
cally advanced M&IG industrial
products a 100% subs id iary -
Chetra Machinery India Pvt. Ltd was
established.
CHETRA had a nicely built stall, with the display of following popular model of machines in the stand.
Crawler Dozer with 90 hp power,
Model: VT90
Crawler Dozer with 310 hp power,
Model: T20
Crawler Dozer with 419 hp power,
Inauguration of the Stall
Model: T25
Pipe Layer with 65ton lifting capac-ity, Model: TG301
Undercarriage parts for Dozers & Pipe Layer.
All the Indian Dealers & Business associates were present in the CHETRA's exhibition stall and they could interact with potential customers. CHETRA's stall was inaugurated by Mr. Mikahil Rapota, Trade commission of Russia in India, in General counselor for Russia in India Mumbai, Mr. Alexey Novikov, Vice Presidents Association Of Equipment Manufacturers, Ms. Megan Tanel, in presence of Company's Vice Presidents Mr. Vladimir Lepin &
The bC India 2011 show focusing
on construction machinery for
the Indian subcontinent was a
resounding success which saw 508
exhibitors from over 30 countries show-
casing their latest product and technol-
ogy offerings. The show held from 8-11
February 2011 at the MMRDA Grounds,
Bandra Kurla Complex, Mumbai
attracted over 22,000 business visitors.
There were several companies for
whom this was the first time that they
participated in an Indian expo. Machin-
ery & Industrial Group N.V. (M&IG is a
producer of Russian industrial machines
CHETRA) was one amongst them, with
the company making an immediate
Announces Plans for ProductionUnit at the bC India 2011 Show
M&IG (A producer of Russian industrial machines CHETRA)
Ermotec International Pvt.Ltd
Pioneer India
Ramtec
Mr. Vadim Kalabashkin.
CEO of CHETRA Machinery India, Mr. Ben Callow did the presentation of products CHETRA's has exhibited during the show.“ Today the company offers dozers with the power range 90-590 hp, pipe layers with the lifting capacity 25-104 t for the pipelines with the tube diam. 200-1420 mm; wheel loaders with the bucket capacity 3. 5 to 6. 7 cm. and operating power range 140-600 hp; various types of special equipments for Pipeline cleaning, priming, heating & Insulation works; excavators with 23 ton operating capacity,” company CEO Mr.Ben Callow said during the stand inauguration. The main competitive advantages of the Russian machines are price, robust construction and the use of the best Russian technology, he added.
One of the highlights for the com-pany during the show was the visit by Dr. Mikahil Bolotin, President of M&IG, the holding company, who had visited the country for the expo.
During the show CHETRA launched its 90 hp dozer, VT90 for the Indian market.
CHETRA also launched its Indian edi-tion of Quarterly Corporate news Maga-zine during the expo.
CEHTRA Machinery & Industrial Group organized a Presentation and press meet on the first day evening to announce its long term plans for India and announced that Company will com-plete its assembly units set up in India by 2011 end. The session saw the com-pany's top management team give detailed presentations on the various products that it had on offer for the Indian market and its future plans.
CHETRA as a whole group has got a
Launches from CHETRA
Press meeting & Presentations
CHETRA M&IG's long terms plans for
India
196 The Masterbuilder - March 2011
M&IG (A producer of Russian industrial machines CHETRA) Announces Plans for Production Unit at the bC India 2011 Show
BC 2011: Post Event Report
types of special equipments for pipeline
cleaning, priming, heating & Insulation
works as well as excavators.
Innovative machines by M&IG are used in biggest state and private compa-nies of India, like KCC, Jaihind, Punj Lloyd, Coal India, etc. Company's share at the Indian pipe layer market has already reached 30 percent. As esti-mated by the market players, taking into account the demand of mining and con-struction industries, it may reach 40-50 per cent soon.
Speaking during the press meeting
M&IG Vice-president for global markets
Mr. Vladimir Lepin said that the estab-
lishment of the production unit will
strengthen Russian producer's position
not only in India, but in the whole South
East Asia region as well. Australia,
Malaysia, Indonesia, Thailand, and
South Korea have already shown special
interest in Russian CHETRA machines.
“By the end of 2015 the number of
yearly produced machines will have
reached 200”, said Mr. Lepin at the pre-
sentation of the project. “Besides, Rus-
sian specialists will carry out educa-
tional and qualification-raising pro-
grams for the Indian engineers partici-
pating in CHETRA production and ser-
vices,” he added.
Russian Trade Representative in India Mr. Rapota emphasized the impor-tance of such international projects that promote scientific and technical co-operation of the two countries. “I am absolutely sure that the future Russian machinery production unit in India will cover the demand for these highly com-petitive industrial machines and become the contribution of the Russian machine-builders into the economy of the partner state.” The company is expected to come out with the formal announcement of the exact location of the production unit in the near future.
wide range of machines in 40 various
product lines. Today the group holding
company “Machinery & Industrial Group
N.V” has become the 3rd largest indus-
trial machinery manufacturer in World.
After having a series of success sto-
ries in Russia, Europe and other devel-
oped & developing countries across the
world, CHETRA M&IG is now focusing on
the growing Indian market in a big way
now. The establishment of a subsidiary
company for India “CHETRA Machinery
India Pvt. Ltd” was the initial step towards
this and the company is now looking at
the option of setting up a manufacturing
unit in India. The company is also in the
process of establishing an even wider
dealership network across the country.
The company is considering estab-
lishment of a CHETRA Production unit in
India, something that could be a reality
very soon. M&IG products were being
imported in India since 1999. To fulfill
the growing demand of Indian custom-
ers in technically advanced industrial
machines there was established a 100%
subsidiary - CHETRA Machinery India
Pvt. Ltd. Today the company offers doz-
ers, pipe layers; wheel loaders; various
Production Unit in India
197The Masterbuilder - March 2011
M&IG (A producer of Russian industrial machines CHETRA) Announces Plans for Production Unit at the bC India 2011 Show
BC 2011: Post Event Report
BC 2011: Post Event Report
198 The Masterbuilder - March 2011
DMI Engineering and Manufac-
turing (DMI E&M) Co Ltd, is one
of the reputed manufacturer of
Asphalt batch mix plants and Concrete
batching plants. The company has made
good presence into the fast growing
Indian market in recent times. The
recently held bC India 2011 show saw
DMI Engineering & Manufacturing Co
Ltd, promote its range of high quality
products in a big way.
Speak ing exc lus ive ly to the
Masterbuilder at their stall during the
show, Mr.Rin-Kwon, Managing Director
of the company said, “The response has
been very positive, “a sentiment that is
shared by Mr.Parag Shah, CEO of
Vimtech Corporation, which represents
DMI in India. Going into the company's
strength, Mr.Parag Shah highlighted that
“Durability, service and prompt after-
sales service support, have been behind
our growth story.” Another area of
strength for the company is the fact that
since almost every component in the
asphalt plant is manufacture red by them
and not outsourced, service and avail-
ability of spares is always prompt.
Asphalt mixing plant and concrete batching plants from the company are known for their high quality standards. The superior technology incorporated in the machines is evident from the lower cost of operations, a result of lower fuel consumption and superior engineering. The entire erection and installation pro-cess has been simplified. The entire asphalt plant can be erected within a week. The company's mobile asphalt mix plants have also been very successful in India. Observed Mr.Shah, “Our mobile asphalt plants have been highly success-
DMI Engineering & Manufacturing Co LtdSuperior Technology and Service Enable DMI to Stay Ahead
ful. That is because of the unique, user-friendly design features that we have incorporated in our plants.” The com-pany now offers asphalt mix plants rang-ing in capacity from 40 TPH to 400 TPH.
