India s Leading Infrastructure Monthly On Methods, Materials & Machinery Vol. 33 No.

06 June 2020

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 www.cecr.in Advisory Editorial Board

Editor

Dr. R. Kuberan

Prof. Mahesh Tandon, Dr. P.R. Swarup, Dr. I.K. Pateriya, Dr. Ajoy K Mullick,
MD, Tandon Director General, Director (Projects), Former Director General,
Consultants Pvt. Ltd. CIDC NRIDA NCB
Executive Editor

Er. Vinay Gupta,

President, IIBE; President, ICI;
Director & CEO, Tandon Consultants Pvt. Ltd.

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Former Joint Director, NCB Consultant
Associate Editor
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4 CE&CR
CE&CRMarch
June 2020
 CONTENTS
CE&CR JUNE 2020 • VOL. 33 • NO.06
NEWSCAN
News 10
Construction Sector and COVID-19 14
International News 15
ENGINEERING MARVEL
Hong Kong-Zhuhai-Macau Bridge 18
FACE-TO-FACE
Mr. Debasis Bhattacharya, Head – Marketing, 21
Sales and Product Support,
AJAX Engineering Pvt. Ltd.
Mr. Alakshendra Singh, General Manager 23
Corporate Communication, Eros Group
TALL BUILDINGS
Wind Loads On Unique Building Facades 26
By Mr. Rahul P. S.
Needs And Challenges Of Multi-Storeyed Construction 30
By Dr. K M Soni
Chemicals For Enhancing Durability And 34
Passive Fire Protection Of Tall Buildings
By Ms. Ishita Manjrekar, Mr. Sourabh Manjrekar
FIBRE REINFORCEMENT
Polypropylene Micro Synthetic Fibres 36
For High Rise Building
6
FEATURE - REAL ESTATE
40 Mapsko Group Soaring New Heights
EARTHQUAKE RESISTANCE
42 Costonomial Earthquake Resistant Flat Slab
No Drop No Head Through Hidden Beam
By Dr. S.V. Deodhar, Er. Bhupendra Singh Thakur
CONSTRUCTION TRENDS
44 Construction Safety
RUNWAY CONSTRUCTION
46 Tight Timeframe No Problem For Tarmat
And Ammann India
FEATURE - CONCRETE PUMPING
48 Second Kolia Bhomora Setu Bridge Project
SPECIAL REPORT - CONCRETE PUMPS
50 Putzmeister India’ Concrete Pumps
SCAFFOLDING AND FORMWORK
52 Layher Allround Scaffold Ideal for
High Rise Industrial Structure
SPECIAL STORY - CRANES
54 Sparkline’s Overhead Industrial Cranes
SKID STEER LOADERS
55 CASE SR130
56 ADVERTISERS’ INDEX
CE&CR June 2020
 Technology Behind A
Mile-High Skyscraper
There could be at least a mile-high skyscraper by 2050. There is also likely to be a trend of
buildings over 3,200 feet high. The current record holder is the Burj Khalifa in Dubai, at 2,717
feet, or about half a mile. Its successor, the Kingdom Tower in Jeddah, Saudi Arabia, will
Dr. R Kuberan be the first building to surpass 1,000 metres or 3,281 feet when construction is completed.
To prepare for the next generation of supertall buildings – those over 300 metres or
984 feet – engineers are working on innovations such as carbon fibre cables for elevators
and mass dampers, weights that reduce sway from the wind. An elevator that uses magnets
instead of cables could move through buildings sideways.
from the editor’s desk

Rethinking Structural Design: As building and material science advanced, tall buildings
were designed on a tube system rather than a rectangular design of the earliest skyscrapers.
The tube works well to a point – the width and depth must rise in proportion with the height.
Pretty soon you end up with millions of square feet of mostly undesirable office space.
The Burj Khalifa used a buttressed core. A central hexagonal concrete core is supported
by three triangular buttresses, like the fins on a rocket. The tower is supported by a central
core, which is braced by 2-foot-thick concrete walls that line the double-loaded corridors in
each of the three wings in the tripodal structure.
Experts think it is possible to use the buttressed core design could be used to build a tower
mile-high tower. One variation under consideration would use a hollow base, like the Eiffel
Tower. The bottom would be open; otherwise, the ground floors would be too big to make
effective use of as the building rose to the sky.
Building Sway: The biggest problem from building sway is occupant comfort. Humans can
detect slight movements that pose no threat to the building. A light breeze at ground level may
feel like a hurricane 150 floors above, whipping the building enough to make people feel ill.
Many modern tall buildings incorporate a tuned mass dampener. The size and weight of the
damper are customized based on the mass and height of the building. The other approach is
not to fight the wind but confuse or redirect it. Buildings incorporate aerodynamic features
to ensure the wind can build up dangerous levels of pressure. Architects are learning to direct
the wind through and around the building use channels, fins and soft curves.
Modern Materials: Raising a supertall
building will require rethinking materials.
High-tech concrete reinforced with
microfibers in a complex recipe of super
materials could rival the compressive
strength of structural steel. Because it is
more massive, a concrete tower can have
the same resistance to the wind in a thinner
profile. Engineers are looking at aerospace
materials like carbon fibre. It is exceptionally
light, extraordinarily strong, and expensive.

8 CE&CR June 2020

nationalnews
DMRC Resumes
Construction Of Phase-IV   
T
he Delhi Metro Rail Corporation (DMRC)
has resumed construction work of its
much-delayed Phase-IV project and extension
of the Airport Express Line (AEL) and Grey
Line (Dwarka-Najafgarh).
DMRC had prepared a detailed standard
operating procedure for resumption of
construction work following the guidelines as
workers were available at its sites.
At present, DMRC has about 3,500 workers
available across five to six different sites in the city,
including actual work sites of Dhansa, Airport
Express Line expansion work in Dwarka as well
as sites and casting yards for Phase-IV projects.
The work is going on at its 1.2 km long
underground extension to Dhansa Stand.
Construction work has also resumed extending
AEL from Dwarka Sector 21 to exhibition-cum-
convention centre at Dwarka Sector 25.
NHIDCL Invites Bids For
Road Widening In Assam
T he National Highways and Infrastructure
Development Corporation (NHIDCL) has
invited bids for road widening of Loring-Thepi-
Ganapath Gaur Gaon section.
  The scope of work involves widening/
improvement to four lane with paved shoulder
from 81.000 km to 95.400 km (design ch 80.930
to 96.400) of Loring-Thepi-Ganapath Gaur Gaon
section (Package-4) of NH-29 in the state of Assam
under Bharatmala Pariyojana on engineering,
procurement and construction (EPC) mode.
 The estimated value of the project is Rs 176.4
crore with completion period of 18 months.
10
Tata Power SED Secures Rs 1,200 Cr Contract
T he Tata Power Strategic Engineering Division
(Tata Power SED), a division of Tata Power
Company, has signed a contract with the Ministry of
Defence, Government of India, for modernisation of
infrastructure of 37 Airfields of the Indian Air Force,
the Indian Navy and the Indian Coast Guard.
 The estimated value of the contract is around
Rs 1,200 crore. The work involves supply, installation
and commissioning of modern airfield equipment like
Cat II Instrument Landing System and Cat II Airfield Lightning System along with other Navigational
Aids and Air Traffic Management system, besides creating the required civil and electrical infrastructure.
 The contract has to be executed over a period of next four years. The contract is continuation of
the previous order with additional 37 airfields undergoing modernisation.
CMPDI To Implement CBM Projects
T he Central Mine Planning & Design Institute
(CMPDI), the exploration and consultancy
arm of Coal India, will be the implementing agency
for its proposed Rs 3,000 crore coal bed methane
(CBM) projects.
A memorandum of agreement (MoU) was
signed with subsidiaries, Bharat Coking Coal and
Eastern Coal Fields, for developing such projects
in their respective leasehold areas.
CMPDI will be the principal implementing
agency for the subsidiaries and facilitate methane extraction to supplement domestic demand
for gas and enhance safety of mines and coal production.
The first project is likely to be undertaken by Bharat Coking Coal, at Jharia coalfields in
Jharkhand.
The second project will be undertaken at Ranigunj in West Bengal by Eastern Coalfields.
NHAI Invites Bids For Flyover In AP
T he National Highways Authority of India
(NHAI) has invited bids for construction of
a flyover in the state of Andhra Pradesh.
  The scope of work involves construction
of three-lane western side flyover from design
0.300 km [existing 1098.680 km (before Jyothi
Mahal Junction)] to design 2.770 km [existing
1096.210 km (beyond Ramesh Hospital
Junction)] on NH-16 in Andhra Pradesh on engineering, procurement, construction (EPC) mode. 
 The estimated value of the project is Rs 99.72 crore with a completion period of 18 months.
CE&CR June 2020
 nationalnews
Work In Full Swing At Balanagar Flyover NHAI Opens NH-44
In Ludhiana For Traffic
T he Hyderabad Metropolitan Development Authority (HMDA) is
speeding up works at Balanagar flyover in Hyderabad, Telangana. All
efforts are being made to commence operations on the flyover by August T he National Highways Authority of India (NHAI) has
opened both sides of the NH-44 flyover, situated near
2020. Mohan Dai Oswal Cancer Hospital, for movement of traffic.
Work on the flyover was dragging on due to delay in land acquisition, The flyover is a part of Jalandhar-Panipat highway project and
traffic regulation and other reasons. Now, with the Greater Hyderabad has been hanging fire for around nine years.
Municipal Corporation (GHMC) almost completing the land and property The Sherpur Chowk flyover is expected to be completed soon,
acquisition and demolishing 357 structures, HMDA is executing the civil of which one side -- from Delhi to Jalandhar -- has already been
works on a war-footing.
opened for traffic.
HMDA is constructing the 1.13 km flyover at a cost of Rs 387 crore.
With the completion of the flyover, the traffic is expected to
Of this, Rs 265 crore is earmarked for land acquisition and the rest for
increase at Samrala Chowk
civil works.
as truckers who used to exit
The six-lane flyover
the highway from Moti
will be 24 m wide. The
Nagar point will now have
carriageway beneath the
structure is also being to exit from Tibba Road
widened from 30 m to point and move towards
45 m to facilitate smooth Transport Nagar through
flow of traffic. Samrala Chowk.

Work At Kashi Vishwanath Ammann’s Nationwide

Corridor Gathers Momentum Free Monsoon Check-Up Camps

A s many as six buildings of Kashi Vishwanath

Corridor have started taking shape ever since
construction works on the project, also known as
Kashi Vishwanath Dham project, restarted amid
the lockdown on 17 April 2020.
At present, some 155 workers and five engineers
are engaged in the project in Varanasi. The project is
being undertaken by Shri Kashi Vishwanath Special
Area Development (KVSAD) Board. PSP Projects
is working on construction of the temple platform,
passenger safety centres 1 and 2, spiritual book store and
refreshment centre. Four engineers of the state public
works department have also been deployed to ensure
quality of the construction as per the set standards.
The project is likely to be completed by June 2021.
Ammann India, which is the
country’s largest road construction
equipment manufacturer by value, has
announced a nationwide free monsoon
check-up camp for its Asphalt plants,
Pavers, Soil Compactors, Tandem
rollers and Pneumatic tire rollers, from
July 15 - October 15, 2020.
The customers can avail of free
check-up of Ammann Plants and
Machines, and discounts of up to 10% on Ammann’s original parts, lubricants and labour charges.
Commenting on the initiative, Sunil Sapru, Region Director, Ammann India operations
said, “At Ammann India, we put customers first. We aim to enhance the user experience
by providing best-in-class service to our esteemed customers. With our many decades of
experience and interactions with all project stakeholders, we thoroughly understand our
customer’s needs and hence are rolling out this monsoon service check-up camp beginning
15th July through 15th October, 2020. The larger objective of this initiative is to build a strong
bond with our valuable customers and offer them trouble-free performance of Ammann
Plants & Machines.”
During this free monsoon check-up camp, customers can avail of host of benefits like
free 60/30-point comprehensive health check-up of Plant/Machines by our specialists and
discounted offers on Operation and Maintenance Contracts, Annual Maintenance Contract.
Other sweeteners include special offers on Retrofit and Machine refurbishment, and training
on safe operating techniques by experts.

