Editorial MB

couple of issues back, our editorial focused on the profound impact of

A global capitalism and eco design for sustainable communities, which are
set on a collision path, resulting in conflict and bloodshed. The terror
unleashed on the Nandigram community and subsequent bloodshed, and
unofficial reports of gang rape, proves the point. Should developmental projects
be allowed to sharpen the divides between the haves and the have-nots, between
the rural and urban, between the privileged and less privileged?
EDITORIAL
If we look at human history, we can see a powerful relationship between the
worldviews that people hold and the kind of society they construct, that is between
the way people believe their world is and the things they do to one another. All
through history, we are now aware; people thought the way they saw the world was
the way the world really was - be it religious, political, or scientific - which resulted
in wars, hot or cold.
The shift from the Paleolithic view of world (co-operative) that treated nature as the
great Mother Goddess to the Hebrew-Christian world view (dominant) of a
patriarchal god who created the world for man, and to the mechanical world view
(exploitative) in the golden age of science that treated the entire universe as
mechanical have had great impact the way societies / communities / nations
responded to a particular challenge.
The theory of evolution through natural selection of the fittest in a great
competition for limited resources was so easily adopted by the industrialists of
Darwin's period. And it has been used as a shield to cover the cruelty in the human
world - the exploitation of resources and labour by the rich was justified on the
grounds that it was natural! The focus was not on cooperation, but on competition
contrary to the evolutionary theories brought out by the Russian scientists that
argued that cooperation in nature produced more fit natural creatures than did
competition. And what an irony, the left government of Bengal that should have
protected the agricultural land, and the communities' right to their livelihood,
subscribe to such a world view, and become an oppressor.
It was heartening to note that even the present budget has given more impetus to
agriculture, underlining the importance of being 'inclusive'. Maybe it is better to
remember what Toffler said: “We stop looking at every ideas in terms of whether it
comes from the left or the right and see instead whether it takes us forward or
backward. And the best way to see is to look at living systems and how they function
when healthy.”To sum it up, as Elisabet Sahtouris, an evolution biologist puts it,
“The sooner we recognize ourselves as being in transition from exploitative and
divisive practices on all fronts to a united and harmonious living system, and the
sooner we recognize that there are natural models to guide us, the sooner will we
complete our healthy evolution by our own choice and efforts.”
The process of development is irreversible, and we need more industry to come up
to further the process. The point is any developmental project has to be inclusive,
and should, instead of sharpening the divide as has been the case earlier, bridge
the divides, that can act as catalyst to our slow march towards sustainability.

Agith G. Antony
Editor-in-Chief
editor@masterbuilder.in

MB 6 April 2007
Cover Story
Infrastructure Project
Funding as a Guide to
Steel Capacity Planning 48
TanmayRoy, Deputy General Manager (C&IT)
of Steel Authority of India Limited

Roofing
Versatility of Steel as
Roofing Material 62 A MAD RUSH?
Alok Baishya, Senior Manager Are the investments to add
(Civil & Structural) Institute for Steel
Development & Growth (INSDAG) Kolkata Steel capacity Justified?

Roofing Trends
Intelligent Buildings 118
Metal Roofing & Cladding
for Modern Industrial Buildings 66 Dr. (Mrs) Samta Jain
Assistant Professor
Akruti City Gold University, Mumbai
Case Study R&D
Beyond the Rainbow
Radiative Property Control Studies on Fly Ash Concrete Role of
in Coil Coating Systems 70 Hydration Promotor Catalyst 88
James Maxted V.K. Ravikumar, Managing Director, Cera Chem Private Limited, Chennai
S. Sen, Technical Advisor, Cera Chem Private Limited, Chennai
Admixtures An Experimental Investigation On Silica Fume Concrete
Containing Combination Of Admixtures 100
Liquid Sand™ -
A Step Forward 78 D.K. Kulkarni, Rajarambapu Institute of Tech.
Upen Patel, Marketing Manager, BASF Dr. K.B. Prakash, K.L.E Society’s, College of Engg &Tech.
Construction Chemicals (India) Pvt. Ltd.
Fire Protection of Steel Structures
Technology Ensuring Integrity Against Fire On
Microstructure Study & Behaviour of HDPE Offshore Installations Part - II 122
Fibre Reinforced Concrete 94
Richard Holliday, Market Manager, International Paint Ltd
K.Manjula Vani, M.Potha Raju, N.Madhu Babu, A.Jaya Prabhakar Reddy

