Editorial

This Issue. . .
R
oads connect people. Good roads are absolutely vital for a country and a continent’s
economy and welfare. As the world population grows, the world becomes “flat,” and
humanity pushes its frontier into the far corners of the globe, the need for transporting
goods and people faced with new technical challenges such as accommodating heavy
vehicles, increased number of load repetitions, use of new materials for increased and
improved pavement life and building through difficult terrain grow significantly. At no time in
the history, the need has ever been so great to build and maintain long lasting and good
performing pavements. The developing countries of the world have embarked on the task of
building new roads in an unprecedented scale, while developed countries are facing a
Herculean task of maintaining and rehabilitating their existing road assets.
At the same time, building, maintaining, and rehabilitation of roads pose a tremendous
challenge to the society – in the form of their adverse impact on our environment. And this
dichotomy – need versus harmful effect – offers a grave challenge. Stated simply, the
challenge is how do we design and construct good pavements so that they perform well,
last longer and the construction has a minimum or no impact on our environment?
Before delving into books full of equations and complex theories, we need to take a step
back and ponder on three very basic issues: One—how do we effectively utilize the
advances in modern science and technology in building better and long lasting pavements?
Two—how do we properly consider the pavement network as part of our overall built
environment in which we live? and three—whose responsibility is it to face the above
challenge - the government or the private enterprise or the public?
The building of better performing and long lasting pavements is itself a sustainable
practice – it provides a safe and functional mode of transportation to all and helps us
prolong the maintenance and rehabilitation cycles and thus helps us reduce the use of new
materials and energy. Thus, it provides social, economic, and environmental sustainability.
Advanced concepts and practices of utilizing materials, mix design, construction techniques
and proper specifications can help us achieve this goal. While Professor Kandhal’s
comprehensive article on advances in bituminous road construction provides an overview of
all relevant topics, Sehgal and Abele’s article gives a perfect example of the application of
advanced concepts in the form of stone mastic asphalt. Since pavements are not isolated
systems, their construction, maintenance and rehabilitation must be considered in conjunction
with the other parts of our natural and built environment. Proper layout design, selection of
type of pavement and construction practices can effectively reduce or eliminate the harmful
effect on our environment, as discussed in an article on sustainable pavements by
Mr. Mallick and Mr. Veeraragavan.
The answer to the last question lies in the concept of shared responsibility. We, as
world citizens, are all responsible for the construction of an efficient infrastructure that has
minimum impact on our environment. Shared responsibilities, partnership and cooperation
between private and public organizations, and the availability of properly trained personnel
are the key factors to ensure the most efficient construction process that can result in a
significant improvement in the transportation infrastructure – as evident from Mather’s and
Kumar’s excellent article on the East Link project in Australia.
Enjoy!

A. Veeraragavan
Guest Editor

16 NBM&CW MARCH 2011

 Contents MARCH 2011

Roads & Highways

50 Sustainable Pavement Engineering Rajib B. Mallick

66 Advances in Bituminous Road Construction

Prithvi Singh Kandhal

100 WHITE TOPPING An Excellent Solution for

Pavement Rehabilitation V. Ramachandra

120 Concrete Overlays

38 Asphalt
News 86 Experiences with Stone Matrix Asphalt (SMA)
Bernd Abele
24 Industry News
108 Asphalt is Green Blesson Varghese
28 Companies in Limelight

38 Real Estate

42 SEZs

44 Equipment News

Project Briefs
244 Infra Developments

246 Road & Highway Projects

251 Port Projects

251 Airport Projects 108

252 Railway Projects

New Approaches
254 Power Projects
122 Enterprising Approaches in the Successful Construction
of a Toll Motorway (East Link) Through Suburban
Melbourne, Australia
Arun Kumar

Concrete Additives
130 Effect of Dosing Sequence of Micro Silica on Slump
& Compressive Strength of Concrete
S.B.Kulkarni

Alternative Material
136 Use of Cement Fly Ash and Gypsum as an
Alternative Material for Low Cost Housing
(Feasibility Study) N.S.Naik
66

20 NBM&CW MARCH 2011

 Contents MARCH 2011

154

Investigation Post Event Report

146 Experimental Investigation on Flexural Behaviour 154 bC India—Displays CE Progress and Promises
of Reinforced Concrete Beams Strengthened by
Ferrocement Laminates B.Sivagurunathan
¨ Manitowoc ¨ Sandvik ¨ TIL ¨ Caterpillar ¨ Soilmec
¨ VDMA ¨ Volvo ¨ LIEBHERR ¨ Mahindra & Mahindra
Equipment & Machinery
Ltd ¨ Putzmeister ¨ Wirtgen India ¨ Terex MPS
135 Powerscreen India Serves Oman ¨ Greaves ¨ Sany ¨ Kobelco ¨ Proman ¨ BHS
263 Linden Comansa Sonthofen ¨ Voltas Ltd ¨ Manitou BF ¨ CHETRA ¨ ABG
Cranes ¨ Normet ¨ Fayat Group ¨ Sicoma Mixers India
Products & Technologies ¨ ACE ¨ PALFINGER ¨ Apollo Infratech ¨ Conmat
64 Allison Transmission-equipped Water Tankers ¨ Liugong ¨ DOZCO ¨ Puzzolana ¨ Jaypee ¨ Ajax Fiori

152 Polished Concrete Floors ¨ Revathi ¨ Sree Parijatha ¨ Propel ¨ Sennebogen

¨ Tyrolit ¨ Haulotte Group ¨ EPIC ¨ Wolffkran
Steel Construction ¨ Australian Crane ¨ Electromech ¨ Hidrokon ¨ Strong
256 Design Flexibity in Construction with Steel Plant ¨ Topcon ¨ Hess ¨ Godrej & Boyce ¨ Fushun
Rajesh Maheshwari
Cranes ¨ Cosmos ¨ Macons ¨ Anupam ¨ Jaso Tower

DEPARTMENTS Cranes ¨ Maxmech ¨ Powerscreen ¨ Manforce Trucks

Event Diary------------------- 264 ¨ Mait India ¨ AMW ¨ Unipave ¨ Pakona ¨ Ammann

Marketrends------------------ 248-249 ¨ Te re x C o r p . ¨ S c h w i n g S t e t t e r ¨ R o t a r y
Subscription Form ---------- 229 ¨ Speedcrafts ¨ Nawa Engineers ¨ Universal
Advertisers' Index----------- 230 ¨ Lonking ¨ Jamshedji ¨ Kaushik ¨ Arrow Machinery
¨ Unisteel ¨ MARSMAN

22 NBM&CW MARCH 2011

NEWS Ind. News
ADB’s Assistance
ADB has announced its $7.4 billion
assistance to India. Bank’s
communication said that the ADB
and the Union Government have
agreed to a new three-year
business plan that will provide
lending assistance of $7.4 billion
to support inclusive and
environmentally sustainable growth
in the country. A major thrust of
ADB’s India Country Operations
Business Plan (COBP) for 2011-13,
the communication said will be to
support infrastructure development,
particularly through PPP
programmes. The Bank has noted
that supporting the government‘s
efforts to redress inter-state
development and economic
disparities is also the key
cornerstone of the COBP which is
aligned to the country’s XI Plan
(2007-12). Continued assistance for
development of the vital energy
sector by means of programmes
involving clean and renewable
energy is another key focus area.
The assistance is aimed at initiating
projects in different states of energy,
urban development. We are looking
forward to work closely with India in
implementing the programmes in
COBP to help promote inclusive
growth and reduce poverty in the
country, said ADB Country Director
(India) Hun Kim.
Indian Firms Keen
on Hajigak Mines
Leading private and public sector
firms including Tata, Essar, Sail,
NMDC, and RINL are among the
15 Indian companies who have
shown their interest in developing
the Hajigak mines in Afghanistan.
These companies may bid for the
assets to offer in consortia, or may
go alone in the upcoming auction.
Afghanistan has invited EOI’s for
24
Industry News
multiple exploration concessions
falling within the Hajigak mines. The
Afghan government is very excited
with the participation of Indian firms
in this deal and also expects that
the Indian companies should set
up steel and mines processing
plants near Hajigak. The country is
reported to be sitting on over $2.5
trillion worth of untapped mineral
deposits with huge copper reserves.
Global Productivity
Trends
Global economic productivity which
rallied strongly last year due to
economic recovery, is likely to drop
down in 2011 in advanced
economies. However, the Indian
productivity is increasing faster than
China, says a report. Though
China’s productivity has driven its
growth story, the wheel could soon
be turning. With investment surging
in India, its productivity is set to
grow over four percent compared to
three percent of China. An ICRIER
study report states that between
2004 to 2009, India’s productivity
has grown by 3.9 percent per
annum while in China it has been
much less. But sustaining this
growth for long is not an easy task
unless the manufacturing chips in
to overtake productivity trends seen
in telecom, which is pushing
productivity graph in India higher. If
resources become more productive
and unorganized manufacturing
gets organized, productivity in the
entire manufacturing could go up.
At present, manufacturing lags due
to high share of unorganized sector.
This holds good for other sectors
with mushroom growth of
unorganized players in every sectors
from textiles to transport and related
activities.
DDA Urges to Rope
in Private Builders
The new minister of UD, Mr. Kamal
Nath in a review meeting on the
working of DDA said that DDA
should go in for public partnership
model and shift its focus from being
land-owning agency. Though the
proposed model for DDA is yet to
be firmed up, various options are
under consideration. In case of LIG
projects, private sector could be
roped in to develop malls, hospitals
and schools along with the
apartments. Another option is to
rope in the private sector to build
on DDA's land bank. PPP model
has been tried in the case of the
CWG Village where Emaar MGF
built the complex on the banks of
Yamuna, where DDA incurred
losses in the transaction. The new
minister is also reviewing the
schemes under JNNURM and
called for required reforms in
municipal bodies.
24th Builders
Convention
Addressing the 24th All India
Builders Convention, held
recently at Chennai, the Union
Finance Minister has urged
the builders to be socially
conscious and the
construction should work
closely with governmental
bodies. Rapid urbanization
and infrastructure growth are
NBM&CW MARCH 2011
NEWS Ind. News
Mr. Pranab Mukherjee, Union Finance
Minister with Mr. G.K.Vasan, Union
Minister of Shipping, at the All India
Builder's convention in Chennai
not just a commercial opportunity
for builders but also a social
challenge that must be addressed.
Builder should work closely with
the Government to tap this
opportunity to address the challenge
of affordability in housing,
technology and skilled human
resource constraints in
infrastructure, said the Finance
Minister. He urged the construction
industry to work with the National
Skill Development Corporation to
enable skill creation by setting up a
Construction Sector Skill Council.
The NSDC estimates that
construction sector will need 3.3
crore more skilled workforce by
2022. In the process, the
construction industry will benefit
from the rapid infrastructure growth
Technology support, customers
needs, cost and adequate skilled
workforce need to come together
for the target to be achieved, he
underlined. The Convention
chairman Radhakrishnan, called for
BEHR lndia Gears up for
Euro 4 Emission
Standards
BEHR India, a joint venture between
BEHR GmbH & Co.KG, Stuttgart, a
systems partner for international
automobile industry and Anand
Automotive Limited, one of India’s
leading manufacturers of automotive
components and systems,
announced the introduction of
‘Exhaust Gas Recirculation (EGR)
technology in India. The EGR
technology will help heavy trucks
26
the establishment of a ministry of
construction to address the needs
of this sector. Documents relating
to government contracts need to be
updated to suit modern requirement
and to be on par with international
practices, he emphasized.
Budget Wish Lists of
Infra Builders
It is a Budget time in the country
and there are unending Budget
memoranda across sectors
including industry and trade giving
their wish lists. Highway developers
have asked for service tax exemption
on toll. The National Highways
Builders Federation (NHBF) wants
tax holiday to be extended. The
developers have also asked the
Government to amend rules with
regard to dividend distribution tax
to prevent cascading effect. NHBF
has asked the Finance Minister to
allow usage of duty-free imported
capital goods for road construction
business rather road projects. It has
also asked the term for tax holiday
to be defined with greater clarity. A
10-year tax holiday is available to
enterprises developing new
infrastructure facility, but the term is
not well defined, said the Federation
in its Budget memorandum.
Realtors on the other hand,
want tax holiday to stay and so
sops for buyers in the housing
market. The Confederation of Real
and ultra light commercial vehicles
to meet the upcoming Euro 4
standards in India.
Speaking on the launch of
Exhaust Gas Recirculation
technology, Mr. Sunil Kaul, President
& COO, BEHR India Limited said,
“In anticipation of new Euro 4
emission standards in India, we
are happy to introduce EGR
technology. The new technology will
help reduce pollutant emission and
it has been introduced keeping in
mind our commitment towards
public health and safety.”
Estate Developers Association of
India (Credai) has sought extention
of tax holiday to industry parks up
to March 2015, and amendments
to help townships of 10 acres and
above to qualify for tax deduction
under infrastructure facility. This is
in addition to tax sops for the first
time home-buyers from 2011,
besides enhanced income tax
deduction limits. It has asked
service tax abatement to be
increased from 75% to 90%.
The construction equipment
sector too wants rationalization in
tax regime, excise duty cut,
clarifications on multi-tax regime
and uniformity in state taxes and
levies. This was the wishlists of
most captains of construction
equipment companies who
interacted with NBM&CW at the
Mumbai equipment Expo. They were
of the firm view that in the
forthcoming budget well – concrete
steps would be initiated to promote
investment in infrastructure and
priority areas well identified and
certain imbalances corrected for the
future growth and well being of
country’s economy.
Using a new kind of material
coating, BEHR has succeeded in
minimizing the level of corrosion on
the aluminum, so that the charge
air cooler can now be used as a
component over the full service life
of EGR systems. BEHR India has
already received 4 business
nominations from various
customers, while some of the
projects are still under acquisition.
Behr India is all geared up for this
product and plans to launch with
“Zero PPM & Zero warranty” tag.
NBM&CW MARCH 2011
NEWS Companies in Limelight
Companies in Limelight
♦ Saint-Gobain Goes for
`400cr Solar Plant
Saint-Gobain Glass India has
embarked on an ambitious plan to
set up a facility to manufacture base
glass for solar photo voltaic
modules involving an investment of
`400 crore. The company is
currently catering to the domestic
demand by importing the product
from its bases in abroad. It has
already identified the locations at
Bhiwadi in Rajasthan and Chennai
in Tamil Nadu and a decision to
this effect would be announced very
shortly, said, Managing Director,
B Santhanam.
He revealed adding that the
capacity of the new facility is
expected to be about 500 mw per
annum and its second glass plant
in India is being built on war footing
at an investment of `1,500 crore in
Bhiwadi. The Bhiwadi facility which
is being built in a phased manner,
is meant for new production lines
and is set to be commissioned by
the end of this year.
♦ Trimex to Set up Plants in
India
The Dubai-based Trimex Group,
through its wholly owned arm,
Trimex Sands Private Limited, in a
recent decision has planned to set
up a Titanium plant at Srikakulam
in Andhra Pradesh at a location
exactly where the company is
currently making ilmenite by way of
28
beach sand mining at an investment
of `2,250 crore.
The company has targeted this
investment for the next couple of
years to make 45,000 tons titanium
pigment plant, said Executive
Director, Pradeep Koneru.
♦ Tata Steel Targets $2.4bn
Annual Expansion
The Tata Steel in a move to push
capacity addition has decided to
invest $2.4 billion per annum for
the next three years. As part of its
capacity augmentation plans the
company is also carrying out a
mega expansion by pushing its
production by 3 million tons per
annum and is funding the
expansion more from debts than
equity, Chief Financial Officer,
Koushik Chatterjee said.
♦ JSW Infuses Investment in
Ispat Industries
The JSW Steel in a recent move
has infused a staggering sum of
`3,800 crore into Ispat Industries
which it acquires recently at an
investment of `2,157 crore. The fund
infusion will take place in a phased
manner spreading upto three years,
Director, Commercial, JSW & Ispat,
Jayant Acharya said. Company
sources claimed that Ispat
Industries, which has a debt burden
worth `9,800 crore, is recasting the
entire funding plans to be
completed before September this
year. The integration of the Ispat
Industries intended to push its
capacity from the current 3.3 million
tons per annum to five mtpa.
Currently, the Ispat Industries official
are negotiating with the Board for
industrial and financial
reconstruction and is filing a report
in this connection, he claimed.
♦ Adani Inks Infra Deal in
Indonesia
A flagship company of Adani Group,
Adani Enterprises in a recent cache
has secured rail, port and power
projects from the regional
government of Sumatra Selatan,
Indonesia and PT Bukt Asam Tbk
which is a government of Indonesia
coal mining company involving an
estimated investment of $1.65
billion.
According to the Chairman,
Gautam Adani, the rail and port
projects are expected to be executed
by Adani Global, a subsidiary of
Adani Enterprises in 48 months.
The project work included the
construction of a 250km railway line
and port infrastructure which Adani
requires for the transportation and
ship loading of up to 60 million
tons per annum of coal. The
upcoming rail line will help connect
Tanjung Enim, the rich coal mining
area where the group will set up a
world-class port for evacuation of
the coal.
♦ MEL Unveils Steel Plants
Worth 1200cr
In an attempt to expand its steel
manufacturing production, the
Mineral Enterprises Limited (MEL)
is setting up two steel making plants
at Hassan and Chitradurga in
Karnataka entailing an investment
of `1,200 crore, Managing Director,
Basant Poddar said. He added that
the company has already initiated
the process of acquiring land and it
would be completed in next six
months. The company requires
NBM&CW MARCH 2011
NEWS Companies in Limelight
about 150 acres in Chitradurga and
400 acres in Hassan to set up the
proposed units at a cost of `200
crore and `1,000 crore respectively.
Both these plants will open up
employment opportunities for over
500 locals and are expected to go
on stream in the next two years.
♦ GVK Eyes Coal Assets in
Australia
GVK Power and Infrastructure
Limited, a Hyderabad based
company has set its eyes on the
$2 billion Australian mining giant
Hancock Coal, as the company has
submitted a preliminary bid for a
controlling stake in the coal mine.
The company is also reported to
be one of the six bidders shortlisted
in an auction process being
conducted by Hancock Coal for the
sale of its Kevin’s Corner mine
located in the coal rich Galilee basin
of Queensland in Australia.
♦ SEW Infra Secures Road
Project
The overseas arm of SEW
Infrastructure Limited, a Hyderabad
based company, in a recent cache
has secured a major infrastructure
project involving building of a road
30
in Indonesia and a memorandum
of understanding (MoU) to this effect
has been signed with Surya
Kapenjen, an Indonesian company.
The agreement was inked between
the SEW Trident Global Pte Ltd. a
subsidiary of the Hyderabad based
infra major and Indonesian
company. The road building deal
includes the development of 84km
hauling road on build own operate
model. Apart from this, the company
will also build a port for feeding the
cargo in East Kalimantan province
of Indonesia, Director, C Srikanth
said.
♦ PowerGrid Gets Mega
Project
Country’s power transmission giant,
PowerGrid Corporation of India has
secured a mega power project
worth `1,600 crore in Jharkhand to
build transmission system in the
state. The transmission venture,
which is expected to be completed
in the next 18 months, involved
laying transmission lines on a 1,000
kms length and also involved
setting up 10 sub stations in the
state.
♦ SAIL-Kobe Plans Power
Plant
The Steel Authority of India and
Kobe Steel of Japan have decided
to initiate the revival work of the
second phase of the Jagdishpur
steel unit involving an investment of
`2,500 crore. The steel making
project along with a 1,000mw gas
based power plant, will be
commissioned in the next three
years and a feasible study in this
connection is already in progress
and its report is expected in the
next couple of months, SAIL
Chairman, C S Verma said.
He claimed that apart from two
units, a warehouse with a capacity
of 12,000 tons per annum and a
Galvanised Sheet Corrugation unit
with 13,000 tons per annum
capacity is in the final stages and
would be commissioned very
shortly. The revival work on the first
phase of the unit at an investment
of `100 crore is currently in full
swing, while work on two more units
under the same phase has already
been initiated.
♦ Lanco Launches `3,000cr
Solar PV Unit
The Lanco Group has decided to
invest `3,000cr in setting up a solar
photovoltaic manufacturing unit at
Rajnandgaon district of
Chhattisgarh with an annual
capacity of 250mw for local sales
and exports to countries including
Europe and USA. The upcoming
project which would be set up in
two phases by Lanco Solar, a
special purpose vehicle of the
Lanco Infratech, has been aimed at
making solar energy equipment,
Chairman, L Madhusudha Rao
said.
The PV unit is being created
with a 75:25 debt equity ratio and
will entail an investment of `1,370cr
in the first phase and is expected
to be completed in the next 15
months and the entire
manufacturing unit is slated to be
commissioned by 2014.
♦ Suzlon Secures Caparo
Contract
The wind energy turbine making
major Suzlon has secured an order
worth $1.28 billion from Capro
Energy India to set up wind turbines
to build 1,000mw power projects in
the next two years of which units
with a generating capacity of 500mw
would be commissioned by March
next year.
NBM&CW MARCH 2011
NEWS Companies in Limelight
According to the Chairman and
Managing Director Tulsi R Tanti, the
current year is going to be very
strong period for the Indian power
sector as large players like Caparo
have come in droves to enter into
the market and the emerging trend
is that large wind IPPs in the
country are major force alongside
small sized segment is also getting
very active in the process.
♦ OPIL Unveils `1,800cr
Cement Plant
The Orient Paper & Industries
Limited (OPIL) in a recent decision,
has embarked on setting up a
`1,800cr green field cement
manufacturing plant with a capacity
of three million tons per annum
together with a 50mw power plant
at Gulburga in Karnataka and has
already secured all the mandatory
clearances from the state
government in this connection.
An industry insider informed that
the power and cement projects,
which are coming up on a 1500
acre of land, in all likelihood will be
financed by a mix of internal
accruals, debt and equity. The OPIL
aimed at adding 3 million tons
cement capacity to become a
15 mtpa company over a period of
time and has been looking to build
its cement making capacities for
quite some time and has recently
expanded its capacities at the
Andhra Pradesh and Maharashtra
units and is currently going all out
to boost its overall cement
manufacturing capacity to achieve
its laid down targets.
32
♦ Finland Firm Sets up
Welding Equipment Unit
Kemppi Oy of Finland, a leading
name in the field of arc welding
has set up a manufacturing plant
near Chennai. The facility is
expected to go on stream by April
this year.
In the initial phase, it will have
capacity to make 3,000 units a year,
(from left) Anssi Rantasalo, Global
CEO, Jouko Kemppi, Chairman, Kemppi
Oy, Finland and Arvind Vasu,
Managing Director, Kemppi India, at a
press conference, in Chennai.
which will be doubled in two years,
said Arvind Vasu, Managing Director,
Kemppi India, adding that the
parent company would invest
around $10 million over the next
two years in the Indian subsidiary.
Initially, the Indian subsidiary would
commence with the launch of a
single product for India—the HiARC
M4ooi. Over a period of time
Kemppi India would add more
product to its portfolio. The company
plans to set up a customer training
centre. Our vision is to provide the
joy of welding at every level as its
impact is very wide in all industrial
applications, said CEO Kemmpi Oy.
♦ Enam Infra Gets FDI Nod
The Mauritius based Enam India
Infrastructure Fund gets a leg up in
the fund raising initiatives with the
Union Government clearing a
proposal of the company to
undertake foreign direct investment
(FDI) worth `3,450 crore and these
funds would be invested in equity
and equity linked investments in
infrastructure projects across the
country.
According to reports, the
approval has been granted to invest
and subscribe to class A units to
be issued by Enam India
Infrastructure Fund. The Cabinet
Committee on Economic Affairs
(CCeA) which was also chaired by
the Prime Minister, Manmohan
Singh cleared the proposal after it
was referred to it by the Foreign
Investment Promotion Board in the
recent past. The Enam India
Infrastructure Fund, Maurituius,
would make the investment in its
Indian arm which is a part of the
brokerage group of Enam.
♦ HNGL Initiates Work on
`700cr AP Plant
Hindustan National Glass &
Industries Limited (HNGL) has
recently started the construction
work on the Phase-I of its glass
making complex at Naidupeta in
Nellore area of Andhra Pradesh.
The green field complex which is
spread across 210 acre area
entailing an investment of `700
crore, will have a single large
furnace with a capacity of
manufacturing 650 metric tons per
day. On completion, the new plant
will house three container glass
and two floating glass plants with a
total capacity of 3,500 metric ton
per day.
According to the Chairman, C
K Somany, the plant has an ideal
location and it will play a pivotal
role in the company’s business
plans to consolidate its presence
in the southern parts of the country.
It expects that the liquor industry is
a major client in the South for its
glass products as over 65% of the
glass demand is emerging from
the southern and western regions
of the country. The new facility is
expected to meet the demand with
high quality products and its
location near major ports will also
help the company serve some of
the demand for glass in the
overseas market, he said.
NBM&CW MARCH 2011
NEWS Companies in Limelight
♦ Chiria Mines Get `5,000cr
SAIL Funding
Close on the heels of Chiria mines
securing environmental clearance,
the Steel Authority of India has
announced a whopping investment
plans for worth `5,000 crore to
develop mines with an initial
capacity of 7 million tons per
annum. The mines, which reportedly
have world’s largest quality and high
grade iron ore reserves of about 2
billion tons, is expected to meet the
SAIL’s iron ore requirement of upto
40% for its plant in areas including
Bokaro, Durgapur, Rourkela and
Burnpur as these plants are
currently accounting for about 70%
of its steel production.
Because of its ore enriched
mining resources and the trend of
spiraling iron ore prices renowned
steel makers including ArcelorMittal,
among others, are vying for the
exploitation right of the ore deposits.
Chiria iron ore reserves were a
part of the erstwhile Indian Iron and
Steel Company, which was merged
with SAIL in way back in 2005. The
SAIL will exploit the mines to the
hilt and will try its best to adhere to
the environmental concerns
ensuring sustainable development
of the area and the company plans
to push a staggering sum of
`10,000 crore in mining over the
next three to four years, said SAIL,
Chairman, C S Verma.
♦ Logistics Touching $200bn
Revenue Mark
Given the consistency in growth rate,
which is currently hovering around
nine percent per annum in the past
couple of years and heading for a
record growth of about $90 billion
during the current fiscal, India’s
logistic market is set to cross $200
billion per annum revenue mark by
2020, concluded Frost & Sullivon in
its recently released report on the
Indian transportation and logistics
sector.
The findings are based on the
fact that the market recorded
revenues of about $82.10 billion in
34
`100 crore and the nodal agency
has already floated tenders for the
upcoming project. The funicular new
rail link system with a length of
over 1.3 km from Dodhani village
near Panvel to Mailot Spring Point
will have double reversible with two
passenger cars and an attached
goods trolley. The scope of work
2010 thereby posting a growth of includes designing, construction,
about 9.2 percent over the development, financing operation
preceding years. This is all due to and maintenance of the system
the strong growth recorded by key between Matheran and Dudhani.
manufacturing industry sectors
including automotive, engineering,
pharmaceuticals, food processing
and textiles, among others.
Moreover, with the booming end use
industry market is likely to witness
a consolidation wave indicating the
reviving fortunes for the sector. That
apart, the sector also witnessed
According to the Additional
scores of notable acquisitions in
Metropolitan Commissioner,
the logistic industry including
MMRDA, Ashwini Bhide, as of now
FedEx’s acquisition of AFL Logistics
a narrow gauge railway line
and Transport Corporation of India’s
connects Neral and Matheran with
TCI 51% equity stake acquisition in
the Central Railway’s Mumbai Pune
Infinite Logistics Solutions.
route with a length of about 20 km.
Apart from this, companies
The lower terminal point close to
including Toll Global Logistics,
Dudhani is ideally located about
Allcargo Global Logistics and FH
1.3 km beyond the village of
Bertling have been actively seeking
Dudhani at an altitude of 260 metre
to expand their business sizes
and the upper terminal point is at
across the country. Besides private
Matheran. The upcoming rail link
equity firms and leading finance
as per estimates will take about 10
organizations are actively investing
minutes to make for the distance.
in the Indian logistics sector.
Matheran is a very popular tourist
Multilateral lending institutions like
destination and funicular rail link
International Finance Corporation
will be an added attraction for
had already invested $5 billion in
tourists by providing connectivity to
Snowman Frozen Foods, a
the attractive hill station and will be
Bangalore based company and
a landmark for the nodal agency as
Bredene Capital, the UK-based
it would give huge boost to tourism.
fund house has also invested in
logistics project in India apart from ♦ Powertech Secures `364cr
picking up 90% stake in MJ Funding Infusion
Logistics, the report concluded. The Sembcorp Utilities Pte Limited
♦ MMRDA Clears Cable Car in a recent initiative has infused as
a part of its first tranche of `364
Links
crore into the Gayatri Project Limited
After years of dilly dallying the
for its joint venture Thermal Power
Mumbai Metropolitan Region
Corporation India Limited (TPCIL).
Development Authority (MMRDA) has
The TPCIL which is a joint venture
recently cleared a cable car project
between Gayatri Energy Ventures
for Metheran on the outskirts of
GEVL, a special purpose vehicle of
Mumbai entailing an investment of
NBM&CW MARCH 2011
NEWS Companies in Limelight
Gayatri Projects, and Sembcorp’s
wholly owned Utilities business, is
set up on build, own and operate a
1,320mw (2x660mw) capacity coal
fired power plant at Krishnapatnam
SPSR, Nellore district in Andhra
Pradesh.
According to reports, the
company has already secured the
financial closure and has signed
memorandum of understanding with
the lenders for `5,151 crore and
construction activities have already
been initiated in the upcoming
power plant. As per the terms and
conditions of the agreement, the
plant will be operated and
maintained by Gayatri, Sembcorp
O&M Company, which is a separate
entity for maintenance incorporated
for the purpose. The company will
subsequently expand its capacity in
the same location by building
another 1,320mw power plant in
phase second thereby taking the
total capacity to 2,640mw.
♦ PFC Paves Way for $260m
Offshore Finance
The Power Finance Corporation in
a recent achievement has arranged
$260 million from a bunch of three
banks based in Tokyo, Singapore
and Hong Kong and the proceeds
will be invested in the infrastructure
project and also for refinancing its
existing debt. The company which
has recently secured `1,000 crore
loans refinanced from the India
Infrastructure Finance Corporation
Limited, also going in for a follow
on issue comprising 15% fresh
issue and 5 percent divestment by
government. In totality, it is all set
to collect a staggering sum to the
36
tune of `7,000 crore by the end of
current financial year.
According to sources, the
syndicated transferable loan facility
has been secured from Bank of
Tokyo-Mitsubishi UFJ), Mizuho
Corporate Banking Corporation.
The transferable term loans can be
traded between lenders to lessen
credit risk of banks financing the
loan. The company has sanctioned
loans worth `13,462 crore in quarter
ending December 2010 and pushed
its financing up to 277% from 3,571
crore over the same period last
year. Similarly, its disbursal goes
up to 25% to `7,641 crore during
the third quarter of current fiscal
from `6,123 crore in the
corresponding period previous year.
In the process, it has recorded 17%
push in its net profit to `659 crore
from `564 crore in the
corresponding quarter of the
previous year, they said.
♦ Morgan Infuses $200m into
Spanish Infra
Morgan Stanley owned Global
Infrastructure Fund is infusing a
staggering sum of $200 million as
an equity stake in the domestic
subsidiary, Isolux Corsan. The
Spanish infrastructure major
currently building roads in northern
parts of the country and the latest
infusion will be the second
investment in the country by the
fund.
Last year, the company along
with Goldman Sachs infra fund,
General Atlantic, Norwest Venture
Partners and Everstone Capital has
decided to invest $425 million in
Asian Genco, a Singapore
headquartered firm, which owns
energy generating units in the Indian
power sector. Isolux Corsan
operates in engineering
construction, property development
and manufacturing, currently
operates in over 32 countries and
as of now is getting aggressive in
the Indian construction and
infrastructure sector. Not just this,
many global players with huge
funds including Blackstone and
Kohlberg Kravis Roberts, have
announced multi billion dollar
funding plans for the Indian
infrastructure sector, while a few
have already initiated the investment
process.
♦ R Power Unfolds `22,000cr
Infra Forays
Announcing its largest foreign
investment in Indonesia, Reliance
Power has set aside a staggering
invest worth `22,000 crore for
setting up projects in South Sumatra
and Jambi provinces. The areas of
investment include coal mining,
railway lines, ports and power
projects. Company sources claimed
that the project in Sumatra involved
development of a 2 billion mt coal
mine and a 200 km railway line,
2,000mw power plant and a port
entailing a total investment of $3.5
billion. While infra investment in
Jambi will cover another coal
mining unit together with a port,
railway line and small power plant
at a cost of $1.5 billion excluding
the power project.
♦ Thermax to Set up a Plant
To expand its footprint in
geothermal energy, Pune-based
engineering company Thermax is
to set up a plant in Maharashtra. It
NBM&CW MARCH 2011
NEWS Companies in Limelight
has a joint venture with an Iceland–
based company for developing the
geothermal energy business in
India.
The joint venture is developing
a 3mw geothermal plant in Puga
valley, Leh on an experimental basis.
For its proposed plant in
Maharashtra the company has
already been allocated a block
around Raipur for exploring
geothermal energy, said company’s
Managing Director, Unikrishnan. He
said that currently it is difficult to
predict the size of the plant. If we
come across a large geothermal
energy field, which could produce
about 100mw of power, then we
could even form a separate
company to set up the plant. He
added around `10 crore required for
developing one megawatt of
geothermal energy. Since the heat
NBM&CW MARCH 2011
continuously emanates from the
earth‘s crust the load factor of the
plant is 99% making the power
traffic comparable to a thermal coal
plant, he clarified.
♦ Coastal Projects Clears
`108cr Acquisition
The Hyderabad-based civil
engineering and construction
company with expertise in tunneling
and underground excavation for
hydro electric, irrigation, rail and
road and mining ventures, has
recently acquired 26% stake in SELI
of Italy at an investment of `108
crore.
According to reports, Societa
Escuzione Lavori Idraulici (SELI),
which has already displayed its
talent by carrying out operations
across the world including in India,
is very expert in designing and
building hard rocks and soft ground
tunnels boring machines and
auxiliary equipment in its
manufacturing facility located in Italy.
It has already completed more than
520 km of tunnels with the use of
mechanized excavation systems
and has executed 68 projects
around the world. Similarly, the
Indian players have also completed
more than 75km of tunneling work
and have 250km of tunneling jobs
currently under construction. Apart
from Indian operations, the joint
venture will also take up projects in
South Asia as the nature of
business has good potential in
these countries in the region as
increased number of tunneling
projects in India is expected to be
implemented using Tunneling
Boring Machines.
37
NEWS Real Estate

Siemens’ Space
Fetches `400cr in
B’lore
Making it perhaps the biggest real
estate deal in the downstream
Bangalore, Siemens’ land parcel
measuring 8 acres reportedly
secured a top bid of `400 crore
from RMZ, a local property builder.
The German power equipment and
transmission giant, has put up its
8 acre plot of land in Bangalore on
the block for sale, which is a
regular exercise of the company for
reviewing its non core realty assets
for optimum utilization and
consolidation of its business,
according to sources.
Real Estate
hospitality sector, Hilton Worldwide
has set a target to add five to seven
hotel properties on an annual basis
thereby adding over 1200 room
inventory in areas including Delhi,
Mumbai, Chennai, Bangalore, and
Gurgaon.
According to the President, Asia
Pacific, Hilton Worldwide, Martin
Rinck, the company currently has
just three trading hotels in India
and is all set to double its trading
assets this year itself and its prime
focus is on full service brands
including Hilton, Conrad Hotels and
Resorts and Doubletree. It has
currently 19 new hotels under
various states of development
across the country and all of them
will be running in the next couple of
years.
mega tourism park matching global
facilities at an investment of `2100
crore and also setting up a Film
City Studio on 100 acres of land at
an investment of `500 crore.
In addition, Indo-Gulf Securities
is building a resort worth `700
crore and Renee Industries has
lined up `550 crore investments to
set up five star hotels and beach
resorts at Suvali and also building
similar hotel in Saputara, the only
hill station in Gujarat. While Ravani
Developers planned a hotel cum
golf club at a cost of `310 crore
and Parshwanath Project is building
a resort cum amusement park of
about `250 crore and similar
amount is being invested by the
Trilliant Hospitality in setting up
Surat Sheraton in the city.