CE&CR June 2020 11

nationalnews
AP Govt To Auction Nine
Land Parcels
T he government of Andhra Pradesh intends
to auction nine land parcels as part of
its ‘Mission Build Andhra Pradesh’ initiative
to promote infrastructure development and
resource mobilisation.
The reserve price of these land parcels
has been fixed at Rs 208.62 crore. The state
government, along with with NBCC (India),
is auctioning vacant government land parcels
through e-auction on an ‘as is where is’ basis
in phases. Six land parcels in Visakhapatnam
and three in Guntur have been identified for
sale in Phase-I.
The reserve price of the identified parcels is
pegged at Rs 208.62 crore and the government is
expecting more than this in the auction.
MoRTH Invites Bids For
Road Improvement Works
In Assam
T he government of India, Ministry of Road
Transport & Highways (MoRTH), has
invited bids for road improvement works in
the state of Assam.
 The scope of work includes improvement
of existing single/intermediate lane of NH-44 to
two lane with paved shoulder from 230.200 km
to km 247.000 km, 261.504 km (ex ch 260/109)
to 263.191 km (ex ch 261.761) and 272.241 km
(ex ch 271.000) to 284.033 km (ex ch 284.053)
(total length-30.28 km) under SARDP-NE
(Phase-A) in Assam.
  The estimated value of the work is
Rs 139.49 crore with a completion period of 20
months, including rainy period.
12
J Kumar Infraprojects Receives LoA
J Kumar Infraprojects has received letter of acceptance from the Mumbai Metropolitan Region
Development Authority (MMRDA) for Mumbai metro rail project.
 The scope of work includes construction of part design and construction of balance works of
Package 1, Line-7 elevated viaduct (excluding stations and station viaduct, architectural finishing
and pre-engineered steel roof structure of station) from chainagech (-) 525.903 m (Pier P1E) to
ch (+) 5801.297 m (Pier P 278) Andheri (East)-Dahisar (East) corridor of Mumbai Metro Rail Project.
The value of the work is Rs 174.76 crore.
Indian Navy Invites Bids For Infrastructure     
T
he Indian Navy has re-invited bids for
infrastructure at Naval Base, Karwar in Karnataka.
The scope of work involves design and
construction of residential buildings/towers,
townships along with related common facilities
trunk infrastructure and utilities within site C1 and C2, including operation and maintenance of
elevators during elevators maintenance period at Naval Base, Karwar in Uttara Kannada district
of Karnataka through design-build works contract (DB-04).
 The estimated value of the project is Rs 1,100 crore.
Roads To Use Coir-Geo Textiles
T he Central government has planned to use coir geo-textiles in the construction of rural roads
under Phase-III of Pradhan Mantri Gram Sadak Yojana (PMGSY-III).
They will be used for construction of rural roads
under PMGSY-III. As per the PMGSY new technology
guidelines for road construction, 15 per cent length of
roads in each batch of proposals is to be constructed
using new technologies.
Out of this five percent roads are to be constructed
using Indian Roads Congress (IRC) accredited technology. Accordingly, 164 km of roads will be
constructed using coir geo-textiles in Andhra Pradesh, 151 km in Gujarat, 71 km in Kerala, 328 km
in Maharashtra, 470 km in Odisha, 369 km in Tamil Nadu and 121 km in Telengana.
UP RERA Gives Extension To Projects     
T he Real Estate Regulatory Authority (RERA) of Uttar Pradesh has given extension of validity
period for registration of real estate projects in the state by six months.
All registered projects for which the completion date expires on or after 25 March 2020, the
registration and completion date is automatically extended by six months due to the outbreak of
COVID-19 pandemic.
The Central government had issued an advisory on 13 May 2020 regarding extension of
registrations of real estate projects due to ‘force majeure’ under the provisions of Real Estate
(Regulation and Development) Act 2016 (RERA).
The authority also decided that the time limit for various compliances including any of the
previous quarterly progress reports and annual audit reports of projects which were due to be
submitted by 31 March 2020 is extended up to 30 June 2020 without any payment of late fee.
CE&CR June 2020
construction sector and COVID-19
Tata BlueScope Ramping Up
Health Infrastructure
T
o address the ever-increasing demand
for high quality, ready-to-install health
infrastructure, Tata BlueScope Steel have
introduced high strength, modular and quick
to install steel structures, which would help to
combat COVID-19.
EZYBUILD® the light structural steel building
solutions from Tata BlueScope Steel has designed
and developed customized life-care solutions in
form of Isolation & Quarantine units, Testing &
Sample collection booths and Doctor’s Cabins.
Mr. Riten Choudhury, MD Tata BlueScope
Steel said, “With COVID-19 pandemic,
optimizing healthcare facilities for the affected
is the need of the hour…At Tata BlueScope
Steel, we are committed to fight back the virus
with our easy to build and maintain structures
that are designed, keeping in mind patient’s
comfort and healthcare worker’s security.”
Legrand India To Facilitate
Quarantine Centres
L
egrand India, a global specialist in electrical
and digital building infrastructure has
initiated supporting the local Govt. in the
creation of quarantine centres and isolation
wards in Kolkata, Odisha and Chhattisgarh.
They are working with various government
stakeholders across the nation with electrical
products to be used for creating isolation wards
and quarantine centres.
Legrand is also supporting govt. hospitals
and quarantine centres with disposable isolation
beds to accommodate the migrant returns in
the respective districts’ quarantine facility.
The company is providing personal protective
equipment (PPE) to doctors and medical staff
in Tamil Nadu, Maharashtra, Delhi and Kerala
to support the frontline workers.
Legrand India has also provided 2.6 lakh
PPE to electricians, journalists (Chennai Press
club), NGO health workers, drivers’ community
and police officials.
14
RREL Becomes Highest Producer Of N-95 Masks
R ashmi Rare Earth Limited (RREL), the electronics
manufacturing unit of a multi-dimensional business
conglomerate, Rashmi Group has become the highest
manufacturer of N-95 masks in India.  Running at 85%
capacity, the plant currently manufactures approximately
2 lakh N-95 masks per day along with over 3 lakh surgical
masks.  
 RREL commenced manufacturing of masks in mid-
April. Utilizing the already existing space, set up and manpower at their facility in Noida, Uttar
Pradesh, RREL produces essential medical masks at an accelerated speed.
The company is also ensuring that they follow all government directives and protocols to the
‘T’. Also, to support ‘Make in India’ project by the Indian government, major raw materials are
being sourced from within domestic borders along with some imported machinery. 
Redevelopment Of Dehradun Railway Station
Witnesses Progress
A midst National Lockdown, Rail Land
de velopment Aut hor ity (RLDA)
successfully conducted the online pre-
bid meeting for the redevelopment of the
Dehradun railway station.
Over 22 developers including GMR Group,
Omaxe developers, Adani Road transport Ltd,
Mahindra Lifespaces, among others, participated in the meeting.  The meeting was attended by Vice-
Chairman, RLDA Sh. Ved Parkash Dudeja and Vice Chairman, Mussoorie Dehradun Development
Authority (MDDA) Sh. Ashish Srivastava.
The railway station will be developed under PPP model and the railway station’s mandatory
cost will be Rs. 125 Cr. After, finalization of eligible developers (bidders) through RFQ, request
for proposal (RFP) will be floated by RLDA sometimes in July-2020.
Sany Donates Masks To Govt Of Maharashtra
S upporting the Government of Maharashtra in its fight against
the COVID, Sany, a leading manufacturer in the construction
sector, donated 1 lakh N95 masks and 5 Lakh 3 Ply Masks to the
Government of Maharashtra through MIDC.
Mr. Deepak Garg, Managing Director, Sany South Asia &
Sany India handed over the masks to Shri Rajesh Tope, Minister
for Public Health & Family Welfare, Government of Maharashtra.
Garg said, “We firmly believe that the fight against covid
should be a combined effort of the government, corporate
houses/industries, healthcare professionals and the citizens in
general. Within the company, we are adhering to all possible measures to ensure the safety of all
our employees and stakeholders.”
CE&CR June 2020

TANZANIA
Construction Work Of
Stadium Project Begins
T anzania’s Dodoma Stadium project
has moved closer to the construction
stage following the completion of seismic,
topographical and feasibility studies. The
project has been in the pipeline since 2017.
The national government has already
acquired land for Dodoma Stadium project,
which is even more than the initial requirement.
The proposed mega stadium upon completion
will have the capacity to accommodate
between 85,000 and 1,00,000 spectators.
The delivery of the new stadium will put
Tanzania in a better position to bid for hosting
major continental events such as the Africa Cup
of Nations (AFCON), the African Canadian
Soccer & Cultural Association (ACSCA), as well
as other top athletics events.
EGYPT
Contractor Appointed For
ZED Sheikh Zayed Mega Project
O rascom Construction, a contractor, has
been appointed by Ora Developers to
build Phase-I of the ZED Sheikh Zayed mega
project in Egypt. Work on making the master
plan and architectural design of the project has
been completed by WATG International.
As per the terms of the contract, Orascom
Construction is required to build approximately
600 housing units in this phase, along with a
three-storey garage, a two-level mall, and four 17 storey apartment towers.
The initial phase will be financed by Banque Misr, following a loan agreement worth
approximately US$ 63 million signed with Ora Developers. ZED Sheikh Zayed mega project
will be built in six phases and upon completion, it will feature over 4,500 residential units and an
administrative commercial complex.
CE&CR June 2020 15
internationalnews
MALAWI
Construction Of Bridge
Commences
C
onstruction work has commenced on
Chimenya Bridge in Traditional Authority
(TA) Mkhumba in Phalombe district, Malawi.
Minister of Transport and Public Works
Ralph Jooma performed the ground breaking
ceremony for the project.
The bridge entailing an investment of
US$ 1,34,694 will be constructed along Phalombe
river. It will not only allow people of Mpasa and
Likulezi wards to connect with each other, but
it will also provide them access to markets for
their farm produce at the Boma and Mkando
in Mulanje.
  The construction is being done by the
Roads Authority with funds drawn from fuel
levy. The construction of the 30 m long bridge
is expected to take 120 days.
PAKISTAN
Pakistan Gives Green Light
To Indus Dam
A Chinese-Pakistani joint venture has
been awarded the project to build a
dam on the River Indus in the disputed
Kashmir region between India and Pakistan.
When completed in 2028, the Diamer
Bhasha dam, China’s first major civil
engineering scheme in Kashmir, will have
a 272-metre-high barrage, making it the
tallest roller-compacted concrete dam in
the world.
The project will be part of the China-
Pakistan Economic Corridor (CPEC),
making itself part of China’s Belt and
Road Initiative. It will have a generating
capacity variously given as 4.8 GW and
6 GW, and will be situated in the Pakistan-
administered region of Gilgit-Baltistan,
about 320km from the Chinese border.
In addition to power, the dam will
create a 200 sq. km reservoir, greatly
increasing Pakistan’s water security.
internationalnews
CHINA
Beijing Launches
First 5G Construction Site
C hina’s first construction site to use
5G technology has been activated
in Beijing, where around 40 contractors
building a high-tech business district
have upgraded their systems to make
use of a network that transmits data at
10 gb/second.
Among them are “AI glasses” that allow
engineers to see what workers are seeing
on site from their offices, and communicate
with them. Other applications that may
be deployed include robotics, multi-
dimensional, real-time monitoring, the
use of blockchain to verify information,
and the use of the internet of things to
automate progress reporting.
The site has also implemented a system
to monitor the health of each worker by
measuring 10 indicators, including blood
pressure and electrocardiography, and
issue physical examination reports.
China’s Ministry of Industry and
Information Technology issued its first
5G licence last year. The system on the
Yizhuang site is being provided by China
Unicom, a state telecoms company.
16
FRANCE UK
Vinci, Spie Batignolles Win Amey Wins £45 m Roads
€800 m Contract Upgrade Contract
A €800 m contract to build the first section
of a rail link between Orly airport and
Versailles has been awarded to a joint venture
between Vinci and Spie Batignolles.
The link, to be called Line 18 of the Grand
Paris Express, will initially run between Orly,
to the south of Paris, and the southwestern
suburb of Massy-Palaiseau. The work will
involve digging 12 km of tunnels and building
three stations, to be called Antonypôle, Massy
A mey Consulting has won the £45 m design
contract for the A66 TransPennine road-
dualling project.
Opéra and Massy-Palaiseau. The appointment was announced as
Vinci will take a 75% share of the Highways England unveiled its preferred route
joint venture. Its team will be led by Vinci for the £1 bn project, which will link the M6 at
Construction Grands Projets, and will also
involve Vinci Construction France, Dodin
Campenon Bernard and Botte Fondations.
Penrith in Cumbria with the A1(M) at Scotch
Corner in North Yorkshire. Arup will also work
on the design of the project.
The remaining 25% will be made up of Spie
Highways England is proposing upgrades
Batignolles Génie Civil and Spie Batignolles
including an underpass at the Kemplay Bank
Fondations.
roundabout near Penrith, a northern bypass
When fully complete in 2030, the Grand of a three-mile section between Penrith and
Paris Express will add four lines to the city’s rail Temple Sowerby and a northern bypass at
network, comprising 200 km of track – 90% of Kirkby Thore.
which will be underground – and 68 stations.
Other improvements set to take place
include a bypass at Crackenthorpe and dualling
a five-mile section between Appleby and
Brough, and a 1.9-mile section north of Bowes.
Improvements will also be made to the
existing junctions between Barnard Castle and
the A66 at Bowes and Rokeby.
ROMANIA
Astaldi Wins €356 m Contract For Motorway
I talian contractor Astaldi has won a €356 m
contract for a 30 km section of the Sibiu to
Pitesti motorway in Romania. Astaldi’s contract
involves work on Lot 5 of the motorway for the
state-owned CNAIR.
The engineering, procurement and
construction job is 85% funded by the EU, and
15% from Romania’s state budget. An advance Astaldi’s order backlog in Romania is now
payment is expected to help start work. worth €1 bn, and includes work on CNAIR’s
Work on the project will take five years, Braila Bridge, a 2 km-long suspension bridge
with one year dedicated to design and four for over the Danube, and 20 km of the Ogra to
construction. Campia Turzii motorway.
CE&CR June 2020
ENGINEERING MARVEL
Hong Kong-
Zhuhai-Macau Bridge
M
easuring 55 km-long, including connecting roads,
Hong Kong-Zhuhai-Macau Bridge (HZMB) is the world’s
longest sea bridge and the longest fixed link on earth.
It connects the west side of Hong Kong to Macau and the city of
Zhuhai in Guangdong province, China. HZMB is a project of national
and international significance; the desire was to ensure that it was
constructed to the highest standards. The three Governments and the
Authority completed the project with a target to achieve a 120-year
design life for the crossing, with normal levels of regular maintenance.
The 55 km crossing consists of three cable-stayed bridges,
boundary crossing facilities and link roads in the three cities, reducing
the travelling time between Hong Kong and Macau/Zhuhai from an
hour’s ferry ride to a 40-minute car journey. The functions of the bridge
is to meet the demand of passenger and freight land transport among
Hong Kong, the Mainland (particularly the region of Pearl River West)
and Macau, to establish a new land transport link between the east
and west banks of the Pearl River, and to enhance the economic and
sustainable development of the three places.
Construction
Preliminary design of the main bridge began in March 2009. The
construction started in December 2009 and was completed in February
2018. The 29.6 km-long Hong Kong-Zhuhai-Macau Bridge (HKZMB)
was inaugurated in October 2018. The total cost of the project was
RMB 120 bn ($17.3 bn), while $87 m in funding was sanctioned
for preliminary design and site investigation and $47 m for the
18
World’s longest sea bridge
preconstruction works initially. Hong Kong Legislative Council
approved an additional HK$8.8 bn ($1.1 bn) for the project in April 2012.
The project included the construction of HKZMB, Hong Kong
boundary crossing facilities (HKBCF), and a Hong Kong Link Road
(HKLR). It also included related infrastructure development such as
environmental protection, landscaping and drainage works, street
lighting, traffic control, and surveillance systems.
The Hong Kong Port is located on a piece of reclaimed land
of 150 hectares at the waters off the north-east of the Hong Kong
International Airport (HKIA). The port also consists a passenger
clearance building (PCB) which provides passenger clearance services,
vehicle clearance plazas (VCPs) and public transport interchanges (PTI).
Several types of plants were used to provide greenery and
colour in different patterns covering over 30% of the Hong Kong
Port. In addition to emphasising the green landscape, the project
contributed to sustainable development via creative engineering
design, including independent sewage treatment system, district
cooling system, eco-friendly building design, non-dredge reclamation
method, among others.
Structural Details
The structure consists of three cable-stayed bridges, three
artificial islands and one undersea tunnel spanning 55 km through
the Lingdingyang channel. The route connects the three major cities
of Hong Kong, Zhuhai and Macau on the Pearl River Delta – one of
the world’s busiest shipping channels.
CE&CR June 2020
 ENGINEERING MARVEL

Formed from pre-stressed concrete box sections, the bridge was

constructed using the balanced cantilever method. The total length of
the crossing is approximately 41.6 km, of which 12 km is in Hong Kong
territory and 29.6 km is in Guangdong. Forming a bridge-cum-tunnel
structure, the bridge comprises a double three-track carriageway.
It lands on two artificial islands created on the east and west of the
Hong Kong special administrative region.
A scheme using a bridge and tunnel combination was adopted for
The method advanced the construction progress, enhanced the
the main part of the crossing within mainland territory. It comprises
quality of works and reduced the risk of working at height. Different
land and marine viaducts about 9.4 km in length, a 1 km tunnel and
from the ordinary prefabricated modules, the roof modules were
a 1.6 km road section.
composed not only of structural steel frame, but also the pre-installed
building services, as well as architectural builder works and finishes,
Project Summary saving on-site construction time.

Environmental Innovative Reclamation Technology

12 km 13.4 km
29. 6 km
Hong Kong Link Zhuhai Link
Main Bridge
Road Road
The Promat team worked on the HZMB project for a number of
years. The designers chose the RABT curve up to maximum 1200°C
and determined the need for 25 mm thick PROMATECT®-H to be
fixed directly to concrete according to the design and regulatory
specifications. Approximately 290,000 m² of PROMATECT®-H and
8,000 tubes of 600 ml PROMASEAL®-A Acrylic Sealant are employed
in the HZMB tunnel, making it one of the largest fire resistant board
construction jobs for the tunnel segment business of Promat worldwide.
Non-dredge reclamation was the first-ever reclamation method
adopted in Hong Kong. It greatly cut the amount of dredging and
dumping of marine mud by about 22 million m3 and reduced the use
of approximately half of the backfilling material.
This led to a lower impact on water quality and less marine
construction traffic during the building stage. This helped to preserve
marine ecology, especially the habitat of the Chinese white dolphins.
Long-Span Viaducts
The HKLR viaduct section features long spans as the carriageway
crosses two navigation channels and Sha Lo Wan Headland, a
designated Site of Archaeological Interest, where no construction

Challenging Iconic Design With An Innovative

Construction Method
With a wavy roof designed to simulate undulating waves, the
passenger clearance building (PCB) is an iconic building standing at
the Hong Kong Port next to the airport.
To tackle the challenge of airport height restrictions, an
innovative construction method was adopted to construct the PCB’s
roof by using the prefabricated modules assembly method. The
large-scale prefabricated modules were lifted one by one, pushed
into position horizontally and connected together.  Problems posed
by the huge size, as well as the airport height restrictions, were
overcome.