An Experimental Study on the Effect of Sustained Editorial 6

Elevated Temperatures on the Strength Properties of News & Events 10
Fibrous Ferrocement Using GI Fibers 109
N.K.Patil, Assistant Professor, DY Patil College of Engg. & Tech. FaL-G : CDM Project Signed with the World Bank 40
Dr. K B Prakash, Professor of Civil Engg. K.L.E. Society’s College of Engg. & Tech.
Exclusive Showroom for Waterproofing
Ondulit and the Multilayer Protection. Products in Chennai 42
The Advanced Performances of the System 84
SREI and EBRD in Strategic Alliance 44
Coatings Sankalpan Group Unveils National Expansion Plans 46
Excel Coatings Freedom from Heat -
Affordable Way 86 Supershield Technology 116
Cover Courtesy : Arizona Cardinals Stadium Classifieds 127
www.tekla.com
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MB 8 April 2007
News & Events
RIL Signs $4.5 bn Deal
for Gas Fields
Reliance Industries Ltd has signed
contracts worth $4.5 billion to develop
its gas fields off India's southeast coast.
The spending will be part of $5.2 bn of
investment the company plans for the
area, according to RIL's president for oil
and gas PMS Prasad. India's current
gas supplies of 85 million cubic meters
a day, including imported liquefied
natural gas, falls short of the potential
demand of 170mn cubic meters,
according to estimates by the Oil
Ministry. Gas consumption may rise to
400 million cubic meters a day by 2025
if the economy grows at the projected
rate of 7 8 % a year. RIL had said last
year that the gas field off the country's
east coast will produce twice the
quantity previously estimated. The KG
DWN 98/3 field, discovered in 2002, will
produce 80mn cubic meters a day,
compared with the initial estimate of 40
million cubic meters, the company said.
CIDC to Set Up 6
Retrofitting Clinics
Construction Industry Development
Council (CIDC) in pursuance of
Government policy for national disaster
mitigation is establishing a National
Network of Retrofitting Clinics in all the
districts of the country falling in
earthquake Zones III, IV and V. In the
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DIAL partner Malaysia Airports Wins
World's Best Airport Award
Malaysia Airports, a partner in Delhi
International Airport (P) Limited (DIAL)
and GMR Hyderabad International
Airport Limited (GHIAL) has won the
World's Best Airport Award in the 15-25
million passengers per annum category
by the Airport Council International's
Airport Service Quality (ASQ) Awards
2006. It was given this award for
Malaysia's flagship airport, the Kuala
Lumpur International Airport (KLIA).
first phase CIDC is setting up 6 such
clinics with the initial expense of
Rs. 6 Crores. State Governments
of Rajasthan, Haryana and Madhya
Pradesh have joined hands with
CIDC in setting up these clinics in their
respective states. Several academic
institutions have already agreed to
be partners in this effort and being
designated as 'Identified and
Accredited Centers' of CIDC.
Retrofitting clinics enable owners of
buildings get health and structural
strength assessed for their houses or
buildings. Health of existing housing and
buildings are a matter of concern for the
State and Central Government, as India
is one of the most disaster prone
country when it comes to natural
disasters like earthquake, cyclones,
floods, landslides etc. Recognizing the
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DIAL is the joint venture company
led by GMR Group formed to
modernize and restructure the
Indira Gandhi International Airport,
Delhi and GHIAL is a GMR led joint
venture developing the new
Hyderabad International Airport.
San Diego Airport in the US and
Zurich Airport in Switzerland were
placed second and third in the
category at the award presentation
ceremony, which was held in Dubai
in conjunction with the two-day Airport
Council International (ACI), Airport
Business and Trinity Forum. KLIA
also maintained its third place in
both the Best Airport Worldwide and
Best Airport in Asia/Pacific categories,
behind Incheon Airport, Korea, and
Hong Kong's Chek Lap Kok Airport
while Singapore's Changi Airport
was fourth.
high vulnerability profile of the country,
Government of India has come up
with the Disaster Management Act, 2005
and set up the National Disaster
Management Authority, under the
chairmanship of Hon'ble Prime
Minister. According to a study done
by Sh.T N Gupta, Former Executive
Director, Building Material Technology
Promotion Council (BMTPC) and
Sr. Advisor to CIDC, “Nearly 80 percent
of our housing stocks which lie in
non-engineered category are highly
vulnerable to natural hazards like
earthquakes, cyclone etc, besides
a large stock of buildings which have
become aged and lie in disaster prone
regions. Large stocks of ageing
buildings in our urban and rural
settlements add another dimension
to the vulnerability profile.”
April 2007
News & Events
C Congratulations
Dr. S.K.Manjrekar, a well-known
material scientist from India, has been
recently given “Board Committee
appointment” on International
Committee of ACI for a 3 year term.
The mission of this committee is to
develop and coordinate ways and
means to promote communication
and co-operation between ACI and
international chapters, International
Partners, and organizations and
institutions beyond the U.S. and
Canada that share common interests
with ACI. The International Committee
is authorized to approve the formation
of international chapters and the
establishment of their boundaries,
Mumbai's 2nd Airport to Cost Rs. 9,000 Crore
The cost of Mumbai's second
international airport at Panvel, which
will be fully operational by 2009, is to
cost Rs. 9,000 crore. The airport is
likely to get Union Cabinet approval
shortly, according to Mr Sanjay Ubale,
Secretary, Special Projects,
Government of Maharashtra.
CIDCO, the city's planning agency
for Navi Mumbai has already acquired
90 per cent of the land required for the
airport. Soon after Cabinet approval,
and after environment impact
assessment which is being done
by IIT Bombay, tenders would be
issued for the project, and the
airport would be fully operational by
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to provide a forum for International
Partners, and to provide input on
international issues and relations to
the Board of Direction as appropriate.
Dr. Manjrekar also happens to be one
of the three Indians to be a “Fellow”
of the American Concrete Institute,
USA since 1999 in recognition for his
outstanding contributions to the ACI
and to Concrete Technology.
He has already been bestowed upon
with International Chapter Activities
Award at the ACI spring Convention
at Vancouver, Canada in 2003.
This was due to his dedicated service
to the ACI India Chapter and years of
service to the concrete industry.
He is a member of ACI International
committee 364 and on certification viz.
'IC-Cert'. The mission of this committee
is to develop and report information and
maintain standards for rehabilitation,
renovation and preservation of concrete
and masonry structures.He is the
President of India Chapter of ACI
and Chairman and Managing Director
of M/s Sunanda Speciality Coatings
2009, according to sources. A special
purpose vehicle is being established
for the project. The Maharashtra
Government and the Airports Authority
of India will hold 13 per cent stake
each in the SPV, while the private
developer will hold 74 per cent.
The estimated cost of the airport
is expected to be Rs.9,000 crore.
MB
Pvt. Ltd, Mumbai, a firm that specializes
in manufacturing state of the art
construction chemicals.
Reliance Energy to
Develop Namakklal
Karur highway
Reliance Energy (REL) has recently
bagged a contract under National
Highways Development Project phase
IIIA for developing the Namakklal Karur
highway - a stretch of 80 km in Tamil
Nadu for Rs 516 crore. According to
the sources a Special Purpose Vehicle
will be floated by REL to execute the
project which includes the high traffic
density corridor from the Trichy Karur
project and is contiguous to the
Namakklal Karur project on NH 7,
which is already being developed
by REL. As per the sources REL
has already received the letter of
acceptance from the National Highways
Authority of India and will be initiating
work on the project at the earliest.
In 2006, REL had won contracts for
two road projects in Tamil Nadu and
invested around Rs 750 crore.
The first project was a 34 km stretch
from Namakkal to Karrur, with another
10 km for maintenance, and the
second, a stretch of 54km from
Dindigual to Samaynallur.
April 2007
News & Events
India, Japan to Iink Comprehensive Economic Pact
A Comprehensive Economic
Partnership Agreement (CEPA)
between Japan and India is under
constructive discussion and Japan
has committed that a special economic
relationship will be clinched within one
year, said Mr. Ashwani Kumar, Minister
of State for Industry, Ministry of
Commerce and Industry at the
Symposium on 'Japan-India
Strategic Partnership in the era
of Asian Regional Integration',
organized by the Confederation
of Indian Industry (CII), recently.
Work Begins to Facilitate
Aircrafts Movement
at Delhi Airport
In an effort to enhance passenger
comfort and to ensure more efficient
aircraft operations, Delhi International
Airport Pvt. Ltd. (DIAL) is carrying out
work involving two new taxiways
U and V. This will facilitate faster
runway clearance from Runway 10 side
towards the international terminal.
The Runway occupancy time will be
reduced with increase in its capacity.
Since, the holding time for aircraft
awaiting clearance to land at Delhi
Airport would reduce further; the
passengers and airlines will be
benefited. The construction work
would require the closure of a portion
of taxiway P for aircraft movements
between 0800hrs to 2200hrs (non-peak
hours) for a period of approximately two
MB 14
Mr. Katsuhito Asano, Senior Vice
Minister, Ministry of Foreign Affairs,
Japan mentioned that later this month,
the first strategic dialogue on the
Economic Partnership Agreement
(EPA) at the foreign minister level will
be held in Japan. The Japan-India
EPA should serve as a model of a
high quality economic partnership
towards 'open regionalism' in Asia,
he said, expressing the hope that India
will take bold steps to this end. Japan is
a major donor to SAARC countries and
considering the regional dynamism in
South Asia, the two countries might be
able to establish new, more efficient
methods to utilize this assistance for
regional projects, said Mr. Asano.
The main hurdles facing Japanese
investment in India were inadequate
infrastructure, complicated legal
and taxation system and insufficient
months starting March 16, 2007.
The proposed alternate taxiing route
through the domestic apron for aircraft
from International Terminal (Terminal 2)
towards runway 28/27 may lead to an
additional taxiing time of a few minutes.
However, the taxiway P would be made
available everyday during the peak
hours of international traffic, i.e. from
2200 hrs to 0800 hrs.
Ispat signs MoU
for Integrated Steel Plant
Ispat Industries has recently signed a
memorandum of understanding (MoU)
with the Jharkhand government for
setting up an integrated steel plant at
Manoharpur in West Singhbhum district
with an estimated cost of Rs 6,750
crore. The initial production will be 2.8
million tonne, which will later be scaled
up to five million tonne in phases. The
MoU was signed between Vinod Mittal,
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rules and regulations for interstate
transactions, said Mr Mikio Sasaki,
Chairman, Mitsubishi Corporation.
These challenges could be met by
the India - Japan EPA (Economic
Partnership Agreement), for which
negotiations had already been initiated,
government initiatives through a
judicious mix of grant aid, Yen credit
loan and technical assistance, and
India - Japan Strategic Global
Partnership, he suggested.
The Japan International Cooperation
Agency (JICA) would continue to
support India in the four priority
sectors of Infrastructure, Environment,
Social Development and Human
Resource Development, as agreed
upon by the Prime Ministers of both
countries in their joint statement last
December, said Dr Sadako Ogata,
President, JICA.
managing director, Ispat Industries and
K K Khandelwal, secretary department
of industries in Ranchi. This is the
third major investment plan announced
by Ispat in the recent past. Earlier Ispat
signed an MoU with the Chhattisgarh
government for setting up a 600
megawatt power project at an estimated
investment of Rs 2,500 crore apart
from an MoU with the Maharashtra
for capacity expansion of its integrated
steel plant at Dolvi.
April 2007
News & Events
6th Greentech
Safety Gold Award to
REL's Power Plants
REL's Dahanu and Goa power
stations have bagged the prestigious
Greentech Safety Gold Award for
year 2006 in thermal and gas power
category respectively. The award
was presented to the company by
Mr. Tony Smith of the National Safety
Council, USA in a function held in
Mumbai recently. Dahanu Thermal
Power Station and Goa Power Station
are ISO 14001 certified andhave also
won various prestigious awards that
include the Greentech Foundation
Award in Environment for year 2005
and 2006 respectively.
Reliance Energy, a part of Reliance -
Anil Dhirubhai Ambani Group, is India's
JSPL Plans $2.1 b Investment at the El Mutun
Jindal Steel and Power Limited
(JSPL), part of Rs.20,000 crore Jindal
Organisation, has reached an
agreement with the Bolivian
Government on the terms of the
planned $2.1 billion investment in
mining and steel-making at the El
Mutun iron ore mines. El Mutun,
believed to contain one of the world's
biggest iron-ore reserves, contains an
estimated 40 billion tonnes of iron ore
of medium-grade quality. Bolivian
President Evo Morales and JSPL's
Senior Management team led by
Mr. Vikrant Gujral, Vice Chairman &
CEO and Mr. Sushil Maroo, Director-
Finance agreed on the tax rate and
natural gas prices for the iron and
steel project. A definitive contract will
be signed with the Government later.
JSPL plans to invest USD 2.1 billion
over the next 8 years in creating an
integrated steel plant, which would be
capable of producing 1.7 MTPA of long
MB 16
leading private sector utility group,
with aggregate estimated group
revenues of Rs 10,500 crore (US$ 2.3
billion), and total assets of Rs 10,800
crore (US$ 2.4 billion). The group
distributes nearly 21 billion units of
power to over 5 million consumers in
Mumbai, Delhi, Orissa and Goa,
across an area covering 1,24,300 sq.
Kms. Reliance Energy generates 941
MW of power, through its power plants
located in Maharashtra, Andhra
Pradesh, Kerala, Karnataka and Goa.
Tata BP Solar
Awarded Niryat Shree
Gold Trophy
Tata BP Solar has been awarded
the Niryat Shree Gold Trophy for
outstanding export performance in the
electronics and computer software
products of steel, and will also have
DRI (Direct Reduced Iron /Sponge
iron) Plant of capacity 6MTPA and a
pellet plant of capacity 10MTPA. The
company will also be setting up
supporting infrastructure for the
proposed plant including a 450 MW
Power Plant. The project will allow
Bolivia to develop a steel-making
industry for the first time and is the
biggest investment in a single project
in Bolivian history. The investment by
JSPL will create gainful direct jobs in
the iron ore mine and the steel plant.
The deposit is located southeast of
Bolivia, near the Brazilian border.
MB
products (non-SSI category) for the
year 2003-2004 and the Niryat Shree
Silver Trophy for 2004-05. The awards,
instituted by the Federation of Indian
Export Organisations, were presented
by Kamal Nath, honourable minister of
commerce & industry, government of
India, at New Delhi on December 26,
2006. Rahul Kshetrapal from the
northern regional office received the
award on behalf of Tata BP Solar.
Mr S. Bhattacharya is
SAIL's New Director
(Finance)
Mr. Soiles Bhattacharya has assumed
charge as Director (Finance) of Steel
Authority of India Limited (SAIL).
Prior to this he was Executive Director
(Finance & Accounts) in SAIL's
Central Marketing Organisation.
After graduating as a Metallurgical
Engineer from Banaras Hindu
University, Mr Bhattacharya joined
SAIL as Graduate Trainee in 1974.
Continuing to pursue his academic
interests, he completed his ICWA in
1989 while in service. Mr Bhattacharya
has served in different units of SAIL
and has earned accolades for
spearheading several key initiatives
in the organisation. He has been
credited with setting up the cost
control department during his stint
at SAIL's Rourkela Steel Plant.
Mr Bhattacharya also had an opportunity
to serve as a certified Action Leadership
tutor at SAIL's Management Training
Institute located at Ranchi.
April 2007
News & Events
Anil Kumar Sardana Appointed
Executive Director of Tata Power
The Tata Power Company has
appointed Anil K Sardana as
Executive Director with effect
from March 1, 2007. Prior to this
assignment, Sardana was the
Managing Director of North Delhi
Power Limited (NDPL), an associate
company of Tata Power for power
distribution in New Delhi. Sardana
will be responsible for strategy and
business development function at Tata
Power. In addition to transforming
NDPL to deliver an improved
Pavement Engineering
with Geosynthetics
A Short term Course on Pavement
Engineering with Geosynthetics will
be organized under the aegis of FITT,
IIT Delhi. The course will provide a
comprehensive idea of all the related
users of use of geosynthetics in
pavement structure and for drainages.
The objectives of the course primarily
targeted for engineering college
teachers and highway engineers are:
Familiarise with uses of modern
pavement materials and the design
methodology & Testing, Ascertain
the type of design method required,
Use the design methods,
Characterization of geosyntetic materials,
Using Geosynthetic in pavements etc
Pavement construction techniques.
MB 18
performance in substantive ways,
Sardana has demonstrated a track
record of delivery and senior level
interface. He has received the Asian &
South Pacific Utilities Associated
CEO of the Year Award 2005 and
Asian Power CEO of the year 2006
award announced by the Asian Power
Journal, Singapore. An electrical
engineer with 27 years of professional
experience in the power industry,
Sardana has previously worked with
NTPC and BSES.
For details e-mail: gvrao@civil.iitd.ac.in
Web Page: http://paniit.iitd.ac.in/~transpn/
Coordinators
Prof. G.Venkatappa Rao
Dr. Kalaga Ramachandra Rao
CIDC Joins Hands with
IGL for Worker's Training
Construction Industry Development
Council (CIDC) and India Gypsum
Limited (IGL) have decided to work
together in collaboration to undertake
the task of skill upgradation and training
of construction workers in the area of
application of Gypsum Products for
interior finishes. CIDC and IGL agree to
launch this Project at India Gypsum Ltd
Training Centers at Mumbai, which
would be henceforth become CIDC
Accredited Training Centres. According
to the MoU, CIDC will also facilitate
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launch of these training programmes
at other CIDC Centers on agreed terms.
The MoU was signed in Delhi by
Sh. P.R.Swarup, Director General
CIDC and Sh. Sanjay Bahl, Finance
Director, IGL. The MoU, provides IGL
accreditation under CIDC-HRD scheme
for conducting construction workers
training, testing and certification
programmes for their existing training
centers. “This agreement will help us
to achieve our goal to train each and
every construction worker for their
skill enhancement and ensuring
higher construction quality. It is further
extension of our work in western part
of the country”, Said CIDC Director
General Sh P.R.Swarup.
According to Sanjay Bahl, “Finance
Director, IGL “Our company's
philosophy is to upgrade the skills of
construction workers in the area of dry
construction techniques towards false
ceiling, partition / walls, cladding in
building interiors for meeting specific
standards towards fire safety, sound
insulation and use of green products /
systems in order to improve the quality
of building construction, that is why we
are here. At present, we are running our
programme at Wada, near Mumbai and
we wish to run this programme along
with CIDC in other parts of the country."
All successful certified construction
workers get 'Skilled Construction
Workers' Certificates awarded by CIDC
(jointly promoted by the Planning
Commission and Indian Construction
Industry). CIDC is actively engaged in
skill upgradation of construction workers
for last ten years. Recently, the state
Governments of Haryana, Rajasthan,
Madhya Pradesh and Bihar have
allotted 29 Industrial Training Institutes
(ITIs) to the Construction Industry
Development Council (CIDC) for five
years for testing skills and imparting
training to construction workers CIDC.
April 2007
News & Events
SAIL Wins SCOPE Gold Trophy
Prime Minister Dr Manmohan Singh
presenting the SCOPE Gold Trophy to
SAIL Chairman Mr S.K. Roongta.
Steel Authority of India Limited (SAIL)
has been conferred the Gold Trophy of
the 'SCOPE Award for Excellence and
Outstanding Contribution to the Public
Sector Management' in the
Institutional Category for the year
2004-05. The award was presented by
Tandon Gets
Structural Engineer
of the Year Award
In a glittering National Award
presentation ceremony recently,
Prof Mahesh Tandon was accorded
the Archidesign Hindware Award
for the 'Structural Engineer of the year
2006' by the Foundation for Architecture
& Environmental Awareness.
Prof Tandon received the award from
Mr R K Somany, Chairman Archidesign
Awards. Earlier in the year he was
honoured by the Institution of the
Engineers (India) in recognition of
his eminence and contributions to the
MB 20
the Prime Minister of India,
Dr Manmohan Singh, to SAIL Chairman
Mr S.K. Roongta at a function held
at the Parliament Library Building in
New Delhi this morning. SAIL, the
largest steel maker of the nation, was
one of the leading PSUs that received
the award on the occasion. Instituted
by the Standing Conference of Public
Enterprises (SCOPE), the apex body
of public sector organisations, the
award aims to reward, recognise
and encourage the contribution of
public enterprises as well as of
outstanding individuals for their vision
and leadership qualities in creating
national wealth. The five-member
jury for the awards was headed by
Justice P.N. Bhagwati.
profession of Civil Engineering.
At the FIB Congress at Naples, Italy,
he was invited to present a keynote
paper on 'Elevated Viaducts of Delhi
Metro' and the project was also
nominated for the Outstanding
Structures Award' in recognition
of its positive influence and reputation
and promotion of concrete structures.
Dubai's Three Best Sellers
Now In India
Expomedia Events India the Indian
subsidiary of London based Expomedia
Group plc in association with dmg world
media Dubai in a few weeks time are to
run the third edition of its co-located
events Interiors International India (III)
and India International Construction &
Contracting Exhibition (ICON) and the
second edition of Hospitality
International India (HII) to be held at
India Expo Centre EXPI XXI from 3 rd
May - 5th May 2007. The co-located
exclusive B2B exhibitions are aimed at
bringing together the entire spectrum of
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the interiors, hospitality and
construction industry on a common
platform. The last edition of the events
saw participation of 137 companies
from 14 countries including 6 country
pavilions. The 2007 edition of the
shows will see participation from 18
countries across the globe - Germany,
Spain, France, Italy, UK, Taiwan,
Thailand, Philippines, China, Malaysia,
Turkey, UAE, Jordan, Greece, Australia,
Lebanon, New Zealand & India.
The three day exhibition will provide
a great sourcing opportunity for trade
visitors with a wide range of products
on display under one roof. The exhibits
would include an exhaustive range
of interiors, construction and hospitality
products, services & technology.
Apart from the display of best of
products, technologies and brands
from across the globe, the events will
also feature the Annual Day Conference
of Indian Institute of Interior Designers
(IIID) and important seminars by
Federation of Hotel & Restaurants
Association of India (FHRAI), and
Indian Association of Structural
Engineers (IAStructE) providing an
opportunity to interact with leading
national and international personalities.
For further details contact:
Rajnish Sinha
Manager- Marketing
Expomedia Events India
Somdatt Tower, K-2, Sector-18
Noida, India
Phone No.0120-2516110, 2516144
April 2007
News & Events
IDFC PE to Invest
Rs 400 crore
IDFC Private Equity (IDFC PE) is
planning to invest in the oil and gas
sector in a big way, especially in city
gas distribution companies.
The company is investing about $60
million (Rs 270 crore) in Krishna
Godavari Gas Network Ltd (KGGNL)
a gas distribution company aimed at
building intra-state transportation grid
in Andhra Pradesh. IDFC PE, which
would be the majority stakeholder in
KGGNL, has roped in Gujarat State
Petroleum Ltd and Andhra Pradesh
Industrial Development Corporation,
the investment arm of the Andhra
government, as equity partners for
the project. While announcing IDFC's
equity participation in Quipo
Infrastructure Equipment Ltd (QIEL),
Satish Mandhana, Executive Vice
President of IDFC PE, said the total
corpus of IDFC PE is about Rs 2850
crore, consisting of two funds. "The
first fund, which is of Rs 900 crore,
has been exhausted, while 40% of the
second fund has been committed.
We aim to exhaust the second fund
by December 2008."
Road Shows Abroad to
Attract Overseas Funds for
Ambitious Core Projects
In order to attract overseas funds for
ambitious core projects, the Kerala
government has recently floated an
infrastructure public-private participation
firm - Inkel, and it is understood that
The first of the series of overseas
roadshows for Rs 100-cr InKel will get
going from UAE in April this year.
Roadshows in Europe and the US are
also in the pipeline and expected to
fetch captial for the new firm. The state
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7% Increase in NHDP Allocation
A 7% increase in National Highway
Development Programme (NHDP)
allocation to Rs 10,667 crore was
announced for the roads sector. In step
with all the hype over development of
roads, Finance Minister P Chidambaram
has hiked the allocation for developing
highways in the Budget for 2007-08
by more than Rs 700 crore. This has
been viewed many as not sufficient
as the allocation is just sufficient for
conducting feasibility studies and
govt has invited 50 NRI businessmen of
Kerala origin for discussions to detail
the capital-base & operations of InKel
Four places in Kerala, including
Thiruvananthapuram and Kochi, are
identified for setting up parks for
enterprises in sunrise industrial
segments. Roadshows abroad,
beginning next month, are expected to
fetch captial for the new company. The
dates of the roadshows in Europe, West
Asia and the US will be decided.
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ground work by the National Highways
Authority of India (NHAI) before
inviting bids in different phases.
Another welcome initiative by
Chidambaram is the announcement
on declaring the Rs 1,700 crore
road-cum-rail bridge at Bogibeel,
Assam, over the Brahmaputra, as a
national project. This is on the lines
of the road-cum-rail bridge at Munger,
Bihar, over the Ganga. This move
will ensure central assistance to the
project given the resource crunch
of Assam. The project otherwise
would not have been possible.
Completion of the project is expected
to improve connectivity of the north-
east region both with the rest of the
country and also with neighbouring
countries like China.
Greentech Safety
Gold award 2006 to
Noamundi
Noamundi Iron Mine has been bestowed
with the 6th Annual Greentech Safety
Gold Award 2006 in miming and
metal sector. The award was presented
on 22nd February 2007 at Bombay
Exhibition Centre by Mr. Tony Smith,
Executive Director, National Safety
Council, USA. On behalf of the
company Mr. Sachindra Mahato,
President, Noamundi Mazdoor Union
and Mr. Rajesh Kumar, Sr. Manager
(Safety) received the award.
April 2007
News & Events
Tata Steel Conferred the "Award for Corporate
Social Responsibility in Public Health”
Tata Steel has been conferred "Award
for Corporate Social Responsibility in
Public Health" by US-India Business
Council (USIBC), Population Services
International (PSI) and The Center
for Strategic and International Studies
(CSIS) at an event organized by FICCI
held at Taj Mahal Palace & Tower
in Mumbai. Mr. B. Muthuraman,
Managing Director, Tata Steel received
the award from Ms. Ashley Judd,
acclaimed Hollywood actress and
PSI board member. Tata Steel has
been selected for the award for their
outstanding contribution done for
combating HIV/AIDS. Receiving
the award, Mr. B Muthuraman,
Managing Director, Tata Steel said,
"As a corporate citizen, for almost a
century, Tata Steel Ltd is committed
to improving the quality of the life of
its employees and also the community
that we operate in. We have set some
global benchmarks in corporate social
responsibility and this award is yet
again recognition the exemplary work
undertaken by Tata Steel in controlling
SREI Concludes Rs 400cr
Business in an Evening
at "Paison Ki Nilami”
SREI Infrastructure Finance Limited has
raked in business of a whopping Rs 400
crore in a single day "Paison Ki Nilami"
event held on February 16th at the
Pragati Maidan in New Delhi. The
enthusiasm exhibited by customers
bidding for the lowest possible interest
rate on loans availed by them was
phenomenal given the unprecedented
turnout at the venue itself. On the CII
platform for the first time, "Paison Ki
Nilami" attracted over 700 customers to
the 'reverse auction', which allowed
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and prevention of a life threatening
disease like HIV/Aids.”
Tata Steel Ltd's involvement towards
preventing HIV/AIDS dates back to
early 90s when the organisation
realised that the disease had acquired
epidemic proportions and accepted
that its control or prevention was not the
sole responsibility of the government.
In 1994, the management of Tata Steel
Ltd evolved a Corporate Sector Model to
prevent STD/HIV/AIDS and constituted
a Core Group - AIDS and Nodal
Centre - AIDS to focus on this disease
and formulate strategies for its control
and prevention. Since more than a
decade, annually approximately 250
AIDS Awareness Programmes are
conducted within the workplace.
them to hammer down coupon rates on
loans sought by them for infrastructure
equipment purchases. Simultaneously,
SREI also ran its other popular schemes
such as SREI Lotto, where luck played
a part in the freezing of the interest rates,
and SREI Money Bag, a passbook
scheme with pre-determined credit limits
to customers. The advantage of such
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a scheme is that customers can draw
upon amounts or tranches of loan as
per their requirement subject to a
maximum limit.
The three schemes attracted over 1,500
customers across the country including
over 900 registered bidders resulting in
an aggregated business profile of Rs
400 crore in just a single day which
underscores SREI's success in event
based marketing programmes. The
equipment pool for the Delhi show
ballooned to over a 1,000 numbers
valued over Rs 400 crore. Eight
hundred and sixty of the equipment
pool was attributed to the "Paison Ki
Nilami" event itself, while around 200
odd equipment were sought by
customers through the other schemes
SREI Lotto and SREI Money Bag.
K K Mohanty, executive director said,
"the entire credit for this success goes
to our valued customers who have,
over the years, exhibited tremendous
confidence in our innovative and holistic
value-added offerings in partnership
with manufacturers."
Echoing Mr Mohanty's words, the CEO
of asset finance, SREI, D K Vyas said
that "events like "PKN" provides the
right platform to buyers and sellers
for concluding large numbers of
transactions within a short time.
This is in consonance with our objective
of working with our customers and
manufacturers as partners, enabling
them to conclude large business within
the shortest time with least interest."
"PKN", on SREI's calendar for the
last two years has unleashed four
such editions, the first time being in
November 2004 in Kolkata. The maiden
event attracted nearly 300 bidders
and a business of over Rs 100 crore.
Traversing through Bhubaneswar,
Hyderabad and now New Delhi,
"PKN" has come a long way, the
business as well as the customer
base having grown substantially.
April 2007
News & Events
Tata Steel Acquires
100 per cent Equity in
Rawmet Industries
Tata Steel Ltd pursuant to the Definitive
Agreement signed on 15th January
2007, has acquired 100 per cent of
equity stake in Rawmet Industries
Private Limited (Rawmet), a company
having its registered office at Kolkata,
at an enterprise value of Rs 101 crores.
This is the second 100 per cent
acquisition of Tata Steel Ltd in Orissa.
In September 1991, Tata Steel took
over the Ferro Alloy Plant in Bamnipal.
Rawmet has a Ferro Alloy Plant near
Cuttack, consisting of two 16.5 MVA
semi closed electric arc furnace having
a capacity of producing around 50,000
tonnes per annum of High Carbon Ferro
Chrome. The Board of Rawmet has
been reconstituted with nominees of
the Company. Its Board now consists
of five Directors out of which four are
nominees of Tata Steel Ltd. Prior to this,
Tata Steel had taken over the Ferro-
alloys plant in Bamnipal in Keonjhar
district, which was considered as one
of the first successful disinvestment.
In September 1991, Tata Steel took
over the then "sick" unit for Rs. 156
crores from erstwhile OMC Alloys.
The plant has now surpassed its installed
capacity of 50,000 TPA of charge
chrome/ ferro-chrome. The new feather
in the Tata Steel's cap is yet another
step to further strength the hundred
year's relationship between the State
and the Company.
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8,000 MW from
2 Mega Projects
13 states will be benefitted from 2 ultra
mega power projects in Tilaiya
(Jharkhand) and Cheyyur (Tamil Nadu),
which is expected to generate 8,000MW
These two ultra mega power projects is
developed by PFC at the cost of
Rs16,000 cr and Rs.20,000 cr. Though
the process of identifying companies
that will build the projects involves
competitive bidding, the government has
decided to sign power purchase
agreements even before a developer is
decided. The government had initially
New Hyderabad Airport Ties up
Rs. 718 crore for Expansion
GMR Hyderabad International Airport
Ltd, (GHIAL) which is developing the
international Greenfield airport at
Shamshabad, has executed financial
agreements for borrowing Rs. 718
crore from three banks: Abu Dhabi
Commercial Bank, Andhra Bank and
Vijaya Bank recently. This investment
is for creation of additional facilities,
common fuel farm and business hotel
in the airport. The extra amenities
being created include more aircraft
parking stands, rapid exit taxiways, full
length parallel taxiway and additional
office space for airlines, extra cargo
terminal space, additional car parking
for passengers and public, extra
immigration desks, self-check-in
kiosks and bus gate lounges. The
money would also be used to finance
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planned to set up nine ultra mega
projects to add capacity in a country
with a total yield of 1,28,182 MW.
150 MW Wind Power Project
Reliance Wind Energy, an arm of
Reliance ADA Group has finalised
arrangements to set up 150 MW wind
power project with Suzlon Energy.
Suzlon Energy will set up the Wind
Farm in Sangli District in Maharashtra
at a cost of Rs 900 crores. This order
of 150 MW will make Reliance ADA
Group as one of the biggest wind energy
generators in the country. Reliance
has plans to set up 500 MW of wind
power in over the next 2 - 3 years.
installing additional security
equipments for meeting the safety
standards of BCAS.
While the rupee term loans of Rs 200
crore are being extended by Andhra
Bank and Vijaya Bank, Abu Dhabi
Commercial Bank would extend the
remaining Rs 518 crore in US Dollars
in the form of external commercial
borrowing (ECB). The ECB has a
repayment moratorium of two years
from the date of commencement of
the airport operations, and the
repayment schedule is spread over
14 years thereafter. Speaking on the
occasion, Mr. T. Srinagesh, COO,
GHIAL, said: “We are happy to have
Abu Dhabi Commercial Bank, Vijaya
Bank & Andhra Bank on board for
funding of additional facilities at the
new airport. The money would be
used to achieve our business goal
of continuously meeting the demands
of services for increased passenger
growth.” He added that the work is
progressing at a rapid pace and the
airport would take-off as per schedule
in March 2008.
April 2007
News & Events
Tata Steel Acquires Two Steel Rolling Mills in Vietnam
As part of the Company's focus on
regional consolidation, Tata Steel
through its wholly-owned subsidiary
NatSteel Asia Pte. Ltd. (NSA), has
entered into an agreement to acquire
controlling equity stake in two rolling
mills located in Haiphong, Vietnam,
has entered into a conditional
agreement with Vietnam Industrial
Investments Ltd (VII) to acquire: A
100% stake held by VII in Structure
Steel Engineering Pte Ltd (SSE(S)),
and also A 70% stake held by VII in
Vinausteel Limited. The remaining
30% share is held by Vietnam Steel
Corporation (VSC). By virtue of the
acquisition of the respective stakes,
NSA will effectively have acquired
two rolling mills located in Haiphong,
North Vietnam: A 250k tpy bar/wire
rod mill operated by SSE Steel Ltd
(a wholly-owned subsidiary of SSE(S)),
A 180k tpy reinforcing bar mill operated
by Vinausteel Ltd. The enterprise
value for the acquisition is USD41
Essar Power to invest
firms up Rs 13,000 Crore
Essar Power is planning to investment
over Rs 13,000 crore in power and
mining projects during 11th plan.
The company proposes to set up
1,000 MW each coal based power
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million, subject to certain closing
adjustments on completion.
The transaction should be completed
by June 2007. Mr Oo Soon Hee,
President and CEO of NSA, said:
“The Vietnamese steel market has been
growing at a healthy rate over the past
five years. NSA believes the market for
steel products in Vietnam will continue
to grow at a strong pace as consumption
of steel products in Vietnam on a per
capita basis is relatively low. We are
glad to have this opportunity to work
closely with VSC to enhance our
strategic presence in Vietnam.”
projects in Maharashtra and Jharkhand
while it has launched development of
1,200 MW pit head coal based power
project in Madhya Pradesh.
The company last week has been
allotted a captive coal mine at Chakla,
Jharkhand with the potential coal
reserves of 110 million tonne while
Essar Power in joint venture with
Hindalco has launched development
of captive coal mine allotted in Mahan,
Madhya Pradesh last year with the coal
reserves of 180 million tonne. In case of
Madhya Pradesh mining venture, Essar
Power and Hindalco would contribute
50% equity each in the total 30% equity
while raise 70% debt. The entire project
entails an investment of Rs 400 crore
and the JV company would be able to
start coal production from 2010,
according to the sources.
MB
L&T Consortium bags
Rs. 1400 crore Order for
Vizag Steel Plant Expansion
Larsen & Toubro Limited (L&T) and its
international consortium partners of
Paul Wurth Italia and India have bagged
an EPC package, valued over Rs. 1400
crores, for the expansion of Vizag Steel
Plant of Rashtriya Ispat Nigam Limited
(RINL). This is the largest single-value
EPC order by the client and was
bagged against stiff international
competition from Chinese, Korean and
Russian firms. In line with the National
Steel Policy envisaging production of
110 million tonnes per annum (MTPA) of
steel in the country by the year 2019-20,
RINL has embarked upon a capacity
expansion at Vizag. It had invited bids
for installation of a new third blast
furnace to double its capacity to 6.5
MTPA of hot metal from the present
level of 3.2 MTPA. L&T will construct
this blast furnace - a state-of-the-art
3800 cu.m. unit with a capacity of 2.5
million tonnes of hot metal per year.
This is the second biggest blast furnace
in India. L&T's Construction Division,
ECC, will execute this contract in
consortium with Paul Wurth Italia within
a stringent time-frame of 30 months.
L&T's scope of work includes complete
detailed engineering apart from certain
areas of basic engineering based on the
process-engineering being supplied by
Paul Wurth. The complete indigenous
manufacturing and supply of equipment
lies in the scope of L&T. Apart from
this, complete site services including the
civil and structural works and erection
of equipment will be undertaken
by L&T, with specialized supervision
being provided by Paul Wurth.
L&T's contract-value in this project
is around Rs. 810 crores.
April 2007
News & Events
Electrical Engineers Key
for Tapping Rs. 10,000cr.
Energy Saving Potential
CII-Sohrabji Godrej Green Business
Centre recently organized a national
level seminar on "Electrical Systems",
exclusively for Electrical Engineers,
in Hyderabad. The seminar provides
a platform for information sharing,
disseminate information on latest
international contracting agency
technologies & networking with experts.
committed to tapping India's long term
While addressing the gathering,
potential across the infrastructure sector
Mr. K N Shenoy, Past President,
covering express highways, airports and
CII & Chairman, Sobis Software
(India) Pvt Ltd, mentioned about the
technological development in the areas
of power generation, transmission,
utilization and demand - side Energy
Efficiency. He mentioned that
improvement in power electronics
provides increased functionality,
intelligence & compactness to the system.
He emphasized the importance of
adopting world-class maintenance
practice and employee empowerment
on new trends & latest technologies.
Mr. L S Ganapathi, Chairman, Electrical
Systems 2007, in his theme address
highlighted the necessity of proactive
and systematic approach to meet the
generation capacity expansion planned,
which requires huge infrastructure facility.
He also highlighted the challenges for
providing reliable & quality power at input
stages. The national electrical energy
saving potential is about 2500 MW
equivalent to Rs. 10,000 Crores. The
electrical engineers have a major role to
play in tapping the energy saving potential.
DLF forms JV with
Laing O'Rourke
DLF and Laing O'Rourke has entered
into a strategic alliance in the form of a
JV, DLF Laing O' Rourke (I) Pvt. Ltd.
The JV formed will be the first
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Dutch delegation in Kolkata
Stating that the Dutch ranks third in
the world in terms of infrastructure and
IT industries, Mr Marten Van Den berg,
Deputy Director General, Foreign
Economic Relations, Ministry of
Economic Affairs, Govt of Netherlands
said that the economy of India has
undergone major changes vis a vis
the India of the 80's. Mr Van Der Berg
said that though the Netherlands
ranks as one of the top investors in
India, the country is “very choosy”
about selecting companies to do
business with. He stressed that the
business interests of his country lies
in water coinnectivity, infrastructure,
cold storage, food processing, agri
and horticulture.
The Netherlands rank 5th in the list of
countries in terms of cumulative FDI
inflows into India during the period
August, 1991, till January, 2006. The
total inflows from the Netherlands
during this period amounted to US $
1.991 billion and accounted for 6.51%
of total FDI inflows into India during
the above period. In terms of
approvals granted by the Government
of India, the Netherlands ranked 7th
with cumulative approvals for
investments worth US $ 2.473 billion.
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hi-tech construction involving
power plants and mega projects.
The JV, which is a 50:50 partnership,
will bring together world class
competencies in design, construction,
safety, speed and post completion
services, making significant investments
and creating employment opportunities.
DLF Laing O' Rourke will be staffed by
the world's leading construction team
comprising of the best of professionals
from India and overseas. The JV will
undertake execution of a large number
of DLF's mega projects across the
country as well as other projects.
This was stated by Mr Hemant
Kanoria, Chairman, Infrastructure sub
committee, CII Eastern Region in an
Interactive Session on Indo Dutch
Cooperation today. Mr Kanoria said
that the Dutch investments in India
have been mainly in the field of
telecommunications, services sector
(financial and non-financial), trading,
food processing industries and
chemicals. Over a hundred Dutch
companies have a vibrant presence in
India and ABN AMRO, Shell, Rabo
Bank, ING Bank and ING Insurance
are virtually household names in India.
The Netherlands is already among the
three largest investors in India, with an
increasing interest in offshoring
opportunities on the part of Dutch
companies. He said that his own
organisation, SREI Infrastructure has
51% Dutch stake in it.
April 2007
News & Events
West Gujarat Expressway
West Gujarat Expressway Limited
is a Special Purpose Vehicle promoted
by IL&FS and group company, IL&FS
Transportation Networks Limited
(ITNL) for the conversion of the
68 km Jetput-Gondal-Rajkot and
Rajkot Bypass section of NH-8B
into an access controlled four-lane
highway and improvements to Gondal-
Rajkot section The project is the first
of its kind being implemented under
the Viability Gap Funding Scheme of
NHAI and part of the prestigious
East-West corridor programme of NHAI.
The total project cost is Rs 2402 mn
financed by a debt equity of 2.25 :1
IL&FS Investsmart Limited (IIL) was
the sole arranger for the senior debt of
Rs 1662 mn financed in the debt
equity of 2.25:1 with Punjab National
Bank as the Lead alongwith a
consortium of 7 banks. The project
involves the widening of existing
Jetpur-Gondal Section from 2-Lane to
4-Lane (26 km), improvement of the
Tata Steel's Bearing
Division wins the
Golden Peacock National
Quality Award 2006
Tata Steel's bearing division has won
the Golden Peacock National Quality
Award 2006 in the 'large manufacturing
enterprise' category. The award is given
every year to organisations for their
outstanding contribution to the field
of business excellence that lead to
sustenance of business and customer
delight. This prestigious award has been
instituted by the Institute of Directors.
The jury for the current year's award
worked under the chairmanship of
justice P N Bhagawati, former chief
justice of India and member,
U N Human Rights Commission.
MB 32
existing 4-Lane Gondal-Rajkot
Section (32 km) and widening of the
existing Rajkot bypass from 2-Lane
to 4-Lane (10km) on National Highway
No. 8-B in Gujarat on Build-Operate-
Transfer (BOT) basis. The project
cost is Rs 2402 m IL&FS and IL&FS
Transport Networks Limited (ITNL)
have incorporated West Gujarat
Expressway as the SPV to implement
the project Financial close has been
achieved and the construction has
commenced. The operations are
expected to commence by February
2008. IL&FS and its group companies
are sponsoring, developing and acting
as merchant bankers to this project
ADB Supporting
Infrastructure
Development in India
with $50 Million Loan
ADB and the Infrastructure
Development Finance Company Limited
of India have signed a $50 million loan
to support the development of
infrastructure in the country. “India
needs substantial investment in
infrastructure if it is to achieve its
economic growth targets,” said
Seethapathy Chander, Deputy Director
General with ADB's Private Sector
Department. “The Infrastructure
Development Finance Company
performs a critical role as the only signifi
cant domestic financial institution fully
dedicated to infrastructure.” The loan
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supports the Government's strategy of
encouraging private-sector participation
in infrastructure development in light of
the large investment requirements and
the limited amount of public-sector
financing available. The loan will also
help free up Government resources
from investments in infrastructure to
invest in other types of expenditure,
including social development projects.
The $50 million was offered without a
Government guarantee and has a
longer tenor than previous US dollar
borrowings by other Indian financial
institutions from the market. As a result,
the loan will enable the company to
offer dollar denominated sub-loans to
eligible subprojects in the infrastructure
sector in the country.
AMP plans $500 m
Infrastructure Fund
AMP Capital Investors, the fund
management unit of Australia's biggest
life insurer, may raise as much as $500
million to invest in Asian power and port
projects, with more than half destined
for India. The fund management unit of
AMP Ltd. will start raising the money
once it has finished investing $102
million from an existing fund that
focuses on Indian infrastructure
projects, according to the sources. AMP
Capital will continue to invest in ports as
container volumes grow, and has also
focuses on power generation, seeking
to capitalize on surging demand for
electricity, he said. India produces about
8 % less electricity than it needs, cutting
gross domestic product by a 10th,
according to the finance ministry.
April 2007
News & Events
US $ 5 billion in Capital for Infrastructure Projects in India.
Infrastructure Development Finance
Company Limited (“IDFC”), Citigroup
Inc. (“Citi”), India Infrastructure
Finance Company Limited (“IIFCL”)
and Blackstone Group Holdings L.P.
(together with its affiliates, “Blackstone”)
announced the launch of “The India
Infrastructure Financing Initiative”,
a collaborative effort to deploy
approximately US $ 5 billion in capital
for infrastructure projects in India.
The plan is to deploy about US$ 2
billion in equity capital and US$ 3
billion in long term debt financing
with maturities exceeding ten years.
The equity financing program will be
managed by IDFC and will invest in
greenfield, brownfield and operating
projects primarily in roads, power,
airports, ports, and industrial and
commercial infrastructure. IDFC,
Citi and Blackstone will together
invest US$ 250 million. The balance
is expected to come from reputable
international investors as well as
Centre to Set Up Two
Nuclear Power Plants
The proposal of the Department of
Atomic Energy to set up two major
nuclear power plants, one in Rajasthan
and the other in Gujarat has been given
a go ahead by the UPA Government.
The two plants with four heavy water
reactors of 700 Mw capacities each will
add 2800 Mw nuclear capacity.
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selected domestic institutional
investors including IIFCL.
The agreement was signed recently by
Dr. Rajiv B. Lall from IDFC, Mr. Sanjay
Nayar from Citi, Mr. S.S. Kohli from
IIFCL, and Mr. Robert L. Friedman
from Blackstone in the presence of
Mr. P. Chidambaram, the Finance
Minister of the Government of India.
“This initiative is an important milestone
in our search for innovative solutions
to meet the vast challenge of financing
the development of India's burgeoning
infrastructure sector”. Mr. Deepak
Parekh, Chairman IDFC, added that
“This initiative sets a new benchmark
for collaboration between a domestic
These two nuclear power projects are
being set up in consonance with the
Vision 2020 of the nodal department,
according to which the installed nuclear
power capacity is expected to be
ramped up to 20000 MW. As per the
sources the Environment Ministry has
already given clearances based on
recommendations of the Gujarat
Pollution Control Board after conducting
public hearing to locate the nuclear
power plant at Kakrapar.
Chennai Metro Phase-I
to cost Rs 9,347 Crore
The first phase of the proposed
Chennai Metro project which envisages
corridor-1 from airport to Thiruvotiyur,
31.54 km, and corridor 2 EVR Periyar
Salai to Fort , 13.54 km, is to be
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partner such as IDFC with deep domain
knowledge in infrastructure, foreign
financial institutions with wide reach
into global financial markets and the
Government of India to solve India's
infrastructure financing problems”.
Reiterating Citi's commitment to India,
Mr. Charles Prince, Chairman and
CEO of Citi had, in this context, stated
earlier that Citi was excited about this
opportunity to make an impact on the
development of infrastructure projects,
which are critical to the country's
growth prospects and to be a partner
in this important initiative, which
was born out of a request from the
Government of India at the Indo-U.S
CEO forum held in December 2006.
Mr. Stephen A. Schwarzman of
Blackstone had stated that India being
an important part of Blackstone's
global strategy, this initiative would
give them an opportunity to make
a meaningful contribution to India's
infrastructure development.
completed in 66 months at an estimated
cost of about Rs 9,347 crore, according
to the brief project profile submitted
to the state government by the Delhi
Metro Rail Corporation (DMRC).
According to the sources the state
government would soon set up a
'Metro Rail Project Committee to
implement the project. For the time
being, the project is treated as a 'special
initiative under the administrative
control of the planning development
and special initiatives department.
April 2007
News & Events
Unitech to Pump
Rs. 2,250 crore
for 100-acre Township
Unitech Ltd has recently announced
that it would be investing about
Rs 2,250 crore for the development
of a 100-acre residential township
called `Uniworld City' in Greater Noida.
According to a company release this
Tata Power Signs MoU
Tata Power signed a MoU with the
Government of Chhattisgarh for the
setting up of a 1000 MW coal fired
mega power plant in the State.
The project is estimated to entail
an investment of Rs. 5000 crore and
is slated to be set up in the Raigarh
district of the State. The Company
is now in the process of carrying out
a detailed feasibility study for the
project. Work on the 250 MW coal
based plant and 100 MW DG Sets
for Mumbai, 120 MW Met Coke Project
in Haldia, 100 MW wind power plants
in Maharashtra and 1000 MW Maithon
project is progressing well.
The Tata Power Company Limited is
India's largest private sector power
utility with an installed generation
capacity of over 2300 MW.
The company has emerged as a
pioneer in the Indian power sector,
with a track record of performance,
customer care and sustained growth.
Tata Power has a presence in all the
segments of the power sector viz
MB 36
largest integrated development is
designed by HOK, the second largest
architects in the world. As per the
release the project has the capacity to
accommodate 4,000 households and
would have features such as piped gas
lines for each home, sewage treatment
plant, rain water harvesting, electronic
security and surveillance etc. According
to Mr Sanjay Chandra, Managing
Director, Unitech, "Uniworld City is
among Unitech's premier projects which
will redefine the paradigms of residential
development in the country,”
L&T in Talks with Toshiba
to Set Up JV in power
Larsen & Toubro is in talks with Japan's
Toshiba Corporation for setting up a
joint venture in India to manufacture
generation (thermal, hydro, solar
and wind), transmission and distribution.
The Company won the bid for Ultra
Mega Power Project at Mundra (Gujarat)
and has successful public-private
partnerships in generation, transmission
and distribution “North Delhi Power
Limited” with Delhi Vidyut Board for
distribution in North Delhi, 'Powerlinks
Transmission Ltd.' with Power Grid
Corporation of India Ltd. for evacuation
of Power from Tala hydro plant in
Bhutan to Delhi and 'Maithon Power
Ltd.' with Damodar Valley Corporation
for a 1000 MW Mega Power Project.
MB
power plant equipment. As per the
reports L&T would hold majority stake in
the joint venture, which will invest about
$173 million to build plants for steam
turbines and power generators. The
joint venture aims to have an annual
turnover of 20 billion yen in five years.
Toshiba, which has been expanding its
power business, acquired the US
nuclear power plant maker
Westinghouse for $5.4 billion last year.
L&T's entry into this critical segment of
the power sector follows its recent tie
up with Mitsubshi Heavy Industries,
another Japanese major, for
manufacture of boilers for power
projects. The joint venture L&T Boilers
Ltd plans to invest Rs 450 crore.
Government to Remove
Stamp Duty
The stamp duty on property
transactions will soon be removed, and
the same would only be imposed on the
first transaction of land, as per the 2006
National Urban Housing Policy. The
provision is waiting for the final nod
from Cabinet. As per the sources at
present, stamp duty is being charged
on both the land and the apartment,
and moreover, its percentage varies
from state to state, as it's not uniform.
So the shift, it is expected would bring
high profits for property buyers.
April 2007
News & Events
RAK Ceramics JV with Smaltochimica
R.A.K. CERAMICS , the global leader
in the ceramic & porcelain tiles and
sanitaryware business and the
Smaltochimica group of Italy have
joined hands to form a new venture
RAK CHIMICA, to manufacture state
of the art chemicals for the ceramic
industries. This is the beginning of
a new era in the Middle East as such
specialised chemicals are to be
Punj Lloyd to Build
Expanded Capacity
Fuel System of NDIA
Punj Lloyd Limited (PLL), a global EPC
services provider in energy and
infrastructure domains, has received
approval of extension of their existing
contract with New Doha International
Airport (NDIA). The extension will
enhance the capacity of the fuel system
to take care of phase II expansion of the
new airport. The extension order is
valued at Rs 258 crore. With this
approval, the contract value for the
extended scope becomes Rs 618
Crores. The new contract with extension
involves the engineering, procurement
and construction of fuel farm, fuel
receiving station, jet fuel hydrant
system, ground service equipment fuel
system, ground service equipment
washing system, portable water station
MB 38
produced & exported for the first time
in the region's chemical history.
The joint venture will have a modern
manufacturing set up at Ras Al
Khaimah, close to the RAK group's
manufacturing complex which is
spread over 2,000,000 sq.mt . The
new chemical plant will initially
produce printing oils for the ceramic
industries . Smaltochimica is a world
leader in the production & art of
decoration chemicals products for the
ceramic industry. The joint venture
will manufacture in its fully automated
environment around 460 Tonnes per
month (or 5520 Tonnes per year),
assuming 1 shift's working. The
quantum of production is planned to
be increased soon. This year RAK
CHIMICA will implement chemicals for
the ceramic body preparation for an
additional 400 tonnes per month.
and operation office, parking facility
for hydrant dispenser vehicles, triturator
facility, special fuel system equipment,
special systems in building / facilities
(BMS/CCTV) etc. The project would
be completed by December 2008.
Punj Lloyd is at an advanced stage
of completing engineering phase for
the fuel system and Client's approval
of extension of the contract reinforces
the confidence of project management
consultant, Overseas Bechtel Inc.
In Punj Lloyd.
Punj Lloyd to Build
300ktpa LDPE Plant
Punj Lloyd Limited (PLL), a global EPC
services provider in energy and
infrastructure domains, has through its
subsidiary - Simon Carves Ltd - signed
a Letter of Intent (LOI) to build a new
300 ktpa LDPE plant in Saudi Arabia for
MB
the Saudi Kayan Petrochemical
Company, an affiliate of Saudi Basic
Industries Corporation (SABIC).
The plant, due to start up in the first
quarter of 2010, is to be built at Saudi
Kayan's petrochemical complex
at Al-Jubail Industrial City, KSA, and
will incorporate technology from Basell
GmbH. The Letter of Intent is on the
basis of a fixed price for Contractor's
services and a conversion to a lump
sum Engineering, Procurement,
Construction (EPC) price, once detailed
engineering is sufficiently defined.
GE Finance May Fund
Mumbai Metro
GE Finance, the investment arm of
GE, is eyeing to fund the Rs 20,000
crore Mumbai Metro project and the
western freeway between Worli and
Nariman Point sealink as part of its
push on infrastructure investments in
India. The first phase will be developed
by Reliance Energy at a cost of
Rs 3500 crore. The financial closure
for the project is yet to be completed.
The tender for the western freeway is
yet to be tendered. As per the report
$ 8 billion investment target for India
announced by Jeffery Inmelt the GE
chief on his last visit to India, was
likely to be met much before the
2010 deadline.
April 2007
CDM Project
FaL-G : CDM Project Signed
with the World Bank
T
HE CARBON CREDIT PROJECT which
INSWAREB has been relentlessly pursuing, is
ultimately signed recently with The World
Bank. Ms Gayathri Ramachandran, Special Chief
Secretary & Director General-EPTRI, Government of
Andhra Pradesh, and Mr Michael Rathnam, Task
Manager-Carbon Finance, The World Bank,
Washington, addressed and conferred the “Certificate
of Participation” to the Privileged Entrepreneurs of
the FaL-G brick/block Plants, enlisted as Sub-Project
Entities (SPEs) in the project.
Despite holding a patent on FaL-G technology,
INSWAREB has been disseminating the
technology to tiny sector without any royalties, as
a service to Ecology. To accelerate the proliferation
through incentive mechanism carbon revenue was
considered as an opportunity and, INSWAREB
approached World Bank way back in the year 2000,
offering carbon credits generated out of FaL-G
brick/block production. But the proposal did not
come through, as India was not a signatory to the
Kyoto Protocol at that time. Subsequently, India
became a signatory to the Protocol in 2002. In the
same year The World Bank launched another
carbon fund instrument, Community Development
Carbon Fund (CDCF). INSWAREB took the
opportunity and filed the first project with the
World Bank highlighting the following features of
FaL-G brick/block activity to serve
the community:
FaL-G bricks replace clay bricks, conserving the
precious topsoil, otherwise necessary to protect the
fertility of agriculture lands. Each FaL-G brick plant
in tiny sector can absorb 10-15 workers. Thus over
2500 plants working throughout India have
40
“At the ongoing proliferation of over
200-250 FaL-G units every year, not only the
World Bank but a couple of more proactive
agencies such as JCF, Japan, and KFW,
Germany, would be tagged with projects very
soon” says INSWAREB.
contributed to employment to over 30,000 workers
with a further potential for 6 lakhs workers, when
the 50,000-unit target could be accomplished.
Contrary to the seasonal employment in clay brick
industry, FaL-G brick plants provide yearlong
employment with handsome wages over clay brick
units. Such job security would relieve the worker
from the status of bonded-labour, which is more
prevalent in clay brick industry.
By not using thermal energy, each million FaL-G
bricks conserve over 200 tons of coal or equivalent
fuel. Thus carbon emissions are abated. In view of
holistic compliance to the Sustainable Development
indicators and Community Development agenda,
the World Bank agreed to take up FaL-G as CDM
project. But as there was no specified approved
methodology for total energy avoidance, it was
opined that a new methodology would be needed,
that took considerable time. Ultimately the project
is registered with an approved methodology under
Type II-D. Energy Efficiency and Fuel Switching
measures for Industrial facilities.
Promoting a carbon abatement activity as
CDM project is a laborious exercise, involving a
lot of effort and record work. Keeping in view the
consultancy from high profile experts, the
April 2007
 CDM Project