Construction BPEP Injects `350cr

Source said that the company
has been shedding its certain
assets in India from time to time
and even in the recent past, it has
sold about a dozen premium
apartments in Mumbai under the
same exercise. The RMZ has
decided to build a residential
complex on the patch of land for
which other bidders including
Hiranandani Upscale and Nitesh
Estates had also participated.
Hilton Heightens
Hotels Plans in India
Inspired by the huge future
business potentials in the Indian
Corners `35,000cr in Century Realty
Investment in Surat Baring Private Equity Partners
(BPEP) with its investing partners
The recently concluded Vibrant
is financing `350 crore into a
Gujarat Global Investors’ Summit
Bangalore based Century Real
(VGGIS) has virtually turned the
Estate. Baring, which has already
diamond city of Surat in Gujarat as
initiated the investment process,
the fast emerging hospitality and
has committed about $53 million
recreational hub. The township is
while overseas investors are
getting decked with over 50 hotel
contributing to the tune of $20
buildings, residential towers and
million.
film city studios attracting a
whopping investment of `35,000
crore thereby opening up lakhs of
employment opportunities to locals.
According to reports, the
hospitality sector cornered the lion
share of investment as
memorandum of understandings
(MoUs) worth `18,000 crore have
already been signed with the state
government. The hospitality majors
that are descending in the city
droves included Mumbai based
Atlanta Limited which is setting up
luxurious beach resort and hotels
worth `9,500 crore. The Trans
Globe Infrastructure is building

38 NBM&CW MARCH 2011

NEWS Real Estate
According to industry insiders,
the Baring and its co-investors are
picking up about 26% stake in the
holding company with one of the
largest land aggregators with an
estimated 3,000 acres of land bank
in the downstream southern parts
of the country.
Viceroy Hotels Plans
Expansion
A Hyderabad based major
hospitality player is all set to add
three more properties in areas
including Chennai and Bangalore
entailing an investment of `1,200
crore. The latest expansion push
will take the company’s inventory of
hotel properties up from the current
560 room to 1,250 rooms from its
six hotels. This also includes two
marquee properties in Chennai and
Bangalore, Chairman and Managing
Director, P Prabhakar Reddy said.
He added claiming that 387
rooms JW Mariott project, which is
coming up at MRC Nagar in
Chennai at an investment of `650
crore, is touching completion and
will be commissioned in the next
one month. The Bangalore venture
which will again be a part of the
Marriott brand Renaissance, is also
a 277 rooms project and is among
the tallest structures with 22-storey
and 4.5 lakh of built up facility. It is
going to be commissioned very
shortly, he claimed.
DLF on Make Over
Drive
India’s largest real estate builder,
the DLF Limited in a bid to further
consolidate its land holdings, has
decided to make quarterly
investment worth `400 crore over
40
the next couple of quarters of the the emerging super power and the
next fiscal to acquire land in areas industry needs to come out of box
including New Delhi, Gurgaon and to build infrastructure compatible
Chandigarh, Chief Financial Officer, and matching global standards.
Ashok Tyagi said adding that the That is exactly what Vigneshwara is
demand in realty sector is picking doing as it feels the pulse of people
up by the day and the company and build customized and
has also initiated the process of ulitararian projects.
land acquisition and the move has
resulted in exceeding its capital Govt Goes for
expenditure by `500 crore during
`1,000cr Realty Fund
the third quarter of the current
In an attempt to streamline the
financial year.
smooth financing options for the
Alongside, the company is also
real estate sector, the Union
divesting its non core assets, even
Government has decided to set up
in the last quarter it sold some of
a fund worth `1,000cr which in turn
its non-contiguous land, which was
would act as a guarantee corpus to
not giving much economic value.
make it easy for banks to lend
To date, the company has made
finance for real estate projects. The
`403 crore through divestment of
National Housing Bank (NHB)
non core assets during the third
would be a nodal agency for
quarter of the current fiscal thereby
monitoring the functioning of the
taking its total realization from
proposed fund, which is being
divestments to `2,900 crore.
announced in the forthcoming
AIML Launches Budget, according to sources.
The real estate sector which
Dental Hospitals has an estimated debt of `75,000cr
Alliance Medicorp India Limited of which about `25,000cr is
(AMIL) in a partnership with expected to be repaid during the
Chennai-based Trivitron Group and current financial year, find it
Apollo Hospitals, has drawn up an increasingly tough to raise funds
ambitious plan to set up dental as banks are wary and cautious in
hospital chain across the country lending for housing sector largely
involving an investment of `100 due to recent spate of scams and
crore. In this connection, the allegations of siphoning of funds
company has already invested more by the developers for other
than `30 crore and some of the purposes. By taking such an
clinics would be ready by the end initiative, the government is aiming
of the current fiscal. to put banks at ease by offering
guarantee in case of default.
Vigneshwara’s
Hi-Tech Park Project
Administering technological push to
Gurgaon, the Haryana State
Industrial Infrastructure Development
Corporation (HSIIDC) is setting up
a 150 acre technology corridor at
Manesar on the NH-8 in the
Gurgaon district and work on the
project has already been started by
the Vigneshwara Developers.
The Managing Director,
Vigneshwara Group, Sunil Dahiya
said India is on the threshold of
NBM&CW MARCH 2011
NEWS SEZs
Chem Fires `1,160cr
Booster in SEZ
The pharma special economic zone
(SEZ) is being built in partnership
by the JB SEZ Private Limited with
HBS Realtors of Mumbai and JB
Chemicals, at Panoli in Gujarat. It
is slated for commissioning in the
beginning of next year and is all
set to get `1,160 crore financial
booster from its promoters.
According to company sources,
the promoters are investing about
`160 crore in building roads and
creating the related infrastructure
and the rest `1000 crore to set up
other facilities including power,
water effluent treatment and
machinery plans. The SEZ
stretching across 312 acre of land
is being financed through a
combination of models, depending
on the facilities that are being set
up, besides debt financing.
Greater Noida IT/ITeS
SEZ Project
The Uttar Pradesh government in a
recent development has cleared a
new IT/ITeS special economic zone
for Greater Noida on the outskirts
of Delhi. The project, which is
stretching across 10 hectares will
entail an investment of `612 crore,
is being set up by the Delhi-based
Artha Infratech Private Limited. The
project is said to be the first to get
approval after a period of two years
42
SEZs
indicating that the recession is a
thing of past and companies are
aggressively coming forward for
investment. The project in question,
which has taken the total number
of projects in the state to 37, is
reportedly getting huge investment
response from across segments
and will provide 20,000 direct and
indirect employment opportunities to
local masses.
GMR-Rotorcraft Inks
Aerospace SEZ Pact
GMR Aviation SEZ Limited which is
a GMR Group company, in a recent
move, has agreed in principle with
Indian Rotorcraft Limited to fix a
space for the AW119ke helicopter
assembly and flight testing facility
at the GMR Aerospace Park in
Hyderabad.
The site for the proposed
project has been selected by the
Indian Rotorcraft after an exhaustive
process of evaluation of other
potential sites across the country
and the partners are all set to start
construction after securing
necessary and appropriate
governmental approvals. The first
aircraft is scheduled to be delivered
from the new facility in 2012. The
Tata Sons and AgustaWestland are
leaders in their respective fields and
the GMR group takes pride of being
chosen partner to these two
companies, Chairman, GMR Group,
G M Rao said.
He claimed adding that the 8-
seat AW119Ke is currently top of
the range helicopters in the single
engine market with over 190
copters have already been ordered
to date in around 30 countries by
90 customers. The helicopter is
suited to perform a wide range of
tasks including law enforcement,
utility, firefighting, EMS, VIP transport
offshore transport, besides carrying
out military missions. Stretching
across 10 acres, the aviation
specific economic zone of the Aero
Park is being set up with an option
for expansion as and when need
arises.
K Urban Plans for
SEZ Projects
The prominent real estate player,
Kumar Urban Development Limited,
in a recent decision has planned to
arrange $100 million at the special
purpose vehicle level for its new
township and SEZ projects and the
company is scouting for SPV level
funding and expects to raise $100
million for its project. The prevailing
period is the most opportune for
PE funds and some companies
have already made the most of the
prevailing scenario, Chairman, Lalit
Kumar Jain said.
He added that about $60
million is being raised for the
company’s SEZ project, the balance
would be for the township project
as both the projects are coming up
in Pune and expecting
overwhelming response and
valuation from investors. So far as
the township projects are
concerned, the company has
already roped in an anchor tenant
and is going to get potential
investors with a strong business
plan, he claimed.
NBM&CW MARCH 2011
NEWS SEZs / Equipment News
BEML Launches
`360cr Aero-plant in
SEZ
The BEML Limited is all set to
launch an aerospace manufacturing
complex on an area of 25 acre in
the aerospace special economic
zone at Devanahally on the outskirts
of the Bangalore city. Alongside the
company is also scouting to acquire
small firms to strengthen this
business vertical, Chairman and
Managing Director, V R S Natarajan
said. The new plant, which will
manufacture gears for helicopters,
jigs for aircraft structures matching
aerospace components, fabrication
of structural sub assemblies for Su-
30 aircraft and variety of ground
Schwing Stetter Launches Pumps for Skyscrapers
Schwing Stetter, the makers of
concrete pumping equipment, has
recently launched 2 pumps reaching
beyond 100 metres in height and
above or wherever the concrete
required to be poured by booms.
The latest product SP 2880
machine with capacity of pumping
concrete vertically upto a height of
250 metres and SP 8800, which
can reach and take concrete right
up to 500 metres of height,
Managing Director (India) Anand
Sundaresan said.
44
support and ground handling
equipment, will become fully
operational in 2012-13. In fact, the
BEML is scouting for opportunities
to acquire firms to achieve its
business targets up to `100 crore
annually in three years and it will
strive hard to notch `1,000 crore
businesses by 2016-17 and the
current order book of the company
stood at `4,300 crore, he claimed.
P Lloyd Secures SEZ
Construction
Contract
Punj Lloyd which is a renowned
builder engaged in the construction
business, has secured a contract
for building two commercial
structures in a township belonging
Equipment News
Elaborating on the latest
launches, he claimed that initially
the company will import the new
products from its overseas
facilities and will subsequently
manufacture the latest versions
of concrete pumps in its Indian
facilities and indigenization will
also lead to a drastic cut in the
manufacturing cost thereby
reducing prices up to 40% at
current price lines. Constructing
highrise buildings is increasingly
becoming the order of the day in
India and as many as
35 highrise projects
with varying heights of
250 metres are
currently coming up in
Mumbai metropolitan
city only thereby
opening up huge
business potentials
for the new concrete
pumping equipment,
he claimed.
to the Hirco Group at Panvel in
Maharashtra. The township, which
has been named as Hiranandani
Place Gardens, is a part of Hirco’s
Panvel SEZ in the state and is
expected to be ready in the next 24
months.
The contract includes the
construction of two commercial
buildings and a podium stretching
up to an area of about 2 million
square feet. The first of the two
buildings will be ready within 12
months. The township is a mixed
use project which will boast of the
world class residential complexes,
offices, educational institutions,
healthcare facilities, the commercial
towers would be built in the
proximity of the residential
apartments, they added.
Doosan Buys AE&E’s
Chennai Unit
The South Korea-based Doosan
Heavy Industries and Construction
Company in a recent buyout, has
reportedly completed the acquisition
of Chennai unit of Austrian power
company AE&E. With the latest deal,
Doosan has secured manufacturing
base in the growing Indian market
for power plant boilers.
According to industry insiders,
the company in the recent past has
been getting contracts in India as it
secured a contract for a supercritical
boiler for NTPC owned Sipat
3x600mw power plant. Shortly after
that, Tata Power ordered Doosan to
supply five supercritical boilers of
800mw each entailing an
investment of $1 billion and also
secured a contract from the GMR
Energy to build the Raipur and
Chhattisgarh thermal power plants
involving similar amount of
investment.
They said adding that AE&E,
which is an engineering design
services subsidiary (IDEA), had a
NBM&CW MARCH 2011
NEWS Equipment News

few months ago secured its first
order for the supply six CFBC-type
boilers of 150 mw each from the
Essar group for the Salaya III
project. With the Doosan arrival in
Chennai, Tamil Nadu will have one
more power equipment
manufacturer after BHEL, Cethar
Vessels, Ansaldo Caldale, Toshiba
and BGR-Hitachi catering to the
boilers and turbines market in the
emerging Indian power sector
scenario.
M&M Enters into
Equipment Biz in Big Way
Breaking into the league of
companies, among others,
Mahindra & Mahindra launched the
indigenously built backhoe loader,
EarthMaster, has recently chalked
out an ambitious plan to
manufacture the entire range of
construction equipment in next
couple of years.
The company is aggressively
entering into the construction
equipment market as India is
currently the single largest market
for backhoe loaders in the world
with requirements of about 25,000
units per annum and expected to
record 15% growth year on year
basis. The equipment, which is
largely used in building ports, road,
building and mining, the backhoe
loader is a frontline machine and
is currently dominated by JCB with
a lion share of the market. The
company plans to bring out the
complete range of these products
as the infrastructure sector of the
country will entail an investment
worth `4 to 5 lakh crore recording
a seven percent of the GDP and
demand for these equipment is
bound to reach new highs in the
near future, Senior Vice President,
Automotive Strategy and Business,
Kairas Vakharia said.

Beijing Sany Heavy Machinery Ltd,
a SANY group company and the
largest manufacturer of Piling rigs
in the world, announced its tie up
with one of the leading foundation
engineering solution providers in the
country, Suretech. Sany which
produces 1200 rotary piling rigs has
over 50% market share in China
with sales of more than 800 units.
With the acquisition of distribution
of Sany piling rigs, the foundation
Suretech—Sany Tie-up
engineering range of Suretech is
complete. Suretech, already a lead
player in Driven piles technology
being the largest seller of Vibratory
Hammers and Hydraulic Impact
hammers, is confident of creating a
space for itself in the rotary piling
rigs market with the distribution of
Sany.
Beijing Sany is in the process
of setting up its infrastructure in
India and Suretech has been
chosen as their first distributor in
the country to represent them in in the capabilities of Suretech which
western India. Beijing Sany, like all also reflects in their decision to
Sany group companies intends to appoint Suretech as their first
achieve a leadership status in piling distributor in India for selling piling
rigs market in India by its rigs. Managing Director of Suretech,
aggressive sales and competent Mr. Surajit Mukherjee indicated that
product support services. One of piling rig market is rapidly expanding
the main reasons for selection of and there is ample scope for Sany
Suretech as a partner is because products to carve out a niche for its
of Suretech’s reputation in providing product in a market crowded by
excellent product support. Suretech Italian players. The Chairman of
has been consistently enhancing Suretech, Mr. Sunil Newatia feels
its reputation for more than 2 that Sany has risen above the
decades by providing excellent and market perception “Chinese quality”
effective after sales service to its and is a significant player in India
customers. known for its quality in the concrete
The General manager Sany, products. Sany shall follow the
Mr. Wen expressed his confidence same path with piling rigs as well.

46 NBM&CW MARCH 2011

Budget 2011-12
Budget Opens New Vistas for Infra & Housing Sectors
Targeting a double digit growth for
the 2011-12 fiscal the government
in its Budget proposals has injected
the biggest ever hike in infra
spending by 23 per cent to
`2,14,000 crore and ensuring free
flow of funds to achieve the growth
target. It has also pushed the limit
for FIIs investors in five years
tradable infra bonds from the current
$5 billion to 25 billion per annum.
Alongside the domestic investors
have also been allowed to invest
`30,000 crore in tax free bonds
ensuring sufficient funds for key
infrastructure segments including
railways, ports, highways and
housing sector. In addition, the
government in its Budget proposals
has allowed National Highway
Authority of India (NHAI) to increase
its fund raising limit from the current
`4,000 crore to `10,000 crore per
annum by way of selling tax free
bonds. Ensuring sufficient funds for
the infra spending, the government
apart from allowing the purchase of
tax free bonds and extending
income tax exemption on tax saving
in infrastructure bonds up to `20,000
for one year, it is also setting up an
infra debt fund to promote foreign
investment in the infrastructure
The railways budget rolled out an
invetsment worth `57,630 crore, the
highest ever annual planned
investment. It gave greater thrust to
infrastructure projects in terms of
laying new lines with a length of
1,000km entailing an investment
worth `9,830 crore.
The planned investment is to be
financed through a gross budgetary
support of `20,000 crore and
external source of financing through
PPP model and various other
sources contributing about `1,776
48
sector.
Pushing affordable housing
sector to new high, the government
has increased the interest subsidy
on a home loan up to `15 lakh from
the current `10,000 to `15,000 per
annum, which will in turn boost low
cost housing across the country.
Similarly, the government in its
Budgetary proposals has also
The Railways Budget
extended the tax holiday by a year
till 2011-12 in the form of excise
exemption on domestic power
equipment and reduction in
withholding tax and the initiative is
all set to boost to the power sector.
Extending an open invitation to
foreign companies engaged in port
and logistics business, the
government in its Budget proposals
has allowed them to invest ` 5,000
crore in tax free bonds. It has also
provided full exemption from import
duty on spares and capital goods
required for ship repairing units.
However, steel and cement prices
may go northward as the Budget
proposed a 2 per cent increase in
excise duties on steel products and
in regard to cement it is proposing
to replace the existing dual excise
rates on cement, based on selling
price with a single rate, which will
result in pushing the retail price of
the product. So far so good, the
Budget gives a well deserved leg-
up to infrastructure and housing
sector. How these proposals
implemented in a timely manner to
boost infrastructure development are
the concern, hope and expectation
across the board.
crore. Apart from laying new lines,
the projects lying on hold will also
be completed during the fiscal. In
the process, `5,406 crore and
`2,470 crore will be granted for
doubling and gauge conversion of
the projects to complete 876km and
1,017km rail lines respectively.
Meeting the shortage of wagons in
the Railways, including coaches and
locomotives, a sum of `13,820 crore
has been set aside for the
acquisition of rolling stock.
NBM&CW MARCH 2011
Pavement Engineering

Sustainable Pavement Engineering

Rajib B. Mallick, Associate
Professor, Civil and A. Veeraragavan,
Environmental Engineering Professor, Indian
Department, Worcester Institute of Technology,
Polytechnic Institute (WPI), Madras (IIT-M),
Massachusetts, USA, Chennai

We Need Pavements are irreversible). Thus, pavement compatible and if possible,

engineering is a destructive and complementary to the other two
The need for safe, durable and
high impact activity. But remember components – buildings and nature.
smooth riding pavements on
the first sentence of this paragraph This means construction and
highways and in airports cannot be
– and herein lies the dichotomy of maintenance of pavements should
contended. Construction and
modern civilization – you build not be taxing the natural resources,
maintenance of pavements cost
something that you need but in the energy utilization should be
money – which is mostly provided
process you affect the earth in an minimized, byproducts in the form
through taxes that are collected from
irreversible harmful way. So what is of emissions should not be harmful
the citizens. The money is spent on
the solution? to the environment, and the layout
employing workers, quarrying and
There is most likely not “a” of the pavement should not be
manufacturing usable products,
solution, but multiple ones. In fact, significantly impacting the natural
transporting them, and laying down
they are more like “tools” that exist environment. Broadly speaking, this
and compacting the materials. In
in the pavement engineer’s toolbox, includes layout and type, design
this whole process, which gets
which could be used, as the need and construction of pavement. It is
repeated to different extents during
arises. It is the intent of this article only through this process we can
the maintenance and rehabilitation
to describe a few of such important ensure that our future generations
cycles, man-made material is laid
tools and their impacts. will have no/less problem of
down to cover virgin (most likely
continuing the work of building or
arable) ground (making it un-arable First Consideration maintaining/rehabilitating the
from that point onwards), a
First and foremost, the pavement pavement infrastructure. And, this is
significant amount of natural
infrastructure should be viewed as the very essence of sustainability.
resources is utilized, (non
part of a larger “system,” and not True sustainability consists of three
renewable) energy is consumed,
viewed alone. Buildings, pavements aspects - social, economic and
landfills are created, and different
and natural ground/water bodies environmental sustainability. The
types of chemicals (in the form of
(nature) form the built environment discussions in the following
gases) are emitted to the
in which we live and breathe. paragraphs refer to either one or
environment (all of these processes
Hence, pavements need to be

50 NBM&CW MARCH 2011

Pavement Engineering

more of these three different types construction of new pavement Construction of

of sustainability. should be made. Proper
forecasting methods and Pavements
Design of Layout of mitigation procedures should be For construction of asphalt
adopted.
Pavements 7. Consideration of traffic growth
pavements the key factors that need
to be considered are using local
Some of the more important issues
and providing adequate room for materials (to reduce transportation
with the layout/geometric design of
further growth should be made, related energy expenses), lowering
a pavement can be summarized as
such that traffic saturation does the need for new materials,
follows:
not lead to a drastic change in reducing production and
1. Protection of forests: forests
the character of the community construction temperature, using
provide a home to many species
and significant construction activity more environment-friendly products
of plants and animals and at the
could be avoided for a longer (such as bio-asphalt), and
same time serve as a source of
period of time. environment-friendly layers/mixes
economic products such as
The issues listed above can (such as those that would allow
timber and enjoyment for tourists.
be represented in terms of the percolation of water into the
Roads should be preferably
problems such as deforestation, soil layers and hence facilitate
designed away from forests, or in
noise pollution, crossing of habitat recharging of aquifer, and those that
a way that creates minimum
areas, flooding/storm water have reduced noise levels), utilizing
impact on them.
management, creation of wastage, mixes that would allow recycling or
2. Protection of wild life:
urban heat island effect, drinking reuse of discarded materials, and
Considerations must be made to
water pollution, air pollution, traffic longer lasting pavements, and
provide features that would
jams, soil erosion, and use of conducting a proper life cycle
minimize the effect of road
natural resources and energy. analysis.
construction on animals and
The above problems could be The favorable impact of using
subsequent vehicle-animal
solved with the use of one or more sustainable pavements is far
collisions (such as protected
of a variety of methods, which reaching. For example, if a recycling
cross overs).
include habitat connection across procedure is used to rehabilitate
3. Consideration of unique
roadways through underpasses or an existing pavement, then the
geological conditions, such as
overpasses, fencing along the road following benefits can be ensured:
steep slopes with vegetation or
for animal protection, amphibian 1. Less use of new natural
caves/landforms should be made.
rescue fences, storm water pollution resources such as mineral
Precaution should be taken to
prevention plan, pedestrian, bicycle, aggregates
avoid such areas where a slight
and transit access, noise barriers, 2. Significant reduction in
disturbance of the landscape
buffer zones, or specially planted transportation cost of new
would lead to a significant
slopes/embankments to reduce materials
irreversible disturbance of the
noise pollution, intersections with 3. Less amount of energy use in
local environment.
interchanges, use of pervious obtaining and processing new
4. Context-sensitive design should
surfaces in pavement or shoulders, materials (aggregates)
be adopted: the layout of the road
runoff treatment practices to clean 4. Less amount of energy use in
should conform to the values of
runoff water, avoiding
the communities through which it
sensitive aquifers,
is passing, by making sure that it
making the locations of
is integrated with the local
service connections
character – such as flora and
easily accessible,
fauna in rural areas.
providing easy access to
5. Access to critical areas, such as
emergency services, and
hospitals and police stations
defining an
should be provided, such that the
implementation strategy
road helps the local communities
to be followed during
and in return the people value
construction.
the road.
Some of these
6. Consideration of the impact of
desirable features are
diversion routes on the local Figure 1: Elements of a sustainable pavement
shown in Figure 1.
environment, during the infrastructure system (Courtesy: American Concrete
Pavement Association)

52 NBM&CW MARCH 2011

Pavement Engineering
manufacturing new materials
(asphalt binder, cement)
5. Less emission and pollution of
the environment
6. Reduction or avoiding of filling
up precious landfill space
7. Significant reduction in overall
transportation energy, specifically
if an in-place recycling process is
utilized.
There is a variety of recycling
techniques that are available today,
each having its applicability under
specific conditions, as shown in
Table 1.
A pervious layer in roads would
allow the percolation of rain water
to the lower layers, and offer the
following benefits, that are related
to both groundwater as well as
storm water/flood control:
1. Recharge of ground water, and
hence a reduction in the potential
of lowering of groundwater and
the related problems.
2. Detention of rain water and hence
a lowering of the storm water
volume that ends up in road
sewer system;
3. Filtering of storm water that is
contaminated by different methods
on the road; studies show that a
significant amount of suspended
solids, phosphorous, zinc and
hydrocarbons are removed.
For asphalt pavements, a typical
pervious pavement is obtained by
using asphalt treated permeable
base over a layer of pervious stone
layer over the subgrade (with filter
material) as shown in Figure 2. For
concrete pervious pavements, there
54
Figure 2: Pervious pavement cross section (Courtesy: Richard Bradbury, US Federal
Highway Administration)
is the option of using interlocking/
segmented concrete pavers. Even
if not used in mainline, storm water
tree trenches can allow the
detention of a significant amount of
storm water for sufficient time
before releasing it into the sewer
system (Figure 3).
Low energy mixes, particularly
warm mix asphalt are becoming
more common these days, because
of their inherent advantage of lower
energy cost and lower emission
potential. Another key factor in
considering warm mix asphalt is
the fact that because of lower
temperature, the asphalt binder
undergoes less aging, and hence
a better pavement mix is obtained
during construction – which
translates to longer life and hence
less frequent rehabilitation cycles.
There are different types of WMA
techniques available, such as
zeolites, wax, emulsion and foam -
with newer products and techniques
being developed, and one or more
suitable methods can easily be
adopted for regular use by the
industry. The selection of the
specific method should be made
on the basis of the availability of
the material, expertise and
experience with that specific
technology.
The use of binders
manufactured from bio-resources is
being researched and conducted in
different parts of the world. These
binders are essentially derived from
biomass – agricultural and forest
residue with the help of biochemical
or thermochemical processes. One
such example of bio binder which
is fully derived from vegetable is
Vegecol from COLAS. Such binders
can be utilized for modifying asphalt
(< 10% replacement), extending
asphalt binder (>25% replacement)
or totally replacing asphalt. Different
grades of such binders could also
be used for cleaning road
equipment or partially replacing
fluxing agents. The advantages of
using such binders are significant
reduction in pollution – no SOx and
major reduction in NOx emissions,
and manufacturing from 100%
renewable agricultural products.
Furthermore, the temperature of mix
production could be reduced
significantly.
One of the most exciting
technologies that are being
developed in pavement engineering
NBM&CW MARCH 2011
Pavement Engineering
Figure 3: Stormwater tree trench concept applied in Green Street project in
Philadelphia (Courtesy: Glen J. Abrams, AICP, Watersheds Planning Manager,
City of Philadelphia)
is the combined use of the recycling
and warm mix concepts to produce
good performing and long lasting
pavements. Binder from renewable
source could also be used in this
process. Using sophisticated
materials and plant/process control
technology, it is now possible to
effectively recycle close to 100%
reclaimed asphalt pavement (RAP)
material, at a reduced temperature
(for example below 130 o C as
opposed to 150 o C) to meet
emission requirements, and still
obtain a pavement which has
excellent performance under both
high and low temperatures, and
which can be opened to traffic
quickly after construction, even at a
temperature which is higher than
that at which conventional
pavements could be opened.
Overall, this translates to savings
in money and time, materials and
natural resources and energy, and
56
significant reduction in emission.
Example of such a project (in
Germany) is shown in Figure 4.
Recycling of discarded tires in
the form of crumb rubber in asphalt
pavement mixes is now an accepted
practice in many parts of the world.
Apart from allowing the user to avoid
the filling up of precious landfill
space with hazardous waste, this
process allows the user
to:
1. Incorporate more
asphalt binder (thicker
film) in mixes to make,
them longer lasting and
durable
2. Use a coarser
gradation for specific
uses such as drainage
of water.
3. Reduce noise levels
from pavements Figure 4: High RAP content recycling in Germany
significantly. (Courtesy: Gerhard Riebesehl, Storimpex Asphal Tec
Matthias Nölting, Sasol Wax GmbH)
The key to successful use of
rubber modified asphalt binder is
successful incorporation and
retention of the rubber into the
binder/mix. As is the case for many
technologies, this is heavily
dependent on available plant and
construction equipment. For
example, appropriate technology
must exist to uniformly blend the
crumb rubber mechanically or
chemically with the binder, ensure
that the binder remains in that state
during transportation, and for proper
quality control test methods to test
and prevent the separation of the
rubber and the binder prior to
laydown and compaction. In terms
of recycling of other materials,
artificial aggregates such as blast
furnace slag, generated from steel
and iron production could be
successfully incorporated in paving
mixes.
The production of Portland
cement, the key constituent in
concrete pavements and clinker
required for manufacturing of
cement, are a major source of CO2
emission in the modern world. The
use of limestone and supplemental
cementitious materials (SCMs, such
as fly ash from thermal power
plants using coal, and rice husk
ash) provide attractive options of
reducing the use of cement and
thereby cutting down its CO 2
footprint. Blended cement,
consisting of Portland cement and
SCMs are becoming popular. For
maintenance of concrete
NBM&CW MARCH 2011
Pavement Engineering
pavements, modern techniques
such as dowel bar retrofits, cross
stitching, partial-depth repairs, joint
and crack resealing, slab
stabilization, diamond grinding could
be used to improve the conditions
of concrete roads and at the same
time avoid or reduce the need for
energy intensive major repairs/
rehabilitation work.
The concept of perpetual
asphalt pavement has been recently
proposed as a sustainable
technology. The objective of this
technique is to provide thick and
appropriately constructed (with
specific mixes for different layers)
layers such that the critical
responses (such as tensile strain)
in the pavement are kept very low,
and as a result no major structural
failure could be expected for a long
period of time. The only
deterioration that could be expected
will be in the form of surface
distresses, which could be relatively
easily and economically addressed
by less involved rehabilitation
procedure, such as in place surface
recycling. Obviously, these
pavements would cost more than
conventional pavements initially but
if constructed properly, they allow
the users and the highway
agencies to enjoy a better quality
and durable pavement with
significantly reduced cycle of
rehabilitation (the pavements need
to be maintained properly), and
hence significant reduction in
activities that could negatively impact
the environment.
In terms of longevity, proponents
of the concrete pavement industry
argue that the longer life of concrete
pavements translates to reduced
needs for new natural resources,
energy and waste disposal. Another
important factor is that because of
lower deflection in concrete
pavements and hence lower rolling
resistance, the mileage is
increased by about 3.85% in
concrete pavements over asphalt
pavements (with similar
60
smoothness) – which translates to
lower amount of fuel spent and
hence lower amount of greenhouse
gas emission. Furthermore,
because the surface of a concrete
pavement reflects a higher amount
of solar energy than asphalt
pavement, concrete pavement helps
in reducing the indirect contribution
of pavements towards the urban
heat island effect. And at nighttime,
the lighter color of the concrete
pavement surface helps in a
significant reduction in the amount
of energy that is needed for
illumination. However, note that
smoothness has a significant
positive effect on gas mileage,
asphalt pavements are in general
smoother than concrete pavements,
and the reflectivity of asphalt
pavements can be improved by
using surface gritting or chip seals
with light colored aggregates,
colorless synthetic binders and
surface paints, and the surface
temperature could be reduced with
the help of open graded friction
course.
Life cycle analysis (LCA) in
pavement engineering is an
established concept, and is utilized
in many, if not most, high cost
projects. However, traditionally, the
cost is evaluated in terms of
materials/construction/salvage cost
only. For sustainable pavement
engineering, the environmental and
social cost must also be evaluated.
Furthermore, the cost of extending
the life of a pavement (and thus
lowering the life cycle cost) must
be evaluated in the context of the
amount of natural resources and
energy that are spent on producing
the premium materials that are
used to extend its life. The impact
of the pavement construction/
maintenance and rehabilitation
should be evaluated in terms of all
three components of sustainability
– social, economic and
environmental. Examples of such
framework and components of
framework are the Sustainability Life
Cycle Assessment (SLCA), the IRF
Greenhouse Gas Calculator, and
PaLATE (Pavement Life-cycle
Assessment Tool for Environmental
and Economic Effects).
Workers
Hundreds of thousands of human
beings – men, women and in many
cases even children work in
pavement related projects all over
the world. In many cases, this work
goes on under extreme conditions
of weather, in areas that are remote
from basic facilities such as school
or hospitals, and under conditions
of emissions/pollution from
construction conditions (smoke/gas/
particulate emission). This makes
the entire realm of pavement
engineering socially unsustainable.
Conditions must be improved such
that environmental and economic
justice is prevalent among the
pavement workers. While there are
many things that need to be done,
first and foremost, it is the
responsibility of pavement
engineers to select materials and
methods such that working
conditions are improved. For
example, switching to warm mix
asphalt instead of hot mix asphalt
will reduce harmful emissions
significantly (Figure 5). Secondly,
engineers and authorities must
enforce strict safety regulations and
provide for the basic necessities
such as protective body and eye
wears.
Pavement-Building-
Nature-Symbiosis
As pointed out earlier, pavements
need to be considered as part of
the built environment – going one
step forward, in the future;
pavements need to be considered
as part of a symbiotic system that
also includes buildings and the
nature. Imagine a day when we will
have smart pavements, that will be
able to self control temperatures
and adapt to changing
environmental conditions to sustain
NBM&CW MARCH 2011
Pavement Engineering

United States, which awards silver,

gold and platinum certifications for
projects in increasing order of
contribution towards “improving
performance across all the metrics
that matter most: energy savings,
water efficiency, CO2 emissions
reduction, improved indoor
environmental quality, and
stewardship of resources and
sensitivity to their impacts.”
Regulatory bodies such as the
Environmental Protection Agency
(EPA) in the US enforce strict
emission standards to prevent the
emission of harmful gases and
particulates into the atmosphere.
Figure 5: Range of reduction in emission through the use of Warm Mix Asphalt

loads without deforming or cracking,

will be able to harvest heat energy
from the solar radiation falling on
them, and supply this to buildings
for various uses, and in return, the
buildings will be keeping the
pavements below a critical
temperature, thus extending their
lives, and also reducing the amount
of heat that is radiated back into
the environment, and hence
indirectly reducing the urban heat
island effect. Multidisciplinary
research, as indicated in Figure 6,
needs to be conducted to make
this vision a reality.

Regulatory Bodies
and Impetus for
Sustainability
Adopting sustainable practices can
reduce many of the environmental
impacts of pavement construction.
However, both impetus and
regulations (“carrots and stick”)
need to be in place to accelerate
the adoption of sustainable
practices. Impetus in the form of
prestigious certification, first
voluntary, and then gradually,
mandatory, should be introduced.
Example of such certification is the
US Green Building Council’s
Leadership in Energy and
Environmental Design (LEED) in the Figure 6: Multidisciplinary approach to consider pavement infrastructure as part
of the built environment

62 NBM&CW MARCH 2011

Pavement Engineering

Human Factor education on existing and new

concepts of sustainability can be
Pavements are engineered
transmitted by this method, the
systems that need to be planned,
centers should also focus on
designed, constructed,
developing, through research,
maintained and rehabilitated by
new sustainable concepts and
knowledgeable and skilled
practices. And in that research, it
people. However, for achieving
is vital that engineers look at the
sustainable pavement
future – innovative, sophisticated
engineering, we need socially
materials and techniques, as
responsible engineers, with
well as into the past – to
broad vision and compassion for
determine what has survived over
humanity and respect for nature.
centuries without harmfully
Therefore, the preparation for
affecting our environment.
sustainability starts today in our
This has been a fairly long
Colleges and Universities with
article, and it is time for the
the students who will be joining
authors (and perhaps the readers
the profession tomorrow.
as well) to relax and sip a cup of
Professors, administrators and
tea– preferably in an Indian clay
the tax paying general public
cup– have you ever wondered
need to be educated on the
what a marvel of sustainable
impacts of pavement engineering
engineering the Indian clay cup
and the different ways to
is? It comes from the earth,
minimize such impacts. This can
serves its purpose in the most
be achieved by establishing
efficient way – even adds flavor
multidisciplinary centers of
to the tea, and then goes back
excellence in sustainable
completely into the earth, without
pavement engineering in major
leaving any lasting impact on the
colleges and Universities in
environment. We, pavement
conjunction with the industry and
engineers, have a lot to learn from
the government in the different
it!
parts of the country. While

NBM&CW MARCH 2011 63

Equipment & Machinery
Allison Transmission-equipped Water Tankers
A
llison Transmission is relied
upon by fire and rescue
services around the world for
its fully automatic transmissions,
which provide a host of benefits to
this most critical application. Easy
to operate in an emergency, they
ensure reliability and maximum
vehicle performance over any terrain.
Low, and therefore less costly,
transmission maintenance
requirements, enable vehicles to be
kept on the road and ready for
action. Besides regular fire-fighting
trucks, Allison supplies
transmissions to water tankers,
have played a significant role in
rural area fire-fighting, as
experienced by Clare County Fire &
Rescue Service, in Ireland.
This fleet has five Allison-
equipped water tankers – four Hino
500 Series trucks acquired in 2009
The Hino 500 Series water tankers are equipped with a number of features to help
support the specific demands on the Clare County fire brigade. For example, a water
monitor on the roof can be directed remotely from inside the truck’s cab to spray forest
fires as the truck drives along the adjacent road.
64
and 2010 and a Hino FS 6x4
purchased in 1992 – out of a total
fleet of 24 vehicles of which 14
have Allison transmissions. This
high proportion of water tankers
among the fleet reflects the remote
locations served by the brigade.
Allison transmissions have
been specified on Clare County Fire
& Rescue Service’s vehicles since
the early 1990s. Now most new
vehicles, ordered through
bodybuilders, come with an Allison,
and they have made then mark for
their reliability and durability.
The Hino 500 Series water
tankers are equipped with a number
of features to help support the
specific demands on the Clare
County fire brigade. The tanker
carries a dam (an inflatable water
pool), which it fills from the tank at
the scene of the incident while
‘‘The transmission is crucial in ensuring
that the 18 tonne (gross vehicle weight)
tanker arrives to the incident immediately
behind its 11 tonne fire-fighting
counterpart,” explains Al Meaney, Clare
County’s maintenance supervisor.
tending to the fire. This allows fire
fighters to continue extinguishing
the fire while the tanker leaves to
extract water from the nearest
source such as a river or lake. A
water monitor on the roof can be
directed remotely from inside the
truck’s cab to spray forest fires as
the truck drives along the adjacent
road. A further pump located under
the front bumper is configured to
spray a mix of water and foam
additive to break up oil spills at
road traffic accidents.
Allison Transmission, Inc.
(Allison) is the premier global
provider of commercial duty
automatic transmissions and hybrid
propulsion systems. Allison
products are specified by over 250
of the world’s leading vehicle
manufacturers and are used in
many market sectors including bus,
refuse, fire, construction,
distribution, military and specialty
applications.
For further details please contact:
Tel: +31 (0)78-6422 174
E-mail:
miranda.jansen@allisontransmission.com
NBM&CW MARCH 2011
Composites Pavement

Advances in
Bituminous Prof. Prithvi Singh

Road Construction
Kandhal, Associate Director
(Emeritus), National Center
for Asphalt Technology
(NCAT), Auburn University,
Alabama, U.S.A.

Introduction bituminous mixes, and recycling. penetration bitumen samples from

There is a need to incorporate these different refineries may have similar
An ambitious road construction plan
advances in MORTH specifications consistency (stiffness) at 25oC, but
is underway in India, which primarily
which are about 10 years old, to one may be softer than the other
involves bituminous pavements. At
keep abreast of latest technologies. when tested at 60oC, which is close
the present time, Ministry of Road
to the highest pavement
Transport & Highways (MORTH) Materials temperature on a hot summer day.
Specification for Road and Bridge
Paving Bitumen Bitumen which is very soft at high
Works, 2001 Edition is used for
Prior to July 2006, penetration temperature is undesirable because
construction of all roads including
graded road paving bitumen such it can cause rutting in bituminous
national highways. Advances in
as 60/70 was used in India. This pavement under heavy loads.
bituminous construction
grading system was based on Therefore, the Bureau of Indian
technologies are made in the world
empirical penetration test, which is Standards (BIS) adopted a viscosity
almost every year. This paper
conducted at 25oC. The penetration grading system for paving bitumen
describes such advances in terms
test measures the consistency of in July 2006 by issuing standard
of materials, mix design, special
bitumen. Although two 60/70 IS:73:2006. This system is based

66 NBM&CW MARCH 2011

Composites Pavement
on viscosity testing at 60 o C.
Penetration graded bitumen 60/70
was deleted and substituted with
viscosity graded VG-30. Similarly,
penetration graded bitumen 80/100
was deleted and substituted with
viscosity graded VG-10.
Although the preceding
advancement has been made, there
is a need to advance further by
adopting performance graded (PG)
bitumen, especially for national
highways. The viscosity grading
system gave excellent performance
results in the US for over 20 years.
However, the viscosity grading
system, although more rational than
the penetration grading system,
was still based on experience. A
50-million dollar, 5-year Strategic
Highway Research Program (SHRP)
was undertaken from 1987 to 1992
to develop a performance based
grading system for bitumen, which
was based on engineering
principles to address common
asphalt pavement distress
problems. The so-called Superpave
(acronym for Superior Performing
Pavements) performance grading
system includes new bitumen tests
and specifications with the following
salient features:
1. Tests and specifications are
intended for bitumen “binders,”
which include both modified and
unmodified bitumens.
2. The physical properties
measured by Superpave bitumen
tests are directly related to field
performance by engineering
principles rather than just the
experience.
3. A long-term bitumen aging test,
which simulates aging of
bitumens during 5-10 years in
service, was developed and
included for the first time.
4. Tests and specifications are
designed to eliminate or minimize
three specific types of asphalt
pavement distresses: rutting,
fatigue cracking, and thermal
cracking. Rutting typically occurs
at high temperature, fatigue
cracking at intermediate
70
temperature, and thermal cracking
at low temperatures.
5. As shown in Figure 1, the entire
range of pavement temperature
experienced at the project site is
considered. New testing
equipments were developed/
adopted for testing bitumens for
this purpose. A rotational
viscometer is used to measure
the bitumen viscosity at 135oC. A
dynamic shear rheometer is used
to measure the viscoelastic
properties of the bitumen at two
temperatures: high temperature
corresponding to the maximum
7-day pavement temperature
during summer at the project site,
and intermediate temperature
corresponding to the average
annual temperature of the
pavement at the project site. A
bending beam rheometer and a
direct tension tester are used to
measure the rheological
properties of the bitumen at the
lowest pavement temperature
during winter at the project site.
The Superpave performance
grade (PG) bitumen is based on
climate. For example, PG 64-22
bitumen is suitable for a project
location, where the average 7-day
maximum pavement temperature is
Figure 1: Superpave performance grade bitumen testing is conducted over the entire
range of temperature experienced at the project site
as much as 64oC, and the minimum
pavement temperature is –22oC.
The high temperature grades
are PG 52, PG 58, PG 64, PG 70,
PG 76, and PG 82. The low
temperature grades are –4, – 10, -
16, -22, -28, -34 and so forth. Both
high and low temperature grades
are in increments of 6 Celsius
degrees.
Example: A project location in
Rajasthan has a maximum record
7-day pavement temperature of
70oC in summer and a minimum
record pavement temperature of –
3oC. A PG 70-4 bitumen will be
specified for paving that project.
Aggregate
Many advances have been made in
characterization of coarse
aggregate, fine aggregate and
mineral filler used in bituminous
construction. However, one simple
test for characterizing particle shape
& surface texture of fine aggregate
(sand) passing 4.75 mm sieve can
be implemented easily in India. It
is desirable to have angular fine
aggregate particles in mix so as to
resist rutting in bituminous
pavements. Whereas angularity of
coarse aggregate (retained on 4.75
mm sieve) can be evaluated by
NBM&CW MARCH 2011
Composites Pavement
naked eye, it is not easy to do so
in case of fine aggregate particles.
The schematic of the test
equipment for measuring fine
aggregate angularity (FAA) is shown
in Figure 2. It can be fabricated
easily in India. FAA test procedure
has been adopted as standard
AASHTO Test 304.
A calibrated cylindrical measure
is filled with fine aggregate of
prescribed grading by allowing the
sample to flow through a funnel
from a fixed height into the
cylindrical measure. The fine
aggregate is struck off at the rim,
and its mass is determined by
weighing. Uncompacted void
content in the fine aggregate is
calculated as the difference between
the volume of the cylindrical
measure and the absolute bulk
volume of the fine aggregate
collected in the measure. Bulk
volume of the fine aggregate is
calculated from its mass and its
bulk dry specific gravity.
This test is based on the
concept that round particles pack
closer than angular particles and
therefore produce lower
uncompacted void content, that is,
lower FAA value. A FAA value of 45
or more is desirable to ensure that
the fine aggregate is angular and
does not contain any natural sand,
which normally has rounded
particles.
Figure 2: Schematic of equipment for
testing fine aggregate angularity (FAA)
72
Mix Design specimen with gyratory action (see
schematic of SGC in Figure 3)
Marshall Mix design is currently
rather than impact compaction as
used in India for designing
is done with Marshall hammer.
bituminous mixes. In any mix
Gyratory compaction also simulates
design, it is desirable to compact
field compaction with rollers in
laboratory specimens to a density
terms of aggregate particle
which is expected to be achieved in
orientation. Depending on the traffic
the bituminous course after 2-3
level in ESALs (equivalent single
years of densification under traffic.
axle loads) expected on the
For designing bituminous mixes for
highway, desired compaction level
heavy traffic, 75 blows each are
can be obtained in SGC by varying
applied with a Marshall impact
the number of gyrations without
hammer on both sides of the
causing any significant degradation
specimen. This laboratory
of aggregate in the mix.
compaction level worked well in the
Another advantage of SGC is
past. However, it was observed in
that a densification curve (number
the US during the 1980s that the
of gyrations versus compacted
field density of in-service
density of specimen) is obtained
bituminous pavements was
during the compaction process. At
significantly higher than the
least three different gradations of
laboratory design density obtained
the proposed mix are evaluated in
with 75 blows. This was attributed
the Superpave mix design to select
to increased truck tyre pressures
the gradation which has the
and new tyre designs with stiffer
strongest aggregate skeleton.
side walls. Therefore, 75-blow
compaction level appeared Special Bituminous
inadequate. Increasing the number
of blows was not desirable Mixes
because it merely caused Stone Matrix Asphalt
degradation (breakage) of Stone matrix asphalt (SMA) was
aggregate particles in the developed in Germany in the mid
specimen. 1960 and it has been used very
During SHRP, a new Superpave successfully by many countries
mix design method was developed including US as a highly rut-
in the US. A Superpave gyratory resistant bituminous course, both
compactor (SGC) was developed for binder (intermediate) and
which compacted the laboratory wearing course for heavy traffic
Figure 3: Schematic of Superpave gyratory compactor
NBM&CW MARCH 2011
Composites Pavement
Fig. 4a Stone matrix asphalt cross-section
roads. SMA is tough, stable, rut-
resistant mix that relies on stone-
on-stone contact to provide strength
and a rich mortar binder to provide
durability.
Figure 4 provides a cross-
sectional representation of the
difference between SMA and dense-
graded conventional bituminous mix.
In a conventional dense graded mix,
coarse aggregate particles (retained
on 4.75 mm sieve) are separated
by fine aggregate matrix, which
primarily carries the load. In SMA,
coarse aggregate particles have
stone-on-stone contact forming a
stone skeleton which carries the
load.
Since SMA mix has relatively
higher bitumen content, cellulose
fiber is added to the mix to minimize
drain down of bitumen in trucks
during transportation of the mix from
plant to project site. Although the
cost of SMA is typically about 25-
30% higher than the cost of dense
graded bituminous mix, it is still
economical considering life cycle
costs.
SMA has been widely used in
the US since 1991 for heavy-traffic
roads. It must also be used in
India for heavy corridors especially
when overloading is also common.
Indian Roads Congress (IRC) has
recently published a tentative
specification for SMA (IRC:SP:79-
74
Fig. 4b Conventional hot mix asphalt cross-section
2008), which was drafted by the
author to facilitate its use in India. A
manual containing detailed
guidelines for designing and
constructing SMA mixtures was
developed by the author in the US
for practicing engineers.
Open Graded Asphalt
Friction Course
Open graded asphalt friction course
(OGFC) is an open graded hot mix
asphalt mixture with interconnected
voids that provide improved surface
drainage during rainfall. The
rainwater drains vertically through
the OGFC to an impermeable
underlying bituminous layer and
then laterally to the day lighted
(exposed) edge of the OGFC
onwards to shoulder. In addition to
minimizing hydroplaning potential
during rainfall and providing
improved friction values on wet
pavements, the OGFC offers the
following advantages compared to
other dense graded surfaces: (a)
reduced vehicle splash and spray
behind vehicles, (b) reduced tyre-
pavement noise, (c) enhanced
visibility of pavement markings, and
(d) reduced night time surface glare
in wet weather.
Numerous states in the US
currently using OGFC have
experienced excellent performance
in terms of safety (improved wet
pavement surface friction) and
durability. This has been
accomplished by one or more of
the following: use of polymer
modified asphalt binders, relatively
higher bitumen content (by using
cellulose fibers), and/or relatively
open gradations.
Figure 5 shows an interstate
highway in the US, where OGFC
was used in the lanes on the right
side and dense graded bituminous
mix was used in the lanes on the
left side. Note the dramatic
difference: there is no standing
water and absence of splash/spray
on the lanes on the right side during
rain.
A manual giving detailed guidelines
on design, construction and
maintenance of OGFC was
developed by the author for use by
practicing engineers in the US. Due
to economic considerations, OGFC
should be used in India selectively
in regions with heavy rainfall and
stretches of roads prone to
accidents resulting from skidding
on wet pavement.
Warm Mix Asphalt
Warm mix asphalt (WMA) is a fast
emerging new technology which
has a potential of revolutionizing
the production of asphalt mixtures.
WMA technology allows the mixing,
lay down, and compaction of
NBM&CW MARCH 2011
Composites Pavement

and non visible) from the because the loss of lighter oils
burning of fossil fuels at a will be less at relatively lower
significantly reduced level mixing temperatures. This may
compared to HMA (Figure enhance asphalt pavement
6). This would permit durability.
asphalt plants to be located ♦ Extended paving season. By
in and around non- producing WMA at normal HMA
attainment areas such as temperatures, it may be possible
large metropolitan areas to extend the paving season into
that have air quality the colder months of the year or
restrictions. in places located on high altitudes
♦ Decreased fumes and since the WMA additives or
Figure 5: Lanes on the right have OGFC and lanes on odour. WMA produces lower processes act as a compaction
the left have dense graded hot mix asphalt on a fumes and odour both at aid. Further by narrowing the
interstate in the US. Note absence of standing water the plant and the paving difference between compaction
and splash/spray on the lanes on the right side.
site compared to HMA. This temperature and ambient air
would also result in temperature the rate of cooling is
asphalt mixes at significantly lower
improved working conditions at decreased. WMA may also be
temperatures compared to hot mix
both places. transported over longer distances
asphalt (HMA). The technology can
♦ Decreased binder aging. Short- as compared to HMA with reduced
reduce production temperatures by
term aging of liquid asphalt binder loss of mix temperature in the
as much as 30%. Asphalt mixes
takes place when it is mixed with hauling units. This advantage
are generally produced at 150°C or
hot aggregate in pug mill or should facilitate the Indian Border
greater temperatures depending
mixing drum. This aging is Roads Organization (BRO) in
mainly on the type of binder used.
caused by the loss of lighter oils constructing asphalt roads in high
WMA mixes can be produced at
from the liquid asphalt binders altitude and/or remote areas far
temperatures of about 120°C or
during mixing at high away from hot mix plants.
lower.
temperatures. It is believed that ♦ Compaction aid for stiffer mixes.
The development of WMA was
the short-term aging of the binder WMA additives and processes
initiated in Europe in the late 1990s
will be reduced significantly may be used to improve the
primarily in response to the need
for greenhouse gas reduction under
the Kyoto Protocol. WMA
technologies such as Aspha-min,
WAM Foam, and Sasobit were
developed during that time. New
WMA technologies such as
Evotherm, Rediset WMX, REVIX, LEA
(Low Energy Asphalt) and Double
Barrel Green were later developed
within the US.
Warm mix asphalt offers the
following significant advantages:
♦ Energy savings. The most
obvious benefit of WMA is the
reduction in fuel consumption.
Fuel is used to dry and heat the
aggregate. Studies have shown
that lower plant mix temperatures
associated with WMA can lead to
as much as 30 percent reduction
in energy consumption. Figure 6: Emission can be seen from the hot mix asphalt at 320 F (160 C) in left
♦ Decreased emissions. WMA truck. No emission is visible from the truck in right containing warm mix asphalt at
produces emissions (both visible 250 F (121 C). (Photo courtesy: Matthew Corrigan, FHWA)