CE&CR June 2020 19

ENGINEERING MARVEL
works were allowed. A massive, bespoke straddle carrier was used
to construct the long-span viaduct of 180 m in length. At the time it
was erected, it was the longest, dual three-lane pre-stressed precast
concrete bridge span in Hong Kong. The design minimised the visual
and environmental impact and has also become a feature of the area,
complementing the natural scenery of North Lantau.
Innovative Methods Adopted
The HKLR viaduct, mainly situated at open waters, is the first bridge
in Hong Kong to adopt pre-stressed precast pier construction method
and precast concrete pile cap shells to minimise underwater works. This
ensured a safer working environment and eliminated tidal constraints.
Floating concrete batching plant was introduced, which was the
first of such facilities in Hong Kong and significantly reduced the
logistics and ensured the best quality of concrete produced.
The construction of two separate tunnel tubes of the HKLR to
cross under the existing Airport Express Line (AEL) is one of the most
challenging works for the HZMB project in Hong Kong.
As the AEL is an important railway link between Hong Kong
International Airport and the central business district, the normal and
safe operation of the AEL must be maintained at all times.
To ensure undisrupted operation of AEL during the tunnelling
works, box jacking was adopted – the first time it was used at such
scale in Hong Kong. It involved pushing the constructed tunnel box
20 CE&CR June 2020
segments forward by hydraulic jacks sequentially in a ‘caterpillar’
motion, with a design jacking force of 19,400 tonnes – enough to lift
70 empty Airbus A380s in one go.
Challenges
Besides the large scale of the project, there were a range of
physical conditions to be overcome during the construction of HZMB,
including the sub-tropical weather, typhoons, heavy rain, and the
hydrology and hydrodynamic aspects of the Pearl River estuary. Other
factors included the geotechnical complexity of the site, the multiple
navigation channels with high numbers of shipping movements
and height restrictions for nearby airports. The HZMB also crosses
environmentally sensitive areas — particularly the conservation area
of the Chinese White Dolphin — which meant that high standards
of environmental protection were set to minimise any effects on the
marine ecosystem and fishery resources.
References
1. https://www.arup.com/projects/hong-kong-zhuhai-macau-bridge
2. https://en.wikipedia.org/wiki/Hong_Kong%E2%80%93Zhuhai%
E2%80%93Macau_Bridge#Sections_and_elements
Amrita Batra
Associate Editor
Civil Engineering and Construction Review

“AJAX Is All Set To Bounce Back With
Resilience And Resourcefulness Like Ever”
Mr. Debasis Bhattacharya
Head – Marketing, Sales and Product Support
AJAX Engineering Pvt. Ltd.
“To set the ball-rolling, AJAX has become
more resilient, adaptive and competitive like
ever in this complex and uncertain period of
pandemic with resilience and resourcefulness”
says Debasis Bhattacharya, Head – Marketing,
Sales and Product Support at AJAX Engineering
Pvt. Ltd., in conversation with Civil Engineering
and Construction Review.
Civil Engineering and Construction Review: How has
your organization strategized to tackle this sudden
pandemic and economically challenging scenario?
Debasis Bhattacharya: AJAX has evolved over time by
adapting to the needs of its customers with a clear and
consistent goal towards becoming the most customer-
centric organization with a strong customer focus.
AJAX has become more resilient, adaptive, and
competitive in this complex and uncertain period of
pandemic. We have a strong focus on the capabilities
needed to succeed in the constantly changing market
dynamics, especially, in this COVID-19 pandemic time,
thanks to our technological innovations that have been
CE&CR June 2020 21
face-to-face
able to meet up the challenges and continuously align with the fast-changing
industry trends amidst lockdown.
With the sudden emergence of a deadly new coronavirus, we had instilled
the right confidence into our work-force to face the uncertainty phase with a
clear mind, a new set of collaborative principles, coherent thought process,
more cohesive effort to engage our customers.
In the RESPONSE/RECOVER phase of COVID-19 outbreak, AJAX has leveraged
its capabilities with a strong network of over 100 touch points and over 30
dealers with triple S facilities – sales, service, and spare parts. We add value
to our close to over 18,000 satisfied customers. They have seen, realised and
experienced the value we have brought in. And we will keep on adding value
to our customers. AJAX keeps in touch with all its stakeholders through digital
channels and leverages digital solutions to engage customers, provide support
and add value-propositions that are unique to them.
CE&CR: Focus of Innovation as a way of life at AJAX amidst lockdown.
Debasis Bhattacharya: The big takeaway is to see what’s possible when innovation
is in AJAX’s DNA. Describing the focus of innovation at AJAX, AJAX has always strived
to be a ‘360° concreting solutions provider’ to its customers, and the company is
moving towards artificial intelligence and other advanced manufacturing concepts.
AJAX self-loading concrete mixers are versatile and have hydraulic sensing,
meaning a pressure transducer and a device to add the weigh batching of
aggregate, cement, and water. AJAX has been focusing on improving the accuracy
of weigh batching that is critical in the quality of the concrete. Of late, we have
come up with a load cell-based weigh batching system (patent pending).
During EXCON 2019, AJAX also launched a first-of-its-kind next-gen self-
propelled boom pump, SPBP25ZX. This patent-pending product has been
designed to handle tough terrain and manoeuvre narrow roads and job
sites at ease, and effectively use its full boom length to revolutionize the way
concreting is being done in housing and infrastructure projects.
AJAX slip form paver SPX1204, the first indigenous paver designed and
manufactured in India launched during EXCON 2019 has been incorporated with
high-quality components and features on par with any of the pavers offered by
the global players. This paver has flexibility to offer paving width varying from
3.5 m to 12 m.
CE&CR: In your opinion, tell us about the possible impact the situation will
have on India’s manufacturing sector and on the economy.
Debasis Bhattacharya: “India would witness a big slump in the current and
coming quarter; however, it is all set to bounce back post recovery of this
face-to-face

COVID-19 pandemic stated by leading financial rating agencies.

This would drastically affect the construction equipment sales in
India that are expected to drop very significantly during FY 202-2021
due to this coronavirus outbreak. Our Construction Equipment (CE)
industry is also set to bear the brunt of the effects of COVID-19. This
pandemic has dented our economy very badly, impacting the overall
CE industry growth with severe repercussions on the future growth
prospects. But, the full financial impact of the coronavirus crisis cannot
be gauged right now as it will be too early to assess. Even after the
crisis is brought under control and construction works start to roll,
the upcoming monsoon will be another big blow that will add further
onus onto the growth and severely impedes the construction works
likely from June 2020 onwards.

CE&CR: Post-lockdown what would be your organisation’s

agenda to sustain a possible market slowdown/downfall.
Debasis Bhattacharya: AJAX is geared-up to fight the slowdown
blues. To set the ball-rolling, AJAX has come up with the rebound
strategy, a detailed business continuity management plan that enlists
a set of protocols and standard guidelines that would comply with the
newly established norms and regulations by our Government for safe
and best practices. This would be religiously followed in the factories,
offices, and business establishments of AJAX pan India.
When organizational preparedness being the real key to combat
post COVID-19 lockdown with resilience and resourcefulness, AJAX
will redo the Value-stream mapping across their supply-chains as this
would deem to be a right opportunity to rethink, revisit, reinforce
our supply-chains.
1. Channel partners: Distribution strategy/delivery model as a
defragmented channel structure thro’ integrating dealer network
over the digital platform is being contemplated by AJAX.
2. Efficiency accelerators: Firstly, with social distancing norms at
factories, logistics, and warehouses, the need for reducing people
density across the supply chain has become a mandate now and
AJAX would chart out a plan for that by deploying ‘alternate
shift’ practices in the factories. Secondly, with the elimination of
non-value added activities that would improve the value of its
products and services, AJAX would look into optimizing direct
and indirect cost that would result in significant cost reduction,
strengthening cash flow and emerging from this downturn with
a stronger and more competitive profile.
3. Digitization: As the entire nation is struggling to cope with this
outbreak and all sectors face some form of disruption, COVID-19
is silently shaping business transformation. AJAX is active in the
digital platform and maintains a strong digital footprint. This
helps AJAX underscore the importance of digital transformation
by providing unparalleled opportunities to offer personalized
service to customers. Customer focus, as a way of life is the basis
for AJAX’s digital transformation decisions.
CE&CR: What is the need of the hour from the government post
covid-19 scenario?
Debasis Bhattacharya: In the wake of slowdown like this, liquidity is
one of the major challenges that has adversely impacted construction
equipment sales as well as the rate at which projects are completed. It
is one of the major areas of challenges what the CE industry is facing
today. There have been some delinquencies especially contractors
not getting paid by the principal clients. Customers have become
hesitant to new equipment, especially first-time buyers. But we
expect reasonable amount of business soon. There is no dearth
of projects, but financial closure has become an alarming issue.
Delinquencies, especially contractors not getting paid by principal
clients is a concern as is the diversion of funds from infra-related
projects to social spending. Customers have become hesitant to buy
new equipment, especially first-time buyers. CE industry is looking for
a good stimulus in infrastructure and housing industry to pave the
way for the economy to get rolling and to reinvigorate confidence
in the construction sector.

22 CE&CR June 2020


“The Plea For Affordable Housing Is
Expected To Stay High”
Mr. Alakshendra Singh
General Manager Corporate Communication
Eros Group
EROS Group is a recognized real estate giant
in India with special strength in and around
Delhi. The group has created some of the most
pioneering episodes of real estate promotion and
town planning for a period of over 70 impressive
years. Mr. Alakshendra Singh, in conversation
with CE&CR, shares his views on affordable
housing, its demand-supply scenario and effect
of the pandemic on the real estate sector.
Civil Engineering and Construction Review: What is
your take on affordable housing and what is your
company doing in that direction?
Alakshendra Singh: As we are going through a
tough time, I must say that affordable housing section
with the existing crisis is likely to be one of the worst
affected due to the COVID-19 epidemic, as concerns
over the target audience’s restricted income and
joblessness continue to rise. This section has been
CE&CR June 2020 23
FACE-TO-FACE
leading the sales traction in real estate for the more than a year. Also, the
government has set an aspiring goal of providing ‘Housing for All by 2022’.
It is projected that the government would continue to deliver additional
push to affordable housing once the crisis gets over. Also, as the relocation
of people belonging to lower income from rural and semi-urban areas to
urban areas endures unabated, the plea for affordable housing is expected
to stay high.
We have our affordable housing project in Greater Noida in the name of
Eros Sampoornam. This is our first group housing project in Greater Noida,
where we have invested almost 225 crores. It is a RERA register project.
CE&CR: Which challenges are being faced by the Delhi-NCR realty
segment, owing to the several instances of malpractices by some
builders?
Alakshendra Singh: There have been some mutual problems confronted
by most of the financiers and buyers in the real-estate market. The most
common concerns that are met by them are the deferrals in projects, high-
price, poor quality of building and modifications without prior information.
Apparently, due to the influx of new act like RERA, all such problems will no
more be in the picture.
The act’s main purpose is to preserve transparency in the market. While
there is a necessity for developers to make certain they are compliant with
new rules, buyers too should change their viewpoint about the market now.
The government should also try and make the land bill unchanging to promise
better land procurement. Also, the single window clearance would bring in
several agreements on time.
CE&CR: Tell us something about the current residential properties’ demand
and supply scenario.
Alakshendra Singh: The unparalleled effect of COVID-19 is now intimidating
to change the demand and supply scenario. The real estate industry has
already started to witness a radical fall in sales, which in the backdrop of
the high inventory held by realtors, should also end in a drop in prices. The
affordable housing section, which had raised a significant amount of grip
over the last few years, may also take a hit by COVID-19. The epidemic will
significantly upset affordable housing’s target audience. With limited salary
and employment fears, buyers of affordable housing may defer purchase
choices, leading to a rise in certain percentage of unsold stock within this
segment in 2020.
FACE-TO-FACE

CE&CR: What are the improvements needed

in government policies to streamline the real-
estate business?
Alakshendra Singh: The Indian economy and
particularly, the real estate sector is going
through a stimulating phase now. However,
the affordable housing section has also started
feeling the impact of COVID. The realty sector
is no doubt observing a stagnancy in new
projects, but the affordable housing segment
is moving comparatively fast. To rationalise
the Indian real estate sector, government
needs to take additional steps to implement
RERA. The industry has been for a long waiting
for quicker/single window allowance since
long. A faster window will help in justifying the cost of growth CE&CR: Going forward, what are the opportunities that you are

and make real estate more affordable.
The government should also take steps to restore the fresh
NBFC crisis that has exaggerated developer subsidy in the country.
Despite the recent revitalisation in the market, Indian real estate
suffers from an enormous quantity of unsold inventory and deferred
projects, and therefore, necessitates systematic involvement from
the government and regulatory bodies.
The industry also anticipates justification of taxes by inclusion
stamp duty under GST. This will give an additional thrust to the
business by easing out the cost of progress.
seeking in the ‘Smart Cities’ domain?
Alakshendra Singh: The growth of a smart city grants an
enormous prospect, mainly from the real estate viewpoint. The
very nature of these smart cities - the setting up of information
and communications equipment facilities fixed with social facilities
would make them very beautiful; specifically, the services sector.
Growth of technologically bigger workspaces, which offer facilities
such as smart workstations, very high speed Internet, etc., at
reasonable rates, is sure to lure organisations to shift focus to such
newer locations. These could also include IT SEZs, proving to be
eye-catching destinations for IT companies.