Speaking about the trend that is
being seen Mr.Shah explained, “An
increasing number of projects today are
being built on BOT basis. Bigger projects
have meant that the demand for higher
capacity plants is rising. We want to con-
centrate on plants with capacity of 200
Bridge Seminar
200 The Masterbuilder - March 2011
TPH and upwards.” Added Mr.Rin-Kwon,
“The typical Indian client has evolved
from a price conscious customer to one
who wants more value in the form of ser-
vice and technical support. These are our
areas of strength and reasons which
make us competitive.”
Dwelling on the technology that goes
behind the plants, Mr.Shah observed
that,” We have a team of trained techni-
cal professionals with us. In fact, in a vast
majority of cases, we don't need the
assistance of our Korean principles, as
we are ourselves capable of resolving
issues.” The asphalt mix plants of the
company feature user-friendly mouse-
operated controls. The control panel is
connected to the Internet in the plants
and this enables engineers from the com-
pany's Korean head quarters to under-
take repairs on any plant situated in a
remote location.
The company chose the bC India 2011 platform to promote the latest addi-tion to its product line DMI Recycle Asphalt Plant. “Recycling is going to be the future and we offer an excellent solu-tion,” quipped Mr.Shah, who was sec-onded by Mr.Rin-Kwon who added,” DMI is the market leader in the field of recy-cling plants in the highly competitive mar-ket of Korea.” One of the advantages of the recycling plants is that it can be attached to plants of other companies too, a fact that gives it an edge over com-peting products. Apart from its wide range of asphalt mix plants, the company also manufactures concrete batching plants in the 30 cubic meters to 360 cubic meters per hour capacity range.
Excellent service backup and a strong R & D focus, with a strict commitment to the highest standards of quality have been the reasons fueling the growth of DMI Engineering. With India in the midst of its biggest infrastructure development spree, the company is well and truly on its way to attaining market leadership in the highly competitive market.
DMI Engineering & Manufacturing Co Ltd: Superior Technology and Service Enable DMI to Stay Ahead
BC 2011: Post Event Report
?????????
Greaves Cotton now brings to India
the most advanced, state-of-art
BOMAG Milling Machines. With fea-
tures like Front Loading, Track Mount &
Steering and Auto Control & Auto
Engine power regulation; these
machines are the latest technology in
the road construction industry. These
features enhance steering ability, load
distribution, safety & operator conve-
nience and efficiency resulting in preci-
sion finish of roads. The range comes in
1 to 2 metres and is backed by Greaves
service and support assurance.
Also on offer is the Paver, this state-
of-the-art equipment offers 9.2 metres
of paving width and comes with
enhanced screed features offering
superior compaction, resulting in high
quality finish and undulation effect on
roads. The features in the Paver offers
faster operation, better productivity,
low and easy maintenance and opera-
tor comfort which is a hallmark of Bomag
technology-World leaders in road con-
struction equipment technology.
Greaves Cotton LaunchesPremium Range of Construction Equipment
at bC India 2011 Show
Greaves Cotton LaunchesPremium Range of Construction Equipment
at bC India 2011 Show
201The Masterbuilder - March 2011
Greaves Cotton, a leading name
in the construction equipment
domain, launched a premium
range of construction equipment for
the infrastructure industry at bC India
2011 show. With this launch, Greaves
Cotton augments its already formida-
ble presence with its wide range of
products in the 3 segments of Concret-
ing, Soil and Asphalt in the infrastruc-
ture equipment industry.
The range of products launched
includes:
1. Milling Machines
2. Paver
3. Loader
4. Twin Shaft Batching Plant
Continuing from its earlier range of loaders; Greaves now launched its 5T (ton) loader, extending its range from the already available 3T loader. This loader comes with components from world renowned manufacturers and is manufactured by Greaves technology. With ergonomically designed and fully air-conditioned operators' cabin as a standard feature coupled with brilliant enhanced features like single lever bucket operation and tilt steering col-umn, this loader sets a new benchmark in this segment with operators comfort resulting in improved productivity and efficiency.
Complementing its existing range of batching plants, Greaves now brings the 60cbm Twin Shaft batching plant; an advanced global technology with twin shaft mixer technology offering a range of features for safety and enhanced productivity. This plant comes with a fully automatic software controlled operation and a rigid struc-ture. With the promise of service and support round the clock, this world class technology product is low on main-tenance. This product further estab-lishes the leading position of Greaves Cotton along with its varied and wide range of batching plants, stationery & mobile concrete pumps and concrete mixers in the concreting segment of the construction equipment business.
“Greaves Cotton and BOMAG have had a long standing relation and with these set of new product launches it enhances its presence in the construc-tion equipment segment. With world class BOMAG technology, enhanced value additions, a formidable National Network with 24X7 anytime anywhere service and support; thus offering a tri-ple benefit of Technology, Value and Reach to its customers”, said a com-pany spokesperson commenting on the occasion.
202 The Masterbuilder - March 2011
Greaves Cotton Launches Premium Range of Construction Equipment at bC India 2011 Show
BC 2011: Post Event Report
?????????
Dwelling on the company's growth
Mr.Raman Joshi, Managing Director,
Manitowoc Cranes India, said that the
company is well positioned in the country.
“We have long seen the potential of India
and have invested heavily here,” he said.
“We're now seeing our vision becoming a
reality as the country starts to achieve its
true potential. At bC India, we will be
increasing awareness of Manitowoc
Crane Care and showing our latest cranes,
each of which has features and benefits of
interest to Indian customers.”
Manitowoc showcased a Potain MC
125 model from the top-slewing tower
crane range and an Igo 32 self-erecting
crane, during the show. The MC 125 com-
bines a cost-effective lifting tool with
industry leading performance. The new
crane will be manufactured at the
Manitowoc factory in Pune, India and is
considered perfect for a variety of city
centric and general building projects.
Giving his views about the latest mar-
ket trends Mr. Joshi observed, “2010 was
Wide Range on Display
good rebound for the tower crane indus-
try. Another good thing that we are seeing
is that a good percent of our buyers now
are first time buyers.” Pointing out to the
rapidly evolving marketing, Mr.Joshi said,
“India is and always has been a price sen-
sitive market. But today people are willing
to spend money, if they are provided
value.”
The 4 t capacity Igo 32 is part of Potain's range of self-erecting cranes that offers significant timesaving on small and medium sized job sites that was on display during the event. They are often more cost-effective than other material han-dling options.
Also on display was the GT 25-5A from the Dongyue mobile truck crane product line. bC India marked the first time that these cranes were being shown in India. Manitowoc's national office will sell the cranes directly and the full Manitowoc Crane Care support is in place for them. Besides the equipment, a simulator allowed visitors to the booth to sit in a rep-lica crane cab and experience what it is like to operate a Manitowoc crane.
Manitowoc Emphasizes Commitment Manitowoc Emphasizes Commitment to Indian Market at bC India 2011 Showto Indian Market at bC India 2011 Show
203The Masterbuilder - March 2011
Manitowoc is a name that has
become synonymous with lift-
ing equipment globally. The
company offers a wide range of cranes
including, lattice-boom cranes, mobile
telescopic cranes, and tower cranes. It is
the first global company to manufacture
tower cranes in the country in its Pune
manufacturing facility. The company had
displayed its range of lifting equipment
and accessories during the bC India 2011
show, which highlighted its market lead-
ership in India.
Raman JoshiManaging Director, Manitowoc
?????????
204 The Masterbuilder - March 2011
up to 85 kmph. There are four variants
of the 6540 available in the market 16
cum box and rock body, 18 cum box
body and 20 cum box body.