76 NBM&CW MARCH 2011

Composites Pavement
compactibility of stiff mixes when
mix is produced closer to typical
HMA production temperatures.
Smaller reductions in temperature
may also be possible. There is
extensive experience with the use
of certain types of WMA with SMA
in Europe.
♦ Increased amount of RAP.
Research has shown that the
percentage of reclaimed asphalt
pavement (RAP) can be increased
in WMA compared to HMA during
hot recycling.
♦ Generation of carbon credits for
India. Developing countries like
India can earn CERs (Certified
Emission Reductions) or
popularly known as carbon credits
under the Kyoto Protocol if
technologies such as WMA are
introduced and implemented.
At the present time a mix is
considered warm mix in the US if
the mix produced at the plant has
temperature exceeding 100ºC but
significantly below that of a normal
hot mix. WMA has a wide range of
production temperatures ranging
from slightly over 100ºC to about
20 to 30ºC below typical HMA
temperatures. WMA technologies are
also applicable to mixes made with
polymer modified asphalt binders.
WMA technologies can be
classified broadly as (a) those that
use water, (b) those that use some
type of organic additive or wax, and
(c) those that use chemical
additives or surfactants.
Technologies which introduce
small amounts of water to hot
asphalt binder, take advantage of
the phenomenon: when water turns
into steam at atmospheric pressure
it expands in volume by a factor of
1,673. This causes tremendous
increase in the volume of asphalt
binder which not only helps in
coating the aggregate easily but
also lowers the mix apparent
viscosity. Processes to introduce
water into the asphalt binder consist
of foaming nozzles, use of
hydrophilic material such as zeolite
80
or use of damp aggregate. Asphalt
binder temperature typically is the
same as that used for hot mix
asphalt.
Technologies that use organic
additives or waxes lower the asphalt
binder viscosity above their
respective melting points. It should
be ensured that their melting points
are above the in-service pavement
temperatures during hot summers
so that permanent deformation or
rutting does not become a problem.
Technologies that use some
chemical additive and /or surfactants
produce a variety of different
mechanisms to coat the aggregate
at lower temperatures.
It appears WMA technology is
about to take off in India. There is
a need to incorporate WMA
specifications in MORTH
specifications.
Recycling of
Bituminous
Pavements
Recycling of existing asphalt
pavement materials to produce new
pavement materials results in
considerable savings of material,
money, and energy. The specific
benefits of recycling can be
summarized as follows:
1. When properly used, recycling
can result in substantial savings
over the use of new materials.
Also, the cost of haulage can be
avoided if recycling is performed
in place. The need for economic
consideration is felt now more
than ever, because of tightening
budgets and ever increasing cost
of materials.
2. Recycling can help in
conservation of natural resources
by reducing the need for new
materials. This translates to
substantial savings in aggregate
resources and demand for
asphalt binder (bitumen),
especially during supply
interruptions. Even though there
may be an abundant supply of
aggregates, the distribution of
these sources does not always
coincide with the location of need.
3. Recycled materials have proven
to be equal or even better than
new materials in quality. Hot mix
asphalt (HMA) overlay on recycled
base is expected to perform better
than an HMA overlay on the
existing surface, even though they
have the same thickness,
because the former can
substantially reduce the potential
of reflective cracking through the
surface course.
4. Recycling can maintain pavement
geometrics as well as pavement
thickness. The existing pavement
structure can be strengthened by
recycling without adding
substantial overlays. In some
cases, the traffic disruption is
lesser than that for other
rehabilitation techniques.
5. Recycling can save considerable
amount of energy compared to
conventional construction
techniques. This factor is of
significant importance during an
energy crisis like the one
experienced during the 1972 Arab
oil embargo.
Over the years, recycling has
become one of the most attractive
pavement rehabilitation alternatives.
With the continuous accumulation
of performance data, field and
laboratory evaluations of recycled
mixes, and with the simultaneous
development of realistic
performance oriented guidelines it
is expected that recycling will
continue to be the most attractive
rehabilitation technique.
Different recycling methods are
now available to address specific
pavement distress and structural
needs. A brief description of these
recycling methods follows.
The Asphalt Recycling and
Reclaiming Association define five
different types of recycling methods:
(1) Cold Planing; (2) Hot Recycling;
(3) Hot In Place Recycling; (4) Cold
In-Place Recycling; and (5) Full
NBM&CW MARCH 2011
Composites Pavement
Depth Reclamation.
Cold planing is described as
an automatic method of removing
asphalt pavement to a desired
depth and restoration of the surface
to a desired grade and slope and
free of humps, ruts and other
distresses. This method can be
used for the roughening or texturing
of a pavement to improve frictional
resistance. Cold planing is
performed with a self propelled
rotary drum cold planing machine
with the reclaimed asphalt
pavement (RAP) transferred to
trucks for removal from the job site.
The resulting pavement can be
used immediately by regular traffic
and overlaid at some future time or
left as a textured surface.
Hot recycling or hot mix
recycling is the process in which
reclaimed asphalt pavement (RAP)
material is combined with new
materials, sometimes along with a
recycling agent, to produce hot mix
asphalt (HMA) mixtures. Both batch
and drum type hot mix plants are
used to produce recycled mix. The
RAP material can be obtained by
milling or ripping and crushing
operation. RAP at ambient
temperature when introduced in
weigh hopper of the batch plant
(Figure 7) or drum of the drum
Figure 7: Hot mix asphalt recycling in a batch plant
82
plant is heated by superheated
virgin aggregate. If the amount of
RAP exceeds 15-20 percent, a
softer asphalt binder is used to
rejuvenate the aged asphalt binder
in the RAP. The mix placement and
compaction equipment and
procedures are the same as for
regular HMA. Typical RAP to new
aggregate ratio varies from 10:90
to 30:70 with a maximum of 50:50
(drum plant). The advantages of hot
mix recycling include significant
structural improvement, equal or
better performance compared to
conventional HMA, and capability to
correct most surface defects,
deformation, and cracking.
Hot in place recycling (HIR)
consists of a method in which the
existing pavement is heated and
softened, and then scarified or hot
rotary mixed to a specified depth.
New HMA or recycling agent may
be added to the RAP material
during the recycling process. HIR
can be performed either as a
single pass or a multiple pass
operation. In single pass operation,
the restored RAP material is
combined with new material. In
multiple pass operation, the
restored RAP material is
recompacted first, and a new
wearing surface is applied later. The
depth of treatment varies between
20 to 40 mm (3/4 in to 1½ in). The
Asphalt Recycling and Reclaiming
Association (ARRA) has identified
three HIR processes; (a) surface
recycling, (b) repaving, and (c)
remixing. In a surface recycling
operation the existing asphalt
surface is heated and scarified to a
specified depth. The scarified
material is combined with
aggregate and/or recycling agent.
The mix is then compacted. A new
overlay may or may not be placed
on the recycled mix. In the second
type of HIR method, repaving, the
surface recycling method is
combined with a simultaneous
overlay of new hot mix asphalt
(HMA). Both the scarified mix and
the new HMA are rolled at the same
time.
In the case of remixing, the
scarified RAP material is mixed with
virgin HMA in a pug mill, and the
recycled mix is laid down as a
single mix. The advantages of hot
in place recycling are that surface
cracks can be eliminated, ruts and
shoves and bumps can be
corrected, aged asphalt binder is
rejuvenated, aggregate gradation
and asphalt content can be
modified, traffic interruption is
minimal, and hauling costs are
minimized.
In cold in place recycling (CIR),
the existing pavement material is
reused without the application of
heat. Except for any recycling agent,
no transportation of materials is
usually required, and, therefore,
haulage cost is very low. Normally,
an asphalt emulsion is added as a
recycling agent. The process
includes pulverizing the existing
pavement, sizing of the RAP,
application of recycling agent,
placement, and compaction. The
use of a recycling train, which
consists of pulverizing, screening,
crushing, and mixing units, is quite
common. The processed material
is deposited in a windrow from the
mixing device, where it is picked
up, placed, and compacted with
NBM&CW MARCH 2011
Composites Pavement
conventional hot mix asphalt lay
down and rolling equipment. The
depth of treatment is typically from
75 to 100 mm (3 to 4 in).
The advantages of cold in place
recycling include significant
structural improvement, treatment of
most pavement distress,
improvement of ride quality,
minimum hauling and air quality
problems, and capability of
pavement widening.
Full depth reclamation has been
defined as a recycling method
where all of the asphalt pavement
section and a predetermined
amount of underlying material are
treated to produce a stabilized base
course. It is basically a cold mix
recycling process in which different
types of additives such as asphalt
emulsions and chemical agents
such as calcium chloride, Portland
cement, fly ash, and lime, are
added to obtain ail improved base.
The four main steps in this process
are pulverization, introduction of
additive, compaction, and
application of a surface or a
wearing course. If the in place
material is not sufficient to provide
the desired depth of the treated
base, new materials may be
imported and included in the
processing. This method of
recycling is normally performed to
a depth of 100 mm to 305 mm (4
to 12 in). The advantages of full
depth reclamation are that most
pavement distresses are treated,
hauling costs are minimized,
significant structural improvements
can be made (especially in base),
material disposal problems are
eliminated, and ride quality is
improved.
Summary
This paper describes recent
advances in bituminous road
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84
construction in terms of materials,
mix design, special bituminous
mixes, and recycling. These include
performance grading system for
paving bitumen; measuring particle
shape of fine aggregate; Superpave
mix design; stone matrix asphalt
(SMA); open graded asphalt friction
course (OGFC); warm mix asphalt
(WMA); and four types of asphalt
pavement recycling.
References
♦ Kandhal, P.S. An Overview of the
Viscosity Grading System Adopted
in India for Paving Bitumen. Indian
Highways, Volume 34, No. 4, April
2007.
♦ Roberts, F.L., P.S. Kandhal, E.R.
Brown, D.Y. Lee, and T.W.
Kennedy. 'Hot Mix Asphalt
Materials, Mixture Design and
Construction.' NAPA Education
Foundation, Lanham, Maryland,
Second Edition, 1996.
♦ Kandhal, P.S. and F. Parker.
'Aggregate Tests Related to
Asphalt Concrete Performance in
Pavements.' Transportation
Research Board, National
Cooperative Highway Research
Program Report 405, 1998.
♦ Kandhal, P.S. 'Aggregate Tests
for Hot Mix Asphalt:' State of the
Practice. Transportation Research
Board Circular No. 479,
December, 1997.
♦ Kandhal, P.S. Design,
Construction, and Maintenance of
Open-Graded Asphalt Friction
Courses. National Asphalt
Pavement Association Information
Series 115, May 2002.
♦ Kandhal, P.S. Designing and
Constructing Stone Matrix Asphalt
Mixtures State-of-the-Practice.
National Asphalt Pavement
Association Quality Improvement
Publication QIP-122 (Revised
Edition), March 2002.
♦ Kandhal, P.S. Warm Mix Asphalt
Technologies: An Overview.
Journal of the Indian Roads
Congress, Volume 71-2, 2010.
♦ Kandhal, P.S. Recycling of
Asphalt Pavements: An Overview.
Association of Asphalt Paving
Technologists, Asphalt Paving
Technology, Vol. 66, 1997.
♦ Kandhal, P.S. and R.B. Mallick.
Pavement Recycling Guidelines
for State and Local Governments.
Federal Highway Administration
Publication No. FHWA-SA-98-042,
December, 1997.
About the Author
Prof. Prithvi Singh Kandhal is
Associate Director (Emeritus) at
the National Center for Asphalt
Technology (NCAT) based at
Auburn University, Alabama, U.S.A.
NCAT is the largest asphalt
(bitumen) road technology center
in the world. Prior to joining NCAT
in 1988, Kandhal served as Chief
Asphalt Engineer of the
Pennsylvania Department of
Transportation for 17 years. He is
the first person born outside North
America, who has held the
following three very prestigious
positions in the asphalt technology
area:
♦ President, Association of Asphalt
Paving Technologists (with
members from all continents in
the world)
♦ Chairman, American Society for
Testing and Materials (ASTM)
International Committee on Road
Paving Standards (responsible
for over 200 highway standards
used worldwide)
♦ Chairman, Transportation
Research Board Committee on
Asphalt Roads, U.S. National
Academy of Sciences
Prof. Kandhal has published
over 120 technical papers and has
co-authored the first ever textbook
on asphalt road technology, which
is used by more than 25
universities in the U.S.
NBM&CW MARCH 2011
SMA

Experiences with
Stone Matrix Asphalt (SMA)
Sant Kumar Sehgal and Bernd Abele

Review In 1975, the use of studded the German ZTV Asphalt (Technical
tires was banned. In the following Specifications and Guidelines for
In the sixties and early seventies,
time surface courses with asphalt the Construction of Asphalt
studded tires were used in
concrete and prototype SMA mixes Pavements), issued by the Federal
Germany during wintertime. The
showed a different performance of Department of Transportation.
wear of asphalt surface courses
heavily trafficked higways: asphalt Years after the successful
under the spikes was extreme.
concrete with a high bitumen application of the Stone Mastic
Research and investigations on the
content was disposed to permanent Asphalt principle in Germany, other
performance of surface courses of
deformation, whereas asphalt European countries are using this
asphalt concrete (AC) and
concrete with a low bitumen content philosophy also for heavy traffic
gußasphalt verified that wear and
was disposed to aging and roads. Now, many countries
rutting by studded tires was
preliminary cracking. However under worldwide have taken over the
increased by:
equal conditions both types of philosophy of the Stone Matrix
♦ high air void content of the surface
distress were not observed with Asphalt.
course,
SMA - surface courses. Practical
♦ low bitumen content, The Philosophy of
experiences and observations
♦ inadequate quality and quantity
proved that SMA is a better mix
of aggregates.
than asphalt concrete. Since high
The SMA - Concept
In the end of the sixties, these The philosophy of the SMA - concept
performance highways, especially
results were the starting point for can be summarized briefly as
the “Autobahn,” have been an asset
several large companies of the follows:
of the transportation-system, there
asphalt paving industry to develop ♦ High stability to permanent
has been constant strive for better
specific mixes which were deformation and high wear
pavements and asphalt mixes.
published under different proprietary resistance by an excellent particle
Consequently, SMA has gradually
names. Later, all these mixes were interlock and a high content of
improved by investigations, tests
standardized and called Stone crushed premium aggregates.
and feedbacks from highway
Mastic Asphalt or Stone Matrix ♦ Longevity and durability to
projects. Finally in 1984, SMA
Asphalt like in India (see premature cracking and raveling
passed the stage of a contractor`s
IRC:SP:79:2008). by a very high content of bitumen
proprietary product. It was
and a void less mastic mortar
standardized and became a part of

86 NBM&CW MARCH 2011

SMA

which fills the voids of the stone

skeleton and binds it together:
high quality and quantity of
bitumen are prerequisite for a long
useful service life.
♦ Stabilizing additives assurances
the homogeneity (no binder
drainage) of the mix during the
manufacturing, transportation and
laying. As a side effect, they
improve the stability.
Summary: High quality and high
quantity of bitumen and coarse gap-
graded aggregates are the
essentials for a long service life of
SMA.
Figure 1 shows the gradation
Figure 1: Gradation curve SMA 11
curve for SMA 11 according to
German ZTV Asphalt specification.
♦ High stability against permanent performance
Advantages of Stone deformation ♦ Broad range of application
♦ High wear resistance ♦ Longer service-life
Matrix Asphalt ♦ Slow aging and durability to ♦ Higher asphalt content
The SMA-Concept has shown premature cracking of the asphalt ♦ Premium materials and additives
significant advantages for heavy ♦ Good low temperature ♦ Better long-life behavior
traffic roads worldwide:

NBM&CW MARCH 2011 87

SMA
Specifications
Technical specifications and
guidelines for the construction of
asphalt pavements are always the
conclusion of experience. In the
following, some requirements of
SMA and its ingredients are
explained. The European and
German specifications for Stone
Matrix Asphalt can be found at Table
1 and Table 2.
90
Aggregates
Double crushed tough premium
aggregates of definite size,
soundness, shape etc., e.g. max.
20% of flaky and elongated
aggregates; all aggregates
(aggregates, sand, filler) need to
be under a permanent quality
assurance, which is independent
an from a third party.
Mineral type
The mineral type is specified in the
TL Gestein (technical deliver
specifications of mineral
aggregates). The TL-Gestein is
based on the European
Specification EN 13043. As
minerals should be used granite,
diabas, basalt etc. Limestone,
sandstone and “soft” minerals
shouldn’t be used. Because of the
longevity of the SMA and the low
content of crushed sand, the
minerals/aggregates must have a
high resistance to polishing (high
polished stone value; PSV 48) and
they also need to have a good
aggregate abrasion value (LA 20).
Furthermore, if available, the use of
two different types of minerals can
improve the performance and skid
resistance.
Filler
Usually mineral filler (grounded
limestone) is used.
Sand
100% of the sand fraction must be
crushed.
Gradation
Gap-graded: very high content of
crushed coarse aggregates, see
Figure 2.
If you have no problems with
the aggregates used in asphalt
concrete, you will also have no
problems in the SMA-mixture. If you
have problems with the aggregates
used in asphalt concrete you will
have more problems using these
aggregates in SMA.
Bitumen
The use of the particular bitumen
quality predominantly depends on
climate and traffic conditions. Paving
grade bitumen and polymer
modified bitumen is specified by
European standard EN 12591 and
EN 14023 (PmB).
NBM&CW MARCH 2011
SMA
Figure 2: Good coarse aggregate skeleton
Additives
According to the specifications the
following additives are permitted:
♦Cellulose fibers
♦ Polymers
♦Artificial silicious material.
The selection of the additive
and its quantity is a part of the
duties and responsibilities of the
contractor.
Reclaimed asphalt isn’t being
used for SMA; the feasibility has
not yet been evaluated and
92
experienced. More requirements are
given in Table two.
Range of Application
SMA is adequate and it is
recommended for any surface
course. It is especially used for all
heavy traffic roads: SMA is much
more economical (Long-life Asphalt
pavements 2007, EAPA) than
asphalt concrete. Since the
specifications were introduced in
1984, the use of SMA has
significantly increased.
The Stone Matrix
Asphalt is appropriate
for:
♦ Highways
♦ Federal roads
♦ Rural roads
♦ Urban roads
♦ Airports
♦ Industrial areas
There are no
special regulations in
the European
Specifications 13108-5
for the design of SMA
surface courses. The
choice of SMA mix
design is at the
discretion of the client
when preparing the
RFP (requirements for
pavement). For the
highway projects, SMA
is the most favourite
and acceptable
asphalt mix and
therefore - by
experience – it is used intensively
for these highway pavements.
By the selection of SMA, there is a
strong tendency to a smaller top
size, i.e. from 11 mm to 8 or 5 mm
top size aggregates, because of
the following reasons:
♦ Lower unit price per sq. m
because of smaller thickness is
necessary
♦ Less noise under traffic
♦ Better skid resistance
By the same reasons a SMA 16
mm surface course is not
standardized in 16 mm SMA mixes
of 16 mm and even larger top size
are not used:
♦ a larger top size requires a
greater thickness which means a
higher unit price per sq. m,
♦ larger top sizes generate more
traffic noise; but there is a strong
demand of public to reduce traffic
noise.
Mix Design
There is no specific mix design
method for SMA, but there are
NBM&CW MARCH 2011
SMA
information sheets for initial
suitability tests on hot mix asphalt.
The steps of the evaluation of
an appropriate job mix formula
(JMF) according to the information
sheet mentioned above are as
follows:
a) In accordance with the RFP
(requirements for pavement) and
with respect to its experiences
with former JMFs, mixing, paving,
performance during the time of
warranty, and - last but not least -
the price, the contractor selects
the aggregates and the filler. with
the selected material (aggregates,
sand, filler, additives) and on the
basis of the feedback from other
sites and JMFs, a tentative
gradation is chosen. But there
are requirements for abrasion
value, polish stone value, freezing-
thawing-test, etc.
b) Mixes with the required
minimum asphalt content and
with three adjacent asphalt
contents are prepared.
c) Marshall specimen are
prepared at 135/145 ± 5°C and
by 50 blows on each side the
Marshall tests are running for the
evaluation of the air void content
which must range from 3 to 4 %
by volume (i.e depending on
German climate conditions). If the
required air void content is not
achieved, the following alterations
of the tentative mix within the
enforceable limits of the
Figure 3: Schellenberg Binder Drainage Test
94
specifications are recommended:
♦ Change total content or content
of single sizes of crushed
aggregates
♦ Change filler content
♦ Change mortar content
It has to be emphasized that
the Marshall-stability and -flow are
not an adequate basis for the right
choice and evaluation of the SMA
job mix formula.
d) Drain-down test: Additives are
necessary to avoid drainage of
binder from the coarse
aggregates during mixing,
transportation and paving.
Therefore, a drain-down test must
be performed for the evaluation
of the appropriate and necessary
content of the additive. The
Schellenberg Binder Drainage
Test (Figure 3) is standardized in
Germany and in the European
Union (EN 12697-18: Bituminous
mixtures – Test methods for hot
mix asphalt – Part 18: Binder
drainage).
On the basis of the mix design
results, the contractor decides on
the JMF and submits it to the client
for his approval.
Additives
Although fibers, polymers and
silicious materials are also
permitted, cellulose fibers are used
very extensively. By tests, trials and
by experience, it was discovered
that only the use of polymer is not
adequate to avoid segregation of
the gap-graded coarse aggregates
and the high bitumen content. The
additive has to be a bitumen carrier;
polymer as a bitumen improver is
not sufficient. All SMA-JMFs with
polymers also had a lower bitumen
content than required or they had
additionally fibers mixed in to
achieve the requirements of each
country.
Cellulose fiber shows no chemical
reaction with the bitumen and it is
inert to mixing temperatures and it
works excellently. Because of the
performance of the cellulose fibers,
the technical assistance of the
supplier and - last but not least -
the relatively low price of the fibers,
the usage and the market share of
the different types of additives for
SMA e.g. in Germany is as follows:
Cellulose fibers 95%, the rest
mineral fibers and other additives.
Mixing
Mixing and paving is neither
specified in the specifications nor
in the RFP. Method and equipment
are within the assigned
responsibility of the contractor. His
technical expertise and
accountability are essential.
Drying of the unbound coarse
material needs less heat than it is
necessary for standard asphalt
concrete (AC) and therefore the heat
of the dryer must be reduced. Short
term aging of the asphalt is very
likely when it is mixed with too hot
coarse aggregates. Drying of the
minerals needs to be executed at
such a temperature that the heat of
the mix in the pugmill does not
exceed 190°C.
The lower limit values are valid
for the discharged asphalt mix at
the construction location;
NBM&CW MARCH 2011
SMA

The upper limit values are valid

when the asphalt mix leaving the
pugmill or silo at the mixing plant.
Mixing times depend on the type
of plant.
In Europe, there are mostly
batch mixing pugmills. Drum mixing
is possible by using bitumen coated
cellulose fiber pellets. As an
example, the time and sequence of
the mixing process is demonstrated
in Figure 4. Figure 4: SMA mixing times with bituminous coated fiber pellets
To enhance and improve the
quality, the mixing time must be
♦ Dosing by big bag with automated Additionally and as a general rule,
extended. Accordingly, the production
dosing system (see Figure 5). a quality assurance of the mixing
rate of SMA is lower than of asphalt
♦ Small packages – dosing by plant by an independent third party
concrete: Quality has its price.
hand; this procedure needs much is required.
Exact proportioning of the fibers
manual labor; it is obsolete, but
is important. A variation of the fiber
still practiced (see Figure 6). Paving
content ± 0.1% can result in a
According to the specifications, Paving and compaction procedure
variation of the bitumen content ±
quality control by the contractor is is similar to every standard asphalt
1.0% without being recognized
always necessary and required. Figure 7.
visually.
Samples for quality control are to ♦ Trucks must be covered until the
There are different possibilities
be taken, i.e. every 500 tons. SMA is discharged into the
to dose the fibers:

NBM&CW MARCH 2011 95

SMA
Figure 5: Automatic dosing
system
material hopper at the front of the
road paver.
♦ Although the asphalt content of
the SMA is very high, a tack coat
is recommended to ensure and
improve the bond between the
layers.
♦ The temperature of the SMA in
the road paver should be at least
150 (140)°C.
♦ An adapted pre-compaction of
the asphalt paver is useful and
should be achieved.
♦ Compaction should be started
as soon as possible and the
roller should move as close to
the paver as possible. Steel
wheel rollers of approximately
eight to ten tons for compaction
are necessary. Vibrating should
be executed mostly two or three
times. There is a hazard of mortar
enrichment on the surface, if
using too much vibrating roller
passes. The consequence is a
very low initial skid resistance.
Vibrating is not advisable on thin
layers of approximately less than
25 mm thickness and at layer
temperatures under 100°C, see
Figure 8. Since sucking up of the
mortar is very likely compacting
with a pneumatic roller can be a
hazard.
♦ Because of the high asphalt
content, the initial skid resistance
can be low and it can cause
safety problems on high traffic
highways. Therefore, a surface
96
♦ Stone Matrix Asphalt Binder
Course (SMA-Binder, see Figure
9)
♦ Noise Reducing Stone Matrix
Asphalt
♦ Porous Asphalt (PA)
♦ Twin Layer Porous Asphalt (TLPA)
Authors
Mr. Sant Kumar Sehgal,
Rettenmaier India,
E-mail: santkumar.sehgal@jrs.de,
Website: www.sma-viatop.com
Figure 6: Manual dosing system
Mr. Bernd Abele, J. Rettenmaier &
Söhne GmbH + Co KG Germany,
E-mail: bernd.abele@jrs.de,
treatment is recommended by Website: www.sma-viatop.com
spreading 0.5 to 1.0 kg of fine
crushed aggregates per
sqm. After the first or
second roller pass
aggregates which are free
of fines and 1/3 mm
should be used.
♦ During, the execution of
the work there is a quality
assurance by the client at
every 6,000 sqm: SMA -
samples are taken from
the paver and tested for: Figure 7: Paving of SMA
♦ Drain-Down Test
♦ Asphalt content
♦ Fiber content
♦ Gradation
♦ Marshall air void content
♦Softening point ring and
ball tested at the recovered
bitumen
♦Cores are taken from the
layer and tested on:
♦Air void content of the
layer
♦Compaction ratio
♦Bond between the layers Figure 8: Compaction temperature of SMA
Solutions for
Future Demands
Due to the advantages of
SMA, a variety of new
developments, with gap-
graded principle, has been
the result. Solutions which
will be able to serve future
demands.
Figure 9: SMA-Binder; Autobahn A73 - Germany
NBM&CW MARCH 2011
White Topping

WHITE TOPPING
An Excellent Solution for
Pavement Rehabilitation Dr. V. Ramachandra,
Zonal Head (Tech),
UltraTech Cement
Ltd., Bangalore

Introduction this objective, overlays also restore economics of cement concrete and
the ride-ability of the existing rapidly changing traffic scenario (in
Concrete Roads were first built by
pavements which have suffered terms of volume as well as axle
Romans (300 BC – 476 AD). They
rutting and deformations, in addition loads). In addition, rapid
were quite innovative in the
to rectifying other defects such as developments in concrete material
construction with the use of
loss of texture. In our country, technology and mechanization (both
innovative materials viz., use of
bituminous overlays have been in concrete production & its laying)
‘Pozzolana’ cement from the village
popularly constructed in the past are favouring concrete overlays as
Pozzouli near Italy, horse hairs as
mainly due to abundant supply of a sustainable option. In recent times
fibres in concrete, admixtures in
bitumen, its amenability to stage PPP (Public-Private Partnership)
their primitive form (like animal fat,
construction and manageable traffic models are becoming popular in
milk & blood). These roads,
conditions, in terms of volume and road construction shifting the focus
scientifically designed and
axle loads in addition to the comfort on selection of overlays based on
constructed had a long life and thus
levels of construction methods life-cycle costs rather than initial
lead to the adage ‘all (concrete)
among engineers. It was also costs. India is currently producing
roads lead to Romel.’
making economic sense to make about 240 million tonnes of cement
Portland Cement Concrete
bituminous pavements as it was and cement industry is quite
(PCC) overlay on an existing
relatively cheaper. In recent times matured and equipped to meet the
bituminous pavement is commonly
all these advantages are reversed challenges in terms of various
known as White topping. The
viz., petroleum industry is using grades of cements as well as high
principal purpose of an overlay is
refined processing technology quality blended cements suitable
either to restore or to increase the
leading to reduction in the for making Pavement Quality
load carrying capacity or both, of
production of bitumen leading to Concrete (PQC).
the existing pavement. In achieving
increased imports, favourable cost

100 NBM&CW MARCH 2011

White Topping
Overlay Solutions for
Rehabilitation
Type of overlays is chosen
depending upon the condition of
the existing pavement. Bonded
overlays are preferred when the
condition of existing pavement is
good and the design will ensure
that the thickness of overlay is
relatively less. This is due to the
fact that the pavement system
behaves as a composite structure,
utilizing the flexural strength of
flexible pavement as well. In case
the pavement is already
deteriorated, it can only be regarded
as a base; to separate it from the
concrete overlay (in order to avoid
reflective cracks), a separation layer
is provided.
Concrete overlays have been
used to rehabilitate bituminous
pavements since 1918 in USA.
There has been a renewed interest
in whitetopping, particularly on Thin
White Topping (TWT) and Ultra-Thin
White Topping (UTWT) over
Conventional White Topping. Based
on the types of interface provided
and the thickness of overlay,
classification is as follows:
i) Conventional White topping –
which consists of PCC overlay of
thickness 200 mm or more,
which is designed & constructed
without consideration of any bond
between existing overlay &
underlying bituminous layer
(without assuming any composite
action).
ii) Thin White topping (TWT) – which
has PCC overlay between 100 –
102
200 mm. It is designed either
considering bond between overlay
& underlying bituminous layer or
without consideration of bond.
High strength concrete (M 40 or
higher) is normally used to take
care of flexure requirement.
Joints are at shorter spacing of
0.6 to 1.25 m.
iii) Ultra-Thin White topping (UTWT)
– which has PCC overlay of less
than 100 mm. Bonding between
overlay & underlying bituminous
layer is mandatory. To ensure
this, the existing layer of bitumen
is either milled (to a depth of 25
mm) or surface scrapped (with a
non-impact scrapper) or gently
chiseled. Joints are provided at
a spacing of 0.6 to 1.25 m.
Advantages of White
topping
♦ Reduced thickness – due to
thickness of overlay remaining
constant for over 2 decades.
♦ Fast-Track construction – making
use of innovations in concrete
technology & batch mixing,
concretes can be designed to
have 3 –days’ compressive (&
Concrete roads require lesser illumination during night
flexural) strength, so as to open
the road for traffic within 5 days
of construction.
♦ Reduced maintenance – as the
concrete overlays live for over 2
decades, with least maintenance.
♦ Cost-effective compared to asphalt
overlays – when Life Cycle Cost
is taken into consideration.
♦ Improved service life – with better
riding quality, improved fuel
efficiency of vehicles.
♦ Little pre-overlay repairs
♦ Improvement in safety in view of
the increased reflection of light –
particularly on city roads, it would
save 24% less electricity
compared to flexible pavements.
♦ Reduction in operational costs and
lower absorption of solar energy
Improving the environmental
benefits – as concrete roads are
much greener and less polluting.
Technology
Demonstration
Project
In India, concrete overlays on
existing flexible pavement (white
topping) have been constructed in
recent years in Mumbai, Nagpur,
Indore among other places. In
South India, several new concrete
roads were constructed during the
last century which have given
excellent service for over four
decades, the examples being the
Bangalore-Mysore road constructed
by the then Maharaja of Mysore, the
coastal roads in Kerala etc. Due to
lack of experience and expertise in
white topping, these roads were
converted to flexible overlays in
recent times.
NBM&CW MARCH 2011
White Topping

With a view to familiarize with the advantages of

white topping, a Technology Demonstration Project was
undertaken in Bangalore jointly by the Bruhat Bangalore
Mahanagara Palike (BBMP), Task Force for Quality
Assurance, Govt. of Karnataka and Cement Manufacturers’
Association. The objective of this project was to
demonstrate the advantages of white topping by making
use of the advances in construction equipments and
methods.
Characterisation of the existing flexible pavement on
the trial stretch on Hosur Road in Bangalore yielded the
following data.

Design of Pavement and Concrete

Mix
Design of the overlay was carried out using Westergaard’s
Equation and warping stress as per IRC:58 -2002 and
IRC: SP: 76 – 2008. Total stress (including temperature
stress) was obtained as 30.83 Kg/cm2 and corresponding
flexural strength requirement was 4.7 MPa. Design was
done by M/s L.R. Kadiyali & Associates, New Delhi.
Thickness of white topping was 150 mm.
Concrete mix design was arrived at by evaluating trial
mixes and the design mix was arrived at with a cement
content of 430 kgs, fly ash – 30 kgs, with a w/c ratio of
0.283, achieving a slump of 40 – 60 mm at site.

Details of Construction
In order to achieve the desired advantages of concrete
roads, three essential conditions need to be satisfied.
i) Production of concrete in a RMC plant or in a dedicated
batching plant.
ii) Using either fixed form or slip form mechanical pavers
iii) Strict quality control at site including testing of fresh,
hardened and extracted specimens of concrete and
tests on pavement quality.
In this project design and production of concrete was
carried out by UltraTech RMC; Fixed form paver provided
by M/s Allen Buildwell Pvt Ltd., was used. Quality control
at site and testing were jointly done by the Technical
Services team of UltraTech and M/s Civil Aid Technoclinic
(P) Ltd., Bangalore.