24 CE&CR June 2020

TALL BUILDINGS Wind Effect
Wind Loads On Unique Building Facades
Rahul P. S.
Regional Technical Head/Associate,
RWDI Consulting Engineers India Pvt. Ltd.
W
hen it comes to the design of any kind of structure, there
will be always multiple levels of discussions regarding
the structural design and its implications. It is true that
structural layout is the backbone of any design and hence, it should
be properly scrutinized. But at the same time, the exterior cladding
or glazing also needs proper attention from the conceptual stage
onwards, because it is evident from all the previous extreme wind
events that the cladding elements are the most vulnerable part in
any structure. With the advancement of latest technologies, the
conventional façade elements are also improved not only in term
of its aesthetics, but also in its performance in all other aspects. In
this article, we discuss how to design a unique building façade of a
high-rise building to withstand the wind pressures, by making use of
advance testing and analysis methods.
Introduction
The first thing that we notice about any structure is its outer
appearance. Even though it is true that we should not judge a book
by its cover, the external appearance and aesthetics of a building is the
first thing that draws our attention, and this is heavily dependent on
the external cladding elements. Nowadays, there are a lot of advanced
cladding systems which are very good looking and highly effective in
terms of their performance in enhancing the building performance
and providing better user experience.
Among the various advanced techniques used in façade claddings,
multi-layered façade or double-skin façade is one of the most widely
used system, in which the two layers of the façade are separated by a
Fig. 1: Advanced Cladding Systems with Multiple Layers
26
gap in the range of 0.5 m to 3 m. A few advanced cladding systems,
with multiple layers are shown in Fig. 1. A major source of concern in
the performance of these building envelopes, is their susceptibility
to rainwater penetration. Screened wall systems use an additional
exterior layer, the screen (outer wall layer or rainscreen), to keep the
rainwater out of contacting the inner wall layer or air barrier. Further,
a cavity is often placed in screened wall systems to provide gravity
drainage and capillary break in case of any rainwater penetration
through the screen. Pressure Equalized Rainscreen approach to
wall design has been suggested to minimize the wind-induced
pressure difference across the outer wall layer and thereby, reduce
the rainwater penetration through the screen. This wall system is a
special case of the modern screened wall systems. The wind loading
on this type of complex cladding systems are quite different, when
compared to conventional cladding systems; hence, special attention
is needed to understand the flow patterns through these multiple
layers of façade systems.
The building considered in this article is a high-rise structure,
which consists of a 2-layer façade system with a gap of about 2 m
between the layers. The external façade is a complicated one made
of flat panels and glass fins. The glass fins are placed with a clear gap
of 1.2 m between them, while the clear gap between the flat panels
are 0.25 m. Wind can flow through the gaps in the external layer and
can pressurize the cavity between the two layers.
Wind Effects On Conventional Façade Systems
Typically, the pressures acting on the conventional exterior façade
systems are determined through wind tunnel tests carried out in a
boundary layer wind tunnel, as shown in Fig. 2. The technique that is
used to make these predictions consists of conducting a wind pressure
study. The basis of the approach is to instrument a rigid wind tunnel
model of the building with pressure taps that adequately cover the
exterior areas exposed to wind. The test model (study model and
surroundings) is mounted on a turntable, allowing any wind direction
to be simulated by rotating the model to the appropriate angle in the
wind tunnel. The wind tunnel test is typically conducted for 36 wind
directions at 10° intervals. The mean pressure, the root-mean-square of
pressure fluctuations, the peak negative and peak positive pressures
are measured at each tap using a system capable of responding to
pressure fluctuations as short as 0.5 to 1 second at full scale. The
measured data are converted into pressure coefficients based on the
measured upper level mean dynamic pressure in the wind tunnel.
CE&CR June 2020
Wind Effect TALL BUILDINGS
Fig. 2: Boundary Layer Wind Tunnel with Study Buildings and Surrounding
Buildings
Fig. 3: Peak Pressure Distribution on
the External Facades Presented as
Block Diagram
CE&CR June 2020 27
For elements exposed to
wind on the external surface only,
an internal pressure allowance
must be applied to the measured
external pressure to determine
the net pressure applicable for
design. In strong winds, the internal
pressures are dominated by air
leakage effects. Important sources
of air leakage include uniformly
distributed small leakage paths over
the building’s envelope. Further, the
wind loads provided after wind
tunnel tests are net pressures,
which include an allowance for
wind-induced internal pressure
based on a building without any
large or significant openings.
To obtain the net peak negative
pressure on the building’s cladding,
the negative exterior pressures
were augmented by an amount
equal to the positive internal
pressure. Likewise, the net peak
positive pressures were obtained
by augmenting the exterior positive
pressure by an amount equal to the
magnitude of the negative internal
pressure. For elements exposed to
wind on opposite surfaces such
as parapets and canopies, the net
pressure acting on the element was determined by measuring the
instantaneous pressure difference across the element.
Once the wind tunnel tests are over, the net wind loads acting
on the cladding elements are determined by accounting the
contributions from the external surface (measured directly on the
scale model during the wind tunnel test) and internal surface of
the element (determined through analytical methods and the wind
tunnel test data). Finally, a summary of the expected peak positive
and negative wind pressures acting on the exterior envelope of the
structure are provided, as shown in Fig. 3.
Procedure For Determining The Wind Loads On
Multi-Layered Facades
In the design of advanced façade systems like the double skin
facades or similar multi-layered façade systems, conventional wind
tunnel tests conducted at a model scale of 1:300 or 1:400 may not
be enough because of multiple reasons. When there are multiple
layers of façade, there are two types of flow scenarios occurring in
these systems: one is the flow through the exterior layer of the façade
and second one is the flow through the gap between the exterior
and interior layer. Typically, in 1:400 model scale wind tunnel tests,
both these flows, i.e., flow through the exterior façade, as well as the
flow through the gap between the layers becomes quite small. As a
result, the flow through the gaps becomes laminar, whereas the flow
is turbulent in full scale. So, to address this issue, initially the wind
tunnel test at 1:400 model scale will be carried out in which both the
external pressures on the inner layer and the net pressures acting
across the external layer are measured. Then these pressures will be
modified or adjusted by a factor obtained from a large-scale model
test conducted for a specific section at 1:50 or 1:100 scale. The issues
with the 1:400 model scale test mentioned above can be adjusted by
this large-scale model test.
Details Of 1:400 Scale Model Wind Tunnel Test
The wind tunnel tests were carried out on a 1:400 scale model
of the building in the presence of all existing and in-construction
surroundings as shown in Fig. 4. The tests were carried out in RWDI’s
2.4 m x 2.0 m boundary layer wind tunnel facility. In addition to
the surrounding buildings, the impact of the upwind terrain on
the planetary boundary layer was simulated by incorporating
appropriate roughness elements on the wind tunnel floor and flow
conditioning spires at the upwind end of the working section for
each wind direction. This simulation and subsequent analysis of the
data from the model was targeted to represent open and suburban
upwind terrain conditions simulating realistic condition of the site.
All pressure measurements were carried out with a free stream wind
velocity of about 15 m/s.
TALL BUILDINGS Wind Effect
Fig. 4: Wind Tunnel Study Model with Surroundings at 1:400 Scale
Details Of 1:100 Scale Model Wind Tunnel Test
Due to the unique two-layer façade system of the tower, a
large scale (1:100) model was constructed and tested to obtain
greater resolution of the cladding wind load predictions. In the
1:100 scale model, two sections of the tower which replicated all
important different façade conditions were selected and taps were
installed for measuring wind pressure on the interior and exterior
facades, as shown in Fig. 5.
Fig. 5: Wind Tunnel Study Model at 1:100 Model Scale
The distribution of taps reflected a higher concentration of taps
than would be possible at a smaller 1:400 scale. The scale model
of the tower sections was instrumented with a total of 204 taps.
28 CE&CR June 2020
Two rows of taps were simulated approximately at 2/3rd and 1/4th
heights of the tower, covering conditions such as net pressure
across glass fins, net pressure across solid panels and pressures
on interior facades with various external façade conditions, as
shown in Fig. 6.
Fig. 6: Pictorial Representation Showing Large Scale Model Sections
During the test, the blockage within the wind tunnel cross-
section was kept to a maximum ratio of 10% by truncating the
model height and by raising the roof of the tunnel. Splitter plates
at the top and bottom of the instrument section were used to avoid
unrepresentative 3D flow conditions around the 1:100 scale model.
For these tests, the same wind profiles used in the 1:400 scale model
tests were simulated since it placed the instrumented tower sections
at approximately the same heights as in 1:400 scale model. Velocity
scale factors were applied directly to the test data on a direction by
direction basis, to account for any remaining mismatches between
the wind flow properties of the 1:100 and 1:400 scale tests. These
tower sections were placed at appropriate heights with the rest being
non-instrumented parts.
Comparison Of Results Between 1:400 And 1:100 Model Scale Tests
First, the external pressure coefficients were compared between
the two model scale tests. Based on the comparison, it was noted
that the external pressure coefficients on exterior façade as well as
Wind Effect TALL BUILDINGS

on interior façade, behind the glass fins, matched reasonably well and the interior façade (external pressure from wind tunnel data and
between the different scales of test, indicating that it is viable for us internal pressure determined through analytical methods).
to use a majority of the 1:400 scale test results. We can safely conclude During the final stages of the analysis, the derived peak negative
that the flow at 1:400 scale test is adequately representative of actual pressures and peak positive pressures were plotted at corresponding
flow for determining cladding loads in those regions. However, some tap locations. Thereafter, taps with similar pressure values have been
differences between pressure coefficients (Cp’s) were observed while categorized into a particular pressure zone. The pressure zones
comparing the external pressures on the interior façade behind flat
have been created with 0.25 kPa increments so that the pressure
panels. Mainly, the Cp’s were reduced in some cases in the 1:100 scale
indicated the maximum pressure in that particular zone. A sample
test, especially in the middle of the façade. This could be due to the
recommended peak negative pressure diagram corresponding to the
increase in time lag in 1:100 scale test in comparison to the 1:400 scale
top portion of the east elevation, which is shown in Fig. 7, where the
test where the pressure equalization may be more due to the smaller
recommended cladding pressures for design are provided for both
gap volume. This way, the induced pressure on the interior façade is
exterior and interior facades. Similar pressure diagrams corresponding
reduced. However, since the differences are minor and 1:400 scale test
to all the elevations and roof plan are provided to curtain wall
results are slightly conservative, 1:400 scale test results were used for
consultant for the appropriate selection of cladding elements.
all the external pressure calculations on exterior and interior facades.
However, the time lag differences between the tests became
obvious while comparing the net pressure coefficients across the
exterior façade. In 1:100 scale test, the time lag is more, considering
the larger gap volume; consequently, higher net pressures across
the exterior façade were experienced. In the analysis, the ratio of net
pressures to the external pressures were determined at all the tap
locations in 1:100 scale tests and the trends were captured. Further, the
exterior façade was categorized into zones based on either glass fins or
flat panel, and edge or central regions. For each zone, an appropriate
ratio (net/external) was derived based on 1:100 scale test. These
factors were then applied to 1:400 scale external pressures to obtain
the net pressures on exterior façade. For edge regions, the external
positive pressures had to be amplified to get appropriate net positive
pressures across the façade. This could be due to bleeding of flow
across the edges in the gap. Also, at the central regions, the external
positive pressures had to be reduced to obtain net external positive
pressures, due to pressure equalization. In general, the net negative
pressures at most of the regions were lower than the corresponding East Elevation – Exterior Façade East Elevation – Interior Facade
negative external pressures. The exterior façade acts like a shroud, Fig. 7: Sample Recommended Pressure Diagrams
reducing negative pressures overall.
Conclusion
Recommended Cladding Design Loads The advanced facades of tall buildings are becoming increasingly
The design coefficients were converted to pressures based on the complex, considering the functional requirement of rainwater
reference dynamic pressure determined corresponding to the 50-year penetration resistance, ventilation, resistance against solar radiation,
return period wind speed. Further, the site-specific directionality of the aesthetics, etc. In two-layer façade systems, wind loads on both layers
wind was combined with the directional pressure values of the taps to need to be determined for the proper design of these systems. Wind
come up with a single recommended pressure value for each tap location. tunnel testing is a way to determine the wind loads on two-layer
For the design of cladding elements, the net wind load acting across façade systems; however, traditional small-scale model tests may not
an element must be considered. The results were provided in the form be sufficient. At times, larger scale model sections must be tested to
of wind loads acting on both the exterior façade (net wind pressure confirm/modify the findings of the small-scale model tests, which will
measured directly on the scale models during the wind tunnel tests) help to design the advanced façade systems.

CE&CR June 2020 29

TALL BUILDINGS Challenges

Needs And Challenges Of

Multi-Storeyed Construction
(iii) Aesthetic: Tall buildings have more aesthetics due to its aspect
Dr K M Soni ratio and the architectural features that can be incorporated in
Addl. Director General (Retd.), such buildings.
CPWD, New Delhi
(iv) Sturdy and Quality Construction: High rise buildings are
designed by well-known architects, structural engineers, and
constructed by big and capable construction firms due to high
cost and intricacies involved; hence, the quality is good.

W
ith rise in population and growth, multi storeyed
construction has become a necessity for Greenfield as well
as Brownfield development, particularly in metropolitan
and their satellite cities. Apart from this, coastal cities have limited
space and Brownfield development will also be taken up with multi
storeyed structures through redevelopment. Redevelopment of
Bhendi bazaar in Mumbai and east Kidwainagar of New Delhi are
examples of such Brownfield development.
Multi-storeyed structures are now classified in many categories.
Terms like mid-rise, high rise, skyscrapers and super tall buildings
have come up. Mid-rise buildings are said to have 4 to 12 storeys,
high rise 12 to 40 storeys, skyscrapers more than 40 storeys with
height less than 300 m, and super and mega tall multi storeyed
buildings are those exceeding 300 and 600 m height, respectively.
This shows how tall buildings are gaining importance all over the
world.
(v) Well Ventilated: Pollution level at upper floors in high rise
buildings is generally low, whereas at lower levels, various
services are designed. Further, ventilation and panoramic views
attract many to opt for high rise buildings.
(vi) Energy Efficient: Good ventilation, and use of lightweight
materials, recycled water and energy efficient materials make
the buildings energy efficient. Mostly, such buildings are also
designed as green buildings.
(vii) Fascination: Some architects, builders and planners are
fascinated by tall buildings, and as such, they plan to construct
high rise multi-storeyed structures. They prefer to go for tall,
highly aesthetic, unique, and expensive buildings for certain
class of rich people, resulting in higher profit despite high cost
and investment.

Need For Multi-Storeyed Buildings

Multi-storeyed buildings are adopted due to the following
reasons:
(i) Cost-effective Construction in High Land Cost Areas: In
case land cost is very high, multi storeyed construction is cost-
effective, as land cost gets distributed over large number of units
being constructed because such construction has large built up
area over small ground coverage. Most of the metropolitan cities
and their suburbs have high land cost.
(ii) Space Constraints in Coastal Cities: Since in coastal cities, land
is limited, vertical construction must be preferred. Therefore,
multi storeyed buildings are preferred in coastal cities with low
Petronas Twin Towers, Burj Khalifa Tower, Dubai
land coverage. Kuala Lumpur, Malaysia

30 CE&CR June 2020

Challenges TALL BUILDINGS

(viii) Iconic buildings for publicity: Tall buildings are also
constructed for publicity. A builder, architect, individual
owner or even government may opt for construction of iconic
buildings that are highest or unique in a city, state, country or
even world. Cities, towns, and countries are then known by
these buildings. Petronas twin towers of Malaysia, Burj Khalifa
of Dubai, Kingdom tower of Jeddah (under construction),
Shanghai tower of China, Imperial towers, Polais Royale (under
construction), World one tower of Mumbai and Spira tower
(under construction) of Noida, are some of the examples
role for minimising wind forces and as such, circular, chamfered
cornered square or nearly circular and square shaped buildings
are preferred.
Light Weight Structure
High rise structures are designed as lightweight, making selection
of materials for structural and non-structural members a challenge
during planning and execution. It becomes essential to make use of
high-performance concrete (HPC), pre-stressed concrete, composite
construction with steel, high strength steel, light weight masonry for

which have actually made cities famous and the buildings
have become synonymous to the cities or countries. They have
also provided worldwide publicity to the architects, engineers,
builders, owners, and governments.
It is not always that multi-storeyed construction has only benefits,
it does have some limitations like higher maintenance and O&M cost,
higher requirements of fire safety measures, higher risk of damage in
case of failure of structural/non-structural members due to disasters.
Tall buildings have many challenges in investigations, architectural,
structural and MEP designs, construction, and maintenance. Some of
these are discussed here briefly:
Geotechnical Investigation
Foundation of high-rise structures needs special attention, both
during geotechnical investigation and construction. Basic principle
of geotechnical investigation is to go deeper and deeper as buildings
are planned higher and higher. Further, special design of foundation
may also be required with detailed analysis.
Provision Of Basements
Since, there is large requirement of parking and services in case of
high-rise buildings, provision of basements becomes almost essential,
and as such construction of basements, retaining walls, diaphragm
walls and underground waterproofing pose a challenge for designers
and engineers.
walls and partitions, etc.
Provision Of Efficient Plumbing Services
Plumbing services are critical in high rise structures. Designing
of water storage, water pressure at various floors, recycled water
system, soil and waste drainage system, and rainwater piping are
challenging tasks, along with maintenance and repair of plumbing
services.
Efficient Vertical Transportation System
Vertical transportation system must be highly efficient and fast in
case of high-rise buildings, particularly if used in a single run. Super
light rope technology with a carbon fibre core and high friction
coating or further advanced technology will be favourable. Though
large number of elevators may be required in present times, but in
future, these will be optimised considering the advancement and
cost of space.
Construction And Fire Safety
Safety in high rise tall buildings is to be inculcated through
structural safety, workers safety during construction and maintenance,
safety from falling components, fire safety, and safety from lightening,