transaction costs are very high that deter small entrepreneurs in order to compute Emission
scale and tiny sector units in staking their claims Reductions (ERs) annually. These credits are
for credits, despite virtuous activity to earn them. reported to the World Bank vide ‘Annual Emission
To overcome this stalemate, INSWAREB opted Reduction Report’.
to avail the scope of ‘Bundling’ provided by There upon, the World Bank would get the
UNFCCC in small scale activity, by which, over credits verified by its Designated Verifiers within
108 micro industrial plants producing FaL-G one and half month, based on which ECPL would
bricks, each with a potential to generate over submit a ‘Transfer Form’ to the World Bank for
1000 credits every year, are being tied up into a transfer of ERs. The carbon proceeds are released to
few bundles and offered as CDM projects. ECPL within 60 days of receipt of Transfer Form,
In order to handle the commercial deals and which would, in turn, be transferred to brick units
agreements, a separate corporate outfit by name, Eco based on their earning of credits.
Carbon Pvt. Ltd., has come into existence, “At the ongoing proliferation of over 200-250
committing to transfer to the World Bank 600,000 FaL-G units every year, not only the World Bank
tons of CO2 credits under contractual obligation and but a couple of more proactive agencies such as
200,000 credits under call option. Back to back JCF, Japan, and KFW, Germany, would be
agreements were signed with each FaL-G brick plant tagged with projects very soon”
committing over Rs. 50,000 per each million bricks says INSWAREB.
(equivalent to 1540 cu.m) as the carbon revenue till
2015. In addition to carbon revenue to the
entrepreneurs, this activity provides certain privileges
to the workers under Community Benefit Program, at
a budget of over Rs. 2.80 crores during the project
period. These are:
h Providing self-protection gadgets such as
gumboots, helmets, nose masks and gloves to
the workers.
h Water purifying systems at each FaL-G plant for
serving drinking water to the workers.
h Construction of bathroom cum toilet for workers.
h Health and life insurance to workers every year.
h Health check up once in a year.
h Aids-awareness program.
“Not all FaL-G brick plants can take part in the
project. Those units, came into existence on or
after 1st January 2004, are only eligible to
participate. Diligent production practices in
maintaining quality and adhering to statutory
compliances are additional mandate to enlist the
units for this project,” says INSWAREB, who
monitors the plants all along the project period for
due diligence. Under the ‘Monitoring Plan’, ECPL
audits production records of all the accredited

April 2007 41
Waterproofing
Exclusive Show Room
for Waterproofing Products
in Chennai
S
HREE BHUVANESWARI INC (SBI) has
opened an exclusive showroom for
waterproofing products in the main building
materials market at Koyambedu, Chennai.
According to Mr.S.Muthuperumal - Managing
Director of M/s M.P Integrated Roofing Pvt. Ltd
and promoter of M/s Shree Bhuvaneswari Inc., this
is the first of its kind in the country to have an
exclusive showroom for both imported and locally
manufactured waterproofing products for various
job specifications such as Roofs, Basement, Water
Tanks, Walls, Toilets, Swimming Pools and for
other applications. We offer you the after sales
technical support by our trained and experienced
engineers. Our line of products include APP & SBS
modified bitumen membranes for new and
maintenance jobs. We can also provide turnkey
solutions for new basement jobs with our wide
range of imported membranes.
We are also stockiest for leading crystalline
waterproofing system like ICS PENETRON- USA,
42
The main advantage of Crystalline
waterproofing system is to arrest ,water
seepage in existing basement by coating the
crystalline chemicals from negative side (
from inside )the basement.
GREEN SEAL – MALAYSIA.
The main advantage of Crystalline
waterproofing system is to arrest ,water seepage in
existing basement by coating the crystalline
chemicals from negative side ( from inside )the
basement. The technology behind this system is to
prevent the movement of water through the
concrete by plugging or blocking the natural pores
and capillaries found in all concrete.
Since this system is now followed in many new
upcoming mega IT parks, the crystalline products are
available at a affordable prices.
Other allied products like Acrylic , Silicone and
PU sealants are also available from leading
international brands at whole sale price.
It is intended to focus and serve the DO IT
YOURSELF market.
Enquiries related to the water leakage problems in
a building are recorded and solutions are given to the
customer from our vide range of products. If
necessary we are even deputing our technicians at a
reasonable charges.
Moreover, seminar and presentations are to be
organised for Institutions, Architects,
Consultants, Builders, Contractors and end users to
update with the latest products and methods
followed across the globe.
April 2007
Joint Ventures
SREI and EBRD in
Strategic Alliance
S
REI INFRASTRUCTURE FINANCE LIMITED
will shortly enter into a strategic partnership
with the European Bank for Reconstruction and
Development (EBRD), one of the world’s leading
international financial institutions. The strategic
partnership comprises an investment by the EBRD
in the equity of SREI Russia and extension of credit
lines to support the business of the overseas
company. While the equity stake will be
formalized at the EBRD board meeting later this
month, the multilateral funding agency has agreed
to invest in principle roughly 15 per cent in the
Euro 5 million equity of SREI’s Russian venture.
Credit lines, however, will be project specific.
Interacting with newspersons in Mumbai, Mr
Jean Lemierre, the EBRD president said it is
actively pursuing investment models, which will
encourage Indian business houses to invest in East
Europe and Central Asia. “We do not only invite
44
“EBRD has been a great partner to us in
our foreign endeavor. Their understanding
of the conditions in Russia has enabled us to
look at the huge potential that welcomes us
in the Russian infrastructure sector
development,” according to Mr Hemant
Kanoria, vice chairman and managing
director of SREI
business groups but also share risks in the projects
where we facilitate foreign investments”, Mr
Lemierre said. Mr Hemant Kanoria, vice chairman
and managing director of SREI, the first Indian
company to partner EBRD overseas said, “EBRD
has been a great partner to us in our foreign
endeavor. Their understanding of the conditions in
Russia has enabled us to look at the huge potential
that welcomes us in the Russian infrastructure
sector development.”
This will be the first direct project of the
EBRD with an Indian company and it’s
association is likely to pack a punch to the growing
involvement of SREI’s foray into the construction
equipment leasing sector in Russia. SREI’s growth
graph is well known given its strong linkages and
relationships with the multilateral financial
institutions, vendors and its successful experience
in India.
Having set up its operation is Russia in the latter
half of 2005, the company has chalked out plans to
scale up businesses by rapidly entering the strategic
infrastructure space in the region which today is
experiencing a boom.
April 2007
 STEELFAB

Incorporated in 1970 under the leadership of late

Mr. Pramod P. Shah, Steelfab has carved a niche in
designing, engineering, detailing, manufacturing,
erecting & cladding of pre-engineered buildings, apart
from manufacturing trapezoidal profiled colour
coated galvalume sheets, bare galvalume sheets,
PPGO sheets, G.I. sheets, space frame structures and
modern steel scaffolding systems. Steelfab’s team
consists of resourceful which leverages on emerging
trends with effortless ease. Armed with over three
decades of experience and top of the line expertise,
steelfab offers the best in terms of quality and
durability. Ongoing efforts at the research cell results
in sourcing quality materials from all over the world
at the best prices.
Every component is checked time and again before
installation, during installation and after installation
to eliminate even the slightest doubt of error. The
design and research cell takes each suggestion and
opinion from our clients seriously and starts working
on it almost immediately. The competitive pricing is
the result of understanding the value of money. Its
just in time approach has enabled the company to
perform under strict deadlines and three decades of
experience has added value to its commitments. The
quick response is not limited to the delivery of the
structure, but also the after sales service, which is the
company’s forte.
Steelfab is equipped in dealing with turnkey
projects as it has a fully-equipped design department
with latest international design softwares, fully-
equipment production facility for PEB & Sheets.

April 2007 45
Technology
Sankalpan Group
Unveils National
Expansion Plans
M
UMBAI-BASED SANKALPAN GROUP,
India’s foremost and fastest growing
integrated realty and premium infrastructure
services provider having interests in architectural design
consultancy, turnkey fit-outs, infrastructure projects and
commercial real estate development, has recently
unveiled its business expansion plan across the country.
Detailing on Sankalpan’s current projects, Mr. Atin
Kulkarni, Vice-Chairman said, “Having already executed
46
more than 600 projects across India, Sankalpan is ready
for more and set to unveil innovations. We have recently
bagged a $ 2 million interior fit-out turnkey project for a
leading NASDAQ listed IT major. We will be designing
700 seats facility at one of the SEZ in Chennai that will
have the latest imported furniture, fittings and finish, not
to forget an interior design that matches the
international standards with Sankalpan’s touch
all across.”
Mr. Ninad Randive, Chairman, Sankalpan
Group said,” There is great potential in India
wherein the IT Parks and Retail infrastructure
requirements are fast escalating. In near future,
single point sourcing for all construction activities
will be the rule of the game. Anticipating this
trend much in advance, we are already providing
integrated services to our clients easing their
complex tasks. Sankalpan is currently looking for
potential partners who would bring in financial
strength while we contribute our expertise in
project management. As of now, we have our
presence felt in all the major metros and several
strategic cities across India. Now we intend to
explore business opportunities in potential
tier -2 cities.
Sankalpan will soon be launching its facility
management services as a new business venture and is
looking for potential partners. With globalization,
there is tremendous pressure to match international
workplace standards. This is where a huge need for
trained facility managers is being felt across the
country and Sankalpan would like to bridge this gap.
Sankalpan is expecting a turn over of around $ 35
million this fiscal.
April 2007
Cover Story

Infrastructure Project
Funding as a Guide to
Steel Capacity Planning
TanmayRoy
Deputy General Manager (C&IT) of Steel
Authority of India Limited

T
HE INDIAN ECONOMY is on a roll with
GDP galloping at more than 8% per annum
and promising to cross the threshold of double
digit growth in near future. There is considerable
euphoria about everything, be it construction,
manufacturing or service etc. the key sectors of the
national economy. Both infrastructure and
manufacturing sectors are major drivers of domestic
demand of steel as well. The bullish performance of
the domestic economy is generating huge interest in
the market place, especially among the steel barons
who are on an unprecedented spree to add capacities
at breakneck speed. A kind of ‘mad’ rush appears to
have gripped the domestic steel industry giving rise
to a rather pertinent question, “Are all these
investments justified in the long run?” Let’s explore
and examine.
Issue
Risk & Uncertainty are integral to any investment
decision and steel sector is no exception. It is always
prudent to examine any such investment decision
from as many diverse and different angles as possible.
More such analyses are carried out, it is better for the
investor as it enables him or her to prejudge the
available options and decide on the best course of
action. Such analyses help reduce the element of risks
Source %Share $ billion pa Rs crorepa
Private Sector
Fund 22% 15.00 67,500
ODA 11% 8.00 36,500
Public Sector
Fund 67% 47.00 2,11,000
Table 1
The objective of this paper is to examine
the reliability of the capacity expansion spree
in the steel sector currently being witnessed
by the country vis-a.-vis the emerging
pattern of funding in the infrastructure
sector of the national economy.
and uncertainties often associated with such projects
by generating more incisive information of the same.
Purpose
The objective of this paper is to examine the
reliability of the capacity expansion spree in the steel
sector currently being witnessed by the country vis-
a.-vis the emerging pattern of funding in the
infrastructure sector of the national economy. Nearly
half of the total volume of steel consumed by the
domestic economy end up in the construction of
infrastructure projects in the public and private
domains including the household sector of the
country. The balance portion is consumed by the
manufacturing sector of the economy.
So the pattern of investment in the infrastructure
sector holds an important key to the growth and
performance of the steel sector. And in this context,
the resource mobilizing ability of the economy,
especially the union government is the most
significant factor having maximum impact on the
demand and consumption level of steel in the
domestic economy.
Funding
The approach paper to the eleventh five-year plan
prepared and circulated by the Planning Commission
in June 2006 targets a GDP growth of 8.5 % p.a. for

48 April 2007
 Cover Story
Steel Capacity Planning

the period 2007-08 to 2011-12. The plan document

estimates that investments in infrastructure will have
Given the all out efforts of the
to be raised substantially in order to sustain the government in mobilizing the necessary
projected growth of the economy. It aims to raise the ingredients for growth in the infrastructure,
current level of infrastructure investment from 4.6 % the future of steel sector appears to be
of the GDP to nearly 8 % by the end of the plan bright and bullish. The industry is robust
period. The total requirement of infrastructure enough to take in its stride aberrations if any
investment during the entire plan period has been arising out of normal inflationary pressure
estimated to be $ 350 billion or Rs.15,75,000 crore. or otherwise and still grow at a frenetic pace
This works out to $ 70 billion or Rs. 3,15,000 crore of 15% CAGR.
per annum.
Where from this massive level of investments billion or Rs 22,500 crore would be mobilized
will be mobilized is a big issue. The government through this route per annum.
plans to mobilize resources from three possible
This leaves a balance of $ 10 billion to be raised
sources as in Table 1.
Private Sector Funding
from the domestic capital markets through IPOs,
bonds and commercial borrowings from banks and
Sourcing of capital from private sector covers both
financial institutions. Given the robust corporate
foreign direct investment (FDI) and money received
balance sheets of the financial institutions, the
from the domestic capital market. The FDI inflow in
commercial banks and the surging stock markets, it
the current fiscal is estimated at $ 15 billion or Rs
should be collectively possible to raise the targeted $
6,75,000 crore. The Investment Commission has also
10 billion or Rs.45,000 crore pa.
projected that the level of FD I to domestic economy
would be of the order of $ 15 billion by 2007-08. At ODA Funding
the current rate, the projected FD I by the end of The current level of disbursements of funds by
the plan period, i.e. by 20011-12 would reach $ 20 the World Bank, ADB, DFID and other multi and
billion per year. Assuming 25% of the total FDI bilateral agencies is of the order of $ 5 billion pa.
flow ends up in infrastructure sector, about $ 5 The government views the availability of such funds
from multi lateral agencies is a huge
Type of Material Equip- Labour Finance /\dm Surplus opportunity which needs to be exploited far
Project ment exp more aggressively so that the same can be
Building 60% 4% 12% 8% 10% 6% raised to $ 8 billion or Rs 36,000 crore pa
Roads 44% 21% 11% 8% 10% 6% during the plan period.
Bridges 47% 17% 12% 8% 10% 6% Public Sector Funding
Dams 44% 21% 11% 8% 10% 6% The central and state governments
including the public sector companies need to
Power 43% 22% 11% 8% 10% 6%
mobilize the balance $ 47 billion or Rs
Railway 52% 7% 17% 8% 10% 6% 2,11,000 crore per year which represents 67 %
Mineral of the total annual requirement of fund of $ 70
Plant 42% 21% 13% 8% 10% 6% billion in the infrastructure sector.
Med lnd 51% 8% 17% 8% 10% 6% Presently, the GCFI : GDP ratio is 4.6 %
Trans- which means that in the current year 2006-07,
mission 50% 6% 20& 8% 10% 6% the level of investment in the infrastructure is
to the tune of Rs.161,000 crore across all
Table 2 systems. Making an allowance for the private

April 2007 49
Cover Story
Steel Capacity Planning

and multi lateral agencies which together account for

25 %, the Public Sector is presently pumping in 75 %
Subject to realization of the planned
of the infrastructure capital which comes to targets of raising resources and spending of
Rs.1,21,000 crore. This leaves a gap of Rs.90,000 the same in project construction, the country
crore ( 2,11,000 - 1,21,000) that needs to be is set to witness a massive expansion of steel
organized additionally every year from the current demand exceeding 84 million tones in the
level to meet the resource gap projected in the form of finished steel or 98 million tonne or
eleventh plan period. nearly 100 million tonne in the form of crude
The government is, however, optimistic that it steel by the year 2011-12. This estimate
would be able to mobilize the additional Rs.90,000 surpasses the government’s projected capacity
crore pa for the infrastructure sector by bringing in expansion plan of 80 million tonnes of crude
more innovative ideas and ‘thinking out of the box’. steel by a healthy margin.
Construction Cost
The Planning Commission had commissioned a The intensity of steel indices will however depend
study to determine the costing pattern of various on the unit in which the projects are evaluated and
types infrastructure projects ranging from buildings, measured. Let’s take, for example, the cost of steel
roads, bridges, dams to power plants, railway projects versus cement. Presently, the country consumes about
etc. The study identified that the cost of construction 40 million tones of steel and 140 million tones of
materials alone ranging from 40 to 60 % depending cement which gives the ratio of Steel: Cement as 1
on the nature of the project, dominates the cost of an :3.5, when expressed in quantitative terms or physical
infrastructure project. The project wise distribution ofunits. Given the wide disparities between the unit
major cost components of infrastructure projects is prices of steel and cement, the ratio becomes radically
furnished in the following table 2. different, almost opposite as 7.5:1, when expressed in
Steel: Cement Ratio absolute rupee or value units. However, taking into
In infrastructure project construction, steel and account the current consumption pattern of both the
cement constitute the bulk of the construction materials in the domestic economy, the relative or
materials. Hence the cost of steel and cement weighted average ratio comes to 2:1. This is evident
dominate the overall cost of construction materials. from the following table 3.
Besides steel and cement, materials like sand, stone, This exercise analyses the impact of infrastructure
ballasts, timber, etc. also add to the cost of materials.
funding on the demand of steel in value measure.
Nevertheless, steel and cement, being consumed in Hence, steel intensities are expressed as percentage of
relatively higher volumes dominate the cost of the cost of materials in Re or value unit. From
construction materials as a whole. the above table it is evident that constructional
steel items account for 2/3rd or 67% of the
Quantity Measure Value Measure material cost. This index will be useful for
Consump- Ratio Price Absolute Weighted crosschecking the accuracy of the size of the
tion in Ratio Ratio steel market derived later.
Million Steel : Rs / Tonne Steel : Steel :
Tonne Cement Cement Cement Steel Intensity
Steel 40 --- 30,000 The intensity of steel vis-a.-vis the other
1: 3.5 7.5: 1 2: 1 materials vary widely from one type of project
to another. For example, the infrastructure
Cement 140 4,000
projects of the railways, energy, ports and
Table 3 shipyard sectors which comprise of fabricated

50 April 2007
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Steel Capacity Planning

steel structure in a big way have a greater intensity of

usage of steel as compared to those of the irrigation,
aviation, housing where cement in the shape of plain
and reinforced concrete plays a more dominate role.
The steel intensity therefore varies widely from one
type of project to another.
In value terms, depending on the type of
construction involved, it may vary from as high as
90% of the construction materials for the Railway
projects which by design are extremely steel intensive
to as low as 30% for the projects in Roads and vj denotes the investment in the ith type of project,
Highways sector. Energy and Port sectors are the cj denotes the % share of the cost of construction
other steel intensive sectors. Aviation, Irrigation and materials for the ith type of project,
House constructions generally reflect 50 -60% steel Sj denotes the steel intensity expressed as % of the
usages among construction materials expressed in total cost of the construction materials for the ith type
value terms. of project
Market Size in Value Measure Then,
Recognizing the relevance of the differential rates of The demand or the market size of constructional
steel intensities vis-a-vis the type of projects and also steel in value measure for the ith type of project is
keeping in mind the variability, however small may it defIned by
be, in the nature of the cost of the construction
di = vj X cj X Sj for each i = 1, ,n and the
materials explained earlier, it is possible to derive the
overall market size of constructional steel in value
potential market of contraction steels market by measure across all types of infrastructure projects is
evolving a simple empirical relationship as under
given by
Let,
n n
Total number of infrastructure projects = nand
Dy = L dj = L Vj X Cj X Sj i i
Infra- Construction Constructional i
structure Material Cost Steel Market The above formula has been applied to the
Project In-
Sectors vestment projected investment figures as set out in the
Steel various documents of the government to arrive
% Intensity at a plausible or most likely size of the
Rs. Crore Share Rs. Crore (%) Rs. Crore constructional steel market in value unit
Highways 2,20,000 44% 96,800 30% 29,040 during the plan period 2007-08 to 2011 -12 as
Railways 3,00,000 52% 1,56,000 90% 1,40,000 shown in table 4.
Energy 5,40,000 43% 2,32,000 80% 1,85,760 Cross-Check
Airports 40,000 51% 20,400 60% 12,240 The above model or the empirical
Ports 50,000 50% 25,000 70% 17,500 relationship based on the type of infrastructure
Irrigation 80,000 44% 35,200 60% 21,200 project wise coefficients of material costs, steel
Others 3,45,000 60% 2,07,000 50% 1,03,500 intensities etc. generates an overall market size
of Rs 5,09,560 crore for the constructional
Total 15,75,000 49% 7,72,600 66% 5,09,560
steel in the country for the Xth plan period.
Table 4 This figure yields an overall or weighted

52 April 2007
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Steel Capacity Planning

average steel intensity level of 66% or 2/3d of the

construction material costs. The fact that this figure
matches closely with the index of steel intensity as
determined from the approach of regressing the same
with the cement consumption index in the country
further substantiates the stability or the accuracy of
the computational method adopted in this exercise.
Market Size in Quantity Measure
From the above table, it is evident that the
constructional steel comprising of Bars & Rods,
Structural, Railway Materials and Plates have a
domestic market to the tune of Rs. 5,09,560 crore for
the entire plan period. Assuming that the projected
investments in the infrastructure sector would for all
practical purposes be taken to be uniform, the average
size of the market comes to Rs 1,01,912 crore per
annum for each of the 5-year period.
In order to translate the above market calculated
in value measure into quantity measure or physical
units, it is necessary to obtain realistic estimates of
the average transaction prices of the constructional
steel proftles consumed by each of the different types
of construction projects. The construction steel as
defined in this exercise comprises of Bars & Rods,
Structural, Railway Materials and Plates. Obviously,
there is no fixed pattern of consumption of these steel However, this is not the total or final demand of the
profiles across different types of steel projects. For constructional steel in the country. This projection
example, Rails and Plates will largely dominate the needs to be suitably modified and augmented because
Correction of the deficiencies of the published statistics on
investment or capital formation of the nation .. The
Thus the infrastructure investment approach yields
GCFI : GDP ratio fails to adequately map the total
a demand of 31.39; say 31.4 million tonnes of
level of consumption of constructional steel in the
construction steel materials by the year 2011-12
domestic market. This will be evident from the
based on the empirical relationship defined earlier.
analysis of the current year’s (2006-07) level of
Demand by 2011-12 in Mill Tonnes investment vis-a-vis domestic consumption furnished
Constructional steel 47.0 here under.
Non-constructional steel 37.0 h Infrastructural investment during 2006-07
Total 84.0 Rs.1,61,000 crore
Long Products 39.0 h Share of constructional materials (49%)
Rs.78,890 crore
Flat Products 45.0
h Share of constructional steel (66%)
Total 84.0
Rs.52,067 crore
Table 5 h Steel market size @ Rs.32,466/ - per tonne