NBM&CW MARCH 2011 103

White Topping
Surface preparation and alignment of rails for paver
Surface texturing on green concrete
Salient features of
Construction
i) Surface preparation: In case of
TWT, bond between PCC overlay
& existing bituminous pavement
is atleast partly desirable; in case
of UTWT, effective bond is
essential. To ensure this any of
the following method can be
adopted.
♦ Milling the existing bituminous
surface to obtain a uniform surface.
Milling can be used to remove
surface distortion like cracks in
the top portion and adjust cross
slopes. Thickness of milling
usually is in the range of 25 to 50
mm.
♦ Surface scrapping is carried
out on bituminous surfaces which
are quite hard. This can be for a
depth of 10 mm and carried out
with tools which have vertical
104
Paver machine in operation
Spraying of curing compound on fresh concrete
impact control, so that the sub-
grade is not damaged.
♦ Chiselling of the surface at
regular intervals, if the existing
surface is hard.
The minimum thickness of
existing bituminous pavement
(excluding the milled/scrapped
thickness) shall be 75 – 100 mm
to ensure a reliable & strong base.
ii) Profile correction is carried out
with the objective of filling existing
potholes, ruts and wide cracks
and also to ensure a level surface
for resting the pavement. Profile
correction and correction of
camber can be carried out
together with a thin bituminous
leveling course or with dry lean
concrete (DLC).
a. If the existing road surface is
good & only a few localized
potholes / cracks exist, they can
be repaired with a bituminous mix
before concreting is done.
b. If potholes/ cracks are wider
than 3 mm, they have to be treated
with bituminous emulsion, slurry
seal after trimming them to shape
and cleaning out loose fragments
with compressed air. Milling of the
existing surface also addresses
this problem.
iii) Laying of PQC is quite similar
to the construction of new
concrete pavement. As mentioned
earlier, concrete should be made
either in an RMC plant or in a
weigh batching plant. Use of
either fixed form pavers or slip
form paver machines is an
essential ingredient for getting a
good quality pavement. In the
current project, a fixed form paver
was used with a fixed side
formwork (steel channel box
section) with 16mm diameter
steel rods of 1 m length as tie
NBM&CW MARCH 2011
White Topping
Groove cutting in progress
rods @ 500mm c/c) and the paver
had gang mounted vibrators
equally spaced with variable rpm
and three integral steel tubes with
8 Tonnes vibratory rollers for
screeding, levelling, compaction
and finishing.
iv) Finishing of the surface is mostly
achieved by the paver itself. But
to achieve uniform finish, a simple
hand operated bull float is used
when concrete is still in its fresh
state. After the bull float operation,
uniform surface texture is
provided by using steel wire
brush.
v) To avoid evaporation of surface
water from concrete surface
(which leads to plastic shrinkage
cracks), wax based curing
compound is sprayed. As an
additional measure, plastic
sheets are spread over the
pavement surface till normal
curing process starts.
vi) Contraction joints are
provided by cutting groves (for
a depth of one-third of the
depth of white topping, 150
mm in this case) at a spacing
of 1.2 m in longitudinal as
well as transverse directions.
The joints are cut using
electrical grove machines
106
within about 8 to 10 hours of
pouring concrete. These joints
are sealed with high quality
sealant (either bitumen or poly
sulphides) to prevent moisture
and incompressible infiltration
into the overlay system.
vii) To ensure effective load transfer
across the longitudinal segments
as well as transverse construction
joints, tie bars and dowel bars
are provided.
Test Results
Strict quality control not only during
mix design and production of
concrete, but also testing for quality
at regular intervals (for every 50
cum of concrete) was carried out.
These tests included:
♦ Tests conducted on fresh
concrete (slump test at site)
♦ Tests on hardened state
(compressive strength of cube &
cylinder specimens for 1, 3, 7 &
28 days), split tensile strength,
flexural strength of concrete beams
♦ Fatigue and abrasion tests on
pavement quality (results awaited).
♦ Test on extracted specimens
of concrete (core tests) would be
conducted to assess the long
term performance of concrete.
All the above tests are
conducted by Civil Aid Technoclinic
(P) Ltd., Bangalore and the results
obtained so far are tabulated. The
road was opened for traffic after 5
days of curing.
Conclusions
Due to advances in the area of
mechanization and fast track
construction, concrete roads and
white topping provide a sustainable
as well as cost effective option for
pavement construction. This
technology demonstration project in
Bangalore has evoked positive
response from people across the
spectrum viz., technical consultants,
construction industry, academic &
research institutions. The
Government of Karnataka, BBMP
and other civic agencies have come
forward to adopt this technology.
On behalf of the cement industry,
NBM&CW MARCH 2011
White Topping
CMA (Cement Manufacturers’
Association) has come forward
to assist all those involved in
the construction on concrete
roads/ white topping by way of
several useful publications, user-
friendly software for analysis,
design and estimation of
quantities (and comparative
cost), conducting training
programs for engineers and
providing the necessary
technical assistance.
References
♦ Concrete Overlays – White
topping of roads, Cement
Manufacturers Association,
2010
NBM&CW MARCH 2011
♦ Tentative guidelines for
conventional, thin and Ultra-thin
white topping, IRC: SP: 76 –
2008, The Indian Roads
Congress, New Delhi, 2008
♦ Handbook on Cement Concrete
Roads, Cement Manufacturers
Association, 2010
♦ Michael E. Ayers & Dale
Harrington, Selection and use
of concrete overlays, The Indian
Concrete Journal, May 2010
♦ Guide to Concrete Overlays –
Sustainable solutions for
resurfacing and rehabilitating
existing pavements, National
Concrete Pavement Technology
Centre, USA, Sept. 2008.
107
Asphalt
Asphalt is Green
R
aising environmental
concerns, fuel costs and
the steadily declining
natural resources affect not only the
cost of asphalt mixes per se, but is
forcing the industry to go green.
Today, every professional in the field
understands that going green is
not just a fashion statement or
eyewash, but it is posing a very
crucial question about survival. It
is impossible to be profitable
without being green.
Sustainability is no longer a
‘nice to have’ accessory for
business – it is an essential
requirement, and must be built into
all our goals and policies. The
benefits of working responsibly and
sustainably are immediate as well
as long term. Many of our
customers are looking for us to
demonstrate publicly our
commitment to working sustainably
and report on performance.
108
There are numerous methods
that the road building industry has
adapted to reduce their energy
consumption and to be more
carbon friendly. The urgency is so
great that at each level starting form
equipment design to production and
laying techniques, focus has to be
consistently placed on reducing the
carbon emission.
This technical note describes
the various techniques available
and presently being implemented
world over for production of Low
energy asphalts or Carbon friendly
mixes. Production techniques for
warm and half warm mix asphalt
either use chemical or mechanical
solutions. The modifications made
to existing plants in order to produce
low energy asphalt by chemical
methods (additives) are minor,
whereas more significant
modifications must be made to
mechanical methods (foam bitumen
Blesson Varghese,
Director, Marini
Fayat India.
or sequential coating). This paper
covers the possible solutions and
provides A summary on its
advantages.
Beginnings
It is highly unlikely that we can put
an exact date on the emergence of
the concept. Since the mid 20th
century, and the industrial
development of hot mix asphalt
(HMA), engineers have had a cheap
energy source at their disposal with
the environment only a minor
concern. Good Practice stipulated
that the asphalt had to be around
150°C. Since bitumen is
hydrophobic, coating is that much
easier when the aggregates are
dry. The European production
standard nevertheless states that
the maximum residual water
content of HMA is 0.5%. In the
1970s, when TSMs (dryer drum
mixers at parallel flow) developed,
NBM&CW MARCH 2011
Asphalt
excellent results at 130°C were
nevertheless noted, with a residual
water content of 1%, especially
during compaction.
Coating attempts with foam
bitumen subsequently developed in
the 1990s in the UK, South Africa,
the Netherlands and France. The
concept of warm and half warm
mix asphalt was first mentioned in
the late 1990s, particularly by
JENKINS [1] , and alternative
techniques to foam bitumen
flourished in all countries, notably
Scandinavia, with sequential coating
techniques using several types of
bitumen.
A typology of the mixes was
officially described by Dr. Jacques
Bonvallet from FAYAT Group in 2000
[2], with reference to the heating and
drying energy used during the
process. The 100°C border is
widely discussed and there are two
schools of thought: one that
recommends staying shy of the
100°C mark for the sake of making
vaporisation energy savings (1/3 of
the total energy), and the other
which recommends vaporising
water while remaining within the
110 to 130°C range, which also
saves around 30%.
The last decade, in Europe at
least, has been characterised by
Figure 1: Mixes typology FAYAT GROUP [2], Low ambient température, medium
moisture content
110
an increase in methods – some of
which are experimental. We have
recently been seeing a segregation
of processes that are becoming
simpler and can be split into two
families:
- chemical processes in which the
use of an additive makes it
possible to reduce the bitumen
viscosity and perform high-quality
coating;
- mechanical processes, which
either involve sequential coating
or coating with foam bitumen.
We can suppose that
processes will become more
industrial and develop considerably
over the coming years. In France
they certainly accounted for some
500,000 t in 2009 for 40 million
tons of asphalt; the room for
progression may be significant, but
certain.
Low energy
production
One trend that seems to be
emerging is the production of
warm mix asphalt around
120/130°C using bitumen
with additives. The hypotheses
put savings at between 10
and 20%.
Without recycling and
depending on the humidity
(ignoring any water additions), the
calculated consumption levels of the
burner are as follows:
Some techniques are based on
temperatures below 130°C, and
even below 100°C. Reductions of
40 to 50% in energy consumption
or emissions are claimed,
especially during low-temperature
and/or low energy processes (LEP
and LTP) [3], [4].
Several studies conducted
jointly by inventors and the French
Public Works Research Laboratory
are under way, some equipping a
production plant so as to be able
to compare calculations to the test
data.
Chemical solutions
These solutions require the
injection of either solid or liquid
additives into the mixture. These
can be incorporated into the
bitumen or during the mixing stage.
In all cases, the plant must be
fitted with systems for storing,
transporting and metering additives
(flowmeter).
All of these processes
implement coating of the same
quality as HMA, whereas under
standard conditions, the bitumen
viscosity would not allow the
NBM&CW MARCH 2011
Asphalt
Photograph 2a & 2b: Introduction and monitoring of liquid additives, Specific pump for additives, Specific incorporation of part of the
aggregates to be properly coated.
Adding water to monitor the water
content is always necessary, and it
is water that bestows workability
and therefore the aptitude for
compaction.
Mechanical solutions
These solutions are perhaps more
complex and based either on the
process using foam bitumen,
injected with a system of injectors
placed above the mixer, or on the
creation of foam in the mixer over a
very short timeframe in dispersed
Photograph 3: Containerised metering kit of liquid asphalt
112
aggregates or additives
form. To do this, the company
applies a sequential process,
bringing the water and hot bitumen
into contact in the mixture.
Several methods co-exist – the
injection of foam directly by injector
seems simpler and less expensive
to implement, for less investment.
Fairly exhaustive laboratory
studies were published in 2008 on
this matter [5].
The peripheral equipment
required is fairly simple and shown
in photograph 3 and 4.
Photograph 4: Storage of liquid
The Ultimate
sustainable mix
production
The combination of low energy with
recycling is a worthwhile solution
likely to be pushed to the extent of
obtaining high recycling levels. It
seems to us that the most suitable
equipment and – in all cases – the
most flexible for meeting these
objectives is that which comprises
two drums and an external mixer,
like the RMS TSR in photograph 5.
NBM&CW MARCH 2011
Asphalt
Photograph 5: TSR25
Since the energy consumed for
the RAP on the one hand and the
virgin materials on the other is
controlled in two drums, there is
total independence and optimised
rational management.
Advantages of Low
energy mix
production
♦ T° decrease by 30 or 40°C
♦ Substantial reduction in CO 2
emissions
♦ Combustible savings: 15 to 30%
♦ No bitumen vapour emissions
♦ Hot-mix easy-to-use
♦ Possible high recycling rate
MARINI Control system – ready for RAP mixes & Low energy mix production
114
MARINI MAC – Recycling & Low energy production ready
Is India ready ?
Most of the mechanical components
required for various techniques
used for low energy mix production
can be added on to any advanced
asphalt plant as an add-on kit.
Processing of RAP requires that
the plant is supplied with
adequately designed dryer drum,
bag house filter, burner system,
mixer unit, process automation and
control systems. The challenging
part of the operation is to add and
mix the special chemical /
sequence in the already fully
automatic process of asphalt mix
production.
Marini’s global experience and
expertise in the field allowed them
to anticipate the raise of these
technologies in India and hence
the plants supplied in India are
already configured with the required
accessories and process
automation, making production of
these energy saving mixes instantly
adaptable in India.
Comment on warm
mix asphalt
compaction
The influence of the temperature
on asphalt workability has long
been known, and summarised in
the Table below from the
manufacturer BOMAG. We can
particularly see that the necessary
energy for obtaining an equivalent
compaction between 120°C and
150°C is multiplied by 4.
In reality this means a higher
compaction requirement, either
through more passes or by using a
more powerful compactor.
The solution adopted in Europe
to monitor the subject firstly involves
controlling the residual water –
which improves workability and
therefore compaction in a small
amount – and secondly using
variable-energy compactors
belonging to the category of so-
called smart compactors, such as
Asphalt Manager [6].
Conclusion
We are going through a pivotal
period in which the significant rise
NBM&CW MARCH 2011
Asphalt
Photo 8: Bomag Asphalt Manager Bw 174 Ad
in sustainable development is
completely changing the way we
perform analyses. Carbon footprints
are still incomplete and our
profession is aware of the long
way we still have to go. That said,
use of eco-software is on the rise,
allowing for more accurate
analyses. The next step is
unquestionably the experimental
validation of these analyses.
Manufacturers of both continuous
and batch mix plants are now
offering tried and tested solutions,
and are willing to improve them. It
seems to us that French
techniques, particularly combining
recycling, integrated humidity
116
continuous production, are
producing an arsenal of adapted
solutions that have been developed
over the last decade and from which
our Indian customers can benefit
usefully and above all swiftly today.
With these new types of mixes, the
color of asphalt can be green, both
in terms of profitability and
sustainability.
References
♦ Mix design considerations for
cold and half Warm bituminous
mixes with emphasis on foamed
bitumen. Kim Jenkins, Thesis
September 2000, Stellenbosch
♦ IRF Congress in PARIS 2000,
Les mousses de bitume un
technique émergente
incontournable. J. Bonvallet
♦ Enrobage à basse énergie (EBE)
aux performances des enrobés à
chaud. A. Romier, M. Audéon, J.
David, Y. Martineau. RGRA No.
831 September 2004
♦ Les enrobés à basse
température: EBT. F. Ollard, C. Le
Noan, P. Huon. RGRA No. 846.
February 2006
♦ Effect of process parameters on
foam bitumen based Road
Material production at ambient
temperature Road Materials and
pavement Design journal
Cazacliu, Peticila, Colange,
Leroux, Bonvallet, Blaszczyk. 2008
♦ BOMAG Compaction guideline.
management, low energy and – for Handbook Boppard.
major projects – in-place
NBM&CW MARCH 2011
Equipment & Machinery
Concrete Overlays
T
he need has never been
greater for engineered
strategies to preserve and
maintain the nation’s pavements.
With shrinking budgets, ever
increasing traffic volumes and loads,
and the critical emerging focus on
infrastructure sustainability, highway
agencies and local road
consultants and municipal bodies
are being asked to “do more with
less” in managing their pavement
networks.
Agencies need to be proactive,
sustainable pavement mountainous
and rehabilitation strategies that
last longer and at reasonable costs.
In many situations, concrete
overlays or similar to “Thin White
Toppings” represent such
strategies. They offer cost effective,
versatile, short-and long-term
solutions for the full range of
concrete, asphalt, and composite
pavements needs. In addition, they
contribute to more sustainable
construction practices by preserving
pavement service for several
decades beyond original service life.
120
Many concrete overlays have
been in service for decades,
extending the life of the original
pavement structures for 30 years or
more! Because concrete distributes
the traffic loads over a wide area,
the underlying pavement does not
experience highly concentrated
stresses. As long as the original
pavement remains stable and
uniform, a concrete overlay can be
placed, replaced, or recycled as
needed for maintenance and or
rehabilitation cycles.
In this manner, the concrete
overlay systems can be sustainable
for 100 years or longer. Rather than
removing and reconstructing on year
on year basis adding top coats
which give away within weeks of
facing rains or heavy traffic
conditions, a concrete overlay
effectively returns its original
investment within 2-3 years of the
differential cost and does away with
yearly maintenance and suffering to
the general public and saving a lot
for nations spending.
There are several genuine
benefits of the Concrete Overlays:
1) Concrete Overlays consistently
provide cost effective solutions.
Rupee for Rupee they are one of
the most effective long-term
maintenance and rehabilitation
options for the existing pavements
with distress.
2) Concrete Overlays can be
constructed quickly and
continently as
a) The existing pavement does not
need to be removed.
b) Simple operations of surface
milling or scarifying is enough for
“bonded overlays”
c) Few or no pre-overlay repairs
are necessary or even desirable
in most cases.
d) Concrete Overlays are placed
better using TRTP Fixed Form
with Gang Mounted Vibrators or
such machines with normal
construction practices.
e) Many concrete overlays can be
opened to traffic within 3-4 days
to traffic from date of placement.
NBM&CW MARCH 2011
Equipment & Machinery
f) Accelerated construction practices
can be used throughout the
normal construction season.
3) Concrete Overlays are easy to
repair.
4) Concrete Overlays are durable
rehabilitation tool and most cost
effective option
5) Concrete Overlays can survive in
and of themselves, as complete
preventive maintenance or rehab
solutions, or can be used in
Keeps You Updated With all Aspects of Civil Engineering
and Infrastructure Projects.
Subscribe Today for Just `960 per year
NBM&CW MARCH 2011
conjunction with spot repairs of
isolated distress.
6) Concrete Overlays enhances
pavement sustainability by
improving surface reflectance,
increasing structural longetivity
and enhancing surface profile
stability.
A recent event has carried this
feature at a heavily trafficked junction
near Electronic City where with the
joint inputs of Ultratech and ACC
NBM&CW
“Disseminates to Develop”
and the vital study by
their team and the
approval of the Bruhat
Bangalore Mahanagar
Palike a 4 lane road
stretch of almost 10,000
SQ. Mtrs with equipment
from Allen Concrete
Pavers (USA) a leader in
Fixed Form Paving
technology with more
than a dozen machines
performing at various
sites in India was
selected for this sensitive
task. The project has
been successfully
executed to the
satisfaction of the
general public and the
inspection agencies too.
Once the outcome is
quantified and
c o m m e r c i a l
considerations weighed
against the age old practice of
asphalt top coats and repeated
costs etc are tabled, it is expected
to save the agency enough to divert
funds to more creative infrastructure
needs while the Concrete Overlaid
pavements meets the best ride
quality and almost nil involvement
of rehab for years to come is a
new chapter herald by the citizens
of Bangaluru.
For further details please contact:
Fax: +91-22-2556 8044
E-mail: chetansk7@gmail.com,
abpl@bom5.vsnl.net.in
121
New Approaches
Enterprising Approaches in the
Successful Construction of a Toll Motorway
(East Link) Through Suburban Melbourne, Australia
Ken Mathers, Chief
Executive Officer,
Linking Melbourne
Authority, Australia
Overview
A 39 kilometer toll motorway was
constructed on budget (A$2.5 billion)
and five months ahead of time. It
was opened in June 2008. This
project involved 17 interchanges, 88
bridges and twin three lane, 1.6 km
tunnels. It has three lanes in each
direction for 33 km and two lanes
in each direction for 6 km. EastLink
connects the eastern suburbs of
Melbourne and was delivered under
a Public Private Partnership (PPP)
arrangement by Connect East (listed
on the Australian Stock Exchange)
for the Victorian Government agency,
Southern and Eastern Integrated
Transport Authority (SEITA). Project
development was undertaken by
two of Australia’s largest contracting
organisations, Thiess and John
Holland, in a joint venture
arrangement.
This paper describes the
uniqueness of the project,
construction practices and the
working relationship with owners
and contractors that led to a
successful outcome. This project
has set new standards in design,
construction speed, safety,
122
Arun Kumar, Professor
of Infrastructure
Management Queensland
University of Technology,
Brisbane, Australia
environmental impact, community should be achieved. Interestingly,
engagement and significantly the document produced was a
enhanced the urban amenity of the fraction of the size of a normal
corridor. specification, yet spelt out the
Background State’s requirements. It had set
targets such as a 100 year design
The road reserve for this corridor
life for structures.
was planned in the early 1960’s.
The specifications provided for
Environmental impact statements
the road to fall within a certain route
were developed and consulted with
envelope but the exact alignment
the community living along the
was variable; the shape of the
corridor in the 1990’s. As Melbourne
continued to expand, the
construction of the Motorway
became imperative. Work
commenced in March 2005 and
was completed in June 2008. An
overview of the motorway section is
being presented in Figure 1.
Performance Based
Specifications
Right at the tendering stage,
considerable thought was given to
encourage competition in the private
sector to achieve the best outcome
for the Motorway. One of the key
elements was devising the
performance based specifications
that would make it clear what was
needed without specifying how it
Figure 1: EastLink Motorway overview
NBM&CW MARCH 2011
New Approaches
interchanges was open to variation,
and the pavement had to perform
to a certain standard yet its make-
up was not prescribed. Urban
design had to be a part of the mix
and the bids had to show that they
reflected community expectations
along the route. The requirement of
the tolling system was that it had to
be fully electronic and it had to be
interoperable with other electronic
toll roads in Australia. Toll levels
were not prescribed with the only
requirement deemed that escalation
had to match movements in the
Consumer Price Index (CPI) with
changes being applied annually.
Both design and construct contracts
were self-monitored by Quality
Assurance (QA) procedures and
checks as work progressed.
The Independent
Reviewer
The Independent Reviewer (IR) was
appointed jointly by the Government
and the Concessionaire. The IR’s
role involved a general overview and
reasonable checking in order to be
satisfied that the various detailed
checks and monitoring processes
were carried out correctly and, in
order to ensure compliance with
the design construction
requirements. This organisation
reported jointly to the two
employers, ensuring impartiality
between the two client sides. All
design and construction information
developed by the contractor had to
be provided to the IR who had the
responsibility to certify completion
before the road could be opened.
Working
Arrangements
For the processes to be efficient,
tight timelines for making
comments were agreed by all
parties to ensure the contractor was
not unduly held up waiting for
responses. This arrangement was
successful as effective working
relationships and flexibility were
124
established between the people
working on the project (the
contractor and the two client
bodies). An electronic tracking
system was implemented and
improved the efficiency of the
documentation flow.
Another efficient process
implemented was that construction
itself was subjected to Quality
Assurance (QA) processes. The
contractor was responsible for
auditing and guaranteeing its own
systems according to appropriate
QA standards.
The Construction
Challenge
The Tunnel: The construction of the
$600 million twin tunnels was a
complex operation. The diameters
of each tunnel exceeded 16 meters
with special ventilation buildings at
the exits. These buildings
incorporated large fans to capture
the air leaving the tunnel and the
car exhaust contained in it. The
excavation was undertaken by four
large machines known as road
headers. These have a rotating
head with cutting teeth at the end
of a pivoting boom for cutting away
the material at the heading of the
tunnels, Figure 2.
Figure 2: The road headers carving the rock away with multi-toothed
rotating pick-axes
The tunnel was also fully
“tanked.” This means that it was
made watertight, rather than
allowing water to trickle in the tunnel
and then draining it out. This was
done by having a circular cross
section for the tunnel and using a
drainage blanket and waterproof
lining, Figure 3. An overview of the
tunnel is presented in Figure 4.
The Bridges: For most of the
88 bridges, pre-cast reinforced
concrete units were used for speed,
quality and economy. In the case of
an operational railway line which
overpassed the new road, the
construction schedule was planned
in such a way that it was closed
only for a very short time. This was
achieved by first, installing the
foundations and final columns of
the new bridge and then the
crosshead supports for the bridge
super structure. The foundations of
the four-span bridge comprised 1.8
metre diameter bored concrete
piles which could be installed
outside the train “envelope,” Pairs
of the piles at each of three pier
positions and for the abutments
were put in through the existing rail
embankment. They went into the
ground as support but stood free in
the top few metres once the ground
was excavated around them,
NBM&CW MARCH 2011
New Approaches
Figure 3: Full tanking (waterproofing) with a membrane
forming the columns of the bridge.
The super structures, complete with
new rail tracks for the new railway
overpass, was built alongside the
operational railway on the
extensions of the crossheads.
Times for completion is
simultaneously with the bridge
structure. The super structure was
slid in after a weekend so that the
railway was ready for the peak rail
operation at the beginning of the
working week.
A 500 tonne mobile crane was
used for lifting heavy crossheads
Figure 4: Tunnel overview
126
wall panels, retaining wall fascia
units and bridge pier sections. This
ensured tight quality control of all
structural elements and other pre-
cast products and achieved a better
result than that normally achieved
by onsite casting. Most of the bridge
beams were Super Tee Beams, a
V-shaped trough with a flat base
and flat projections at the top. The
special design was developed in
Australia and is now widely used
on major road projects. A key
advantage of the design is that it
can be produced in various depths
for different span lengths.
The tolling system: A multi-lane
free-flow Electronic Toll Collection
(ETC) system was used. The
recognition by vehicles is automatic
and beams for bridge construction
through electronic tags mounted
throughout the project. Some of the
inside the vehicle which are not
bridges including the rail bridge over
required to slow down or stop as
the motorway are shown in
Figure 5.
Use of precast segments for
construction: The contractor
decided to establish a special
precasting yard for the manufacture
of pre-cast reinforced concrete
elements. During the two year
operation, the yard produced over
23,000 pre-cast units, of a wide
variety from bridge beams and
parapet panels to assorted noise
Figure 5: Newly constructed bridges over the
motorway
NBM&CW MARCH 2011
New Approaches

Noise walls: Over 13,000 noise

wall panels were installed. The
sections of noise walls were
different in shape and colour to
improve the visual appearance and
better integrate with the surrounding
environment and look as natural as
possible. Typical wall panels,
including transparent sections, as
shown at Figures 7 and 8 were
manufactured precast at the precast
fabrication yard.
Road construction: The
construction work involved three
lanes in each direction for 33 km,
two lanes in each direction for 6
km. This involved over 7 million
Figure 6: Free flow electronic tolling system cubic metres of earthworks, 1.1
million tones of asphaltic concrete,
and 380,000 cubic metres of
concrete. Asphalt laying was a highly
coordinated large scale logistics
exercise in its own right during
construction (Figure 9).

Concluding Remarks
EastLink has proven to be one of
the most successful toll road
projects in Australia delivered as a
Public Private Partnership. Thirty
months after opening, traffic growth
is continuing at an incredible 10%
per annum and neighbouring
communities are praise worthy of
the delivered outcomes.
Key success factors included
clarity in contractual documentation
Figure 7: Typical coloured noise wall and understanding of the roles of

they pass under the toll gantries.

This electronic tag complies to
agreed standards and can be used
throughout Australia on all other toll
roads. Along its 39 km length
EastLink has 13 tolling points each
with two gantries (Figure 6). This
tolling system has the ability to
handle 4.5 million vehicle passages
(transactions) per day. The twin
gantries also enable vehicle
detection systems to record
registration plate details should
vehicles not be equipped with the
electronic tag. Video tolling is also
possible. Figure 8: A typical noise wall along the Motorway

128 NBM&CW MARCH 2011

New Approaches

respective parties, early

establishment of organisational
structures, the rapid recruitment and
training of human resources,
establishment of a project specific
pre-casting yard, bridge construction
using standardised pre-cast
elements to the maximum extent
possible, establishment and
retention of highly effective working
relationships between the project
parties, continuous community
engagement and the early resolution
of construction issues, as well as
environmental enhancements and
the provision of urban amenity
outcomes throughout the corridor.

Reference:
EastLink: Melbourne’s Motorway
Figure 9: Asphaltic concrete laying Masterpiece, Connect East SEITA

NBM&CW MARCH 2011 129

Concrete Additives

Effect of
Dosing Sequence of Micro Silica
on Slump & Compressive Strength of Concrete
Silica fume has been successfully used in production of high performance
and high strength concrete for the past couple of years. The benefits of
using silica fume for enhancement of durability and improvement in the
S.B.Kulkarni - AVP, Technical
microstructure of concrete are already well established through various
Services & Hemendra S,
researches and other developments. Few years back, it was a normal
Manager, Technical Services.
practice to introduce silica fume in the concrete mix in slurry form.
UltraTech Cement Ltd.
However, currently silica fume is dosed in dry form at most of the batching
Mumbai.
plants. In this paper, an effort has been made to study the effect of dosing
sequence of silica fume in the concrete mix in dry form, on the slump and
strength characteristics of concrete.

Introduction ♦ Setting of plant involved an different dosing sequences and the

additional capital investment. results were compiled.
Micro Silica is a mineral composed
♦ The pot life of SF slurry is in the
of ultrafine (fineness in the range
range of 30 to 40 minute, so it Sequence of Micro silica
of 15,000, m2/kg) amorphous, glassy
had to be used within short span dosing in dry form in the
spherical particles of silicon dioxide
of time. concrete mix:
produced during manufacture of
♦ Traffic Jams delayed the
silicon or ferro silicon. The average A. General Practice:
movement of transit mixer and
particle size is less than 0.5μ It has been observed that at most
sometimes led to dosing of slurry
meaning that each microsphere of of the batching plants, the various
even after the lapse of pot life
silica fume is about 50 times ingredients of concrete and micro
period.
smaller than an average cement silica are loaded in mixer in the
♦ If slurry is not used within pot life
grain particle. The ultrafine particles following sequence:
period, the interaction between
of micro silica fill the gaps between 1) Coarse Aggregate and Fine
water and silica fume particles
the cement particles thereby helping Aggregate
brings down the effectiveness of
to fill the micro voids in the fresh 2) Cement & Micro silica + Additives
silica fume.
concrete. These particles also act (Fly ash / Slag)
♦ In Metro cities, it might be difficult
like ball bearings and make the 3) Mixing of (1) & (2) for approx 30
to allocate an additional land to
concrete more cohesive. Earlier it sec
set up separate unit for silica
was a common practice to use 4) Water & Chemical Admixture
fume slurry production.
micro silica in slurry form in order 5) Mixing for another, approx 30 sec
As such use of silica fume in
to ensure uniform distribution of 6) Unloading the mix
dry form is considered the most
micro silica in the matrix. However, B. New Practice explored for
suitable and convenient system.
there were many issues faced at experiment.
However, the effect of sequencing
site in introducing silica fume in It was decided to explore
of dosing of micro silica on concrete
slurry form. possibility of changing the dosing
slump and strength properties (at 7
Issues faced earlier while using system of micro silica while
and 28 days) need to be studied.
silica fume (SF) in slurry form: keeping the mix design proportion
To study the impact of dosing of dry
♦ Separate plant has to be set up same for all the ingredients and to
silica fume, experiments were
for converting silica fume into study its effect on slump and
conducted in the laboratory with two
slurry form. compressive strength of concrete.

130 NBM&CW MARCH 2011

Concrete Additives

For this experiment various mixed together for 90 seconds and

materials used were: thereafter balance ingredients
♦ Cement – UltraTech Slag cement namely Fine Aggregates, Cement
conforming to IS 455. etc. are added. In both the cases,
♦ Admixture – Reobuild R620 of initial slump was measured
BASF. followed by slump measurement at
♦ Micro Silica – Elkem. 30 minutes & 60 minutes. Total 12
Grade of Concrete – M35. cubes were casted for each trial for
Trials were conducted in the measuring the compressive
laboratory in Pan Mixer: (40 litre strength by
Capacity) 1. Accelerated Curing Test
Trial A- In this first Trial, 2. At 3 days View of Cube Casting under progress
following sequence was followed 3. At 7 days
for introducing silica fume in the 4. At 28 days Discussion on Test
mix The results as referred above
1. Coarse Aggregates were compiled as given below: Results
2. Fine Aggregates Location: UltraTech RMC Lab, i. Slump test results (as per IS
3. Cement Mumbai. 1199 — 1959)
4. Micro Silica ♦ Initial Slump — In
5. Water Trial A slump was
6. Plasticizer 115mm whereas in
7. Mix all together for 2 minutes. Trial B initial slump
was 170mm
indicating that there
was increase in
slump by 55mm
(47.8% increase).
♦ Slump at 30
minutes — In Trial A
slump was 80mm
whereas in Trial B
slump was 140mm
indicating that there
was increase in
Mixing of ingredients in the process slump by 60mm
(75% increase).
♦ Slump at 60
Trial B- The following sequence
minutes — In Trial A
was followed in second trial, as
slump was 70mm
given below:
whereas in Trial B
1. Coarse Aggregates + Micro Silica
slump was 125mm
followed by
indicating that there
2. Dry mixing for 90sec
was increase in
3. Fine Aggregate
slump by 55mm
4. Cement
(78.5% increase).
5. Water
6. Plasticizer Slump Test for Trial A Slump Test for Trial B
7. Mix the ingredients for 90
seconds.
From the above two trials, it
can be seen that in Trial A silica
fume is added after all Coarse
Aggregates + Fine Aggregates +
Cement have been put in the mixer,
whereas in Trial B silica fume is
added after Coarse Aggregates and

132 NBM&CW MARCH 2011

Concrete Additives
It is interesting to see that in
Trial A & B the quantity of various
ingredients is same, that includes
quantity of water & plasticizer used.
Normally, the slump increase
happens either by increase in the
quantity of water or plasticizer or
both. But in this case, it is seen
that without changing the mix
design proportion or adding extra
quantity of water / plasticizer the
slump for trial B has increased
between 47% and 78% just by
changing the sequence of dosing
of silica fume (as given in Table 2).
ii. Compressive Strength test
result:
a) Accelerated Curing Test cube
results (Conforming to IS 9013 –
1978 - Reaffirmed 1999)
As mentioned above in the
article, concrete cubes were tested
by using Accelerated curing test
method and results were tabulated
as mentioned in Table 3. It is seen
that for Trial A, the anticipated 28
days strength was 43MPa, whereas
for Trial B it was 45.56MPa. In this
case also, the change in sequence
of micro silica dosing has resulted
into increase in accelerated curing
test result value for Trial B by 5.95%.
b) Concrete cube results (as per
IS 516 – 1959 - Reaffirmed 1999)
Concrete cubes (150x150x150mm)
were casted, cured and tested for
3,7 & 28 days compressive strength
as per standard procedure. From
Table 3, it is seen that for Trial A
the 3, 7 & 28 days strength was
noted as 24.58MPa, 31.76MPa &
40.16MPa respectively, whereas for
Trial B the compressive strength
was noted as 27.87MPa, 37.29MPa
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134
& 45.66MPa respectively. It is again
interesting to note here also that
the compressive strength for 3, 7 &
28 days for Trial B have increased
by 13.38%, 17.41% & 13.70%
respectively as compared to test
results of Trial A. Here also except
for change in dosing sequence of
micro silica no other changes were
made in the mix.
Conclusion
♦ It can be seen that introduction
of micro silica in the mix
immediately after adding coarse
aggregates and then mixing the
same for 90 sec, has changed
the test results considerably both
in terms of slump and
compressive strength.
♦ The test results show that without
adding additional water or
plasticizers the slump values
have enhanced by 47% to 78%
and the compressive strength
values have enhanced by 13% to
17%.
♦ The results are very encouraging
as increase in slump values can
facilitate reduction of plasticizer
dose & enhancement in
compressive strength can facilitate
reduction in the cement content
thereby leading to optimisation in
the cost of concrete mix.
♦ It is felt that at construction site
the Quality Managers should
conduct similar trials based on
the findings of the above referred
article and try to get best benefit
in terms of additional retention of
slump or reduction in the
plasticizer dose resulting in ease
in placing, compaction & finishing
of concrete, reduced honey comb
and also optimization of the
concrete mix design cost without
spending extra penny for the
same.
♦ It is hoped that the contents of
the article would give further
guidance to Quality Managers for
exploring the benefits of changing
the dosing sequence of micro
silica, to their full advantage.
Acknowledgment
Authors acknowledge the
experience shared by Mr. S.C. Verma
Ex HCC, Q/C Head, on the similar
trials conducted earlier.
References
♦ IS 456 – 2000 – Plain and
Reinforced Concrete – Code of
Practice.
♦ IS 455 —1989 — Portland Blast
Furnace Slag Cement.
♦ IS 10262—2009 – Concrete Mix
Proportioning – Guidelines.
♦ Neville on Concrete by Adam
Neville.
♦ Construction Technology by Prof.
M.S. Shetty.
♦ Mineral Admixtures in Cement &
Concrete Vol 4 by S.N. Gosh & S.
Savkar.
♦ Concrete Micro structures,
Properties & Material by P.K.Mehta
& P.J.M. Monteiro.
♦ IS 1199 – 1959 (Reaffirmed
1999) - Methods of Sampling &
Analysis of Concrete.
♦ IS 9013 – 1978 (Reaffirmed
1999) – Method of making, curing
and determining compressive
strength of Accelerated cured
concrete test specimens.
♦ IS 516 – 1959 (Reaffirmed 1999)
– Methods of Test for Strength of
Concrete.
NBM&CW MARCH 2011
Equipment & Machinery

Powerscreen India
Serves Oman
P
owerscreen, one of the world’s leading
providers of mobile crushing, screening and
washing equipment, has announced that its
state-of-the-art manufacturing plant in Hosur, Southern
Bangalore, has expanded distribution in India and
also across emerging world markets.

In one recent example, Arabian Transport for

Heavy Equipment purchased a Powerscreen ®
Chieftain 2100X Screening plant from General
Engineering Services Est which was manufactured
at the Powerscreen Hosur facility. The Chieftain 2100X
is working in combination with the Powerscreen®
4242SR already owned by Arabian and is producing
aggregates of 0-5 mm, 5-10 mm, 10-20 mm and 20-
40 mm for a commercial construction company who
have been awarded a massive road construct project
in the Sultanate of Oman. “We were in need of a
screening plant which could achieve our desired
output and cater to the demand of our clients and
what better brand can be thought of other than
Powerscreen” said Mr. Awadh Shanfari, Chairman for
Arabian Transport for Heavy Equipments.
General Engineering Services Est, the
Powerscreen Dealer in Oman, entered into the market
with mobile crushing and screening plants and soon
found its sales figures going up. The dealership
sold more than 50 crushers and screens in four
years.
General Engineering Services Est brings world
class track mobile crushers and screens with sales,
parts and after-sales support. General Engineering
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For further details, please contact:
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E-mail: rajen.khoda@terex.com

NBM&CW MARCH 2011 135

Alternative Material

Use of Cement
Fly Ash and Gypsum as an
Alternative Material for Low Cost Housing
(Feasibility Study)
In Civil Engineering traditionally, we are using different materials in the
form of building units. Some of the building units which we are using for N.S.Naik, Asst.Prof., Civil Engg.
construction are bricks and concrete blocks. Especially for bricks we Dept. SRES C.O.E. Kopargaon,
have to use good plastic clay as primary raw material. This clay is often U.P. Naik, Professor, Civil
obtained from prime agricultural land, causing degradation as well as Engg.Dept. PREC Loni,
economic loss due to diversion of agricultural land. Manufacturing of Tal.Rahata, Dist. Ahmed Nagar
bricks produces harmful gases which results in significant air pollution. and M.S.Purkar, Professor.,
This feasibility study is an attempt to use cement, flyash and waste gypsum Civil Engg. Dept. SRES C.O.E.
for the manufacturing of building units so as to replace the traditional Kopargaon.
building material at least partially.