Currently, the Russian-Indian JV
domiciled in Hosur, Tamil Nadu will
assemble 1000 locally produced
KAMAZ trucks as per its business plan
which has been approved in February
2005. At the moment this JV is
producing a single truck model
KAMAZ-6540 but in future the plant
which has been designed for annual
output of 5,000 trucks, will start to
produce road tractors , KAMAZ-5460
(4x2) and KAMAZ-6460 (6x4) , specially
designed for the local conditions, as
well as the KAMAZ-6520 dump trucks
along with rigid KAMAZ-6540 of
205The Masterbuilder - March 2011
KAMAZ Vectra Showcases Russian Trucks of European Quality for India
BC 2011: Post Event Report
w a s t h e d u m p t r u c k m o d e l
KAMAZ-6540 (8x4) which belongs to
the family of heavy duty trucks with 19t
legal payload, GVW upto 31t and
comes with a host of attractive
features, besides being well known for
its productivity and efficiency.
The KAMAZ-6540 is equipped with
KAMAZ V8, 260 hp Euro 2 engine and
the Cummins 285 hp Euro 3 engine. In
addition, two fuel tanks of 210 litres
displacement each allow for lengthy
truck operation without the need for
refueling. Another feature is the
comfortable cab for the driver. The
truck platform is worth of special
description. It can accommodate 18
cubic metres of cargo and its tipping
angle during the unloading can reach
55 degrees. Fully loaded KAMAZ-6540
can easily accelerate and reach speeds
KAMAZ Vectra Motors Ltd, which
is a joint venture between
KAMAZ OJSC and Vectra group,
showcased a wide range of products at
the recently held bC India 2011 show.
The show gave the company a good
platform to show its technologically
superior products to prospective
customers.
On display at the company's booth
like Daimler AG CUMMINS, ZF,
Knorr-Bremse SfN GmbH Bosch, etc,
along with the introduction of specially
developed set of lean production
methods (KAMAZ Manufacturing
System), which has radically improved
the technical capabilities and quality of
our products.
T h e c o m p a n y h a s a l r e a d y
estab l i shed a wel l deve loped
dealership network in India. In October
2010, the company signed 11
cooperat ion agreements w i th
dealership companies. The company
has already covered about 87 percent
area through KVML dealers. It has also
appointed one overseas dealer to
reach its customers in Lhachhen
Mineral Industry, Timphu, Bhutan.
original design. Such trucks as the
KAMAZ-6540 can be operated on
concrete roads, which have been lately
constructed in India and do not allow
vehicles with excessive axle loads.
T h e n e w l y e s t a b l i s h e d
manufacturing facility is focused on the
specific market to approach domestic
customers with its unique vehicle
o p e rat i n g co n d i t i o n s . K V M L ' s
engineering team has done specific
modifications to make the vehicle, the
best in its class. Localization process is
on fast track and more than 70 percent
localization has been achieved.
KAMAZ is having JV and close
cooperation with world's leading
truck and component manufactures
KAMAZ VECTRAKAMAZ VECTRAShowcases Russian TrucksShowcases Russian Trucksof European Quality for Indiaof European Quality for India
?????????
204 The Masterbuilder - March 2011
up to 85 kmph. There are four
variants of the 6540 available in the
market 16 cum box and rock body, 18
cum box body and 20 cum box body.
Currently, the Russian-Indian JV
domiciled in Hosur, Tamil Nadu will
assemble 1000 locally produced
KAMAZ trucks as per its business plan
which has been approved in February
2005. At the moment this JV is
producing a single truck model
KAMAZ-6540 but in future the plant
which has been designed for annual
output of 5,000 trucks, will start to
produce road tractors , KAMAZ-5460
(4x2) and KAMAZ-6460 (6x4) , specially
designed for the local conditions, as
well as the KAMAZ-6520 dump trucks
along with rigid KAMAZ-6540 of
205The Masterbuilder - March 2011
KAMAZ Vectra Showcases Russian Trucks of European Quality for India
BC 2011: Post Event Report
was the dump truck model
KAMAZ-6540 (8x4) which belongs to
the family of heavy duty trucks with 19t
legal payload, GVW upto 31t and
comes with a host of attractive
features, besides being well known for
its productivity and efficiency.
The KAMAZ-6540 is equipped with
KAMAZ V8, 260 hp Euro 2 engine and
the Cummins 285 hp Euro 3 engine. In
addition, two fuel tanks of 210 litres
displacement each allow for lengthy
truck operation without the need for
refueling. Another feature is the
comfortable cab for the driver. The
truck platform is worth of special
description. It can accommodate 18
cubic metres of cargo and its tipping
angle during the unloading can reach
55 degrees. Fully loaded KAMAZ-6540
can easily accelerate and reach speeds
KAMAZ Vectra Motors Ltd, which
is a joint venture between
KAMAZ OJSC and Vectra group,
showcased a wide range of products at
the recently held bC India 2011 show.
The show gave the company a good
platform to show its technologically
superior products to prospective
customers.
On display at the company's booth
like Daimler AG CUMMINS, ZF,
Knorr-Bremse SfN GmbH Bosch, etc,
along with the introduction of specially
developed set of lean production
methods (KAMAZ Manufacturing
System), which has radically improved
the technical capabilities and quality of
our products.
T h e c o m p a n y h a s a l r e a d y
estab l i shed a wel l deve loped
dealership network in India. In October
2010, the company signed 11
cooperat ion agreements w i th
dealership companies. The company
has already covered about 87 percent
area through KVML dealers. It has also
appointed one overseas dealer to
reach its customers in Lhachhen
Mineral Industry, Timphu, Bhutan.
original design. Such trucks as the
KAMAZ-6540 can be operated on
concrete roads, which have been lately
constructed in India and do not allow
vehicles with excessive axle loads.
T h e n e w l y e s t a b l i s h e d
manufacturing facility is focused on the
specific market to approach domestic
customers with its unique vehicle
o p e rat i n g co n d i t i o n s . K V M L ' s
engineering team has done specific
modifications to make the vehicle, the
best in its class. Localization process is
on fast track and more than 70 percent
localization has been achieved.
KAMAZ is having JV and close
cooperation with world's leading
truck and component manufactures
KAMAZ VECTRAKAMAZ VECTRAShowcases Russian TrucksShowcases Russian Trucksof European Quality for Indiaof European Quality for India
?????????
206 The Masterbuilder - March 2011
company” said Mr.Subhamoy Ghosh,
Managing Director, PALFINGER India.
PALFINGER is presented both prod-
uct innovations and time-tested sys-
tem solutions at bC India where the
focus on its booth was squarely on the
company's efficiency in the construc-
tion and waste management industry.
The presentation of the PS 8000 4.0
model was the highlight. PALFINGER is
launching this 3-tonne telescopic
truck-mounted crane, specifically tai-
lored to the Asian market, for mounting
on small and medium-sized trucks.
PALFINGER also exhibited a
PK 38502 and a PK 1000 Performance
from its extensive range of knuckle
boom cranes. PALFINGER knuckle
boom cranes are the perfect work-
horses on any construction site due to
their lightweight design, power, and
maneuverability.
The combination of the PK 10000
truck-mounted crane with a T 13
PALIFT TELESCOPIC hookloader,
mounted on a 16-tonne truck including
waste container, demonstrated the
interesting and powerful range of
applications that PALFINGER system
solutions can handle in the construc-
207The Masterbuilder - March 2011
PALFINGER Launches Stiff Boom Crane at bC India 2011 Show
BC 2011: Post Event Report
PALFINGER India has huge range of
truck mounted cranes, hook loaders,
specialized log handling and recycling
heavy duty cranes in its platter to offer
to the Indian customers.