April 2007 53
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Steel Capacity Planning

16.0 million tonnes

This estimate falls short of the 24.8 million tonnes
of construction steel market out of a total consumption
of 43.4 million tonnes estimated by the steel experts
for the current year 2006-07. The infrastructure
investment approach, therefore, leaves a gap of 8.8
million tonnes (24.8-16.0), which is roughly one third
or 33 % of the level of domestic consumption.
One may wonder as to the cause of this deficiency.
One reason could be the fact that a part of the real
estate sector is financed by ‘black’ or unaccounted
money, which do not figure in the official books of
accounts of the nation. The other reason could be the
inefficiency of the government machinery to comes to 47.0 million tonnes (31.4 x 1.5).
adequately measure the extent of the economic Currently, constructional steel materials account
activities, especially the capital formation taking for 56 % of the total steel consumed by the economy.
place in the private house hold sector beyond the The balance 44% of steel comprising of sheets, coils
reach of the official data collecting agencies. etc. are primarily consumed by the manufacturing
Thus, the forecast of 31.4 million tonnes derived sector of the economy. Thus, the total projected
on the basis of the projected level of planned demand of steel comprising of both the constructional
investments in the infrastructure projects needs to be and non-constructional materials comes to 84.0
multiplied by a factor of 1/0.67 or 1.5 to arrive at the million tonnes (47.0/0.56) by 2011-12. This implies
likely level of demand by the year 20011-12. Thus, that the manufacturing sector is also likely to
the estimated level of demand of constructional steel experience the same kind of growth envisaged in the
infrastructure sector of the economy so that their
mutual shares continue to remain stable in the years
Demand by 2011-12 in Mill Tonnes to come.
Bars & Rods 29.5 Capacity Projection
Structural 7.4 The above estimate is in terms of finished steel
Rly Materials 2.1 only. Making an allowance of 95 % yield from crude
Total Long Products 39.0 to finished steel and further allowing for 90 %
Plates 8.3 capacity utilization in the domestic steel sector, the
H R Coils & Skelp 19.3 corresponding steel capacity in terms of crude steel
would be of the order of 98.0 million tones (84.0 /
HRSheets 0.9
(0.95x.0.90)).
C R Coils & Sheets 8.4
h Market Size (Rs crore for the plan period) 5,09,560
GP/GC Sheets 3.9
h Market Size (Rs crore per annum)............ 1,01,912
Electrical Steel Sheets 0.6
h Market Size (MT 1 annum) for infrastructure
Tin Plates 0.7 demand ......................................................... 31.4
Pipes 2.9 h Market size after allowing for possible non- plan
Total Flat Products 45.0 consumption @ 30% (31.4/0.67) ................... 47.0
Total Finished Steel 84.0 h Total market including manufacturing demand as
Table 6 well (MT/annum) (47.0/0.56) ......................... 84.0

54 April 2007
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Steel Capacity Planning

h Equivalent capacity in terms Crude Steel (95%

yield) and allowh”lg 90% capacity utilization
(MT/annum) ..................................................98.0
Product-Mix
The study has so far estimated the future demand
of steel in the form of ‘constructional steel’ used for
constructional purposes and ‘non-constructional
steel’ consumed by the manufacturing sector.
However, it is more convenient to present the
results of this exercise in the conventional break-up
of long and flat groups of products.
The constructional steel includes all long
products, like bars & rods, structural and railway
products and also steel plates, which normally come Projection Comparison
under the ambit of flat products. Therefore, the The Ministry of Steel is currently working with a
results of the study have been restructured by demand level of 70.34 million tone of finished steel
shifting the quantum of plates from the group of and a capacity estimate of 80.23 million tonne by the
constructional steel to the other group. The revised end of the terminal period of the plan 201-12. The
break-up of the long and flat groups of products of findings of the study for the terminal year of XI plan
the projected demand is as in table 5. are also placed in table 7
Although the objective of the present study is to Thus, the estimated demand potential of the
obtain an aggregated level of demand in the form of domestic steel industry which stands at 84.0 million
long and flat products a glimpse of the likely tones in terms of finished steel and a corresponding
category wise distribution of the same is presented capacity requirement of 98.0 million tonne by the
primarily on academic interest. The total demand year 20011-12 derived from the sector wise projection
has been split category wise on the basis of current of investments in the infrastructure sector and a
domestic consumption trend of the country as shown corresponding growth of the manufacturing sector, as
in table 6. per the eleventh five year plan document is likely to
exceed the demand projected by the Ministry
(Million Tonnes) of Steel for the same period by a substantial
Government Study margin. The extent of increase is 13.66
Projections Results million tonne, the maximum of which is
expected to happen in Long products - 10.0
2007-08 2011-12 201-12
million tonne and the Flat products
Production ( Crude) 50.37 80.23 98.00 accounting for the rest of nearly 4 million
lDemand: 21.88 29.02 39.0 tonne.
Long / Flat 28.40 41.32 45.0 Steel Intensity Norms
Total Demand (Finished) 50.28 70.34 84.00 The results of this macro level study throw
Supply: 21.10 36.10 up some interesting indices, which are of value
Long / Flat 25.60 41.30 to those who are engaged in the areas of
forecasting and assessing the future of the
Total Supply (Finished) 46.70 77.40
metal in the domestic market. Infrastructure
Table 7 Government Projections & Study Results investments being the most important driver

56 April 2007
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Steel Capacity Planning

of domestic demand of constructional steel, table 8

shows the relationship may be of particular interest to
the researchers in this field.
Room for Optimism
The findings of this explorative exercise led to a
set of inferences which may be broadly classified as
optimistic and skeptic. There are enough reasons to
believe that the projected plan investments will result
in a major boost to the domestic steel industry. Some
of these are indicated below.
h There exists a high degree of synergy among the
plans drawn up by the Planning Commission, the
projections made by the Steel Ministry and the
policy initiatives adopted by the Finance Ministry.
h The government is gearing up to mobilize the
required amount of resources to the tune of $ 350
billion or more in order to ensure success of the
eleventh five year plan targets, especially, in the
infrastructure sector.
h Government is also adopting innovative measures
to bolster the project formulation and execution
capabilities of the nation by leveraging the power
of the private sector in relevant areas of
operations.
If the resources are mobilized and spent as per the
plan drawn up, the macro economic analysis of the
current paper suggests that the demand of crude steel
projected by the Steel Ministry to the tune of 80
million tonnes by 2011-12 will in all likely hoods be
Steel Intensity: Tonnes / Crore of
Infrastructure Investment
Highways 42
Railways 135
Energy 106
Airports 108
Ports 111
Irrigation 84
Other Constructions 96
Over all ( Construction Steel) 100
Table 8
surpassed by a healthy margin. It may even exceed
100 million tonne mark much sooner than
anticipated.
Cause of Concern
Synergy of planned targets among the various
Ministries and the Planning Commission do not
however eliminate the risk and uncertainties
associated with such a massive endeavor. The possible
areas which might derail the projected plan of
infrastructural spending and the developmental efforts
of the economy are -
h Mobilisation
h Projectisation
h Execution
Needless to add that mobilizing the massive level
of investment is a challenge facing the nation. In spite
of the optimism oozed by the government, the
skeptics may continue to express their concern
whether the same would be achievable, keeping in
view the none-to-happy records of performance in the
past. The estimates are as accurate as the projected
investment levels laid down in official documents.
Any slippage will trigger a chain of adverse reaction
on the demand of steel. The government needs to be
more proactive and play the role of a ‘visionary
entrepreneur’ in the infrastructure sector.
The sectoral requirements of funds do not
automatically translate into deployment of funds.
Infrastructure projects typically take about four to
five years from the concept to commissioning. The
success of the planned level of investment would

58 April 2007
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Steel Capacity Planning

imply that projects worth Rs.15,7 5,000 crore should

be ready so that the same level of investment can be
absorbed during the course of next five to seven years
by 2011-12.
Nobody really knows how much of the projected
fund has really been projectised. The experts feel that
only about 20 % of the funds can be considered to be
projectised by now. The absence of a systematic
statistical superstructure capable of collecting data on
projects actually happening on the ground levels like
the central, state, municipal and rural across the
public and private domains is standing in the way of
monitoring the project implementation in an
authentic way.
concern. Obviously, the relevant agencies, the central
The story at the rural, urban, municipal and state and state governments, need to substantially improve
levels is also not very encouraging. their project planning and execution machinery so
Barring exceptions, the pace of project that funds once made available can be translated into
implementation continues to be a cause of serious actions without any loss of time. The country needs

April 2007 59
Cover Story
Steel Capacity Planning
to increase its project structuring and execution
capacity by a minimum factor of three immediately.
Though the major builders are fast emerging as
project developers with self-financing models
shedding their age-old image of contactors, the
project execution capability of the country’s
construction sector is not fully known. The major
builders are already having their capacities
overbooked with orders. The country’s construction
segment is likely to be stretched beyond its limit
unless new players come forward and shore up the
capacity in a big way.
Innovative Measures
Responding to the urgency of the nation’s
infrastructure building effort, the government is busy
innovating new measures to counter the negative
effect of the underlying risk and uncertainties as
discussed above.
In resource mobilization area, the government is
really thinking out of the box .. Among the various
measures the government is contemplating the
following deserve special mention
h Canalizing a part of the massive foreign
exchange reserve to the tune of $ 177 billion for
funding the infrastructure projects. This is
proposed to be done by the Special Purpose
Vehicle (SPV) like India Investment Company
with a capital of $ 10 billion. This would enable
RBI to earn more instead of parking the fund in
the treasuries abroad.
h Utilizing a part of the pension fund for funding
60
investment projects.
h Launching and encouraging Viability Gap Funding
through Special Purpose Vehicles to make non-
commercially viable projects attractive to the
private developers and commercially feasible.
h Raising caps of external commercial borrowings so
as to enable the major domestic players to raise
fund earned abroad.
h Persuading private wealth managers to finance
India’s infrastructure projects by putting in place
necessary safeguards.
h Raising the domestic rate of savings and creating
long term savings instruments so as to enable
banks and financial institutions to raise funds for
investment in infra structural projects.
In the project formulation and execution areas the
government is innovating too. The following deserve
special mention among the slew of measures initiated
by it to propel the country into a higher and faster
orbit of growth
h Evolving the concept of Private-Public-Partnership
or PPP model in major nation building projects in
areas of power, highways, aviation, railways etc so
as ensu5re success through synergizing the
expertise and capital between the public and the
private sector.
h Introduction of various project execution models
like Built-Operate-Transfer (BOT), Build-Own-
Operate-Transfer (BOOT, Annuity models,
Negative Grant etc. so as to encourage the private
builders participate in a big way, not necessarily as
constructors, but very often as builder-partners
with necessary capital as well.
h To mlt1gate the likely shortfall in the availability
of skilled manpower, government is taking steps
to revive 500 Industrial Training Institutes in the
country in terms of curriculum and technical
revamping. About 100 such ITls would be
promoted and run by private bodies.
Conclusion
From the foregoing analysis, it can be safely
concluded that subject to realization of the planned
targets of raising resources and spending of the same
April 2007
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Steel Capacity Planning

the all out efforts of the government in mobilizing

the necessary ingredients for growth in the
infrastructure, the future of steel sector appears to
be bright and bullish. The industry is robust
enough to take in its stride aberrations if any
arising out of normal inflationary pressure or
otherwise and still grow at a frenetic pace of 15%
CAGR. The faith bestowed by the investor
community transcending national and international
barriers appears, therefore to be fully justified.
Acknowledgement
The author, while offering his quantitative
approach to the issue of assessing the impact of the
infrastructure investments to the demand of steel in
the XIth plan period, wishes to acknowledge in
collective to those who provided the basic input
materials to this paper through their individual
contributions in the major economic dailies of the
in project construction, the country is set to witness a country in the recent past.
massive expansion of steel demand exceeding 84
million tones in the form of finished steel or 98
million tonne or nearly 100 million tonne in the form
of crude steel by the year 2011-12. This estimate
surpasses the government’s projected capacity
expansion plan of 80 million tonnes of crude steel by
a healthy margin.
However, the above estimate is based on the fact
that the projected spending in infrastructure sector
will bee achieved during the plan period from 2007-
08 to 2011-12. Any failure or laxity on the part of the
government either on mobilization of resources,
projectisation or execution will lead to adverse
implications in so far as the demand and consumption
of steel in the domestic economy is concerned.
The other factor, which may dampen this rather
euphoric growth, is the inflationary pressure on the
economy. Unless inflation is contained and kept
within a manageable limit, the projections are likely
to take a beating. An annual inflation of 4-5% may
result in a downward revision of as high as 20-25
million tones of demand by the same time frame.
The Indian economy, which is already orbiting
in a higher trajectory of growth, is radiating
optimism and exudes confidence all around. Given

April 2007 61
Roofing
Versatility of Steel as
Roofing Material Alok Baishya
Senior Manager (Civil & Structural)
Institute for Steel Development &
Growth (INSDAG) Kolkata
P
RE-ENGINEERED STEEL buildings (Fig.1 &
Fig.2) or building systems with steel roofing
are gaining popularity very fast for its several
advantages. Though, the concept is quite old with
proven technology in advanced countries, the concept
is still considered almost new in Indian context.
Elegant aesthetic views of the pre-engineered
buildings with numerous profiles of steel roofing and
least construction time are the reasons for quick
popularity. The steel metal buildings are finding its
suitability in warehouses, sport-complexes, factories,
workshops, distr ibution centres, cold storages,
supermarkets, aircraft hangers etc.
Steel Roof
Steel roofing is known for its strength and long-
term durability to most designers and builders. In
advanced countries architects, designers and owners
are going for steel roofing for aesthetic reasons, as
well (Fig.3). Several recent applications help showcase
the versatility of steel roofing, which has come into
its own as a design element, not only for roofs but
62
During the past half decade or so the
scenario has changed a great deal in favour of
steel roofing due to a number of advantages
in its favour such as: long life, improved
paint systems, fast track construction, life
cycle costs, advanced paint systems,
aesthetics, wide variety of profiled shape
options, availability of acoustics and heat
insulation materials, choice of different
colour shades, etc. has impressed upon the
users, architects, consultants and designers to
opt for steel roof sheeting.
also for mansards, vertical panels and other highly
visible applications.
While institutional buildings feature innovative
applications of standing seam steel roofing, many of
today’s residential installations utilize steel to
faithfully replicate the look of conventional roofing
materials, such as wood shakes, tile and slate and at
the same time return the obvious long-term
environmental, safety and durability benefits of steel.
Steel’s appeal is based on more than aesthetics alone,
of course. Steel has long been the material of choice
for those who demand strength and long life, and in
recent years alloy coatings have further extended the
life of steel roofing systems. From a structural point
of view, there’s the added appeal of steel’s lightweight,
fire resistance, and 100 percent recyclables.
Finally, durability makes steel the most cost-
effective choice, both long-term and short-term.
Moreover, steel’s long life typically adds significantly
to a building’s resale value.
April 2007

Roofing Types
Overseas, apart from steel roofing, tiles of mud or
concrete and asphalt roof are also in use.
The average life span of an asphalt roof is 12 to 20
years. This lifespan can be shorter depending on the
pitch of the roof and the climate in the location.
Made of oil impregnated paper or fiberglass, asphalt
begins to deteriorate as soon it is exposed to normal
weather. Steel roofing, however, never decomposes.
Other roofing materials like wood shingle and tile
have varying degrees of weather-related problems that
will lead to breakdown. Wood shingle often needs
replacement before twenty years. Concrete tile roofs
can crack and warp in the freeze/thaw cycle in
extreme climates. All of the above roofing materials
are well-outlasted by steel roofing, which retains its
good looks and durability decade after decade.
No matter what kind of steel roofing style is
chosen, one has never to worry about the roof again.
Most come with a true 30 to 50 year warranty, plus,
new steel roof will add to the resale value of the
building, save money on the energy bills, and will
give a piece of mind that the owner is never likely to
have to re-roof again.
Today’s steel roofing available profiles is made
to look exactly like common roofing material -
such as asphalt shingle, clay tile or slate roofing -
only stronger and more durable, there’s certain to
be a style and finish to match any building in and
April 2007
Roofing
Versatility of Steel Roofing
around. One can expect steel roofing to last at
least 2 to 3 times longer than a regular roof in
proper maintenance and care is taken.
When installed with solid sheathing (polyurethane
foam, glass wool etc.), steel roofing will silence noise
from rain, hail and bad weather as well, if not better
than any other roofing material.
A metal roof can withstand decades of abuse from
extreme weather like high winds, heavy snow,
hailstorms, and even wildfires. Steel roofing can
withstand wind gusts up to 120 miles per hour. Under
high wind conditions steel roofing systems have more
wind and uplift resistance than comparable materials
and it gives a sense of relief in that one can use the
best material to meet those criteria.
In locations, where there are heavy snowfalls,
metal roofing has been the choice of building owners
for years. It sheds snow fast, which protects the
structural integrity of the roof. And it can eliminate
ice damming at the eves, so water can’t back up and
collect under the roof then leak into the building.
The recycled content of the steel in a metal roof is
about 56% from production to installation to reuse -
far superior to asphalt.
A metal roof on an average is 50% lighter than an
asphalt shingle roof, and 75% lighter than concrete
tile, fiber cement shakes. With metal roofing, weight
on a structure is never an issue.
Types of Roof
If the roof is made by using roof panel without
insulation, there are following two types of roof
systems:
Standing Seam Roof: The standing seam steel
roof is one of the most exciting breakthroughs in
roofing technology in the last 25 years. It fulfills the
building owner’s need for durable, puncture-resistant
protection against the weather, while working in
concert with the forces of nature.
The roofing system has established track record in
new construction where it has been used in some 50%
of all low-rise commercial, industrial and institutional
buildings erected in the last several years. Standing
seam metal roofing can now be seen on virtually
63
Roofing
Versatility of Steel Roofing
every type of building, from shopping centers to
schools, churches to libraries, skyscrapers to residential
buildings. The system currently accounts for well over
one billion square feet of roofing in US, with potential
to capture a much larger share of the commercial and
residential building market. The standing seam roof
made of steel is the most durable building material.
And yet, the lightweight metal roof panels weigh a
relatively modest about 6-7 kg per square meter.
The standing seam metal roof assures adequate
drainage from rain and snow effectively, ponded water
problems, leaks and other related troubles commonly
associated with flat built-up roofs. Unlike flat built-
up roofs, which require frequent maintenance, the
standing seam metal roof offers 20 years and beyond
of trouble-free performance with little or no
maintenance expenses. The panel fastening systems is
uniquely designed to handle the potentially damaging
effects of thermal movement. Precisely formed,
factory-made metal panels are locked in place by clips
inside a raised seam standing 50 – 75 mm above the
roof surface. The clips have a moveable feature
allowing the panel to expand and contract with
temperature changes. The concealed clip system
means fewer through roof fasteners, reducing the
chances of leaks.
Standing seam metal roof system has nearly
become the most preferred roofing system for a
growing number of commercial, industrial and
institutional buildings because of the following reasons.
Weather-proof Joints: It is designed as a water
64
barrier. The raised seam assists drainage. Organic
sealants are factory applied inside the seams.
Automatic field seaming machines produce
weatherproof connections between metal roof panels.
Energy Efficient: Systems accommodate up to
300 mm of heat and cold and minimizing
condensation under roof panels. The roof expands and
contract independent of insulation, giving the roof
surface a “float” action.
Durable: Concealed sliding clips handle thermal
shock for permitting movement without damage.
Cost Effective: Life expectancy is longer, less
maintenance is required and life cycle costs are lower
than for any other type of roof. Twenty year material
warranties are customary for metal roofing systems,
considerably longer than the standard protection for
built up single ply systems.
Coluor-coated and Corrosion Resistant:
Offering a wide range of colors and textures, along
with the concealed clip system, the standing seam roof
is one of the most attractive roofing system for almost
any building. Metal roof panels resist corrosion with
the help of a zinc, aluminum, or aluminum-zinc alloy
metallic coating applied to the base steel.
Environmentally Responsible: In most retrofit
projects, the standing seam metal roof can be
installed over an existing flat roof, eliminating costly,
disruptive and potentially hazardous tear-offs. In
addition, the metal roofing is completely recyclable.
Design Flexibility: Steep slope, low slope and flat
roof profiles can all be designed with the standing seam
metal roof. The structural roof is the industry’s
alternative to flat built-up and singly ply systems. The
architectural standing roof is used for visually exposed
roofs, mansards, fascia, and similar applications.
Tile Design Roof
Pre-painted steel panels are formed to create the
appearance of clay or concrete tiles (Fig.5). Wide sheet
widths and long lengths eliminate many joints found in
clay and concrete tile roofs. As heating and cooling is
one of the important operating expenses in a building, it
is desirable to have proper insulation in the roof systems.
The building with insulation exhibits low thermal
April 2007
 Roofing
Versatility of Steel Roofing

conductivity with the environment. The cost efficiency resisting decay, discoloration and mildew.
achieved makes it viable to adopt single skin insulated h Steel roofs have excellent performance in wind
(Fig.6) or double skin insulated (Fig.7) building roofs. resistance, water, snow, and ice shedding.
Single Skin Insulated Roof h Steel roofs provide an excellent method for re-
Single skin insulated roof construction comprises roofing of existing roofs.
roof insulation underneath the cladding as underdeck h Steel roofs increase building’s resale value.
insulation. The insulation is rolled over the purlins or h Steel roofs may be used in re-roofing and steep or
girts and then roof panels are fixed to the secondary low-sloped roof applications.
framing through insulation.
h Reduces burden to landfill areas by eliminating
Double Skin Insulated Roof
the requirement for the disposal of the existing
Double skin insulated roof construction comprises roof made of other materials.
of internal liner panels directly screwed to the
h Light colors reflect heat in warm climates and
secondary framing, sub-girts screwed through spacer
save energy.
blocks and liner sheet to the purlin below, roll-
insulation with vapour barrier is laid over the sub- h Many re-roofing applications permit added
insulation between the old and new roof,
girts and finally the outer panel is screwed to the
subgirts through the insulation. resulting in an environmentally friendly system
that can reduce building’s energy consumption.
Cost Aspect
Residential steel roofing offers the owner a premium
product with a long life expectancy. Residential steel
roofs are competitively priced in a stable market. When
examining steel roofs through a “Life-Cycle Costing”
perspective, in addition to installation cost, one considers
factors such as the length of life of the system,
maintenance, repair requirements, ease of replacement,
resale value and environmental considerations such as re-
cyclability and the cost of disposal.
Benefits of Steel Roofing
Advantages of steel roofing are not limited to
those indicated below:
h Steel roofs are attractive in appearance coming in
a broad spectrum of colors, designs, thicknesses
and accessories such as trim, flashing and
formed accessories.
h Steel roofs are easy to work with and lightweight.
h The strength of steel allows for increased design
flexibility.
h Steel roofs allow for fast installation and quick
building occupancy.
h Steel roofing is non-combustible and therefore
provides fire resistance.
h Steel roofs are low maintenance and long lasting,

April 2007 65
Roofing
Metal Roofing & Cladding
Metal Roofing & Cladding for
Modern Industrial Buildings
T
HE AUTHOR DISCUSSES the features and
application of colour coated metal roofing &
wall cladding sheet systems, scientifically
engineered roofing for industrial and institutional
buildings, resorts, houses etc.
Metal Roofing And Cladding
Base Metal: The basic material is cold rolled steel
sheets in thickness ranging from 0.45mm to 0.8mm.
This steel is available with an yield strength of 240
MPa for roofing and cladding applications from
manufacturers in India. High yield strength sheets of
300 MPa / 550 MPa are available from abroad in
thicknesses ranging from 0.42mm to 0.8mm.
Base Metal Protection: The steel sheets used for
building applications are corrosion protected with
Metallurgical coating having a density of 180 gsm. To
275 gsm galvanizing. Zincalume / galvalume sheets
have metallurgical protection of 55% hot dipped
coated aluminium, 43.5% zinc and 1.5 silcon. The
66
Coating density is either 150gsm or 200gsm. The
Zinc – aluminium alloy coating provides excellent
corrosion resistance coupled with sacrificial protection
provided by the zinc in the alloy.
Organic Coatings: Organic coatings provide
aesthetic finish to galvanized / zinclalume coil stock.
Choice of coating depends on the environmental
conditions at the point of the use. Architectural
polyester coating is provided by indigenous
manufacturers and modified polyester, PVF2 Coatings
etc., are available with sheets made available from
abroad. Protective coatings are available in
aewthetically appealing shades whose durability
without chalking or fading can be guaranteed for
known exposure conditions.
Profiles: Different types of profiled sheets are
available from various manufacturers using roll
forming technique., However trapezoidal, hi-rib
profile with anti siphoning flute which drains the
water entering through the capillary action, are being
widely used in the industrial buildings. Aesthetically
appealing profiles like ‘Mangalore Tile’ profiles etc.,
are also available for resorts and other buildings.
Profiled sheets are available in lengths upto 12 metres
(limited only by transportation considerations)
Types of Roofing And Cladding Systems:
Roofing and cladding systems are broadly
classified into pierced and fastened system and
concealed fixing system.
Pierced and Fastened Systems: In the pierced
and fastened systems the profiled sheets are fixed to the
purlins /girts with carefully engineered self drilling &
April 2007
 Roofing
Metal Roofing & Cladding

self tapping screws provided with EPDM washer and attractive roofs in single storey units in an industrial
matching colour coated UV stabilized caps. These site to break the monotony. Decking sheets having
systems are widely used in our country and offer the high rib profile are used in industrial buildings as
best solutions to most of the industrial roofs. permanent shuttering / insulated built up roofing,
Concealed Fixing Systems: This systems features featuring an external metal skin on the weathering
a patented concealed clop which is fixed to the purlins side and insulation material sandwiched between the
with special fasteners and the profiled sheet are two sheets.
clipped on the concealed clips. Provisions are Ancillary Materials for Roofing and Cladding
available in this systems to make it water tight. This Systems
system was basically developed to cater to the Fastened system utilizes a large quantity of self
buildings having shallow slopes (as low as 20). An drilling self tapping fasteners and there are many
extra – ordinary feature of this systems is that it is types of screws available from various manufacturers.
possible to roll form at site to any length and make it Carefull selection of screws is very important for
possible to rollform at site to any lengh and make it fastened system. Profiled HDPE end closures,
possible to have a single sheet from eave to ridge flashing with poly carbonate/ FRP sheets etc have to
without any end laps. It is also possible to provide an be carefully designed and applied to make the
“end to end” continuous length of joint-free roofing building water tight.
where shallow curved roofs are involved. Thermal insulation is an important element in
Insulated Roofing and Cladding Systems
Built up Roofing & Cladding systems: Roofing &
Cladding can be built up layer by layer, with insulation
to meet the requirements of thermal comfort as well as
noise control. Combination of fastened and concealed
fixing systems are effectively utilized today in many
building roofs. Double skin fastened insulated roofing
and cladding systems are commonly used economical
building envelopes these days.
Composite Roofing & Cladding System:
Prefabricated sandwich panels with PUF / rockwool or
combination of PUF & Rockwool as core are also
available today for insulated cladding for cold rooms,
D.G. set rooms to reduce the heat ingress and noise
transmissions respectively. These composite panels
comprises of two metal skins with PUF/ rockwool
core. Prefabricated sandwich panels with PUF core
and with profiled sheet on the weathering side and
slightly ribbed plain sheets on the inner side are also
commonly used for insulated roofings / claddings in
many industrial and commercial buildings.
Special Roofing Systems: Mangalore tile type
profiled sheets are available for resort and other
buildings where importance is given to aesthetics. It
is common to see designers featuring these very