Wind And Earthquake Resistant Design

Wind and earthquake forces are the most predominant loads that
demand lateral design of structures. Further, many may have nausea
effect, in case of large deflections and vibrations; hence, the buildings
must be designed for both earthquake safety and comfort conditions.
In the buildings with base isolation, the response of the building gets
modified in such a way that the ground below is capable of moving
without transmitting no or minimal motion to the structure above;
hence, base isolation is adopted for tall buildings.
Usually, wind loads are the governing factor of structural design
in case of tall buildings. Shape of the building plays an important Kingdom tower, Jeddah Shanghai tower, China

CE&CR June 2020 31

TALL BUILDINGS Challenges
etc. Fire incidences in high rise structures in Mumbai have resulted
into heavy damages and as such, safety is the top priority for high
rise construction. Safety from falling objects during construction
and maintenance of tall buildings is another challenge; hence, the
materials for external facade must be selected carefully.
Speed Of Construction
Speed of construction in tall buildings is another challenge.
New construction technologies are always adopted in high rise
structures for speed, which also ensure quality, safety, and economy.
Prefabricated steel, composite and RCC structures with high strength
concrete are adopted in high rise construction with latest formwork
techniques. Pumping of concrete, lifting of materials and equipment,
and working at higher levels in tall buildings are major challenges for
attaining the speed.
Repair And Maintenance
Repair and maintenance of high-rise tall buildings and services
including facade cleaning are other challenges and as such robotic
maintenance may replace manual maintenance partially, if not
completely in the future. Maintenance and repair cost are also high
in such buildings. Providing easy access for maintenance of services
is also a challenge for architects and engineers. Use of maintenance
free materials or requiring least maintenance is to be given priority
in multi storeyed construction. The materials used in the services
and in components not easily approachable have to be compatible
to the life of the buildings as maintenance and their replacement is
difficult in tall buildings.
Use Of Information Technology (IT)
IT is required in planning and construction of multi-storeyed
construction for architectural, structural and MEP designs,
execution and operation and maintenance. Building Information
Imperial towers, Mumbai
32 CE&CR June 2020
Modelling (BIM) has already become almost a necessity in such
structures. Controls will also be automatic, and IT controlled for
qualifying to smart services, smart parking, smart equipment, and
smart building.
Adoption Of High Rise Construction
High rise construction is taken up as Greenfield development
and Brownfield development during redevelopment projects. In
Greenfield development, it is relatively easy to design services as per
requirement, but in Brownfield development, existing services are to
be taken into consideration before deciding for such construction.
Tall buildings are small townships in themselves and as such,
services are important for such buildings, both provided in the
buildings and existing services in which services of such buildings
are finally connected. Traffic management, social infrastructure, and
institutional infrastructure have also to be considered along with
such development.
Conclusion
Multi-storeyed construction is a necessity for all types of
buildings in cities and coastal towns due to land scarcity for
sustainability. The challenge in multi-storeyed construction is in its
design, construction, and maintenance for which, new construction
technologies, mechanization, IT, robotics, and smart equipment will
have to be adopted for timely quality construction suiting various
climatic conditions. Capacity building in architects, engineers and
contractors will also be immediately needed to cope up with such
future requirement.
References
1. Soni, K M (2018). Post Tensioned Construction Technology for Multi-
Storeyed Buildings. CE&CR, Vol. 31(3), 63-68.
2. Soni, K M (2018). New Materials and Techniques in Construction of
CBI Office in Mumbai. CE&CR, Vol. 31(2), 54-56.
3. Soni, K M (2019). High Rise Structures - Consideration of Benefits
and Limitations, CE&CR, Vol 32(9), 26-28.
4. Soni, K M (2019). Multi-storeyed High-Rise Structures. CPWD
Seminar on High Rise Buildings, Vigyan Bhawan, New Delhi,
27-32.
5. https://www.burjkhalifa.ae/en/the-tower/facts-figures/
6. https://thetowerinfo.com/buildings-list/jeddah-tower/
7. https://en.wikipedia.org/wiki/Shanghai_Tower
8. https://www.indiamart.com/proddetail/residential-imperial-
towers-mumbai-14117030855.html
9. http://www.alcox.in/blog/multi-storey-buildings-classification-
benefits/
TALL BUILDINGS Durability
Chemicals For Enhancing Durability And
Passive Fire Protection Of Tall Buildings
Ishita Manjrekar
Technical Director and R&D Head,
Sunanda Global
Sourabh Manjrekar
Director (Operations),
Sunanda Global
Introduction
According to the Global Tall Buildings Database of the CTBUH
(Council on Tall Buildings and Urban Habitat), till now 1,622 buildings
taller than 200 metres have been erected.
Among the most pressing issues that have spurred tall building
development, is the exponential increase in urban population
worldwide, in conjunction with wealth accumulation. Currently,
almost half of the world is urban; when 20 years ago, it was only one-
third. By 2030, it is expected that about 60% of the world’s population
will be urban. In 2050, over 80% of the world population will live in
urban areas when the world’s population is expected to reach 9 billion.
At that time, all major cities of the world, particularly those in Asia,
Africa, and Latin America, will have enormous populations, probably
ranging from 30 million to 50 million, or more. Accommodating such a
large population in cities will be a colossal challenge. Horizontal scale
of cities is continually being strained with no alternative, but to build
upward to accommodate people.
The development of high-rise buildings is inextricably linked to the
search for efficient construction materials. Technological achievements
in material engineering have gradually shaped the form, height and
construction, as well as energy efficiency of buildings. Initially, steel
was the leader in building constructions, as the technology of concrete
was not sufficiently developed, and because the produced concrete
had a much lower strength than steel. At present, there is a growing
interest in concrete as the main structural material in this type of
buildings. While there are arguments that support both the use of steel
and concrete in high rise construction, the structural engineering and
architectural community seems to favour composite structures, which
34
allow them to blend the advantages and limitations of both materials
and build a modern marvel.
Currently, among the 100 highest buildings in the world, nine are
built as steel structures, 30 as reinforced concrete, five as steel and
reinforced concrete, and 56 as composite structures.
This article aims to provide a high-level overview on the chemical
aids and products that are proven to offer significant benefits in
solving the problems of passive fire resistance of structural steel and
durability of concrete foundations in tall buildings.
Passive Fire Protection Of Tall Steel Structures
The only recorded structural failures in tall buildings in the last
30 years are earthquake and fire related. Steel is extensively used in
all forms of tall building construction, and while it has a high melting
point of 1300°C, it suffers from 3 key failings under fire conditions.
–– With loss of strength at 600°C, a steel beam may lose two-third
of its strength.
–– It is a good thermal conductor which allows rapid heat transfer
to other materials not directly exposed to fire.
–– It has a high co-efficient of thermal expansion, which can lead to
collapse on account of structural deformations.
Because of its limitations in fire, when used in tall buildings, steel
is required to be given additional passive fire protection, in the form
of a sacrificial cladding or a barrier and most advanced spray applied
fire resistive materials and intumescent coatings.
SUNNOFLAME IPTM Intumescent Coatings are thin chemical films
that are spray applied over structural steel members. These coatings
expand under high temperature and form a durable, adherent, fire
resisting cellular foam layer as gases within attempt to escape. While
the foam layer chars, its low thermal conductivity creates a reduced
thermal capacity that acts to retard heat flow to the steel. The foam
layer acts as an appreciable heat sink during intumescence, then
as a reasonable insulator. Intumescent consists of a primer which is
typically used to pre-treat the steel surface, followed by application of
the intumescent coating at the recommended thickness, to achieve
the desired fire rating, and finally an aesthetic topcoat. These coatings
are applied by roller, brush, or spray equipment.
Intumescent protection is increasingly being used to protect
structural steelwork in new and refurbished buildings due to the
low thicknesses and decorative nature of the product. As with other
CE&CR June 2020
Durability TALL BUILDINGS
types of fire protection, specification and application requires care to
ensure that the intended fire safety is provided.
Intumescent coatings can be safely designed and applied for
fire ratings of up to 3.5 hours in tall buildings, in keeping with global
standards and codes.
Durability Of Concrete Foundation Of Tall Buildings
The durability design of tall buildings and especially foundations
is frequently given very little attention, in comparison to strength and
serviceability design issues. However, durability can be an important issue,
especially if the concrete foundation system is exposed to aggressive
ground conditions. Durability is not a specific property of a material but
relates to the environment to which the material is exposed. For example,
a concrete pile which is durable for non-aggressive soils may have
inadequate durability when exposed to a coastal or marine environment.
Durability of reinforced concrete gets drastically affected due to
presence of sulphates and chlorides in the vicinity of concrete and its
reinforcement respectively, through soil and ground water. Sulphate
attack causes loss of bond between cement paste and aggregates,
resulting in excessive cracking, delamination, and loss of strength of
concrete, whereas chloride penetration through the concrete, causes
corrosion in the reinforcement steel bars. Each of the two types of attack
is a serious problem and is responsible for premature failure of many
reinforced concrete structures.
Chemical Aids To Increase Durability And Mitigate
Corrosion
1. Corrosion Inhibiting Admixtures – A typical corrosion inhibiting
admixture prevents deleterious expansion and cracking caused by
the formation of rust during over-induced corrosion. POLYALK CP
293TM, Sunanda’s line of bipolar corrosion inhibitors are proven to
inhibit corrosion of rebars in concrete when exposed to chlorides
and marine conditions. The product has a twenty plus year track
record and has been used across India with excellent results.
2. SUNANODETM Passive Cathodic Protection (CP) or Sacrificial
Anodes Cathodic Protection (SACP) - Despite the proven benefits,
ease of use, and widespread adoption in the rest of the world, this
technology is just recently coming of age in India. Galvanic anodes
are galvanic devices designed to neutralize or slow down new
corrosion cells, which would otherwise develop in the structure,
thereby extending the services life. These discrete units are designed
to be attached structure. Based upon many of the same principles
used for protecting pipelines and ships from corrosion, these anodes
are ‘sacrificial’ in nature. The anodes take advantage of the natural
galvanic differences which exist between different metals. As the
anode corrodes, it releases a supply of electrons. This electrical
current travels through the tie wires, into the surrounding steel to
reduce new corrosion activity on the steel. The output from the anode
varies according to numerous variables, including resistivity of the
CE&CR June 2020 35
steel, moisture content, temperature, and quantity of steel. In the
same way that climatic variations affect the degree of corrosion in
an unprotected structure, the environment into which the anode is
installed has significant influence on its current output. In humid and/
or warm climates, the anodes tend to corrode more aggressively than
in cool and/or dry regions. There, fluctuations in the current output
of the anode vary with changes in the corrosion activity of the steel.
3. Tanking to be provided for the substructure (for external concrete
surfaces of pile-caps and shallow foundations, and their columns/
pedestals only, including at the bottom of foundations by applying
on the top of PCC), i.e., external protective barrier/coating of
water-proofing compound having acid-resistant properties.
Liquid applied membranes like chemically resistant High Build
Coal-tar Epoxy based Coating SUNEPOXY COALTAR HBTM having
minimum DFT of 400 microns offer good resistance to sulphate
and chlorides in underground structures. Pre-formed membranes
like high density polyethylene sheets SUNPRUFETM are also a good
choice, though they are jointed membranes. In this case, special
precautions should be taken with respect to careful sealing of joints.
4. Permeability Reducing Admixture SUNCRYSTALMIXTM -
Concrete is a porous material and water can penetrate concrete
through pores and microcracks due to capillary absorption/
wicking or due to hydrostatic pressure. In some cases, the porosity
may be exacerbated by external factors, such as incomplete
consolidation and curing leading to reduced durability. In addition
to good concreting practices such as well-proportioned, properly
consolidated, and cured concrete, produced with a low water-
cement ratio, utilizing supplementary cementitious materials to
reduce porosity. Permeability reducing admixtures have gained
widespread acceptance as an effective way to enhance the
durability of concrete by controlling water and moisture movement
as well as by reducing chloride ingress and permeability.
5. High Range Superplasticizers and water reducers like
POLYTANCRETE HPTM have become ubiquitous to the production
of good concrete and have a profound effect on the durability of
concrete as a material.
6. Pozzolans such as fly ash, silica fume, metakaolin and GGBS can
be employed to effect improvement in the resistance of concrete
to sulphate attack and reduce permeability of the concrete. As an
effect of pozzolans, the pozzolanic reactions consume Ca(OH)2,
which is needed for reaction with sulphates.
Conclusion
Passive fire protection of steel structures and durability
enhancement of concrete foundations of tall buildings are both
significant subjects that require much thought and consideration in the
design and construction of tall buildings. Chemical products, coatings
and admixtures are effective tools to help solve these problems and
contribute to sustainable and safe tall buildings.