Introduction
Traditionally, we are using burnt clay
bricks for construction. It is a clay
product which proved its importance
since the dawn of civilization. For
production of bricks, we are using
good plastic clay as primary raw
material. This clay is often obtained
from prime agricultural land,
causing land degradation as well
as economic loss due to diversion
of agricultural land. Though clay is
easily and abundantly available in
nature, its resources has a
threshold limit and utilization of clay
has reached such a point in
construction. Excess use of good
clay caused erosion of fertile soil
and soil degradation and disturbed
the ecology.
The burnt clay brick industry in
India produces over 60 billion clay
bricks annually resulting in strong
impact on soil erosion and
unprocessed emissions. For
production of these bricks about
160 million tones of top soil, making
barren 7500 acres of fertile land.
(1) Because of all these ill effects,
this is proper time to search an
alternative of the burnt clay bricks.
Use of Cement, Fly Ash
and Phosphogypsum As
An alternative for burnt
Clay Bricks
This is new technology which works
with the strength of fly ash, lime
and gypsum chemistry. The slow
chemistry of fly ash and lime is
maneuvered by tapping ettringite
phase to its threshold limits through
sufficient limit of gypsum. Therefore,
it does not require heavy duty press
or autoclave, which is otherwise
required in case of only fly ash and
lime. The process completely
eliminates the thermal treatment
(except open air drying) and does
not require combustion of any fossil
fuel. The ingredients of the units
such as bricks and blocks, fly ash,
lime (from OPC) and gypsum are
well-known minerals that are widely
used in the industries. All these
minerals are available in the form
of wastages and by-products from
industrial activities. In certain areas
where by product lime is not
available in adequate quantity,
Ordinary Portland Cement (OPC) can
be used as the source of lime
producing the good quality of bricks
and blocks. This technology is
proved to be environmentally safe
and sound.
Materials
Fly ash used for the present study
is obtained from the Thermal Power
Plant, Eklehara, Nashik. As good
quality of lime is not available in
the vicinity OPC is used as a
source of lime and Phosphogy-
psum (CaSO4 2H2O) is obtained
from Savil Agrovates, a Kopargaon
based company producing
agricultural product where

136 NBM&CW MARCH 2011

Alternative Material
phosphogypsum is available as a
waste.
Mix Proportions
As our main intention is to search
an alternative material for the
conventional burnt clay bricks by
using the waste materials and to
produce a low cost building
material, emphasis is given to use
the waste products to the maximum
extent and hence following mix
proportions are used for the present
study. The mix proportions are given
in the Table No.1 are in terms of
dry weights of the ingredients.
Shrinkage cracking is a major
weakness in gypsum based blocks.
Shrinkage cracking can be
minimized by keeping the water
content of the binder as low as
possible.
Methodology
Mixing of Raw Materials
The weighed quantity of
Phosphogypsum, Cement and fly
ash were thoroughly mixed in dry
state in a pan with the help of a
trowel. The mixture in dry state is
mixed till it attains a uniform color.
When the mixture attains uniform
color weighed quantity of water is
added in the mixture of fly ash,
cement and phosphogypsum. After
addition of the required quantity of
water the mixture is thoroughly
mixed with the help of trowel in a
pan. After mixing the mix initially
with the trowel the mixture is again
mixed thoroughly by kneading until
the mass attained a uniform
consistency.
To calculate the quantity of
water to be added Standard normal
consistency test was performed and
140
the water content for the normal
consistency was determined. The
water content used in the mix for
strength tests was 90% of that
required to produce the standard
normal consistency.
Preparation of Mortar
Blocks
Standard cement mortar cube
moulds of size 70.7mm x 70.7mm
Graph No.1: Variation of Compressive
x 70.7mm were used for preparation Strength with age for M-1 Mix
of blocks. The mixed binder was
placed in the cube mould and was
compacted properly by rod. Excess
paste was hand finished. The
mould was filled in three layers
and each layer was compacted
properly.
Method of Curing
The blocks were taken out from the
moulds after 24 hours. After removal
from the moulds the blocks were
kept for air drying for 2 days. After
sufficient strength was gained,
these blocks were transferred to
water filled curing tanks.
Experimental Work
To check the feasibility of Cement,
F.A. and P.G. binder as an alternative
material for traditional burnt clay
bricks following tests are performed
on the binder.
1) Compression Strength Test
2) Water Absorption Test
Above tests were performed as
per Indian Standards (18), (19)
Graph No. 2: Variation of Compressive
Strength with age for M-2 Mix
NBM&CW MARCH 2011
Alternative Material
Graph No.3: Variation of Compressive
Strength with age for M-3 Mix
Graph No.4: Variation of Compressive
Strength with age for M-4 Mix
Water Absorption Test
After casting the cubes of each mix
proportion, the cubes were
immersed in water and after 28
days of curing the cubes were taken
out of the curing tank and their
saturated mass was recorded after
the cubes were kept in oven at
1050C and dried to a constant
mass and dry mass of the cubes
was recorded. After that finding the
difference between the saturated
and dry mass percentage water
absorption was calculated.
142
Density Test
After 28 days of casting, the cubes
was dried to a constant mass in
an oven at 1050C they were cooled
to room temperature and their
density was obtained
Summary of Test
Results
Table No. 2 shows summary of all
tests results.
Test Results and
Discussions
A large number of blocks were
made with different proportions of
fly ash, cement and phosphogyp-
sum. The experimental results are
presented in graph No.1 to 4 and
Table No. 2. The results of
compressive strength are presented
in Graph No.1 to 4, Graph No. 1 to
4 show the compressive strength
of cubes having different proportions
of fly ash and phosphogypsum. The
results indicate that the
cement, F.A. and P.G. Mix have
potential to use as building
material as an alternative for
traditional burnt clay bricks.
This is due to the fact that fly
ash acts as a source of
reactive Silica and Alumina, to
give Calcium Sulphoaluminate
and Silica hydrates, which are
responsible for strength. It is
observed that the strength of
these blocks increases with
age. The maximum
compressive strength of these
blocks can be obtained with a
specific proportion of the
ingredients. It can be observed
from the test results that the
strength of the cubes
decreases as the percentage
of fly ash and phosphogypsum
increases. From the results
of water absorption, For mix
M-1 (with 50% fly ash and
phosphogypsum) and for M-2
(with 60% fly ash and
phosphogypsum) the
percentage water absorption is
almost same. For 70% and 80% fly
ash and phosphogypsum water
absorption decreases.
For economy, the fly ash and
phosphogypsum content should be
kept as high as possible. The
minimum average crushing strength
prescribed in Indian code for burnt
clay bricks is 3.5 MPa (20). As the
compressive strength at 7 days for
M-4 is 5.63 MPa and that at 14
days is 9.96 MPa, it can be said
that the material is having adequate
strength to produce bricks
from it.
From Table No.2 it can
be observed that the water
absorption of cubes in the
present investigation was
obtained to be in between
24.91% to 30.37%. As per
NBM&CW MARCH 2011
Alternative Material
the code (20) the water absorption
of ordinary burnt clay bricks should
not be more than 20% by weight.
Clearly the water absorption for
some proportions is more
compared to that of traditional burnt
clay bricks. Nevertheless such
bricks can be used for curtain wall
and partition walls where the
consequences of the high water
absorption capacity will be less
severe. However, this aspect
certainly needs further investigation.
The weights of various
designated cubes are found to be
less than that of ordinary burnt clay
bricks. The reduced weight of
Cement, F.A. and P.G. will provide a
working comfort and ease of
handling, in addition to reduction in
dead weight of structures.
Conclusion
Based on the experimental
investigation reported in this study,
following conclusions are drawn.
Unique possibility exists for the
bulk utilization of fly ash in
producing bricks from Cement, F.A.
and P.G. in the proximity of thermal
power plants, phosphoric acid and
fertilizer industries.
The test cubes are having
sufficient strength and have
potential as a replacement for
conventional burnt clay bricks.
Cementitious binder with fly ash
and phosphogypsum content equal
to 80% gives better compressive
strength and 20.25% water
absorption and thus suitable for use
in construction industry.
Being lighter in weight, Cement,
F.A. and P.G. mix will reduce the
dead weight and material handling
cost in multi storied constructions.
The utilization of wastes in
making cementitious binder will
help in solving the disposal and
health hazard problems. It is further
needed to develop awareness
among users, professionals and
financial supporters for using these
waste materials for techno-
economic reasons in addition to
balance economy and achieve
144
energy conservation. The use of fibers on compressive strength of
these wastes for building industries Kaolinite, proceeding of National
will definitely reduce the conference at Ludhiana, CEMCT-
environmental pollution which will 2006,Nov.2006,pp.207-210.
be there because of use of burnt ♦ Ismail Demir et al., Effece of
clay bricks. Such products can be Silica fume and expanded perlite
used for low cost construction addition on the technical
practices. properties of the fly ash-lime-
gypsum mixture, construction and
References
Building Materials, 2007
♦ N. Bhanumathidas and N.
♦ Stefania Grzeszczyk et al., Effect
Kalidas, The role of Fal-G, The
of Super Plasticizers on the
Indian Concrete Journal, July
reheological properties of fly ash
1992, pp.389-391.
suspensions containing activators
♦ R. Ambalavanam and A. Roja,
of the pozzolanic reaction, Cement
Feasibility studies on utilization of
and Concrete Research, June
waste lime and gypsum with fly
2000,pp.1263-1266.
ash, The Indian Concrete Journal,
♦ Amit Mittal et al., Parametric Study
Nov.1996,pp.611-616.
on Use of Pozzolanic Materials in
♦ Kumar Sunil, Utilization of Fal-G
Concrete, New Building Materials
bricks in buildings, The Indian
and Construction World, October
Concrete Journal, July 2001,
2006,pp94-112.
pp.463-466.
♦ Environmental and Social Review
♦ Kumar Sunil, Utilization of Fal-G
for Fal-G bricks projects, Eco
bricks and blocks, Construction
Carbon Private Limited, Jan 2006,
and Building Materials,.
pp.6-14.
♦ Dr. D. Sree Rama Chandra
♦ Manjit Singh, Dr. Mridul Garg,
Murthy et. Al., Conventionally
Environment Friendly Building
reinforced concrete beams with
Materials from Waste Gypsum,
Fal-G cement in flexure, CE and
NBM&CW, June 2007, pp.116-126.
CR, Sept.2006,pp.47-53.
♦ www.Science direct.com
♦ S.Marinkovic and A. Kostic-Pulek,
♦ www.fal-G projects.com
Examination of the system fly ash-
♦ I.S.4031-1968, Method of physical
lime-calcined gypsum –water,
tests of hydraulic cement ( Part-I),
Science Direct Journal of Physics
Bureau of Indian Standards, New
and Chemistry of solids,
Delhi.
2007,pp.28-30.
♦ I.S.269-1976, Specification for
♦ ‘Shiqun Li, Jishan Hu, et.al, Study
Ordinary Portland Cement and low
on the weathering resistance of
heat cement, Bureau of Indian
fly ash-lime compacts, Science
Standards, New Delhi.
Direct, Cement and Concrete
♦ I.S.1077-1976, Specifications for
Research,34,2004,pp.753-758.
common burnt clay building
♦ Luciano Santoro and Ignazio
bricks, Bureau of Indian
Aletta, Hydration of mixtures
Standards, New Delhi.
containing Fly ash, lime and
♦ T.T.T.I., Chandigarh, Civil
phosphogypsum, Thermochimia
Engineering Materials, Tata
Acta,98 ,1986, pp.71-80.
McGraw- Hill Publishing Company
♦ A.K.Choudhary and J.N. Jha,
Limited, New Delhi.
Characteristics evaluation of fly
♦ M.S.Shetty, Concrete Technology,
ash for the stabilization of an
S. Chand and Company Ltd, New
expansive soil, proceeding of
Delhi
National conference at Ludhiana,
♦ M.L. Gambhir, Concrete Manual,
CEMCT-2006,Nov.2006,pp.199-
Dhanpat Rai and Sons, New
203.
Delhi
♦ Jagroop Singh, Effect of fly ash,
cement and randomly distributed
NBM&CW MARCH 2011
Investigation

Experimental Investigation
on Flexural Behaviour of Reinforced
Concrete Beams Strengthened by
Ferrocement Laminates
This paper investigates the flexural behaviour of reinforced concrete beams
B.Sivagurunathan, Selection
strengthened by ferrocement laminates. Totally five beams of length 3200mm,
Grade Lecturer in Civil
width 150mm and depth 250mm were cast and tested. A flat ferrocement
Engineering, Thiagarajar College
laminate 125mm wide, 25mm thick and 3000mm long was cast using cement
of Engineering, Madurai.
mortar as binder and weld and woven mesh as reinforcement. The experimental
Dr.B.Vidivelli, Professor in Civil
study shows that the ferrocement laminate increases the flexural bahaviour of
and Structural Engineering,
the distressed reinforced concrete beams. The aim of this project is to bond
Annamalai University,
ferrocement laminates to reinforced concrete beams and strengthen it against
Annamalai Nagar.
flexure.

Introduction
Increase in service loading,
environmental degradation, damage
of structure due to poor quality of
material and inferior design,
upgrading of old structures as per
new code and need of seismic
retrofit leads to the need of repair
and rehabilitation. Rehabilitation of
deteriorated civil engineering
infrastructure such as beams,
girders, bridge decks, parking
structures, marine structures, roads
etc has been the major issue in
the last decades. The need to
upgrade the deteriorated civil
engineering infrastructure greatly
enhances with the ever increasing
demands. Therefore rehabilitating
existing civil engineering
infrastructure has been identified as
an important issue to be addressed.
The strengthening of concrete
structures to resist higher design
loads, correct deterioration-related
damage, or increased ductility has
been traditionally accomplished
using conventional materials and
construction techniques. Externally
bonded steel plates, FRP and ferro-
cement laminates are some of the
traditional techniques available. In
the context of strengthening
problem, advanced composites
have the potential to prove another
promising solution.
Introduction to
Ferrocement
Ferrocement is a form of reinforced
cement mortar (micro concrete) that
differs from conventional reinforced
or pre-stressed concrete primarily
by the manner in which the
following elements are dispersed
and arranged. It consists of closely
placed, evenly distributed multiple
layers of mesh or fine rods
completely embedded in cement
mortar. Widespread use of
ferrocement in construction industry
has occurred during the last 40
years. The main worldwide
application of ferrocement
construction to date has been for
silos, tanks, roofs, irrigation
channels, manholes & covers, and
mostly boats. The construction of
ferrocement can be divided in to
four phases:
♦ Fabricating the steel rods to form
a skeletal (cage) framing system;
♦ Tying or fastening rods and mesh
to the skeletal framing;
♦ Plastering and
♦ Curing.
Review of Previous
Work
Ong.K.C.G, Paramasivam.P and
Lim.C.T.E. (1992),
In this study the methods of
strengthening of reinforced concrete
beams using ferrocement
laminates with skeletal bar attached
onto the soffit of the beams are
reviewed. The methods of
anchorage of the ferrocement
laminates in the strengthened
beams have been investigated. The
methods of increasing the ultimate

146 NBM&CW MARCH 2011

Investigation
load of the original beams using
ferrocement laminate and to control
the cracking behavior of the beams
as well the effect of the damage of
original beams prior to repair are
examined.
It is concluded that the
strengthened beams have
performed better in cracking
behavior, reduction in mid-span
deflection and increased ultimate
load. Further, the pre-cracked
beams prior to repair did not affect
the ultimate loads of the
strengthened beams tested.
Mohd Zamin Zumaat and
Ashraful Alam (2006),
In this study, methods of
strengthening of reinforced concrete
beams using ferrocement
laminates with skeletal bar attached
on to the soffit of the beams are
reviewed. The addition of
ferrocement laminates with skeletal
bar to the soffit (tension face) of
the beams substantially delayed
the formations of first crack,
restrained the crack widths and
increased the flexural stiffness and
load capacities of the strengthened
beams. The effects of curtailing the
ferrocement laminate short of the
supports were studied. In the
strengthening carried out in the
present work, the ferrocement
laminates were extended over the
supports. This however would be
difficult to achieve in practice.
Vidivelli.B, et al (2001),
In this study, the damage due
to overloading is considered. A total
of three beams were cast and
tested. One beam (control beam)
was tested to ascertain the load
deflection behaviour and ultimate
load. The remaining two beams
were damaged by overloading. After
unloading the damaged beam
specimens were repaired with
ferrocement laminates with single
layer at tension face using epoxy.
Static test was conducted on all the
beams to determine the load
deflection behaviour and ultimate
load. A comparison was made on
crack width, deflection and ultimate
148
strength at different load
stages between control,
damaged and repaired
beams.
Experimental
Programme
Material Used
For the beam specimen, the
concrete with design Figure
compressive strength of M20
was used. The concrete mix
proportions are given in Table1. 43
grade Portland Pozzalana Cement
(PPC) confirming to IS: 1489 –
1991, having a specific gravity of
2.92 was used. Locally available
river sand having a fineness
modulus of 2.61, specific gravity of
2.65 and coarse aggregates of
20mm maximum size, having a
fineness modulus of 6.97 and
specific gravity of 2.9, were used.
High yield strength deformed bars
of Fe 415 were used as
reinforcement in the concrete beam
For casting of the ferrocement
laminates Portland cement mortar
matrix, woven and welded meshes
of size 24 gauge are tied together
to act as reinforcement.
Ferrocement may require chemical
additives to reduce the reaction
between the matrix and the
reinforcement.
Figure 2: Preparation of distressed beam surface
Figure 3: Ferrocement laminate
1: Cross section and reinforcement
details of RC Beams
Details of Test
Specimen
Five beams were cast for flexural
test out of which one beam was
control beam the second and third
were tested for service load and
rehabilitated and the fourth and fifth
beams are retrofitted. For
rehabilitation and retrofitting
ferrocement laminates were used.
The details of reinforcement used
in the beam are as shown in the
Fig.1. Wooden moulds satisfying the
above specimen size were used.
Before casting, machine oil was
applied on the inner surfaces of
moulds. Concrete was mixed using
tilting type laboratory concrete mixer
and was poured into the moulds in
layers. Each layer of concrete was
compacted well. The specimens
NBM&CW MARCH 2011
Investigation
Figure 4: Bonding of laminnates to the beam
Figure 5: Experimental setup
were removed from mould after 24
hours of casting and then cured
using jute bags. All specimens were
moist cured for 28 days.
Bonding of
Ferrocement
laminate to beam
Before bonding the fabricated
ferrocement laminates on the soffit
(tension side) of the concrete beam,
surface was made rough using
sand blasting and cleaned with an
air blower to remove all dirt and
Figure 6: Load vs Deflection
150
The rehabilitated and retrofitted
beams were again tested by two
point loads and at the end of each
load increment; the deflection was
carefully observed and recorded.
The recorded values are graphically
represented and are shown in Fig.6.
Results and
Discussions
From the test results summarized
in Fig.6, it can be concluded that
the rehabilitated beam with
ferrocement laminates 12% lesser
load than the controlled beam. The
retrofitted beam carries 18% more
load than that of control and 24%
of rehabilitated beam. Fig.6 shows
the ultimate load carrying capacity
of the beams with different
configuration.
Acknowledgements
The experimental work was carried
debris. Once the surface was out in the Structural Engineering
prepared to the required standard, Laboratory of Thiagarajar College
the epoxy resin was mixed in of Engineering, Madurai and
accordance with manufacturer’s Tamilnadu. We would like to thank
instructions. Mixing was carried out the faculty members of Structural
in a metal container with base to engineering Department,
hardener ratio of 1:2 and was
continued until the mixture obtained
AnnamalaiUniversity, Annamalai
nagar.
uniform colour. Then it was applied
both on laminate and beam surface References
and bonded properly without any ♦ Mohammad taghi kazemi and
air gap. Reza morshed (2005), “Seismic
shear strengthening of RC
Experimental set-up columns with ferrocement jacket”,
Two-point loading system was Journal of structural Engineering,
adopted for the tests. Vol.1.
At the end of each load ♦ Ong, K.C.G, Paramasivam. P and
increment, deflection Lim, C.T.E (1992), “Flexural
and ultimate load were strengthening of Reinforced
carefully observed and concrete beams using
recorded. The ultimate ferrocement laminates”, Journal of
load for the control Ferrocement, Vol.22, No.4, PP. 331
beam was found out. - 342.
Then the other two ♦ Vidivelli.B, Antony Jeyasehar.C,
beams (S) were tested Srividya P.R. (2001),”Repair and
for service load and Rehabilitation of Reinforced
rehabilitated with concrete beams by Ferrocement,”
ferrocement laminates. In proceedings of the Seventh
The other two beams International conference on
(R) were retrofitted with ferrocement, Singapore, PP. 465
ferrocement laminates. – 470.
NBM&CW MARCH 2011
Products & Technologies
Polished Concrete Floors
Anant Shekhar Sahay,
Vice-president Business Development-
South East Asia, Bomanite India.
A
lthough currently there are no
industry standards specifying
concrete tolerances specific
to polished concrete, manufacturers
as well as installers are coming up
with their own set of standards to
obtain a quality polish job. On new
concrete installations that will
ultimately receive polishing, certain
performance criteria need to be met
so the polishing company can
perform a uniform quality job.
On new concrete installations,
the concrete mix design is critical.
Using a cement-rich concrete
(typically 3,500 psi) provides a
dense surface free of voids for the
polishing process. We can also
use many times water-reducing
admixtures to keep a low water
cement ratio without jeopardizing the
workability during the concrete
placement. Wet curing of the new
slab is an excellent way of curing
but many times it is not practical. If
this is the case, dissipating liquid
applied curing compounds are a
152
good way to cure the slab. Any
remaining curing compound that
does not dissipate over time is
usually easily removed during the
coarse-grinding phase of the
polishing process.
Of equal importance to the
appropriate mix design is how the
concrete is placed and finished. The
flatness and levelness of the
concrete substrate is crucial not
only for a uniform polish, but also Adding colors to polished
how the project is bid. Floors that concrete, either integrally or with
have excessive highs and lows will stains and dyes, can create a
require a tremendous amount more distinctive look for your floors.
Acid staining or dyeing is a
grinding, increasing your labor costs
great method of achieving color on
as well as the costs of your
polished floors. Different applicators
diamond tooling.
have different methods and time
According to industry standards,
frames of applying the stains and
finished concrete shall have a
dyes. We have had excellent results
minimum Floor Flatness rating of
with applying dyes around the 400-
at least 40. The industry standard
grit phase. Let’s review the process:
for terrazzo is no more variance
♦ Coarse grind with 40-grit metal
than 1/4 in. in a 10-ft. span, which
bond (if necessary)
can also be applied to polished
♦ Grind with 80-grit metal bond
concrete. If the slab is being
♦ Apply densifier
machine troweled with walk-behind
♦ Grind with 150 metal bond
machines, it is imperative to not
♦ Remove scratch pattern from 150
leave indentations or boot marks
grit with 100/200 resin bond
behind since they are not easily
♦ Remove scratch pattern from 100/
removed during the polishing
200 grit with 400 resin bond
phase.
♦ Apply color stains or dyes
The main methods of coloring
♦ Polish with 800-grit resin bond
polished concrete consist of
♦ Polish with 1,500-grit resin bond
integrally coloring the concrete mix
♦ Polish with 3,000-grit resin bond
or staining or dyeing the surface
There are certain situations that
after the fact. By far the easiest and
the consumer may not choose a
most controllable method is to
3,000-grit polish. Most Home
integrally color your concrete. Most
Depots or Lowe’s, for example,
integral color is either in the liquid
typically are polished to 800 grit.
or powder form and added at the
There are many levels of polished
ready-mix batch plant and then
mixed for a specified time. Color
loads for integral color should never
be smaller than 3 cu. yds. for color
consistency. Colored aggregate or
crushed glass can be added to the
concrete mix or hand seeded into
the top layer of the mix. The
polishing process will reveal the
underlying aggregate.
NBM&CW MARCH 2011
Products & Technologies

an extremely hard surface and

helps preserve the finished floor.
Because most of the material
penetrates the surface and is
applied very thin, scuffing or
scratching is usually not a problem.
Dealing with edges up against
walls is always an issue. If the
polished surface is to terminate
directly against the wall, there are large investment. Talk with
floors that stop short of truly being
walk-behind machines to address manufacturers of polishing
“polished concrete,” but have their
this. Most of the time, tooling by equipment and ask why their
own unique and distinctive look.
hand with grinders and diamond equipment and services are better
For the professional polisher, it
pads is necessary. Another way to than others. Make sure you have a
is often debatable if some type of
address edges is to use different market to support the hefty
topcoat is needed with some
mediums and create a border investment. Polishing machines can
claiming that it defeats the purpose
making the edge an architectural also be used for other applications,
of polishing relative to the ongoing
feature. We have had great results such as adhesive and coatings
maintenance. Especially when
saw-cutting a border in and then removal or to prepare surfaces for
using dyes, we feel that it is
using cement based skims or decorative overlays, to name a few.
necessary to apply two thin coats
colored epoxy.
of reactive penetrating sealer to help For further details please contact:
If you are considering to pursue
lock the color in. If applied properly Tel: +91-22-30400329, 30500781 (D)
the polished concrete market, make
- over a clean surface in multiple Fax: +91-22-24385770
sure you do your homework. The
thin coats (1,500 to 2,000 sq. ft. Email:anantsahay@bomaniteindia.com
purchase of equipment can be a
per coat per gallon) - this provides Website: www.bomaniteindia.com

NBM&CW MARCH 2011 153

 Post Event Report

bC India
Displays CE Progress
and Promises

154 NBM&CW MARCH 2011

 Post Event Report
The first edition of bC India was
successfully organized jointly by bC
Expo India, AEM, and MMI along
with BAI at Mumbai from February 8
to 11, 2011, effectively projected
technical, marketing and managerial
capabilities of the construction
equipment industry. The mega
event not only brought global
market leaders of the industry
together but also offered an
extensive range of construction
equipment products and services
with special focus on construction
equipment market in India
representing earthmoving
equipment, mining, production of
building materials, components,
and services. Over 500 exhibitors
from 30 countries participated in the
show with overwhelming presence
of around 70% international
exhibitors and remaining being
Indian exhibitors. The event had
nine international pavilions from
Australia, China, Finland, France,
Germany, Italy, Korea, Spain, and
the UK. Coinciding with the event,
there were number of conferences,
seminars, and buyers meets;
several new products and services
were launched by the participating
NBM&CW MARCH 2011
and services available globally, the
best B2B opportunities to all the
national and international
participants of this trade fair.
In his presentation, Eugen
Egetenmeir, Managing Director of
Messe Muchean International (MMI)
stated that in construction
equipment manufacturing and
marketing, there has been
movement from West to East. The
huge international presence at bC
India, shows the serious interest of
the global players to understand
the Indian CE manufacturing and
marketing so as to take the best
advantages of the emerging
opportunities that India’s
infrastructure development and
progress offered. He urged the
authorities to facilitate creation of
state-of-the-art exhibiting facilities as
demand for such events is
increasing in this country. President
national and international
AEM, Dennis Slater said he was
companies.
convinced that bC India will indeed
Speaking at the inauguration of
play a very important role in the
bC India, Thomas Loffler, CEO, bC
Indian market in the near future.
Expo India said that the endeavour
The three days mega event
at their end has not only projected
witnessed high ranking visitors from
the best of national and
national and international
international technical
construction equipment companies
developments in construction
leveraging the event to project CE
equipment manufacturing relevant
progress in India and abroad under
to completion of infrastructure
one roof. More than 22,000 visitors
projects in India but also offered an
from 69 countries attended this
opportunity to compare products
event.
155
 Post Event Report
As the curtain of bC India show
drew, a strong feeling was lurking
in the minds of all those who
participated and attended the event:
Will bC India turn to be a “Doosara,”
hopes and concerns persisted.
Whatever the way it goes, it was a
well availed opportunity to project
participants commitment and
concern towards progress and
promise of construction equipment
community to manufacture and
supply quality products and proven
services to the clients. Said one of
the important captains of the
industry, it is too early to give the
156
right assessment but what has
been seen in three days, is very
promising. India is a huge market
with potentials of continuous and
sustainable growth.The event
witnessed brisk sale of products
and services.
All is Well at CE End
At bC India, NBM&CW had an
opportunity to interact with a number
of national and international
captains of construction equipment
industry to supplement their
phenomenal efforts on expansion,
product development and new
products, and marketing initiatives
including their plans to build their
brands in India’s high growth
market. In such, interactive exercise
busy schedules at both the ends
was an important factor in the
reckoning. The detailed reports on
interactions in the form of Interviews
and new launches would follow in
the next issue of NBM&CW, but
some of the interactions are
reported in brief in this edition.
During the interactions all
appeared to be well for most
companies as they were quite
optimistic towards their business
performance. With market becoming
more competitive, the companies
were seen to be diversifying into
new business areas, fine tuning
their existing operations, unveiling
their ambitious investment
plans and gearing up fast to encash
emerging business opportunities
that the growing infrastructure
offered in India. Markets are
expanding and so were the ways of
the companies to reach them was
the common theme of this
interaction, sending a strong and
loud message about their inherent
technical fundamental and
capabilities, nationally and
internationally, reports NBM&CW's
Editorial Team.
NBM&CW MARCH 2011
 Post Event Report
The demand for cranes is going up
in almost all sectors due to
increasing infrastructure
development work in the country,
more so in port and power sectors.
Of late, it is picking up in the
construction sector (such as cement
and real estate), said Mr. Raman
Joshi, Managing Director, Manitowoc
Cranes India. Manitowoc, he added
is well-equipped to fulfill and serve
the burgeoning market with Grove
mobile cranes, Potain tower cranes
and Manitowoc crawler cranes. The
demand in the tower crane
segment is also going up.
Manitowoc’s factory in Pune
manufactures tower cranes of
various capacities up to 10 ton
which is adequately fulfilling the
project needs of the country. Such
top slewing tower cranes are
competent enough to fulfill the
needs of construction related
projects. The Pune factory is well-
equipped to manufacture quality
Potain tower cranes. The higher
capacity Potain tower cranes, from
Manitowoc’s factories in Europe, are
160
Manitowoc
also being used in the important
Government and private sector
projects.
Manitowoc has also invested a
lot to further upgrade Manitowoc
Crane CARE Service facilities. It is
altogether different service concept
from those available in the market.
It is a satisfying concept for our
clients assuring them of maximum
investment return on their crane
assets. The service is rendered
from different locations in the country
as per requirement. Manitowoc
places great importance on training
and retraining personnel, operating
and maintaining for safe operation
of its crane so that no untoward
mishaps can take place while
operating the crane. Feedback
received from the users of our
cranes indicates that Manitowoc
products are of superior quality,
reliability, serviceability and
unmatched technical attributes with
capacity requirements and global
engineering concepts integrated in
the manufacturing thus enabling us
to provide innovative mobile
solutions, said Mr. Joshi.
Maximum jib length on the MC
125 is 60 m and in standard form,
the crane has five possible jib
lengths, including the 60 m
maximum. The others are 30 m, 40
m, 50 m and 55 m. It also has a
maximum free-standing height of
44 m but can reach much higher
by telescoping and tying off to
structures. The crane’s maximum
capacity is 6 t while at the 60 m jib
end, it can lift 1.15 t.
The crane’s lifting technology
includes a double trolley allowing it
to lift 3 t when working with a single
trolley or 6 t when working with
both. Two versions of Potain’s
established 24 kW 33PC15 hoist
are available with the crane.
When working with a 480 V
power supply, the 33PC15(GH),
which has 400 m of rope available
for high-rise building work, can offer
lift speeds of up to 96 m/min when
carrying 1.5 t on the hook. The
regular 33PC15, which has 260 m
of wire rope available, can reach
90 m/min when working with the
same load.
The GT25-5A is a 25 t capacity
crane mounted on a three-axle
carrier. It has a five-section 40.2 m
telescopic boom that offers a 49 m
maximum lifting height when
working with the jib. Power for the
crane comes from a Sinotruck
WD615.92 engine, compliant to
Euro III standards, offering a power
output of 196 kW at 2,200 rpm.
The engine drives a hydraulic
system that includes a four-circuit
pump that automatically combines
pump flows to speed up operations,
as needed. In addition, a variable
flow hydraulic motor provides the
flexibility for optimal line speed. The
crane is suitable for tower cranes
erection and to set up industrial
projects.
NBM&CW MARCH 2011
 Post Event Report
Sandvik Mining and Construction
unveiled many exciting products at
the show including its first
representative of a brand new range
of Basic Breaker BA2424 specially
designed for the Indian market.
bC India 2011 was not only
seen as the perfect opportunity for
Sandvik to launch its Basic Breaker
line in India but also to showcase
recent developments with a
particularly Indian flavor and to
highlight commitment to the Indian
sub-continent market place as a
whole, and to India in particular,
said R Srinivasa Raghavan, Vice
President Construction Segment,
Sandvik Mining and Construction
Limited.
Simple in design, Sandvik’s
new Basic Line utilises fewer
working parts for reduced
maintenance, together with lower
ownership and operating costs. The
Basic Line Breakers includes many
162
Sandvik
innovative design elements; they
possess a sealed nitrogen piston
type accumulator in order to protect
the carrier’s hydraulic pump during
operation from pressure peaks in
the breakers hydraulic circuit. The
design also incorporates a long and
heavy piston that is aligned with a
genuine Sandvik tool, there-by
ensuring optimum impact energy
transfer with less recoil, in order to
minimize carrier wear.
Available in three different
housings – Box type, Side plate,
and Pin on type – the Basic Line
Breakers are easy to mount and
operate. Silenced box type housings
offer increased noise reduction,
making them specifically suitable
for urban applications. Although
simple, the Basic Line benefits from
proven technology, the use of
genuine Sandvik parts produced
from only the highest quality raw
materials, all manufactured to
Sandvik quality control standards.
In order to highlight
commitment to India, Sandvik’s
impressive stand also had different
product lines, interactive
presentations and unprecedented
access to key people within the
Sandvik Mining and Construction
organization. Some of the products
shown include: Breakers (BR3288,
BR4099 and BR2155), Basic Line
breakers (BA2424),
crushing (the Indian
produced UJ300/310,
US310/UH310 and
UV310 semi mobile
plants & CJ 411 Jaw
Crusher, SV1262 Grizzly
feeder), Tunnelling
(DT820 Booms), Drilling
(DQ500 drill rig).
All Sandvik products
have been developed
working in conjunction
with some of the world’s
leading quarrying and
construction companies.
This ensures that
Sandvik produces the
right equipment, for the
right application with all
features that ensure
customers benefit from
the highest levels of
productivity, but the
lowest levels of cost of
ownership and vitally
with minimal environmental impact.
Sandvik Mining and
Construction has recently
experienced a dramatic increase in
sales throughout the Indian sub-
continent. This growth has been
particularly strong in the product
lines that have been developed for
India’s specific requirements, many
of which are manufactured in India
itself. The increasing demand for
Sandvik products demonstrates that
Indian buyers are keen to utilize
advanced, high-quality construction,
and mining equipment.
NBM&CW MARCH 2011
 Post Event Report
Tractors India Limited
Tractors India Limited (TIL)
launched its new TMS 875 truck
crane at bC India. The five axles
truck crane has a maximum lifting
capacity of 75 tons at 3 meters
working radius and comes with a
four section trapezoidal boom with
boom length varying from 11.0
meters to a maximum of 34.6
meters with 360 degree slew.
Maximum road speed of the truck
crane is 50 km/hr and is powered
by AL 680 TCAC 235 HP engine @
2200rpm.
According to Mr. S.K. Bhatnagar,
Director & President, Materials
Handling Division, TIL “TMS 875
comes with a purpose built chassis
designed and manufactured by TIL
itself, made out of extra high
strength steel obtained from
Japanese and European sources.
Drive line has been sourced from
Indian manufacturers. Four
164
outriggers have been provided to power of 118hp@2500 rpm. The
provide extra stability to the gross vehicle weight is 10,500kg.
machine. Hydraulics have been As per Mr. Bhatnagar: “TMS 10 will
obtained from leading European compete in certain areas with pick
manufacturers.” He said “with the n carry cranes in the Indian market.”
quality features, the product is a Mr. SK Bhatnagar also briefed
better offering as compared to about TIL Group’s plans to expand
European and Chinese cranes to its product portfolio, particularly its
Indian customers at a competitive crane range and related expansion
price.” and diversification programme, The
Material Handling solutions division
at present manufactures, markets
and services
equipment pertaining
to diverse material
handling needs, as
well as port and road
building solutions.
Currently, TIL produces
nearly 200 mobile
cranes a year at its
Kolkata factory. A
second factory is being
set up in Kharagpur to
manufacture higher
capacity crane
products with an
investment of Rs 100
crore. The new facility
which will be fully
modernized and state
of the art is expected
to be ready by 2013,
he informed.
TIL compreh-
ensive product portfolio
TIL also launched its new TMS covering various critical sectors,
10, 10 ton truck mounted crane.TMS along with its upcoming
10 can lift 10 tons @ 3 meters manufacturing facilities is expected
working radius. The crane comes to transform the Group into a
with a three section boom varying formidable and forceful icon in the
from 7.8 meters to a maximum of construction equipment and
19 meters. The maximum working material handling solutions space,
radius of the crane is 17 meters large enough and strong enough
and maximum tip height is 25.7 whose impact could be seen in the
with jib. The two axle truck with four next 2-3 years or even earlier as it
outriggers is mounted on Indian, proceeds with its most ambitious
Ashok Leyland chassis with rated and diversified expansions.
NBM&CW MARCH 2011
 Post Event Report
Discussion with Mr. Kevin R
Thieneman, President Caterpillar
Asia Pte Ltd covered
Remanufacturing as Cat’s new
focused area, global and Indian
construction equipment market
scenario, policy
measures impacting business
environment and strengthening of
Caterpillar’s presence in India.
On Remanufacturing in which
the company has been a big votary
both at WTO and in India, Kevin
made his stance very clear that it is
the most economical manufacturing
route. In the present contest, it
appears to be a good concept
where cost of manufacturing counts.
It is a time tested and economical
concept offering best solution for
high end and other sophisticated
products. Low quality products lack
sophistication and high tech
attributes rendering operations
unproductive as well as
uneconomical. It is going to be
economically unviable to
manufacture these like inventing the
166
Caterpillar
wheel once again and hence the services acquired. Playing on
prime need for promoting pricing for a foothold in the
remanufacturing suitable to a business is no longer valid in the
particular region’s industrial present context. Competition is
requirement. Remanufacturing per becoming more stiff where service
se should not cause worry as being components, product life cycle would
seen in some quarters. The sway buyers choice. Internal cost
impression that it could lead to reduction in manufacturing and
dumping second hand products is product development, enhanced
not quite well founded and there is cost absorption and increased
no need to cry wolf about it, was efficiency level would hold the key
the advice from Kevin. to sustain competition. Competition,
we firmly believe will
drive the growth for
all, he opined.
B u s i n e s s
environment in India
has improved a lot.
But concerns are still
there on policy
dithering taking place
from time to time
especially on
environment issues
and this need to be
sorted out for a
stable policy regime.
We have great
confidence on Indian
market place. This
has been our focus
in the past and it
would continue in
future too, offering
new product line
towards meeting
The markets scenario India growing infrastructure
internationally and nationally in India development needs. Our road map
is undergoing a sea change. With for India is constantly evolving,
recovery now being more broad- depending on the need of local
based, demand and supplies are demand. We are expanding our
improving a lot. So is the profile operations with appropriate
and mind-sets of the buyers. investment plans and, strengthening
Buyers in the market place are our market reach. With these
being seen as far less sensitive to measures and reorienting them
the price factor as was the case in from time to time as local
the past. They are gradually requirements and demand, we will
becoming more value addition continue to serve as effectively as
conscious demanding better possible and participate in the
technical attributes and assured infrastructure development in India
comprehensive back up technical not only actively but also proactively.
support for the products and
NBM&CW MARCH 2011
 Post Event Report
The just concluded bC India was
really a very well-arranged and in
fact it was for the first time when
such an event took place in India
where all major Indian construction
equipment manufacturers and a
good number of suppliers from
different parts of the world were
present. Due to this magnificent
Talking about German participation
at bC India, Mr. Rajesh Nath,
Managing Director VDMA India said
VDMA office in India is an important
contact point for Indian companies
168
Soilmec
success, it has now become one
of the most important construction
exhibitions in India for future, said
Mr. Sanjoy Chakrabarty, MD, Soilmec
India on the sidelines of the event.
He further stated that the
association of BAI for this event
was indeed one of the major
reasons for its success, good
VDMA
to interact with German construction
equipment manufacturers as more
than 65 important companies from
Germany have participated in this
mega event under German pavilion.
The Indian office of VDMA
has facilitated their
presence in this show.
According to Mr.
Nath, German machinery
manufacturers view India
as a good market for
their products and
services and are very
attendance of builders and
contractors from all over the country
and BAI session at the same time
in Mumbai offered opportunities to
its members to visit the show. The
number of visitors from all over the
world including SAARC countries
was really beyond our expectations
and as an exhibitor we were more
than happy to see this that people
took this event very seriously.
At the show, we displayed CFA
kit and an innovation of the 24mts
CFA conversion kit to fit on a std
SR-40 which is going to be the
future of India once CFA starts
working. Also displayed were our
SR-30 with a grab which could
travel with a grab mounted, SM-14
and also locally manufactured
products like tools and Desanders
in various panels.
Soilmec had a very attractive
two-storied stand of prefab structure
from Trimo where people loved
sitting on the terrace with a
panoramic view of exhibition ground
overlooking the BKC business
district skyline in the evening. We
did good business there and have
made a few good deals with some
important customers.
keen to participate in this growing
market, which is growing fast at
present both in size and in its
technological status. Apart from
setting up their manufacturing
facilities in India, many companies
are participating in Indian market
place through sales and services
outfits–all together promoting and
contributing to Indo–German trade
and economic ties. The total export
of German Construction Equipment
and Building Machinery export to
India touched `1080 crores in 2010.
NBM&CW MARCH 2011
 Post Event Report
Volvo Construction Equipment used
its extensive display at the show to
demonstrate its commitment to
improving fuel consumption and
lowering emissions in its products
– and also to underline the
company’s expanding product,
manufacturing and distribution
capabilities.
The star of the show was a
pair of the latest Volvo excavators –
the EC140BLC Prime and the
EC210B Prime ; the latter specially
adapted for work in granite, marble
& aggregates quarry applications.
These excavators are powered by
Volvo engine and engineered to
match the hydraulic for superior
excavator performance. EC140B
Prime comes with the bucket
capacity of 0.52/0.57/0.75 Cu.m and
operating weight of 14 tons where
as EC210B has bucket capacity of
0.85/0.92/1.22 Cu.m and operating
weight 22 ton. Both the models are
equipped with correct boom/arm/bkt
170
Volvo
configuration and undercarriage to
suit the tough site conditions and
delivers 20-25% more productivity
and economical in terms of Tons /
Litres.
Volvo provided the full range of
road building equipment – Hydraulic
Excavators, Wheel loaders, Motor
Graders, Soil and Asphalt
Compactors, Pneumatic Tyre
Rollers and Paver Finishers. This
show was featured with display of
two types of road machineries –
ABG 4361 Paver Finisher and DD
80 model Asphalt Compactor.
ABG 4361 is the virtual partner
in paving business of every road
construction company - A result of
optimum Owning cost, High degree
of Paving quality and Ease of
operation and transportation. It is
extremely versatile in operation with
paving width that can be
continuously varied from 2.5m to
4.75m, with the extensions up to
5.5.m with add-on segments and
can pave up to 300 mm thickness.
Volvo DD 80 Asphalt Compactor
provided with multi layer thickness
capability with 8 amplitude settings
ensuring faster compaction. Its
automatic reversal of eccentrics
matches the direction of travel for
smooth mat finish, combined with
higher dynamic linear loads to
achieve densities with minimum
passes.
L120F is powered by fuel
efficient Volvo engine
and engineered to
match the drive train
and hydraulics for
superior wheel loader
performance. The
engine develops high
torque at low rpm
enabling excellent
load carrying
capabilities’ at low
engine speed thus
saving on fuel
consumption.Volvo’s
patented lift arm
system TP Linkage
combines high
breakout force and
excellent parallel
movement throughout
the entire lifting range.
Volvo also used
this platform to
highlight its extensive
portfolio of products
and services that are designed to
support the range of machines.
Emphasizing on the benefits of
Genuine Volvo Parts in servicing
and maintenance duties, the Volvo
stand promoted the introduction of
Reman Hydraulic components into
the Indian market.
Volvo has recently invested in a
new factory Remanufactured
Component Centre in Bangalore
whose technicians expertly restore
a range of components to an often
NBM&CW MARCH 2011
 Post Event Report
better-than-new standard (‘Better’
because components are upgraded
to the latest iteration of that unit’s
development). 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. This program is a
natural extension of Volvo’s
commitment towards a greener
Liebherr displayed its LR 1600/2,
600 ton crawler crane at BC
2011.According to Mr. A.K. Somani,
Representative Director, Liebherr
India Private Limited: “The crane
with its versatile features and 10
percent more lifting capacity as
compared to a contemporary
product of similar class, is most
suitable for Indian applications.” He
explained: “Irrespective of weight
and size, the crane is ideal for
transportation as jib sections can
be inserted in main boom section
for transportation. Besides, the
172
environment. In short, Volvo
Reman is the economical,
convenient and reliable way to
maximize uptime and extend the
service life of the machine.
Another highlight at Volvo stand
was a CareTrack – Volvo’s
telematics system that allows
remote monitoring and machine
diagnostics on all general purpose
machines – which is now available
in India as standard and comes
LIEBHERR
crane can self load and unload its
superstructure and self fit its
crawlers, thus making it ideal for
working in rural and altogether
remote areas in India, where
getting skilled manpower is quite
critical. The crane comes with
special attachments, making it ideal
for wind mill construction projects.”
Liebherr handed two LR 1600/2
two Bharat Heavy Electricals
Limited for construction of 800 MW
power projects. As per Mr. Somany,
the crane can be used for
construction of thermal power plans
from 500MW-800 MW.
with a free three-year subscription.
While CareTrack offers customer a
number of advantages, a primary
one is the ability to effectively
manage machine maintenance,
servicing and repair through the
system’s ability to ‘see’ how the
machine is performing, Genuine
Volvo Parts and CareTrack are both
proving useful in maintaining
machinery in optimal condition and
achieving maximized uptime.
The crane can lift maximum
600 tons at11 metres working
radius with a boom length of 42
metres. With 48 metres boom
length, LR 1600/2 can lift 600 tons
at 10 metres working radius. Main
boom of the crane is 108
metres without derrick. It
can be extended to 144
metres at which it can lift
83 tons at eight metres
working radius. Luffing jib
is 96 metres. Combination
with main boom and luffing
jib is 188 metres. With
main boom the derrick
attachment is138 metres
and fixed jib is 36 metres.
190tons is the main
counterweight and 65 tons
at the carbody. With derrick
attachment, the main
counterweight can be 150
tons and 65 tons at the
carbody. The derrick ballast
can be provided at as tray
type and wheeled bogie
type.
Mr. Somani informed: “LR 1600/
2 comes with a novel boom system
with only one head section. The
crane has variable derrick
adjustment system without guiding
under load . It can be used with
main boom and luffing jib without
derrick configuration. While working
continuous, change of derrick
radius can be undertaken.
NBM&CW MARCH 2011
 Post Event Report
Liebherr handed the displayed
LR 1600/2 to Western India based
crane hiring company, Shethia
Erectors and Materials handlers
Limited. The key was handed by
Mr. Jan Liebherr. Sister Ms. Sophie
Liebherr was present during the
occasion.
Liebherr also displayed its 71
EC-B5 Flat top tower crane. The
Mahindra & Mahindra Ltd
Mahindra & Mahindra (M&M)
launched its ‘EarthMaster’ Backhoe
Loader at bC India. The launch
coincided with Mahindra’s official
announcement of entering into the
construction equipment business.
Highlighting the technical
attributes of the EarthMaster,
Mr.Kairas Vakharia, Business Head
-Construction Equipment, M&M said,
“Earth Master is powered by
Mahindra’s DITEC Engine, a
compact 3.3 litre engine which
delivers best in its class 83 HP.
The design of the DITEC engine
combined with direct injection with
turbo charger & intercooler delivers
over 10% fuel savings per hour as
compared to contemporary
174
crane can lift a maximum load of
5tons at 15.0 metres jib length,4.15
tons at a jib length of 20 metres
and at 50 meters maximum jib
length it can lift 1.0 tons at 2.4
metres working radius. According
to Mr. Hans Martin Frech, Marketing
Director, Liebherr-Werk Biberach
GmbH, : “71 EC-B5 does not require
products. The DITEC engine is fully
loaded with latest technology to
minimize emissions that meets BS
III norms.” The Earth Master is
manufactured at Mahindra’s plant
at Chakan in Pune at a state of
the art plant with integrated welding,
painting and assembly facilitates..
The project cost of the new
business is Rs.300 crores.
The EarthMaster is the only
backhoe loader in India with
standard joystick controls, and is
also equipped with the latest
generation of hydraulics,
comparable to those on large
crawler excavators, that allows for
precise, simultaneous movements
of the backhoe. The EarthMaster
separate vertical sections to be
created, as it gets pushed up by
hydraulics during the course of
construction of the building. With
the hydraulic pushing system, the
crane can be deployed in lift shafts
and at outside the building as well.
“The crane is suitable for highrise
construction above 260 metres.
comes with a unique
REMOTECARE ™ feature enabling
its owner to keep track of the
machine’s operating status using a
mobile phone. In addition,
EarthMaster has a cockpit that
provides voice and text messages
to operators related to machine
functions and warnings in six
different Indian languages.
In terms of customer support
the EarthMaster will come with a 2-
year warranty unlimited hours
warranty. The company has made
a dedicated sales and service
network to cater to the requirements
of it construction equipment
customers, which will include over
200 dealer sales, service and
spares parts outlets, 200+ service
vans to reach customers’
construction sites, 12 area offices,
one central parts warehouse, and
regional parts warehouse to supply
dealers and a call centre supporting
nine languages.
Mr. Vakharia estimated that the
backhoe loaders market size is
about 25,000 units wherein M&M
has installed a capacity of 200
machines per month which could
be scaled up very quickly as the
demand increases. The company
is planning to venture into the
production of other earthmoving
equipment. However, he declined
to give any time frame set by the
company for the new products.
NBM&CW MARCH 2011
 Post Event Report
Putzmeister GmbH, Germany, a
leader and global supplier of
Concrete Pumps, Tunneling
Machines, Industrial Pumps and
Mortar Machines made a notable
present at bC India. Mentioning
about their presence in India on
the sidelines of the show, Mr
Michael Schmid – Lindenmayer, MD
said, ‘Putzmeister has its state-of
the-art manufacturing plant in Goa
which is spread over 100,000 sq
m. Also we have a countrywide
sales and service network with
regional offices all over the
country. Our company is committed
to bring latest Technology to India
and believe in Best Products, Best
Quality & Best Service.’
Commenting on their products
Mr. Lindenmayer stated, Putzmeister
pumps have been deployed at
various prestigious projects and are
176
Putzmeister
the first choice of real estate and
infrastructure companies across
India. Our company is the champion
in highrise pumping and major
projects worldwide are executed
with our equipment. Putzmeister has
the Largest Truck mounted concrete
Pump in the World – M 70. In the
prestigious project of Burj Khalifa
Tower in Dubai, Putzmeister has
broken again its own World record
by achieving a pumping height of
over 606 m. Last year our BSA
1407 D made history by pumping
concrete up to a distance of 800 m
at the Delhi Metro Tunnel site, he
added.
He said further, our company
has been very active in introducing
new technology and products to this
strong growing market. It has
implemented new models for
customers which are very simple to
operate and very cost competitive
at the same time. Among the latest
introduction is Stationary Concrete
Pump BSA702D, designed for 20
cubic m/h and can be delivered by
a reversible drum mixer. Other in
line is BSF20.07, a very price
competitive and an ideal starter
boom placer for road contractors
and RMC companies which are still
not capable enough of
investing in a bigger
boom placer.
As far as the high
end products are
concerned, Putzmeister
has introduced the
BSA1409D based on
free flow hydraulics for
customer who requires
a higher output. In
addition, BSA1408HD,
a high pressure pump
which can pump
building with a height of
200 to 250 m was
presented. This model
accomplishes to be the
industry standard for
buildings of these
heights. And in order to
place the concrete on
top of the building
Putzmeister has
introduced stationary
boom systems called MX
in combination with the
pipelines, valve system, cleaning
stations, and accessories.
The Indian arm of Putzmeister
is also exporting its products to
Srilanka, Bangladesh, S. Africa and
South East Asia. In 2010,
Putzmeister in India has grown by
160% and has further increased its
market share in all product
categories.
NBM&CW MARCH 2011
 Post Event Report
Wirtgen India Pvt Ltd.
Wirtgen India, displayed its total
range of solutions involving Vogele
pavers, Wirtgen Road milling
machines, recyclers, slipform
pavers and the new Hamm 311
Soil compactors manufactured at
the Wirtgen India Pune facility.
Talking about their new
development Mr. P. Ramesh, CEO
& Managing Director, Wirtgen India
said that with the production of
Hamm single-drum compactors
311, we have developed a model
that is designed specifically for the
Indian market. This single drum
compactor corresponds to the high
standards of quality of the Wirtgen
Group but is manufactured locally
so that the pricing allows us to
prevail on this highly competitive
market. The 11 tonne single-drum
compactor for earthworks is a high-
180
performance compactor that caters
perfectly to the customary bidding
requirements in India. A team of
engineers and technicians from
India and Germany developed the
product and established and
qualified a new logistics chain
onsite in Pune that ensures that
the production line is supplied with
high-quality components, he
explained.
On the group presence in the
country, Wirtgen Group has
maintained a strong presence in
India since 1995 with local sales
and service centres in Mumbai,
Ahmedabad, New Delhi, Hyderabad,
Bangalore, Chennai, and Kolkata.
With the start of production of the
Hamm single-drum compactors the
workforce is being increased to
roughly 185 employees. We are at
the beginning of a major success
story in India and the country will
make its way in the world just like
the other emerging markets in
Brazil and China. And all brands of
the Wirtgen Group will profit strongly
from the market success because
we have made timely investments
in a local production facility.
Wirtgen India has
sold hundreds of
Wirtgen Group
machines in Indian
market in the last ten
years. With the start
of additional major
road construction
projects, this number
will increase
dramatically over the
coming years. In
order to guarantee
that the machines
would be overhauled
regularly and the
spare parts are
available for the entire
country, the Wirtgen
Group also invested in
a new workshop and
a large spare parts
centre in Pune.
Maximum four machines can be
overhauled at a time at the highly
advanced workshop which is also
equipped with a 20 tonne overhead
crane. The regional stores are
supplied with original Wirtgen Group
parts from the new main spare
parts depot that covers an
additional 600 m2 of floor space.
Customers can also be supplied
directly from Pune if necessary. The
entire parts dispatch process is
controlled via SAP.
NBM&CW MARCH 2011
 Post Event Report