April 2007 67
Roofing
Metal Roofing & Cladding
building design which imparts thermal comfort to
occupants and drastic reduction in power required
when the space is cooled or heated to maintain
desired temperatures. Insulation for a building is an
important step from the point of view of acoustic /
noise reduction requirements of the building as well.
With new multi-national and trans-national
companies setting up projects in our country, comfort
to personel working in the factory sheds has assumed
major importance in non-air –conditioned industrial
buildings. Insulation products are specified and
demanded as manufactured in India or from overseas
sources. Two products – rockwool /glasswool in the
form of rolls and slabs with lamination of either
aluminium foil / vinayl are being used for both roof
and wall insulation. Thicknesses of thses materials
specified are 25 mm. Or 50 mm with rockwool at a
density of 48 kgs/cu.m./ glasswool at a density of 24
kgs/cu.m as per design requirement.
Buildings enclosing gas turbines / D.G. Sets for
power production are to be noise insulated to bring
down the noise level outside the building. Specially
made rockwool panels with a core of rockwool
sandwiched between two metal sheets are being used
for walls of such buildings. These panels bring down
the noise level substantially ( by about 25 to 28 db)
In-situ built-up triple skin/ double skin insulation
systems can be designed to offer much higher noise
level reduction where desired.
Buildings are used for cold stores and in these
projects, closed cell rigid polyurethane foam (PUF)
sandwich panels comprising of CFC-free PUF,
sandwiched between two metal facings are featured to
maintain storage temperatures as required in such
buildings. These storage temperatures can be from
plus temperatures to all the way down to -40 deg. C.
Auditoriums / conference halls require a certain
optimum “reverberation time”, depending upon the
kind of performances for which the halls are designed.
These conditions are achieved through a Proper design
of walls and roof with absorptive insulation. Mineral
wool products are commonly used in these
applications, finished with a variety of commonly
available facing materials.
68
Installation of Metal Roofing & Wall Claddings
Roofing: The roof sheet of the given dimension
with the overhang at the eave is placed first. The
roofing work would proceed from the eave upwards
towards the ridge. All end laps should have suitable
sealant mastics correctly placed without any gaps.
Insulation if may is to be placed first over a weldmesh
retention prior to fixing the roofing sheets in single
skin insulated roofings.
Wall Cladding: Wall cladding work is commenced
and progressed from the end which is away from the
prevailing wind or the most viewed direction so that
the sheet overlaps are not visible. Foam closures
should be installed on the base angles prior to fixing
the wall sheeting. Wall insulation shall be clamped to
the eave strut or secured with double faced tape and
pulled tight before fastening the wall sheeting.
General Notes: Bundles of roof and wall cladding
sheets should be stored in such a way that one end is a
higher elevation than the other end to allow speedy
drainage of water. Sheets should be kept covered with
tarpaulin during the times of rain. Usage of
polythene sheet cover should be avoided as it can
cause vapour retention within the bundle and
subsequent condensation. The use of chalk line is
always recommended for accurate drilling and
screwing of sheets to the support structure. This
gives better appearance and less risk of leakage due to
misdrilling. Roofing sheets should always be crest
fixed to eliminate chances of water leakage while wall
cladding sheets could be valley fixed. While walking
on the roof, always walk on the low ribs and
preferably along the purlin line. Standing on the hi-
ribs can cause severe damage, which could lead to
possible leakage of water. Do not walk on skylights.
Maintenance: Steel roofing/ cladding systems
require minimum maintenance. The roof should be
inspected immediately after installation to check if the
clearing of the roof has been carried out fully preferable
on day to day basis. It is very often seen that the
drilled out metal and debris are not swept away. These
can act as initiators of corrosion and lead to premature
failures. Installed roofing must be inspected at least
once in a year. Any exposed metal that can rust or has
April 2007

rusted should be painted. Leaves, branches and trash
should be removed from, gutters, at ridge caps and in
corners. Also a watch should be kept on discharge from
industrial stacks and particulate matter which could get
piled up and overload the roof and choke the rain water
drainage system.
Roof top ancillaries and air-conditioner
supports, drains and housing should be checked
periodically. Particular attention should be paid to
add-On roof ancillaries that create new roof
penetrations. Roof top air-conditioner and
extractors should be installed on kerbs designed to
avoid ponding of water. Condensate from air-
conditioning and refrigeration equipment should
never be allowed to drain directly on the roof
sheets. Drained water may contain ions from
condenser coils that accelerate corrosion in the
event of roof leak, do not indiscriminately Plaster
April 2007
Roofing
Metal Roofing & Cladding
the suspected leak area with tar or asphalt or use
repair tape. Water can collect under the repair
material causing corrosion. Instead, have an
experienced roofing foreman locate the leak,
identify its cause and properly repair the roof.
Conclusions
Metal roofing and cladding concepts have carved
for themselves an enviable position in the
construction industry in view of their being ideally
suited to the situation and needs of the modern
Engineering Industry. It would be very difficult to
imagine how we could have met requirements for
large enclosures with thermal and acoustical
features demanded by the users of today without
these concepts. The major advantage of the high
speeds of design and construction afforded by metal
roofing and cladding has contributed to their
premier position in the industrial building sector.
69
Case Study
Beyond the Rainbow
Radiative
Radiative Property
Property Control
Control
in
in Coil
Coil Coating
Coating Systems
Systems
James Maxted
A
RCHITECTURAL COIL COATINGS present
the formulator with a continuous series of
challenges. Efficient application is just the
starting point. Long term appearance must be very
stable, demanding increasingly durable topcoats
incorporating systems to minimize dirt pick-up and
improve dirt shedding properties. Metallic finishes,
special effects and high-chroma colours are required
and now they must be free of heavy metals. Then
there is corrosion to contend with, demanding high-
build and flexible primers to maximise protection,
again free of heavy metals.
In all these areas it is Beckers’ policy, not just to
develop coatings from raw materials available, but to
undertake fundamental research into such areas as the
mechanisms of topcoat degradation and corrosion
inhibition. This work is often done in association with
universities around the world. So when it became
Graph 1 Terrestrial Solar Irradiation
70
In effect the low emissivity coating acts as
a thermal energy barrier - blocking a
significant proportion of the thermal energy
transfer across the coating by inhibiting
radiative energy transfer. And it works
equally well on heating degree days as
cooling degree days.
clear that coatings could have a useful role to play in
energy control, Beckers went back to first principles.
Graph 1 shows the typical irradiance spectrum of
sunlight (taken from ASTM E159-98). The wavelengths
from the sun falling on the earth’s surface range
between 0.3 to 2.5µm with differing intensity at each
wavelength. Only about 5% of this energy is in the
invisible ultra violet at ground level. This is a small but
deadly portion causing coating degradation and other
malign effects such as skin melanomas. In
the visible range we can actually see and feel
a significant proportion of the sun’s energy.
But over 50% of the solar energy is in the
invisible, infra red region. On a hot day that
is a lot of energy that potentially can be
absorbed by a coating and then transferred
into the interior of a building by conductive
and radiative processes.
On cold days, the sun is not the only
important source of energy. When the heating
inside the building is turned up and it is then
warmer inside than out, the net heat flow
moves in the opposite direction. Under these
circumstances every object in the building acts
like a ‘little sun’ (a black body) as it radiates
low energy heat. This time, however, the
April 2007

energy is radiated not in the UV, visible or near
infrared like the sun, but in the mid infrared - in
the region of 2.5 to 25µm wavelength.
Thermal control coatings need to control
electromagnetic radiation from UV
wavelengths at 0.3 microns right through to
those in the mid infrared at 25 µm wavelength.
What properties are required of thermal control
coatings as theyinteract with this
electromagnetic radiation?
Figure 1 shows what is happening on a hot
day which generates a net heat flux into the
cooler room area.
The main source of heating is the sun’s energy,
acting upon the coated surface of the metal roof. A
portion of the sun’s energy will be reflected or
scattered in the visible (giving the colour and gloss of
the coating). In the near infra red some of this energy
may also be reflected. With a conventional dark
coating much of the energy will be absorbed,
resulting in heat build up in the coating to
temperatures as high as 80°C. Some of this absorbed
solar energy will then be re-emitted by the coating
back out into the environment, now as higher
wavelength, lower energy radiation in the mid
Figure 1 – Heat transfer mechanisms on a hot day
April 2007
Case Study
Coil Coating Systems
Graphic 2 Spectral Reflectance of Different Pigments
infrared part of the electromagnetic spectrum. Wind
and air flow on the surface of the coating will also
reduce the surface temperature by convection.
However considerable energy will remain in the
coating that can then be conducted through the metal
towards the cooler inside of the building.
The interior organic coating will behave like the
exterior coating when the conducted energy from
outside meets it. The coating will first absorb the
energy and then re-emit it into the inside of the room
as energy in the thermal or mid infra red region.
Convection and conduction again play a part
in energy transfer into the room causing the
temperature to climb and the air
conditioning to be switched on.
It is clear from this that not only is energy
reflection important in designing coatings for
thermal control, but so too are emittance (or
absorption) properties.
Considering first the exterior coating:
what properties are required for
thermal control?
h To minimize degradation the coating
needs to be transparent or have minimal
absorbance in the UV (from 0.25 -
0.3µm). This should apply to all elements
in the formulation, not just the binder.
h In the visible (from 0.4 to 0.7µm) the
coating needs to reflect certain
71
Case Study
Coil Coating Systems
wavelengths depending upon the colour
required. It will also scatter some of the
visible light depending on the gloss level,
but elsewhere the solar energy will be
absorbed.
h In the near infra red (from 0.7 to 2.5 µm)
the coating system needs to be as
reflective as possible. The solar energy is
invisible here and only heats up the
coating if the energy is absorbed.
h The coating will inevitably absorb some
energy, so it is important that it is also an efficient
re-radiator of this absorbed thermal energy. The
coating needs to exhibit high emittance in the
thermal or mid infra red.
And of course, the coating still has to provide
long-lived aesthetic properties – it has to be both UV
durable and corrosion resistant!
A bright white coating would be the most
reflective and thus the coolest option. It reflects 60 -
70% of all the solar energy right across the visible and
near infra red as Graph 2 shows. By contrast, a
conventional black coating absorbs all but 5% of the
total solar energy across the same spectrum. It is easy
to understand why white coatings are cool and blacks
hot. But architects don’t always want white roofs!
Reflectance alone fails to explain why unpainted
metal is often hotter to touch than black-painted
metal. As might be expected, the total solar
reflection of unpainted metal is very high compared
Graph 3 Reflectance of Unpainted and White Coated Subnstrates
74
Graph 4 Specular Reflectance of Leaves and Paint
to black (70% and 5% respectively) – indeed it is
comparable to white as Graph 3 shows. The problem
is that the thermal emittance of absorbed energy is
very much lower for unpainted metal compared to
black (10% and 90% re-emittance respectively).
Unpainted metal simply can not get rid of the
thermal energy it has absorbed and hence is hotter to
touch. Emittance properties cannot be ignored.
Neither does the above pattern explain why a dark
green leaf is apparently cool to touch whereas a
painted steel panel of the same colour is much hotter.
In this case, the reflectance spectrum of the leaf is a
very different pattern to the green coating. You can
see the step change in solar reflectance at 0.7 µm.
The leaf has the right colour in the visible to enable it
to photosynthesize, but it also has the ability to
appear white in the near infrared and thus be cool
enough to avoid cooking! In effect this is what we
want from a cool coating – and as ever nature
has got there first!
If we consider the interior coating of
the system it is apparent that we need
quite different properties to those of the
exterior coating.
For the source of energy is not now
radiative, from the sun, but thermal – from
the heated metal core of the coil coated
material. The paint system therefore needs to
be able to reflect this thermal energy back in
the direction it came from rather than absorb
and then re-emit it in the mid infrared. To
April 2007
Case Study
Coil Coating Systems
put it another way the coating has to have a low
rather than a high emittance in the thermal infrared.
When the net heat flow is reversed, as in the case of
a cold day with higher temperatures inside than out,
the interior coating has to function in the same
manner, only of course this time the source of thermal
energy is in the room interior. Under these
circumstances the coating needs to reflect the radiated
thermal energy back into the room rather the allowing
this precious heat energy to be absorbed into the wall
or roof and thus be conducted and lost to the outside.
In effect the low emissivity coating acts as a thermal
energy barrier - blocking a significant proportion of the
thermal energy transfer across the coating by inhibiting
radiative energy transfer. And it works equally well on
heating degree days as cooling degree days.
The challenge for Beckers was been to formulate an
organic coating to behave as a low emitter, since most
organic coatings are by their very nature high emitters.
How does the performance of this composite coating
system behave and how can we quantify performance?
Fortunately, most of the confusions of
measurement and some of the spurious claims of the
Graph 5 - Outdoor Testing: Evaluations in Republic of South Africa
76
Figure 2 – BeckryTherm test sheds in Shanghai
early days are being resolved with the adoption of a
number of internationally recognized standard
methods within the cool roof community – the Cool
Metal Roofing Coalition website
(www.coolmetalroofing.org) lists the standard ASTM
procedures.
Developing the BeckryTherm range has required
immense amounts of data-gathering from around the
world. But Graph 5 shows, in a useful snapshot, the
benefits of BeckryTherm, based on real-time data
measured in South Africa.
The chart shows how the interior surface
of the panel is cooled as a result of using both
the exterior solar reflective and the interior
thermal reflective coating together. In this
set of measurements, for a range of typical
roofing colours which are identical to the eye,
the average reduction was nearly 8°C. This is
typical of the temperature differences seen in
this location.
8°C may not sound a big reduction but it
can often be the difference between a room
that is comfortable to work in and one that is
very uncomfortable, requiring air
conditioning.
Beckers has also constructed a series of
test sheds in Shanghai (Figure 2) which
evaluates BeckryTherm’s performance day
and night, summer and winter. Internal
April 2007
 Case Study
Coil Coating Systems

After construction BeckryTherm will

benefit the building owner through:
h Reduced air conditioning usage and costs
h Reduced heating fuel consumption & costs
h Improved thermal comfort
h In some jurisdictions, tax credits and rebates
h Longer life of the roof
BeckryTherm will benefit the
environment through
h Lower peak loads on energy producers
h Reduced ‘heat island’ effect and
Graph 6 – Exterior Durability Performance: Gloss Retention global warming
h Reduced consumption of fossil fuels
temperatures, heating and air conditioning loads are
continually monitored. h Improved durability & product lifetimes
Cool? Sure!
This sort of practical testing, at sites around the
world, forms a key part of Beckers’ product For details: visit www.beckrytherm.com.
development. Real time testing is vital to assess the
ability of the coating to control aesthetics and corrosion.
In addition to the usual Florida test stations, Beckers
runs its own world wide weathering and thermal control
programmes at various sites around the globe.
One result of this programme has been to show the
extent to which BeckryTherm’s lower surface
temperatures slow down the degradation of the coating.
Graph 6 shows that after 2 years’ Florida exposure, all
BeckryTherm versions of each colour show significantly
lower gloss reduction than their standard equivalents –
and in three cases show no loss of gloss at all!
Beckers can therefore be confident that BeckryTherm
will benefit building owners and the environment
whenever there are large temperature differentials
between the interior and exterior of a building. These
benefits are over and above the environmental benefits of
building with coil coated metal, such as low mass, long
life, recycled content and recyclability.
Benefits start at the point of construction.
Contractors cannot work on or with roofing panels
that are 60°C or more. With BeckryTherm there is
less down-time because of overheating and
construction crews have noticed that the panels are
more comfortable to handle and work on.

April 2007 77
Admixtures
Liquid Sand ™ -
A Step Forward
Upen Patel, Marketing Manager, BASF
Construction Chemicals (India) Pvt. Ltd.
T
HE TERM “LIQUID SAND” describes the
effects of adding Rheomac viscosity modifying
admixture (VMA) to significantly enhance
concrete workability and rheology. The Liquid Sand
program is the application of innovative BASF
Admixtures, Inc. technologies to improve the
consistency and workability of concrete using the most
cost-effective fine aggregates available to the producer.
The Liquid Sand program offers concrete manufacturers
the option of using less-than optimal fine aggregate
materials (gap-graded or manufactured sands) while
maintaining excellent workability characteristics in the
pumping, placing and finishing operations important to
contractors and customers. This article introduces
Liquid Sand program as popularized by BASF
Construction Chemicals.
Why focus on fine aggregate?
Natural sand is ideal for producing workable
Fig. 1: The Effect of Liquid SandTM
78
The Liquid Sand program offers concrete
manufacturers the option of using less-than
optimal fine aggregate materials (gap-graded or
manufactured sands) while maintaining excellent
workability characteristics in the pumping,
placing and finishing operations important to
contractors and customers. This article
introduces Liquid Sand program as popularized
by BASF Construction Chemicals.
concrete, however, it can be very expensive, and/or in
limited supply. As circumstances have forced producers
to use less-than-ideal fine aggregate sources, such as
manufactured sand and poorly or less-than-optimally
graded sand, the result is a concrete mixture that is
difficult to pump, place, and finish and is potentially
prone to excessive bleeding. Even when using a less than
ideal fine aggregate source, concrete producers can still
market a value-added, easy-to-place mix that increases
profitability and maintains satisfied customers by
instituting a Liquid Sand program. For example, in
Northern California, there is a shortage of natural sand.
To extend the natural sand supply and reduce material
costs, producers incorporate manufactured sand into
concrete mixtures. The down side to this is that it makes
the concrete more difficult to pump and finish and elicits
complaints from contractors. Incorporating a Rheomac
VMA admixture into the concrete produces a
completely different and highly enhanced workable
mixture. Rheomac VMA admixtures not only make a
concrete mixture more cost effective but also maintain
the workability characteristics preferred by contractors.
Concrete mixtures containing a Rheomac VMA
admixture by BASF Construction Chemicals produce a
April 2007

much more manageable mixture to place, speeding
production by lowering the effort required to place the
concrete. Contractors have reported that mixtures
containing a Rheomac VMA admixture pump extremely
well-noting that “pump pressures have dropped between
10 and 15%.” In addition, “pump trucks no longer shake
during the positive pump stroke while placing the
concrete.” The result is less wear and tear on capital
equipment. The concrete finishes dramatically better as
well. Finishers report that the concrete “closes better and
easier resulting in fewer surface defects.” The potential
for over-finishing concrete flatwork is also reduced as
Rheomac VMA admixtures in the mixture allows for
fewer passes of the trowel or float. Properly finished
concrete enhances durability.
Liquid Sand™ Program Benefits
h Reduce Costs: Optimize the use of natural sand
and manufactured sand content while maintaining
April 2007
Admixtures
Liquid Sand - A Step Forward
™
the same level of workability and finishability.
h Add Value: Offer a branded “pump and finishing
mixture” to contractors.
h Improve Aesthetics: Increasing the coarse
aggregate content and decreasing the fine
aggregate content can reduce concrete shrinkage,
yet maintain good finishing qualities.
h Improve Durability: Easier finishing results and
less potential for over-finishing which can drive
entrained air out of an air-entrained concrete slab
surface making it susceptible to scaling in areas
that experience cycles of freezing and thawing.
Uses for Rheomac Viscosity Modifying Admixtures
Rheomac VMAs can be used in virtually every
concrete application. Concrete contractors can benefit
from using concrete containing Rheomac VMA at low
dosages to provide “more body” to facilitate pumping
79
Admixtures
Liquid Sand ™ - A Step Forward
and finishing procedures. At higher dosages in
Rheodynamic ® Self-Compacting Concrete (SCC),
Rheomac viscosity-modifying admixtures provide
stability and serve as an insurance policy against
segregation. The use of a VMA also increases the
number of applications for SCC because more
mixtures can be proportioned for a wider range of
applications. Variations in aggregate moisture
content, in particular that of the fine aggregate and
mixture ingredient batching can lead to segregation,
excessive bleeding and SCC performance
inconsistency. The use of a VMA in an SCC mixture
can improve consistency and control segregation and
bleeding in mixtures with excessive water contents,
depending on VMA type. Rheomac VMAs are also
recommended for use in concrete containing “gap-
graded” aggregates, lean concrete mixtures, and
concrete containing coarse, manufactured sand as
bleeding is controlled and rheological properties are
improved to facilitate pumping and finishing, and
improve surface appearance. Rheomac VMAs are also
ideal for use in concretes containing high coarse
aggregate contents. An architectural exposed-
aggregate precast panel is difficult to produce using
conventional SCC because a high loading of coarse
aggregate will have a tendency to segregate. This can
cause a non-uniform appearance in the final product.
The stabilizing effect of a VMA provides cohesiveness
to the mixture and facilitates the use of higher coarse
aggregate contents [>1000 kg/m3] in this type of
application. The net effect is a uniform exposed-
aggregate finish.
Fig. 2 : Test apparatus – to determine the effectiveness of Rheomac VMA
80
The Technologies behind Rheomac VMA
Products
VMAs can be categorized under two main
groupings based on the mechanism by which they
function; thickening-type or binding-type.
Thickening-Type VMA
Viscosity-modifying admixtures in this group
function by thickening the concrete, making it very
cohesive without significantly affecting the fluidity of the
mix. By modifying the viscosity of a very fluid concrete
mixture such as SCC, it becomes more stable and less
prone to segregation during and after placement.
Binding-Type VMA
These VMAs function by binding water within the
concrete mixture. This mechanism results in an
increase in the viscosity of the mixture, while reducing
or eliminating concrete bleeding. This type of VMA is
more potent in modifying the viscosity of a SCC
mixture compared to a thickening-type VMA.
Concrete treated with a binding-type VMA also takes
on a thixotropic characteristic, which means that fresh
concrete may gel up if left in a mixing vessel, truck, or
form without agitation. Simply re-mixing the concrete
can restore workability. This characteristic in the
plastic state will be apparent until the concrete begins
to gain rigidity due to hydration.
Rheomac Viscosity-Modifying Admixture Products
Rheomac products are formulated to provide
enhanced performance attributes in concrete. The
Rheomac family of viscosity-modifying admixtures is
comprised of three products. As a concrete producer
or contractor, you have your choice of Rheomac VMA
to meet your specific needs.
Rheomac VMA 358
h Thickening-type viscosity modifier
h Easy-to-dispense
h Controls bleeding
Rheomac VMA 362
h Thickening-type viscosity modifier
h Easy-to-dispense
h Controls bleeding
h Imparts thixotropic characteristics
April 2007

Rheomac VMA 450
h Binding-type viscosity modifier
h Controls bleeding
h Imparts thixotropic characteristic to
concrete mixture.
Rheomac VMA Features and Benefits
Whether you are meeting a daily concrete
production schedule or developing high-performance
concrete for a specific application, the premier line of
Rheomac viscosity-modifying admixtures provides
you with the additional flexibility and confidence to
meet industry demands and challenges for quality
concrete. With Rheomac VMA admixtures, concrete
producers and contractors can achieve desirable
performance characteristics such as:
h Enhanced concrete viscosity
h Thixotropic properties
h Improved stability during transport and placement
April 2007
Admixtures
Liquid Sand - A Step Forward
™
h Enhanced pumpability
h Enhanced finishability
h Controlled bleeding
The unique features of Rheomac viscosity-
modifying admixtures provide the following benefits
for the entire construction team:
h Provides flexibility in mixture proportioning and
batching
h Provides superior and predictable in-place concrete
properties
h Reduces sagging helping plastic concrete maintain
its shape on slopes and arches
h Facilitates production of highly-fluid concrete
mixtures such as Rheodynamic® Self-Compacting
Concrete
h Enhances surface appearance
Overall, a VMA can provide flexibility in mixture
proportioning, enable the use of more normal mixture
81
Admixtures
Liquid Sand ™ - A Step Forward
proportions without the need to increase fines content
in SCC mixtures, and assure stability with varying
mixture ingredients.
Products for Liquid Sand
BASF Admixtures offers two products specifically
for Liquid Sand programs:
h Rheomac VMA 358 admixture
h Rheomac VMA 362 admixture
As a result of the many positive attributes offered
by a Rheomac VMA admixture producers can now
proportion their mixtures in several advantageous
ways using either Rheomac VMA 362 or Rheomac
VMA 358 admixture as a “liquid sand”.
Liquid Sand – An local evaluation report
The Purpose was to compare the workability and
finishability characteristics of natural sand vs.
manufactured sand, to demonstrate the effect of adding
a Rheomac Viscosity-Modifying Admixture (VMA) to
a mixture that incorporates manufactured sand. Four
diffrent mixes were studied and compared as under:
Test Apparatus
3 – Paper cups with sand + cement, 1 - Rheomac
VMA 358, 1 - cup with cement only (for use in mix
#4), 1 - Rheomac VMA 362, 4 - petri dishes w/ lids
+ paper insert, 4 - water vials (25 ml), 2 - plastic
pipettes, 4 - mixing sticks
Mix design
The following mix design was used as the basis for
the experimental mixes included in this test.
Cement : 300 kg/m3
w/c : 0.4
water : 120 litre
Air : 1%
VMA : 0.25 % by wt of cement
Instruction
h Add 25 ml of water to dry ingredients in each cup
h Mix thoroughly (approx. 100 revolutions/strokes)
h Place mixture in petri dish
h Screed with narrow edge of mixing stick
h Finish with wide edge of mixing stick
h Set petri dish at an angle, using mixing stick as
82
wedge. See Figure 2.
h Allow to sit for 5 - 8 minutes
h Apply petri dish lid (with paper) on top of each
petri dish
h Carefully remove lid after 30 seconds
h Observe water stain pattern
Mix1 - Natural Sand : Contains natural sand , Mix2 -
Manufactured Sand 1: Contains manufactured sand,
Mix3 - Liquid Sand Program (Manufactured):
Same as Mixes 1 & 2 except
h Prior to Step 3 (Placing mixture in petri dish), add
5 drops of VMA (358 or 362) with pipette
h Mix thoroughly
h Continue with steps 3 through 10
h Compare water stain pattern vs. previous mixes
Mix 4 - Manufactured Sand 2
Same as Mixes 1 & 2 except:
h Prior to Step 1, add 130 g of locally sourced
manufactured sand to mixing cup
h Prior to Step 3 (Placing mixture in petri dish), add
5 drops of VMA (358 or 362) with pipette
h Mix thoroughly
h Continue with steps 3 through 10
h Compare water stain pattern vs. previous mixes
Results of the testing
During mixing, compared texture differences of
mixtures with natural and manufactured sand. The
angular surface of the manufactured sand leads to the
tendency to bleed. The manufactured sand
mixture(Mix 2) without the VMA has a higher bleed
rate then Mixtures(Mix 3 & 4) containing a VMA
tend to bleed much less.
Conclusion
BASF Construction Chemical’s Liquid Sand program
using Rheomac viscosity-modifying admixtures can save
money and improve finished product aesthetics.
For additional information on the Liquid Sand™,
contact author at BASF Construction Chemicals
(India) Pvt. Ltd., C-68, TTC Industrial Area, MIDC
Turbhe, Navi Mumbai-400613, Phone +91 22
27619992, Fax 022-27619242, upen.patel@basf.com
April 2007
Technology

Ondulit and the

Multilayer Protection
The advanced performances of the system

Resistance to corrosion
In the Ondulit protected system the steel
The lasting of metal roofing is conditioned by its
is encapsulated in various protective layers
capability to resist to corrosion. The action of the
chemically aggressive substances, mostly if combined
which make it virtually unassailable from
with elevated levels of relative humidity, may aggressive agents, thus offering superior
produce a fast deterioration of the standard metal performances and high reliability over time
roofing, particularly in presence of sharp angles, holes, even in the most severe corrosive
scratches or cuts. atmospheres (marine, industrial, urban)
In the Ondulit protected system the steel is
encapsulated in various protective layers which make protective coating absorbs precipitation impact on
it virtually unassailable from aggressive agents, thus metal and avoids its vibration, the origin of roaring
offering superior performances and high reliability noise. Roofing is therefore aphonous and may
over time even in the most severe corrosive therefore be used in buildings with any destination of
atmospheres (marine, industrial, urban). use.
In fact the specific characteristics of the various Thermal Reflecting Power
components of the protective system, perfectly Metal or cement based roofing highly overheat
integrated one to another, offer a global protection of under the sun action, radiating the most of the heat in
the steel sheet virtually unlimited over time, even in the underlying ambient, creating the so called “grill
the most difficult environmental conditions. effect”. Ondulit system thanks to the reflecting
Sound Deadening Power power of the upper aluminium coating (over 90% of
Any normal metal cladding, subject to rain or hail the thermal load), and the thermal inertia of the thick
beating, causes serious noise problems both in protective layers, dramatically reduces this
underlying and surrounding areas, which constitutes a
limit in their utilization. Ondulit multilayer Material Breaking load Thermal
protected system is unique in having a thick antinoise expansion
protection layer on the external side of sheets. This Coefficient
Rm=N/mm2 min. (mm/m°C)
Steel type
Fe E 250 330 0,011
Aluminium
type 3103 95 - 180 0,024
Copper 250 0,017
Result of the comparative test : “The average sound deadening capability of an
Ondulit roofing is 4,37 times higher than a usual metal sheet of the same profile” Mechanical Resistance

84 April 2007
 Technology
Ondulit and the Multilayer Protection

inconvenience. By highly reducing the thermal load of

Material Breaking load Thermal
the roofing, the natural consequence is that the use of
expansion
additional insulation is often unnecessary. Ondulit
Coefficient
roofing offer the best thermal comfort in comparison
to any other steel roofing. Rm=N/mm2 min. (mm/m°C)
The following diagram shows the results of a Steel type
comparative thermal insulation test between Fe E 250 330 0,011
different types of roofing under the action of a solar Aluminium
spectrum lamp. The test consists of measuring the type 3103 95 - 180 0,024
temperatures achieved inside a testing chamber Copper 250 0,017
having the sample in examination on its upper part,
exposed to the radiations. Thermal Expansion
Thermal Expansion
Mechanical Resistance
The improper use in roofing of products with high
The theoretical condition of use of any roofing,
coefficient of thermal expansion may cause serious
calculated in hypothesis of even distributed loads, are
technical problems. The differential thermal
not enough to guarantee any absence of deformation of
expansion between the roofing (mainly if made of
the roofing. In the event of incautious over stepping or
elements particularly long) and the support structure
excessive tightening of the fastners, or for special
may generate process of degradation of the roofing
circumstances, it may be possible that there could be
itself. In the Ondulit multilayer system the special
local stress exceeding the limit of resistance of some
embossed finishing of the external metal foils and the
materials. In the Ondulit multilayer system the
soft characteristics of the interposed layers have the
mechanical resistance value is that specific of the steel
capability to make absolutely compatible the effects
which constitutes its internal support. This makes the
of the thermal expansion of the various components.
roofing unbreakable, with no risk of damages and offers
In this way the thermal expansion coefficient of the
adequate resistance to over stepping and overloads. In
system is that proper of the steel. In this way there
the next table sheet are reported the values of tensile
are not limitations in the use of single and long
strength and thermal expansion coefficients of the
sheets. In the following table sheet there are reported
metals more commonly used for roofing purpose.
the values of tensile strength and thermal
expansion of the metals more commonly used
for roofing purpose.
Aesthetic Values
In modern projects roofing is often used as
distinctive element qualifying the entire
building. For their characteristic of absolute
reliability and pleasant aesthetic aspect,
Ondulit roofing systems are always more used
for any kind of building typology. In fact the
special embossed finish of the external foils
eliminates the cold aspect of the metal roofing.
Furthermore the wide choice of pre-painted
colours available and the valuable alternative
copper finish allow their harmonic use in any
Thermal Reflecting Power architectonic and environmental context.