Polypropylene Micro Synthetic Fibres
For High Rise Building
Introduction
Polypropylene fibres have been
applied for reinforcement of cement
mortars and concrete for many years.
They restrict crack propagation and affect
many concrete parameters. Good results
are obtained by application of fibrillated
fibres with the net-like structure obtained
from the polypropylene. The fibres
are chopped to specified lengths and
used for the reinforcement of concrete
and cement mortars. The beneficial
effect of fibres on the compressive
strength of concrete is revealed after
freezing and thawing cycles. For mortars
reinforced with fibrillated fibres, a
significant increase in the bending
strength is observed by mechanical
anchoring, which results from opening
of the network structure and splitting of
fibrillated fibres
The highest bending strength was
registered for micro fibre ranging length
of 20 mm and the fibre content of 0.1% of
total concrete. By this length, during mixing
of the mortar, the fibres remain straight and
do not bend or tangle. Fibres have relatively
large contact surface to form a sufficient
number of adhesive connections with the
mortar components and to provide high
friction forces during pulling fibres ends
out of the matrix.
PP Fibres added to the concrete
improve the parameters of a fresh
concrete. The beneficial effect of these
fibres is revealed after freezing and
36 CE&CR June 2020
thawing cycles. After multiple freeze/
thaw cycles, the compressive strength of
reinforced concrete exceeds the strength
of plain concrete. Simultaneously, the
reinforced concrete exhibits lower water
absorbability.
Cracks play an important role as they
change concrete structures into permeable
elements and increase the risk of corrosion.
Cracks not only reduce the quality of
concrete, but also make structures out
of service. Therefore, it is important to
reduce the crack width and this can be
achieved by adding polypropylene fibres to
concrete. due to their flexibility and ability to
The addition of fibres in cement
concrete matrix, bridges these cracks and
restrains them from opening further, as
shown in Fig. 1. In order to achieve more
deflection in the beam, additional forces
and energies are required to pull out or
fracture the fibres. This process, apart
from preserving the integrity of concrete,
improves the load-carrying capacity of
structural member beyond cracking. This
Fig. 1: Bridging of Crack Using
Polypropylene Fibres
FIBRE REINFORCEMENT
improvement creates a long post-peak
descending portion in the load deflection
curve as shown in Fig. 2. Reinforcing
short discontinuous fibres have the
advantage, however, of being uniformly
mixed and dispersed throughout the
concrete.
The major reasons for crack formation
are plastic shrinkage, plastic settlement,
freeze thaw damage, fire damage, etc.
Plastic shrinkage occurs when surface
water evaporates before the bleed water
reaches the surface. Polypropylene fibres
reduce the plastic shrinkage crack area
conform to form. The addition of 0.1%
by volume of fibres is found effective
in reducing the extent of cracking up
to 90%. The extent of crack reduction is
proportional to the fibre content in the
concrete.
In case of high-rise structures,
high rate of bleeding and settlement
combined with restraint to settlement
leads to settlement cracking. In case of
Fig. 2: Typical Load-Elongation Response in
Tension of FRC
FIBRE REINFORCEMENT
PFRC, fibres are uniformly distributed and
as they are flexible resulting in negligible
restraint to settlement of aggregates.
Small addition of polypropylene
fibres in concrete reduces the flow of
water through the concrete matrix by
preventing the transmission of water
through the normal modes of ingress. The
implications of these qualities in concrete
technology with polypropylene fibre
additions are that cement hydration will
be improved, separation of aggregate will
be reduced and the flow of water through
concrete that causes deterioration from
freeze/ thaw action and rebar corrosion
will be reduced, creating an environment,
which will enhance durability of high rise
structures.
In high-rise buildings, heat penetrates
the concrete resulting in desorption of
moisture in the outer layer. Moisture
vapours flow back towards the cold
interior and are reabsorbed into
voids. Water and vapour accumulate
in the interior, thereby increasing
the vapour pressure rapidly causing
cracks and spalling in the concrete. The
polypropylene fibres melt at 160°C,
creating voids in the concrete. The vapour
pressure is released in newly formed voids
and explosive spalling is significantly
reduced as shown in Fig. 3.
Spalling of Homogenous Structure of Concrete
due to Insufficient Capillary Pores
Fig. 3: Flowing out of steam Pressure through the Melted PP Fibres in the Case of Fire
38 CE&CR June 2020
Table 1: Properties of Bajaj Fibre Guard
Material 100% Virgin
Polypropylene
Design Fibrillated
Melt Point 160 -165°C
Equivalent Diameter 30-50micron
SpecificGravity 0.91
Electrical Conductivity LOW
Acid and Alkali Excellent
Resistance:
Water Absorption Nil
Properties Of Polypropylene
Fibres
Before mixing the concrete, the fibre
length, amount and design mix variables
are adjusted to prevent the fibres from
balling. The aspect ratio for the fibres are
usually restricted between 100 and 200,
since fibres, which are too long tend to
‘ball’ in the mix, and create workability
problems. As a rule, fibres are generally
randomly distributed in the concrete;
however, placing of concrete should be
in such a manner that the fibres become
aligned in the direction of applied stress
which will result in even greater tensile
and flexural strengths. There should be
sufficient compaction so that the fresh
concrete flows satisfactorily and the PP
fibres gets uniformly dispersed in the
mixture. The fibres should neither float to
the surface nor sink to the bottom in the
Developed Explosion Channels due to
Melting of PP Fibres
fresh concrete. Chemical admixtures are
added to fibre-reinforced concrete mixes
primarily to increase the workability of
the mix. Air-entraining agents and water-
reducing admixtures are usually added to
mixes with a fine aggregate content of 50%
or more. Superplasticizers, when added
to fibre-reinforced concrete, can lower
water-cement ratios, and improve the
strength, volumetric stability and handling
characteristics of the wet mix.
Polypropylene fibres are used in two
different ways to reinforce cementitious
matrices. One application is in thin sheet
components in which, polypropylene
provides the primary reinforcement. Its
volume content is relatively high exceeding
0.5%, to obtain both strengthening and
toughening. In other application, the
volume content of the polypropylene is low,
less than 0.15% by volume, and it is intended
to act mainly as secondary reinforcement
for crack control, but not for structural load
bearing applications. The performance and
influence of the polypropylene fibres in the
fresh and hardened concrete is different
and therefore, these two topics are treated
separately.
Effects On Fresh Concrete
The slump values decrease
significantly with the addition of
polypropylene fibres. The concrete
mixture becomes rather clingy, resulting
in increasing of the adhesion and
cohesiveness of fresh concrete. During
mixing, the movement of aggregates
shears the fibrillated fibres apart, so
that they open into a network of linked
fibre filaments and individual fibres.
These fibres anchor mechanically to
the cement paste because of their large
specific surface area. The concrete mixture
with polypropylene fibres results in the
fewer rate of bleeding and segregation
 FIBRE REINFORCEMENT

as compared to plain concrete; this is
because the fibres hold the concrete
together and thus, slow down the
settlement of aggregates. Due to its high
tensile and pull-out strength, the PP fibres
even reduce the early plastic shrinkage
cracking by enhancing the tensile capacity
of fresh concrete to resist the tensile
stresses caused by the typical volume
changes. The fibres also distribute these
tensile stresses more evenly throughout
the concrete. As the plastic shrinkage
cracking decreases, the number of cracks
in the concrete under loading is reduced.
If shrinkage cracks are still formed, the
fibres bridge these cracks, reducing at
the same time their length and width.
Moreover, as the rate of bleeding
decreases, the use of polypropylene fibres
may accelerate the time to initial and final
set of the concrete as this leads to a slower
rate of drying in the concrete.
Effects On Hardened Concrete
The addition of polypropylene fibres in
the concrete do not significantly affect the
compressive strength and the modulus of
elasticity, but they do increase the tensile
strength. Splitting tensile strength of PFRC
approximately ranges from 9% to 13% of
its compressive strength. Addition of PP
fibres in concrete increases the splitting
tensile strength by approx. 20% to 50%.
Conclusion
Innovations in concrete technology
and construction design engineering,
which often call for new building
materials, have made polypropylene
fibre-reinforced concrete applications.
In the past several years, an increasing
number of constructions have been
taken place with concrete containing
polypropylene fibres, such as foundation
piles, pre-stressed piles, piers, highways,
industrial floors, bridge decks, facing
panels, flotation units for walkways,
heavyweight coatings for underwater
pipe, etc. This has also been used for
controlling shrinkage and temperature
cracking.
Due to enhance performances
and effective cost-benefit ratio, the
use of polypropylene fibres is often
recommended for concrete structures.
Polypropylene FRC is easy to place,
compact, finish, pump and it reduces
the rebound effect in sprayed concrete
applications by increasing cohesiveness
of wet concrete. Being wholly synthetic,
there is no corrosion risk. The use of PFRC
provides a safer working environment and
improves abrasion resistance in concrete
floors by controlling the bleeding, while
the concrete is in plastic stage. The
possibility of increased tensile strength
and impact resistance offers potential

Table 2: Bajaj Fibre Guard as per the IRC:15-2017 and MORTH Specifications reductions in the weight and thickness
S.No. Property IRC:15-2017 MORTH Bajaj Fibre Guard of structural components, along with
(Ministry of Road Transport (tested From VNIT reducing the damage resulting from
and Highway) Nagpur)
shipping and handling.
1 Effective Diameter 8-300 micron 10-100 micron 46 micron
2 Length 6-18 mm 6-48 mm As per requirement
3 Sp. Gravity 0.90-1.36 >0.91 0.91
For further information,
4 Dosage 0.6-2.5 kg/m3
0.6-2 kg/m 3
0.91 kg/m3 visit: www.bajajreinforcementsllp.com
5 Water Absorption Less than 0.45% Less than 0.45% Nil
6 Melting Point Should not be Should not be Less than 163.28
Less than 160°C 160°C Abhishek D. Khupsare
7 Aspect Ratio 200-2000 200-2000 434.78 Technical Officer,
8 Alkali and Acid Good Good Good Bajaj Reinforcement LLP
Resistance

CE&CR June 2020 39

Feature - REAL ESTATE
Mapsko Group
Soaring New Heights
M
APSKO Builders Pvt. Ltd. is a
leading and growing real estate
organization, reckoning its
position among the top-notch developers.
For over a decade, the company has
consistently set quality benchmarks
in property development by creating
world-class townships and commercial
spaces in prime locations. Mapsko has
done multiple projects in realty with
commercials, housings, and residential
township.
Mapsko MountVille is an ar tistic
representation customized for those
who apprehend the merit of luxury and
abundance of greenery. Nestled in sector-79,
Gurugram, offering 3-4 BHK luxury fully
loaded apartments in Gurgaon, it is a pure
model of urban architecture, which is
designed to perfection.
Mapsko MountVille is a RERA registered
projec t which nests all the modern
amenities and benefits in a sprawling
40
landscape. Built on a
16.5-acre site, it has
756 apartments at
the foothill of Aravalli
hills with lush green
surroundings.
Planning
The 3-4 BHK luxury apartment structure is
raised by Shapoorji Pallonji, the architectural
layouts have been designed by Hafeez
Contractor, and the landscaping is designed
by LSG Inc., USA. The property has fully air-
conditioned double height lift lobbies with
double height stilt for greenery and open
area. Mapsko Group offers state-of-the-art
club house with numerous amenities within
the residential society. Amenities increase
the pleasure and enjoyment of the residents
and decrease the stress level of occupants’
professional life.
In today’s hustling life, people hardly
have time to enjoy lavish luxurious life
after the day’s work and that is exactly the
winning point Mapsko Mount Ville provides.
It promotes extreme luxury besides high
end apartment, and the habitants are going
to relish their stay tremendously.
The state-of-the-art club provides the
best possible facilities and amenities in any
residential group housing in town under
a single umbrella. The club also caters to
café and restaurants besides guest lounges
for comfortable and luxurious stay for the
guests of the habitants.
Process
The project was envisioned keeping
the luxuries in mind and was executed as
planned. A lot of nitty gritty and thought
was given to the minutest of details and
strong work force was placed to supervise
all operations.
Challenges
During the process of raising the
structure, several defining laws were
formulated by administration from time to
time, making things difficult initially before
the change was accepted wholeheartedly,
and moved in the logical direction of
incorporating changes and executing
accordingly.
CE&CR June 2020

Current Status
The project presently is in last leg of
deliverance and occupational certificate
has been applied. The apartments are
being readied as per the requirement and
by the end of the present year, we foresee
over 50% of the project being occupied by
the clients.
Mr. Rahul Singla
Director, Mapsko Group, innovative modules to sustain sales post
in conversation with
Civil Engineering and
Construction Review… have forced developers to adopt the
CE&CR: Technology is transforming Indian
real estate. Which new technologies have
you incorporated in the construction work
of your projects?
Rahul Singla: Today’s construction is
mechanised and reliability on labour
has reduced considerably. Tower Cranes
are used for ease of construction, and
concreting is done by mechanical booms
and cradles. Batching plants are used
extensively, and concreting is done more
conveniently and effectively through
concrete boom placer. The project is
CE&CR June 2020 41
internally coated with zipplast to give it
a perfect smooth finish and level plast
is carried externally to get rid of plaster
falling due to rain/seepage, etc. Bricks
used in today’s construction are fly ash
type and AAC (Aerated Asbestos cement)
blocks are used to reduce the weight of
the construction and hence, are stronger.
Reinforcement cutting machines and bar
bending machines are used, tremendously
r e d u c i n g l a b o u r d e p e n d e n c y, a n d
minimizing human induced errors.
CE&CR:  How are developers working on
the, lockdown?
Rahul Singla: The present difficult times
digital route and major thrust is put
on digi-tours/virtual tours, slice view,
social media platforms, and drone shoots
depicting clear view of the shape, size and
feature of the project besides clarity on
location. Websites are virtually going to be
a showroom where every nitty gritty could
be put to give a better glimpse to the client
and ease of finalizing the project before
actual site visits can be planned.
CE&CR:  Mapsko has innovative projects
like Mapsko Casa Bella, Mapsko Paradise,
among others. How is this being mapped to
Housing for All, Smart Cities, Infrastructure
Development, etc.?
Rahul Singla: Gurgaon has seen
tremendous growth over the years and
Feature - REAL ESTATE
has been relegated as a smart city with
huge growth and thrust on Infrastructure
development, forcing the city to go
vertical in growth. Mushrooming of MNC’s
forced the government to revise the
Master plan for the city time again and
again, and it became virtually imperative
for various developers to cater to varying
demands of the masses. We, at Mapsko,
took this opportunity to develop our
projects for the masses, which were full
of amenities, attracting elite class and yet
provided housing to the people who could
ill afford expensive residential units in the
main town land.
 CE&CR: How do you see the Indian realty
sector shaping up? What is your vision for
future urban development?
Rahul Singla: Residential realty sector
is a continuous need of the people and
obvious strategic advantage of Gurgaon
makes it the most wanted city. The city
has huge potential and many years of
fruitful realty market for all sections
to invest and get great returns. Major
metro and cosmopolitan cities in India
would see substantial growth in at least
three decades; more and together with
planned government infra development
shall boost the realty sector. In tune with
requirements, we plan to launch more
residential and commercial projects in
years to come and give our impetus to
the industry.
EARTHQUAKE RESISTANCE Hidden Beam

Costonomial Earthquake Resistant Flat Slab

No Drop No Head Through Hidden Beam
completed building elevation. Details of the building, including its
Dr. S.V. Deodhar plan, section, reinforcement details are given herewith.
Retired Director,
SSVPS College of Engineering Dhulia (Maharashtra) Property Details
The building belongs to Mr. Rajesh Gupta at Sheshadri Nagar, Near
Marimatta Square, behind Indian Oil Police Petrol Pump Indore, MP. It
Er. Bhupendra Singh Thakur consists of a plot measuring 40’ x 60’ = 2,400 sq. ft (223.26 sq. m), with
Consulting Engineer, a total construction area of 1,867.79 sq. ft (173.75 sq. m) having a total
Bhupendra Singh and Associates of three floors, i.e., Ground Floor + two floors. The flat slab is provided
at the First Floor and Second Floor roof slab with no drop and head.
Hidden beams extending from column are provided as shown in figure.