The bC India 2011 show saw
PALFINGER participate in a major way ,
true to its motto ,” Efficiency and Reli-
ability” and how it is all about innova-
tive and attractively-priced lifting,
loading and handling solutions that
make day to- day work easier for the
user.
As a leader in technology and after-
sales service, the PALFINGER brand is
considered to be the epitome of quality
and reliability all over the world. A clear
strategy based on the three pillars of
innovation, internationalization and
diversification, with committed
employees and an affirmed philosophy
of “making customers more success-
ful” in their jobs are the ingredients of
this recipe for success. “A competitive
edge gained through technological
innovation and a high level of product
quality has always been central to the
Established in 1932, PALFINGER
has for many years been among
the leading international manu-
facturers of hydraulic lifting, loading
and handling systems. As a multina-
tional company group with its head-
quarters in Salzburg , Austr ia ,
PALFINGER has manufacturing and
assembly sites in Europe, in North and
South America, as well as in Asia. Inno-
vation, further internationalization and
diversification of products and services
form the strategic pillars of the corpo-
rate strategy.
PALFINGER enjoys over 30 % of mar-
ket share globally in the manufacture
and marketing of truck mounted
cranes. The company established facil-
ity at Chennai in 2008 to develop, manu-
facture and distribute products “for
India and other Asian market from
India”, by using local resources.
PALFINGER Launches
Stiff Boom Craneat bC India 2011
PALFINGER Launches
Stiff Boom Craneat bC India 2011
tion and waste management industry.
An EPSILON M110L97 recycling
crane mounted on an MAN truck with a
gross vehicle weight of 25 tonnes dem-
onstrated just how much power and
efficiency is packed into these cranes
that have been specially designed to
deal with huge dynamic loads. Addi-
tional truck-mounted crane attach-
ments and equipment for every even-
tuality completed the exhibition dis-
play of the company.
Subhamoy GhoshManaging Director, PALFINGER India
?????????
206 The Masterbuilder - March 2011
company” said Mr.Subhamoy
Ghosh, Managing Director, PALFINGER
India.
PALFINGER is presented both prod-
uct innovations and time-tested sys-
tem solutions at bC India where the
focus on its booth was squarely on the
company's efficiency in the construc-
tion and waste management industry.
The presentation of the PS 8000 4.0
model was the highlight. PALFINGER is
launching this 3-tonne telescopic
truck-mounted crane, specifically tai-
lored to the Asian market, for mounting
on small and medium-sized trucks.
PALFINGER also exhibited a
PK 38502 and a PK 1000 Performance
from its extensive range of knuckle
boom cranes. PALFINGER knuckle
boom cranes are the perfect work-
horses on any construction site due to
their lightweight design, power, and
maneuverability.
The combination of the PK 10000
truck-mounted crane with a T 13
PALIFT TELESCOPIC hookloader,
mounted on a 16-tonne truck including
waste container, demonstrated the
interesting and powerful range of
applications that PALFINGER system
207The Masterbuilder - March 2011
PALFINGER Launches Stiff Boom Crane at bC India 2011 Show
BC 2011: Post Event Report
PALFINGER India has huge range of
truck mounted cranes, hook loaders,
specialized log handling and recycling
heavy duty cranes in its platter to offer
to the Indian customers.
The bC India 2011 show saw
PALFINGER participate in a major way ,
true to its motto ,” Efficiency and Reli-
ability” and how it is all about innova-
tive and attractively-priced lifting,
loading and handling solutions that
make day to- day work easier for the
user.
As a leader in technology and after-
sales service, the PALFINGER brand is
considered to be the epitome of quality
and reliability all over the world. A clear
strategy based on the three pillars of
innovation, internationalization and
diversification, with committed
employees and an affirmed philosophy
of “making customers more success-
ful” in their jobs are the ingredients of
this recipe for success. “A competitive
edge gained through technological
innovation and a high level of product
quality has always been central to the
Established in 1932, PALFINGER
has for many years been among
the leading international manu-
facturers of hydraulic lifting, loading
and handling systems. As a multina-
tional company group with its head-
quarters in Salzburg , Austr ia ,
PALFINGER has manufacturing and
assembly sites in Europe, in North and
South America, as well as in Asia. Inno-
vation, further internationalization and
diversification of products and services
form the strategic pillars of the corpo-
rate strategy.
PALFINGER enjoys over 30 % of mar-
ket share globally in the manufacture
and marketing of truck mounted
cranes. The company established facil-
ity at Chennai in 2008 to develop, manu-
facture and distribute products “for
India and other Asian market from
India”, by using local resources.
PALFINGER Launches
Stiff Boom Craneat bC India 2011
PALFINGER Launches
Stiff Boom Craneat bC India 2011
tion and waste management indus-
try.
An EPSILON M110L97 recycling
crane mounted on an MAN truck with a
gross vehicle weight of 25 tonnes dem-
onstrated just how much power and
efficiency is packed into these cranes
that have been specially designed to
tional truck-mounted crane attach-
ments and equipment for every even-
tuality completed the exhibition dis-
play of the company.
Subhamoy GhoshManaging Director, PALFINGER India
Structural Engineers World Congress (SEWC)
Structural Engineers World Congress (SEWC)
Putzmeister - Showcasing a Wide Range of Products for the Indian Market
BC 2011: Post Event Report
210 The Masterbuilder - March 2011
in introducing new technology and
products into the strong growing
Indian market. It has implemented new
models for customers, which starts
with concrete placing machinery,
which are very simple to operate and
very cost competitive at the same time.
The company introduced the station-
ary concrete pump model BSA702D,
which is designed for 20 cubic m/h out-
put, which can be delivered by a revers-
ible drum mixer.
The global leader in concrete equip-
ment also introduced a very price com-
petitive boom placer, the BSF20.07,
which is the ideal starter boom placer
for road contractors and RMC compa-
nies, which are still not capable enough
of investing in a bigger boom placer.
The introduction of the price competi-
tive boom placer was part of the com-
pany's strategy to cover a wider seg-
ment of customers. Explained
Mr.Lindenmayer on the market condi-
tions prevailing in India , “ On one hand,
there is demand for high tech concrete
pumps for large projects, while on the
other hand, the mass market needs low
cost equipment, with the focus on pro-
211The Masterbuilder - March 2011
and has further increased its market
share in all product categories. The bC
India 2011 show offered the perfect
platform for the company to introduce
new technology and products. Express-
ing his views about the event
Mr.Michael Schmid- Lindenmayer,
Managing Director of the company's
Indian arm said "We had crowds of visi-
tors at our stand, and lots of contacts,
including many new customers. The
quality of the visitors was very good.
India definitely needed bC India. We
shall certainly be taking part again next
time, with a stand of at least the same size."
The company has been very active
Putzmeister Concrete Machines
Pvt Ltd, India, the 100 percent
subsidiary of Putzmeister
GmbH, Germany an acknowledged
world leader and global supplier of con-
crete pumps, tunneling machines,
industrial pumps and mortar machines,
showcased a wide range of products at
its booth during the recently held bC
India 2011 show.
The Indian arm of the company has
been growing rapidly and is also
exporting its products to Srilanka, Ban-
gladesh, South Africa, and South East
Asia. In 2010, Putzmeister in India has
grown by an astonishing 160 percent
PutzmeisterPutzmeisterShowcasing a Wide Range ofProducts for the Indian Market
Putzmeister - Showcasing a Wide Range of Products for the Indian Market
BC 2011: Post Event Report
210 The Masterbuilder - March 2011
in introducing new technology and
products into the strong growing
Indian market. It has implemented new
models for customers, which starts
with concrete placing machinery,
which are very simple to operate and
very cost competitive at the same time.