April 2007 85
Coatings
Ex
Excel Coatings
Excel
Freedom from Heat -
Affordable Way
T
HIS IS THE RIGHT TIME to think about
your industry’s summer management. The
biggest problem ahead you is ‘HEAT’. Now a
greatest opportunity to beat the heat off. Just don’t think
our product is just a ‘coat of paint’. Think of our coatings
h Reduction of roof heat up to 45% (8º C to
15º C)
h Blocks 90% of solar infrared rays and 85% of
ultra violet rays.
Excel CoolCoat, when coated on the roofing
materials, reflects sunlight to a greater extent and
prevents the roofing materials from getting heated
up, even in peak summer afternoons. Since the
coating itself in not getting heated up, the air below
the roof never gets hot, keeping the departments cool
and comfortable.
Resulting In
h your building remains cool even under intense
sunlight conditions.
h Your staffs remain cool and maintain higher level
86
of productivity.
h Your humidification and air conditioning costs
cut drastically.
EXCEL CoolCoat reduces internal temperature by
up to 45% and cuts cooling cost up to 70%. Further,
EXCEL CoolCoat eliminates the necessity for
sprinklers, which consume precious and scarce water
and power. 100% of this expenses is saved.
In the buildings with asbestos roofing or metal
sheet roofing, an astonishing lowering of roof
temperature is achieved from 8º C to 15º C. One of
the many advantages of EXCEL CoolCoat heat
reflective paint is the proven ability to re-radiate up
to 90% of infrared rays and 85% of ultra violet rays
back to the atmosphere resulting in achieving
impressively lower internal temperature upto 15º C.
EXCEL CoolCoat, when applied effectively, you
gain a new roof, simply at the cost just a little more
than mere painting.
Do you know that asbestos and metal roofs absorb
80% of solar heat? Where does the heat go?
Inwards! Do you know that your air conditioning/
humidification to cool the interior of the buildings
actually causes the roof heat to be sucked in?
The radiation from the roof top is great. Here
you can save 60% of the humidification/air
conditioning cost as EXCEL CoolCoat reflects and
re-radiates substantial 90% of surface heat back to
atmosphere where as the surface of your roofing
remains comfortable to touch even in peak
summer afternoons.
h EXCEL CoolCoat blocks 90% of solar infrared rays
and 85% of ultraviolet rays, keeping your roof cool,
April 2007

even in peak summer, Eliminates the necessity for
false ceiling, Drastic reduction of heat up to 15º C
in peak summer, More the heat, more will be the
re-radiation, Can be coated on any roofing material
/ side walls, Suitable for petroleum storage/tankers
to control loss of evaporation, Improved working
environment resulting in improved efficiency,
Controls and checks leaks, resistant to water, fungus
and mould, Ideal for textile mills, warehouses,
factories, and residence areas, Improves the
efficiency of roof ventilators, Buildings looks
brighter and new with all these advantages.
Comparative thermal performance of EXCEL
CoolCoat on corrugated roofing materials.
Thermal Test
Ambient temperature = 38º C
Unpainted asbestos roofing = 53º C
Unpainted GI sheet roofing = 56º C
April 2007
Coatings
Excel Coatings
Painted with CoolCoat = 41º C
This result proves the continuous rejection of solar
heat, preventing the roof from getting hot. Maximum
surface temperature will be only 2.5º C more than
ambient temperature. Properties of the coating does
not depend on the thickness of the coating. In hotter
environments, the roof ventilators struggles to keep
the heat off. Along with EXCEL CoolCoat, the roof
temperature is dramatically lowered due to re-
radiating properties. Your ventilators perform a
wonderful job.
For details
C-76, Sikkandar Basha Street, Gandhinagar,
Udumalpet - 642 154.
Tamilnadu, India. Ph : +91 4252 - 223839
Cell: +91 94437 - 23839, +91 99949 - 23839
E-Mail : ravi@xlcoatings.com
Website : www.xlcoatings.com
87
R&D
Studies on Fly Ash
Concrete Role of
Hydration Promotor Catalyst
B
LENDED CEMENTS CONTAINING
Pulverized Fuel Ash (PFA) have certain
distinct advantages over ordinary Portland
Cement (OPC) in respect of low heat of hydration,
superior resistivity against carbonation, chloride and
sulphate penetration, improved permeability
resistance, increased resistance to Alkali-Silica
Reaction (ASR) etc. But PFA has the inherent
problem of slow gain of early mechanical strength
compared to OPC. In the present study, a chemical
activator, (hydration promoter catalyst) composed of
oxides and salts of alkaline earth metals called
“CERAPROOF PXL” was used as admixture and
incorporated at a dose of 5% on weight of Fly ash into
a M-30 concrete mix containing 30 : 70 ratio of PFA :
OPC. An identical concrete mix was made using OPC
as sole binder. A reference Fly ash mix of same
stoichiometry was prepared without addition of any
chemical activator.
The rheological properties and compressive
strength of all the three concrete mixes were
evaluated. It was observed that the concrete with 30
: 70 ratio of PFA : OPC admixed with
“CERAPROOF PXL” developed higher strengths
viz., 29.5%, 33.9% and 6.5% at 3, 7 and 28 days
respectively over the reference concrete. It was also
observed that at 28 days age, the chemically
activated PFA concrete developed 3.5% more
strength than its OPC counterpart.
It is revealed, therefore, that hydration promoter
catalyst plays pivotal role in developing mechanical
strength in Fly ash concrete at rapid pace, particularly
during early curing. PFA, an environmental pollutant,
thus can be conveniently transformed into a concrete,
superior than OPC, by use of chemical energy of
88
V.K. Ravikumar, Managing Director
Cera Chem Private Limited, Chennai
S. Sen, Technical Advisor
Cera Chem Private Limited, Chennai
Hydration promoter catalyst plays pivotal
role in developing mechanical strength in Fly
ash concrete at rapid pace, particularly during
early curing. PFA, an environmental pollutant,
thus can be conveniently transformed into a
concrete, superior than OPC, by use of
chemical energy of activation instead of
conventional and costlier thermal curing.
activation instead of conventional and costlier
thermal curing.
Introduction
Chemical Activators which increase the speed of
hydration reactions of secondary cementitious
materials like PFA (Pulverized Fuel Ash), GGBS
(Granulated ground blast furnace slag), SF (Silica
Fume) in admixture with hydrated lime, Portland
cement etc. can be broadly divided into four types;
h Caustic Alkali (Na, K or Lithium Hydroxide)
h Non-Silicate Salts of Acid (R2 CO3, R2 SO3, R2 S or
RF (R= Na, K or Li)
h Silicate salts of type M (R2O) N (Si O2 ) and
h Alkali metal chloride, Nitrate, Lime, Gypsum,
etc. [1]
There are many patents on those activators or
hydration promoter, apart from a few branded
products of manufacturer in Europe, Canada and
USA. Alkali and silicate activators, although boost up
early strength of concrete (for example sprayed
concrete or shotcrete), they suffer retrogression of
strength sharply. Moreover, with reactive silicious
aggregates, use of such admixture may cause
expansive disruption of concrete. For this reason, the
April 2007
R&D
Fly Ash Concrete Role of Hydration Promotor Catalyst

demand for alkali-free accelerator is on increase in MIX DESIGN FOR M-30 GRADE CONCRETE
Hydel Power Projects, dams etc. Design stipulation
While investigating on hydration promoter which h Specific minimum characteristic N/mm2
can impart early strength to PFA concrete. The Compressive strength at 28 days 30
authors made studies with “CERAPROOF PXL”
h Maximum size of aggregate 20 mm (angular)
stated to be a powder composed of oxides and salts of
alkaline earth metals, non-chloride, bulk density 1350 h Degree of workability 0.9 compacting factor
kg/m 3, aqueous solution is neutral to litmus (pH h Degree of Q.C. Good
value 7). It is therefore, neither alkali nor silicate type
h Type of exposure Moderate
composition. Test data for materials
h Cement h Cement Used OPC 53
OPC 53 Grade h Specific gravity of cement 3.15
h Fly-Ash
h Specific gravity of course aggregate
Source Kalaghat Thermal Power Station WB State 2.85, water absorption 1.2%
Electricity Board, Field 3, ESP
h Specific gravity of fine aggregate (River sand
Physical Characteristics conforming to Zone II, IS:383 1970, FA – 2.93)
h Specific Gravity - 2.27 2.68, water absorption 0.5%
h Wet Sieve Analysis - 8.6 Target mean strength
(Percent retained on 325 BS Sieve) 30 + (6x1.65) = 39.90
h Specific Surface (cm2/g, Blaine) - 4016 Water-cement ratio
h Lime Reactivity (kg/cm ) 2
- 78.5 0.46
Chemical Analysis % Following ACI method on absolute volume basis
h SiO2 - 59.3 the following quantity of ingredients were required
h Al2O3 -
18.8 per cubic meter of concrete;
h Fe2O3 -
8.6 Cement - 398.45 kg Water - 189.29 ltr
h CaO - 5.7 Fine Aggregate - 860.64 kg Extra Water - 4.30 ltr
h MgO - 3.2 CA 20mm - 631.14 kg or absorption
h Loss on Ignition (LOI) - 5.2 CA 10mm - 420.76 kg of F.A (0.5%)
h Fine aggregate, River sand, sieve analysis is given Extra water - 12.62 ltr
in Table 1. Needed for CA (1.2%)
h Course aggregate, 10mm and 20mm as given in Total extra water for FA and CA - (4.30 + 12.62)
Table 2 respectively. = 16.92 ltr
Concrete W/C Cement Fly Slump Admixture Experiment
Mark Ratio OPC 53 Ash Ceraproof 3 sets of concrete were prepared in the
(Kg) (Kg) (mm) PXL (Kg) laboratory as per standard practice marked
[A] 0.46 398.45 - 30 - as [A], [B] and [C]. The workability,
setting, and strength development of each
[B] 0.46 278.91 119.53 60 -
set were measured following IS:456.2000
[C] 0.46 278.91 119.53 55 5.98 (Code of practice for plain and reinforced
Table 1 concrete, third revision). Quantity of

90 April 2007
R&D
Fly Ash Concrete Role of Hydration Promotor Catalyst
concrete prepared was 0.025 cubic meter in
each case.
h [A] represents a concrete mix of M-30 grade using
only ordinary Portland cement, 53 grade
h [B] represents the same mix but 30% of the OPC
is substituted by PFA collected from Kolaghat
Thermal Power Station, Field 3, ESP
h [C] represents mix [B] in which 5% of CERAPROOF
PXL, on the weight of PFA was admixed amounting
to 398.45 x 0.3 x 0.5 = 5.98 kg
The results of workability and compressive
strength are given in table 1 & 2.
Chemistry of Fly Ash Hydration
The hydration chemistry of cementitious products
is a reaction between acidic and basic constituents,
which manifests through their courses of dissociation
and/or association to give rise mineralogical phases,
which render strength, hardness and impermeability
to the matrix.
When OPC hydrates, Tricalcium silicates (C3S)
and dicalcium silicates (C2 S) upon reaction with
water, produce C3 S2H3 and CH (Calcium hydroxide or
hydrated lime). Fly ash reacts with it to produce
further phases of C-S-H. But this reaction is slow
Slow
Pozzolana + CH + H ----------- C-S-H
(Hydrated Lime) (Water)
Strength development is slow [2]
A hydration promoter catalyst makes the rate of
formation of C-S-H faster. The role of catalyst is to
imbibe activation energy (Free energy, in
thermodynamic terminology) to make the reaction
Concrete Mark 3 Days 7 Days 28 Days
[A] 19.6 30.1
[B] 14.2 21.2
[C] 18.7 28.4
(+29.5%) (+33.9% (+6.5%)
Table 2
Figures within bracket indicate percentage increase of mix [C] over [B]
92
It is interesting to observe that at 28 days
the catalytically activated fly ash concrete
has developed 3.5% more strength than its
OPC counterpart.
faster. However the catalyst remains unchanged in
chemical composition at the end of reaction. The
chemical energy therefore, enhances the speed of C-S-
H formation in such case, unlike heat energy required
as curing of concrete.
Discussion of Results
As seen from experimental results, concrete [C]
develops 29.5%, 33.9% and 6.5% mere strength
than concrete [B] at 3,7 and 28 days respectively
which clearly reflects the efficacy of catalyst in
imparting high early strength to fly ash concrete.
It is interesting to observe that at 28 days the
catalytically activated fly ash concrete has
developed 3.5% more strength than its
OPC counterpart.
Conclusion
h Use of hydration promoter catalyst imparts high
early strength to fly ash concrete
h Fly ash (a patent environmental pollutant) in blend
with OPC can be gainfully converted into concrete
having superior strength and durability than OPC
by use of catalyst.
h Fruitful utilization of chemical energy through
catalytic process – saving of thermal energy
References
h K.C. Jha and S. Sen - Blended cements and early
strength enhancing phosphate based additive for
Portland slag cement.
h NCB International Seminar, New Delhi 21 – 24
November 2000
42.4
41.2 h Mehta P K & Paulo J M Monterio – Concrete-
Microstructure, Properties and materials, the
43.9
Megraw-Hill companies, Inc, New York; 1993 PP
190-216
Courtesy: “Special Concretes” conducted by Indian
Concrete Institute, Chennai Chapter
April 2007
Mechanical Resistance
Technology
Microstructure Study &
Behaviour of HDPE
Fibre Reinforced Concrete
I
T IS TIME FOR CIVIL ENGINEERS to think of
the disposal of non-biodegradable waste generated
from construction field to reduce the
environmental pollution. Huge number of empty
cement bags available in construction field are made
of jute plastic i.e. High Density Ploy Ethylene
(HDPE). An attempt has been made to make use of
these bags as fibres in the concrete to form HDPE
fibre reinforced concrete. The compressive, tensile,
flexural strengths and durability of the concrete were
compared with normal concrete. The present study
on HDPE fibre reinforced concrete has shown an
improvement in the concrete properties. As a part of
study Microstructure of M20 HDPE fibre reinforced
concrete using the scanning electronic microscope
was studied.
Non Bio- Degradable materials have become a
serious problem due to the large usage of polymers
and other hydrocarbon constituent products like
polythene sheets, covers, disposable plastic glasses,
Acc.V Spot Magn Det WD |--------------------------------| 20 mm
20.0 kV 4.0 1600x SE 10.2 M20-Conventional
Sample No.1 Conventional HDPE fibre reinforced concrete
94
K.Manjula Vani,
M.Potha Raju,
N.Madhu Babu,
A.Jaya Prabhakar Reddy
The present study on HDPE fibre
reinforced concrete has shown an
improvement in the concrete properties. The
compressive, tensile, flexural strengths and
durability of the concrete were compared
with normal concrete As a part of study
Microstructure of M20 HDPE fibre
reinforced concrete using the scanning
electronic microscope was studied. The scope
of this study is to minimize the
environmental pollution, improve strength
properties of concrete, increase crack
resistance of concrete, increase ductility of
concrete, to reduce cost of construction by
using HDPE fibres as building material.
syringes, jute plastics, fiber reinforced plastic
sheets and other petro-chemicals products in
day-today activities.
Plain concrete possess a very low tensile strength,
limited ductility and little resistance to cracking.
Internal micro cracks are inherently present in the
concrete. To resist these cracks attempts have been
made to impart improvements in tensile properties
by using reinforced steel bars. These methods provide
tensile strengths to the concrete members but they
however do not increase the inherent tensile strength
of concrete itself.
When loaded the micro cracks in content
propagate and open up owing to the effect of stress
concentration. The development of such cracks is the
main cause of deformation in concrete. It has been
recognized that the addition of small, closely spaced
April 2007
Technology
HDPE Fibre Reinforced Concrete
and uniformly dispersed fibres to concrete would act
as crack arrester and would substantially improve its
static and dynamic properties. This type of concrete is
known as “Fibre Reinforced Concrete”.
Recycling is found to be the best way by means of
segregating NBD’s from solid waste and reusing them
in some other form. Using NBD’s as an alternate
material contain further spread of these materials into
the environment. The used up NBD material can be
used as an additive to the cement concrete. This will
not only relieve the threat to environment from
NBD’s but also result in reducing the cost of
construction. To use the NBD waste as building
material it should be made into small pieces with
fixed aspect ratio. NBD waste pieces are then mixed
with other constituents to prepare the concrete of
appropriate mix.
The scope of this study is to minimize the
environmental pollution, improve strength properties
of concrete, increase crack resistance of concrete,
increase ductility of concrete, to reduce cost of
construction by using HDPE fibres as building
material.
Literature Review
R. Siddique and C.B. Kukreja (1999)1 carried
out investigation on san fibre reinforced high fly ash
concrete. In this investigation the effects of
replacement of cement (by mass) with three
percentage of high fly ash content, and the effect of
addition of san fibres on the slump, veebe time,
Fig.1 Compaction Factor of HDPE Fibre reinforced Concrete
96
Microstructure photographs proved that
the porosity has been controlled to the
maximum extent by the addition of HDPE
fibres to concrete. Adding HDPE fibres in
concrete upto 3.5% decreases voids ratio.
HDPE concrete with 3.5% fibres has shown
improvement in all properties when
compared with the conventional concrete.
compressive strength, split tensile strength and
compressive stress-strain behavior of high fly ash
concrete were studied. Cement has been replaced by
mass with 40% , 45% and 50% of fly ash content,
and three percentages of san fibres (0.25%.0.5% and
0.75%) of 25 mm in length have been used in this
investigation. The test results indicated that
replacement of cement with fly ash increased the
workability (slump and veebe time ) and decreases
compressive strength, split tensile strength and
static modulus of plain concrete. Addition of san
fibres reduced the workability, and it does not
significantly effect the compressive strength. Split
tensile strength of high fly ash concrete increased
with increase in percentage of fibres. San fibres
reported not to have significant effect on the static
modulus of high fly ash concrete. However, ductility
of high fly ash concrete was found to increase with
an increase in fibre percentage.
G. Appa Rao and B.K. Raghu Prasad (March,
2005)2 conducted some experimental investigations
on the fracture energy and tension softening behavior
of high strength concrete. With a small fraction of
steel fibre, 0.62% by volume, the mode of failure
changes from catastrophic to gradual. Further with
the addition of steel fibres, the energy absorption
capacity of concrete increased very significantly. The
compressive strength of fiber reinforced concrete was
70 N/mm2 where as tensile strength was 4.0 N/
mm2.
Mosel (1961)3 conducted tests to study the
internal conductivity of the fibre-reinforced mortars
and concluded that the thermal conductivity of the
fibre reinforced mortar is increased.
April 2007

Experimental Programme
Microstructure study of HDPE fibre reinforced
was carried out by using scanning electron
microscope (SEM). SEM is an incredible tool,
which shows very detailed 3- dimensional images
at much higher magnifications. SEM samples are
coated with a very thin layer of gold by a machine
called splitter coater to conduct electricity. After
wards the HDPE fibre reinforced concrete
specimens are tested for compressive strength,
tensile strength, flexural strength, durability, crack
width. The HDPE fibre content varied from 1 to
5.5% in the increments of 0.5%.
Analysis and Discussion
General: SEM images have been used to display
the different phases within hydrated/hydrating
cement concrete samples. For a given SEM image,
materials with differing molecular weight appear in
different shades of grey. The greater is the
molecular weight the lighter the shade. This
characteristic will be used to identify the location
of the various materials within the sample. The
output from the electron microscope will be a
standard grey-scale image stored in a standard file
format such as tiff.
The porosity of the sample will be depicted by
black along with the darkest shades of grey while
the un-hydrated cement shows up as white along
Fig.2 7 Days Compressive Strength of HDPE Fibre reinforced Concrete
April 2007
Technology
HDPE Fibre Reinforced Concrete
Acc.V Spot Magn Det WD |--------------------------------| 20 mm
20.0 kV 4.0 1600x SE 12.2 M20-3.5 jute
Sample No.2. 3.50% HDPE fibre reinforced concrete
with the lightest shades of grey. These regions are
generally well defined. The hydrated phases of the
cement reside in the middle shades of grey between
the extreme shades of the voids and the un-
hydrated cement. Within this region there will be a
range of hydrated products. Unfortunately the
distinction between the hydrated phases is not as
well defined as for the voids and
un-hydrated cement.
Microstructure of HDPE fibre reinforced
concrete
It was observed from sample 1(Micro structure of
conventional concrete) that the voids percentage is
3.31%, unhydrated cement percentage is 13.81 %.
Sample 2 consisting of 3.5% fibre illustrates that
the voids percentage is 0.98%, unhydrated cement
percentage is 3.25 %. It has been also observed that
compaction of the constituent materials was more
and the porosity was less.
It was observed from sample 3 consisting of 5%
fibre that the voids percentage is 8.71% and
unhydrated cement percentage is 28.69 %. The
percentage of voids in conventional concrete are
increased with the increase of percentage of fibres.
Strength of HDPE Fibre Concrete
It was observed that with the addition of fibers the
compaction factor decreased (Fig.1). The compaction
factor of concrete is decreased by 12% with the
addition of 1% of HDPE fibers and reduced by 9%
97
Technology
HDPE Fibre Reinforced Concrete
with addition of 3.5% of HDPE fibers. Compression
strength of concrete increased with addition of HDPE
fibers up to 3.5% volume and decreased later.
Optimum value of percentage of HDPE fibers was
found to be 3.5 % with the increase in compressive
strength being 5.12% (Fig.2). HDPE fiber concrete
exhibited improved tensile strength of 4.39% (Fig.3)
and increased flexural strength of 13.14% compared
with conventional concrete9 (Fig.4).
Conclusions
h Microstructure photographs proved that the
porosity has been controlled to the maximum
extent by the addition of HDPE fibres to concrete.
Adding HDPE fibres in concrete upto 3.5%
decreases voids ratio.
h HDPE concrete with 3.5% fibres has shown
improvement in all properties when compared
with the conventional concrete.
h The compaction faction of concrete is decreased by
12% with the addition of 1% of HDPE fibers and
regains to 9% with addition of 3.5% of HDPE
fibers.
h The Compressive strength of concrete increased by
5.12% with the addition of 3.5% fibres.
h The Split tensile strength of concrete increased by
4.39% with the addition of 3.5% fibres.
h The Flexural strength of concrete increased by
13.14% with the addition of 3.5% fibres
h HDPE fibres are mainly drawn from cement
Fig 3. Split Tensile Strength of HDPE Fibre reinforced concrete
98
Acc.V Spot Magn Det WD |--------------------------------| 20 mm
20.0 kV 4.0 1600x SE 14.2 M20-5.5 jute
Sample No.3. 5.50% HDPE fibre reinforced concrete
bags making the entire construction site free
from its own non-biodegradable waste. For one
cubic meter of HDPE fibre reinforced concrete
50 bags at 3.5% of fibres by volume
are required..
h HDPE fibres can be used in sewerage pipes,
manhole covers, compound walls, retaining walls
etc as fibres to exhibit enhanced tensile properties.
h The brittle failure in plain concrete has been
changed to ductile failure in HDPE fibre
reinforced concrete.
References
h R. Siddique & C.B. Kukreja, Properties of San
fibres Reinforced High Fly Ash concrete, Journal
of Ferro cement, Vol. 29, No. 3, July 1999, PP.
197 – 206.
h G. Appa Rao and B.K. Raghu Prasad, Fracture
energy of Fiber reinforced high strength concrete ,
Journal of Structural Engineering , Jan-March,
2005, PP- 249-255.
h Mosel.K.C, The thermal conductivity of steel fibre
reinforced Portland cement mortar, M.S. thesis
Clarkson college of Technology, Potsdam, N.Y.,
Sept. 1961.
h Ashour S.A and Wafa, F.F, Flexural behavior of
high strength fiber reinforced concrete beams”.
ACI Structural Journal, May-Jun 1993, vol.90,
No.3, PP- 279-287.
April 2007
 Technology
HDPE Fibre Reinforced Concrete

microstructure of the glass fiber-cement paste

interfacial zone in long-term durability of
gfrc composites,
h Durability of Concrete; Second International
Conference Montreal, Canada; Ed. by V. M.
Malhotra; American Concrete Institute,
Detroit, MI, 1991, Vol. 2, PP- 799-819.
(ACI SP-126)
h Khajuria, A., Bohra, K., and Balaguru, P, Long-
term durability of synthetic fibers in concrete,
in Durability of Concrete; Second International
Fig 4. Flexural Strength of HDPE Fibre reinforced concrete Conference Montreal, Canada; Ed. by V. M.
Malhotra; American Concrete Institute,
h Bayasi, Z. and Zeng, J.”properties of Detroit, MI, 1991, Vol. 2, PP- 851-868.
polypropylene fiber reinforced concrete”ACI (ACI SP-126)
Materials Journal, Nov-Dec 1993, Vol. 90, No. 6, M.S. Shetty, “Concrete Technology”, Theory
pp 605-610. and Practice S. Chand & Co. Ltd. Ram Nagar,
h Kawamura, M. and Igarashi, Significance of New Delhi, 2001