Introduction Structural details

Hidden beam is a beam provided in a slab with its thickness RCC Slab 8” (200 mm) is thick with slab reinforcement as shown
equal to that of the slab. It does not extend either at the top or at the in Fig. 3, provided with 12 mm bars at 17.5 cm, centre to centre both
bottom of the slab, hence it is not visible. An experimental study on way with hidden beam of size 7” X 8” (175 mm x 200 mm), having four
hidden slab was conducted by Deodhar and Dubey on slabs of size
1
bars of 16 mm diameter, two at top and two at bottom with rings of 6
1.2 m by 1.5 m, with a slab thickness of 50 mm. They found that such mm at 150 mm C/C. M20 Grade concrete and Fe 415 TMT Steel is used
hidden beams improve the load carrying capacity of slab considerably, with MSA of 20 mm and down black basalt with PPC Ultratech Cement.
reducing deflection and increasing stiffness.
Structural Designer and Government of India Valuer: Er. Bhupendra
In case of multi-storey buildings, ground floor and basements are Singh Thakur
generally provided for parking with no internal walls called as soft
www.nviboi.com,
story. Flat slab is a reinforced concrete slab constructed with or without
drop, with or without column head, and with no beam. However, it is
rarely constructed without drop or column head. The drop provided
in general is either square or rectangular as per slab shape. Deodhar2,3
have recommended that if flat slab is constructed with hidden beams
at various places in the slab, in column head, or in drop, its earthquake
resistant capacity can be improved considerably. However, his
studies are not based on sufficient experimental work and he too has
recommended that institutions having good research facilities if could
conduct some experimental studies on this subject, good findings can
be achieved and appropriate conclusions can be drawn, which will
help engineers in constructing innovative construction.
With this concept in mind, a building was constructed in Indore,
where hidden beams were provided with no column head and no
column drop. Fig. 1, Fig. 2, and Fig. 3 show the plan and structural plan
of both building and hidden beam. The reinforcement of slab, hidden
beams and types of hidden beams provided are given and shown in
Plate 1 through Plate 3 in subsequent paragraphs and Plate 4 shows Fig. 1: Plan of Building Fig. 2: Hidden Beam Plan

42 CE&CR June 2020

Hidden Beam EARTHQUAKE RESISTANCE

Fig. 7: Plate 4 Front (Elevation) Photo of Completed Building

Design Concept
It is designed on the concept of Wide Beam Theory. Punching
action of column is managed by shear strength of the hidden beams
and coddle provision such as IS 456, IS 1893, IS 875, IS 13920 and other
relevant codes. Brief review of design is as follows:
–– Using M20 & Fe 415 Assuming D = 200 mm (Consider for 3 m,
D = 100 mm)
–– Bending Moment is Calculated = 1.5 x 0.21 WL2 = 53.0 x 106 NMM
–– M = 2.7 bd2 = 84.5 x 10^6 NMM >BM; hence, ok.
–– Provide Fe 415 TMT steel 12 mm dia @ 150 mm C/C on top and
bottom of slab.
Fig. 3: Reinforcement Details on Top/Bottom of the Slab
–– % Steel 0.78% Tc = 0.56 N/mm2 Vu = 1.5 WL = 47.7 KN
–– Vc = (PTc) + NTc bd = 112.13 KN, Vc>Vu; hence, safe.
–– The hidden Beam is provided for L/4 length because shear force
reduces towards centre.

Conclusion
As such, a building constructed in year 2015 has performed well
till date. It shows that a flat slab without column head and drop can
be constructed, which serves intended function of the residential
Fig. 4: Plate 1 Hidden Beam at Intermediate and Boundary Edge Column
and commercial structure. It is also likely to remain stable during
earthquake, if any of the buildings has been designed considering
earthquake forces.

References
1. Deodhar SV, Dubey. “Hidden Beam A New Concept of Slab Design”.
CE&CR, November 2004, pp. 54-58.
2. Deodhar, SV. “Building Resistant against Earthquake Forces”.
CE&CR, June 2012, pp. 138-139.

Fig. 5: Plate 2 Hidden Beam at Fig. 6: Plate 3 Slab Reinforcement 3. Deodhar, SV. “Earthquake Resistant Building Through Hidden
Intermediate Column Beams”. CE&CR, February 2016, pp. 78-82.

CE&CR June 2020 43

Construction Trends
Construction Safety
By Amrita Batra
Through implementation of safe work practices, training, and compliance with federal, state, and local regulatory
requirements, the construction-related hazards can be identified, controlled, or eliminated.
S
afety is the most important part of every construction site.
Between heavy machinery, dangerous demolition equipment
and dizzying heights, any construction project is fraught with
hazards. According to Occupational Safety and Health Administration,
in the US, 23 per cent of private sector work-related deaths occurred
in the construction industry.
In fact, in recent years, the number of work-related injuries has
been on the rise due to the boom of the construction industry with a
concurrent decrease in inspections, and companies cutting corners to
alleviate mounting competitive costs. Construction also results in many
non-fatal injuries that cost companies millions of dollars per year. This
makes safety paramount in the industry. While safety measures and
precautions can be costly upfront, their ROI can be massive.
Safety Training
Safety training is critical in the construction industry because of
the high-risk factor. Dangerous situations are a part of the everyday
working environment, which leads to a constant challenge for
construction companies to create and deliver effective safety training.
Every year, new trends appear in the industry from safety training to
technological advancements. And many of the trends make construction
work easier and more efficient, so it is important that construction
companies educate and train their employees to be safe on jobsites.
44
According to a survey by Dodge Data & Analytics, jobsite workers
and supervisors agree that onsite training is more valuable than online
or classroom instruction. In most cases, showing a worker how to do a
job safely and correctly in an actual work setting is better than simply
telling them how to execute their craft properly.
For new employees, there are two types of onsite training that
should be incorporated into on boarding. The first is a walk-through of
responsibilities. This training will demonstrate how a new hire should
perform the job and explain why certain procedures are in place.
Offering the “why” can dramatically lower a new hire’s potential for
cutting corners or inaccurately believing that they can come up with
a faster, more effective way to do a task. The second type of training
to consider is a buddy system, in which experienced workers spend
time enforcing workplace procedures and policies, thus cutting down
the risk of a new hire developing unsafe habits.
Further, the training should be ongoing, especially as comfort sets in
for seasoned employees; for instance, workers are most prone to injuries
and fatalities around noon, when people may become less focused due
to lunch or similar break times. Taking the time to introduce staff to new
equipment or doing quarterly “refresher” courses can be great ways to
offer continuous training that keeps experienced employees engaged,
reducing the likelihood of accidents in the long run.
CE&CR June 2020

By educating and testing employees outside of their general
orientation, site managers and superintendents can avoid indirect
costs that are double those of direct ones. These indirect expenses
can result from workplace incidents, such as time lost due to work
stoppages and investigations, losses associated with recruiting and
training new employees, and loss or damage to material property.
When a worker is not trained correctly and supervised, he or she
will more than likely not be as efficient in their work. Efficiency costs
money, and if a product is not installed correctly the first time, it must
be taken out and re-installed. There are inherent risks and exposures
involved, depending on those tasks are required to be done again.
Thus, safety observations play a large role in worker behaviour.
At the time the observation is made a peer to peer review of that
observation and a solution should take place.
Technology
A myriad of new technologies are making their way into the
construction market and helping to improve worker safety. The
technology comes in two main forms: hardware in the form of
wearable technology, and software that improves safety alerts
and data analysis for long-term improvement. Virtual reality (VR),
wearables and drones are gaining acceptance on jobsites and leading
to fewer injuries, consequently driving improved safety benefits and
cost savings, far outweighing the initial investment.
Virtual Reality
VR can help create a first-hand, experience-based training that
workers and supervisors prefer. The technology can help capture
images of existing project conditions and repurpose these images to
Virtual reality Demo for Safety Training
UAV or Drone Solutions
CE&CR June 2020 45
Construction Trends
Exoskeletons in Construction
display training environments that employees and supervisors can
“walk through” to identify hazards and safety concerns.
Wearables
One of the latest trends in construction safety is wearable
technology that streams a worker’s location and status at all times
while on site. Many of these wearables are linked to already present
check-in/check-out procedures.
While these wearables usually come in the form of lightweight,
waterproof badges or sensors that can be worn on belts or vests,
there are mobile apps that turn a worker’s existing smartphone into
a safety device connected to the cloud, automatically notifying key
personnel of an incident.
Many construction companies are also going beyond the
common definition of wearables (such as smart watches) to deploy
exoskeletons that support a worker’s body by conserving energy and
avoiding any extreme strains. Exoskeletons work by transferring the
worker’s weight onto the ground or other parts of their body instead
of putting pressure on their back or their arms. Overexertion is one of
the leading causes of disabling workplace injuries, and can be largely
overcome through the use of exoskeletons.
Drones
Small Unmanned Aerial Systems (UAS) provide project teams with
accurate real-time jobsite data. They help supervisors understand
the layout where tasks are being performed and where equipment
is being used, and whether jobs are being conducted safely through
photo/video feeds. According to Goldman Sachs, only 18 per cent of
contractors use drones today, and by the end of 2020, it is forecast
that one in four firms will use drones on the jobsite.
Achieving sustained improvements in one’s safety culture can
be difficult, but these practices and new technologies help reduce
error rates and injuries on the job, improving overall job quality and
employee safety.
RUNWAY CONSTRUCTION
Tight Timeframe No Problem For
Tarmat And Ammann India
T
armat Ltd. eagerly took on the
reconstruction of the Cochin Airport
runway, but that doesn’t mean the
Indian construction company expected it
to be easy.
“There is no greater test of men
and machines than an active runway
construction,” said Jerry Varghese, the
founder of Tarmat, based in Mumbai. “It is
tough and demanding work that requires
meticulous planning and timely execution
with stringent quality assurance.”
The project required 3,000 tons of
asphalt mix to be placed daily – and in a
five-hour working window. The resurfacing
also included a profile correction of the
runway at the airport, located in the city of
Kochi in the state of Kerala, India.
“We were issued a timeframe of eight
months to complete the project but have
managed to execute over 90 per cent of the
work in four months,” Varghese said.
The crew must be productive to accomplish
so much in such a tight timeframe. Varghese
pointed to plant and machine uptime as the
force behind the productivity.
“One of the key success factors is that
we did not miss out on our productive
hours by even a minute,” Varghese
said. “I would attribute this high
46
productivity, which was instrumental
to our success on the Cochin Airport runway
project, to Ammann India and its employees.”
Tarmat utilized several key Ammann
products on the project, including two
Ammann ABC 140 ValueTec Asphalt-Mixing
and runways. The company is headquartered
Plants and an Ammann sprayer.
in Mumbai with operations spread across the
Varghese further stated that, “People states of Maharashtra, Tamil Nadu, Karnataka,
make all the difference.” He said the Kerala, Mizoram, Gujarat, Delhi and Jammu
Ammann team offered help in some
and Kashmir.
specific ways during the project.
Tarmat has mainly provided engineering,
-- Customer support. “The Ammann
procurement and construction services for
customer support team has been very
infrastructure projects sponsored by the
cordial and co-operative in extending
central and state governments. In 1988, the
on-site parts support,” he said.
company landed its first major contract for
-- Training. “Ammann India deployed
construction of roads and the container yard
trained operators and technicians at
for the Nhava Sheva port. “We completed
the site, which helped us significantly
the project within the stipulated period of
in becoming productive instantly.”
24 months,” Verghase said.
-- Monitoring. “Ammann engineers have
Tarmat has an abundance of airport
been monitoring the condition of ABC
experience, including resurfacing,
ValueTec batch plants and machines on
extending, strengthening, and constructing
a regular basis, almost daily.”
runways, gates, and aprons. Work has been
-- Maintenance. “The plants and
completed at multiple airports, air bases
machineries were maintained pro-
actively, ensuring zero breakdowns.” and helipad sites across India.
Some of Tarmat’s noteworthy projects
-- Scheduling. “The best part is, the
maintenance routines were scheduled are the MES Arakkonam Naval airport, which
by Ammann India in such a way that our has one of the longest runways in India;
productive hours were not impacted at Jamnagar Airport; AAI Mumbai International
all,” Varghese said. “The suggestions given Airport; and Delhi IGI International Airport.
by Ammann India towards pro-active More projects are coming – and some are
maintenance were very helpful and gave already underway. “We are currently executing
our team a new perspective on how to major runway and airfield construction
achieve more with Ammann products.” works at Chennai, Tuticorin, Trichy, Rajkot and
Pathankhot,” Varghese said.
Tarmat
Tarmat, established in 1986, is an
infrastructure construction company that For further information,
often engages in the building of highways visit: www.ammann.com
CE&CR June 2020
FEATURE - CONCRETE PUMPING

Second Kolia Bhomora

Setu Bridge Project
Introduction
Road and bridges connect and link all
parts of our country. The infrastructure push
by the Government of India in the north-
eastern region has materialized into various
projects of national importance. One such
shining example is the second Kolia Bhomora
Setu bridge project. It took 54 months to complete the 21 it comes to concrete truck mixers, it is only

Assam, Tezpur: The plummeting waters pillar and 19 pillar structure and it will take Schwing Stetter equipment that comes

of the Brahmaputra river are now home another 12 months to hand over the project. to our mind. They are our only preferable
mixers which are so easy to operate
to the second Kolia Bhomora Setu bridge
In an inter view with and maintain. Schwing’s truck mounted
which connects Sonitpur on the North bank
Mr. Hasim Alam, DPM, concrete boom pump stands out in the
with Nagaon district on the south bank.
Gammon India about the crowd as the specified performance is
The project consists of 3.015 km over river
second Kolia Bhomora Setu always delivered.
bridge, 8 minor bridges, 6 box culverts and
Bridge project…
13 pipe culverts. Concrete grades used are What is your experience with Schwing
M30 and M50. Total volume of concrete to Stetter India’s service support?
be poured and produced in this project is Why have you partnered with Schwing Service is good and over the phone
around 105,000 m so far. This NHIDCL project
3 Stetter for your concreting solutions? assistance from Schwing Stetter’s service
is being constructed by Gammon India and Throughout my 15-year journey in team was very much helpful in keeping the
SP Singla Construction using Schwing Stetter construction, I have found that 90% of project on the go without any breakdowns.
India (SSI) equipment as listed: the concrete production, transportation
Why do you never buy spares from
and placement are exclusively done using spurious market?
Material Model Quantity Schwing Stetter India’s (SSI) concreting Spares from Schwing Stetter are very
Schwing BP1800 (Barge 4
equipment. Also, SSI equipment is present much productive and I would say that
concrete pump mounted)
Schwing truck S17, S36X 3
in all projects of national importance. For Schwing Stetter products are more than
mounted (Barge concreting in the challenging waters of hundred percent successful. The quality
concrete boom mounted)
Brahmaputra, Stetter’s concrete batching of the equipment beats the cost and the
pump
Schwing concrete RVH18 (Barge 1 plant CP30 was more than compatible. equipment has zero down time helping with
placer boom mounted) Monthly about 5,000 m3 of concreting concreting round the clock.
Stetter concrete CP30 3 (2 -2014
was done using Stetter equipment, which
batching plant model, 1
-2008 model) were reliable throughout the project. The
Stetter concrete AM6SHN2 16 contract value is estimated to be 588 crores
truck mixer (Barge
and the contract period is 48 months. At
mounted),
AM6SHC2 present, 60% of the work is completed
XCMG motor GR150 1 using Schwing Stetter India’s reliable and
grader
productive concreting equipment. When