The company introduced the station-
ary concrete pump model BSA702D,
which is designed for 20 cubic m/h out-
put, which can be delivered by a revers-
ible drum mixer.
The global leader in concrete equip-
ment also introduced a very price com-
petitive boom placer, the BSF20.07,
which is the ideal starter boom placer
for road contractors and RMC compa-
nies, which are still not capable enough
of investing in a bigger boom placer.
The introduction of the price competi-
tive boom placer was part of the com-
pany's strategy to cover a wider seg-
ment of customers. Explained
Mr.Lindenmayer on the market condi-
tions prevailing in India , “ On one hand,
there is demand for high tech concrete
pumps for large projects, while on the
other hand, the mass market needs low
cost equipment, with the focus on pro
211The Masterbuilder - March 2011
and has further increased its mar-
ket share in all product categories. The
bC India 2011 show offered the perfect
platform for the company to introduce
new technology and products. Express-
ing his views about the event
Mr.Michael Schmid- Lindenmayer,
Managing Director of the company's
Indian arm said "We had crowds of visi-
tors at our stand, and lots of contacts,
including many new customers. The
quality of the visitors was very good.
India definitely needed bC India. We
shall certainly be taking part again next
time, with a stand of at least the same size."
The company has been very active
Putzmeister Concrete Machines
Pvt Ltd, India, the 100 percent
subsidiary of Putzmeister
GmbH, Germany an acknowledged
world leader and global supplier of con-
crete pumps, tunneling machines,
industrial pumps and mortar machines,
showcased a wide range of products at
its booth during the recently held bC
India 2011 show.
The Indian arm of the company has
been growing rapidly and is also
exporting its products to Srilanka, Ban-
gladesh, South Africa, and South East
Asia. In 2010, Putzmeister in India has
grown by an astonishing 160 percent
PutzmeisterPutzmeisterShowcasing a Wide Range ofProducts for the Indian Market
crete pumping at the Burj Khalifa
Project in Dubai and long distance
pumping to a distance of 2015 m at the
Le Refrain construction project in
France.
The company has its state of the art
manufacturing facility at Goa, spread
over 100, 000 sq m. The company has
also got a countrywide sales and ser-
vice network with regional offices all
over India. In addition to its technologi-
cally advanced products, Putzmeister
also offers its customers competent
advice and individually designed con-
cepts.
The philosophy behind the com-
pany's rapid growth in the Indian mar-
ket was aptly summed up by
Mr.Lindenmayer when he said
“Putzmeister is committed to bringing
latest technology to India and we
believe in best products, best quality
and best service,” attributes which are
expected to contribute to the contin-
ued growth of the company in the near
future.
212 The Masterbuilder - March 2011
Putzmeister - Showcasing a Wide Range of Products for the Indian Market
BC 2011: Post Event Report
system, cleaning stations and accesso-
ries.
As the pioneer in R & D in concrete
pumping technology, the company
offers a wide range of concrete pump-
ing solutions. The company has created
records in both vertical and horizontal
pumping of concrete high rise con-
ductivity and
reliable tech-
no logy,” a
combinat ion
that the company
intends to achieve
through its new product
offerings.
As far as the high-end products
were concerned, the company
introduced the BSA1409D
concrete pump, which is
based on free flow
hydraulics for cus-
tomers who require
higher output.
The BSA1408HD, a
high pressure pump, which
can pump buildings in the
height range of 200 to 250 m,
was another introduction from
the company. The new model hopes to
be the industry standard for buildings
of these heights.
In order to place concrete on top of
the building Putzmeister introduced
stationary boom systems called MX in
combination with the pipelines, valve
The Masterbuilder Subscription Form
player in the construction equipment field
for long time now.
“There is a huge demand for piling rigs
for small and medium pile diameters from
400 mm to 750mm in many construction
sites like commercial complexes, power
plants, SEZ etc. Today Piling Contractors
either depend on the big machines to do
the job, which means higher cost by way of
fuel, transportation, and maintenance, or
resort to the conventional methods, which
mean very low productivity. REL and TES
CAR together will address this gap with
their 'CF' series” said Mr. M Sunil, Associ-
ate Vice-President, REL.
TESCAR range begins with the CF 2.5
which can be mounted on a variety of Base
machines and can do up to a depth of 15
Meters for Pile Diameters ranging from
400 mm to 800 mm. “The most popular in
the CF 2.5 range is CF 2.5A, an 8Ton
machine with 'Telescopic Mast' and on a
'Bobcat' Base which is a sought after model
world over due to its flexibility and also the
ability to operate in very confined area
REL (Revathi Equipment Ltd), a part
of the Renaissance group headed
by Mr. Abhishek Dalmia, have
entered the ground engineering equip-
ment segment by augmenting their con-
struction equipment range with hydraulic
drilling rigs. The company is already a
major player in the domain of concrete
equipment segment.
REL in association with M/s. TESCAR Srl,
Italy, launched the “CF” series Piling
Rigs at the recently concluded bC
India 2011 show in Mumbai. REL
will be targeting the emerging mar-
ket for Mini Piling Rigs and is con-
fident of making a mark in this
niche segment. The company
already has a strong distribution
network, having been a leading
REL-CED forays into Foundation Equipment - Launches
“CF” Series Piling Rigs at bC India Show
Mr. M. SunilAssociate Vice-President Marketing
REL- Construction Equipment Division
BC 2011: Post Event Report
214 The Masterbuilder - March 2011
with very low head room.TES CAR has a
patent for their design of this telescopic
mast ” informed Mr. M Sunil.
“The country's long coastal Belt throws up huge opportunity for medium range piling rigs for depths up to 30 meters and pile diameters between 500to 800 mm. TES CAR 'CF-6' is an ideal machine for this application with a total weight of 20 Tons on a 'Hitachi' Base and 66 kW engine. 'CF-6' will be a very cost effective solution for the Indian Piling Contractors and also the rental segment , which will combine Productivity with Low operating Costs”, pointed out Mr. Sunil , before adding
“We are betting on this machine to do well in Indian Market and our plans include phased indigenization to make the offer better”.
TES CAR is also the leading manufac-turer of Tools including Kelly Bars, and supplies to every leading manufacturer of Piling Rigs in the world.REL, Construc-tion equipment Division offers a 'Full Liner' in concrete equipment with tech-nical collaboration with leading German manufacturers. “Every product from REL-CED stable has certain feature incomparable and offering value addi-tion to clients in terms of productivity, saving in operating cost or additional safety features.” Mr. Sunil explained.
The THP 45 D High pressure Con-
crete Pump launched in 2010 is already
rated high by users due to its capability
to pump up to even 100 meters vertical
height at the same time giving a very
good output.REL also have expanded its
own Network to all four regions of the
country and have currently 13 Dealer-
ships to provide after sales support to its
range.
PilingPilingRigsRigs
iling is a kind of ground treatment for Pstrengthening the ground soil in order to
make it capable of supporting the load of the
project. It basically involves driving the pile into
the ground below the ground level. Generally,
piles are of the following types: concrete piles,
timber piles, steel piles and bored piles.
Equipments used to drive these piles into the
ground are called Piling rigs. A piling rig is an
equipment mainly applied to drill in sandy soil,
clay, silty clay etc. and widely used cast-in-
place piles, diagram walls, foundation
reinforcement and other foundation projects.