Excel Coatings

April 2007 99
R&D
An Experimental Investigation On
Silica Fume Concrete Containing
Combination Of Admixtures
I
T IS OFTEN ACKNOWLEDGED, based on the
relicts of Mohenjo-DorO and Harappan that the
use of lime pozzolana mixture for hydraulic
cement in India was started in prehistoric times, but
it may not be common knowledge that after the
adoption of the western portland cement concrete
technology in India in the early part of twentieth
century, the usage pattern of cement substitute
materials had followed a distinctive pattern leading to
early popularization of blended cements.
Manufacturing of Portland cement is one of the most
energy intensive processes of any industrial
manufacturing process. The extreme heat required to
operate kilns creates a significant demand for energy.
Thus, the production of cement is highly energy
intensive and it will create the atmospheric pollution.
Besides this, it causes the depletion of natural
resources like limestone and shale.
Thus to save the nature from pollution and to save
the natural resources, researchers and concrete
Fig 1 Variation of compressive strength of concrete with different percentage
replacement of cement by SF
100
D.K. Kulkarni
Rajarambapu Institute of Tech.
Dr. K.B. Prakash
K.L.E Society’s, College of Engg &Tech.
The main aim of this experimentation is to
find out the effect of addition of combinations
of admixtures on the properties of concrete
produced by replacing cement by silica fume in
various proportions. The combination of
admixtures used is superplasticiser + air
entraining agent + waterproofing compound.
technologists throughout the world are carrying out
research work to use some supplementary
cementatious materials (SCM) which can partially
replace the cement. Some of the industrial wastes/ by
products possessing pozzolanic properties like fly ash,
silica fume, ground granulated blast furnace slag, rice
husk ash, etc., show excellent pozzolanic reaction and
can act as supplementary cementatious materials.
Many situations including ready mix concrete demand
the use of more than two admixtures. Therefore, it is
essential to study the properties of concrete
containing more than two admixtures.
The main aim of this experimentation is to find
out the effect of addition of combinations of
admixtures on the properties of concrete produced by
replacing cement by silica fume in various
proportions. The combination of admixtures used is
(Superplasticiser +Air entraining agent + Water
proofing compound).
Introduction
In today’s environment conscious world a more
responsible approach to a healthy environment is to
use the waste of one industry. Recently trend has
developed to use GGBS, silica fume, fly ash in the
construction industry1. Silica fume is a pozzolanic
April 2007

material widely used in concrete mixtures. It
increases paste strength due to its pozzolanic activity
and leads to a refinement of the pore structure and to
a better bond at the aggregate paste interface. It is a
finally ground material and, as such, generally
increases the water required for a given degree of
workability at low water-cement ratio. Thus, a high
range water-reducing admixture is often introduced to
promote the workability of silica fume mixture2.
From waste to wealth is the concept with which
concrete technologists, civil engineers and researchers
are constantly working in this direction in exploring
the properties of almost all the materials available
both as natural and artificial resources, which can
partially replace cement. Research work has shown
that certain materials in nature possess pozzolanic
property. Pozzolanic materials possess little or no
cementatious value within themselves but when come
in contact with moisture and calcium hydroxide
exhibit cementatious properties3. With the advent of
the portland cement concrete cult in India in the early
part of the twentieth century, there was close
adoption of the technological practices of the west;
however the local materials had to be adopted to the
local market conditions and the native sentiments had
to be fully respected. This led to preferred
development of blended cements over the alternative
practice of using cement substitute materials in site-
Fig 2 Variation of tensile strength of concrete with different percentage
replacement of cement by SF
April 2007
R&D
Silica Fume Concrete
“EBRD has been a great partner to us in
our foreign endeavor. Their understanding of
the conditions in Russia has enabled us to look
at the huge potential that welcomes us in the
Russian infrastructure sector development,”
according to Mr Hemant Kanoria, vice
chairman and managing director of SREI
mixed concrete, which was limited to large mass
concreting project sites only4 .
The use of pozzolanic and cementatious materials
in the cement and concrete industry has risen sharply
during the last fifty years as a mineral admixture. The
reasons behind it are many. Cement requires high
energy during its manufacturing process whereas fly
ash, blast furnace slag and silica fume are the
industrial by-products that are easily available and
require little or no much of processing having
inherent cementitious properties5 . One of the major
effects of adding silica fume to concrete is
modification of the transition zone. In general, the
presence of silica fume results in a denser, less porous
and more homogeneous microstructure in the
interfacial region as compared to ordinary Portland
cement concrete6. Recently, mixes incorporating silica
fume have been used to produce low permeability
concrete. It is well known that silica fume has a large
specific surface, so it is very active in reacting with
the hydrates of cement, but its price is very high.
Therefore, the combination of utilization of silica
fume and fly ash should be a good choice in reducing
the cost of concretes7.
Research Significance
Sometimes, it becomes very essential to use
combinations of admixtures in concrete. In some
constructions where waterproofing is essential, a
combination of admixtures like (Superplasticiser
+Air entraining agent + Water proofing compound)
may be required to be used. In such situations the
knowledge of behaviour of concrete containing three
admixtures is essential.
Experimental Programme
The main aim of this experimentation is to find
101
R&D
Silica Fume Concrete

out the effect of Admixture Abbreviationsused Chemical Dosage used

addition of
combinations of
admixtures on the
properties of concrete Superplasticiser
produced by Air entraining agent
replacing cement by Water proofing
silica fume in various compound
proportions. The
combination of
admixtures used is (Superplasticiser +Air entraining
agent + Water proofing compound). 43 grade
cement and locally available sand and aggregates were
used in the experimentation. The specific gravity of
fine and coarse aggregate were 2.66 and 2.85
respectively. The different percentage replacement of
cement by silica fume adopted in the experimental
programme are 0%, 2%, 4%, 6%, 8%, 10%, 12% and
15%. The experiments were conducted on a mix
proportion of 1:1.26:2.51 with a w/c ratio of 0.41
which corresponds to M20 grade of concrete. The
admixtures, their chemical content and dosages used
in the experimentation are shown in table 1.
The compressive strength test specimens were of
dimensions 150x150x150 mm. The specimens were
tested on compressive testing m/c of 2000KN
capacity after 28 days of curing. The splitting tensile
Fig 3 Variation of flexural strength of concrete with different percentage
replacement of cement by SF
used content (by weight of cement)
percent
S MLS + SNF 1.1
AEA Vinsol resin 0.1
W SNF + Stereate 0.4
Table 1: Details of admixtures used
strength test specimens were of dimensions 100mm
dia. and 200mm.height cylinders. The flexural
strength test specimens were of dimensions
100x100x500 mm. Two point loading was adopted
over an effective span of 400 mm while testing these
specimens after 28days of curing. Impact strength test
specimens were of dimensions 250x250x30 mm. The
specimens were given impact blows with a ball of
13.03 N with height of fall 1 mt. The impact energy
was calculated by the equation
Impact energy = whN (N-m)
Where w = weight of ball = 13.03N
h = height of fall = 1m
N=average number of blows to cause first crack
or final failure as the case may be
Test Results
Table 2 gives the test results of concrete without
any admixtures. It also gives percentage increase or
decrease of compressive, tensile, flexural, and impact
strength w.r.t. reference mix.
Table 3 gives the test results of concrete with
combinations of admixtures (S+AEA+W). It also
gives percentage increase or decrease of compressive,
tensile, flexural, and impact strength w.r.t. reference
mix. The variation of these strengths are depicted in
the form of graphs as shown in fig.1, 2, 3 and 4.
Discussion of Test Results
1. It has been observed that the compressive
strength of concrete with replacement of cement by
silica fume (SF) goes on increasing up to 10%
replacement. Afterwards the compressive strength
starts decreasing. i.e. the maximum compressive

102 April 2007


strength can be obtained by replacing 10% cement by
silica fume without using any admixtures. The
percentage increase in the compressive strength at
10% replacement of cement by silica fume is found to
be 23.37%.
It has been observed that the tensile strength of
concrete with replacement of cement by silica fume
goes on increasing up to 10% replacement.
Afterwards the tensile strength starts decreasing. i.e.
the maximum tensile strength can be obtained by
replacing 10% cement by silica fume without using
any admixtures. The percentage increase in the tensile
strength at 10% replacement of cement by silica fume
is found to be 18.30%.
It has been observed that the flexural strength of
concrete with replacement of cement by silica fume
goes on increasing up to 10% replacement.
Afterwards the flexural strength starts decreasing. i.e.
the maximum flexural strength can be obtained by
replacing 15% cement by silica fume without using
any admixtures. The percentage increase in the
flexural strength at 10% replacement of cement by
silica fume is found to be 119.90%.
It has been observed that the impact strength of
concrete with replacement of cement by silica fume
goes on increasing up to 10% replacement.
Afterwards the impact strength starts decreasing. i.e.
Fig 4 Variation of impact strength of concrete with different percentage
replacement of cement by SF
April 2007
R&D
Silica Fume Concrete
the maximum impact strength can be obtained by
replacing 10% cement by blast furnace slag without
using any admixtures. The percentage increase in the
impact strength at 10% replacement of cement by
silica fume is found to be 79.97%.
This may be due to the fact that 10% replacement
of cement by silica fume may show the optimum
pozzolanic reaction with optimum filler capacity.
Thus it can be concluded that 10% replacement of
cement by silica fume will yield the maximum
strengths for concrete without any admixtures.
2. It has been observed that the compressive
strength of concrete with replacement of cement by
silica fume goes on increasing up to 4% replacement,
when the combination of admixture such as
(S+AEA+W) is used. Afterwards the compressive
strength starts decreasing. i.e. the maximum
compressive strength can be obtained by replacing 4%
cement by silica fume using (S+AEA+W)
combination of admixtures. The percentage increase
in the compressive strength at 4% replacement of
cement by silica fume is found to be 37.60%.
It has been observed that the tensile strength of
concrete with replacement of cement by silica
fume goes on increasing up to 4% replacement,
when the combination of admixtures such as
(S+AEA+W) is used. Afterwards the tensile
strength starts decreasing. i.e. the maximum
tensile strength can be obtained by replacing 4%
cement by silica fume using (S+AEA+W)
combination of admixture. The percentage increase
in the tensile strength at 4% replacement of
cement by silica fume is found to be 25.66%.
It has been observed that the flexural strength
of concrete with replacement of cement by silica
fume goes on increasing up to 4% replacement
when the combination of admixture such as
(S+AEA+W) is used. Afterwards the flexural
strength starts decreasing. i.e. the maximum
flexural strength can be obtained by replacing 4%
cement by silica fume using (S+AEA+W)
combination of admixture. The percentage increase
in the flexural strength at 4% replacement of
cement by silica fume is found to be 13.90%.
105
R&D
Silica Fume Concrete

It has been observed that the impact strength of

concrete with replacement of cement by silica
fume goes on increasing up to 4% replacement
when the combination of admixture such as
(S+AEA+W) is used. Afterwards the impact
strength starts decreasing. i.e. the maximum
impact strength can be obtained by replacing 4%
cement by silica fume using (S+AEA+W)
combination of admixture. The percentage increase
in the impact strength at 4% replacement of
cement by silica fume is found to be 133.35%.
This may be due to the fact that 4% replacement
of cement by silica fume may show optimum
pozzolanic reaction and optimum filler capacity.
Along with this the use of combination of
admixtures (S+AEA+W) may induce more
workability so that the maximum compaction can
be achieved which enhances the strengths further.
Thus it can be concluded that 4% replacement of
cement by silica fume with combination of
admixtures (S+AEA+W) will yield maximum
strengths for concrete.
4. It has been observed that the concrete produced
by using combination of admixtures (S+AEA+W)
It can be concluded that the use of
combination of admixture (S+AEA+W) will
yield good strength properties to the concrete
without posing any problems of compatibility.
shows more strengths as compared to the concrete
produced without any admixtures. This is
obviously due to the fact that the added admixtures
will aid in compacting the concrete to the fullest
extent which ultimately increase the strength
properties of concrete. Thus it can be concluded that
the use of combination of admixtures (S+AEA+W)
will yield good strength properties to the concrete.
Conclusions
h It can be concluded that 10% replacement of
cement by silica fume will yield the maximum
strengths for concrete without any admixtures.
h It can be concluded that 4% replacement of
cement by silica fume with combination of
admixtures (S+AEA+W) will yield maximum
strengths for concrete.
h It can be concluded that the use of combination of
admixture (S+AEA+W) will yield good strength

Percent- Compres- Percentage Tensile Percentage Flexural Percentage Impact Percent-

age sive increase of strength increase or strength increase of strength age
replace- strength compres- MPa decrease of MPa flexural N-m increase
ment of MPa sive tensile strength of impact
cement strength strength w.r.t strength
by SF w.r.t w.r.t reference w.r.t.
reference reference mix reference
mix mix mix
0(Ref) 31.70 - 3.77 - 2.06 - 21.67 -
2 34.81 9.81 3.82 1.33 3.81 84.95 26.00 19.98
4 35.41 11.70 3.92 3.98 3.87 87.86 30.33 39.96
6 37.33 17.76 3.94 4.51 4.24 105.82 32.50 49.98
8 38.07 20.09 4.11 9.02 4.33 110.19 34.67 59.99
10 39.11 23.37 4.46 18.30 4.53 119.90 39.00 79.97
12 38.37 22.08 3.37 -10.61 3.87 87.86 32.50 49.98
15 37.33 17.76 3.13 -16.98 3.83 85.92 26.00 19.98

Table 2: Test results of concrete without combination of admixtures

106 April 2007

R&D
Silica Fume Concrete

Percent- Compres- Percentage Tensile Percentage Flexural Percentage Impact Percent-

age sive increase of strength increase or strength increase of strength age
replace- strength compres- MPa decrease of MPa flexural N-m increase
ment of MPa sive tensile strength of impact
cement strength strength w.r.t strength
by SF w.r.t w.r.t reference w.r.t.
reference reference mix reference
mix mix mix
0(Ref) 35.85 - 4.56 - 4.46 - 26.00 -
2 36.74 2.48 4.90 7.50 4.81 7.85 52.00 100.00
4 49.33 37.60 5.73 25.66 5.08 13.90 60.67 133.35
6 44.89 25.22 5.46 19.74 4.84 8.52 56.33 116.65
8 41.19 14.89 5.41 18.64 4.75 6.50 52.00 100.00
10 40.74 13.64 4.54 -0.44 4.63 3.81 47.67 83.35
12 39.56 10.35 3.82 -16.23 4.57 2.47 43.33 66.65
15 38.37 7.03 3.76 -17.54 4.51 1.12 30.33 16.65
Table 3: Test results of concrete with combination of admixtures (S+AEA+W)

properties to the concrete without posing any
problems of compatibility. Hence the concrete
containing the combination of admixtures
(S+AEA+W) and silica fume can be
recommended for construction works.
Acknowledgements
The authors would like to thank Dr.(Mrs) S. S.
Kulkarni, Principal, RIT, Sakharale and
Dr.S.C.Pilli, Principal, KLE Society’s College of
Engg. & Technology, Belgaum for giving all the
encouragement needed which kept our enthusiasm
alive. Thanks are also due to the management
authorities and others who constantly boosted our
morale by giving us all the help required. Thanks
are also due to authorities of MBT Pvt.Ltd.
(Degussa) Mumbai India for supplying the
required admixtures.
References
h Pandagale S.B, Magarpatil H.R, Walvekar P.P,
“Use of pozzolanic material for superior concrete”,
Proceedings of INCRAC & CT 2005, pp.97-104.
h Roberto C.A, pinto and Kenneth C. Hover,
“Superplasticiser and silica fume addition effects
on heat of hydration of mortar mixtures with low
water-cementitious materials ratio”, ACI Material
Journal, Sept-Oct 1999, pp.600-604.
h Prakash K.B, Krishnamurthy B.S, “An
experimental investigation on the properties of
concrete containing tertiary blends”, Proceedings
of INCRAC & CT, pp.113-121.
h Chatterjee A.K, “Performance of blended cements
– An Indian perspective”, The Indian Concrete
Journal, July 2000, pp.383-392.
h Tiwari Ashok, Momin Illyas, “Improving early age
strength of PSC with indigenous silica fume”, The
Indian Concrete Journal, Oct-2000, pp.595-598.
h Dale P, Bentz and Edward J. Garboczi,
“Simulation studies of the effects of mineral
admixtures on the cement paste aggregate
interfacial zone”, ACI Materials Journal, Sept-Oct
1991,pp.518-529.
Zongjin Li, Jun Peng, and baoguo Ma,
“Investigation of chloride diffusion for high
performance concretecontaining fly ash, microsilica
and chemical admixtures”, ACI Materials Journal,
May-June 1999,pp.391-396.

108 April 2007


An Experimental Study on the Effect of
Sustained Elevated Temperatures on the
Strength Properties of Fibrous
Ferrocement Using GI Fibers
B
ECAUSE OF LIGHTWEIGHT and thin
sections of ferrocement elements, the
applications of ferrocement are vast
increasing. Ferrocement does not require any special
construction technique and skilled labour.
Ferrocement has its cracking resistance, ductility and
fatigue resistance higher than those of concrete. In
addition impermeability of ferrocement elements is
far superior to that of ordinary concrete. Similarly
fiber reinforced concrete (FRC) has also wide
applications. FRC possesses higher compressive
strength and toughness, increased resistance to wear
and tear, and higher post cracking strength. But these
two materials have limitations also. These two
materials cannot be employed where high vibrations,
high tensile forces and high impact are to be resisted.
Fibrous ferrocement, which is a combination of
ferrocement and fiber reinforced concrete, shows
better improvement in some of mechanical
properties, such as toughness, impact resistance. This
new composite also shows higher compressive
strength, higher tensile and impact strength.
In this paper an attempt has been made to study
the effect of different sustained temperatures on the
strength characteristic of fibrous ferrocement such as
compressive strength, flexural strength and impact
strength. The percentages of GI fibers were varied as
0%, 0.5%, 1.0%, 1.5%and 2.0%. The different
temperatures that are adopted in the experimentation
are 200 oC, 400 oC and 600 oC.
In terms of structural behavior, ferrocement
exhibits very high tensile strength-to-weight ratio and
superior cracking performance. The distribution of
small diameter wire mesh reinforcement over the
April 2007
Technology
N.K.Patil, Assistant Professor
DY Patil College of Engg. & Tech.
Dr. K B Prakash, Professor of Civil Engg.
K.L.E. Society’s College of Engg. & Tech.
In this paper an attempt has been made
to study the effect of different sustained
temperatures on the strength characteristic
of fibrous ferrocement such as
compressive strength, flexural strength
and impact strength.
entire matrix surface provides a very high resistance
against cracking. Moreover engineering properties
such as toughness, fatigue resistance, impermeability,
etc are considerably improved. Sometimes,
conventional reinforcing bars in the skeleton form are
added to thin wire meshes in order to achieve a stiff
reinforcing cage.1
Ferrocement is a particular type of reinforced
concrete although the extent of investment is
relatively less in case of ferrocement construction.
Because of similarity in the nature of the ingredients
of conventional concrete and ferrocement, the
durability characteristics are expected to be similar,
even though the mechanical characteristics may be
quite different. But ferrocement cannot be employed
where high impact, high wear and tear, high
vibrations and high loads are expected.2
FRC is a composite material consisting of cement,
sand, metal, water and fibers. In this composite
material, short discrete fibers are randomly
distributed throughout the concrete mass. The
behavioral efficiency of this composite material is far
superior to that of plain concrete and many other
construction materials of same cost. Due to this
benefit, the use of FRC has steadily increased during
last two decades and its current field of application
109
Technology
Fibrous Ferrocement Using GI Fibers
includes, airport and highway pavements, earthquake
resistant and explosive resistant structures, mines and
tunnel linigs, bridge deck overlays, hydraulic
structures, rock slope stabilization. Extensive research
work on FRC has established that the addition of
various types of fibers such as steel, glass, synthetic
and carbon, in plain concrete improves strength,
toughness, ductility, and post cracking resistance, etc.3
The major advantages of fiber reinforced concrete
are resistance to microcraking, impact resistance,
resistance to fatigue, reduced permeability, improved
strength in shear, tension, flexure and
compression. 4Fibers influence the mechanical
properties of concrete or mortar in all modes of
failure, especially those that induce fatigue and tensile
stress. The strengthening mechanism of fibers
involves transfer of stress from matrix to the fiber by
interfacial shear or by interlock between the fibers and
the matrix.5 Addition of steel fibers in concrete mix
significantly improves the cracking behavior and
ultimate strength of deep beams. Addition of steel
fibers in concrete results in an increase of beam
stiffness. 6 In addition to increase in flexural strength, a
considerable increase in toughness is also imparted by
the fibers.7 The fiber reinforced concrete is also
gaining more importance these days especially in the
earthquake resistant structures, where ductility plays
an important role. 8
In spite of many advantages of FRC, it has some
limitations also. It cannot be employed where high
impact, high vibration and high wear and tear is
expected. Many problems have to be faced during
construction of FRC, especially when quantity of fiber
used is more. The fibers if put in bulk along with
other ingredients do not disperse but nest together.
This phenomenon is called balling effect. The balling
effect may be reduced to some extent by mixing the
fibers and other ingredients in dry foam and then
adding water. The fibers placed in concrete, may
block the discharge port. Since the flow of FRC is low,
the FRC has to be placed near to the place where it is
to be used finally.9
The fibrous ferrocement, which is a combination
of fiber reinforced concrete and ferrocement, can
110
overcome most of the limitations of the FRC and
ferrocement. And it can be used with assurance where
high impact, high vibration and high wear and tear
are expected. In this new material advantages of both
FRC and ferrocement are combined.9
Research Significance
The promise of stronger and thinner elements,
reduced weight, and controlled cracking by simply
adding a small amount of fibers is an attractive
feature of FRC. Even though performance of fiber
reinforced concrete in airfield, pavements, industrial
floors and machine foundations is satisfactory, it
suffers from some limitations. It cannot be employed
where high impact, high vibrations and high wear and
tear are expected. Similar to fiber reinforced concrete
the ferrocement also have many advantages and its
applications are rapidly increasing. The major
limitation in ferrocement is that the percentage of
reinforcement cannot be increased beyond certain
limit. This limitation affects the strength of
ferrocement and it cannot be employed where high
impact or high load are expected.
The fibrous ferrocement, which is combination of
ferrocement and fiber reinforced concrete, can overcome
to some extent the limitations offered by ferrocement
and fiber reinforced concrete and even improve some of
the mechanical and strength properties of ferrocement.
Thus in crucial situations fibrous ferrocement can be
effectively used as versatile material.
Experimental Programme
The main aim of this experimentation is to study
the effect of sustained elevated temperatures on the
strength properties of fibrous ferrocement. Both the
fiber percentage and the reinforcement percentage
were varied in the study. The different temperatures
that are adopted in the experimentation are 200 oC,
400 oC and 600 oC.
Ordinary portland cement of 53 grade and locally
available sand with specific gravity 2.64 and fineness
modulus 2.91 was used in experimentation. To impart
additional workability a superplasicizer
(Algisuperplast – N), 0.5 % by weight of cement was
used. The GI fibers were obtained by cutting GI wires
April 2007
Technology
Fibrous Ferrocement Using GI Fibers
of 1 mm diameter. The aspect ratio adopted for fiber
was 40.The different percentage of GI fibers used in
the experimentation were 0%, 0.5%, 1.0%, 1.5% and
2.0% by volume fraction.
The welded mesh (WM) used in the
experimentation was having square opening of 25 mm
with 2.5 mm diameter. The chicken mesh (CM) used
was having a hexagonal opening with 0.5 mm
diameter. The cement mortar with a proportion of
1:1 was used with a water cement ratio of 0.4.
To study the effect of different temperatures on the
strength properties of fibrous ferrocement, the
compressive strength specimens, flexural strength
specimens and impact strength specimens were cast.
For compressive strength test, specimens of dimensions
150x150x150 mm were cast. For flexural strength test,
specimens of dimensions 100x100x500mm were cast.
These flexural strength specimens were tested under
two point loading over an effective span of 400 mm. 10
The impact strength test specimens consisted of plates
of dimension 250x250x35 mm. Four different methods
of impact test are described in the literature.11 Out of
these methods drop weight method was used owing to
its simplicity. A steel ball weighing 20 N was dropped
from the height of 1.5 m over the specimen, which was
kept on floor. The number of blows required for
complete failure was noted. The impact energy was
calculated as follows.
Impact energy = w x h x n, (N-m). where
w = weight of the ball = 20 N
h = height of fall = 1.5 m
n = number of blows required for complete failure.
The required size of welded mesh and chicken
mesh were first cut according to the mould sizes for
compression test, flexural test and impact test. The
chicken mesh was tied to the welded mesh using GI
wires at regular intervals. This formed cage of
(1WM+1CM). In the similar fashion the cages of
(1WM+2CM) and (2WM+2WM) were prepared.
Now the fibrous mortar was prepared by mixing
the required percentage of GI fibers into the cement
mortar. This cement mortar was placed inside the
mould in which cages were kept. All moulds were
112
kept on the table vibrator and sufficient vibration was
given to compact the mortar. The specimens were
finished smooth after vibration. The specimens were
demoulded after twenty-four hours of casting and
were transferred to curing tank where in they were
allowed to cure for 28 days.
After 28 days of curing, they were taken out of
water and were kept in the oven at different
temperatures such as
200 oC, 400 o C and 600 oC for 24 hours each.
The specimens were cooled down to room
temperature. Then specimens were tested for their
respective strengths.
Test Results
Tables 1,2 and 3 give the compressive strength test
results, flexural strength test results and impact
strength test results for fibrous ferrocement made
from (1WM+1CM), (1WM+2CM) and
(2WM+2CM), using GI fibers after subjecting to
different temperatures like 200 oC, 400 oC and 600 oC.
The tables also indicate the percentage decrease in
the strengths of fibrous ferrocement after subjecting
to different temperatures. In tables WM represents
welded mesh and CM represents chicken mesh.
The figures 1 to 9 indicate the variation of
strength properties of fibrous ferrocement using GI
fibers, after subjecting to different temperatures.
Discussions on Test Results
h It has been observed that the compressive, flexural
and impact strengths of fibrous ferrocement go on
increasing as the percentage of GI fibers in it goes
on increasing. This is true for all the fibrous
ferrocement specimens produced from
(1WM+1CM), (1WM+2CM) and (2WM+2CM).
It has been also observed that all these strengths of
fibrous ferrocement go on increasing as the
amount of welded mesh and chicken mesh in it
goes on increasing.
This is obviously due to the fact of more
percentage of fibers or more percentage of welded
mesh and chicken mesh which enhance all the
strength properties of fibrous ferrocement.
April 2007
Technology
Fibrous Ferrocement Using GI Fibers
h It has been observed that percentage decrease in the
compressive strength of fibrous ferrocement
produced with (1WM+1CM) is 6.53%, 5.73%,
4.55%, 3.45%, 1.66% for 0%, 0.5%, 1.0%, 1.5%
and 2.0% of GI fibers in it respectively, when it is
subjected to 200 oC temperature. And percentage
decrease in compressive strength when subjected to
400 oC and 600 oC are 27.52%, 25.63%, 23.65%,
21.56%, 19.56% and 47.83%, 45.23%, 43.66%,
41.45%, 39.52% respectively.
The percentage decrease in the compressive strength
of fibrous ferrocement produced with (1WM+2CM)
is 5.65%, 4.45%, 3.35%, 2.64%, 1.24% for 0%,
0.5%, 1.0% and 2.0% of GI fibers in it respectively,
when it is subjected to 200 oC temperature. And
percentage decrease in compressive strength when
subjected to 400 oC and 600 oC are 26.62%,
24.32%, 21.41%, 19.87%, 17.44% and 45.73%,
43.45%, 41.52%, 39.65%, 38.53% respectively.
The percentage decrease in the compressive
strength of fibrous ferrocement produced with
(2WM+2CM) is 4.89%, 3.54%, 3.01%, 2.52%,
1.06% for 0%, 0.5%, 1.0%, 1.5% and 2.0% of GI
fibers in it respectively, when it is subjected to 200
o
C temperature. And percentage decrease in
compressive strength when subjected to 400 oC and
600 oC are 24.32%, 22.65%, 19.46%, 17.65%,
16.22% and 43.65%, 41.52%, 38.65%, 37.32%,
36.62% respectively.
h It has been observed that percentage decrease in
the flexural strength of fibrous ferrocement
produced with (1WM+1CM) is 7.33%, 6.63%,
5.44%, 2.62%, 1.15% for 0%, 0.5%, 1.0%, 1.5%
and 2.0% of GI fibers in it respectively, when it is
subjected to 200 oC temperature. And percentage
decrease in the flexural strength when subjected to
400 oC and 600 oC are 29.32%, 28.12%, 27.45%,
25.32%, 22.44% and 53.53%, 52.65%, 51.52%,
49.66%, 47.62% respectively.
The percentage decrease in the flexural strength of
fibrous ferrocement produced with (1WM+2CM) is
6.74%, 5.65%, 4.52%, 3.21%, 1.09% for 0%, 0.5%,
1.0%, 1.5% and 2.0% of GI fibers in it respectively,
when it is subjected to 200 oC temperature. And
114
percentage decrease in the flexural strength when
subjected to 400 oCand 600 oC are 28.42%, 27.32%,
25.61%, 24.64%, 21.55% and 52.61%, 51.23%,
49.31%, 50.74%, 45.42% respectively.
The percentage decrease in the flexural strength of
fibrous ferrocement produced with (2WM+2CM) is
5.54%, 4.44%, 3.55%, 2.98%, 1.02% for 0%, 0.5%,
1.0%, 1.5% and 2.0% of GI fibers in it respectively,
when it is subjected to 200 oC temperature. And
percentage decrease in the flexural strength when
subjected to 400 oCand 600 oC are 26.21%, 24.62%,
22.42%, 21.12%, 18.32% and 50.32%, 48.64%,
47.63%, 46.36%, 45.32% respectively.
h It has been observed that percentage decrease in
the impact strength of fibrous ferrocement
produced with (1WM+1CM) is 7.85%, 6.97%,
5.62%, 2.81%, 1.05% for 0%, 0.5%, 1.0%, 1.5%
and 2.0% of GI fibers in it respectively, when it is
subjected to 200 oC temperature. And percentage
decrease in the impact strength when subjected to
400 oC and 600 oC are 29.84%, 28.63%, 26.66%,
24.52%, 23.06% and 54.67%, 52.16%, 50.63%,
49.11%, 47.17% respectively.
The percentage decrease in the impact strength of
fibrous ferrocement produced with (1WM+2CM) is
6.50%, 5.21%, 4.62%, 3.12%, 0.88% for 0%, 0.5%,
1.0%, 1.5% and 2.0% of GI fibers in it respectively,
when it is subjected to 200 oC temperature. And
percentage decrease in the impact strength when
subjected to 400 oCand 600 oC are 27.22%, 26.12%,
25.43%, 23.63%, 22.12% and 52.33%, 50.26%,
48.25%, 47.86%, 45.63% respectively.
The percentage decrease in the impact strength
of fibrous ferrocement produced with
(2WM+2CM) is 5.82%, 4.31%, 3.97%, 3.04%,
0.81% for 0%, 0.5%, 1.0%, 1.5% and 2.0% of
GI fibers in it respectively, when it is subjected
to 200 o C temperature. And percentage decrease
in the impact strength when subjected to 400 oC
and 600 oC are 26.10%, 24.31%, 23.51%,
21.69%, 20.52% and 49.13%, 48.63%, 46.25%,
45.13%, 43.14% respectively.
The decrease in the strength properties of fibrous
ferrocement subjected to different temperatures such as
April 2007