48 CE&CR June 2020


What challenges were faced while
executing this project?
Concreting is always a challenging task,
especially in a bridge project construction.
Undergoing research methodologies as to
which equipment would prove to be ideal
for which part of the project was highly
challenging and this was put to ease by
Schwing Stetter’s wide range of concreting
equipment.
In an inter view with
Mr. Vishal Thakur, DPM,
S.P. Singla Constructions
about the second Kolia
Bhomora Setu Bridge
project...
Why have you partnered with Schwing
Stetter for your concreting solutions?
Schwing Stetter is the best concreting
equipment manufacturer, known for
good quality, reliable service, and best
maintenance. Service offered is the best by
Schwing Stetter India for all our projects and
CE&CR June 2020 49
FEATURE - CONCRETE PUMPING
is the perfect choice. There was
not any breakdown and even in
rare cases when it occurs, the
service team kept the project
going by addressing it instantly.
Why do you never buy spares
from spurious market?
Getting spares from Schwing
Stetter is easier than getting
it from the market and we are
proud to be the loyal customers
of Schwing Stetter India.
Please tell us about the last time
you noticed and appreciated
Schwing Stetter’s prompt
support?
I would say that Schwing
Stetter’s prompt spares and
service support would be the
two things which would interest other national importance, being the pre-eminent
companies in the concreting industry to single source of concreting equipment
partner with Schwing Stetter India. solution provider.
What challenges were faced while Milestone no. 1 - Transfer of concrete
executing this project? under water and on water through a barge
The one thing that makes Schwing It would not have been easy to transfer
Stetter India unique is their ability to master the concrete over the varied water conditions
the service required to work in remote without Schwing Stetter’s barge mounted
environment with a highly skilled service concrete transit mixers, stationary concrete
team, along with their ability to develop pump, concrete separate placing boom
innovative methods that kept the work and a concrete placer boom. The barge
moving efficiently in a resource thin - bridge helped in pumping and transportation of
on water construction environment. This was concrete through Stetter concrete truck
the biggest challenge which I would consider. mixers, Schwing stationary concrete pump,
Schwing concrete separate placing boom
Adapting to the challenges and reaching
and Schwing concrete placer boom without
milestones - To deal with complicated
any hassles throughout the entire project.
on-water and under-water concreting,
which is hard to work with, Schwing Milestone no. 2 - Concrete placement at
Stetter offers a complete concreting and different heights on water
construction equipment solution from Fluc tuations in the water levels
shore to placement of concrete in flowing was easily managed by Schwing’s truck
water. Schwing Stetter offers engineered mounted concrete boom pumps. The
solutions with experience gained from solution was to add extra flexible pipelines
thousands of applications over 86 years. in the boom pump that helped to place the
Over the past few decades, Schwing Stetter concrete at fluctuating heights without any
has contributed to all the major projects of discrepancies.
SPECIAL REPORT - CONCRETE PUMPS
Putzmeister India’s
Concrete Pumps
O The growth of Concrete Pumps in large
ver the past decade, concrete pumps have become a
mainstay at construction projects, looking to pump and
place concrete efficiently. The market for both Stationary
Pumps and Truck Mounted Concrete Pumps grew till 2018. While the
numbers in 2019 did not match expectations, the market size was still
bigger than pre-2018 levels.
The growth of Concrete Pumps in large part can be attributed to
the push for affordable housing and infrastructure projects by the
Government. If the sector gets the fiscal support it urgently needs,
and with social distancing expected to become the norm till we have
a solution to COVID-19, we could see an uptick in mechanization
of construction practices. This in turn could spur demand for the
solutions we offer. Further, infrastructure and housing projects
will continue to power demand over the coming years. Increasing
adoption of mechanized processes will drive the demand further.
International brands generally have a proven record going back
over decades like we at Putzmeister with over 60 years of presence
in the market. This results in superior equipment technology,
reliability, efficiency, and machine availability. Furthermore, service
and application support experience gathered over many years help
to give the best possible after sales and application support.
Putzmeister pumps are globally renowned for their ability to deliver
performance across a range of application conditions. This is what makes
our brand the preferred choice for pumps in India. Customers rate the
performance of our machine as better than that of other OEMs. They
also rate our technology and service highly. This comes from not only
providing the best-in-class equipment, but also offering dependable and
50
reliable after-sales support. We have a higher ratio of service engineers
to customers, as compared to other OEMs. Our teams comprise not
only of service engineers, but also material and application experts.
On the more challenging projects, we offer customers Operations
& Maintenance support – a crew comprising of a project manager,
equipment operators and service engineers operate and maintain the
equipment in co-ordination with the project and site managers.
COVID-19 And Putzmeister India
The lockdown to prevent the spread of COVID-19 in India is
undeniably taking a toll on the economy. Like Governments around
the world, India too is grappling with the challenge of saving lives
and livelihoods. As the construction activity starts resuming work,
we expect the demand to pick up slowly. We are gearing up to deal
with the emerging challenges.
Ensuring a safe and healthy jobsite is going to take precedence. At
Putzmeister, we have developed guidelines for the safe handling of all our
equipment keeping in mind the prescribed social distancing and regular
sanitization norms. We are training customers, equipment operators and
our after-Sales team to help with smooth resumption of work.
part can be attributed to the push for
affordable housing and infrastructure
projects by the Government.
Mr. Wilfried Theissen
Managing Director,
Putzmeister India
Obtaining raw materials and delivery logistics is a challenge for
everyone. Given the dynamic situation, our planning, procurement, and
logistics teams are working round the clock to support our customers.
The crisis in handling of migrant labour is expected to affect many
industries. Our HR and Production teams have been taking care of all
our factory employees. Regular checks on their health and catering
to any shortages or problems they face in procuring essentials, has
been effectively handled.
Our customers were already plagued by liquidity issues since the
NBFC crisis. These problems appear to have only become worse during
the lockdown. Our sector will need the support of the Government
to ease this situation.
For further information,
visit www.putzmeister.com
CE&CR June 2020
scaffolding and formwork
Layher Allround Scaffold Ideal For
High Rise Industrial Structure
L
ayher produces high-quality
scaffolding systems in Germany. The
company has worldwide presence
with more than 40 sales subsidiaries. The
products are being used by industries like
construction, cement plants, chemical
plants, power plants, as well as shipyards
and offshore.
More Possibilities - Layher Products And
Services
Layher’s present product characteristics
and services help customers achieve long-
term success and increase the profitability
of their companies. The Layher Allround
Scaffolding has been established as a
synonym for modular scaffolds on the
market. The Allround Scaffolding offers
unsurpassed versatility to be used in
construction sites, chemical industries,
power plants, aircraft, shipyards, event
sector, theatres and arenas.
Application Of Layher Allround Scaffold
In Cement Industries
Cement silos are either a part of
the production process in integrated
cement plants, or they are key aspects
of distribution terminals. For the cement
industry, these storage silos are very
important because it allows a continuous
production, while the cement dispatch can
be discontinuous. Largest cement storage
silos in the cement industry are built with
diameter up to 30 m, while typical silos for
the storage of 20000 t cement are typically
4 m to 30 m in diameter and 20 m to 84 m
in height. It is clear that such silos require
an efficient and trouble-free emptying.
52 CE&CR June 2020
Accordingly, highest requirements are
given to overall plant reliability and
practically 100% availability. To achieve a
high availability, flow problems have to be
strictly eliminated. From the theory of flow
in silos, it is well-known that this can only
be achieved with mass-flow.
For cement silos, the central cone
version has become the predominant
design. On one hand, the central cone has
a displacement function for the material in
the silo, while on the other hand, several
designs, especially for multi-compartment
designs become possible. Multi-
compartment silos are used for producing
special cements from a number of main
and secondary cement components.
Not only does the shape of the building
remind of a crystal, it also reminds of the
surface of the façade. To attach the Local
Scaffolder, they solved this task technically
with the Layher Scaffolding and Technical
team; section by section they adapted the
scaffold to the slope of the building with
various brackets on the inside and then
shifted it inwards by one scaffold width.
Scaffold was anchored with the help of
Layher Anchoring equipment; even the
increased wind loads could be transferred
without putting unnecessary strain on the
structure.
The construction of Scaffolding for
maintenance of silo is a challenging task due
to wind pressure. The selection of support
systems (scaffolding with permanent
structure) aids in avoiding obstructions
by bracket or cable tray around the silo.
Layher Allround Scaffolding systems provide
unique, bolt-less connection technique; the
patented Allround joint has replaced the
conventional scaffold technique, especially
in construction of Scaffold for silo up to
height 72 m.
Allround Scaffolding can accommodate
all types of high loads and is the ideal
system for all kinds of support scaffolding.
Also, it has an efficient solution to deal
with all challenges, regardless of whether
they involve false work at great height or
round inner scaffolding. It needs to be built
in a modular scaffolding system for the
maintenance of silo and high rise industrial
structure.
In addition, cement plants are situated
near the sea shore, generating the need to
take care of wind force. Anchoring is essential
for the stability of the scaffolding; it must be
continually installed as scaffolding assembly
progresses. The anchoring is to be provided
only on sufficient strong components; if
necessary, test the anchoring surface by
pull-out tests. A check can be dispensed
with if sufficient load-bearing capacity can
be assessed on the basis of professional
experience and the service value of the
anchoring force does not exceed 1.5 kN, or in
the case of reinforced concrete.
The horizontal ledger is to be
connected with two standard couplers
with very wide scaffolding structures.
It is necessary to anchor with the aid
of a horizontal ledger. The selection of
anchoring configuration depends on the
bay width, the load on the scaffolding, live

Layher Allround Scaffolding with Aluminium Platform Stairway up to
72 m height at Cement Plant in Gujarat, India
load, wind load and the structural height of
the scaffolding. As the load on the scaffold
increases, the anchoring configuration
becomes denser to pass the force safely
into the anchoring surface. The dense the
anchoring configuration, the lower will be
the force on individual wall ties.
Landing – Type Aluminium Stair Access
Up To 72 m Height
With Layher Modular stair tower,
access possibilities that always fit and
that match the system. With the landing
type Aluminum stair tower, it is simple
to construct a 4-standard stairway tower,
either integrated into the scaffolding,
or as a free-standing access structure
CE&CR June 2020 53
anchored on the building. There is no
hindrance to work on scaffolding by
using Aluminum landing type stairway.
Furthermore, a distinction is made between
independent access structures that are
anchored to the silo and access structures
that are integrated into the scaffolding.
The maximum permissible load bearing
capacity of Aluminum stair tower is
2.0 kN/m2. It is easy to construct up to 72 m
height due to light weight components.
The necessary anchoring can be continually
attached in accordance with structural
requirements. Unlike external platform
stairway access, the platform stair tower
has the advantage that work being done
scaffolding and formwork
inside the scaffolding is not hindered by
people ascending or descending.
Allround Scaffolding, thanks to 8
different connections possible at the
Allround connector and the variable choice
of angles, is a simple task of erecting
scaffolding around curved surfaces. Possible
connections and variable angle selection,
curved surface can be enclosed with
scaffolding without any problem. To build
economical large-diameter scaffolding,
the largest possible bay widths must be
planned. In systems solutions using Allround
equipment, two variants have proven their
worth in practice: in the first variant, only
system bays are used, while the second
variant uses intermediate bays. In both
cases, it is recommended that at least the
last bay be selected as an equalizing bay.
Anchoring
Anchoring is essential for the stability
of the scaffolding and must be continually
installed as the scaffolding assembly
progresses. The anchoring shown differ
in their force absorption and are not
interchangeable without a renewed
inspection. Wall ties, other tube and
coupler anchoring must be attached
directly adjacent to the rosettes. Connect
Allround wall tie with standard coupler,
inserting the wall tie into the ring screw.
Anchoring is particularly important if
the scaffolding is covered with nets or
tarpaulins. The subsequent covering
requires additional anchoring.
For further information,
visit: www.layher.co.in
Mithilesh Kumar
Director,
Layher Scaffolding Systems
Pvt Ltd
SPECIAL REPORT - CRANES

Sparkline’s Overhead Industrial Cranes

S
parkline represents the Overhead
Industrial crane market in India. It is
one of the most trusted brands with
a sizeable market share, representing one of
the top three companies in the Indian market.
Sparkline has been present in this
market since the last 25 years; but, the
market demand in last 5 to 7 years or so has
been more or less stagnated and the market
expansion is limited to 3 to 5% in size. The
Indian Overhead Industrial crane market is
estimated to be around Rs. 3,000 crore,
wherein Sparkline represents the niche
European standards market catering to a
wide variety of industries.
Cranes being used for reducing human
efforts has demand in all sectors of the
industry. Some sectors like Automotive,
Construction equipment, Infrastructure,
Agriculture Equipment do drive the
demand more. With the changing needs for
optimizing the resources and automisation
needs of the industries, more impetus will
be seen in demand for Industry standards
in crane industry.
A comprehensive safety
policy and single standard
which guides this industry
and equipment will be the
need of future
Mr S.A. Doshi
Managing Director,
Sparkline Equipments Pvt Ltd.
The demand and supply has a gap
in terms of availability of high quality,
reliable hoists and cranes, which meet the
highest safety standards, it being the most
important factor in this market.
A comprehensive safety policy and
single standard which guides this industry
and equipment will be the need of future.
Currently, a wide variety of global standards
satisfy the needs based on user acceptance.
Sparkline has set the standards by
supplying more than 5,000 hoists and
cranes; we cater the market with reliable, low
maintenance and high life cycle products.
There are cases wherein as low as 0.1% of
project cost as Opex cost per annum has
been achieved by our customers. The need
of value addition and solutions under one
roof is wherein Sparkline is differentiated
in its offering. We cater to the entire MHE
requirements, Cranes, Conveyors, Automation,
Tackles, Fixtures and Services, all under one
roof, bringing peace of mind to the customers.
We work on enabling right selection and
leveraging our international tie-ups in
technology to meet the productivity and
optimisation needs of the industry specifics.
Challenges in these uncertain times
and VUCA world are there to remain, while
challenges of optimizations, changing user
habits, increased safety focus are always
there for betterment. Where we focus is on
our strengths of being proactive, friendly
and expert to provide the right first time
solutions to meet these challenges faced by
various Industries.
In current scenario post the COVID-19,
the need of more atomised cranes and
MHE solutions will be need of the hour.
Least touch points and social distancing
will mean more cabin operated, single man
handling cranes as atomization’s need. On
demand side, some sectors will drive the
cranes market growth like, Food, Pharma,
Health and Infrastructure industries.
Industry and customer specific solutions
under one roof will be in demand, since the
focus of the core teams within industries will
be on quickly ramping up the operations on
one side. The demand will also be to build a
supply chain system which in event of such
occurrences stay stable to meet the demand
of their end customers.
Safety being of prime importance,
used cranes market is a remote possibility
as far as overhead Industrial cranes is
concerned; however, new norms of rental
cranes, billed per hour without going in for
Capex investment can be a future area of
growth. Upgrading of existing cranes for
automisation and scaling up are other areas
of growth envisaged.
Sparkline Equipments Pvt Ltd is present
and capable to meet the wide variety needs
of market with its Customer First Mindset,
the value which drives our existence in
India since our inception in 1991.

54 CE&CR June 2020

 SKID STEER LOADERS

CASE SR130
C
ASE SR130 radial lift skid steer
loader provides a reliable,
economic and productive skid
steer. The loader imported from the USA,
has a rated operating load capacity of
590 kg, and is equipped with ISM Engine
developing 49HP. ISM is one the leading
diesel engine manufacturers in the world in
this segment.
SR130 Skid steer loader is designed
to provide best in class fuel efficiency,
productivity and is suitable to work in
confined spaces for general construction
applications. The main features are:
Productivity: With enhancements in
engine power, torque and auxiliary cab. The SR130 skid steer loader benefits between the control levers and easy access

hydraulics, the CASE SR130 is perfect for from a cab with up to 25% more internal to the seat.

smaller construction and agricultural width, providing greatly improved High Visibility: CASE SR130 has wider
applications. operator comfort. Our cab - the widest glazed surface for safer operations, the

Operator Comfort: The wide door, in the industry - provides plenty of room large glazed surface with ultra-narrow

repositioned grab handles and a lower for comfortable operation, with greater wire side screens, the lowered threshold

threshold provide easy access to the
headroom and legroom, more space
and thinner front pillars provide the best
visibility in the market.
Outstanding Stability: SR130 rides on a
21 per cent longer wheelbase than main
competitor, delivering greater stability
and comfort, allowing increased lifting
capabilities, regardless of jobsite conditions.
Top Ranking Breakout Force: CASE
cylinder and chassis’ design provides
maximized pushing power. The cylinder
geometry optimizes the skid steer and
compact track loader’s push and pull
power, while the bucket support baring
directly on the chassis of the machine
further adds to its pushing power.

For further information,

visit: www.casece.com/apac/en-in

CE&CR June 2020 55

ADVERTISERS’ INDEX

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Complete Dewatering Systems Pvt. Ltd. ................ 51 EXHIBITIONS/SEMINARS:

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56 CE&CR June 2020

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JUNE 2020

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