�T�h�e�s�e� �r�i�g�s� �c�o�m�e� �i�n� �3� �m�a�i�n� �c�a�t�e�g�o�r�i�e�s�:
�S�m�a�l�l� �s�i�z�e�d� � �T�o�r�q�u�e�:� �6�0� �-�1�0�0� �k�N�m�,�
�E�n�g�i�n�e� �p�o�w�e�r� �1�0�8� �k�W�,� �d�r�i�l�l�i�n�g� �d�i�a�m�e�t�e�r�
�.�5� � �1�.�2�m�,� �d�r�i�l�l�i�n�g� �d�e�p�t�h� �4�0�m�,� �t�o�t�a�l�
�q�u�a�l�i�t�y� �4�0�t�.
�M�i�d�d�l�e�-�s�i�z�e�d� �-� �t�o�r�q�u�e� �i�s� �a�r�o�u�n�d� �1�2�0�-
�1�8�0� �k�N�m�,� �e�n�g�i�n�e� �p�o�w�e�r� �1�2�5�-�2�0�0� �k�W�,�
�d�r�i�l�l�i�n�g� �d�i�a�m�e�t�e�r� �0�.�8�-�1�.�8�m�,� �d�r�i�l�l�i�n�g�
�d�e�p�t�h� �6�0�m�,� �t�o�t�a�l� �q�u�a�l�i�t�y� �4�2�-�6�5�t�.
�L�a�r�g�e�-�s�i�z�e�d� �-� �t�o�r�q�u�e� �i�s� �a�r�o�u�n�d� �2�4�0� �k�N�m�,�
�e�n�g�i�n�e� �p�o�w�e�r� �3�0�0� �k�W�,� �d�r�i�l�l�i�n�g� �d�i�a�m�e�t�e�r� �1�-
�2�.�5�m�,� �d�r�i�l�l�i�n�g� �d�e�p�t�h� �8�0�m�,� �t�o�t�a�l� �q�u�a�l�i�t�y� �1�0�0�t�.
STUDENT CORNER
215The Masterbuilder - March 2011
BC 2011: Post Event Report
REL-CED forays into Foundation Equipment - Launches “CF” Series Piling Rigs at bC India Show
projects, including high-rise buildings, power plants, and tunnels.”
Going into further details of the new
launches Mr.Sundaresan said “We have
been seeing increased activity in high-
rise constructions, especially in Mumbai,
which is the high-rise capital in India.
With the kind of development that the
city is facing, we are sure that one will see
a further increase, not only in the number
of high-rise constructions here but also in
terms of the height of the projects. And
this is where our new concrete pumps
will make the difference. We believe that,
going forward, there will be a strong
demand for these products, especially in
a market like Mumbai.”
Speaking about the launch of the two new concrete pumps the company's Chief Operating Officer, Mr.V.G.Sakthikumar said “We are extremely happy to launch our concrete pumps at the prestigious bc India International Trade Fair. Our ability to clearly understand what our customers need and to launch products that meet these requirements has always set us apart. Our objective of unveiling
the new products at the bC India fair is dual in nature on the one hand, it gives us the opportunity to meet with our clients. More importantly, it also gives us the platform to leverage on the demand for such high-capacity equipment in Mumbai, which is seeing a consistent g r o w t h i n t e r m s o f h i g h - r i s e constructions. With their ability to pump concrete upto heights of 250 and 500 metres respectively, we are sure that the SP 2880 and the SP 8800 will meet the requirements of our customers here.”
Mr. John Keenan, Head of Sales Asia-
Pacific, SCHWING GmbH Germany, while
giving his views on the two new launches
said, “SCHWING is known today as a total
concrete equipment solutions provider
and in our endeavor to help our
customers overcome all concrete
handling challenges, we felt a strong
need to enhance our product-line. Thus,
our latest offerings, the BP 8800 and BP
2880 concrete pumps, feature a
combination of advanced technology,
economy, flexibil ity, quality and
exclusively for high-rise constructions.
We are hopeful of providing our
customers with solutions which are both
practical and cost-effective.”
The SP 8800, according to the company wil l redefine concrete pumping, in terms of pumping output, operating convenience, and economic efficiency. Driven by a powerful Deutz Diesel engine and combined with DN 180 and DN 200 pumping cylinders, the customers will have the choice of selecting the specific pump that meets the requirements of a specific project. The open-circuit hydrostatic drives with soft-push controls are characterized by exceptionally soft pushing of the
BC 2011: Post Event Report
SCHWING Stetter (India) Pvt Ltd., a 100% subsidiary of SCHWING Gmbh, Germany, and a leading
player in the Indian Ready Mix Concrete (RMC) equipment industry, unveiled two new concrete pumps new concrete pumps, SP 8800 and SP 2880, for the Indian market at the recently held bC India show at Mumbai from February 8-11, 2011. Aimed at the high-rise construction market in India, the SP 2880 can pump concrete vertically upto a height of 250 metres, while the SP 8800 can pump concrete vertically upto a height of more than 500 metres.
Speaking about at the launch of the new products, Mr. Anand Sundaresan, Managing Director, SCHWING Stetter (India), observed, “We are extremely happy to unveil our two new concrete pumps, SP 8800 and SP 2880. These products are specifically designed for high-rise construction projects, where high capacities are required, for rapid placement of large quantities of concrete, extreme pumping heights and / or distances and difficult concrete mixes. The pumps are ideal for use in the construction of various civil engineering
The Masterbuilder - March 2011
Unveils Two New Concrete Pumps at bc India ShowSCHWING Stetter India
Anand Sundaresan, Managing Director, SCHWING Stetter(India) Pvt Ltd
216
V.G.Sakthikumar, CEO, SCHWING Stetter (India) Pvt Ltd
Truevents, Singapore
leading to substantially lower fuel consumption during transport. The energy-consuming changeover block for the changeover has been shifted from the piston to the rod side and the hydraulic hoses can be detached and reconnected easily. This ensures that there is no oil dripping and no waste of fuel due to changeover block heating. the SP 2880 is also equipped with a noise abatement system, making the pump more environment-friendly.
The pump has impressive controls
with display, which provides all current
operating data like engine speed,
hydraulic pressure, and stroke. The
control system can be enhanced with a
Bluetooth remote control. The modular
structure, including a vert ical ly
adjustable hitch, permits use of two
different axles a construction site axle
and an optional road axle for towing
speeds of up to 80 km/h.
SCHWING Stetter India Unveils Two New Concrete Pumps at bC India Show
concrete column into the delivery line and gentle switchover with no pressure peaks. This makes for smooth running and high service lives. Large upward folding side doors permit effortless, d irect access for servic ing and maintenance purposes.
The hydrostatic drive features rugged, sturdy axial-piston pumps with power regulator and additional output adjustment. All operating and control devices are centrally located, readily visible, and easily accessible. The heart of the concrete pump is the rock-valve, designed for maximum concrete pressure of up to 250 bars, which offers exemplary pumping characteristics, wearing properties and operational safety.
The SP 2880 is a stationary concrete pump that is based on the forward-looking design of the modern plastic casting, with significant weight savings
SS IPL 8800
SSIPL 2880
In August 2009, SCHWING Stetter was recognized internationally for the world record set by the company in pumping concrete vertically up to a record height to 715 meters for the Parbati Hydro-electric project in Suind village, Himachal Pradesh. The project was implemented by the National Hydro-power Corporation. SCHWING Stetter supplied BP 4000 super concrete pumps to Gammon India, which executed the project for pumping concrete from the bottom of the tunnel to the top of the tunnel, which had a total length of 1500 meters and an inclination of 30°.
Besides the new concrete pumps, SCHWING Stetter (India) also unveiled a high pressure water cleaning system at the bC India 2011 International Trade Fair. With the launch of these two new concrete pumps, SCHWING Stetter offers the entire range of concrete pumps, including the BP 350, the BP 1800, theSP 1400, and the LP 1400.