Terex Mineral Processing Systems

Processing Systems Terex® step towards our commitment to Plant was on display which is an
Minerals Processing Systems leads serve the local customers with all electric plant which can easily
the industry with the most advanced locally designed world class be tied into new or existing
portable plants which now includes product range.” secondary, tertiary, and quaternary
the NEW Terex® WJ 1175 Wheeled Terex MPS would be looking at crushing applications.
Jaw and WC1000 Wheeled Cone/ strengthening its presence in India The WJ 1175 consists of Terex
Screen Plant. and across Asia with the launch of JW 42S Jaw Crusher Chamber with
Terex Mineral (Terex MPS) the wheel mounted product range. inlet opening of 1070 mm x 762mm
launched its new Wheel Mounted The product would target the (42" x 30") and comes with
Crushing & screening Plant Range Construction, Quarrying and Mining Hydraulic Closed Side Setting
arrangement. The WC
1000 consists of Terex
TC 1000 Cone Crusher
and Terex IV Deck
Screen. The secondary
chassis has been
designed with on board
hopper and feeder for
proper choke feeding of
the Cone Crusher.
Providing detailed
features of the Wheel
Plant range, Mr.
Shekhar mentioned,
“We now have the full
product range to meet
the needs of the fixed
site customers with our
static, Wheeled and
Modular Product
Range. Terex® Minerals
Processing Systems
provides a complete
range of crushing and
screening process
equipment to
customers around the
in India at the bC India Show. The segments. The machine has been world. With over 100 years in the
Plant consisting of Wheeled Mobile designed with many key customer minerals processing industry, Terex
Primary Jaw Crusher and friendly features and aims to be the MPS is dedicated to offering cost-
Secondary Mobile Cone Crusher best in the industry in terms of set effective solutions for the long
has been designed to suit the up time. term. The equipment range includes
needs of the local market. The Plant The Terex® Wheeled Crushing Terex® Canica, Terex® Cedarapids,
would be built at Terex & Screening Plant consisting of WJ Terex® Jaques and Terex® Simplicity
Manufacturing facility at Hosur, Tamil 1175 and WC1000 is built for models, plus new Terex® models
Nadu. According to Mr. Jaideep portability, especially for applications that we are continually developing
Shekhar, Director Sales & involving hard abrasive materials. to improve performance and
Marketing-Asia, “This is an important At bC India, the WC 1000 Cone efficiency.”

182 NBM&CW MARCH 2011

 Post Event Report
Greaves Cotton launched a
premium range of construction
equipment for the infrastructure
industry and with this, the company
augments its already formidable
presence with its wide range of
products in the 3 segments of
Concreting, Soil and Asphalt in the
infrastructure equipment industry.
Greaves Cotton (CED –
Construction Equipment Division)
launched a range of world class,
state-of-the-art-technology products
including Milling Machines, Paver,
Loader, and Twin Shaft Batching
Plant at the show.
The company brings the most
advanced, state-of-art BOMAG
Milling Machines to India with
advanced features like Front
Loading, Track Mount & Steering
and Auto Control & Auto Engine
Sany with US$ 7.5 Billion revenue
MNC, the largest Construction
machinery maker of China & a well-
known name in the concrete
machinery sector, participated and
demonstrated its comprehensive
product technology and services to
Indian buyers and international
184
Greaves
power regulation. These machines
are the latest technology in the road
construction industry and their
features enhance steering ability,
load distribution, safety & operator
convenience and efficiency resulting
in precision finish of roads. The
range comes in 1 to 2 metres and
is backed by Greaves service and
support assurance.
Also on display was the Paver
which 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 of Paver offers
faster operation, better productivity,
low and easy maintenance and
operator comfort which is a
hallmark of Bomag technology-
World leaders in road construction
Sany
Construction industry leaders. The
exclusive range of products that
were displayed included: Concrete
Pump 30C/40C/50C, Boom Pump,
Truck Mixer, Concrete Batching Plant,
Truck Crane, Crawler Crane,
Excavator, and Backhoe loader.
equipment technology.
Continuing from its earlier range
of loaders Greaves 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
column. This loader sets a new
benchmark in this segment with
operators comfort resulting in
improved productivity and efficiency.
In addition, Greaves also
presents its 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 structure. With
the promise of service and support
round the clock, this world class
technology product is low on
maintenance. This product further
establishes 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.
Sany for the first time exhibited
its backhoe loader and excavator to
the Indian buyers to fulfill the
emerging need of India’s
infrastructure sector. Its excavator
is equipped with an extra ordinary
Mitsubishi engine which is stronger
and most powerful drive with lower
NBM&CW MARCH 2011
 Post Event Report
maintenance cost and fuel
consumption.
Advanced CDCS computer
dynamic control system by electric-
control measures and hydraulic
measures realizes the real-time
match of engine power and main
pump power .It decides exactly how
much power the machine needs
and how much power the engine
provides. 4 power modes ensure
better energy saving result by
optimizing the parameters of power
and hydraulic system through
electric device control, realizing
better match result and maximizing
Kobelco displayed its CKE 2500,
250ton hydraulic crawler crane
which can lift 250 tons at a working
radius of 4.6 metres with a boom
length of 15.2 metres. With a
maximum boom length of 91.4
metres, the crane can lift 21 tons at
17.7 metres working radius. The
minimum and maximum length
luffing boom is 15.2metres and 61.0
metres. Long boom length ranges
from 64.0m to 91.4 metres.
Minimum fixed jib combination is
186
the energy saving effect. Automatic
idle speed arises when work stops.
The throttle opening automatically
reduces and the engine goes to
idle speed condition.
In addition, Sany also displayed
Compact Concrete Batching Plant
SBP05 which provides the complete
concrete solution for every
construction need the most reliable
and portable solutions from small
to mega construction project with
fully automatic and modularized
device for accurate weighing system
of cement, water, aggregate and
additives . This machine is fitted
Kobelco
27.4 m+12.2m and maximum length
combination 76.2 m+30.5m.
Minimum luffing jib combination is
21.3m+21.3m and maximum length
combination is 61m+61m. The
crane comes with a counter weight
of 90t and car body weight of 24.0
tons. The crane is powered by
water cooled Hino Diesel Engine
with rated power of 247kw at 2,000
rpm.
According to Mr. Nilesh Bhorkar,
Manager-Product Sales & Marketing,
with single shaft compulsory mixer
resulting in high efficiency and
homogenous mixing effect & Mixer
is designed with NO dead angle,
minimizing the residue and easy to
clean. The auto-lubricating system
extends the life of mixer and
ensures full reliability and also most
convenient and easy for dismantling
and transportation.
It has an aggregate loading
with boom scraper, eliminating the
need of backhoe loader and
reducing energy consumption. A
user-friendly HMI plus PLC control
system is equipped with a facility of
auto mixing as well as manual
mixing.
Also exhibited was Sany
HBT30C–1006DY Concrete Pumps
which has developed technology of
computer-controlled diesel engine
rotation speed to effectively improve
emission, decrease noises, and
have used most advances S-valve
technology for ideal performance. It
has full hydraulic steering open
system, low oil temperature, local
and remote control. The optimized
hoppers incorporated with lean
manufacturing technology are
featured by higher efficiency of
material suction and lower residue
of material. The maximum diameter
of mixable aggregate is up to
40mm, and concrete slump is 8cm-
23cm.
Kobelco Cranes India Private
Limited, “CKE 2500 is the best
selling segment in India and we
have sold 86 units so far. Seventeen
of CKE 2500 were sold to Bharat
Heavy Electricals for power plant
construction and also to rental
companies. The crane got good
response due to its versatile lifting
capabilities.” Kobelco sells hydraulic
crane with a capacity variants of
60-550 tons. The company has sold
the cranes capacities ranging from
NBM&CW MARCH 2011
 Post Event Report
60 to 135 tons to EPC contractors
in India. Voltas Limited is the
distributor for Kobelco hydraulic
crawler cranes in India.
Kobelco handed CKE 2500,
250ton crawler lattice boom crane
over to crane hiring company
Samarth Lifters Pvt Limited during
PROMAN Infrastructure Services
PROMAN Infrastructure Services Pvt.
Ltd. announced its technical
collaboration with Tesab
Engineering Limited of Ireland to
manufacture new line of mobile
crushers at bC India 2011. Briefing
on the association, Mr. R.S.
Raghavan, MD, PROMAN said,
188
the event. According to Mr. Prakash
Shah, Director Samarth Lifters, the
company will rent out the crane to
EPC contractors executing liquefied
natural gas projects and power
projects.
According to Mr. Nilesh Bhorkar,
“to take on pricing along with
“Under our new technical
collaboration with Tesab, we would
manufacture Tracked crushers and
Wheeled Crushers in a phased
manner. The tracked crushers
would be arrayed with capacity
variants of 100-400 TPH whereas
the wheeled crushers would be
expanding and consolidating
market presence, Kobelco
initially would manufacture
hydraulic cranes from 80 to
100 tons at its upcoming
plant at Sricity near Chennai
in Tamil Nadu whereas 250
tons would be taken up at a
later stage. Sixty percent of
the components would be of
local origin comprising
crawlers and fabrication parts
whereas 40% of the
components comprising
engines, boom would
continue to be imported. We
would also strengthen
customer support for our cranes
through our distributor Voltas.”
There has been a steep
appreciation of Japanese Yen at
the rate of 25-30% making the
Kobelco cranes dearer in India.
arrayed with capacity variants of
100TPH and 300 TPH.”
He stated further that the
competitive features of the tracked
crushers would enable its users to
operate continuously at mining sites
and for big infrastructure projects.
Besides this, the machines would
be cost competitive to operate. The
tracked crushers come with a
Caterpillar power pack and it has a
large rear loading hopper with low
feed in height and hydraulic
adjusting crusher. The wheeled
crushers are self- contained mobile
crushers that come with a
Caterpillar power pack. The tracked
crushers and the wheeled ones are
manufactured under a joint
collaboration and will be co-branded
as PROMAN-TESAB. These mobile
crushers will be offered with Jaw,
Cone, Impactor and Screen
combinations.
NBM&CW MARCH 2011
 Post Event Report
BHS Sonthofen India
BHS-Sonthofen (India) Pvt Ltd also
participated at bC India. Highlighting
the new and forthcoming business
venture in India Mr. Neelesh Desai,
Voltas Limited displayed its new
prototype hydraulic truck mounted
VLTC-25, 25 ton crane which can
lift maximum designated load of 25
metric tons at 2.5 metres working
radius with a basic boom length of
8.8 metres and maximum tip height
of 30.2 meter with 4.6 meter jib. It
190
National Sales Manager BHS-
Sonthofen India said, “to provide
better customer support in terms of
parts availability, we have started
Voltas Limited
can lift 6.25 tons @ 6 metres
working radius. It has four
outriggers with overall width of
5020 mm. The crane is mounted
on Indian, AMW 2518 chassis
powered by turbo charged water
cooled Cummins 6BTAA-BS-II
engines with 178hp @2500rpm.
construction of our own warehouse
at Indirakaran on Hyderabad-
Mumbai road. The location of the
new warehouse would be 40
kilometres away from Hyderabad.
The warehouse would house the
entire range of components for
Twin-shaft batch mixers, continous
mixers, vertical shaft impactors and
others.
He further stated, “we are
contemplating to launch other
models of vertical shaft impactors
during later stage of the current
year in the country.” Mr. Desai ruled
out any immediate possibility of
undertaking any indigenous
manufacturing of the products in
India. He also informed that the
company’s plan to market electronic
waste recycling plants for municipal
applications is on stream.
The maximum speed of the
vehicle is 75kmph with total weight
of 24,550kgs. As per Mr. Aniruddha
Moharir, Deputy General Manager-
Cranes, Voltas Ltd, “commercial
production of the crane is expected
to begin from April 2011 following
its testing.”
Voltas also launched its new
VLPC-12, 12 ton, hydraulic pick and
carry crane that comes with a
three boom extension and has a
maximum lifting capacity of 12 tons
@ 1.9 metres working radius and
minimum of 2 tons at 10.01 metes
working radius. The crane would
be offered in two models, VLPC
12TX SB and VLPC 12TX. VLPC
12 is powered by Bharat stage -2
engines. It can travel at a top speed
of 28kmph without load. Voltas also
manufactures 20; 30.40&45 ton
rough terrain crane.
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Manitou had put on display, MT 1440
SLT ( 14m lift height/ 4000kgs lifting
capacity) ‘Maniscopic’ Rough terrain
telehandlers and 200 ATJ (20m
Working height AWP) ‘Maniaccess’
access platforms and GEHL 4240
‘Skid Steer Loader’ at bC India.
Mentioning about the
Maniscopic, rough terrain
telehandlers, Mr. Ajay Mandahr,
Director, Commercial, Operations,
Manitou BF-India Operations said,
“the competitive positioning of our
Maniscopic telehandlers is based
on the fact that it provides one-
machine-solution for almost all the
material handling applications viz.,
Forklift – handling material on pallet,
Jib Crane & Winch- handling
material with Crane hook, Man
Platform- handling man & material
192
Manitou BF
as an access platform, Loader
Bucket- handling bulk material and
several other attachments for
specific applications- viz., rib
erection for tunnels, tyre handling,
wood log handling, light dozing etc.
“Manitou offer the widest range
of telehandlers with over 50 models,
available at various price points, to
suite the specific need of the
customers in Construction,
Industrial & Mining Sector. The
models range from 4 meters height
with a lifting capacity of 1500kgs
to 30 meters height and a lift
capacity of 5000kgs. We also offer
higher capacity Rough Terrain
machines with a lifting capacity of
21000kgs with 10 meters lift
heights. All the models are on offer
in India, Mr. Mandahr informed.”
On the competitive product
positioning of the product, he further
added, “as compared to the
contemporary product line on offer
in India, Manitou, a world market
leader in all terrain equipments,
offer a wider range of product, better
design & operational performance,
Higher safety standards in
compliance to strict European laws
& updated products. “ In
the Maniaccess range, we
offer some of the most
unique features as self-
diagnostic tools, higher
ground clearance, robust
construction, reliability etc.,
among other features.”
Further he stated,
“Manitou has appointed
different dealers in India
based on their individual
areas of expertise. ECEL
has been appointed based
on their network and
expertise to cater the
requirements of the
Construction & Rental
Industry, Dozco has been
our dealer for the Mining
Industry and Gemini is
promoting our interest in
Industrial Masted Forklifts.
Strong local partners have
complemented our strategy
to provide “application
based solutions” to our
customers at their door
step & to offer superior
after sales support. Currently, we
have in excess of 150 customer
contact points across the length &
breadth of the country; it is one of
the largest network for this product
category in the country.”
Further, Manitou subsidiary in
Singapore is being strengthened to
augment our capability to deliver
faster the products & services to
our customers in India, added Mr.
Mandahr.
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CHETRA, one of the trading units
of Machinery and Industrial Group
N.V. (M&IG)-the largest Russian
international manufacturer of
machineries and equipment has
brought here in India the most
popular Russian industrial
machines which are used in oil &
gas, coal, mining industries, and in
road building sectors. CHETRA’s
share in the Indian pipe layer market
has already reached to 30% and
as estimated by the market players,
taking into account the demand of
mining and construction industries,
it may go upto 40-50% soon.
Today, CHETRA in India offers
dozers with the power range
90-590 hp, pipe layers with the
lifting capacity of 25-104 t for the
pipelines with the tube dia. 200-
1420 mm; wheel loaders with the
bucket capacity of 3. 5 to 6. 7 c.m.
and operating power range
140-600 hp; excavators with 23 ton
operating capacity and various types
of special equipments for Pipeline
cleaning, priming, heating &
Insulation works,” said CMI CEO
Benjamin Callow during CHETRA
stand inauguration at the show. He
said further that CHETRA machines
194
CHETRA
are robust in design and
construction; the metallurgy adopted
for manufacture of critical parts
suits well to the Indian condition
and performance as a whole
extremely satisfactory.
Dr. Mikahil Bolotin, president the
Holding company M&IG has visited
specially to India during this expo,
giving value to the company’s
promises for India.
The inauguration of the
Russian CHETRA stand, attracted
a lot of guests and visitors – The
Russian Consular general in
Mumbai Alexey Novikov, Trade
representative Mikhail Rapota, M&IG
vice-presidents Vladimir Lepin and
Vadim Kalabashkin, vice-president
of the Association of Equipment
Manufacturers Megan Tanel as well
as media, partner and dealer
companies.
During his welcome speech, the
trade representative Mikhail Rapota
mentioned the importance of the
plans of M&IG N.V., the 3-d largest
producer of heavy industrial
machines to create a production
unit here in India that aimed at
fulfilling the growing demand and
implementation of the high-quality
after-sales services. The importance
of those plans has grown
enormously after the official visit of
the Russian President Dmitry
Medvedev in India when a new
technological emphasis of the
international partnership has been
made. Today, CHETRA is fairly
representing Russia in different
global markets, showing the best
scientific and technical develop-
ments of the Russian specialists.
According to Mr. Vladimir Lepin,
Vice-president, global markets,
M&IG, the organization of the
production unit will strengthen
Russian producer’s position not
only in India but also in the whole
South East Asia region. Australia,
Malaysia, Indonesia, Thailand and
South Korea have already shown
their interest, in Russian CHETRA
machines. By the end of 2015 the
number of yearly produced
machines will go upto 200, said
Mr. Lepin. In addition, the Russian
specialists will carry out educational
and qualification-raising programs
for the Indian engineers
participating in CHETRA production
and services.
NBM&CW MARCH 2011
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ABG Cranes displayed its
indigenously developed 80 ton
hydraulic crawler crane named
1080. It has a lifting Capacity of
80Mt at 4meters radius and
consists of Boom – 58meters and
Jib – 18meters, Hydraulic Jacks for
Self Loading/Unloading, Pilot Switch
control, AC Cabin and Safe load
indicator. The 80 ton crane comes
with a 24.3 ton counterweight and
is powered by proven
indigenous diesel engine,
Hydraulics & Winches imported
from reputed brands from Europe
and Boom made from High Yield/
tensile seamless lacing tubes
imported from Japan.
Normet introduced the most
advanced model for concrete
spraying in its Spraymec series at
bC India. The Spraymec 8100 VC
is designed for high performance
sprayed concrete applications in
196
ABG Cranes
A large number of customers
visited our stall from different
industries such as Construction,
mining, logistics and crane hiring
etc. BC India show increased the
visibility of our crane across India
and Visitors were delighted to see
an Indian manufacturer for crawler
cranes designed indigenously with
superior quality, said Mr. R.B.Pandey,
GM and Head Marketing, ABG
Crane.
Several visitors impressed by
the crane also visited our factory to
check our manufacturing facilities
located at Village – Ransai in
between Mumbai and Pune.
Normet
tunnels with cross-sections of 15m2
to 140m2.
The electro-hydraulic self-
propelled mobile concrete sprayer
provides efficient spraying from one
set-up in tunnels of up to 10.3m
Customers were impressed by
seeing the requisite machinery and
equipments such as CNC Profile
cutting machine, Fabrication shop,
Assembly shop, NDT testing, Paint
shop and a shot blasting booth.
They were delighted by seeing one
complete set of spare parts kept
aside for after sales and service for
10 cranes which rolled out of factory
till now.
One of our customers M/s.
A.S.Shipping Agencies Pvt. Ltd who
is using ABG 1080 cranes visited
the stall and told that they &
Chennai port trust railway had
achieved a record performance by
handling Granite Block rake in 5hrs
and 15min on 8/1/2011 at western
yard I using 1080. He told he is
very happy regarding the
performance of the crane and
ordered more of Model 1080. This
shows customer satisfaction and
reason behind the repeat orders.
This was encouraging to us
and we are coming up with 35T
and 160T cranes customers are
eager to know about the
specifications and release date of
those cranes. Most of the
customers showed keen interest on
35T hydraulic crawler crane and
expressed their eagerness to see
the launch of this crane.
Overall we are very satisfied
with the response we got for our
80Mt crane. This success backs us
to be optimistic for our later
releases of 35MT and 160MT
hydraulic crawler cranes.
high x 16m wide. The maximum
vertical spraying reach is 14m. The
machine features NorSmart, the
latest state-of-the-art control system
of the spraying process. The
NorSmart concrete sprayer control
NBM&CW MARCH 2011
 Post Event Report
system provides efficient, productive
and high-quality concrete spraying
with functions that include: Low-
pulsation spraying and pumping,
NBM&CW MARCH 2011
accurate spray boom and nozzle
movements and positioning, real-
time control and fault diagnostics
of the spraying process, including
a kit for accelerator, concrete and
ambient temperature measurement,
logging of all spraying process
related data and USB data transfer
and comprehensive vehicle fault
diagnostics.
According to Mr.Rajeshwar
Singh, Country Manager, “India is
our largest customer base at the
moment and we have sold many
Normet units in the country and the
big Spraymec 8100 VC displayed
here for the first time is sold to
Leightons. Our international
partnership with Tam International
and through its 100% ownership of
TAM Construction Chemicals (India)
will give us a further reach into the
accurate and reliable alkali-free
construction and mining industries
accelerator dosing (control system
in India, he added.”
integrated into concrete output),
197
 Post Event Report
Fayat Group, the road building
equipment major participated at bC
India and displayed its top brands:
BOMAG, MARINI & BREINING.
Fayat’s every brand is world-
renowned for its leading
technologies. Top quality products
including the newly launched
Bomag pavers, milling machines,
Sicoma Mixers India
Sicoma Mixers India displayed its
range of planetary mixers.
Mentioning about the range of
products, Mr. Vinayak Gajendragad,
Area Sales Manager-Indian
Operations, Sicoma India said,
“there has been a rise in demand
198
Fayat Group
compactors, and compaction
equipment were displayed.
Alongside these products, a
comprehensive range of the
intelligent compaction tools and
solutions were also presented.
MARINI, India’s No.1 high
capacity asphalt plant supplier,
of our products in India over the
years and inquiries at bC India
were quite good.
He said, “in order to make the
price of the products competitive,
we would undertake local assembly
of the planetary mixers at our new
presented its entire range of
Hypermobile & Modular asphalt
plants to the visitors. Fuel efficiency,
Green plant technology, and
Recycling systems were the focus
of the Marini presentations.
Marini ROADSTAR – is the
leading hyper mobile asphalt plant
model in India. Marini during the
show announced the launch of RS
1800 and RS 2700 160Tph/ 200
Tph hyper mobile plants for India.
On the Modular asphalt plant front,
the MAC 320/360 range of plants
were also offered to customer in
India who realized the benefits of a
highly reliable and high capacity
asphalt plant there and then.
These products are specifically
designed to cater to the asphalt
mix requirements in the country.
The designs focus on high
productivity, performance and
substantial savings in fuel. These
products are manufactured with
future ready features, which will help
contractors face the ever changing
and demanding environmental
concerns and mix designs.
plant in Bangalore. Productions of
the mixers are expected to begin
during June 2011 from the new
plant. To provide backup customer
support to the OEMs we have a
service team which imparts training
to the OEM’s through scientific
methods.”
Mr. Gajendragad said that
Sicoma would continue to undertake
marketing of the products through
its own marketing network. Products
manufactured by Sicoma includes
concrete planetary mixers and twin
shaft mixers. The products are
imported from Italy.
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Action Construction Equipment
(ACE) launched its new 75 tonne
NBM&CW MARCH 2011
ACE
hydraulic crane ACX 750 which has
a maximum lifting capacity of 75
tons at 3.6 metres working radius
with a boom length of 12 metres.
The crane has a counterweight
of 21 tons. At a maximum boom
length of 57 metres, it can lift 10
tons at 12 metres working radius.
Boom and fixed jib combination
of the crane is 27metres-45
metres+ 9.0metres-18.0 metres.
Jib offset angle of the crane is
10 degree and 30 degree.
ACE 750 comes with fuel
efficient water cooled Mahindra
Navistar Diesel Engine with a
rated power of 220hp @2200 rpm
and a fuel tank capacity of 350
litres. As per Mr.Rajeev Kumar
Divisional Manager, HED ACE, the
company is planning to promote
the product for Power plants,
Metro projects, pipeline
construction and heavy material
handling sectors etc.
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 Post Event Report
At bC India, PALFINGER has
presented both product innovations
and time-tested system solutions.
According to Mr. Subhamoy Ghosh,
Managing Director, PALFINGER
Cranes India Pvt. Ltd 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
flexibilitywith committed employees
and an affirmed philosophy of
“making customers more
Apollo Infratech
There were good numbers of new
product launches by Apollo Infratech.
The Gujarat based concrete
equipment manufacturing major,
launched its new fixed form paver,
trailer mounted stationery concrete
pump and compact batching plant.
Mentioning about the new products
Mr. Mitul Patel, Managing Director,
Apollo Infratech said, “the new fixed
form paver is light machine. This
makes it quite easy to move.
Besides, maneuvering is quite easy
200
PALFINGER
successful” in their jobs are the
ingredients of this recipe for
success. A competitive edge gained
through technological innovation
and high levels of product quality
have always been central to the
company, he informed.
During the show, PALFINGER
launched 4-tonne telescopic truck-
mounted crane, specifically tailored
to the Asian market for mounting
on small and medium-sized trucks.
In addition, it displayed PK 38502
and a PK 10000 Performance from
for the machine. It enables work to
be done much faster as compared
to contemporary products.
Importantly, the machine is quite
fuel efficient.” The fixed form paver
would be finding its application for
the construction of concrete roads,
runways etc. On stationery concrete
pump, Mr.Patel said, “ the pump
comes with s-valve technology. The
SAP-50 concrete pump comes with
a concrete pumping capacity of 50
cum/hr. The machine is quite fast
its extensive range of knuckle boom
cranes which are the perfect
workhorses 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, demonstrates the
interesting and powerful
range of applications that
PALFINGER system
solutions can handle in the
construction and waste
management industry.
An EPSILON M110L97
timber handling and
recycling crane mounted on
an truck with a gross
vehicle weight of 25 tonnes
demonstrated that how
much power and efficiency
is packed into these
PALFINGER cranes that
have been specially
designed to deal with huge
dynamic loads. Additional
truck-mounted crane
attachments and equipment for
every eventuality completed the
exhibition programme.
in pumping concrete.” Mr. Patel
informed, “the pump would be
finding its application in high rise
construction both pertaining to high
rise and real estate projects.
However, the prime new
attraction from the company was
its, compact series batching plant.
Mr. Patel said, “ to be available in
rated capacity range of 20-25-30
cum/ hr, the batching plant is truly
compact in its character. The
machine comes entire assembled
NBM&CW MARCH 2011
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Conmat Systems Pvt Ltd
Gujarat based Conmat Systems
launched its new FULLY MOBILE
AUTOMATIC CONCRETE BATCHING
PLANT with TWIN SHAFT MIXER
technology for the first time in Indian
Market. Giving information about the
new products, Mr. Nagesh Kudva,
Director, Conmat Systems said, that
the mobile plants are available in
various ranges of 20cum/hr, 25 cum/
hr, and 35 cum/hr with a water tank
202
of 750 ltr each. The plant can find
its application for construction of
small culverts, bridges, road
projects and canals. The equipment
comes with fully mobile PLC
controlled plant, compact size for
easy maneuverability. The loading
of 3 / 4 compartment type bins for
aggregate & sand is with normal
tractor loader or backhoe loader
without any ramp assistance. It can
from the plant and can be readily
commissioned at the plant. The
machine is ideal for job sites with
space constraint.” He added, “the
unique feature of the compact plant
is that, with retaining the same
basic structure , the same plant
can be converted to yield the
various rated concrete preparing
capacity as per the requirement of
the contractor. “ Mr. Patel informed
that, ”for providing the requisite
customer support for the users of
the new equipments , we would be
hiring new set of personnel. This
would be supplemented by getting
the present dealers and the existing
service personnel of the company
being trained.
assist in rapid start up as the entire
unit comes assembled from factory
itself. This machine comes with an
added feature of 180 degree
rotation of discharge conveyor for
better space management at site.
The fully assembled plant can be
towed with standard tractor.
Giving more information, Mr.
Kudva said that, during the launch
itself, they have bagged order for 4
nos of 25 cu mt/hr
capacity mobile plants.
Further said that, they
are carrying out certain
modifications in the
software of our existing
concrete batching plant
with certain change in
basic design for easy
maintenance. Besides
this, we would
manufacture our
indigenous concrete
pump and the company
is going to launch truck
mounted concrete pump
in technical collaboration
with European
manufacturer.
NBM&CW MARCH 2011
 Post Event Report
Liugong India displayed its range
of earthmoving products comprising
tracked excavators, wheel loaders
and so on. The Chinese equipment
manufacturing giant, exhibited its
new CLG922D hydraulic tracked
excavator which meets Tier -2 stage
emissions norms and has bucket
capacity of 0.73-1.1cum with rated
power of 112kw @1950 RPM from
Cummins 6BT 5.9 C engine. The
operating weight of the machine is
22,000 kg. According to the
company, the excavator’s heavy
welded under carriage frame
ensures better durability in tough
conditions. Apart from this, the
DOZCO India Private Limited
DOZCO displayed Mini Yanmar
excavator and GEHL skid steer
loader from Japan and USA
respectively that it would market in
India. DOZCO also showed the new
range of hydraulic rock breakers
that they would be marketing for
Indeco, Italy as well. The company
has recently inked distribution
alliance with Indeco and Gehl for
204
Liugong
carrier rollers, and the track rollers
are sealed with a floating oil seal
to provide extended life.
Liugong also displayed its CLG
920D hydraulic tracked excavator,
CLG 856 and CLG835 wheel
loaders. It’s new CLG 920D
hydraulic tracked excavator has a
bucket capacity of 0.73-1.0cum with
rated power of 112 kw @1950rpm
supported by Cummins 6BT5.9-C
engine. The equipment has an
operating weight of 20,500kg with
similar features of undercarriage
like CLG 922D. The machines use
the advanced CAPC system for
power optimization & fuel economy.
marketing and service of their
products in India.
Mentioning on the technical
attributes of the new product line
that DOZCO would be marketing,
Mr. Sandeep Bangur, Executive
Director DOZCO India said, “Gehl
skid steer loaders are globally
proven equipment for their technical
standards and also enjoy outmost
New CLG 856 has operating
weight of 16,800kg with a bucket
capacity of 3cum GP Bucket and
4.5cum Coal bucket. The machine
is powered by Cummins 6CTA 8.3-
C215 engine with a rated power of
160kW @2200 rpm. Whereas
CLG835 has an
operating weight of
10,900kg and a rated
load of 3000 kg and is
powered by Cummins
6BT5.9 engine. Both
the loaders are BS III
compliant.
Mr. Sunil Sapru,
President, Liugong
India said, “with the
new launches, we are
planning to provide
total solutions in
earthmoving to our
Indian customers. The
company is putting its
continuous effort to
localize of its products with the help
of company’s R&D wing. Forty five
percent of capacity utilization is
being undertaken for the newly set
Pithampur plant. The vendor
identification and supply chain
management is in full stream to
further utilize the capacity of the
plant.”
customer reliability. We would further
strengthen our position and will add
values for customer through this
extended product line and their
continued patronage towards our
quality products”.
On Indeco Hydraulic breakers,
Mr. Bangur mentioned, “Indeco
breakers are of premium genre and
are much superior in performance
NBM&CW MARCH 2011
 Post Event Report
when compared to contemporary
products.” He explained, “as
compared to the conventional
technology of breakers where
nitrogen gas is used for moving
the piston, Indeco breakers
operates on hydraulic oil . This
increases productivity, makes
maintenance easy and operating
cost lower. At the same time owing
the same oil from the excavator for
Puzzolana Machinery Fabricators
Puzzolana Machinery Fabricators
announced its technical
collaboration alliance with Guddeti
of Italy for the new product line
206
moving the piston, gas charging of
the breaker is not required.” He
added further that, “We would be
marketing the composite range of
Indeco breakers that can be
mounted on excavators spanning
from 2 tons to 120 tons class.” On
response from customers over
newly launched products Gehl and
Indeco at bC India Mumbai, he
replied “We have got good
during the show. Mr. V.
Venkataramana, Vice President
PMF, part of Puzzolana Group said,
“under the new collaboration tie up,
enquiries from customers, and they
have appreciated the technology
and with their support we have
already opened the account for
these products.”
On DOZCO’s venture in forming
the distribution alliance for material
handling equipments, precisely that
with Manitou for tire handlers and
Terex for rough terrain cranes, Mr.
Bangur mentioned, “DOZCO is well
known to have exposure in selling
products to mining sector, with this
alliance with Manitou, we have
further added values to the
emerging requirements of the
equipment users in mining for
removal and carrying of big size
OTR tires. Manitou trye handlers to
handle tyres of 240 ton class
dumper are already operating in
India. For Terex rough terrain cranes
he mentioned “it would be further
promoted to contractors engaged
in pipe laying and other construction
sectors where DOZCO have well
known requisite exposure. In total,
through these new alliance we
would further reinforce our position
as a one stop equipment and
service support provider.”
we would manufacture entire new
product line consisting of
compactors, graders, rollers etc.
PMF is also entering into two
separate agreements in the
area of coal processing
equipments and track mounted
crushing plants manufactured
in India and customised for the
India requirements.
The key focus is to give
the best quality and latest
technology. We are also
planning to strengthen our
existing supply chain network
from our mother warehouse to
the user points to provide
maximum equipment uptime
and parts availability.
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 Post Event Report
Jaypee India Ltd successfully
participated at the show and
exhibited the best machines with
Fresh with memories of opening of
company’s new plant, the third one
from the company in North
Bangalore last month to produce
batching plants with planetary
mixers, K Vijay, Managing Director,
Ajax Fiori could not hide his
excitement as one of the country’s
leading manufacturers of quality
construction equipment providing
208
Jaypee
the latest technology for which the
company got tremendous response.
The machines displayed were
Ajax Fiori
innovative solutions to the
construction and concrete sector in
India. He said his company caters
to the market with revolutionary
concrete concepts and methods
with large satisfied base of over
1,000 customers across the country.
Talking about the performance
of the company, he said, the
Bending machine B52, Shearing
machine C52, Bending machine
B42, Shearing machine C28,
Shearing machine C52,the new
Bending machine B28, and Radius
bending machine RB36. In addition,
our International partner KRB
Machinery also displayed the
advanced version of Auto Stirrup
Bender COIL FORM 612.
Commenting on the show, Mr.
Ray, GM Sales said the exhibition
proved very successful for Jaypee
and we were more than happy to
see the quality visitors and serious
enquiries. We look forward for the
next edition as such type of
exhibition is very important for our
business. Also overwhelmed with
the response, Mr. Thomas, Manager
Sales rated this event as an
excellent platform for construction
Industry.
company has been
recording almost double digits
growth consistently for the last few
years. With additional capacities, he
expects to achieve better in the next
couple of years. Ajax Fiori products
and services are serving various
important sectors in irrigation, canal
linings, urban infrastructure—roads,
railways, bridges, Sezs, industrial
ports, tunneling jobs and in
RMC and precast. Pointing to the
big gathering viewing company’s
new product launched at bC India,
he explained important technical
attributes of Dragline batching plant
with a planetary pan mixer-DLP 30
and UNI 30, Turbosol plaster
spraying machine. This concept, he
said is new in India and the
company is in the process of
establishing an entirely new
process of plastering.
NBM&CW MARCH 2011
 Post Event Report

Revathi Equipment Ltd

REL (Revathi Equipment Ltd ), a part of
the Renaissance group headed by Mr
Abhishek Dalmia, have entered the
Ground Engineering Equipment segment
by augmenting their Construction
Equipment range with two new products.
REL in association with M/s. TESCAR
Srl, Italy, launched the “CF” series Piling
Rigs at the recently concluded BC India
in Mumbai. REL will be targeting the
emerging market for Mini Piling Rigs and
is confident of making a mark in this
niche segment.
The response was very encouraging
at BC India and REL will commence
trials at various sites shortly. The strategy
is to deploy the ‘Correct’ machine for
each application, as the Indian industry
currently have only choice of ‘Very Big’
Machines. TESCAR machines are widely
known world over for their flexibility and
also the ability to operate in confined
area with very low head room. It also has
a patent for their design of telescopic mast .
The Rigs will be initially imported as CKD and in
due course will be manufactured at their facility in
Tamilnadu.
Another product REL is introducing is the Vibro-
Hammer from Chowa Kogyo Co Ltd, Japan. Chowa ,
market leader in this segment, is entering Indian market
with a vast experience in executing many challenging
projects world over .Chowa ‘s ZERO series of Electric
Vibro Hammers have a market share of over 90% in
Japan and is renowned for its enviro-friendly designs
and high productivity.
REL, Construction equipment Division offers a ‘Full
Liner’ in Concrete Equipment with technical collaboration
with leading German manufacturers, and have its ISO
certified facility in Gummidipoondi, near Chennai. Every
product from REL-CED stable have certain feature
incomparable and offering value addition to clients in
terms of productivity, saving in operating cost or additional
safety features.
The THP 45 D High pressure Concrete 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 has expanded its own network to all four
regions of the country and has currently 13 dealerships
to provide after sales support to its range.