200 o C, 400 o C and 600 o C may be due to fact of
setting up of a temperature gradient across the
thickness of the fibrous ferrocement. The fibers, welded
mesh and chicken mesh present in the fibrous
ferrocement when heated up tend to expand which
ultimately affect the bond and hence delamination may
take place. These effects may bring down the strength
properties of fibrous ferrocement when subjected to
different temperatures such as 200 o C, 400 o C and
600 o C. However it has also been observed that
percentage reduction shows descending trend with
increase in percentage of GI fibers and also increase in
percentage of welded mesh and chicken mesh.
Conclusions
It can be concluded that the compressive strength,
flexural strength and impact strength of fibrous
ferrocement can be enhanced either by increasing
percentage of GI fibers or by increasing percentage of
April 2007
Technology
Fibrous Ferrocement Using GI Fibers
welded mesh and chicken mesh. And there will be
reduction in strength properties of fibrous
ferrocement when subjected to different temperatures
such as 200 o C, 400 o C and 600 o C. The percentage
decrease is very high at 400 o C and 600 o C. But
compared to ferrocement, fibrous ferrocement shows
better fire/heat resisting capacity.
Acknowledgement
The authors would like to thank Dr.S. C. Pilli and
Dr. A. N. Chapgaon, Principals of KLE’s College of
Engineering and Technology, Belgaum and D.Y.Patil
College of Engineering and Technology, Kolhapur for
their encouragement throughout the work. Authors
are also indebted to management authorities of both
the colleges for their wholehearted support, which
boosted the moral of the authors. Thanks are also due
to HODs of the civil engineering department and
other staff for their kind cooperation.
115
Waterproofing
Supershield
Technology
S
UPERRSHIELD DPC (Deep Penetrating
capillary) waterproofing systems improves the
waterproofing and durability of concrete by
filling and plugging pores, capillaries, micro-
cracks, and other voids with a non-soluble, highly
resistant crystalline formation.
The waterproofing effect is based on two simple
reactions, one chemical and one physical. Concrete
is chemical in nature. When a cement particle
hydrates, the reaction between water and the
cement causes it to become a hard, solid mass.
The reaction also generates chemical by-products
that lie dormant in the concrete.
SUPERRSHIELD DPC system adds another set of
chemicals to the mixture. When these two
chemical groups, the by products of cement
hydration and the SUPERRSHIELD DPC system
chemicals, are brought together in the presence of
moisture, a chemical reaction occurs. The end
product of this reaction is a non soluble crystalline
structure.
This crystalline structure can only occur where
moisture is present, and thus will form in the
pores, capillary tracts, and shrinkage cracks in
concrete. Wherever water goes, SUPERRSHIELD
DPC system will form filling the pore, voids
and cracks.
When SUPERRSHIELD DPC system is applied
to the surface, either as a coating or as a dry
sprinkle application to a fresh concrete slab, a
process called chemical diffusion takes place. The
theory behind diffusion is that a solution of high
density will migrate through a solution of lower
density until the two equalize. Thus, when concrete
116
SUPERRSHIELD DPC (Deep Penetrating
capillary) waterproofing technology
improves the waterproofing and durability
of concrete by filling and plugging pores,
capillaries, micro-cracks, and other voids
with a non-soluble, highly resistant
crystalline formation
is saturated with water prior to applying
SUPERRSHIELD DPC system, a solution of low
chemical density is also being applied. When
SUPERRSHIELD DPC system is applied to the
concrete, a solution of high chemical density is
created at the surface, triggering the process of
chemical diffusion.
The SUPERRSHIELD DPC system chemicals
will migrate through the water (the solution of low
density) until the two
solutions equalize.
The SUPERRSHIELD DPC system chemicals
spread through the concrete and become available
to the by products of cement hydration, allowing
the chemical reaction to take place. A crystalline
structure is formed, and as the chemicals continue
to migrate through the water, this crystalline
growth will form behind this advancing front of
chemicals. The reaction will continue until the
SUPERRSHIELD DPC system chemicals are either
depleted or run out of water.
Chemical diffusion will take these chemicals
about 12 inches minimum into the concrete. If
water has only soaked two inches into the surface,
then the SUPERRSHIELD DPC system chemicals
April 2007

will only travel two inches and stop but, they still
have the potential to travel 10 inches further, if
water reenters the concrete at some point in the
future and reactivates the chemicals.
Instead of reducing the porosity of concrete,
like water reducers, plasticizers, and
superplasticizers, the SUPERRSHIELD DPC
system engages the material filling and plugging
the voids in concrete to become an integral and
permanent part of the structure.
Because these crystalline formations are within
the concrete and are not exposed at the surface,
they cannot be punctured or otherwise damaged
like membranes or surface coatings.
SUPERRSHIELD DPC system is highly resistant
to chemicals where the pH range is between three
and 11 under constant contact, and two to 12 under
periodic contact. Crystalline waterproofing will
April 2007
Waterproofing
Supershield Technology
tolerate temperatures between -25 degrees
Fahrenheit (-32 degrees Centigrade) and 265
degrees Fahrenheit (130 degrees Centigrade) in a
constant state. Humidity, ultraviolet light, and
oxygen levels have no impact on the products
ability to perform. In a nutshell SUPERSHIELD
DPC system waterproofs, protects and enhances the
durability of the concrete.
Basic Use
Recommended for use in any concrete or block
structure where it is required to keep water in or
out. SUPERSHIELD DPC system waterproofs,
protects concrete from chemical attacks and
enhances the durability of the concrete.
SUPERSHIELD DPC system are available in
various forms to treat cold joints, faulty and
leaking substrate, cracks, voids and to meet the
requirement of green, new and old concrete.
117
Trends
Intelligent Buildings
Dr. (Mrs) Samta Jain
Assistant Professor
Akruti City Gold University, Mumbai
W
RITING THIS PIECE of article, I am
reminded of my visit to an intelligent
building and I am trying correlating the
same to the 57th year of republican Journey of our
country. My vision is to have our country go further
to the speculation of Goldman Saachs; to have
something which might be called as Brain- drain to
India by the foreign nations; to celebrate the success
of India poised and much more to create intelligent
India by touching faith in the power of technology to
change the society. Let us all try and become the
Master Builders.
“Intelligent Buildings”- There are definitely two
parts of this inaugural stance. The first is
considering the blend of business and technology as
a force of change, a force that needed to be tracked
and analyzed for the development of the country.
The second part is the S 3 as I will call which stands
for the scientific-socio-survival. Intelligent
Buildings can make wonder by reducing the impact
of natural hazards, increase the living standards and
social status and give scientific leverage to the
country. In the light of the fact that vulnerability
profile of India makes the Indian Continent, one of
118
In the light of the fact that vulnerability
profile of India makes the Indian Continent, one
of the most disaster prone regions of the world
with nearly 60% area prone to earthquakes, 8 %
cyclones and 5% to floods, we must try to
reduce this cost by investing high in technology
and going further a long way by demolishing the
large stock of our ageing building and
restructure intelligent buildings to spell the
socio-economic success of the country.
the most disaster prone regions of the world with
nearly 60% area prone to earthquakes, 8 %
cyclones and 5% to floods, we must try to reduce
this cost by investing high in technology and going
further a long way by demolishing the large stock
of our ageing building and restructure intelligent
buildings to spell the socio-economic success
of the country.
With the models of architecture adopted by the
many private organizations, I will be reluctant now
to enter into the musty offices with a chaotic
environment and tables stacked with dog-earned
files. The latest green glass- elevated structures are
sure to drive us all crazy to work in them and for
them. When you enter in buildings of this kind,
you will be extolling the innovation and growth
but I was more struck memorizing the Garden’s
Psychological Paradigm of Human Intelligence and
the very idea of building the kinaesthetics ruled my
thought process. Can an intelligent building against
the contemporary ones help us change everything-
was the thought that came to my mind; can these
features really help and assist in high business
performance and I became keen on writing an
April 2007

article on this, thinking that definitely we can have
intelligent business through intelligent buildings.
Under the business umbrella, there are lumps of
deficiencies and inefficiencies and I thought that
the HR has always been making the headlines and
meeting the deadlines crushing between the time
and energy crisis. Frankly speaking it is not the
headlines of Property Plus or other magazines that
grabbed my attention but rather the footnotes
made me captive and I started giving the
meaningful business descriptions in my own
semantic words.
A Mastered Change
India, the world’s largest democracy has 10 of the
world’s 30 fastest growing cities and is also
witnessing the rapid urbanization with 140 m rural
population moving to the urban areas by 2020. The
land has squeezed to the proportion of the growing
April 2007
Trends
Intelligent Buildings
The intelligent buildings as a part of the
complex system can be really helpful in the
constructions of houses that are socially and
environmentally friendly. Whether they are
houses for the mentally and physically
handicapped or they are constructions to
reduce the vulnerability due to natural
disasters, I firmly believe that synergy and
economic advantage can be achieved through
an integrated implementation.
population and erecting intelligent buildings, which
integrate all sensor systems, computation, materials,
biometrics, energy management and security
workouts can help us. We must not forget that the
icy plains of artic which were fit for no-man once
have been converted into one of the wind –power
suppliers and the arid dunes of the desert has been
119
Trends
Intelligent Buildings
Intelligent Buildings can create a
differentiation in property matters and the
business players must appreciate these as an
asset rather then a liability. They must realize
that they need to be more upfront to get a
bigger-bang in the long run.
converted into green energy. The credit goes all to
techno-engineering innovations.
The intelligent buildings as a part of the
complex system can be really helpful in the
constructions of houses that are socially and
environmentally friendly. Whether they are houses
for the mentally and physically handicapped or
they are constructions to reduce the vulnerability
due to natural disasters, I firmly believe that
synergy and economic advantage can be achieved
through an integrated implementation.
We can install the fiber-optic systems to send
alerts to the managers for handling the immediate
requirements of the products and services when
they run out of stock, we can have sweeping of
security cards, retina color checking, lightening
and cooling of our chambers and have a pay time
with the games and surfing on the plasma screens.
The carbon-di-oxide sensors can detect the number
of people inside and do adjustments with the
temperature and climate control. These smart
building networks can help the institutional
owners, industrialist play smart business and work
well with the strategies of just in time (JIT),
Kaizen and Six Sigma.
In all the sense the provision of these utilities
can increase the net operating income through
operation savings and new revenue streams. We
must not forget that technology is the buzzword
and is not an afterthought but a critical function of
the real estate planning. We are with ample
innovations, permutations and combinations,
thinking every time, What Next?
The Business Zone must be willing to utilize its
infrastructure to its benefit by using the digital
signage strategies, integrated comprehensive broad-
120
band strategies and the internet based building
operations to come out with the next generations
buildings to work more smarter. I am just glazing
the experiences of working at Capital Tower,
Suntec City Singapore, Cyber port, Hong Kong or
to say Sanghai China against the experience of
working in the normal, old buildings that do not
adequately meet the hygiene factors defined
by Herzberg.
We are in the Business age when information
happens to be the fourth utility after water, electricity
and gas. And technology and information are making
the buildings SMARTER than before.
Intelligent Buildings can be customized and given
a wider perspective in terms of the selection of proper
structured system. The advances made in the civil
engineering technology can be speculated to reduce
the disaster from earthquakes, floods and other
natural disasters.
Boon to Business: An Intelligent Initiative
Speculative, as they are, the businessmen must
think of working in a professional environment
with sophistication and energy conservations.
Because 50 years from now, picture a radical
change in the mindsets, systems and strategies and
we won’t be able to resist the tall-old-non-
intelligent-structures (TONS). Intelligent
Buildings can create a differentiation in property
matters and the business players must appreciate
these as an asset rather then a liability. They must
realize that they need to be more upfront to get a
bigger-bang in the long run.
It can provide the security standards through the IP
based security systems and make the place a “high-end
workplace.” Definitely, to say these intelligent smart
buildings have at least a cost covering ROI associated
to them, with demonstrable cost saving and capital
cost avoidance element as well. Further more they
provide the stimulating environments to work. By
providing a single point control of information and
communication network, energy management, security
and critical systems, it reduces the operational
management cost and adds to the complete life
April 2007
 Trends
Intelligent Buildings

performance benefits of integrated services. trendy. A hypothesis that the coming decade will
The businessmen investing for their location of witness a dramatic increase in the quality and
work must also see to the life cycle cost which is quantity of intelligent buildings due to the emerging
important aspect of the building economics. It is filed of pervasive buildings. IT will soon become an
defined as entire cost incurred over the entire life of integrated part of business environment with
the building. In these intelligent buildings this cost is processors, sensors and actuators connected via high-
reduced by the way of periodic maintenance cost and, speed networks and combined with new visualization
cost due to inappropriate construction and cost of devices from projections directly into the eye to
damage. In addition the cost of the process and large panorama displays.
operations are also reduced giving not only efficiency IT as I see, in the intelligent buildings will
but also effectiveness. They also tend to reduce the change from being proprietary, specialized offering
overall operation cost. The security factor is also as to niche segment, to be a part of mainstream mass
important to the companies in terms of the buildings market in the years to come and it is here that the
having SMART EYES to scan the offenders. Security Real Estate Manager have a major role to play. The
monitoring through cameras can have a triggered back counting seems to be started. The Traditional
alarm directed connected to police and then the will soon disappear and integrations will follow.
security videos can help police apprehend the suspects The good news is that now we have no choice
quickly. Energy conservation- physical, mental and but to deliver.
psychological can pave way for innovations, creativity
and dexterity on the employees’ behalf.
These structures if diligently designed can be light
and flexible enough to significant overloads of wind,
earthquakes and explosions thus giving life-security to
the employees. Human comfort and sense of pride
can’t be forgone when considering the structures of
the building. Working in an interactive workplace can
be a high-quality experience for the employees. The
technology called “roomwares” can support and
collaborate with the people at work. The people can
have the ideal thermal comfort with the walls of
insulation performance. The employees working for
these business houses can coordinate multiple
activities in the office hours without a loss of valuable
time-to-revenue and can receive capabilities then
ever. These buildings can simply be add-on to the
human factor working for the organization and
survive with the same cost of functioning with low
maintenance and higher degree of efficiency.
Forecasting the Future
Ever since early 1980’s, when the trade
magazines became the carrier of the stories on
Intelligent Buildings, more demand has grown for
them and they seem to be both economic and

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Fire Protection of Steel Structures
Ensuring Integrity
Against Fire On Offshore
Installations Part - II
Richard Holliday
Market Manager, International Paint Ltd
Design & Selection Criteria
Design of fire protection is not only about
meeting the required fire rating. The system should
be considered early in the design process to ensure
that full understanding of all the factors involved is
understood. Typically the requirements of PFP can be
identified from the decision tree shown in Figure 2.
Fire testing
Fire testing provides a method of evaluating the
performance of PFP systems against a standard set of
criteria, allowing 3rd Party classification societies such as
Lloyd’ Register or Det Norske Veritas to issue Type
Approval Certification against recognised standards. For
Hydrocarbon fire testing, standard test methods have
developed from crude pit burn tests to well controlled,
furnace burn tests to internationally recognised standards
such as ISO834, BS476: parts 20, 21 and 22 Appendix
D, or UL1709. Following the Piper Alpha disaster of
1998 in the United kingdom North Sea, the report into
the incident stated the following [2]:
122
Design of fire protection is not only about
meeting the required fire rating. The system
should be considered early in the design
process to ensure that full understanding of
all the factors involved is understood.
“… it was noted that a major misconception in
the performance of fire protection is the belief that a
fire rating indicates the time the assembly will
survive in an actual fire …”
“… it is accepted that the (standard) time versus
temperature curve method of fire testing is far from
satisfactory …”
“… it is clearly desirable that any (fire) test used
be realistic. The essential problem is not that of a test
per se, but of the information which the test provides
to the designer about the probable behaviour of the
fire barrier in real hydrocarbon fire conditions …”
In his report, Lord Cullen, identified that not only
was the old cellulosic fire test not applicable
for offshore oil and gas installations, but that
an even more onerous test regime was required
to simulate the highly erosive jet fires.
Following this, the United Kingdom
Offshore Operators Association (UKOOA)
and the United Kingdom Health and Safety
Executive (HSE) developed a test program
that tested both at full scale and medium
scale against the effects of jet fire.
These tests resulted in a quasi-standard
test method known as OTI-95-634 [4].
This will shortly be published as a full ISO
standard for the classification of PFP
April 2007
Fire Protection of Steel Structures
Ensuring Integrity Against Fire On Offshore Installations

materials and systems exposed to jet fires.
When considering jet fire testing it is essential to
consider the following factors:
h jet fire duration and possible combination with
other fire types
h configuration of jet fire test – essential that
appropriate test arrangement is used:
h Structural Steel (Web) – for I sections and open
sections of structural steel
h Planar for fire divisions and large diameter
items such as vessels and supports
h Tubular for smaller diameter items such as
Pipework, vales and flanges
h Assemblies – for testing special case systems
such as penetration seals.
h Certification – system should be independently
certified by a recognised classification society such
as Lloyd’s Register.
Explosion Testing
Following the ignition of a gas or vapour cloud,
significant blast pressures can be experiences particularly
in confined or congested areas. Blast loads are the result
The United Kingdom Offshore Operators
Association (UKOOA) and the United Kingdom
Health and Safety Executive (HSE) developed a
test program that tested both at full scale and
medium scale against the effects of jet fire.
of a large number of interacting factors; these can be
modelled using sophisticated computer simulations
packages. Typical loads can be in the region of 0.3 to 1.5
bar but could, in theory, reach as high as 4.0 bar,
although at these levels little of the original steel
structure would remain intact. Test against explosion
resistance is carried out on an ad-hoc basis as there is no
internationally recognised standard for explosion testing.
When considering explosion testing it is essential to look
at the peak level of overpressure expected, the duration
of the blast pulse, positive and negative pressure effects
(drag loads can be significant on PFP systems) and
ensuring that the PFP system is capable of withstanding
any resultant deflection without damage or impairment.
Critical Core Temperature
Steel loses it strength rapidly in the event of a fire.
Without fire protection temperatures within the steel

Cement Based Systems

System Description
Typical Uses Strengths
Shortcomings
Certification & Testing
Performance
Composition of system is generally a cement binder and inorganic insulant (typically
vermiculite). Application methods include spray or trowel applied with mesh retention
system. General no longer used offshore or in costal marine environments, but was
extensively used for structural steel firewalls and underdecks. Still occasionally used
in interior locations.
Structural steel, divisions, pipe work & process vessels. When new system has good
fire performance, with low smoke and toxicity
System is prone to degradation with time due to damage from weathering, thermal
expansion and contraction and general wear and tear. System requires routine
maintenance to maintain its integrity. Common to experience corrosion of both
mesh retention system and underlying substrate.
Generally well tested in as new condition, but performance falls quickly as system
becomes damaged or weathered. Performance
Operating Temperature Limits D Environment Resistance D-E
Space Restriction C Corrosion Protection D
Inspection Access C Mechanical Damage D
Removability C Life Cycle D

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 Fire Protection of Steel Structures
Ensuring Integrity Against Fire On Offshore Installations

can rise to over 500°C within a few minutes causing When considering explosion testing it is
the steel buckle and collapse. Fire protection is used to
essential to look at the peak level of
ensure the structure remains within its design factors
for sufficient period to allow the fire to be brought
overpressure expected, the duration of the
under control or the installation safely abandoned. blast pulse, positive and negative pressure
Structural steel work is normally limited to 400°C for effects (drag loads can be significant on PFP
offshore design, although higher temperatures are systems) and ensuring that the PFP system is
permissible on lightly loaded steelwork. Figure 3 shows capable of withstanding any resultant
typical strength of steel verses steel temperature. For deflection without damage or impairment.
aluminium structures a lower critical core temperature
be expected to limit valves to between 200°C &
is used, typically 200°C, due to its lower melting
300°C for the specified fire period. Actuators are
point. Fire impact on pipework, fittings and vessels can
be even more devastating causing events such as normally limited to between 70°C & 100°C for the
active closure period. Vessels will generally be limited
BLEVE’s . A BLEVE is a Boiling Liquid Evaporating
Vapour Explosion, a well know hazard to fire fighters to between 200°C & 400 °C for the full fire duration
in order to reduce possibility of BLEVE events.
when tackling fires. Without fire protection, the vessel
body rapidly heats up to a point where it can no longer Section Factors
contain the pressures, the vessel shell ruptures with The rate of heating of steel is dependant on the
catastrophic effects producing a massive fire ball and amount of heat input in proportion to the mass of steel
firing burning and molten pieces for great distances. To available to absorb the heat. This ratio is generally
prevent such events it is essential that the temperature described as the section factor (or massivity) of the
of the steel is keep below the critical failure steelwork. It is defined as the surface area exposed to
temperature to ensure pressure containment for the fire divided by the volume (or mass) of steel. Terms
pipework and vessels, prevent failure of the ESD valve such as Hp/A (Heated perimeter/cross sectional area),
to inhibit flow of inventory on the installation or to A/V (heated area/volume) and W/D (weight/heated
ensure blow-down systems function. Typically it may perimeter) are used to describe this ratio.
Wet Applied Intumescent Epoxy Systems
System Description A spray or trowel applied two pack epoxy coating material that is applied directly
onto a clean, prepared steel surface. Once cured the system is ridged and firmly
bonded on place.
Typical Uses Strengths Structural steel, divisions, pipe work & process vessels. Strengths Very long
life, maintenance free, excellent corrosion resistance, capable of taking heavy
mechanical knocks
Shortcomings Once applied are very difficult to remove, no inspection access available, cannot be
applied to hot plant and equipment. Not suitable for internal normally manned
areas. Certain systems appear vulnerable to environmental exposure and are reliant
on topcoat to ensure integrity.
Certification & Testing Extensively tested against fire and blast. The best systems hold extensive test data
and type approval certification for jet fire protection to recognised standards.
Performance Operating Temperature Limits C Environment Resistance A
Space Restriction A Corrosion Protection A
Inspection Access E Mechanical Damage A
Removability E Life Cycle A

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Fire Protection of Steel Structures
Ensuring Integrity Against Fire On Offshore Installations

To enable the correct thickness of PFP to be specified

it is necessary to establish from fire tests tables of
required thickness against section factor for a given fire
type and duration. Appendix 1 shows a typical table.
Corrosion & Durability Testing
The systems shall be designed so that constituent
parts & the final assembly are capable of
withstanding the effects of an offshore environment,
high humidity, saltwater environment, deluge
testing & thermal cycling.
The system should minimise the risk of corrosion The Strengths of Steel
to the underlying substrate/equipment. This
requirement should be inherent to the design of the as well as offering resistance to damage from
system. The system should be capable of personnel traffic in congested areas. The system has
been independently tested with realistic loads &
demonstrating such durability by passing industry
impact velocities.
recognised standards such as NORSOK M-501 [7]
For demountable systems corrosion protection The system shall be designed using materials &
coatings below the system will be required to ensue the construction that will maintain its performance
throughout the design life of the installation or
risks are minimised after routine inspections or
facility. This is typically in the region of 20 to 30
complete removal/replacement of the system
years for new build projects. Again this should be
The system should be designed to withstand a
demonstrated by both appropriate testing and track
high degree of mechanical impact from items such
record in similar environmental conditions.
as dropped objects (hand tools, scaffold clips, etc.) to be contined
Pre-formed Intumescent Epoxy Systems
System Description A pre-formed cast version of the two-pack epoxy coating material that is reinforced
with a structural steel mesh. Components are bolted in place around object using
the object as the support. The system is ridged and applied over a painted surface.
Typical Uses Strengths Flanges, valves & actuators, pipe work & process vessels Long life, maintenance free,
excellent corrosion resistance, capable of taking heavy mechanical knocks, easy access
for routine inspections. Excellent access to weld and bend inspections and flange covers.
Systems retain the inherent weatherability of the epoxy intumescent system and hence
are far more resistant than fibre based systems, with subsequently less risk of corrosion.
Shortcomings Complete removal of system when used on large or complex shapes can be time
consuming, requires additional insulation for use on hot plant and equipment. System
does not provide inherentcorrosion protection, but relies on underlying corrosion
protection system.
Certification & Testing Only certain systems and designs have been extensively tested against fire and blast.
Performance Operating Temperature Limits C Environment Resistance A
Space Restriction B Corrosion Protection B
Inspection Access A Mechanical Damage B
Removability B Life Cycle B

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