BP 8800
The Masterbuilder - March 2011218
BC 2011: Post Event Report
219The Masterbuilder - March 2011
Since 1944, TIL has been partner-
ing India's infrastructure growth.
As a responsible nation builder,
the company remains committed to
India's infrastructure creation by pro-
viding high-technology equipment and
total solutions, with the eventual aim
of enhancing customer value.
Technology, innovation, and leader-
ship are three qualities that have come
to define TIL as an organization and its
philosophy. Over the past six decades
the company has emerged as one of
the leading providers of a wide range of
equipment that represent some of the
finest in global technology. TIL contin-
ues to strive for new ways and better
solutions while serving customers with
cutting edge technology products and
excellent service by constantly innovat-
ing and evolving.
The company showcased several
Story Continues TIL - The GrowthTIL - The GrowthStory Continues
products from its wide range during the
recently held bC India 2011 show. The
company has always been a pioneer
when it comes to introducing material
handling equipment. Explained
Mr.S.K.Bhatnagar, Director & President,
TIL, dwelling on the company's philoso-
phy during the press conference at bC
India 2011 show, “TIL has continuously
and successfully anticipated future
needs of the industry and introduced
state-of-the art products, “before add-
ing, “Whenever there has been a
requirement for a high capacity crane
or whenever there has been a require-
ment for new technology, we have
been the pioneers.” Today TIL is the
only manufacturer in the country that
customer experience, TIL has always
formed a new business association to
expand product portfolio, deepen mar-
ket penetration, and offer superior solu-
tions to a wider cross-section of cus-
tomers. The company has recently
entered into an agreement with Astec
Inc; to introduce equipment meant for
the road construction industry, includ-
ing, cone crushers, high frequency
screens, and hot mix asphalt plants.
As part of the diversification initia-
tive the company had recently intro-
duced hot mix asphalt plants, based on
double barrel technology. Giving
details about the road construction
equipment range Mr.R.Nandagopal,
TIL-ASTEC, Vice President, Equipment
& Project Solutions, explained, “India is
currently a batch mix country. But with
220 The Masterbuilder - March 2011
TIL - The Growth Story Continues
BC 2011: Post Event Report
offers mobile cranes with load lifting
capacity of 40 tonne and beyond.
TIL launched its 75 tonne crane in its
truck mounted series during the bC
India 2011 show. The model- TMS 875,
comes with several key features includ-
ing, 4 section trapezoidal full power
boom, maximum road and speed of 50
km/hr, hoisting speed of 110 m/min. “
Loads are getting heavier and custom-
ers are looking for higher capacity
cranes, “ observed Mr.Bhatnagar on
the trends being witnessed in the
industry.
Going into details about the target
customers and applications for the new
75 tonne crane, Mr.Bhatnagar said,
“This crane will be extensively used in
heavy infrastructure sector, building of
power plants, refineries, chemical
plants, building bridges, etc.” The crane
comes with the benefits of synchroni-
zation that ensures even distribution of
load on the boom sections, better ser-
vice facility, higher mobility, and effi-
cient hoist unit.
The company also launched a 10
tonne truck mounted crane during the
bC India 2011 show. With this the com-
pany now offers customers a choice
from 10 to 75 tonnes. The new model-
TMS 10, comes with key features such
as 3 section full power fully synchro-
nized, mounted on Ashok Leyland Chas-
sis, maximum lifting height of 25.7 m
and less gross vehicle weight.
Speaking about one of the key
advantages of the new launch
Mr.Bhatnagar pointed out, “It is based
on a drive line sourced completely from
Indian companies. What this means is a
cost-effective product that is easy to
maintain. “
In its continuous quest to enhance
increase in road project size, you will
need hot mix asphalt plants which fea-
ture continuous mix or double barrel
technology. “
Apart from the Telesmith 44 SBS
Cone Crusher, AMS 2618VM Screening
solution, the company has also entered
into a licensee agreement with Paceco
Corp, USA, now a part of the Mitsui
Engineering and Shipbuilding Co Ltd,
for the designing and manufacturing of
Rubber Gantry Cranes in India.
Mr.Bhatnagar during the press con-
ference also spoke about the new plant
of TIL that is under construction in
Kharagpur, about 120 km from Kolkata.
With a world-class product line, buoyant
economy and spurt in infrastructure
projects, the TIL growth story looks all
set to continue in the years to come.
Roof India Exhibition
?????????
222 The Masterbuilder - March 2011
ABG 4361 asphalt paver ( which was built in Volvo's Indian factory) sup-ported by the 8,200 kg DD 80 large asphalt compactor and the L120F wheel loader.
The show also saw Mr.Muralidharan
give a lecture on the company's four
pronged approach to improve fuel effi-
ciency. These cornerstones include 'Sys-
tems' such as the OptiShift- a feature fit-
ted to Volvo wheel loaders that inte-
grates a torque converter with Volvo's
223The Masterbuilder - March 2011
BC 2011: Post Event Report
and also underline the company's
expanding product, manufacturing,
and distribution capabilities.
Pointing to the recent market trends, Mr.A.M.Muralidharan, Managing Director of Volvo India Private Ltd and Head of Volvo Construction Equipment Business in India observed, “Volvo Con-struction Equipment enjoyed a sharp increase in sales and profitability in 2010, amid improving conditions for the industry. The company also
i n c r e a s e d u n i t s a l e s b y 70 percent compared to 2009- selling an all-time high of 66,000 machines dur-ing the year, which is significant growth.”
The centerpiece of the company's display during the show was a pair of the latest Volvo excavators the EC 140B Prime and the EC210B Prime; the latter specially adapted for work in granite and marble quarry applications. Road machinery also featured highly with an
At the bC India 2011 show Volvo
Construction Equipment high-
lighted how a package of
advanced engine and support solutions
lies at the heart of the company's
expanding production and distribution
base in India. Volvo Construction
Equipment used its extensive display at
the inaugural Bauma Conexpo India
2011 show to demonstrate its commit-
ment to improving fuel consumption
and lowering emissions in its products
Volvo Drives Home theFuel Efficiency Messageat bC India 2011 Show
Volvo Drives Home theFuel Efficiency Messageat bC India 2011 Show
r e s p e c t t o f u e l e f f i c i e n c y
Mr.Muralidharan quipped, “We have
always been focused on fuel efficiency.
We have been the pioneers when it
comes to offering fuel efficient products.”
With new fuel injection, air man-
agement technology, and advanced
electronics, the inherent potential of
the V-ACT engine is then tailored by
Volvo engineers to meet the specific
performance criteria required by dif-
ferent machine types and applications.
The show also saw the company pro-
mote the introduction of a dedicated
component remanufacturing service
initiative 'Reman' in the Indian market.
Volvo has recently invested in a new Fac-
tory Remanufactured Component Cen-
tre in Bangalore, whose technicians
expertly restore a range of components
to an often better-than-new standard
('better' because components are
upgraded to the latest iteration of that
unit's development). “It's like giving
Reman
patented Reverse By Braking (RBB) tech-
nology. 'Operator Behaviour' is another
cornerstone and programs such as Eco-
Operator highlight good working prac-
tices when using machines to develop
an environmentally-friendly style of
driving. The third cornerstone is 'Fu-
ture Technologies” such as hybrids and
the final element 'Engines' an area
where the company's fuel efficient V-
ACT design excels.
The Volvo diesel engine is at the
heart of the company's wide range of
products. based on well-proven, robust
technology, the Volvo V-ACT engine
range meets the needs of the Indian
customers by providing increased
machine performance along with
reduced emissions. Along with envi-
ronmental improvements, the engine
also represents new achievements in
combustion efficiency and overall
engine performance. Giving an insight
into the company's philosophy with
Volvo Diesel Engine
A.M.Muralidharan, Managing Director of Volvo India Private Limited and Head of VolvoConstruction Equipment Business in India and Dr. Eberhard Wedekind, President - Region Asia,Volvo CE and Chairman - Volvo India
?????????