NBM&CW MARCH 2011 209

 Post Event Report
Sree Parijatha Machinery Works
Sree Parijatha Machinery Works, the
leading manufacturers and
exporters of Block and Tile
machinery launched its latest
offering to the market, the heavy
duty wet press to produce very high
density precast products. Mentioning
Propel Industries
Jaw Crushers, Cone Crushers
Grizzly Screen, VSI, Sand Washers
and Hydraulic Rock Breakers—the
complete product line of Propel
Industries backed by nationwide
sales and service network is
available in India, said Mr. V. Senthil
210
the features of the linear wet press,
Mr. J. Ramesh, Managing Partner,
Sree Parijatha Machinery Works
said, “the wet press manufactured
by us is specially designed to
produce, high density kerb stone,
slabs, and flagstone in large
Kumar Managing Director, Propel
Industries at the sideline of the bC
India show. These products he said
are manufactured at its world-class
manufacturing facility in Coimbatore.
This is accredited with ISO 09001-
2008 and ISO/TS certification with
volumes. Also, we can design
moulds as per customers’ specific
requirements apart from handling
systems and related systems. Also,
we assist our customers in
installation of the plant, providing
optimum mix design and complete
technical support to get the best
out of the plant”
According to the company,
Parijatha has in its range a variety
of very successful machines for
manufacture of Terrazzo Tiles,
Decorative Grooved tiles, Interlock
paving Blocks, Heavy duty slabs,
Hollow and Solid Concrete Blocks.
All these machines proven their
performance over the years for their
trouble free performance, low
working & maintenance costs and
most importantly reasonably priced.
All this with the PARIJATHA
stamp of quality and assurance
goes a long way in providing the
customer the best value for money.
well placed quality systems to
ensure quality products as per
national and international standards.
According to Mr. Kumar, the
product range of the company has
been successfully deployed at
important project with satisfying
performance and benefits to the
clients. The company has in place
an expansion programme as per
market demand, but it has no plans
to move out of Coimbatore, where
there are many vocational
advantages.
Propel has strategic alliances
with leading equipment
manufacturers across the globe,
Socomec which has helped it to
set new benchmarks in its
production and manufacturing, he
informed.
NBM&CW MARCH 2011
 Post Event Report
Giving his brief on Sennebogen, Mr.
Michael Ibarth on the sidelines of
the show informed that Sennebogen
Tyrolit has in its kitty super abrasive
tools using latest concrete
dismantling technologies, said
Deepak Bedi Marketing Manager,
212
Sennebogen
is a family run company starting out
with manufacturing agricultural
machines and later turn to
Tyrolit
Tyrolit India Super abrasive Tools
on the sidelines of bc India.
According to him, the market
for concrete dismantling technology
manufacture construction equipment
products. Today, the company
enjoys immense success with a
broad range of products in the
material handling sector, crane
product and related product for
application in civil engineering.
At bC India, it drew the attention
of visitors showcasing its 690 duty
cycle crawler crane with its new
sales and service partner GMMCO
Ltd. He said that they were happy
to have GMMCO, a competent point
of contact for its customers. Soon
we will present our high value and
innovative crane and lifting
equipment together and we will
actively address the market in this
strongly growing area that India
presents.
is growing year on year. The
technology has inbuilt benefits like
speed, ease of operation, safety
and that too without any impact on
the structures on which it is
applied. At bC India, we have
launched Mini Groover and Grinding
machines. These are useful for
grooving or grinding work at airports
runways, concrete roads and
highways and on industrial floors.
As these machines are diesel
operated, no power is required to
operate these machines, explained
Mr. Bedi.
Adding he said the
company has range of wire saw
systems and hydraulic drill systems
and the USP of company’s product
line is the modularity of product
range.
NBM&CW MARCH 2011
 Post Event Report
Haulotte Group exhibited its range
of aerial work platforms (scissor
lifts, telescopic booms, Articulating
booms rough terrain or electric,
vertical masts, lightweight sef-
EPIC Eco Fiberglass Formwork System
EPIC Group, Slovenia, the
manufacturer of EPIC eco-fiberglass
formwork system, has recently
entered into the Indian Construction
Industry by participating and
displaying its products at the just
214
Haulotte Group
propelled booms, push around and
trailer-mounted booms) and also
its range of telehandlers.
Mentioning about the product line,
Mr. Pierre Saubot, Chaiman and
concluded bC India show. The
company is represented in the
country by Indigo Multitrade Pvt. Ltd,
Mumbai.
EPIC is involved in the
development of shuttering systems
CEO of Haulotte Group, said, “As
European leader, our objective is to
market the full range of aerial work
platfroms in India”
Mentioning the sectors, Haulotte
would promote its products,
Mr. Steven Tan, General Manager of
Haulotte Singapore said, “with the
versatile features, we would look to
promote our products in industrial
and construction sectors in India.
For industrial sectors, the machine
would deliver its utility in better
accessing the location heights with
numerous tools and workers. While
for construction, it would cut down
on the cost of scaffolding. The prime
utility of the machine would be
based on its mobility element that
can transport man and materials
and make them accessed to critical
work points.” He mentioned, “the
machine also provides its utility in
faster turnround of manpower, and
ensuring faster completion of
project.
made from composite fibreglass
and offers formwork solutions for
foundations, walls, columns, ceiling,
and shafts. The company offers
huge reductions in Shuttering costs
and simplification of shuttering.
These are light, durable, solid, and
resistant to temperature changes.
They can be used repeatedly for
Ten years and can sustain pressure
over 60Kn/m 2 . The speed of
panelling with EPIC Eco Systems
is very fast and abundant palette of
elements allows the best possible
panelling composition with all
flexibilities among various projects.
EPIC eco-fiberglass formwork
system brings true revolution in the
building construction industry.
NBM&CW MARCH 2011
 Post Event Report
Wolffkran participated at bC to
disseminate information on its
range of product offerings for the
Indian construction market. The
company has appointed Harsadhan
International for marketing its full
range of tower cranes in India. This
would consist of luffing cranes
having a capacity range from 100
to1250 MT, topless cranes from
0112 to 0224MT and standard trolley
jib cranes from 200 to 630MT.
Australian Crane & Machinery Pvt. Ltd.
Australian Crane and Machinery
participated to explore new
business ventures in India.
According to Mr. Vaibhav Kale,
International Sales, Australian Crane
& Machinery, “we have been
exporting used cranes from
Electromech Material Handling
Systems announced its strategic
alliance with US rubber tyred gantry
crane manufacturer Shuttlelift.
According to Mr. Tushar Mehendale,
MD, “under the collaboration, we
would market and provide technical
support to Shuttlelift RTG cranes in
India. Electromech would distribute
Shuttlelift’s 15tons-1000tons RTG’s
Hidrokon Limited
Hidrokon Limited choose bC India
to highlight its products portfolio for
the Indian market. Mr. Mevlut Acar,
Export Responsible said that we
are in the process of selecting
dealers in India to market our entire
range of products. Through the tie
up, we would market our entire
216
Wolffkran
According to Mr. Mike Nunweek,
Regional Sales Director, Asia
Pacific, “Under the marketing tie
ups, Harshadhan would provide
sales and technical support,
involving erection, commissioning,
servicing, maintenance and parts
support to Wolffkran’s Tower Cranes
in India.”
Mr. Nunweek said, “with project
completion schedules in India
becoming increasingly time bound,
Australia to India for almost three
years comprising crawlers, truck
mounted and all terrain cranes with
capacity range from 40 to 500tons.
The cranes are exported after
getting them rebuilt and repaired
followed by its procurement from
Electromech
in the country. The cranes to be
marketed would be of single beam
shuttle lift, shuttle lift and industrial
shuttle lift models.
The Shuttle lift RTG’s will be
promoted to prefabricated concrete
sectors, steel industry, modular
buildings and wing power
generation sectors. The equipment
precisely will help to overcome
range of truck mounted knuckle
boom cranes from 3 to 90 tons,
truck mounted stiff boom telescopic
cranes having capacity range from
10 to 60 tons and access
platforms from 27 to 45 metres.
We would be much competitively
priced, making our products
our product would provide value to
contractors with increased
equipment uptime based on their
features, involving higher hoisting
speed, low power consumption,
among other features.” The cranes
would be with two years warranty.
Wolffkran has sold five cranes in
India till date to real estate project
developers.
the used market. The used cranes
have been promoted by us in India
with the help of dealers in various
parts of the country. However, our
present strategy is to consolidate
our business and deal directly with
big ticket customers planning to go
for volumes.”
constraints of space availability in
shop floors offering tandem picks
in cost effective manner.”
Electromech plans to sell 100 units
of RTG’s during 2011.
Electromech manufactures EOT
cranes, gantry cranes, electric wire
pore hoists etc. It distributes Abus
EOT cranes in India and has also
tie up with Stahl Cranes systems of
Germany.
affordable to Indian buyers. Mr. Acar
further mentioned that our telescopic
stiff boom cranes have boom with
holigonal design that provides
added strength to the boom
compared to contemporary products
with less strength box type boom.
NBM&CW MARCH 2011
 Post Event Report
Strong Plant Infrastructure Pvt. Ltd.
“After its successful stint in the
Middle East markets in designing
and execution of dewatering and
pile foundation projects, including
analysis of soil investigation reports,
manufacture and supply of tools
and fixtures, we have started our
operations in India; finding it a good
market for such specialized jobs,
where we can add value from
experience “said Ashish Desai,
Managing Director, Strong Plant
Infrastructure Pvt. Ltd., the Piling
and Dewatering specialists.
The market for dewatering and
pile foundation is growing due to
massive infrastructure programs
Topcon Corporation, Japan & its
Product range, was showcased by
its subsidiary Topcon Sokkia India
Private Ltd. Explaining the most
advanced technical features of these
products, Deepak Nehru, Manager-
EBG Division said that USP of
these products is high definition
precision and accuracy. From data
218
and we are keen to chip in. As a
matter of fact, we are currently
working on several important
projects in association with L&T in
Mumbai, rendering dewatering
services. We are also among the
leading performers at IOCL’s
upcoming refinery project at Paradip,
Orissa. We are also in the rental
business of equipment and
accessories as well as supplies.
For the projects in hand, we have
deployed highly skilled and
experienced manpower as well as
state of art technology, to ensure
efficient project execution and
operations’ management for the of
Topcon
collection to job site construction,
Topcon products and services
provide effective solutions to take
control from field operations to
finishes.
Its millimeter GPS provides the
most receptive solution for the
pavers system to build most
precise roads in India. Topcon’s
the projects, Mr. Desai added.
With our highly skilled and
dedicated team, headed by our
Director, Harin Anjaria and G.M.,
Sanjoy Joseph in India, we look
forward to carving a niche for
ourselves in areas of Specialized
Piling Jobs, especially Inclined
Piles and Dewatering Designs and
Execution like Deepwell, Wellpoint,
French Drain as well as sacrificial
Systems, which are grossly lacking
in the industry and we have come
at the right time to fill that void.
Our concept of Vacuum
Dewatering System Sales and
Rental along with Millar G.I.
Couplings and Italian Hoses and
Accessories along with installation
& supervision has gained lot of
appreciation. After having kept the
deepest excavation(-27m), of the
upcoming tallest tower in India, dry
during the peak of monsoon and
achieving the fastest and most
sustainable progress in piling
amongst the best in India, we feel
that we have made a positive start
and with the support of professional
partners who appreciate the value
of quality and fast execution, we
guarantee that we shall soon be
force to reckon with on the Indian
Construction Scene and
systematically grow with the Positive
India story.
IPS2 Mobile Mapping System
overcomes the challenge of
mapping 3D features at a high level
of accuracy with data and dynamic
imaging for any mapping projects,
also a great product for disaster
management. For road construction,
the conventional stakes and strings
system is no longer required as
NBM&CW MARCH 2011
 Post Event Report

Topcon machines control system not

only simplifies work process but also
reduce costs. Apart from road
application, the system works
seamlessly to maximize quality and
efficiency of all earthworks, thus
eliminating possible human errors,
increasing accuracy, reducing time for
survey calculations.
Summing up various systems now
available in Indian market, Nehru said
that this is the time when customers
are ready to accept these advance
technologies. So Topcon Sokkia India
is ready to introduce its machine
control system in domestic markets.
The company has offices and branches
in Delhi, Mumbai and Kolkata. It has a
well equipped Service Centre in Noida
with a team of talented expertise. It
has wide network of dealers covering
almost every part of the country.

NBM&CW MARCH 2011 219

 Post Event Report
Mr Ralf Beier, CEO Hess Group
appeared to be quite delighted
about the response from Indian
market where the Group has
successfully installed a number of
Hess-based plants in a short period
of time since commencement of its
business in India. Hess products
and services are serving the
construction producer market from
concrete blocks, interlocking pavers,
tiles, curbstones, retaining walls,
fly-ash bricks, autoclaved aerated
concrete (AAC) up to steel slag
utilization. All important Hess global
production lines are available to the
Indiamarket, he added.
Further he said that Group
market share is set to grow and he
is satisfied with this positive
response, Hess is in the process
of setting up its manufacturing
220
Hess Group
facility in India and it is expected to
be ready by the end of 2011.
Mr Beier confirmed the importance
of the Indian market to the Hess
Group and that having an own setup
in India is a following the
philosophy of the company. Hess
has always invested in strategic
markets in order to realize the cost
advantage of local production,
hereby saving transport costs and
import duties. The first locally made
machinery was shown at the
bcIndia exhibition in Mumbai. A
further important reason for Hess
to be present in India is to be
close to its customers. For this
reason Hess is also planning to
set up service locations around the
country. Hereby Hess is able to
provide its customers with fast and
competent after-sales service.
He informed that Hess
assignments in India include
commissioning a big RH1500 plant
with mixer and automatic handling
for Ecologic in North India. The
Group is also doing two major
flyash based AAC projects for
UltraTech and has recently
commissioned pipe machine in
Nasik. At present, we are
doing the installation of
wet press system for a
client in Kerala. Two
further orders have been
placed for RH-2000
fly-ash brick production
plants that are due for
installation before the
middle of the year. The
Group is expecting a few
more projects in the next
quarter and at least half
a dozen projects are in
the pipe line at final
discussion stage.
We are at it to
promote Resource
Efficient Construction
products using
mechanized operations,
but creating awareness
about has been a major
challenge. These
products have a number
of advantages over
conventional building products in
terms of faster construction, eco-
friendly, material and energy
conservation, benefits which
ultimately benefit the users in terms
of living quality and expense. Hess
extensive production programme
and application of future technology
concepts are today globally well-
known and the foundation for further
expansion in India and the
introduction of such technology to
the country have been laid, he
added.
NBM&CW MARCH 2011
 Post Event Report
Godrej and Boyce Manufacturing
Company Ltd participated in bC
India along with its principals Merlo
SPA and Imer International SPA of
Italy . The company displayed its 5
tonne diesel and new design 10
tonne diesel fork lift trucks.
Mentioning about Merlo ’s range
of telehandlers, Mr. Neville.H.
Wankadia, DGM-Marketing, Godrej
Material Handling and Mr. Davide
Milano said, “ Merlo ’s rough terrain
telehandlers are multipurpose
machines. It can e ss entially
perform the applications of cranes,
acce ss platforms, pallet handling
on rough terrain, among other
functions. However, we are looking
to make the machines deliver
“Fushun Cranes & Equipments
India Pvt Ltd.”, which is FUWA India
displayed their FUWA QUY 35 -
35MT crane.
The Company also displayed
2.5Mt /3.5 Mt Single & Double Mast
Work Platforms. This is the
replacement of the Scaffolding. They
222
Godrej & Boyce
optimum performance utility to both
construction and industrial
applications by providing value to
the machines through attachments.”
The officials further informed, “under
the collaboration tie up, we would
sell rough terrain telhandlers from
3 to 12 tons. However, we have
also developed a 16 ton machine
for selling it in India. The machines
to be offered would be price
competitive as compared to
contemporary product line available.”
They also informed, “based on the
requirement of the customers in
India, certain degree of
customization would be undertaken
in the telehandlers. However, the
Fushun Cranes
have sold more than 120 units of
them in the last 12 months.
The Modular House was also
displayed. It is a “Quick &
Economical Solution” for housing
labours, site offices, temperature
control warehouses, medical
facilities etc. This is the most ideal
basic machine would remain the
same.” Technical support for the
machines would be offered through
Godrej’s own technicians trained in
Italy .
On Imer Sci ss or Lifts, Mr.
Martin Connolly, International
Distributor Development Manager,
Imer International and Mr. Wankadia
said, “Godrej, will market Imer’s sci
ss or lifts and articulated boom
lifts, branded as Iteco from 6.50 to
19 meter working heights in India.”
On the technical attributes of the
products, the officials mentioned,
“the competitive product positioning
of the Iteco sci ss or lifts comes
from the productivity and higher
capacities it offers. The machines
are certified to handle full load
capacity even at deck extension and
can be driven at full height, an
attribute, no other manufacturer can
claim.”
According to Mr. Wankadia,
“while initially we plan to market
the product, however, in the later
stage, we would plan to go for a
technical collaboration with Iteco for
a ss embling the machine in India
. Sales and service support for Imer
sci ss or lifts and Merlo ’s rough
terrain telehandlers would be
provided through the well
established Godrej support network
of 150 sales and service personnel
at 16 branches of the company and
50 service dealers, he added.”
solutions when thousands of
labours have to be housed at a
virgin site to start work on a new
project site. The entire housing can
be erected in 15 days timing.
FCEIPL – FUWA India
registered a sale exceeding 110
cranes from June 2009 & addition
NBM&CW MARCH 2011
 Post Event Report
20 units order from Port & Erection
Contractors. During the bauma, an
order for 18 Cranes were
concluded, out of which 13 Nos.
were 35T cranes, 2 Nos. 80T
Crane, 2 Nos. 150T Crane, 1 No.
Cosmos Const. Machineries & Equipt.
Interacting at bC India, the company
Director, Mr. Mehul Shah said, “we
have recently launched certain new
products which includes Cosmos
ride on road rollers. Other than this,
224
100T crane & 2 No. of 250T Crane.
This was again a record sale.
It was also registered that the
company was getting a genuine
buyer almost every 10 min for Work
Platforms & Modular House.
we have also launched material
handling equipment for applications
of concrete carrying, bricks carrying
and tiles, sanitary material, sand
carrying etc. The material handling
The FUWA India which is
operating under the name of
Fushun Cranes & Equipments India
Pvt. Ltd. has been promoted by
Mr. Sanjay Vasudeo & Mr. Nitin
Madankar & Mr. Li Yunbo. There are
more than 400 FUWA Cranes
working in India & are supported by
26 service engineers & spare parts
worth more than 0.25 Mill USD at
their ware house at Navi Mumbai.
FUWA India has recorded the
highest sales in 2010 with an order
booking of 148 plus cranes. This
sale was basically a result of Quality
Product, After sales service, meeting
& exceeding customer needs and
Delivery of machines meeting
customer requirement.
The company would like to
continue to hold their No.1
position by rendering the most
economical solution for the
construction Industry through quality
products & quality services.
equipment can undertake 40 loads
per hour resulting in labor savings.
Besides this, our new product-
line also includes on wheel 25 cum
/hr twin shaft batching plant which
can be used for the direct pump
loading and for the transit mixer
loading. Cosmos has a distribution
tie up with Kumkang from South
Korea to market its Formwork
System in India.
The range of construction
equipment manufactured by
Cosmos includes; inline batching
plant, fully automatic revers drum
batching plant, twin shaft in line
batching plant, boom scrapper
batching plant, tower crane,
suspended rope platform, transport
platforms, tough rider articulated
type, and so forth. The company is
in a process of developing newer
products, added Mr. Shah.
NBM&CW MARCH 2011
 Post Event Report
Macons Equipments
Concrete making equipment
manufacturing major Macons
Equipments displayed its Semi
Mobile Concrete batching plant at
bC India.
Mentioning about the product,
Mr.B.R.Gururaj, Vice President Sales
Anupam Industries Limited
Anupam Industries also exhibited
at the show. Mentioning about the
product line offered by the company,
Mr. S.K. Malve, Director Technical,
226
and Marketing, Macons said, “the
semi mobile concrete batching plant
launched by it is available in three
models: 20 cum, 25 cum and 30
cum capacities. As compared to tyre
mounted concrete batching plant,
the new product launched by us is
Anupam Industries Ltd said, “we
are the largest supplier of EOT
cranes, gantry and goliath cranes
in India. Recently, we have formed
of skid mounted variant the
customer does not need any
foundation and can be placed on
the ground and started. The plant
is completely pre-wired and pre-
piped and fully assembled from our
manufacturing plant. This enables
very less site activities and the
customer needs to plug and start
the plant. The machines comes
with added features comprising pan
type mixer for continuous mixing ,
inbuilt water and additive tank and
above all the plant is fully automatic
with electronic weighing of
aggregates sand, water and
cement. The advanced features
provides more accuracy to concrete
mixing and enhanced cycle time.”
He mentioned, Macons has all India
presence for Sales and Service
points for customer support.
an alliance with Alfa of Italy to
assemble and market their cranes
in India.”
Further he added, “there are
many advanced features
our cranes can boast of.
This consists primarily of
the advanced controls
and safety features.
Through constant
research and
development we have
incorporated advanced
features in our cranes.”
On customer support,
Mr. Malve said, “we have
a pan India sales and
service network for
providing technical
support to our equipment.
However, we also provide
customized training to
customers.”
NBM&CW MARCH 2011
 ADVERTISERS’ INDEX MARCH 2011

Equipment & Machinery Telcon 67 HEICO 207

ACE 201 Terex Vectra 2nd Front Cover Industrial & Scientific 245
Ajax 185 Universal 19,68-69,87,111,153,177,231 Sokkia 237
Akona Engg. 213 Unisteel 193 Chemicals & Waterproofing
Allen Buildwell 109 Venus Equipment 211 Ashapura Volclay 88-89
Allen Pavers 187 Walia International 253 Asian Laboratories 243
Ammann 61 Wirtgen India 51 Bomanite 151
Apollo Industries 57 Zoomlion Heavy Ind. 27 CICO 141
Apollo Infra 91, 173 Gubbi Enterprise MT* Ironite 265
Atlas Copco 77 Jeetmull Jaichandlall P. Ltd MT* Kunal Chemicals 149
Ashok 250 Namdhari Engineers MT* MYK - Laticrete 113
BHS Sonthofen 103 Ramaas Enterprises MT* MYK - Schomburg 115
Capious Road Tech 131 Topall MT* STP Limited 143
Changlin 10,11 Saini Concrete Sys. MT* S.W.C. 147
Chetra Machinery 31 Cranes & Material Handling Bunty Builders MT*
Columbia Pakona 107 ABG Cranes 35 P.R.Enterprises MT*
Cosmos 181 ACE 203,205 Vardhman Chemicals MT*
Dominant 225 Anupam Ind. 169 Building Materials
Dozco 157 Comansa 15 Dextra 145
D&G Machinery 53 ECEL 117 Right Vision 241
Esquire-Cmac 191 Electromech 81 Reliance Industries 101
ECEL 117 Esquire - CMAC 215 Sekisui 43
Electro Magnetics 171 J.K. Work 183 Sintex 49,95
Greaves 127 Manitou - BF 17
Pipes & Fittings
Hess 21 Manitowoc Gatefold
Jamshedji 223 Saren Heavy Lift 266 Kitec 41
Jaypee 195 Sany 25 The Supreme Industries 39
Jayem 135 Voltas Cranes 167 Safety Equipments
J.B. Engg. 197 Zoomlion Heavy Ind. 27 Udyogi Plastic 175
JCB India OBC Crushing & Screening Cement
Kaushik Engg. 161
Nawa Engg. 71 Grasim Industries Ltd. 09
Lasco 219
Powersceen 93 Pumps & Gears
Liugong 33
Puzzolana IFC Premium Energy 65
Lonking 12,13
Sandvik 97 KSB Pumps 75
NMF Equipment 137
Terex MPS 73
Macons 227 Oil & Gears
Voltas 133,189
Marini Fayat 55 Valvoline Cummins IBC
Spare Parts
Masa 29 Iron, Steel, Glass & Aluminium
M.K. Vibrators 250 Metco 83
H & K Rolling Mill Engineers 23
Neptune 37 Suyash Tools 209
Jindal Aluminium 261
Powercurber 165 Formwork & Scaffolding
Sintex 255
Prime Technologies 47 Cosmos Sales Corp. 217
Qunfeng - China 14 Fastening Systems
Maruti Steel Fab 221
Revathi Equipment 163 British Scaffolding MT* Asons 257
Sany 25 Continental Scaffab MT* Sohan Lal Gupta 259
Schwing Stetter 125 Scaff India MT* Real Estate
Shandong Front Gatefold J.B. Formwork Systems MT* Landbank 45
Shri Engineering 129
Surveying & Testing Computer Software
Soilmec 105
Accro Tech 199 Tekla 123
SKG Equipment 263
Continental Scientific Syndicate 247
Speedcraft 228
E-Surveying 63
SRS Finlay 85

230 *MARKETRENDS SECTION SEE PAGE NO. 248-249 NBM&CW MARCH 2011
 Post Event Report

Jaso Tower Cranes

Jaso Tower Cranes displayed its City Tower crane
J5010 at bC event which has a maximum lifting
capacity of 2.5 tons at 40 metres jib length and a
minimum lifting capacity of 1 ton at 50 metres jib
length. The crane comes at a free standing height
of 45 metres and anchorage above 45 metres.
According to Mr. Kapil R. Ghai, CMD, Ispat
Infrastructure (India) Limited, “Jaso’s City tower
crane would be appropriate for construction of
affordable residential projects in India.” Ispat
Infrastructure (India) Limited entered into a
distribution tie up with Jaso Tower Cranes in
2009 for marketing its tower cranes in India.
Under this marketing collaboration, Ispat would
market Jaso’s topline tower crane having a
capacity range from 6 to 24 tons having a jib
length from 55 to 80 metres. City Cranes from 2
to 5 tons having a jib length of 35-52 metres and
luffing cranes from 5 to 18tons with jib lengths
ranging from 40 to 60 metres.

Maxmech Equipments Pvt. Ltd.

Gujarat based Maxmech be used to make different types of small box gutters etc. Self-propelled,
equipments displayed its new curb for highways, footpaths upto the machine is driven by a compact
slipform curbing machine which can 1220mm width and 150mm thick, water cooled diesel engine having
a rubber padded crawler
track of 910 c/c & 240 mm
width at front with a
hydraulic motor and gear
box. The complete
machine is mounted on
three hydraulic jacks one
at front and two at rear.
The company also
exhibited its new concrete
lining paver that can be
used for pavement of
canal, airport apron and
runway, roads, flooring,
reservoir, bridges etc. This
paver consists of two
hydraulic power pack
units, the first one is at
fixed console from where
the operator can handle
the machine and the
second one is travelling
unit.

232 NBM&CW MARCH 2011

 Post Event Report
Powerscreen, one of the leading
providers of mobile crushing,
screening and washing equipment,
exhibited their Powerscreen®
1000SR and Powerscreen ®
Metrotrak. Both the machines were
manufactured at the Terex facility in
Hosur, reinforcing the Powerscreen
commitment to the development of
the local economy and
infrastructure.
The 1000SR mobile plant
combines the high performance of
the popular tracked 1000 Maxtrak
with a double deck sizing screen
and a re-circulating system, all on
one single tracked chassis. This
Manforce Trucks Pvt. Ltd.
Manforce Trucks India exhibited new
mobile Schwing Stetter Concrete
batching plant mounted on its truck
MAN CLA 25.280 (6X4). The truck
carrying the batching plant has a
diesel engine of Man D -0836, 6.9
litres, 6-cyl. The maximum output of
NBM&CW MARCH 2011
Powerscreen
configuration enables customers to
take advantage of the site-proven
benefits of the Automax® cone
crusher incorporated into a closed
circuit screening plant, thereby
eliminating the need for separate
screening. This versatile, mobile
plant is ideally suited for secondary
and tertiary applications in
quarrying, where high quality, low
flake, single size aggregate and
sub-base materials are required.
The Metrotrak is a compact,
high performance track mobile jaw
crushing plant featuring the “M”
series single toggle jaw crusher.
With an aggressive crushing action
the equipment is 280hp @2400
rpm with maximum torque of
1100nm @1300-1700r/m. The front
axle of the machine consists of
heavy duty cranked forged I-beam
type with unitized hub bearings
whereas the rear axle consists of
and a high output even at tight
settings, the Metrotrak is ideally
suited for small to medium sized
operators in the mining, quarrying
and recycling industries. The
Metrotrak has an ouput of up to
175 tph and features a vibrating
grizzly feeder that has a heavy-duty
mechanical vibrating unit with twin
cast eccentric shafts. Finger bars
and underscreen allow grizzly fines
to be directed on to the main
product or optional side conveyor
by fitting a blanking mat or wire
meshes with a choice of apertures.
Variable speed control allows
smooth and continuous materials
feed. The integral product conveyor
is 800mm wide and the discharge
height is 2.9 metres. The heavy-
duty crawler track undercarriage,
fully skirted conveyor and remote
control ensure that the plant can be
set up very quickly and easily
moved on site. Dust suppression
sprays are fitted as standard and
among the options available are:
Side/dirt conveyor; radio remote
control; and magnetic overband
separator. Both machines were sold
to Powerscreen distributor Voltas.
Powerscreen stand at the show
was supported by the Powerscreen
sales team and Powerscreen
distributors: Advanced Construction
Technologies; Alpha Technical
Services Pvt. Ltd; Vijay Traders;
Voltas (Limited); Genavco: and
Genserv.
Man H9 & HD 9, 13120 planetary
with hub reduction, differential lock
and interaxle lock with stabilizer on
twin axles. Axle ratio of the vehicle
is 7.63:1. In addition, the company
also displayed its range of tippers.
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 Post Event Report

Mait India Foundation Equipments

Mait India displayed its Drilling Rig
Model HR260 at the show. The rig
has max. torque of 260kNm &
weight of 75 Ton. It is suitable for
drilling big Diameter bores in harder
strata / rock. Briefing about the
future development plans of the
company, Mr. D.V. Brahme, Regional
Manager, Mait India said that the
company is in the process of
developing special tooling and rock
cutting tools for the market.
Modifications are being made in
the existing product line comprising
bored piles, continuous flight
augurs, diaphragm walls, and
Driven / Driven cast in situ piles.
On service support, Mr. Brahme
said, “we would continue to focus
in reducing response time for our
machines working in the field. The
company will post its service
engineers to those locations where
many numbers of machines are
working. The stock of spare parts
is being increased continuously.
Mait India has set up its new
office for sales, service, spare parts
and training centre at MIDC in
Mumbai on Thane Belapur road, he
added.

Asia Motor Works Unipave Engg.

Products

The Gujarat based manufacturer, Unipave displayed

its pavers. At the sidelines of the show, its Director Mr.
Asia Motor Works (AMW) displayed its tipper trucks of
Sanjay Surelia, said, “our pavers are now approved
rock body, box body and trailer variants. In addition to
and tested by ARAI and the company would set up a
this, the company also displayed its standard truck
new plant at Vatva to expand its production capacity.”
models at the show.

234 NBM&CW MARCH 2011

 Post Event Report
Columbia-Pakona Engineering Pvt. Ltd.
“Columbia-Pakona Engineering Pvt.
Ltd. manufactures fully automatic
Concrete Products Plant, and deals
with Vortex Hydra Concrete Roof
Tiles Plant in India and displayed
their product range at the recently
Ammann Schweiz AG
Ammann Schweiz AG of Switzerland
participated in bc India 2011.
Mentioning about the product line
being contemplated for the Indian
market, Mr. Rolf J.Jenny, Senior Vice
President Corporate Development
said, “we are positioned globally
as number one in asphalt batching
plants in terms of volumes. With
our high capacity asphalt batching
plants, we are looking forward to
target big road construction and
rehabilitation projects in India which
require high volumes of asphalt.
NBM&CW MARCH 2011
concluded bC India. Pakona
Engineers (I) Pvt. Ltd. manufactures
vertically cast reinforced Concrete
Pipe Plants under licence from Mario
Croci E Figli Srl, Italy. Elaborating
on the technical attributes of the
The plants can be installed in a
centralized location catering to the
requirements of numerous users.
This will enable the road
construction companies to focus on
their core job of executing the
projects where they can cut down
costs of putting and operating a
batching plant.”
Mr. Jenny mentioned that they
are also planning to develop the
bitumen recycling market in India
with the technological competence
of our machines, although the
concept of bitumen recycling is
much nascent in India.
The Ammann composite
product line would be marketed
through a Ammann group
company formed in India. He
mentioned that in a broader
perspective, we are planning to
provide total equipment
products, a senior marketing officer,
Mr. Soji said, “Our concrete block
machines are structurally strong and
more productive as compared to
contemporary machines.” Our block
machine can cycle at the speed of
6 cycles per minute, a rare feature
which is not available in other
machines. Additionally, our machine
vibrates the mould vertically which
results in stronger product and less
cement consumption. On customer
training program, he informed that
training is imparted to the customer
by our training staff at our plant
and also at customer site. Apart
from this, ensuring prompt supply
of components and parts the
company supplies these products
by utilizing the quick services of air
cargo to deliver parts and
accessories from our warehouses
in Mumbai and Baroda to our
customers at different locations
across the country.”
solutions to the market for asphalt
roads i.e. Asphalt plants, paving,
compaction and rolling equipments
which are all strength of Ammann
group. The Entity being formed in
India would cater to Sales, Service
and Training to Ammann
customers. India base would be
assisted by Ammann middle-east
and Ammann China set ups which
have already very good numbers of
Ammann plants and equipments.
Mr. Narinder Jit Singh an Associate
of Ammann in India mentioned that
very high priority would be given to
after sales service and providing
requisite comprehensive training to
Ammann customers so that the
customers can get full advantage
and high productivity from Ammann
plant and equipments. Such a
service would also be provided at
customer plant location as well.
235
 Post Event Report
Terex Corporation
Initiating the discussion, Mr. Steve
Filipov, President - Developing
Markets and Strategic Accounts of
Terex Corporation, said that
overseas construction equipment
players are indeed euphoric about
the promising potential of their
products and services in India. The
country has various advantages -
cost effective in terms of manufa-
cturing as it offers to be the most
convenient place to export products
and services to South Asian, Middle
Eastern & African markets and a
talent pool that is highly competitive.
In reality, Terex Corporation is more
euphoric than the rest. We currently
have a strong presence in India in
certain product lines and would like
to further strengthen it in the coming
future, he said.
Talking about the Terex
expansion plans, he said that they
have put in place a number of
expansion routes focusing on
introduction of new products and
services that reflect their cutting
edge technology attributes and their
firm dedication to the market and the
customers. Terex has plans to
deliver its global support to Indian
236
construction equipment industrial
stream keeping in view customer’s
prime interest to maximize their rate
of return on product assets
acquired from the corporation. The
corporation looks forward to
increasing its manufacturing, R&D,
marketing and supply chain
presence. There are plans on cards
to double the existing capacities of
our facilities in India and utilizing
the same effectively for our all
business areas. Expanding these
activities would involve significant
investment and we are well-
equipped to do so and play a more
proactive role in supplying
sophisticated and modern products
to help build globally efficient and
competitive equipment market in
India. About the nature and quality
of the Indian markets, he said
gradually it is becoming more
matured with new buyers who do
not seem to be very much price
sensitive as was the case two-three
years back. They value the
additional components, superior
technical attributes and
comprehensive technical
assistance and services which our
products and services ensure fully.
Adding in the discussion, Mr.
Jehangir Ardeshir, President & MD
of Terex India categorized these
buyers into two types where the
first one is not very price sensitive
whereas the second one is very
sensitive to the price factor. Slowly
and steadily, they are also joining
the mainstream buyers recognizing
the fallacy that acquiring technically
advanced quality products does
mean a bit more of initial investment
but their return on investment (RoI)
is better over time. In the process
of acquiring equipment, it must be
realized that it is not only equipment
which is being bought but also
related services – it is all about a
complete solution, he added.
Both Steve and Jehangir
emphasized that India still needs
high tech products and services to
implement various infrastructure
projects at hand and future projects
in its task of infrastructure
development. Terex is appropriately
placed to chip in the process by
working even more closely across
the country through seamless
integration of its global technical
and business practices with local
ones. Terex Corporation is a
diversified global manufacturer
operating in four business
segments - Aerial Work Platforms,
Construction, Cranes, and Materials
Processing. Terex manufactures a
broad range of equipment for use
in various industries, including the
construction, infrastructure,
quarrying, mining, shipping,
transportation, refining, energy and
utility industries. Terex offers a
complete line of financial products
and services to assist in the
acquisition of Terex equipment
through Terex Financial Services.
Greater localization would be the
prime focus of Terex operations in
India.
NBM&CW MARCH 2011
 Post Event Report
Schwing Stetter India Pvt. Ltd.
Schwing Stetter India Pvt. Ltd.
(SSIPL) displayed its new truck
mounted mobile batching plant
mounted on Man chassis and
comes with a capacity of 18 cum/
hr. The machine has a concrete
discharge height of 3.75 metres
while aggregate storage filling
volume is 12 cum. The active
reserves aggregates of the plant
are 12cum and the water tank
capacity is 1000ltrs, whereas the
weighing capacity: aggregate 375kg,
binder 200kg, and water 100kg. The
pump comes with a water pump
capacity of 28cum/hr. The added
feature of this equipment is PLC
based control systems with
maximum number of 5 recipes.
Stating about new mobile plant
Mr. Anand Sundaresan, Managing
238
Director, SSIPL said that the new
product is good for the construction
sites with tight job schedules. The
most notable characteristic of this
product is that it comes with a
mobility element added with a
capacity to batch high concrete
volumes. The equipment can be
best used in road projects having
short duration, canal projects (where
creating heavy foundation is a
critical issue), and ready mix
concrete industry. The machine has
less cost of operation as it is driven
by a power take off engine.
SSIPL also launched its new
SP2880 and SP8800 trailer mounted
stationery concrete pumps for the
Indian construction sector.
Highlighting the application areas
of the products, Mr. Sundaresan
said, “the newly launched high
capacity concrete pumps are
capable of pumping concrete to
200–500 mtrs. in highrise
construction projects and much
suitable for dam projects. The
pumps have proven their worth in
construction of the Petronas towers
in Malaysia and other highrise
constructions globally. With the
introduction of these high capacity
pumps, we are now in
such a position where
we can provide solutions
to any highrise
construction in India.”
SP8800 has a maximum
theoretical output of 94/
63 cum/hr whereas SP
2800 comes with a
maximum theoretical
output of 101/58 cum/hr.
While speaking of
sound proof canopies
being provided by SSIPL
Mr. Sundaresan said that
the canopies will help in
reducing noise of
concrete pumps when
they are used in urban
areas, precisely in areas
where sound levels
needs to be kept less
than 70 decibels. To
provide enhanced
support and customized
concrete solutions to our
customers he said that
we would keep interacting with our
customers to understand their
requirements better to provide them
tailor made solutions. There are
good examples where we have
provided tailor made concrete
solutions to Bandra Worli Sea Link,
Parbati Hydel Power Projects, and
so on.”
NBM&CW MARCH 2011
 Post Event Report
Rotary Construction Machinery India
Rotary Construction Machinery India
participated at bC India 2011 along
with its principals-Allpacks of
Holland, Geax SRL of Italy, and HZ
Vislord Machinery of China.
Mentioning about the Allpacks
hydraulic pile hammers and
vibratory hammers, Mr. Eric
Buitendijk, MD, Allpacks said, “our
equipments are almost 15 -20%
cheaper as compared to
contemporary products and are
fitted with Caterpillar Engines and
NBM&CW MARCH 2011
Rexroth hydraulics. The most
competitive feature of the impact
pile hammer is that it comes with
impact energy analyser which
enables visual check for actual
stroke height and calculation of blow
rates.”
The Chairman of HZ Vislord,
Mr. Li Panfeng said, “the most
advantageous element of our
machine is our competitive price
which is cheaper at least by 20%
as compared to other contemporary
Speedcrafts
products. The machines are fitted
with Volvo Penta engines with a
warranty from Volvo itself and the
company has sold two units in
India so far.
Geax Compact drilling
equipment which is capable of
carrying out small foundation works,
was launched at the event. The
operating cost of the machine is
less and can be easily transported
from one place to another. Geax
entered into a distribution tie up
with Rotary Construction Machinery
India said the senior company
official.
Citing about the technical
support to customers for the
products of the principals, Mr.
Tejdeep Singh, Director, Rotary
Construction Machinery said, “we
would offer requisite technical
support through operators training
which would be provided in house
at our premises in Mumbai. In
addition to this training, we would
also provide training support
through our engineers. We are at a
very good position to provide timely
components availability in terms of
after sales support and also provide
maintenance of the machines at
our own workshop.”
Speedcrafts, introduced its
Asphalt mixing plants used for
road construction at bC India,
manufactured in joint
collaboration with ADM of USA.
The Company manufactures
Asphalt plant, concrete plant,
paver finisher, pothole
repairing machine, road roller,
road sweeper and chip
spreader for the industries.
239
 Post Event Report

Nawa Engineers
Nawa Engineers displayed its
‘Duracone’ hydraulic cone crusher,
Tripleks’ series horizontal screens,
and machinery for crushed sand
production at the show. The
company exhibited its most popular
brand of NAWAPACTORS VSI
Crushers with capacity range of 50-
500 TPH for various applications of
crushed sand production.