222 The Masterbuilder - March 2011
ABG 4361 asphalt paver ( which was built in Volvo's Indian factory) sup-ported by the 8,200 kg DD 80 large asphalt compactor and the L120F wheel loader.
The show also saw Mr.Muralidharan
give a lecture on the company's four
pronged approach to improve fuel effi-
ciency. These cornerstones include 'Sys-
tems' such as the OptiShift- a feature fit-
ted to Volvo wheel loaders that inte-
grates a torque converter with Volvo's
223The Masterbuilder - March 2011
BC 2011: Post Event Report
and also underline the company's
expanding product, manufacturing,
and distribution capabilities.
Pointing to the recent market trends, Mr.A.M.Muralidharan, Managing Director of Volvo India Private Ltd and Head of Volvo Construction Equipment Business in India observed, “Volvo Con-struction Equipment enjoyed a sharp increase in sales and profitability in 2010, amid improving conditions for the industry. The company also
i n c r e a s e d u n i t s a l e s b y 70 percent compared to 2009- selling an all-time high of 66,000 machines dur-ing the year, which is significant growth.”
The centerpiece of the company's display during the show was a pair of the latest Volvo excavators the EC 140B Prime and the EC210B Prime; the latter specially adapted for work in granite and marble quarry applications. Road machinery also featured highly with an
At the bC India 2011 show Volvo
Construction Equipment high-
lighted how a package of
advanced engine and support solutions
lies at the heart of the company's
expanding production and distribution
base in India. Volvo Construction
Equipment used its extensive display at
the inaugural Bauma Conexpo India
2011 show to demonstrate its commit-
ment to improving fuel consumption
and lowering emissions in its products
Volvo Drives Home theFuel Efficiency Messageat bC India 2011 Show
Volvo Drives Home theFuel Efficiency Messageat bC India 2011 Show
r e s p e c t t o f u e l e f f i c i e n c y
Mr.Muralidharan quipped, “We have
always been focused on fuel efficiency.
We have been the pioneers when it
comes to offering fuel efficient products.”
With new fuel injection, air man-
agement technology, and advanced
electronics, the inherent potential of
the V-ACT engine is then tailored by
Volvo engineers to meet the specific
performance criteria required by dif-
ferent machine types and applications.
The show also saw the company pro-
mote the introduction of a dedicated
component remanufacturing service
initiative 'Reman' in the Indian market.
Volvo has recently invested in a new Fac-
tory Remanufactured Component Cen-
tre in Bangalore, whose technicians
expertly restore a range of components
to an often better-than-new standard
('better' because components are
upgraded to the latest iteration of that
unit's development). “It's like giving ld
Reman
patented Reverse By Braking (RBB)
technology. 'Operator Behaviour' is
another cornerstone and programs
such as Eco-Operator highlight good
working pract ices when using
machines to develop an environmen-
tally-friendly style of driving. The third
cornerstone is 'Future Technologies”
such as hybrids and the final element
'Engines' an area where the company's
fuel efficient V-ACT design excels.
The Volvo diesel engine is at the
heart of the company's wide range of
products. based on well-proven, robust
technology, the Volvo V-ACT engine
range meets the needs of the Indian
customers by providing increased
machine performance along with
reduced emissions. Along with envi-
ronmental improvements, the engine
also represents new achievements in
combustion efficiency and overall
engine performance. Giving an insight
into the company's philosophy with
Volvo Diesel Engine
A.M.Muralidharan, Managing Director of Volvo India Private Limited and Head of VolvoConstruction Equipment Business in India and Dr. Eberhard Wedekind, President - Region Asia,Volvo CE and Chairman - Volvo India
components a second life, explained
Mr.Muralidharan, before adding, “The
components are disassembled at our
factory, by trained technicians, what-
ever were the parts required they are
then replaced, before it is sold to
another customer. This way we offer a
very economical way of using the core
and replacing the parts.”
The facility allows users of Volvo
construction equipment to have their
used components renovated at a lower
cost than buying new and consuming
far less new materials and energy. The
program according to the company is a
natural extension of Volvo's commit-
ment towards a greener environment.
The show also highlighted the
CareTrack-Volvo's telematic system
that allows remote monitoring and
machine diagnostics on all general pur-
pose machines- which is now available
in India as standard and comes with a
free three year subscription. The sys-
tem offers customers a number of
advantages, the primary one being its
ability to effectively manage machine
maintenance, servicing and repair
through the system's ability to 'see'
how the machine is performing, has
performed and a range of important
information.
The show also saw company offi-
cials explain the benefits of Volvo's
'hard' machine product solutions as
well as the extensive range of 'soft'
non-machine product and service
offerings. Specialists from the company
were also available to explain the bene-
fits of Customer Support Agreements
(CSAs) which come in several forms,
depending on customer needs and the
work environment the machine oper-
ates in.
CareTrack
224 The Masterbuilder - March 2011
Volvo Drives Home the Fuel Efficiency Message at bC India 2011 Show
BC 2011: Post Event Report
Ermotec International Pvt.Ltd SKG Equipments Pvt. Ltd.
226 The Masterbuilder - March 2011
M BE.Scape
ith an avant-garde approach and forward thinking, Brazilian architect WMike Reyes who’s goal was to provide sustainable homes for the stranded survivors has come up with an emergency shelter that has been inspired by favelas or Brazilian shanty towns.The structures are box-like homes that can be attached onto the facades of other buildings. Reye's’ concept is unique in that it actually enlists able-bodied survivors to assist with the imple-mentation of the shelters – a cool idea, since it empowers them to take action instead of simply sitting around, waiting for help. Reyes envisions that the pre-constructed structures could be airlifted by helicopter to sites where they are needed and then guided into place with the help of survivors. They “clip” onto building facades using leverage.
Each shelter would contain beds, lighting, storage and a skylight and be made of recycled materials from local construction sites. There would also be attachments for solar energy, water purification and organic farming.
n today's modern world when houses even with a few
plants here and there claim to have a garden, this gor-Igeous building in Linkebeek, Belgium is a true blue garden
house. Completely draped with gorgeous greenery, it is a
sight to behold.
The building that has been designed by Samyn and Part-
ners took all of 8 years in construction. It was originally
designed to be draped with ivory and not plants. In fact,
patinated copper material was actually chosen for the roof.
It so happened that the construction process took very
long and the owners finally scrapped the idea of ivory and
copper and instead went for some green façade. The
selections of exotic plants that cover the building have
been chosen by an expert botanist Patrick Blanc.
PVC panels that have been incorporated in the design act
as the support system, apart from helping in irrigation of
the beautiful green façade of the building.
A TrueA TrueGarden HouseGarden House
Emergency Parasitic Homes
n ancient Dominican Church has been transformed
into a spectacular modern book store, thanks to the cre-Aative genius of architecture. The 'brand new' bookstore in
the heart of Maastricht is now attracting visitors by the
hordes, who seem to be as much fascinated by the archi-
tecture, as by the books.
The Church which dates back to the 13th Century has been
briefly used as a parish, before it was converted into a ware-
house and then into a giant parking lot. It was converted into
its present form by architecture firm Merkx and Girod.
There is a special viewing gallery at the back of the structure
from where visitors can admire the spectacular 14th century
ceiling frescoes or relax over a cup of coffee at the café that
is located in place of the former choir.
Ancient Churchbecomes a Modern Bookstore
JSW Serverfield Structures Ltd
Zamil Steel Buildings India.Pvt.Ltd