Universal
Universal exhibited India’s largest
reversible mixer (300 ltr) in addition
to its other products that include
mobile concrete batching plant,
aggregate feeding system, concrete
conveyor, admixture dozing system,
mini dumpers, sand washing and
screening machines, bar bending,
bar cutting and bar straightening
machines, machines for vertical
movement of men and machinery
etc.

Lonking
Lonking, the manufacturer of construction equipment participated at bC India to promote its brand building in the
country and other overseas market. Lonking Machinery India Pvt Ltd is developing strong dealership network,
including customers’ service hotline, spare parts management centre, and focusing on marketing and training.

Jamshedji
Jamshedji, a leading manufacturer
of construction machinery exhibited
its wide range of products including
concrete pump, concrete mixer,
concrete cutter, concrete vacuum
dewatering systems, vacuum pump,
ride on trowel, earth rammer, power
trowel, and surface (screed) vibrator
at the show.

240 NBM&CW MARCH 2011

 Post Event Report

Kaushik Engineering Works

Kaushik Engineering Works (KEW) at the show
displayed its Road Sweeper/Broomer for cleaning
roads, places, factory yards etc. The company offers a
wide range of road construction equipment including
Mobile Drum Mix Plant, Wet Mix Macadam Plant,
Bitumen Pressure Distributor, Concrete Batching Plant
and other allied equipment.

Arrow Machinery
As far as bC India is concerned we exceeded our
expectations allowing us to catch up with many of our
existing customers and introduce our products to a
large number of new prospects, said Mr. Tim Andrews,
Managing Director, Arrow Machinery.
In addition to the local Indian market we fielded
enquiries from 10 other countries including Middle
East, West Africa, Portugal and USA. A large crowd
appeared when we featured a movie of our latest
upgraded ARROW 750XL SLIPFORMER. We highly
recommend bC India to anyone doing business in the
region.

Unisteel MARSMAN
Unisteel disseminated MARSMAN India Ltd, a renowned manufacturer
information about its RCP and exporter of Jaw Crushers, Impact
750 paver, PVR 1001 paver Crushers, Vibrating Screens, Feeders,
and Cement Mortar Lining Hoppers, Conveyors system and its allied
Machine at the show. The equipments of various type and sizes made
company is the manufacturer its notable present at bC India.
of concrete pavement
machineries used in the
development and finishing of
canals, airport runway
concrete surfacing, concrete
for Reservoir, pre-cast
concrete slabs for building
and surfacing roads and
highways etc.

242 NBM&CW MARCH 2011

NEWS Project Briefs
Infra Developments
Infra Agenda
The need for quick delivery of
results has been an ongoing
exercise for the Government to
infuse new initiatives to get better
performance from infrastructure
sectors. But every new change
affected makes the situation
unchanged. To this effect, there have
already been reviews of performance
of infrastructure industries and
departments connected with them
but these have been of no avail
and initiatives have proved to be an
exercise in futility. There is an
undercurrent of expression of
disenchantment over uninspiring
performance of infrastructure
departments. The recent Ministerial
shake up in key economic and
infrastructure ministries in natural
gas, civil aviation, roads and
highways, heavy industries, urban
development has been another soft
handling attempt. The move to re-
jig various ministerial portfolios
came at a time when the country is
facing twin challenge of containing
inflation and improving industrial
performance. At the best, it only
delivers a diffused message that
244
departments need to pull up their
socks and a further exercise would
be undertaken after the budget
session. These changes aimed at
accelerating the pace of work and
improve performance leave
everyone guessing whether they will
achieve what is desired particularly
bringing back the sectors on the
road to recovery as promised by
their predecessors. One can only
hope that in the new dispensation,
the infrastructure sectors
growth would be taken to new
heights and moves ahead on a
visible infrastructure agenda swiftly
under new management structure
and nonperforming system is under
regular scrutiny beyond weak
tinkering.
Raw Materials,
Finance and Labor
Crunch
A number of ongoing projects are
facing a fund crunch to go ahead
with the work. Project developers
are finding it difficult to raise money
to procure raw materials. Added to
it is the deferment of projects from
the governmental agencies,
reluctance of investors to put money,
shortage of trained workforce.
Companies like L&T, HCC and
IVRCL are particularly affected due
to these concerns and are of the
view that core sector could witness
a slowdown spell and have
postponed their projects in hand.
Orders worth more than `50,000
crore have been pushed back by
various governmental as well as
private agencies due to some of
these factors, says L&T President
Construction, Rangaswami. Echoing
the same HCC, Chairman Ajit
Gulabchand said, investors are not
pumping in money and orders are
slowing down. He in particular cited
the example of Lavasa project
which is facing problems due to
environmental issues and has
caused a concern in the minds of
financers. Finances are tight as
banks are unwilling to lend money
to projects which do not have a
clearance in place. Then there is
also the impact of rise in steel and
other building materials prices.
There is also an acute shortage of
construction workers with most
workers opting for government
promoted employment guarantee
schemes. Due to this, wages have
also gone up and the net result is
that raw materials and labor
constraints are slowing down the
pace of works in the construction
sector.
Gold Bonds for Infra
Sector
Banks have mooted a proposal and
have sought Government approval
to raise funds via infra and gold
bonds with long-term tenure. Banks
have stated that they are dominant
lenders in the infrastructure sector,
so they should be allowed to raise
funds through such tax free bonds.
Currently, only infrastructure
financing companies like IDFC, L&T,
REC, PFC, Srei Infrastructure
Finance as well as IFCI and LIC can
issue such bonds. The bankers
have therefore sought level playing
field for them in this area. They
have also sought TDS exemption
on other sources of income
including brokerage income.
NBM&CW MARCH 2011
NEWS Project Briefs
World Bank
Assistance
During 2010, the World Bank has
provided funds assistance to over
500 projects amounting to $85
billion. Of this, IBRD loans amount
to $45 billion while IDA credits stood
at $40 billion. In the recent meeting
with WB group president, India has
negotiated with the Bank for
increasing the SBL. Last year, the
Bank earmarked $3 billion to
support various infrastructure
programmes in mitigating adverse
impact of the global economic
crisis. For this year, WB has hiked
India cap by $2 billion.
Global Project Finance
Global project finance volumes as
per report by Dealogic rose 22% to
record $354.4 billion. In this, India
accounted for $81.4 billion or more
than a fifth of the total and higher
than any other country, through 163
projects. The report of Dealogic
Global Finance Review for 2010
said India was the most active
market as deal volumes increased
73% to $53.6 billion from completed
loans. SBI topped the chart of
mandated arranger ranking with
$25.3 billion from 69 deals. The
strong project finance activity in
India comes amid rising concerns
over headwinds to India’ growth
story. The strong project finance
number should dispel doubts about
the investment activity and India’s
case appears as bright as ever as
NBM&CW MARCH 2011
far long-term investors are
concerned. Despite report about
delays, projects appear to be
reaching execution stage in large
numbers than anywhere else and
India enjoys lion’s share of global
project finance, says the report.
N-E Nets `1000cr
Infra Booster
With private investors across varied
areas including infrastructure,
hospitality, agro-based industries
and education showing increased
interest, the North-Eastern region
of the country is all set to get `1,000
crore investment. After the recently
concluded sixth summit on
investment in the region, the
government is very hopeful
amassing investment worth `1,060
crore, Union Minister of
Development for Northeast Region
(Doner), B K Handique said.
UN Infusing `1,89L-cr
in Construction
Sector
The United Nations and its sister
bodies are all set to fire `1.89L-cr
($42 bn) booster into the Indian
construction sector covering real
estate and infrastructure projects
across the country. In this
connection, top brass of the expert
group of United Nations Joint Staff
Pension Fund (UNJSPF), an expert
group advising UN on where to
invest the pension funds, had
recently held parleys with the Indian
asset managing companies
including Asahi Glass, Hero Honda
group and Avantha group to push
its corpus of pension funds in this
country.
According to the UN Secretary
General’s representative, Warren
Sachs, the world body is keen and
is aggressively scouting for
diversification opportunities for its
investments in the emerging
markets around the globe and
specifically India. Moreover, the
younger age profile in this country
gives the world body more
confidence that Indian economy is
not just vibrant and going to grow
but probably end up growing as
fast as, if not faster than China and
the fact makes India an ideal
choice for the world body to invest
its pension funds, he insisted.
Coimbatore Corners
`3,000cr Infra Facelift
Buoyed by the huge business
potential in the city, the state
government is all set to infuse
`3,000 crore in various infrastructure
facilities in the next couple of years
as top ranking industrial houses
including construction and
engineering giants like Larsen and
Toubro and Suzlon have started
setting up their manufacturing units
across the city.
According to sources, the Airport
Authority of India (AAI) has decided
to invest `400 crore in setting up
its biggest non metro airport in the
area. Apart from the two bypasses
which would provide a virtual
circular road facility, work on the
four laning of NH-47 from
Chengapalli to Walayar on the TN-
Kerala border has already been
started at an investment of `850
crore.
In addition, the National
Highway Authority of India is also
building Eastern bye pass outside
the city from Sulur to Mettupalayam
involving an investment of `660
crore.
245
NEWS Project Briefs

Road & Highway Projects

Private Bank Keen
on Funding Road
Projects
Finding that road projects in the
country are giving good return on
investment, private banks are very
keen to fund road projects. Three–
four years back, there were only
nationalized banks which were
giving such loans as private banks
would not touch these long-term
gestation projects, said a company
engaged in road construction
projects. As a result of which, today
road companies have a wider
choice and the basket of lenders to
this sector has increased. Earlier,
there were five – ten who used to
regularly lend for road projects.
Over the years, lenders have
become more confident about the
road sector, as it has demonstrated
quite a few success stories, said
CEO, IL&FS. Construction costs in
the sector have become more
stable as compared to three-four
years back. Now costs are under
some control. Policy reforms and
more importantly, better project
management, better traffic
estimation, cost, time and contract
management has improved the
perception about the road sector,
said Bank of India. This has
advanced the break-even for many
road projects. It is more so for
national highway projects than state
projects, the Bank added. RBI
extension of loans to infrastructure
as secured loans, where bank can
ensure that infrastructure assets
can be used as a security for the
loan, has given the banks more
headroom to lend to these projects
benefiting the road construction
companies. According to experts
road construction companies are
becoming more efficient, with many
projects being commissioned
without much delays, thus making
banks more confident about their
execution capabilities.
Punjab Focuses
Roads Sector
Assigning top priority to the quality
road building concept, the Punjab
State Road Sector Project (PSRSP),
which has recently launched one of
the largest road projects with a
length of 900km and involving an
investment of `1,500 crore, with a
rider that the road builder’s job will
not just end with the completion of
the project but they will also have
to maintain the road stretch for the
next 10 years, said the state PWD
Minister.
New Technology for
Stronger Roads
Under flak from various quarters
about deplorable roads in the
Capital, MCD is all set to propose
an ambitious `1,000 crore scheme
to build stronger roads across the
capital with 10-12 inches thickness.
We want to ensure longer life
for city roads. The plan is to use
ready mix concrete technology and
pebble machines to build roads
including rural road covering 1,000
to 1,500 km of roads. As per initial
estimate the cost might be `1
crore a km, which could change
after the final estimates, said
chairman of the standing committee
of MCD. He added there will be a
25-year that guarantee for the roads.
For the time being, MCD will zero in
on only two or three companies for
this scheme. To ensure that the
quality is well maintained, MCD
plans to start payment to the
contractors in installment only after
five years. Six km of long life roads
being built using a different
technology, was recently unveiled. A
Ready mix plant has been installed.

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246 NBM&CW MARCH 2011

NEWS Project Briefs
Govt Clears `2,500cr
Port Project
The Vizhinjam International Port and
Deep Water Container Terminal
project in the downstream Kerala,
which involved an investment of
`2,500 crore, has secured green
signal from the Union Environment
and Forests Ministries.
A consortium of banks and
financial institutions led by State
Bank of Travancore is keen to raise
and arrange the required funds to
Delhi Cargo Terminal
The first phase of expansion of the
cargo terminal at Delhi’s
international airport is set to be
completed in few months time.
Turkish group Celebi Holdings is
the company in charge of the
NBM&CW MARCH 2011
Port Projects
carry out the project and a
memorandum of understanding in
this connection would be signed
very shortly, State Minister for Ports,
V Pillai, said. He said that the
clearance came after the State
Secretary, Ports and Managing
Director of special purpose vehicle
Vizhinjam International Seaports
Limited, Sanjeev Kaushik presented
the case before the committee set
up by the Central Government to
look into these issues and it is
currently going through the 14
requests for qualification bids for
taking up more ports projects which
have got entangled in the
environmental issues.
On Anvil: Port Sector
Fund Worth
` 50,000cr
Sensing umpteen investment
opportunities worth `2.87L-cr by
2020 in the Indian port sector, the
Union Shipping Ministry has
Airport Projects
upgradation of the cargo facility at
the airport and the company has
already spent $35.2 million on
construction and $10.2 million for
purchase of new equipment.
The complete expansion of the
cargo terminal which covers an area
of 70,000 sq.m, will be completed
after a year. Commenting on the
expansion of cargo facilities in
India, Canan Celebioglu Tokgoz,
Vice-Chairman of the Turkish
company said, “It is good that India
is looking seriously at its cargo
infrastructure upgrade."
The company expects yearly
revenue of $70 million for its
operations at Delhi’s cargo terminal
chalked out ambitious plans to set
up debt fund with a size of
`50,000cr to meet the day-to-day
financing requirements of the port
sector. In addition, the proposed
fund will also make finance
available to other infrastructure
sectors including road and
highways, power and telecom
projects.
According to sources, the
government is setting up the fund
to address the non availability of
easy bank finance to the sector
which is heading for a massive
capacity addition. The funds lying
idle with the major port trusts would
be used to float the new institution.
As the port projects have normally
long gestation period, banks are
normally averse to finance these
projects as they are also facing an
asset liability mismatch and the
proposed fund would be another
player apart from the IIFCL which is
currently operating with limited
success.
and despite the challenge, it prefers
the brownfield expansion contract.
“We are serious about the
brownfield contract because we
want the customers immediately,”
said the company.
Celebi is now also looking
forward to bid for the cargo terminal
at Navi Mumbai. The company is
already bidding for the cargo
terminal tender at Mumbai’s existing
international airport. According to Mr.
Jungbir Singh, Board Member,
Celebi Holding, and the company’s
India representative, “If the Navi
Mumbai project goes on stream, it
will be very interesting as a lot of
business is likely to move there.”
251
NEWS Project Briefs
Cos Pulling out from
Rly Projects
Desperate at the repeated
postponements of financial bidding,
multinational behemoths could well
pull out of the key PPP projects of
Indian Railways. Engineering giants
Bombardier, Seimens and Alstom
shortlisted for locomotive factory in
Bihar and a coach plant in West
Bengal have indicated so. The
projects are on the priority list of
the railways but financial bidding for
the same has been postponed
several times, upsetting the plans
of these companies who have
similar projects in other countries.
In their communication to Railway
Board, they have indicated that the
repeated postponement in financial
bidding could dampen the spirit of
the bidders which will be
detrimental for the projects
competitiveness. They have asked
railways to stick to the current
deadlines. The Railway Board, is
252
Railway Projects
examining these issues. These
projects are important for the IR as
it has no wherewithal of investing
nearly `3,000 crore required to set
up these facilities in the country.
There has been no addition to
railways development fund and
capital fund in the last two years.
IR Dedicated Rail-
freight Plans
Having sought $9 billion loans from
the World Bank and Japan for the
planned freight railway to link major
cities by March 2017, IR has
initiated discussions for possible
venture with Reliance Infrastructure,
Tata Group and L&T to build an
`8,500 crore ($1.9 billion) stretch of
national freight railway. The project
may invite private participation in a
530 km section linking Son Nagar
and Dunkani, both in eastern India.
Dedicated Freight‘s network will
comprise two corridors totaling
about 3,300 km. The planned
venture could draw a lot of interest
from the private sector companies.
WCS Projects
With the inauguration of first green
railway station at Manwal on the
Jammu-Udhampur route, India gets
its first green railway station, a
small step to have World Class
Stations (WCS). As this tiny station
faced frequent power cuts, it has
been provided with supply of solar
power. And its all systems are
working on solar power. To reduce
the existing load, some of the
surplus fittings have been
removed and energy efficient fittings
have been added. Station building
load has been segregated in two
portions with each portion being
fed by one group of solar power
panels. The complete work has
been done departmentally, without
any outside assistance.
At the other end, the ambitious
programme to go in for WCS with
New Delhi station on active agenda
along with a few others does not
seem to be moving ahead and there
is almost shutters down on these
projects. New Delhi railway station
modernization programme taken up
with great fanfare, after spending
`10 crore in paying consultancy has
been shot down by various local
agencies, NMDC, DDA on technical
grounds.
NBM&CW MARCH 2011
NEWS Project Briefs
Private Hydro
New changes in the national tariff
policy have been made mandatory
for private players in hydro power in
bidding for allocation of hydro
projects. The move is aimed at
creating a level playing field between
the private and public sector
companies. This is expected to keep
checking electricity tariff by
restraining private players from
offering upfront premium to state
governments to bag projects. In
addition, it will introduce a
transparency in bidding for the
projects. It is also expected to alter
the valuation of a host of private
companies, who have bagged a
number of power projects from the
states offering better financial terms
than envisaged under the national
hydro policy. Under the new policy,
projects are allowed to sell up to
40% of their capacity under
merchant route in the market. With
new policy in force, hydro sector
which has been lagging behind will
get a boost, say experts.
Power Firms Seek
Funds from China
As rupee interest rates are soaring
and local banks are failing to keep
up pace with the demand of about
$45 billion, `2 trillion of equipment
orders, power developers in the
country are seeking financing from
China.
Lanco, Adani, SMR Energy and
Moser Baer are talking to China‘s
export banks for loans.
Reliance Power has already
borrowed $1.2 billion from China
Development Bank. Utilities are
turning to China as they are buying
boilers and turbines to help meet
India’s 100,000mw capacity addition
target in the five years ending March
2017. These companies have
agreed to have MoUs with the
254
Power Projects
Chinese power companies for a
total of about $45 billion of
equipment.
JP Power Pushes
`45,000cr Investment
Plans
The Jaiprakash Power Ventures
Limited, which is a part of the
Jaypee Group, has set aside a
staggering sum of `45,000 crore
for building multiple power projects
including hydro power, thermal
power and wind energy plants
across the country in the next five
years. It has decided to set up four
thermal plants, two each in Uttar
Pradesh and Madhya Pradesh with
a generating capacity of 6,120 mw
of power using supercritical
technology.
According to the Managing
Director, Suren Jain, the company
has sufficient funds for meeting the
financial requirements for the on-
going projects but alongside it is
also keen to raise about `2,500
crore after March 2012 for meeting
the future expansion plans. The
company is currently aiming to
generate 13,720mw of power by
2019 by setting up a mix of hydro
and thermal power plants across
the country.
Coal-fired Ultra
Supercritical Project
India is to develop coal-fired ultra
supercritical power projects. A
800mw coal–fired project is being
set up jointly by Bhel, NTPC and
Indira Gandhi Centre for Atomic
Research (IGCAR).
The `10,000 crore plant being
developed by IGCAR would be 5
percent more efficient than the
prevailing supercritical technology.
The project would pave way for
cleaner energy and cut rising
imports of coal for power generation.
The venture is aimed to cut on
rising cost of imports for energy
needs as by 2030 the country would
have to import 55% of the fuels.
The country would be importing 90%
of the crude oil by 2030. The new
plants through this technology would
improve thermal plant efficiency and
cut pollution. The plant is likely to
be in operation by 2017, said
IGCAR.
PAT Scheme
The Union Power Ministry under the
National Mission on Enhanced
Energy Efficiency, has identified
eight industrial sectors to invest a
staggering sum of `30,000 crore in
the next three years. The sectors,
among others, included thermal
power plants, iron and steel,
aluminium and cement.
The official said claiming that
as a result of the investment,
companies would be able to save
up to `30,000 crore annually after
the completion of three years under
the perform, achieve and trade (PAT)
scheme. PAT scheme is an
important mechanism under the
national mission on enhanced
energy efficiency, is one of the eight
missions under the National Action
Plan on Climate Change. It is
mandatory for the notified sector
industries to be a part of this
scheme and may invite a penalty of
`10 lakh for non compliance.
NBM&CW MARCH 2011
Steel Construction
Design Flexibity in
Construction with Steel
Rajesh Maheshwari, Head Technical Marketing (Coated Steel) at Tata BlueScope Steel Limited
S
teel has become a universal
building product due to its
strength, versatility, durability
and economic value. The use of
coated steel for structures, roofing
& wall cladding is growing rapidly
because it offers a variety of benefits
like aesthetic appeal and long
service life. As a result of the
metallic coating (zinc / aluminum /
zinc–aluminum alloy) on the base
steel, today’s metal roof & wall
panels resist corrosion and provide
a service life of 20 years or more of
trouble-free performance. Using
coated steel for framing is an
excellent method to build a building
that will last for generations. These
buildings look like any other and
you would have to be told one had
256
a steel frame. “Steel” buildings can
be constructed in virtually any
architectural style and size with
many pleasing features and
finishes. The result of this is out
there for everyone to see with
numerous examples of Industrial
and commercial applications using
coated steel.
Building
Construction-Design
flexibility with steel..!!!
When we talk of design flexibility of
a building material pertaining to
construction, following becomes
important for its adaptation in the
building design.
Can this material be used for
residential/industrial/commercial
purposes?
Is this material suitable for all i.e.
low, mid and high-rise structures?
How easy is it to use it? Can the
local unskilled labour be used?
Can the small structure be self built
by user?
Aesthetically how would it appeal?
Can one make fancy designs with
it?
Cost wise how does it compare?
Are there choices/variants for
different users with different
financial capacities?
How much time does it require to
build a structure with such a
material?
NBM&CW MARCH 2011
Steel Construction
Can the design with this material
allow for easy expansion/relocation/
reuse?
Can more free space possible
within same buildup area?
What is its compatibility with other
construction materials in same
building?
And very important how easy/difficult
is its maintenance?
And when one thinks of steel
for building construction, its usages
would be presumed primarily for
the strength steel posses. It is a
little difficult to consider that steel
provides the design flexibility also.
But then in the modern era, the
innovative and very impressive
buildings with steel have been in
existence around the world. It would
have been impossible had steel
not provided flexibility in its usage.
Let us discuss how does steel as
building material offers functional
as well as aesthetic qualities and
provides design flexibility.
According to International iron
and steel institute (IISI), 1/3rd of the
total steel produced is consumed
in construction activities and it is
expected to go higher and higher. It
is because of the flexibility it
provides to designer and user. The
very first flexibility steel provides is
for primary members in the form of
rolled sections v/s fabricated one
i.e. conventional building v/s Pre-
engineered Building (PEB)/Metal
Building Systems. But when we
consider coated steel sheeting, we
are talking of the flexibility it provides
in the form of variety of cladding
profiles in multiple options in colors,
paint systems, metal coatings,
strengths (grades), lengths, widths,
thicknesses for nearly every
conceivable building design. Thus
coated steel sheets offer excellent
design flexibility, and contributes to
energy savings through its high
reflectivity, recyclability & reusability.
Reduction in consumption is also
achieved through usage of thinner
and high strength material thereby
contributing towards environment
258
protection. Solutions are there for
urban/suburban, individual, mass
market in prefabricated units,
customized units with high
architectural design, commercial/
residential, Do-it-yourself kits (with
generally pre-punched service
holes for electrical and plumbing).
Long life and low maintenance are
the driving forces behind most
commercial building exterior
treatments. For these benefits, of
the many options available, coated
steel has emerged as the roof or
wall material of choice in many
applications.
Design Aesthetics
Many building owners seeking long-
term roofing solutions are insisting
on metal roofs that offer both curb
appeal and exceptional
performance. Bold design that
inspires and creates a lasting
impression is made possible with
metal. Of it, coated steel is very
flexible because it can be used
with various other materials to
create a contemporary and stunning
look.” Steel can accommodate a
variety of external finishes of
brickwork, insulated renders, timber,
tiles, and curtain walling. Steel can
be easily cut to custom lengths
and widths, so builders can design
to varied choices. Architects and
designers can employ longer spans
without requiring as many structural
or load-bearing walls or partitions.
The result: more attractive design
options, including longer floor
spans, higher ceilings and larger
open spaces. Roofing and walling
sheets come in a range of profile
shapes. Downpipes are available
in square, round or rectangular
profiles, and gutters in a wide range
of styles, shapes and sizes. This
allows flexibility in product suitable
for a number of applications and
designs mean even more flexibility
in design with great aesthetics.
Designing with metal offers
perhaps the widest array of choices
within the construction industry.
Different Paint
Systems
Paint system provides durability and
life. Paint system means paint-
primer-conversion coatings. The
paint is the top coat and back coat.
Paints types of Polyester (RMP,
Super Durable)/SMP/PVDF/Metallic
etc are available. Paint
manufacturers have their own
variants to these classes of paints.
Each has its suitability with
economic value to meet different
requirements. Based on which, best
suiting one is chosen for a design
and environment.
NBM&CW MARCH 2011
Steel Construction
Choice of Colors
Depending on your supplier, you
can choose from standard set of
colours with option of your own one.
You can also choose the natural
look of zinc or copper, or coatings
that make metal look natural.
Coated steel sheets are now
available in many colours to use
singly and in combinations to make
designing flexible. Colour is
important not just for looks; it has
influence on inside comfort and
environment. Thermal efficiency of
building depends also on the colour
of roof and wall.
Metallic Coating
Depending on the life expected from
the building material, the
environment and activities inside,
metallic coating option is exercised
for corrosion protection. 55% Al-Zn
coating compared to Zinc coating
provides much better corrosion
protection in near neutral condition
(typical of most environments).
Possibility of designs
with curves
Flexibility of design allows for both
traditional straight roof sheeting as
well as innovative curved roofing
designs. Coated steel with different
base steel strength provides virtually
limitless design possibilities. Due
to its flexibility, it is capable of
accommodating the double radius
of the curved roof, with great
accuracy of the curves. From flowing
curves to precision flatness, metal
is easy and economical to install.
This freedom of design provides
the architect and owner the
opportunity to build within a wide
range of styles and create an image
that will endure.
Variety of Roof
Designers and users have a choice
of roof & wall with or without visible
fasteners. Advances in technology
such as the standing seam roof
with no visible fasteners and leak
260
proof warranty give designers even
more flexibility for innovating with
building structure and style.
Options of different
slope for roofs
There is choice of low slope and
steep slope for roofs. In both
categories of roofs, steel with highly
durable metallic & paint coatings
could be used and the benefits of
high performance realized. It’s the
metal roofs which added the design
element of steep slope to a building
that separates them from
conventional flat ones. Low slope
roof are more economical, steep
slope metal roofs enhances the
appearance of virtually any building.
Steep slope metal roofs accelerate
the rate of water run-off, reduce the
likelihood of a build-up of debris,
mold and mildew, less likely to
experience staining from acid rain
or UV degradation. The durability
and reliability of steep slope
systems is quite long.
Best utilization of
Space
Larger interior spaces (high
clearances and spans) without
interior columns add flexibility to
design & increase utility. At times
this large span is a must
requirement e.g. aircraft hangar.
However, it could only be achieved
with self-supporting steel framing
system with no need for interior
walls to help bear the weight of the
building. With this self supporting
steel frame interior walls can easily
be eliminated, altered or relocated
and large open floor plan created
including raised ceilings. This
excellent spanning capabilities
offered by steel framing provides
more flexibility in designing internal
spaces that maximise opportunities
for cross ventilation, helping to meet
energy efficiency requirements.
For some things there is simply
no equivalent, like roofing and
walling made from lightweight,
versatile and durable coated steel.
Stronger and lighter as a combined
material than all other alternatives,
steel is giving builders and building
designers greater scope to create
wider rooms and higher ceilings,
as well as support for innovative,
non-conventional roofs that are
increasingly being used to give
properties a style of their own. High
strength (minimum 550 MPa yield
strength) coated steel are fast
becoming the materials of choice
because of its high strength-to-
weight ratio, and the design flexibility
they offers. It gives great spanning
NBM&CW MARCH 2011
Steel Construction
capabilities, especially with unusual
shapes, and can cover a building
with minimal structural support,
allowing for more column free floor
area. To obtain a desired design
you can reduce the width of the
joist but compensate with heavier
gauge steel and not change the
spacing of member.
Time frame Flexibility
Since steel buildings are quick to
erect, the constraint of time is
minimal. Frame, wall and roof made
from steel can be erected quickly
and easily, saving time and stress.
Off-site pre-fabrication ensures
dimensional accuracy and on-site
erection and fixing to be fast and
simple. Service holes can also be
pre-punched for plumbing and
electrical. Steel building has less
weather-dependency (lower “down-
time / construction time”) can be
installed in wet conditions unlike
traditional materials. Swift erection
of a building in steel can cut weeks
off the average construction time.
This way steel building provides
flexibility to designers & builders
as well.
Design Flexibility
Cost?
The variety in steel contributes to
the flexibility of design for costing
as well. These varied options have
different cost associated with them.
Steel construction offers the
potential to build substantially more
covered space with the same cash
flow. Steel building can be built in
much less time without increasing
site resources, thus freeing capital
and finite resources for other
262
projects – “The efficiency of use of
working capital”. Offsite
prefabrication increases the speed,
efficiency, quality and safety of
construction. It is also easy to
integrate into existing structural
systems. The predictability of cost
and program also improves. Time
related savings when specifying a
structural steelwork frame compared
with reinforced concrete can be 2 –
3% of overall building costs.
Components of steel roofing
and walling are supplied to precise
specifications so there is little or
no wastage on site and the cost of
debris removal. Most onsite waste
can be sold afterwards as scrap
that is recycled into other steel-
based products. It is cost wise &
environmentally good. Coated steel
sheet assemblies are economical
and durable under tough
environmental conditions. Cost
arising out of natural calamity is
minimal.
Flexibility to Reuse
Steel building materials have great
opportunity for re-use. At times,
designers use this flexibility for new
projects with new look using old
material. This not only saves cost,
it also reduces impact on natural
resources.
Flexibility to Relocate
The other great comfort of the
flexibility steel building user has is
that it can be relocated. This has
helped many users to release costly
land resource and rebuild the
similar installation with much lower
relocation cost.
Flexibility to Expand
The benefits of steel building
system are seen today, tomorrow
and in the future. When you erect a
metal building today, you have the
benefit of cost efficiency, design
flexibility, and the predictability of
on-time construction deadlines.
Tomorrow, your benefits continue
with minimal maintenance
requirements. In the future, as your
business flourishes or your needs
change, the building is
comparatively easy to expand and
update.
Flexibility to use
Local Labour
On-site construction of steel
building is easy, highly efficient and
safe, which an untrained personnel,
can quickly learn. There is not much
measuring, cutting or wet processes
and the pre-manufactured fit-out can
be integrated with interior and
exterior fittings using local labour.
Workers can be easily trained to
use steel building systems in
combination with other materials as
well.
Conclusion
Steel is such a versatile material
that every object we see in our
daily life has used steel directly or
indirectly. There is no viable
substitute to steel in construction
activities. Steel remains and will
continue to remain logical and wide
choice for construction purpose,
environmentally also, as much of
the steel used is recycled.
Steel building offers more
design and architectural flexibility for
unique or conventional styling. Its
strength and large clear spans
mean the design is not constrained
by the need for intermediate support
walls. As your requirements
changes over the years, you can
reuse, relocate, & modify the
structure.
Coated steel sheets come in a
range of styles, sizes and colour
NBM&CW MARCH 2011
Steel Construction

combinations, and can usually be customised to

suit specific weather conditions. It is a reliable
and long life cladding material suitable for a
range of residential, commercial and industrial
applications in almost any style of building, from
modern to traditional, from big establishments to
small and in almost any chosen shape or design.
In addition to this, it can be used easily with other
materials, a diverse range of options to choose
from. The strength and flexibility of the steel
products enables the construction of buildings/
structures that can better withstand challenging
environmental and meteorological conditions,
including hurricanes, earthquakes, and high
variability in humidity and temperature.

Linden Comansa at
the Conexpo Show
T
ower crane manufacturer Linden Comansa
will participate in the 2011 Conexpo Show in
Las Vegas (Nevada, U.S.A.) through its U.S.
subsidiary Linden Comansa America. Conexpo is
one of the world’s most important trade shows for
the construction industry, and undoubtedly the leader
in the American continent.
Linden Comansa America will exhibit in the
outdoor Gold Lot, in booth 261, and will display the
cathead, slewing table and cabin of a 21 LC 550
18t tower crane. Several representatives from Linden
Comansa America and from the factory in Spain will
be able to show the visitors the benefits of Linden
Comansa’s Flat-Top design, and to explain the
different slewing motors available to increase
productivity.
The Linden Comansa America team is very
excited that several cranes of the same model (21
LC 550) will be on display behind the Las Vegas
Convention Center, on the Fontainebleau Hotel and
Casino jobsite, for the
attendees to see them fully
erected (see pictures).
The Conexpo Show will
take place at Las Vegas
Convention Center from March
22nd to 26th 2011.
For further details, please
contact:
Fax: +86-571-8299 6555
E-mail:
robin.hu@comansajie.com.cn

NBM&CW MARCH 2011 263

NEWS Events

Focus on Energy-
Efficient Buildings
The market for energy–efficient
buildings is set to evolve. People
need to change their mindsets and
should pay more for buildings which
are energy saver. Widening wedge
between builders and buyers is to
be removed for the promotion of
energy efficient buildings in the
country. We need to create
awareness about it so that buyers
start demanding energy–efficient
solutions, said Dr Mathur, Director
General, BEE at the recent
workshop on energy efficient
buildings organised by BEE and
PHD Chamber of Commerce and
Industry. Further he added that the
key aspects of energy-efficient
buildings are orientation, insulation,
insulated windows, window-glass
ratio, efficient chillers and water
heating. BEE on its part has been
promoting these ideas for long but
these have to go down into actual
construction work culture. There is
an urgent need to promote proper
construction materials to construct
green buildings Rating systems
Events
such as LEED is an important tool
to promote energy efficient buildings.
If all of us become conscious and
use common sense, it is possible
to save energy and environment.
Speaking at the workshop, Rao of
IREDA which has been financing
schemes for energy–efficient and
green buildings, called upon all
concerned in construction sector to
reduce energy consumption at all
levels by using energy–efficient
techniques and processes and also
conduct energy audits regularly. We
need to make people aware of the
benefits of energy-efficient buildings
in the residential segment. Market
for such buildings will certainly
grow as the concept gains
popularity and mass recognition and
acceptability was the consensus of
opinions at the workshop. However,
material and manpower deficit in
promoting the concept is a concern
which needs to be addressed so
that focus on energy–efficient
buildings remains as sharp as it
should be.
Partnership Summit
Taking part in the Partnership
Summit organized by CII, Australia
and Morocco have accepted India’s
invitation to participate in India’s on-
going infrastructure development
programmes. Speaking on the
occasion, India’s Commerce and
Industry minister informed that soon
India-Australia joint ministerial
group would meet the CEO's of
different companies to work out the
details of investment needed. At
the Summit, Commerce Minister,
Kingdom of Morocco informed that
his country is looking at investments
in energy and related sectors in
India. As Morocco plans to generate
42% of its energy from solar and
wind energy, some of these
programmes can be adopted in
India with Morocco's participation.

Coming Events
01. Saudi Construction Show 2011 03. Roof India 2011
Date & Venue: 21-25 March, 2011, Riyadh, Kingdom of Saudi Date & Venue: 27-29 May 2011, Bombay Exhibition Centre,
Arabia Mumbai, India
Contact: Raz Islam, Sales Director, CPI Technology & Contact: VB Sudeep Project Director
Business Events Tel: +91-44-24543322 / 23
Tel: +971 4 440 9129, M: +971 4 447 2409, E-mail: info@unitechexpo.com, unitechexpo@gmail.com
+966 54 724 3809 Website: www.unitechexhibitions.com
Email: raz@cpidubai.com, Website: 04. MBSS 2011
www.saudiconstructionshow.com Date & Venue: 23-25 June 2011, Pragati Maidan, New Delhi, India
02. CONEXPO-CON/AGG 2011/ ICON Expo 2011 Contact: Daisy Sequeira Manager - Projects, INIS Enterprises Pvt.
Date & Venue: 22-26 March 2011, Las Vegas Convention Ltd., 116, Atlanta Estate, Vitth Bhatti, Goregaon (E), Mumbai,
Center, Las Vegas, USA India
Contact: Pat Monroe, AEM Tel.: +91-22-28763111 / 40470600 Mob : +91 9322754288
Tel: +1 800-867-6060, 414-298-4141, 414-298-4123 Fax.: +91-22-28765444
(Direct) E-mail: daisy@inis-enterprises.com, daiz17@gmail.com
Fax: +1 414-272-2672 Website: www.inis-enterprises.com
Email: pmonroe@aem.org, Website: www.conexpoconagg.com

264 NBM&CW MARCH 2011